QA/QC FRPMS
I. General Principles
II. QA/QC Activities by Piping Segment
A. Marine Piping (Seawater Bed)
B. Coastal Piping Works (Up to Intake Pumping Station - IPS)
C. IPS to Pretreatment (PT) (DMPF), DMPF to Cartridge Filtration (CF)
D. CF to RO Membranes (Stage 1 & 2)
E. Post Treatment, Reject Water Discharge
F. Post Treatment to Export Pump Station, Export Pump Station to Storage Tanks
III. QA/QC Deliverables (Throughout All Stages)
IV. Responsibilities
Acronyms definitions:
Key Construction Management Team Members & Coordination Roles
I. Field Quality Plan (FQP) File Contents
II. Site Works Conformance File (SWCF) Document List
Construction Specifications for FRP Piping
List of Method Statements Required for FRPMS
List of ITPs Required for FRPMS
List of Inspection Checklists for FRPMS
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QA/QC FRPMS
This framework covers the QA/QC activities for FRP pipe installation from seawater intake to treated
water storage.
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I. General Principles
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System Criticality: Each piping segment (marine, coastal, within plant) will be assigned a
criticality level (C1, C2, C3) according to ACWA Power's Risk Matrix. This determines the rigor of
QA/QC.
Standards & Codes: Adherence to AWWA-M45, AWWA C950, and ISO 14692 is mandatory.
Documentation: All QA/QC activities will be documented, including ITPs, QC reports, test
certificates, and MDBs.
Third-Party Inspection: Independent inspectors (e.g., Bureau Veritas) will be engaged for
critical activities, particularly survival tests and key installation phases.
Qualified Personnel: Only qualified and experienced laminators, jointers, and supervisors will be
allowed to work on FRP systems.
ITPs: Detailed Inspection and Test Plans (ITPs) must be developed and approved by the Owner
for each phase of the project. Hold Points for Review, Witness, or Information shall be clearly
identified in the ITPs.
II. QA/QC Activities by Piping Segment
A. Marine Piping (Seawater Bed)
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Design Review:
○ Verify material selection for marine environment (chemical resistance, corrosion).
○ Review design for marine installation conditions (wave action, currents, seabed
conditions).
○ Confirm marine installation procedures and equipment.
Material Inspection:
○ Witness material testing as per ITP.
○ Verify material certificates (Type 3.1 or 3.2).
Installation Monitoring:
○ Supervise pipe laying and jointing at sea.
○ Monitor underwater connection methods and inspection.
○ Verify marine installation vessels and equipment are adequate and used correctly.
Testing:
○ Witness offshore hydrotesting.
○ Leak testing, if applicable.
Records: Maintain detailed logs of marine installation activities, including weather conditions,
divers' reports, etc.
B. Coastal Piping Works (Up to Intake Pumping Station - IPS)
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Site Preparation:
○ Verify soil compaction and trench preparation.
○ Ensure proper dewatering and water control.
Pipe Laying:
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○ Supervise pipe transportation, handling, and placement.
○ Monitor jointing procedures (Butt & Wrap or Adhesive).
Quality Control:
○ QC checks for Jointing, pipe burying, materials storage and field hydrotesting.
○ Jointing QC sheets to record all parameters.
○ Monitor backfilling and soil compaction (independent testing required).
Testing:
○ Field hydrotesting as per approved procedure.
○ Step test method to address fluctuations and record relevant parameters.
C. IPS to Pretreatment (PT) (DMPF), DMPF to Cartridge Filtration (CF)
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In-Plant Installation:
○ Verify pipe supports and anchoring.
○ Monitor connections to equipment (pumps, filters).
○ Ensure cleanliness and protection of pipes during installation.
Quality Control:
○ QC checks for fit-up, alignment, and supports.
○ Visual inspection of joints.
Testing:
○ Hydrotesting of piping sections within the plant.
D. CF to RO Membranes (Stage 1 & 2)
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High-Pressure Piping:
○ Emphasize material integrity and joint strength.
○ Stringent supervision of lamination and jointing.
