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Installation Guide For GRE Piping
Installation Guide For GRE Piping
Table of contents
1.
1.1.
1.2.
1.3.
Introduction
Scope
References
Notification
5
5
6
7
2.
2.1.
2.2.
2.3.
2.3.1.
2.3.2.
2.4.
Product introduction
Systems
Pipe fabrication process
Advantages and disadvantages of GRE compared with steel
Advantages
Disadvantages
Product identifcation
8
8
8
8
8
8
8
3.
3.1.
3.1.1.
3.1.2.
3.2.
9
9
9
10
11
4.
4.1.
4.2.
4.3.
4.4.
4.5.
4.6.
4.7.
12
12
12
13
13
14
14
14
5.
5.1.
5.1.1.
5.1.1.2.
5.1.1.3.
5.1.1.4.
5.1.2.
5.2.
5.2.1.
5.2.2.
5.2.3.
5.3.
5.3.1.
5.3.2.
15
15
15
15
16
16
16
17
17
17
17
17
17
17
6.
6.1.
6.2.
6.2.1.
6.2.2.
6.3.
6.3.1.
6.3.2.
6.3.3.
6.4.
6.4.1.
6.4.1.1.
6.4.1.2.
6.4.1.3.
6.4.1.4.
6.4.2.
6.5.
6.6.
6.7.
18
18
18
18
19
19
19
20
20
20
20
20
20
20
20
21
21
21
21
7.
7.1.
7.1.1.
7.1.2.
7.2.
7.3.
7.4.
7.5.
7.5.1.
7.5.2.
7.5.3.
7.5.4.
7.5.5.
7.6.
7.7.
22
22
22
22
23
23
24
24
24
24
24
25
25
25
25
8.
8.1.
8.2.
8.3.
26
26
26
26
9.
9.1.
9.2.
9.3.
9.3.1.
9.3.2.
9.3.3.
10.
Repair
29
11.
Tolerances
30
12.
12.1.
12.2.
12.3.
Safety precautions
Resin, hardener, adhesive and lamination sets
Cutting, shaving and sanding
Environment
31
31
31
31
13.
Importand Notice
32
27
27
27
27
27
27 - 28
28
1. Introduction
1.1. Scope
This manual gives general information about various aspects
that are relevant for the installation of Glassfiber Reinforced
Epoxy (GRE) pipe systems. Respect for the requirements,
methods and recommendations given in this guide will
contribute to a successful operating pipeline system.
Authorized, trained and certified personnel can only
contribute to a reliable pipeline system. Note that the
remarks about the various joints in this document are for
guidance only.
More specific and detailed information about underground
and aboveground installations, as well as various joining
methods, is given in manufacturers referenced documents.
1.2. References
Following documentation gives additional and detailed information about various subjects, which are described in this
manual
Chapter
Subject
Reference number
2.4
Product Identification
---
3.1
FP 167
4.1
FP 170
4.2
FP 564
4.3
---
4.4
FP 196
4.5 - 4.6
FP 161
5.1.1
FP 696
5.1.1
FP 453
5.1.1
FP 919
5.1.1
FP 454
5.1.1
FP 455
5.1.1
FP 1022
5.1.1
FP 925
5.1.1
FP 810
5.1.1.3
FP 730
It is the users responsibility to ensure that he has the latest revision of the listed documents.
Documents can be obtained via sales.service@ameron-fpg.nl
1.3. Notification
This manual provides the following information:
2. Product introduction
2.1. Systems
GRE pipeline systems are made from glass fibers, which
are impregnated with an aromatic- or cyclo-aliphatic amine
cured epoxy resin.
This thermoset resin system offers superior corrosion
resistance together with excellent mechanical, physical and
thermal properties.
The glass fiber reinforced epoxy pipeline is resistant to the
corrosive effects of mixtures with a low concentration of
acids, neutral or nearly neutral salts, solvents and caustic
substances, both under internal and external pressure.
A reinforced resin liner can protect the helical wound
continuous glass fibers of the reinforced wall of the pipes
and the structural reinforcement of the fittings internally.
2.2. Pipe fabrication process
GRE pipes are manufactured using the filament winding
method. In this mechanical process, continuous glass fiber
rovings are impregnated with epoxy resin.
The production of GRE starts with the preparation of a steel
mandrel, which may be completed with a socket mould.
The dimensions of these tools determine the inner
dimensions of the pipe, fitting and joint system.
Glass fibers are guided through a resin bath, which is filled
with epoxy resin and are wound under constant tension in a
specific pattern around the polished mandrel.
This process continues until the required wall thickness
is reached. Generally, the higher the pressure class, the
greater the wall thickness of the product will be.
The winding process ends with curing the epoxy resin in an
oven, extraction of the mandrel/ mould from the product,
finishing the product by cutting to length and machining the
ends. The products are subjected to visual and dimensional
controls as well as a hydro test.
......
..........
...
GLASS
100%
0%
30%
70%
E-GLASS
70%
30%
C-GLASS
W
AXIAL
3.1.2. Unloading
The client is responsible for unloading ordered material,
unless agreed otherwise.
