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Prepared by : Anoop Manoharan
GRP Pipe Manufacturing, Inspection, Testing and Installation at site
Course Outline
Design and Build Utilities Chemicals
Objective :
To provide awareness on GRP pipe Manufacturing Processes, Inspection, Testing and installation at
site.
By the end of the programme, participants will be able to :
 Understand the manufacturing process
 Understand the minimum Inspection and Testing requirements at shop
 Understand the installation and testing requirements at site
Course intended for: All Employees
Duration: 30 minutes
Location: Microsoft Team
Training Provider: Anoop Manoharan & Basha Mujib (QA/QC Engineers)
Content
Design and Build Utilities Chemicals
1. Introduction about GRP
2. Characteristics and Advantages
3. References
4. Types of GRP
5. Material used in GRP
6. Manufacturing Process
7. Types of Joints
8. Classification of GRP
9. Shop Inspection and Testing
10. Common Defects
11. Marking & Identification
12. Packing, Handling , Storage & Transportation
13. HSE checks and controls at shop
14. Site receipt inspection and Preliminary Checks
15. Storage of GRP Pipes at site
16. Handling of Nested Pipes at site
17. Pipes laying in Trench
18. Pipes Jointing at site
19. Backfilling
20. Underground and above ground installations
21. Field Tests
22. Gel Coating
23. Quality Requirements
24. Safety Precautions
25. Conclusion
26. Q&A
Shop Activities Site Activities
Introduction
Design and Build Utilities Chemicals
What is GRP?
 GRP (Glass Reinforced Plastics) - Composite of Polymer matrix + reinforced with glass fibers.
 GRP belongs to the family of products known as FRP (Fibre Reinfornced Plastics )
Why GRP ?
Design and Build Utilities Chemicals
Characteristics and advantages :
 Long life; highly durable.
 Low maintenance cost.
 High Corrosion resistance.
 Low lifecycle cost.
 No need for cathodic protection.
 Less transportation and handling cost.
 Environmentally friendly.
 Economic when compared with DSS pipe
REFERENCES
CODES & STANDARDS
Design and Build Utilities Chemicals
International standards
 ASTM Standards - (ASTM D 2992, 2996, 2310, 3262, 3517, 3754, etc.,)
 AWWA - (AWWA C 950 & AWWA M 45)
 BS - (BS 5480, BS 7159, BS 4994, etc.,)
 UKOOA
 DIN.
Legal
 Local legislative documents and specific sections (As applicable)
Metito & Project specific
 Project Specification,
 Applicable Drawings and Data Sheets
 QA/QC Plan, ITP and Testing Procedures
 Method Statements and Risk Assessments
 Metito Standard checklist forms for Site Activities
Types of GRP
Design and Build Utilities Chemicals
Classification based on Raw material composition
Types Raw material used Application
GRUP: Glass reinforced
unsaturated polyester
Isophthalic resin /
Polyester resin + Fiber
Glass
• Temperature up to 60 º C.
• Irrigation, potable water, Sewerage,
Waster water, RO plants
GRV: Glass – fiber
reinforced vinyl ester.
Vinyl Ester Resin + Fiber
Glass
• Better mechanical and chemical
properties when compared to GRP
Pipes.
• Used for temperature up to 90 º C
GRE: Glass – fiber
reinforced epoxy.