Quality Control:
○ Increased QC frequency and detailed reporting.
○ Non-destructive testing (NDT) if required.
Testing:
○ High-pressure hydrotesting with extended hold times.
E. Post Treatment, Reject Water Discharge
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Chemical Compatibility:
○ Verify material resistance to post-treatment chemicals.
○ Check compatibility of gaskets and seals.
Installation:
○ Supervise installation of chemical injection points.
Testing:
○ Hydrotesting and leak testing.
F. Post Treatment to Export Pump Station, Export Pump Station to Storage
Tanks
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Final Piping:
○ Ensure final inspection and documentation.
○ Verify connection to storage tanks.
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Testing:
○ Final system hydrotest and leak test.
○ System walkdown and inspection.
III. QA/QC Deliverables (Throughout All Stages)
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Inspection and Test Plans (ITPs) for each segment.
Material Test Certificates (Type 3.1/3.2).
Jointing QC Sheets.
QC Reports from installation activities (signed by Sub-contractor and Supplier).
Field Hydrotest Reports.
Manufacturing Data Book (MDB) with all records.
List of Qualified Laminators/Jointers.
Non-Conformance Reports (NCRs).
As-Built Drawings.
IV. Responsibilities
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FRP Supplier: Design, engineering, fabrication, material supply, supervision, ITPs, MDB.
FRP Sub-contractor: Installation, jointing, field testing, QC checks, reporting.
Main Contractor: Overall responsibility, coordination, review, and inspection.
Owner: Approval of ITPs, witnessing tests, final acceptance.
Third-Party Inspector: Independent inspection and certification.
This framework provides a comprehensive approach to managing QA/QC for FRP pipe installation in
your seawater desalination project. Remember that detailed procedures should be developed in ITPs
specific to each task and in accordance with the project's criticality levels.
Acronyms definitions:
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FRP: Fiber Reinforced Polymer
QA/QC: Quality Assurance / Quality Control
ITP: Inspection and Test Plan
AWWA: American Water Works Association
ISO: International Organization for Standardization
MDB: Manufacturing Data Book
MPR: Maximum Pressure Rating
EN: European Norm (European Standard)
NDT: Non-Destructive Testing
NCRs: Non-Conformance Reports
IPS: Intake Pumping Station
PT: Pretreatment
DMPF: Media Pre filtration
CF: Cartridge Filtration
RO: Reverse Osmosis
To successfully implement and execute the QA/QC FRP Management Framework, achieve ACWA
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Power approval, and ensure proper handover, coordination among several key construction
management team members is crucial. Here's a breakdown of the major players who need to be
involved and their roles in this process:
Key Construction Management Team Members &
Coordination Roles
1. Project Manager:
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Overall responsibility: Ensure the QA/QC framework is integrated into the project
execution plan.
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Coordination: Oversee and coordinate all team members involved in QA/QC.
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ACWA Approval & Handover: Primary liaison with ACWA Power for approvals and
handover documentation.
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Key Activities: Track progress, resolve issues, ensure compliance.
2. Construction:
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Execution: Direct implementation of the QA/QC framework on site.
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Coordination: Manage the day-to-day activities of subcontractors and inspection teams.
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Key Activities: Ensure resources are available, manage schedules, and enforce quality
standards.
3. QA/QC:
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Development & Implementation: Develop, maintain, and implement the detailed QA/QC
plan based on the framework.
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Coordination: Lead the QA/QC team, coordinate inspections, and manage
documentation.
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ACWA Approval: Prepare and submit QA/QC documentation for ACWA Power approval.
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Key Activities: Conduct audits, issue NCRs, and ensure compliance with standards.
4. FRP Supplier Representative:
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Technical Support: Provide technical expertise on FRP materials, fabrication, and
installation.
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Coordination: Liaise with the QA/QC team and subcontractors on material quality and
testing.
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Key Activities: Review ITPs, witness tests, and provide material certifications.
5. FRP Subcontractor Representative:
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Execution: Responsible for FRP installation and adherence to QA/QC requirements.
