PROJECT / CONTRACT REF.

KNPC Clean Fuels Project

DOCUMENT TITLE :

Training & Qualification Program for

Adhesive Bonded (TB/TS) & Straight Field Lamination of
GRE/GRV Pipes & Fittings of Diameters 25mm to 600mm

NOTE:
This document is the Standard Training Program followed by
Future Pipe Industries (FPI) for the training and qualification of
Pipe Fitters, Supervisors and Inspectors in accordance with
Annex D of ISO 14692-4:2002

22-Jan-15 0 Issued for review and approval REMUS ORASA

REV. Prepared & Approved Checked Approved

DATE NO. REASON FOR REVISION
FPI CLIENT

DOC NO. FPI-SS-CFP-TQP-001 Page 1 + 5 Rev. 0

CLIENT: GS Engineering & Construction Corp.
 Training & Qualification Program for Adhesive Bonded
(TB/TS) & Straight Field Lamination of GRE/GRV Pipes &
Fittings of Diameters 25mm to 600mm

CONTENTS

A. Scope of Work
B. Manpower/ Crew
C. Training Course
D. Training Register
E. Assessment
F. Test Results & Certificates
G. Training Materials
H. Attachments

Project Client Doc. Title Doc. No. Page No.

KNPC Clean GS Engineering & Training &

FPI-SS-CFP-TQP-001 Page 1 of 5
Fuels Project Construction Corp. Qualification Program
Date Printed: 22-Jan-15
 Training & Qualification Program for Adhesive Bonded
(TB/TS) & Straight Field Lamination of GRE/GRV Pipes &
Fittings of Diameters 25mm to 600mm

A. Scope of Work

The scope of work covers the supply of Training instructor and Technician to
train and familiarize the EPC crew on the procedures and techniques of
performing Adhesive Bonded Joints (TB/TS), GRE/GRV Lamination Joints (LJ)
and Flange Jointing prior to their actual execution at site.

Training will be conducted in five days per session at a given site in Kuwait.
Number of session depends on the number of participants and one session
should not exceed 20 participants maximum four (4) persons per crew.

Total numbers of trainees expected is 40 and therefore shall be divided into 2

batches.

B. Manpower/ Crew

The contractor shall depute not more than 20 technicians per training session
which will be divided into 5 groups with assigned crew leader in each group. The
crew leader shall be responsible for the technicians and the main point of contact
during the training. Maximum 4 personnel shall constitute one crew.

C. Training Course

The contractor crew, selected by the company/contractor from his workforce,

shall be trained on the following courses.

1. Proper Handling & Storage (Theory)

A course shall be conducted in proper handling and storage GRE/GRV

materials

Schedule : Day 1
Time : 8:00am to 5:00pm
Attendees : GS Engineering Personnel

2. Tools, Raw Materials & Consumables (Theory)

A course shall be conducted in using the tools, raw materials and

consumables required to prepare and join the pipe ends. The tools, raw

Project Client Doc. Title Doc. No. Page No.

KNPC Clean GS Engineering & Training &

FPI-SS-CFP-TQP-001 Page 2 of 5
Fuels Project Construction Corp. Qualification Program
Date Printed: 22-Jan-15
 Training & Qualification Program for Adhesive Bonded
(TB/TS) & Straight Field Lamination of GRE/GRV Pipes &
Fittings of Diameters 25mm to 600mm

materials and consumables shall be identified and presented one by one. The
safety shall be briefly explained at the same time of presentation.

The instructor shall demonstrate and the crew leader shall be required to
perform the same with the assistance of technician.
The tools and consumables required are listed below.

SN Description Remarks
1 Shaver Machine - (TB/TS) applicable sizes To be provided by GS E&C
2 Heating Blankets - applicable size To be provided by GS E&C
3 Wrap around tape (all applicable sizes) To be provided by GS E&C
4 Curve-o-mark To be provided by GS E&C
5 Pi tape To be provided by GS E&C
6 Spirit level To be provided by GS E&C
7 Pipe vice/ Working table To be provided by GS E&C
8 4 Angle grinder To be provided by GS E&C
9 Grinding disc with backing pad To be provided by GS E&C
10 Cutting disc 4 To be provided by GS E&C
11 Drilling machine To be provided by GS E&C
12 Rubber mandrel To be provided by GS E&C
13 Emery cup To be provided by GS E&C
14 Hand gloves To be provided by GS E&C
15 Marker pen To be provided by GS E&C
16 Paint brush 3 To be provided by GS E&C
17 Come along Jacks To be provided by GS E&C
18 Rubber pad 5mm thick To be provided by GS E&C
19 Latching belts To be provided by GS E&C
20 Rubber hammer To be provided by GS E&C
21 Pipe Clamps To be provided by GS E&C
22 Safety glasses To be provided by GS E&C
23 Blind flanges (applicable diameter) To be provided by GS E&C
24 Calibrated torque wrench and sockets To be provided by GS E&C
25 Gaskets, bolts, nuts and washers To be provided by GS E&C
26 Testing manifolds To be provided by GS E&C
27 Pressure pumps & pressure gauge To be provided by GS E&C
28 Cement kit for 1 training session only To be provided by GS E&C
29 Lamination kits - for 1 training session only To be provided by GS E&C