Amine Cured Epoxy resin
+ Fiber Glass
• Temperature up to 110 º C
• Better properties than GRP/GRV
• Chemical resistance and anticorrosive
• Offshore application, Acid
transportation
Raw materials used
Design and Build Utilities Chemicals
Vinyl ester Resin Chopped strand Mat Woven Roving Mat
Direct Roving
Surface Tissue / Veil UV inhibitor
Pipe Wall Structure
Design and Build Utilities Chemicals
Manufacturing Process
Design and Build Utilities Chemicals
Manufacturing processes :
1. Discontinuous Filament Winding process (DFW)
2. Continuous Filament Winding process (CFW)
3. Centrifugal casting (CC)
Manufacturing Process
Design and Build Utilities Chemicals
1. Discontinuous Filament Winding process (DFW)
• Flexible, High Strength performance, High corrosion resistance, Good Pressure Withstanding
hydraulic performance
Helical winding Polar winding
Manufacturing Process
Design and Build Utilities Chemicals
2. Continuous Filament Winding process (CFW)
• Medium Mechanical performance
• Allows use of high percentages of fillers, siliceous aggregates and additives
• Application of the band in parallel direction (winding angle about 90 °) on a rotating collapsible
mold
Manufacturing Process
Design and Build Utilities Chemicals
3. Centrifugal casting Process (CC)
 Spraying of aggregates and reinforcing cut fibers inside a rotating drum.
 Used for Higher pipe thicknesses
Types of Joints
Design and Build Utilities Chemicals
Flanged Joint
Lamination Joint
Rubber seal lock Joint
Adhesive Joint
Types of Joints
Design and Build Utilities Chemicals
Bell and Spigot Joint Double Bell Coupling
Click here for more details regarding application of different joints
Classification of GRP Pipes
Design and Build Utilities Chemicals
GRP Pipes are mainly classified as,
1. Pressure class (PN): represents pipe’s design pressure in Bar
2. Stiffness class (SN): represents pipe's minimum initial specific
stiffness in N/m² (Pa)
NB : Other pressure class and stiffness class are also available
Inspection and Testing of GRP Pipes
Design and Build Utilities Chemicals
The most common testing used in GRP are,
1. Testing of Raw Materials
 Viscosity (cps or Pa-s) - the resistance to flow of a
liquid
 Specific Density (kg/m3) - the mass per unit volume
of a material
 Curing / Gel time (sec) - to determine the curing
characteristics / the time taken to gel on a surface at
a specified temperature
Gel Time test
Viscometer
Specific density test
Inspection and Testing of GRP Pipes
Design and Build Utilities Chemicals
2. Testing on samples for physical properties
 Stiffness Test (N/m2)- Resistance to
Deflection and Creep
 Axial Tensile Test (N/mm2) – Resistance to
axial tensile load.
 Burst Test (psi or bar)- to determine the
ultimate pressure resistance
 Loss on Ignition test (%) - determine the
ignition loss of a cured reinforced resin
sample
Stiffness Testing
Axial Tensile test
**Sample Lab test Report **Sample ITP
Burst Test
Loss on ignition test
Testing of GRP Pipes
Design and Build Utilities Chemicals
3. Testing on Finished products
 Visual Inspection
 Dimensional Inspection
 UT Thickness check (mm)
 Barcol Hardness Test (B) - measure the
degree of cure.
 Acetone Sensitivity Test- to determine
solubility or chemical resistance
 Hydrotest - to check pipe integrity
under pressure conditions
Hydrotest UT Thickness Check
Barcol Hardness Test Acetone sensitivity Test
** Sample Hydrotest report
Note: During hydrotest care must be taken to detect the seepage/
sweating through minute pores. Thorough visual inspection with
increased holding time (minimum 30 mins) shall be considered.
Dimensional check
Defects in GRP Pipes
Design and Build Utilities Chemicals
1. Visual Defects
Wrinkling Pinhole
Poor adhesion of the Gel Coat
Blister's
Star crazing / cracking
The most found visual defects on GRP pipes are,
** Refer Acceptance as per ASTM D 2563
Defects in GRP Pipes
Design and Build Utilities Chemicals
2. Defect observed during manufacturing
Seepage / sweating noticed on pipe surface through minute pores during
hydrotest
Root Cause: Uneven polymerization due to higher speed of production of pipe
Correction done: Defective pipes rejected and replaced with new ones
Corrective action:
• Calibration of machine done
• Speed chart is pasted near to machine for ready reference.
• Continuous Monitoring required by Production and QC Engineer
Handling, Transportation & Storage of GRP Pipes
Design and Build Utilities Chemicals
 Not only for protection of pipes but also for the safety of the personnel handling them.