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Coordination: Communicate with the Construction Manager and QA/QC team on daily
activities and issues.
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Key Activities: Conduct self-inspections, prepare QC reports, and implement corrective
actions.
6. Third-Party Inspector (Bureau Veritas or similar):
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Independent Inspection: Conduct independent inspections and testing as per the ITPs.
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Coordination: Report findings to the QA/QC Manager and Project Manager.
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ACWA Approval: Provide independent verification and certification for critical activities.
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Key Activities: Witness tests, review documentation, and issue inspection reports.
7. Document Controller:
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Documentation Management: Manage all QA/QC documentation, including ITPs,
reports, certificates, and MDBs.
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Coordination: Ensure timely distribution of documents to relevant parties.
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ACWA Handover: Compile and organize all handover documentation.
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Key Activities: Maintain document control system, archive records, and prepare reports.
8. Safety Manager:
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Safety Compliance: Ensure all QA/QC activities are conducted safely.
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Coordination: Work with the Construction Manager and subcontractors to enforce safety
procedures.
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Key Activities: Conduct safety inspections, provide training, and manage incident
reports.
I. Field Quality Plan (FQP) File Contents
The Field Quality Plan (FQP) is a document outlining the specific procedures and controls to be followed
for quality assurance and quality control during the on-site installation of the FRPMS. Here's a typical
structure and list of contents:
1. Introduction
○ Project Information (Name, Location, Client)
○ Scope of the FQP (Specifically FRPMS field works)
○ Purpose of the FQP
○ Reference Documents (FRP Management System Document, Codes, Standards)
2. Project Organization and Responsibilities
○ Organization Chart for Field Team
○ Roles and Responsibilities (Project Manager, Construction Manager, QA/QC Manager,
FRP Supplier Supervisor, FRP Sub-contractor Representative)
○ Communication and Reporting Structure
3. Quality Control Procedures
○ Material Receiving and Storage
■ Inspection and Verification Process
■ Storage Requirements (Temperature, Humidity, Protection)
■ Handling Procedures
○ Trench Preparation
■ Excavation and Bedding Procedures
■ Soil Compaction Testing Requirements
■ Water Control Measures
○ Pipe Laying and Jointing
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■ Laying Procedures
■ Jointing Procedures (Butt & Wrap, Adhesive, etc.)
■ Environmental Controls During Jointing
■ Qualified Personnel Verification
○ Installation of Supports
○ Backfilling and Compaction
■ Material Specifications
■ Compaction Procedures and Testing
○ Hydrostatic Testing
■ Test Procedure
■ Test Equipment and Calibration
■ Acceptance Criteria
■ Documentation
○ Final Inspection and Walkdown
Inspection and Testing
○ Reference to ITPs (Inspection and Test Plans) for Each Activity
○ Checklists to be Used (Material Receiving, Installation, Jointing, Testing, etc.)
○ List of Tests and Frequency
○ Witnessing and Hold Points
Documentation and Records Control
○ List of Required Documents and Records
○ Document Control Procedures (Revision Control, Distribution)
○ Record Retention Requirements
Non-Conformance Reporting and Corrective Action
○ Procedure for Identifying and Reporting Non-Conformances
○ Corrective Action Process
○ Preventive Action Process
Safety
○ Safety Procedures Specific to FRP Installation
○ Emergency Procedures
Appendices
○ ITPs (Inspection and Test Plans)
○ Checklists
○ Forms (NCR, Inspection Reports, etc.)
