Saddle Lamination Method

Saddle Build-up Lamination
& Nozzle Fixation Method

Statement
Project: SHUQAIQ 3 Independent Water Project-RO Plant
Client: ACCIONA
Document Number: FPI-KSA-FSV-MS-SBL-GRP

Revision: 0
Field Services Department

Revision & Approval Control
DOCUMENT CONTROL
Policy Number FPI-KSA-FSV-MS-SBL-GRP

Saddle Build-up Lamination & Nozzle
Title
Fixation Method Statement
Issue Date 31-12-2020
REVISION CONTROL
Revision Date Description Comments
0 31-12-2020 For Review & Approval N/A
APPROVALS
Name Position Signature Date
PREPARED BY
Abdulaziz
Site Services Engineer 31-12-2020
Sundokji
REVIEWED BY
Saeed Mustafa Site Services Engineer 31-12-2020
Saddle Build-up Lamination & Nozzle Fixation Method Statement| FPI-KSA-FSV-MS-SBL-GRP Page 1 of 12
TABLE OF CONTENTS
1. GENERAL 3
2. PREPARATIONS 3
3. PROCEDURE 3
3. HEALTH AND SAFETY 10
3. RISL ANALYSIS 10
1. GENERAL
This document describes the method to assemble a GRP/GRV Build-up Saddle.
To ensure that the performance of the installed joint complies with the requirements used
for the design, it is essential that all personnel involved in the jointing procedure is familiar
with and fully understands the techniques described in this document.
The instructions in this document are as complete as possible. However, it is not possible
to describe all circumstances that might be encountered in the field. Therefore, our
experienced representative may deviate from the described method to achieve an
optimum solution using the latest techniques and processing method.
Besides, our representative may be consulted for clarification of statements made in this
document and for advice about specific problems encountered in the field.
Any deviation made in this document shall be documented and approved.
Definition of words used in these instructions:
- The word “shall” indicates a requirement.
- The word “should” indicates a recommendation.
2. PREPARATIONS
1. Check the pipes routing as per approved isometric drawings/actual site conditions.
2. Check if any damage has occurred during unloading.
3. Each pipe spool should be internally blown out with air or otherwise cleaned to
ensure that it is free from dust, dirt, sand, etc., prior to installation.
4. Mark and plot the location of the build-up / lamination on the header pipe as
detailed on the drawings (see Figure 1).
3. PROCEDURE
Saddle Build-up
1. Grind the marked bonding area of the header lamination (see examples on Figure 1
& 2) to remove the topcoat of the pipe using an angle grinder with emery disk pad.
The surface should be properly abraded exposing pipe glass fiber to ensure a good
grip between the build-up and the header pipe.
2. Clean this area by dry clean cloth or paintbrush and ensure that it is fully dry.
Figure 1. Build-up Saddle Details Example
Figure 2. Mark & grind the build-up saddle area
3. Mix manually the resin and catalyst in a clean and dry plastic bucket using a clean
and dry wooden stick as per the quantities specified in the recipe to maintain the
right ratio.
4. Impregnate by lamb wool roller the roughened area with the above resin mixture and
apply the glass layers for the build-up lamination. Mixture of the resin & catalyst and
the sequence and the size of glass to be applied are mentioned in the recipe (see
Figure 3).
5. Impregnate by lamb wool roller the above glass layers in an interval of two layers.
6. Repeat the required steps until the required number of layers is applied (see Figure 3).
7. Wait till the lamination is cured under ambient temperature.
8. Curing process is complete when the header lamination cools down.
Figure 3. Saddle build-up
Saddle Lamination to Pipe