 Avoid direct contact of Lifting accessories (Metal chains, Metallic slings, hooks) with GRP
items.
 Use Wide band webbed slings of polypropylene, nylon or similar material.
 Obtain Lifting permits (if required)
 Onload /Offload one pipe at a time
 Do not drop or drag or rolled on the ground
Handling:
Handling, Transportation & Storage of GRP Pipes
Design and Build Utilities Chemicals
 Use Flat bed Trailers.
 Use supports (free of sharp edges or projection)
 Evenly support over their full length
 Do not overhang the vehicle
Transportation:
Handling, Transportation & Storage of GRP Pipes
Design and Build Utilities Chemicals
 Only on flat even grounds
 Away from sharp projections
 Adequate space for movement of lifting equipment
 Protected from direct sunlight for long period of storage.
 Never place in contact with lubricating oil, gasoline and solvents.
 Away from exhaust outlet and other high temp. sources
Storage:
HSE Hazards and Controls at Manufacturer Shop
Design and Build Utilities Chemicals
Common Hazards
 Resins are highly flammable and explosive
 Irritation to skin, eyes, nose and throat
 Excessive inhalation may cause dizziness, drowsiness, loss of
consciousness, cardiac irregularities.
Control Measures
 Use Proper PPEs (dust / vapor mask, safety glass, rubber gloves,
long sleeved shirt, long pants, safety hat, shoes, etc..)
First Aid measures
 If inhaled take victim to fresh air
 Flush eye with flowing water
 Wash skin with soap
 Take medical aid in case of severity
Site Receipt Inspection & Preliminary Checks
Design and Build Chemicals
Utilities
Site receipt Inspections
 Ensure no damages occurred during transit
 Check the quantity
 Verify the spool numbers against the Delivery Note.
 Verify inspection reports.
Preliminary Checks
 Approved documents are available (Piping and trench backfilling Material submittal, Method
Statement, Drawings & RA, EA, PQP, HSEP, ITP)
 Piping route is clear of obstructions, existing services (if any) are well protected.
 Approved subcontractor and competent Engineers, HSE team are available
 Obtain permit to work
Storage of GRP Pipes at Site
Design and Build Chemicals
Utilities
The pipes shall be stored on an even surface. The stacking height depends on
the soil conditions as well as the loading and safety equipment on site as below table
Handling of Nested Pipes at Site
Design and Build Chemicals
Utilities
GRP pipes may be delivered nested (i.e., one or more small pipes inside a larger pipe). Nested
pipes must always be lifted using at least two straps or slings. De-nesting is accomplished
by inserting a forklift/mobile crane boom. Proper padding is essential on the boom.
Pipe Laying Trench Requirements
Design and Build Chemicals
Utilities
Standard Trench
 The trench preparation must comply to approved drawing.
 Foundation & Bedding (soil/gravel or any other forms) as per project specification.
 Side support must provide with shoring or trench box in case excavated soil is not intact but loose.
Multiple Pipes
 Pipes must be laid in the same bottom level.
 The clear spacing between adjacent pipes must be as per below given table.
Pipe Laying Trench Requirements
Design and Build Chemicals
Utilities
Trench Excavation Below Water Table
Dewatering process must be carried out to
ensure trench is dry prior laying the pipeline.
Trench supported with Trench Box
Side support must provide with shoring or
trench box in case excavated soil is not intact
but loose.