○ List of Approved Subcontractors and Personnel
II. Site Works Conformance File (SWCF) Document List
The Site Works Conformance File (SWCF) is a collection of documents providing evidence that the site
works have been performed according to the project requirements and the Field Quality Plan. Here's a
typical document list:
1. General Project Information
○ Project Details (Name, Location, Client)
○ Contract Information
2. Material Documentation
○ Material Receiving Reports
○ Material Certificates (Type 3.1/3.2)
○ Material Test Reports
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○ Storage Inspection Reports
Installation Documentation
○ Daily Site Reports
○ Trench Preparation Reports and Compaction Test Results
○ Pipe Laying Records
○ Jointing Records (Jointing QC Sheets)
○ Welder/Jointer Qualifications and Certificates
○ Support Installation Records
○ Backfilling and Compaction Reports and Test Results
Testing Documentation
○ Hydrostatic Test Reports
○ NDT Reports (if applicable)
○ Calibration Certificates for Testing Equipment
Inspection Documentation
○ Completed Inspection Checklists
○ Inspection Reports
○ Non-Conformance Reports (NCRs) and Corrective Action Reports
As-Built Documentation
○ As-Built Drawings
○ Survey Reports (if applicable)
Correspondence
○ Relevant Communication (Emails, Letters, Meeting Minutes)
Other Supporting Documents
○ Permits and Approvals
○ Photographs of Installation
○ Any other documentation required by the contract or FQP
Attachment of Documents in FQP and SWCF
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Field Quality Plan (FQP): The FQP should reference many of these documents. For example, it
might refer to the "Hydrostatic Test Procedure" but not necessarily include the full procedure in
the FQP itself. Appendices might include templates of checklists and forms.
Site Works Conformance File (SWCF): The SWCF contains actual records. For example, the
completed Hydrostatic Test Report would be included in the SWCF, not just a blank template.
Construction Specifications for FRP Piping
1. General Installation Requirements:
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Installation must adhere to approved Work Method Statements (WMS) from the FRP Supplier.
No deviations are allowed without proper approval.
Instructions from the FRP Supplier's supervisors must be followed. Any uncertainties or
deviations must be reported to the FRP Supplier and Main Contractor.
FRP Sub-contractor is responsible for Quality Control (QC) checks and collecting necessary
signatures from FRP Supplier's supervisor, Main Contractor, and Owner where applicable.
Field joints can only be fabricated by jointers qualified through training and hydrotesting as per
Section 9.4 of the document.
No elbows or tees are to be fabricated on site; these must be factory-fabricated.
Qualified laminators and adhesive bonding teams must be used, with their qualifications verified.
Proper access and facilities like scaffolding and shelters must be provided to ensure suitable field
laminate conditions.
2. Underground Piping Installation:
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Soil Support:
○ Underground FRP pipe must be supported by well-compacted sand, with compaction
verified by AWWA-M45 calculations (minimum 90% Standard Proctor Density per ASTM
D698).
○ Cement or other additives to increase compaction are not allowed without written
approval.
○ Backfill soil should be free of sharp rocks and conform to Class II AWWA M45 table 6.1.
Crushed rock (Class SC1) should generally not be used.
○ Geotextile use is evaluated based on the geotechnical survey and soil types, as per
AWWA M45, section 6.5.2.
○ A larger cover depth is preferred to protect against vehicle loads. The underground piping
design is based on a standard truck conform to specification AASHTO HS-25.
Trench Width:
○ Trench width must be sufficient for joint making and soil compaction, but not excessively
wide.
○ Minimum width: 1.25 times the pipe outside diameter plus 12 inches (300 mm) for a single
pipe.
○ Clear space between multiple pipes must be at least the average of their radii for depths
over 3.5m, and two-thirds of the average for depths under 3.5m.
Water Control:
○ Groundwater must be controlled via dewatering methods (sump pumps, well points, etc.)
to maintain trench stability and prevent pipe flotation. Dewatering should minimize the
removal of fines from the soil.
Separation:
○ When crossing other lines, the separation must be more than the average of the two
pipes and at least 300mm but less than 800mm with proper supports.
Buried Depth:
○ Minimum buried depth must be maintained to protect from traffic loads and prevent
buoyancy.
○ Consideration of potential differential settlement, especially near existing railways or
highways and near landfill areas.
3. Above Ground Piping Installation:
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Pipe supports must have rubber inlays to prevent direct contact between steel and FRP.
Pipe supports must be designed specifically for FRP, with wide clamps to distribute loads.
Special attention is required for valves, which may need direct support to avoid excessive loads
on FRP piping connections.
