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Glass-fiber Reinforced Plastic Pipe (GRP PIPE) Installation Manual of GRP Pipe Above ground Piping [email protected] 1.Introduction .1 2. Field Service Representative . 1 3. Fire Safety . 1 4. Inspecting pipe at the job site ... 1 1.5 Repairing Pipe . 2 6. Jointing Pipes 3 6.1 Overlay joints . 3 6.1.1 Alternative: overlay pack ..... 7 6.1.2 Branch Connection ... 8 6.1.3 Tools for butt joint . 126.1.4 Gel time 126.2 Flanged joints . 136.2.1 Bolt, Nut & Washer 146.2.2 Recommended Bolt Torque. 156.2.3 Recommend Procedure for Flange Installation . 166.3 Other Jointing Method . 17C O N T E N T S ii6.3.1 Flexible Steel Coupling 177. U.V. Resistance .. 188. Pipe Support 198.1. General Rules ... 198.2. Support ... 198.3 Anchor . 208.4 Guide .... 218.5 General Installation .. 239. Passing to the (concrete)Wall ... 2510. Dimension Tolerances .... 2611. Repair Manual .. 2811.1 Cutting Edge .. 3212. Field Hydrostatic Testing ... 33 GILGWANG GREENTECH CO.,LTD. Title Installation Manual of GRP Pipe Above Ground Piping GILGWANG GREENTECH CO.,LTD. Re. Date2006-03-02Doc. No. Page1 1.Introduction ThissectionofthemanualdescribestherequirementsforinstallationofGILGWANG GREENTECH(HereinaftercalledasGGT)pipesaboveground.Inadditionthis manualprovidesguidancehowtoavoidandsolveproblemsduringinstallation.GGT Glass fiber Reinforced Pipe systems offer, by their specific nature, many applications and advantages compared with other materials. 2. Field Service Representative Thesupplier(GGT)canprovideafieldservicerepresentative(Supervisor).Thefield service representative will advise the installer to help him achieve a satisfactory pipe installation.Theservicewillrangefromcontinuoustointermittentdependingonthe job schedule, complexity and installation result. 3. Fire Safety Glass Fiber Reinforced Plastic(GRP) pipe can burn, like virtually all plastic pipe made withpetrochemicals.Thereforeitisnotrecommendedforuseinapplicationswhich areexposedtointenseheatofflames.Duringinstallation,caremustbetakento avoidexposureofthepipetowelderssparks,cuttingtorchflamesorotherheat whichcouldignitethepipematerial.Thisprecautionisparticularlyimportantwhen workingwithvolatilechemicalsinmarkinglay-upjoints,repairingormodifyingthe pipe in the field. 4. Inspecting pipe at the job site Allpipesshouldbeinspecteduponreceiptatthejobsitetoinsurethatnodamage has occurred in transit. Depending on length of storage, amount of job site handling and other factors that may influence the pipes condition, it may be wise to re-inspect the pipe just prior to installation. Inspect the shipment upon delivery is as follows: Makeanoverallinspectionoftheload.Iftheloadisintact,ordinaryinspection whileunloadingwillnormallybesufficienttomakesurethepipehasarrived without damage. Iftheloadhasshiftedorindicatedroughtreatment,carefullyinspecteachpipe sectionfordamage.Generally,anexteriorinspectionwillbesufficienttodetect anydamage.Whenpipesizepermits,aninteriorinspectionofthepipeatthe location of an exterior scrape may be helpful to determine if the pipe is damaged. GILGWANG GREENTECH CO.,LTD. Title Installation Manual of GRP Pipe Above Ground Piping GILGWANG GREENTECH CO.,LTD. Re. Date2006-03-02Doc. No. Page2 Check the quantity of each item against the bill of lading. If any imperfection or damage is found, immediately segregate the affected pipes and contact the supplier. Do not use pipe that appears damaged of defective. If the Field Service Representative is present at the time of your inspection(s), he will be glad to assist you. 5. Repairing Pipe Normally, pipes with minor damage can be repaired quickly and easily at the job site by a qualified individual. If in doubt about the condition of a pipe, do not use the pipe. The field service representative can help you determine whether repair is required and whether it is possible and practical. He can obtain the appropriate repair specification and arrange for the required