Various Underground Installations-Road Crossings
Design and Build Chemicals
Utilities
Pipe Laying
Trench preparation
Various Underground Installations
Design and Build Chemicals
Utilities
Pipes Joining at Site
Design and Build Chemicals
Utilities
Coupling Cleaning Gasket Installation &
Lubricating
Spigots Cleaning and Lubrication
Fixing of Clamps Coupling Joining Pipe Misalignment
Pipes Joining at Site-Lamination Method
Design and Build Chemicals
Utilities
Grinding & Sanding Alignment Resin+Woven Ring application After curing
Pipes Joining at Site
Design and Build Chemicals
Utilities
Fast Curing of Pipe joints using Heating Blanket @1300C or as per specs
Pipes & Fittings Joining at Site-Flanged Joints
Design and Build Chemicals
Utilities
GRP Fixed Flange. Flat Face
Bolting:
 Flange tightening sequence as per pic.1
 Torquing depends on Bolt standard or manufacturer recommendation
 Don’t overdo it to damage base material as well as gaskets
Pic.1
Backfilling
Design and Build Chemicals
Utilities
 Backfilling shall be performed as per client
specification
 Degree of compaction and FDT Tests shall carryout
as per client specification
 Ensure warning tape installed during backfilling
Various Aboveground Installations-Wall Embedded
Design and Build Chemicals
Utilities
Various Aboveground Installations-Skids
Design and Build Chemicals
Utilities
 As per approved Isometric, PID or GA
 supports and clamps are checked for location,
type and span
 GRE flange mounted against a steel valve flange;
the support is preferably fixed to the steel flange.
 All MEICA Items are installed as per PID
 Pipes shall be identified, tagged, color banded,
flow direction marked (if any)
Installation of aboveground pipe systems
Design and Build Chemicals
Utilities
Valve supports Bellow supports
Field Tests after jointing
Design and Build Chemicals
Utilities
Barcol Hardness Test -ASTM D2583
 To determine the hardness of site laminated
joints.
 Degree of hardness depends on the resin
used or by manufacturer recommendation.
Field Tests-Pipe Deflection Test
Design and Build Chemicals
Utilities
**Deflection test sample report
Field Hydrotest
Design and Build Chemicals
Utilities
Piping Hydrotest Test pre-checks
 Pipeline system inside shall be clear of foreign particles, debris, grease etc.,
 All joining procedures and client inspections shall be completed.
 Trenches should be sufficiently backfilled, and joints should be left exposed.
 All supports, guides, and (temporary) anchors shall be in place
 Flange bolts shall be made up to the correct torque.
 Calibrated PG; media filling and disposal area must be agreed from client
 ITP, Method statement including test packs must be approved
 HSE requirements shall be respected.
Field Tests-Leak Test
Design and Build Chemicals
Utilities
Piping Leak Tightness Test Piping Hydrotest Test
Gel Coating
Design and Build Chemicals
Utilities
GRP Gel coated to improve UV and chemical resistance, for color coding of piping and vessels, or for
aesthetics.
Tolerance Chart
Design and Build Chemicals
Utilities
 Tolerance chart for dimension control these
might vary project wise.
 Ensure only competent workers executing
the FRP works
 Ensure only latest approved drawings are
used
 Check for resins shelf life prior to application
Safety precautions
Design and Build Chemicals
Utilities
 Obtain Permit to work
 Work must be carried out strictly under the supervision of
HSE
 Toolbox talks must be carried out at site.
 Proper ventilation must be provided to avoid irritation of
the respiratory system
 Safety precautions must be followed during hydrotest
 GRP material must be protected from hot works
 Comply to confined space requirements and always check
gas detector
 When cutting or grinding GRE materials proper personal
protection is necessary to protect eyes and skin
• A dust mask covering nose and mouth.
• A pair of safety goggles, Gloves and overall.
• Overall sleeves to keep the dust out.
• Protective clothing to protect the body.
SUMMARY
Design and Build Utilities Chemicals
BE Aware of GRP manufacturing process, inspection and tests involved
BE Ahead of manufacturer’s knowledge
BE Able to identify the defects
KNOW the specification and standards
KNOW drawing and design requirements
KNOW the controls and check points
DO Follow Method Statement and Risk Assessment
DO not take short cut – Short cut causes rework
DO not work hard – WORK SMART
In Summary BE…KNOW…DO!
CONCLUSION
Design and Build Utilities Chemicals
In this training – if this is followed what can we expect to see from attendees?