4. Field Jointing:
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Preferred joint type for tensile-resistant field connections is Butt & Wrap, due to lower
susceptibility to errors compared to adhesive bell & spigot joints.
Adhesive bell & spigot joints are allowed but require more supervision. Rubber Seal Lock Joints
are also permitted in certain conditions.
Cementing kits and lamination kits must be sourced from the FRP Supplier.
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Specific working conditions for shop and field laminates must be maintained.
5. Pressure Testing at Site (Field Hydrotest):
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All installed piping must undergo:
○ Integrity Test: 1.5 x System Design Pressure for 1 hour.
○ Leak Tightness Test (Underground only): 1.1 x System Design Pressure for 24 hours.
Pressure fluctuations without leakage can be managed using the 'step test' method per ISO
14692, Part 4, section 4.6.2.3.2.
Testing is done section-wise, with partial backfill for underground piping and joints kept exposed
for visual inspection.
Specific procedures for filling, pressurizing, and recording data during the test must be followed.
Leaking flanges must be remade with new gaskets or replaced; over-torqueing is not allowed.
6. Supervision:
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FRP Supplier must provide at least one supervisor per two teams.
Supervisors are responsible for inspecting joints, witnessing excavation and backfilling, and
ensuring compliance with installation instructions.
Areas Where We Could Potentially Add More Specifics (if needed):
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Detailed Soil Compaction Requirements: More specific values for soil density (e.g.,
percentage of maximum dry density) for different soil layers around the pipe. Specific testing
methods and frequencies for soil compaction.
Marine Installation Details: More detailed procedures for pipe laying, connection, and anchoring
in the marine environment. Specific requirements for diver inspections or ROV surveys.
Chemical Resistance: A more extensive list of chemicals and their specific concentrations that
the FRP pipes must withstand. Specific test methods for chemical resistance.
Non-Destructive Testing (NDT): While not heavily emphasized, if specific joints or critical areas
require NDT (e.g., ultrasonic testing, radiographic testing), detailed procedures and acceptance
criteria would be needed.
Support Details: More specific design criteria for pipe supports, including materials, spacing,
and load-bearing capacities for different pipe sizes and weights.
Jointing Procedures: Highly detailed, step-by-step procedures for each type of jointing method
(Butt & Wrap, Adhesive, etc.), including environmental controls, laminate thickness, curing times,
etc.
Hydrotesting Procedures: More specific details on the hydrotesting setup, pressure gauges,
allowable pressure fluctuations, and documentation requirements.
List of Method Statements Required for FRPMS
1. ITP (Inspection and Test Plan) Method Statements
○ ITP for Component Fabrication
○ ITP for Spool Fabrication
○ ITP for Field Installation
2. Material Handling and Storage Method Statements
○ Storage and Handling Procedures for Glass and Resin
○ Storage Procedures for Pipe, Fittings, and Flanges
○ Storage Procedures for Adhesives (Cementing Kits)
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○ Shipping Procedures for Glass and Resin
○ Shipping Procedures for Pipe, Fittings, and Flanges
○ Inspection Procedure for Goods Arriving at Site/Trench
Jointing Method Statements
○ Pipe Laying and Jointing Procedures for All Joint Types (Butt & Wrap, Adhesive Bell &
Spigot, Rubber Seal Lock Joints, etc.)
○ Lamination Procedure (Shop and Field)
○ Flange Assembly Procedure
Installation Method Statements
○ Installation Procedure for Underground Piping
○ Installation Procedure for Above Ground Piping
○ Excavation and Backfill Procedure (Including QA/QC for Backfill and Bedding)
Testing Method Statements
○ Shop Pressure Test Procedure
○ Site Pressure Test Procedure (Field Hydrotest)
○ Test Procedure for 1000-Hour Survival Test
Supervision and Quality Control Method Statements
○ Supervision Procedure
○ Quality Control (QC) Procedure (Including Hardness, Thickness checks for Butt & Wrap
Joints)
Health, Safety, and Environment (HSE) Method Statements
○ HSE Procedures Specific for Working with Fiberglass and Disposal of Materials
○ Confined Space Procedures for Working in the Trench
Training Method Statements
○ Bonder/Laminator Qualification Procedure
Other Method Statements
○ Document Review Procedure
○ Engineering Procedure
List of ITPs Required for FRPMS
1. ITP for Component Fabrication:
○ Covers the manufacturing of individual components (pipes, fittings, flanges) at the
supplier's factory.