1. Locate the hole to be drilled and bore it using a hollow diamond drill or hole saw.
2. Ensure that the prepared hole on the header lamination perfectly fits the nozzle pipe
to be inserted.
3. In some cases, the drilled hole is not equal to the pipe’s ground OD. And accordingly,
the hole should be rotary ground until the best fit is achieved between the inserted
branch pipe and the ground hole. Refer to Figure 4C & 4D.
4. The bonding area of the nozzle shall be grinded of to remove the topcoat of the
pipe.
5. After ensuring the pipe sections are adequately supported and aligned properly,
check if the prepared bonding surface is clean and free from dust, oil etc., if not,
sand it with an emery paper to make it fresh prior to application of adhesive or Cab-
O-Sil.
6. Once the pipe is inserted, verify the require distance and clean the excess cement
around the joint, as shown in Figure 5A, 5B & 5C
7. Mix and apply the adhesive or Cab-O-Sil putty between the nozzle and the header.
Let it dry under ambient temperature (see Figure 4).
Figure 4A: Checking of Branch OD Figure 4B: Hole Drilling
Figure 4C: Drilled Hole Figure 4D: Using of Rotary Grinder
Figure 4E: Grinding of Branch End Figure 4F: Cementing into the Hole
Figure 4G: Cementing onto the Branch Figure 4H: Inserting of Branch
Figure 5A: Verification of inserted Branch Figure 5B: Cleaning of Excess Cement
Figure 5C: A Fixed Pipe
8. Once the adhesive or Cab-O-Sil is cured, carefully grind to roughen the smooth area
prior to nozzle lamination.
Figure 6. Header/branch lamination
9. Mix manually the Vinylester resin and catalyst in a clean and dry plastic bucket using
a clean and dry wooden stick as per the quantities specified in the recipe to maintain
the right ratio.
10. Apply the glass roving as specified in the recipe provided, impregnating with resin
mixture at every two layers until the required layers mentioned are met. Between
every two layers, use lamb wool roller and/or steel roller to flush/remove the trapped
air and white marks (see Figure 6).
11. Ensure that the gaps between the cut sections of the fiber glass shall be covered by
the next layer until all layers are applied.
12. Apply the required layers of top tape to provide a smooth finish.
13. Wait till the lamination is self-cured at ambient temperature.
14. Ensure that the nozzle lamination is undisturbed until it cures. The curing time varies
depending on the sunlight exposure and temperature.
Stiffener Plate Lamination
1. Locate and mark the stiffener plate location.
2. The bonding area of the stiffener plate shall be grinded off to remove the topcoat in
order to attain a good bonding surface.
3. After ensuring the stiffener are adequately supported and aligned properly, check if
the prepared bonding area surface is clean, dry and free from dust, oil, etc. if not,
sand it with a 40-60 grit emery paper to make it fresh prior to application of Cab-O-Sil.
4. Mix and apply the Cab-O-Sil putty between the stiffener, the branch and header
saddle build-up. Let it dry under ambient temperature.
5. Once the Cab-O-Sil l is cured, carefully grind to roughen the smooth area prior to
application of stiffener plate lamination.
6. Apply the resin mixture by using a lamb wool roller on the prepared bonding surface.
7. Apply a minimum of 7 layers of glass rovings as per the recipe, impregnating with resin
mixture at every layer until the required layers are applied. (See Figure 7).
8. Between every layer, use lamb wool roller and/or steel roller to flush/remove the
trapped air and white marks.
9. Apply the 1 layer of surface mat to provide smooth finish.
10. Wait until the lamination is self-cured at ambient temperature.
11. Ensure that the stiffener lamination is undisturbed until it fully cures. The curing time
varies depending on the sunlight exposure and ambient temperature
4. HEALTH AND SAFETY

During operating with Fibreglass Reinforced Plastic materials, several safety rules must be
observed. Health and safety requirements applicable for the specific project shall be
addressed. This may include but not limited to material handling as per MSDS, training
and certification for working in confined space, etc.
5. RISK ANALYSIS
8.1 Individuals falling to a different level
I. Collective systems and organizational measures
• Clean work areas
• Clearly mark trench with adequate signposting
• Proper orientation of leak-tightness verification valve
• Bring the load close to the body
• Roll or slide the load if possible
• Use auxiliary resources (levers, straps, etc.)
• In the case of exertion between several people, there is only one individual
responsible for manoeuvring Training for difficult transportations
II. PPE: Use of safety harness attached to a fixed point
8.2 Noise Exposure
• Verify exposure values
• If they exceed regulatory limits, use adequate protection systems
II. PPE: Ear protection
8.3 Electrical Contacts
• Do not work in damp areas
• Verify the condition of tool’s insulating elements
• Verify that electrical elements have protection against direct and indirect
contacts
• All electrical equipment and tools should be inspected and tagged.
II. PPE: Safety gloves
8.4 Individuals falling to the same level
• Housekeeping to be maintained
II. PPE: Safety shoes
8.5 Stepping on objects
• Housekeeping to be maintained
II. PPE: Safety shoes
8.6 Dust
• The operator must place him/herself upwind while cutting and sanding piping to
avoid dust
• Provide proper ventilation / suction system (Explosion Proof)
II. PPE: Safety goggles, work clothing and protective breathing elements
8.7 Projection of particles
• Tools must be in perfect condition
• The operator must be trained on handling the tools to operate them
II. PPE: Safety goggles, safety gloves, work clothing and safety helmet
8.8 Explosion
• Avoid flammable materials (resins, acetones) entering in contact with fire or hot
elements
• Prohibit smoking while carrying out this type of work
• Ease ventilation of the work place and the interior area of the pipe with extractors
(in the case of internal jointing), (Explosion Proof unit)
• Verify possible reactions between different chemical agents before joining
physically
• Proper lighting equipment
II. PPE: Safety goggles and gloves, and work clothing
8.9 Exposure to chemical agents by inhalation
• Carry out joints in ventilated areas
• Verify possible reactions between different chemical agents before joining
physically to avoid giving off gases
• Ease ventilation in the interior area of the pipe with extractors (in the case of
interior joining)
II. PPE: Respiratory protections (filter mask)
8.10 Thermal contacts
• Demonstrate and indicate to Field operators that the laminated jointing method
produces a high-temperature reaction
II. PPE: Safety gloves

Saddle Lamination Method

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Saddle Lamination Method

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Saddle Build-up Lamination

& Nozzle Fixation Method

Document Number: FPI-KSA-FSV-MS-SBL-GRP

Field Services Department

Policy Number FPI-KSA-FSV-MS-SBL-GRP

Revision Date Description Comments

0 31-12-2020 For Review & Approval N/A

Name Position Signature Date

Name Position Signature Date

Name Position Signature Date

Saeed Mustafa Site Services Engineer 31-12-2020

Figure 2. Mark & grind the build-up saddle area

Figure 3. Saddle build-up

Saddle Lamination to Pipe

Figure 4A: Checking of Branch OD Figure 4B: Hole Drilling

Figure 4C: Drilled Hole Figure 4D: Using of Rotary Grinder

Figure 6. Header/branch lamination

4. HEALTH AND SAFETY

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