1. Activities involved in Manufacturing and installation of GRP pipes.
2. Understands HSE Risks involved and control measures to be implemented
3. Monitor and carryout Inspections and Tests
QUESTIONS & ANSWERS
Design and Build Utilities Chemicals
Design and Build Utilities Chemicals

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PPT on GRP pipes manufacturing and testing

  • 1. Prepared by : Anoop Manoharan GRP Pipe Manufacturing, Inspection, Testing and Installation at site
  • 2. Course Outline Design and Build Utilities Chemicals Objective : To provide awareness on GRP pipe Manufacturing Processes, Inspection, Testing and installation at site. By the end of the programme, participants will be able to :  Understand the manufacturing process  Understand the minimum Inspection and Testing requirements at shop  Understand the installation and testing requirements at site Course intended for: All Employees Duration: 30 minutes Location: Microsoft Team Training Provider: Anoop Manoharan & Basha Mujib (QA/QC Engineers)
  • 3. Content Design and Build Utilities Chemicals 1. Introduction about GRP 2. Characteristics and Advantages 3. References 4. Types of GRP 5. Material used in GRP 6. Manufacturing Process 7. Types of Joints 8. Classification of GRP 9. Shop Inspection and Testing 10. Common Defects 11. Marking & Identification 12. Packing, Handling , Storage & Transportation 13. HSE checks and controls at shop 14. Site receipt inspection and Preliminary Checks 15. Storage of GRP Pipes at site 16. Handling of Nested Pipes at site 17. Pipes laying in Trench 18. Pipes Jointing at site 19. Backfilling 20. Underground and above ground installations 21. Field Tests 22. Gel Coating 23. Quality Requirements 24. Safety Precautions 25. Conclusion 26. Q&A Shop Activities Site Activities
  • 4. Introduction Design and Build Utilities Chemicals What is GRP?  GRP (Glass Reinforced Plastics) - Composite of Polymer matrix + reinforced with glass fibers.  GRP belongs to the family of products known as FRP (Fibre Reinfornced Plastics )
  • 5. Why GRP ? Design and Build Utilities Chemicals Characteristics and advantages :  Long life; highly durable.  Low maintenance cost.  High Corrosion resistance.  Low lifecycle cost.  No need for cathodic protection.  Less transportation and handling cost.  Environmentally friendly.  Economic when compared with DSS pipe
  • 6. REFERENCES CODES & STANDARDS Design and Build Utilities Chemicals International standards  ASTM Standards - (ASTM D 2992, 2996, 2310, 3262, 3517, 3754, etc.,)  AWWA - (AWWA C 950 & AWWA M 45)  BS - (BS 5480, BS 7159, BS 4994, etc.,)  UKOOA  DIN. Legal  Local legislative documents and specific sections (As applicable) Metito & Project specific  Project Specification,  Applicable Drawings and Data Sheets  QA/QC Plan, ITP and Testing Procedures  Method Statements and Risk Assessments  Metito Standard checklist forms for Site Activities
  • 7. Types of GRP Design and Build Utilities Chemicals Classification based on Raw material composition Types Raw material used Application GRUP: Glass reinforced unsaturated polyester Isophthalic resin / Polyester resin + Fiber Glass • Temperature up to 60 º C. • Irrigation, potable water, Sewerage, Waster water, RO plants GRV: Glass – fiber reinforced vinyl ester. Vinyl Ester Resin + Fiber Glass • Better mechanical and chemical properties when compared to GRP Pipes. • Used for temperature up to 90 º C GRE: Glass – fiber reinforced epoxy. Amine Cured Epoxy resin + Fiber Glass • Temperature up to 110 º C • Better properties than GRP/GRV • Chemical resistance and anticorrosive • Offshore application, Acid transportation
  • 8. Raw materials used Design and Build Utilities Chemicals Vinyl ester Resin Chopped strand Mat Woven Roving Mat Direct Roving Surface Tissue / Veil UV inhibitor
  • 9. Pipe Wall Structure Design and Build Utilities Chemicals