○ Includes material verification, dimensional checks, lamination quality, etc.
2. ITP for Spool Fabrication:
○ Focuses on the assembly of pipe spools (pre-fabricated sections) at the supplier's facility.
○ Includes weld/joint inspections, dimensional accuracy of spools, etc.
3. ITP for Field Installation:
○ Addresses the installation of FRP pipes and spools at the construction site.
○ Includes trench preparation, pipe laying, jointing procedures, backfilling, etc.
4. ITP for Field Jointing:
○ Specifically targets the quality control of field joints (joints made on-site).
○ Includes lamination checks, adhesive bonding inspections, curing, etc.
5. ITP for Pressure Testing at Site (Field Hydrotest):
○ Details the procedures and acceptance criteria for hydrostatic testing of installed piping
sections.
○ Includes pressure hold times, leak checks, documentation of test results, etc.
6. ITP for Qualification Testing (Survival Test):
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Relates to the 1000-hour survival test as described in the document.
Includes test setup, pressure and temperature monitoring, and documentation.
List of Inspection Checklists for FRPMS
1. Material Receiving Inspection Checklist:
○ Verification of materials against delivery documents.
○ Inspection for damage during transit.
○ Checking of material certificates (Type 3.1/3.2).
○ Confirmation of material type, size, and quantity.
○ Verification of storage conditions.
2. Component Fabrication Inspection Checklist:
○ Dimensional checks of pipes, fittings, and flanges.
○ Visual inspection for defects (voids, cracks, etc.).
○ Laminate thickness measurement.
○ Hardness testing (Barcol or Tg).
○ Glass content measurement.
○ Verification of marking and identification.
3. Spool Fabrication Inspection Checklist:
○ Dimensional accuracy of assembled spools.
○ Weld/joint inspection (shop joints).
○ Flange alignment and orientation.
○ Verification of supports and lifting lugs.
○ Review of spool drawings and Bill of Materials.
4. Trench Preparation Inspection Checklist:
○ Verification of trench dimensions and alignment.
○ Inspection of soil compaction and bedding.
○ Confirmation of water control measures (dewatering).
○ Checking for any obstructions or interferences.
○ Verification of trench width and pipe separation.
5. Pipe Laying Inspection Checklist:
○ Inspection of pipe handling and placement.
○ Verification of pipe support and anchoring.
○ Checking for proper alignment and gradient.
○ Confirmation of pipe protection measures.
○ Visual inspection of pipe surface for damage.
6. Field Jointing Inspection Checklist:
○ Verification of jointer qualifications.
○ Inspection of joint preparation (cleaning, beveling).
○ Monitoring of lamination process (materials, techniques).
○ Thickness and hardness checks of field laminates.
○ Visual inspection of completed joints.
○ Environmental conditions during jointing.
7. Hydrotesting Inspection Checklist:
○ Verification of test setup and equipment.
○ Monitoring of pressure and temperature during testing.
○ Visual inspection for leaks.
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○ Documentation of test results.
○ Confirmation of test duration and pressure hold times.
○ Step test if there is pressure fluctuation.
8. Backfilling and Compaction Inspection Checklist:
○ Verification of backfill material type and quality.
○ Inspection of backfilling procedure.
○ Monitoring of soil compaction (density tests).
○ Confirmation of backfill cover depth.
○ Checking for protection of pipes during backfilling.
9. Final Walkdown Inspection Checklist:
○ Overall system check for completeness.
○ Verification of pipe supports and anchors.
○ Inspection of connections to equipment.
○ Review of all documentation (MDB).
○ Final visual inspection for any defects or issues.
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