Schedule : Day 1
Time : 8:00am to 5:00pm
Attendees : GS Engineering Personnel
Project Client Doc. Title Doc. No. Page No.

KNPC Clean GS Engineering & Training &

FPI-SS-CFP-TQP-001 Page 3 of 5
Fuels Project Construction Corp. Qualification Program
Date Printed: 22-Jan-15
 Training & Qualification Program for Adhesive Bonded
(TB/TS) & Straight Field Lamination of GRE/GRV Pipes &
Fittings of Diameters 25mm to 600mm

3. Reading & Comprehension (Theory)

A course shall be conducted in reading and comprehending the isometric

drawings to determine their ability in identifying piping components of the line,
type of joints, general orientation and location of the line.

Schedule : Day 1
Time : 8:00am to 5:00pm
Attendees : GS Engineering Personnel

4. Fabrication and Jointing (Practical)

The crew leader and technicians shall be required to perform the actual
jointing spool fabrication. The course outline shall be as follows.

1. Cutting of pipes
2. Calibration using shaver machine
3. Grinding using angle grinder & drill machine
4. Cement mixing and application
5. Joint assembly TB/TS & GRE/GRV Lamination Jointing (LJ)
6. Joint curing using heating blankets
7. Bolt torquing sequence

Depending upon the performance of the crew leader and technicians, FPI
instructor shall at his own discretion extend the duration of this exercise.

Schedule : Day 2, 3, 4 & 5

Time : 8:00am to 5:00pm
Attendees : GS Engineering Personnel

5. Hydro testing

The fabricated test spools are to be hydro tested at 1.5 times the pipe class
for 1 hour. Prior to testing, the technician shall be trained in using torque
wrench and flange tightening procedure.

Schedule : Day 5
Attendees : GS Engineering Personnel

Project Client Doc. Title Doc. No. Page No.

KNPC Clean GS Engineering & Training &

FPI-SS-CFP-TQP-001 Page 4 of 5
Fuels Project Construction Corp. Qualification Program
Date Printed: 22-Jan-15
 Training & Qualification Program for Adhesive Bonded
(TB/TS) & Straight Field Lamination of GRE/GRV Pipes &
Fittings of Diameters 25mm to 600mm

D. Training Register

The technician shall be required to register during the course of training in the
attendance sheet.

E. Assessment

Contractors personnel shall be assessed in their performance of the skills they

are required to perform. The technician shall sign a form to acknowledge their
understanding of the required skills.

F. Test Results & Certificates

The test shall be recorded on the spool fabricated and tested by GS Engineering
Personnel.

The criteria are as follows.

1. The crew leader and technicians shall be considered qualified to jointing if

the joints fabricated passed the required test pressure. If any of the joints
failed, the crew shall not be qualified.
2. Successful crew leader and technicians shall be provided with certificates
from FPI. The crew who failed will be at the discretion of the contractor to
request similar training at own cost.

G. Training Materials

1. GRE Materials for demo, practice and test spool will be provided by GS E&C.
2. Tools and consumables and testing manifolds including blind flanges, bolts,
nuts and pumps shall be arranged by client.

H. Attachments

1. Training Plan

2. List of tools and consumables

Project Client Doc. Title Doc. No. Page No.

KNPC Clean GS Engineering & Training &

FPI-SS-CFP-TQP-001 Page 5 of 5
Fuels Project Construction Corp. Qualification Program
Date Printed: 22-Jan-15
 Training and Qualification Plan

Project: KNPC - Clean Fuels Project

Location: Kuwait
Contractor: GS Engineering & Construction Corp.