  • 10. Manufacturing Process Design and Build Utilities Chemicals Manufacturing processes : 1. Discontinuous Filament Winding process (DFW) 2. Continuous Filament Winding process (CFW) 3. Centrifugal casting (CC)
  • 11. Manufacturing Process Design and Build Utilities Chemicals 1. Discontinuous Filament Winding process (DFW) • Flexible, High Strength performance, High corrosion resistance, Good Pressure Withstanding hydraulic performance Helical winding Polar winding
  • 12. Manufacturing Process Design and Build Utilities Chemicals 2. Continuous Filament Winding process (CFW) • Medium Mechanical performance • Allows use of high percentages of fillers, siliceous aggregates and additives • Application of the band in parallel direction (winding angle about 90 °) on a rotating collapsible mold
  • 13. Manufacturing Process Design and Build Utilities Chemicals 3. Centrifugal casting Process (CC)  Spraying of aggregates and reinforcing cut fibers inside a rotating drum.  Used for Higher pipe thicknesses
  • 14. Types of Joints Design and Build Utilities Chemicals Flanged Joint Lamination Joint Rubber seal lock Joint Adhesive Joint
  • 15. Types of Joints Design and Build Utilities Chemicals Bell and Spigot Joint Double Bell Coupling Click here for more details regarding application of different joints
  • 16. Classification of GRP Pipes Design and Build Utilities Chemicals GRP Pipes are mainly classified as, 1. Pressure class (PN): represents pipe’s design pressure in Bar 2. Stiffness class (SN): represents pipe's minimum initial specific stiffness in N/m² (Pa) NB : Other pressure class and stiffness class are also available
  • 17. Inspection and Testing of GRP Pipes Design and Build Utilities Chemicals The most common testing used in GRP are, 1. Testing of Raw Materials  Viscosity (cps or Pa-s) - the resistance to flow of a liquid  Specific Density (kg/m3) - the mass per unit volume of a material  Curing / Gel time (sec) - to determine the curing characteristics / the time taken to gel on a surface at a specified temperature Gel Time test Viscometer Specific density test
  • 18. Inspection and Testing of GRP Pipes Design and Build Utilities Chemicals 2. Testing on samples for physical properties  Stiffness Test (N/m2)- Resistance to Deflection and Creep  Axial Tensile Test (N/mm2) – Resistance to axial tensile load.  Burst Test (psi or bar)- to determine the ultimate pressure resistance  Loss on Ignition test (%) - determine the ignition loss of a cured reinforced resin sample Stiffness Testing Axial Tensile test **Sample Lab test Report **Sample ITP Burst Test Loss on ignition test
  • 19. Testing of GRP Pipes Design and Build Utilities Chemicals 3. Testing on Finished products  Visual Inspection  Dimensional Inspection  UT Thickness check (mm)  Barcol Hardness Test (B) - measure the degree of cure.  Acetone Sensitivity Test- to determine solubility or chemical resistance  Hydrotest - to check pipe integrity under pressure conditions Hydrotest UT Thickness Check Barcol Hardness Test Acetone sensitivity Test ** Sample Hydrotest report Note: During hydrotest care must be taken to detect the seepage/ sweating through minute pores. Thorough visual inspection with increased holding time (minimum 30 mins) shall be considered. Dimensional check
  • 20. Defects in GRP Pipes Design and Build Utilities Chemicals 1. Visual Defects Wrinkling Pinhole Poor adhesion of the Gel Coat Blister's Star crazing / cracking The most found visual defects on GRP pipes are, ** Refer Acceptance as per ASTM D 2563
  • 21. Defects in GRP Pipes Design and Build Utilities Chemicals 2. Defect observed during manufacturing Seepage / sweating noticed on pipe surface through minute pores during hydrotest Root Cause: Uneven polymerization due to higher speed of production of pipe Correction done: Defective pipes rejected and replaced with new ones Corrective action: • Calibration of machine done • Speed chart is pasted near to machine for ready reference. • Continuous Monitoring required by Production and QC Engineer