materials and a trained repair technician, if desired. Repair designs can vary greatly due to pipe thickness, wall composition, application, and the type and extent ofthedamage.Therefore,donotattempttorepairadamagedpipewithoutconsulting the supplier first. If you want to more information for repair of pipe, you can obtain in GGT repair manual. GILGWANG GREENTECH CO.,LTD. Title Installation Manual of GRP Pipe Above Ground Piping GILGWANG GREENTECH CO.,LTD. Re. Date2006-03-02Doc. No. Page3 6. Jointing Pipes 6.1 Overlay joints GGTpipesectionsaretypicallyjointedtooverlaymethod.Otherjointingsystems suchasflangesandthreadjointsmayalsobeusedforjointingGGTpipe.GGT jointingsystemonpipeandoverlayisallbuttjointunlessotherwiserequirement (Figure 1.1). Figure 1.1 Overlay Joints Thisjointismadefromglassfiberreinforcementandpolyesterresin.Itistypically usedwhereitisrequiredtowithstandaxialforcesfrominternalpressure.This system provides a strong, leak-proof joint and can be applied either in the shop or in thefield.Jointreinforcingissuppliedinvaryingwidthsandpre-cutforeach particular pressure and diameter. GGT strongly recommends that all GRP joints be installedbytrainedpersonnelwithexperience.Finalassemblyjointsshouldnotbe installed until the system hangers, supports and anchors have been properly located andfixedequipmentconnectionshavebeenmade.Becauseofthehighrateof thermalexpansioninGRPpiping,allmeasuring,cutting,fittingandjoiningmaybe performedatthesameambienttemperature.Standardfieldjointkitsincludeglass reinforcingmaterials,resinputty,resinforlaminating,surfacecoatingmaterialand catalyst. All butt welds are to be made in accordance with ASTM C582 or NBS Specification PS 15-69. The actual procedure will be performed as follows: OVER-LAY JOINTGILGWANG GREENTECH CO.,LTD. Title Installation Manual of GRP Pipe Above Ground Piping GILGWANG GREENTECH CO.,LTD. Re. Date2006-03-02Doc. No. Page4 Procedure for Overlay (Butt Joint) 1. Cutting MeasureofflengthofGRPpiperequiredand usingamarkerandstraightedge,drawaline completely around surface to be cut. Cutpipewithasabersawusingafinetoothed blade or a circular saw with an abrasive blade. 2. Puttying on the pipe Ifnecessary,beforeputtying,Installercanbe bevelingabout15~30andpipesare beveled only to structural layer or middle layer. Pipewillbeplacedinthepositioninwhichthey aretobewelded.Acatalyzedthixotrophic polyester paste will be applied to the joint seam. Makecertainworkareaandsurfacesareas clean as possible and dry. 3. Grinding Afterfilledandenoughcuredinbevelshouldbe grind until same level of the pipe outside. 4. Preparing fiberglass Layoutfiberglassmatstripsonworktable. Length of each strip(fiberglass) should be 50mm longer than circumference of the pipe. The width ofstrip(fiberglass)inaccordancewithGGT manual (See table for length of overlay). Thewidthofthefirstlayershallbe50mm minimum. The woven roving shall not be greater in width than the layer of chopped strand mat. GILGWANG GREENTECH CO.,LTD. Title Installation Manual of GRP Pipe Above Ground Piping GILGWANG GREENTECH CO.,LTD. Re. Date2006-03-02Doc. No. Page5 5. Laminating Mixprescribedamountofcatalystwithrequired amountofresinincleancontainer.Resinwill hardeninabout20-30minutes.Aftermixingthe catalyst thoroughly, apply resin to fiberglass mat by the brush or paint roller. 6. Overlaying Beforeoverlayonpipeinstallershallbeapplied resin on the pipe surface. Pick up the completed weld fiberglass by one end and center it carefully onthepipe.Applythetaperendfirstwiththe narrowest fiberglass on the pipe weld. 7. Remove bubble Besureweldiscentered,withcaretakento avoidwrinklesontheunderorbacksideofthe weld.Finishedjointshouldbebuiltupin successivelayeruniformlyandwithoutair bubble.Successivelayersshallincrease uniformlytoprovideminimumtotalthicknessof overlay which meet the width of the last layer. Do notmoveordisturbwelduntilitisthoroughly cured. 