Training Details:
Adhesive Bonded (TB/TS)
Type of Jointing
Lamination (GRE & GRV)
Adhesive Bonded (TB/TS) & Straight Field Lamination of GRE/GRV Pipes and Fittings of
Training Qualification
diameters from 25mm to 600mm

No. of Participants advised

40
by client

Training Plan:
No. of training Sessions 2
No. of participants per session 20
Training Duration/Session 5 days
Training Start Date TBA
Batch No. 01 & 02
Proposed test spools:
Adhesive Bonded (TB/TS) Test Spool: 150 mm dia EST20

Test Spool No. 1

Joint 1 - TB/TS

TB/FF Flange TB/FF Flange

Total: 4 person per spool

3.0 meters

GRE Lamination Test Spool: 300 mm dia EST16

Test Spool No. 2

Joint 2 - GRE Lamination

TB/FF Flange TB/FF Flange

Total: 4 person per spool

3.0 meters
GRV Lamination Test Spool: 300 mm dia VST16

Test Spool No. 3

Joint 3 - GRV Lamination

PL/FF PL/FF

Total: 4 person per spool

3.0 meters

Test Spool No. 1 10 spools + 2

Test Spool No. 2 10 spools + 2
Test Spool No. 3 10 spools + 2

Materials: 150mm EST20 Pipe, TB/PL, 3 meters - 12 pcs

300mm EST16 Pipe, TB/PL, 3 meters - 12 pcs
300mm VST16 Pipe, PL/FF, 2 meters - 24 pcs
150mm EST20 Flange, TB/FF, ASA 150 - 22 pcs
300mm EST16 Flange, TB/FF, ASA 150 - 22 pcs
Cement Kit: 84 pcs
Lamination Kit: 300mm EST 16 - 12 kits; 300mm VST16 - 12 kits

Hydrotest Pressures
Test Spool No. 1 30 barg
Test Spool No. 2 24 barg
Test Spool No. 3 24 barg

Note Additional materials are to be used for practice and demo.

 Tools and Consumables

Adhesive Bonded (TB/TS)

A. Tools

1. TS shaving machine 25mm to 150mm

2. TS shaving machine 200mm to 600mm
3. Heating blanket 150mm
4. Heating blanket 300mm
5. 4 Angle grinder
6. Drill machine
7. 50m long electrical cables with industrial plug
8. 2 nylon / canvass binders with hook
9. 2 nylon / canvas belt
10. Hand pullers cable type
11. Come along jack
12. Rubber mallet, medium
13. Pipe fitters wrap around
14. Spirit level
15. 25mm to 300mm PI tape
16. Measuring tape, 5m
17. 12 right angle
18. Scissors
19. Wavistrong adhesive kits

B. Consumables

1. Hard cotton gloves

2. Polythene gloves
3. Emery paper, grit 12
4. Emery cups
5. Rubber mandrel
6. 4 grinding disc, grit 24
7. 4 diamond cutting disc
8. Dust mask, 3M 8710
9. Permanent marker
10. Paint brush, 4
11. Cotton rags

Project Client Doc. Title Doc. No.

KNPC Clean Fuel GS Engineering & Tools and

FPI-SS-CFP-TQP-TC-001
Project Construction Corp. Consumables
 Tools and Consumables

GRE Lamination Jointing

A. Tools

1. Heating blanket 300mm

2. 4 Angle grinder
3. 50m long electrical cables with industrial plug
4. 2 nylon / canvass binders with hook
5. 2 nylon / canvas belt
6. Pipe fitters wrap around
7. Spirit level
8. Measuring tape, 5m
9. 12 right angle
10. Scissors
11. Lamination kit

B. Consumables

1. Hard cotton gloves

2. Polythene gloves
3. Emery paper, grit 12
4. 4 grinding disc, grit 24
5. 4 diamond cutting disc
6. Dust mask, 3M 8710
7. Permanent marker
8. Paint brush, 4
9. Cotton rags
10. Plastic bucket
11. Lamb wool roller
12. Roller refill
13. Disposable coverall
14. Digital weighing scale
15. Steel roller

Project Client Doc. Title Doc. No.

KNPC Clean Fuel GS Engineering & Tools and

FPI-SS-CFP-TQP-TC-001
Project Construction Corp. Consumables
 Tools and Consumables

GRV Lamination Jointing

A. Tools

1. 4 Angle grinder
2. 50m long electrical cables with industrial plug
3. 2 nylon / canvass binders with hook
4. 2 nylon / canvas belt
5. Pipe fitters wrap around
6. Spirit level
7. Measuring tape, 5m
8. 12 right angle
9. Scissors
10. Lamination kit

B. Consumables

1. Hard cotton gloves

2. Polythene gloves
3. Emery paper, grit 12
4. 4 grinding disc, grit 24
5. 4 diamond cutting disc
6. Dust mask, 3M 8710
7. Permanent marker
8. Paint brush, 4
9. Cotton rags
10. Plastic bucket
11. Lamb wool roller
12. Roller refill
13. Disposable coverall
14. Digital weighing scale
15. Steel roller

Project Client Doc. Title Doc. No.

KNPC Clean Fuel GS Engineering & Tools and

FPI-SS-CFP-TQP-TC-001
Project Construction Corp. Consumables