  • 22. Handling, Transportation & Storage of GRP Pipes Design and Build Utilities Chemicals  Not only for protection of pipes but also for the safety of the personnel handling them.  Avoid direct contact of Lifting accessories (Metal chains, Metallic slings, hooks) with GRP items.  Use Wide band webbed slings of polypropylene, nylon or similar material.  Obtain Lifting permits (if required)  Onload /Offload one pipe at a time  Do not drop or drag or rolled on the ground Handling:
  • 23. Handling, Transportation & Storage of GRP Pipes Design and Build Utilities Chemicals  Use Flat bed Trailers.  Use supports (free of sharp edges or projection)  Evenly support over their full length  Do not overhang the vehicle Transportation:
  • 24. Handling, Transportation & Storage of GRP Pipes Design and Build Utilities Chemicals  Only on flat even grounds  Away from sharp projections  Adequate space for movement of lifting equipment  Protected from direct sunlight for long period of storage.  Never place in contact with lubricating oil, gasoline and solvents.  Away from exhaust outlet and other high temp. sources Storage:
  • 25. HSE Hazards and Controls at Manufacturer Shop Design and Build Utilities Chemicals Common Hazards  Resins are highly flammable and explosive  Irritation to skin, eyes, nose and throat  Excessive inhalation may cause dizziness, drowsiness, loss of consciousness, cardiac irregularities. Control Measures  Use Proper PPEs (dust / vapor mask, safety glass, rubber gloves, long sleeved shirt, long pants, safety hat, shoes, etc..) First Aid measures  If inhaled take victim to fresh air  Flush eye with flowing water  Wash skin with soap  Take medical aid in case of severity
  • 26. Site Receipt Inspection & Preliminary Checks Design and Build Chemicals Utilities Site receipt Inspections  Ensure no damages occurred during transit  Check the quantity  Verify the spool numbers against the Delivery Note.  Verify inspection reports. Preliminary Checks  Approved documents are available (Piping and trench backfilling Material submittal, Method Statement, Drawings & RA, EA, PQP, HSEP, ITP)  Piping route is clear of obstructions, existing services (if any) are well protected.  Approved subcontractor and competent Engineers, HSE team are available  Obtain permit to work
  • 27. Storage of GRP Pipes at Site Design and Build Chemicals Utilities The pipes shall be stored on an even surface. The stacking height depends on the soil conditions as well as the loading and safety equipment on site as below table
  • 28. Handling of Nested Pipes at Site Design and Build Chemicals Utilities GRP pipes may be delivered nested (i.e., one or more small pipes inside a larger pipe). Nested pipes must always be lifted using at least two straps or slings. De-nesting is accomplished by inserting a forklift/mobile crane boom. Proper padding is essential on the boom.
  • 29. Pipe Laying Trench Requirements Design and Build Chemicals Utilities Standard Trench  The trench preparation must comply to approved drawing.  Foundation & Bedding (soil/gravel or any other forms) as per project specification.  Side support must provide with shoring or trench box in case excavated soil is not intact but loose. Multiple Pipes  Pipes must be laid in the same bottom level.  The clear spacing between adjacent pipes must be as per below given table.
  • 30. Pipe Laying Trench Requirements Design and Build Chemicals Utilities Trench Excavation Below Water Table Dewatering process must be carried out to ensure trench is dry prior laying the pipeline. Trench supported with Trench Box Side support must provide with shoring or trench box in case excavated soil is not intact but loose.