8.U.V(ultraviolet) Coating Afteroverlayingfinish,surfacemayberough grindbysandpapergrinder.Aftersurface grinding,pipeshallbecoatedbyacidresistant and U.V protective gel coat resin. After ultraviolet (U.V)coating,donottouchuntilitisthoroughly dry on the pipe surface. GILGWANG GREENTECH CO.,LTD. Title Installation Manual of GRP Pipe Above Ground Piping GILGWANG GREENTECH CO.,LTD. Re. Date2006-03-02Doc. No. Page6 PuttyL(See Note 1)30 Bevel Angle(If Required)Inside lamination (100x2 mm)(See Note 2)External reinforcing laminationt Figure 1.2 Typical Overlay Pipe SizeOverlay Length( L )mmPipe SizeOverlay Length( L )mm (DN)mm5 bar7 bar10 bar (DN)mm5 bar7 bar10 bar150100100130700270380550 200100120160800310440620 250100140200900350490700 3001201702401,000390540780 3501402002801,100430600860 4001602203101,200460650930 4501802503501,4005407601100 5002002704001,5005808101200 6002403304701,80070010001400 Note1:Therecommendedmaximumtoleranceofbuttjointgapwillnotbeoverthan below dimensions; Note 2: If necessary, over 650mm pipe may be structural laminate in pipe internal. (3mm) Nominal Pipe Sizegap (mm) For 15mm through 500mm2.0 For 600mm through 700mm2.7 For 750mm through 950mm3.6 For Lager than 1000mm4.5 GILGWANG GREENTECH CO.,LTD. Title Installation Manual of GRP Pipe Above Ground Piping GILGWANG GREENTECH CO.,LTD. Re. Date2006-03-02Doc. No. Page7 6.1.1 Alternative: overlay pack The maximum thickness of each pack is approximately 5 mm, but never more than ofthetotallaminationthickness;eachlaminationshallbemadewithatleasttwo superimposed packs, and the joining area shall be staggered. The width of the overlay shall be equal to the width of the whole wrapping. Thewidthofthewrappingcandecreaseattheouterpartofthereinforcement,but jointsinthehoopdirectionarenotallowed.Whenlayingthefiberglassplies,itis essential to create staggers between the strips, at least 25 mm wide, in order to have an overlapping joint between packs. Tissues staggering in each pack25 mmPacks overlappingTissues staggering in first pack25 mmFigure 1.3 Typical Method of Overlay Eachplyofglassreinforcementshouldbesaturatedwithresinandthepack preparedshouldberolledvigorouslysoastosqueezeoutalltheairbubblesandto ensure complete impregnation and compactness. Thepacksaturatedwithresinshouldbepeeledcarefullyfromtheworktableand thenturnedoverandappliedtothezoneofthejointsothatthelaststripisplaced against the surface of the pipe. Whenthepackisappliedonthepipe/jointsurface,makesurethatitisnotwrinkled. The next operation is the elimination of the air bubbles. GILGWANG GREENTECH CO.,LTD. Title Installation Manual of GRP Pipe Above Ground Piping GILGWANG GREENTECH CO.,LTD. Re. Date2006-03-02Doc. No. Page8 6.1.2 Branch Connection Branch connections are in two types: W ith integral sleeve reinforcement, surrounding all the main pipe; W ith pad reinforcement. DmDb Db(TYPE 1) (TYPE 2)Sleeve reinforcement Pad reinforcementFigure 1.4 Fabrication Method of TEE Thetypewithsleevereinforcementisgenerallyusedforbranchpipediameter(Db) equalorgreaterthanofthemainpipediameter(Dm).Thepaddiameteristhen used for Db< Dm. The type to be used is in any case clearly shown in the standard or job dimensional tables. Execution With External Liner Restoration Since it is not possible to work inside the pipe, the bevel shall be on the outer part and withalongtapering(taperingangle710),andreinforcementsappliedasperthe following drawings. TwoCglassveilsandtwoCSM380or480Eglassmatswillbeappliedonthe taperedsurfaces,asshownatsection6.1forbuttjoint.Inordertoincreasethe bending radius of the successive laminations, apply over the liner restoration putty or E glass mat strips resin impregnated. Warning The following drawings are not to the scale, in order to make more clear the different parts of the joint. Actually the lamination has not an uniform thickness and it is shown in the dimensional tables. GILGWANG GREENTECH CO.,LTD. Title Installation Manual of GRP Pipe Above Ground Piping GILGWANG GREENTECH CO.,LTD. Re. Date2006-03-02Doc. No. Page9 BCACCPos. "A"Key PlanDmDb