  • 31. Various Underground Installations-Road Crossings Design and Build Chemicals Utilities Pipe Laying Trench preparation
  • 32. Various Underground Installations Design and Build Chemicals Utilities
  • 33. Pipes Joining at Site Design and Build Chemicals Utilities Coupling Cleaning Gasket Installation & Lubricating Spigots Cleaning and Lubrication Fixing of Clamps Coupling Joining Pipe Misalignment
  • 34. Pipes Joining at Site-Lamination Method Design and Build Chemicals Utilities Grinding & Sanding Alignment Resin+Woven Ring application After curing
  • 35. Pipes Joining at Site Design and Build Chemicals Utilities Fast Curing of Pipe joints using Heating Blanket @1300C or as per specs
  • 36. Pipes & Fittings Joining at Site-Flanged Joints Design and Build Chemicals Utilities GRP Fixed Flange. Flat Face Bolting:  Flange tightening sequence as per pic.1  Torquing depends on Bolt standard or manufacturer recommendation  Don’t overdo it to damage base material as well as gaskets Pic.1
  • 37. Backfilling Design and Build Chemicals Utilities  Backfilling shall be performed as per client specification  Degree of compaction and FDT Tests shall carryout as per client specification  Ensure warning tape installed during backfilling
  • 38. Various Aboveground Installations-Wall Embedded Design and Build Chemicals Utilities
  • 39. Various Aboveground Installations-Skids Design and Build Chemicals Utilities  As per approved Isometric, PID or GA  supports and clamps are checked for location, type and span  GRE flange mounted against a steel valve flange; the support is preferably fixed to the steel flange.  All MEICA Items are installed as per PID  Pipes shall be identified, tagged, color banded, flow direction marked (if any)
  • 40. Installation of aboveground pipe systems Design and Build Chemicals Utilities Valve supports Bellow supports
  • 41. Field Tests after jointing Design and Build Chemicals Utilities Barcol Hardness Test -ASTM D2583  To determine the hardness of site laminated joints.  Degree of hardness depends on the resin used or by manufacturer recommendation.
  • 42. Field Tests-Pipe Deflection Test Design and Build Chemicals Utilities **Deflection test sample report
  • 43. Field Hydrotest Design and Build Chemicals Utilities Piping Hydrotest Test pre-checks  Pipeline system inside shall be clear of foreign particles, debris, grease etc.,  All joining procedures and client inspections shall be completed.  Trenches should be sufficiently backfilled, and joints should be left exposed.  All supports, guides, and (temporary) anchors shall be in place  Flange bolts shall be made up to the correct torque.  Calibrated PG; media filling and disposal area must be agreed from client  ITP, Method statement including test packs must be approved  HSE requirements shall be respected.
  • 44. Field Tests-Leak Test Design and Build Chemicals Utilities Piping Leak Tightness Test Piping Hydrotest Test
  • 45. Gel Coating Design and Build Chemicals Utilities GRP Gel coated to improve UV and chemical resistance, for color coding of piping and vessels, or for aesthetics.
  • 46. Tolerance Chart Design and Build Chemicals Utilities  Tolerance chart for dimension control these might vary project wise.  Ensure only competent workers executing the FRP works  Ensure only latest approved drawings are used  Check for resins shelf life prior to application
  • 47. Safety precautions Design and Build Chemicals Utilities  Obtain Permit to work  Work must be carried out strictly under the supervision of HSE  Toolbox talks must be carried out at site.  Proper ventilation must be provided to avoid irritation of the respiratory system  Safety precautions must be followed during hydrotest  GRP material must be protected from hot works  Comply to confined space requirements and always check gas detector  When cutting or grinding GRE materials proper personal protection is necessary to protect eyes and skin • A dust mask covering nose and mouth. • A pair of safety goggles, Gloves and overall. • Overall sleeves to keep the dust out. • Protective clothing to protect the body.
  • 48. SUMMARY Design and Build Utilities Chemicals BE Aware of GRP manufacturing process, inspection and tests involved BE Ahead of manufacturer’s knowledge BE Able to identify the defects KNOW the specification and standards KNOW drawing and design requirements KNOW the controls and check points DO Follow Method Statement and Risk Assessment DO not take short cut – Short cut causes rework DO not work hard – WORK SMART In Summary BE…KNOW…DO!
  • 49. CONCLUSION Design and Build Utilities Chemicals In this training – if this is followed what can we expect to see from attendees? 1. Activities involved in Manufacturing and installation of GRP pipes. 2. Understands HSE Risks involved and control measures to be implemented 3. Monitor and carryout Inspections and Tests
  • 50. QUESTIONS & ANSWERS Design and Build Utilities Chemicals
  • 51. Design and Build Utilities Chemicals