Mind following:
Use nylon or canvas sling belts with a minimum width
of 100 mm
Standard pipe lengths shall be lifted at minimal two
supporting points
Fix at least one sling belt around the section with the
greatest diameter
Unload one (packed) item at a time
3.2. Storage
In order to avoid damage to GRE products, the following
recommendations shall be respected:
Provide a flat and horizontal supporting surface
Do not store the pipes directly on the ground, onto rails
or concrete floors
Ensure suitable supports such as clean, nail free
wooden beams
Machined ends must be protected (e.g. with PE-foil)
Bell and/or spigot ends may not touch each other
Pipes can be stacked economically by alternating the
orientation of spigot- and socket end
Avoid pipe bending by locating supports between the
layers of stacked pipe vertically above each other
Supports must be spaced at a maximum interval of 3 m
and 1 m from each pipe end
The allowable stacking height is 1.5 m or 2 layers,
whichever is higher
Product diameters may flatten when stacked too high
and/or too long, specially at elevated temperature
Long term storage is recommended under tarpaulins or
PE-sheets
Pipe stacks must have side supports (e.g. wooden
wedges) to prevent rolling or slipping
Unprotected flange sealing faces shall not be placed
directly on the ground or on supporting floors
Spools shall not be stacked
No other materials shall be loaded on top of GRE
products
Do not drop, walk, or stand on GRE products
Avoid point loading due to careless stacking
5.1.1.4 Others
Other non-consumables may be required such as:
5.1.2. Consumables
Consumable tools can only be used once.
Following tools are supposed to be consumable:
Measuring tape
Pair of scissors
Marker
Sand paper/grinding discs P40 P60
Brushes
Rubber scrappers, bucket
Cleaning fluids, joint lubricant
Dust masks, gloves and safety glasses
Powerpull (2x)
Pulling rings (4x)
Joint lubricant
O-ring
Band clamps (2x) Bucket with water
Screw driver
Hammer
Key
5.2. Materials
5.2.1. Adhesive
Different types of adhesive are available depending on the
application. Adhesive can be conductive or non-conductive.
An adhesive kit contains resin, hardener, mixing spatula and
bonding instructions.
Adhesive kits contain chemicals that are sensitive to
temperature and moisture.
5.2.2. O-ring
A rubber O-Ring provides sealing of the mechanical O-ring
(lock) joint. Standard O-rings are made of Nitryl Butadiene
Rubber (NBR).
Depending on the medium and/or temperature, other types
of rubber can be supplied.
O-rings must be stored properly and flat, in a dry, cool and
dark environment, free from dust and chemicals, which may
attack the material.
Direct sunlight must be avoided.
Note that highly plastic and organic soil materials are not
suitable for backfilling and must be excluded from the pipe
zone embedment.
6.6. Settlement
Flexible joints have to be installed in pairs; one joint is
placed at the beginning of the deviation while the other is
located at the end of this area, in order to create a rocker
pipe. The rocker pipe will act as a hinge.
The longer the rocker pipe, the higher the loads on the
joints. This can be avoided by adding more joints that are
flexible. Based on the soil parameters, the number of joints
is determined.
Note that the length of the sections shall be limited in order
to avoid excessive bending which may result in failure of
pipe or joint.
The section length = ID + minimal 0.5 m. Mechanical O-ring
joints shall be installed at both ends to accommodate further
settlements.
6.5. Alignment
Undulating land levels with minor difference in height can be
followed by the flexibility of the system.
Joints or pipe bending, if assessed by system design,
ensures no lateral displacement while allowing angular
deflection.
7.1. Supports
Supports not only provide system fixation, loading relief and
clinching but also protection. Prior to installation, supports
are checked for location, type and span as detailed in
drawings and specifications of the project. Supports can
be differentiated as fixed, guided sliding and free sliding
supports.
7.3. Valves
To avoid overstressing of pipes by the weight of valves
or other heavy equipment it is advised to support pipe
accessories on the flange bolts.
The load on the pipeline by operating the valve shall be
carried by the support of the pipe structure. In case of a
GRE flange mounted against a steel flange, the support is
preferably fixed to the steel flange.
Fig. 7.6. Collars on both sides of the pipe clamp
7.4. Bellows
GRE products can absorb low amplitude vibrations due to
the flexible properties of the composite material.
To eliminate high amplitude vibrations caused by e.g. pumps
and to compensate soil settlement or expansion of e.g.
tanks joined with pipes, bellows can be applied.
7.7. UV-resistance
The topcoat of GRE pipes and fittings consist of a resin rich
layer. This layer offers sufficient protection against
UV-radiation.
When exposed to weather conditions the epoxy topcoat may
be attacked on the long term; this may result in a chalked
outer surface.
After several years of operation, the chalked layer may
be removed and replaced by a resistant, protective
polyurethane paint coating. Contact the manufacturer for
advice.
1.
2.
3.
4.
5.
6.
Inspection
method
Cause
Acceptance criterion
Corrective action
Incorrect spool
dimensions
Visual
Incorrect prefabrication
Accept
Misaligned spools
Visual
Misaligned components
e.g. flanges
Accept
Movement during
cure. Incorrect shave
dimensions
Not permitted
Reject
If accessible, remove
by grinding
Impact, wear, or
abrasive damage
Visual
Incorrect transport or
handling
Leaking joint
Hydro test
Not permitted
Reject
Misaligned joint
Visual
Reject
Reject
Integrity test
The test pressure shall be increased over an agreed
duration at an agreed pressure level in order to prove the
maximum pressure resistance of the system.
Leak tightness test
The test pressure shall be increased to an agreed
pressure level at which the joints can be inspected
visually
9.3.2. Testing
Once the pressure is stabilised, the integrity of the pipe
system is tested first in accordance with agreements.
9.3.3. Depressurising
Depressurisation of the system must be carried out carefully
to avoid a negative pressure.
In the unlikely event, GRE pipes, joints and/or fittings may
have to be repaired. Repair on the pipeline system shall be
performed according described instructions.
10. Repair
The repair procedure shall be prepared and qualified by
the contractor in accordance with the pipe manufacturers
recommendations. It shall be demonstrated that the repair
method restores the specified properties.
Leaks in pipe, fittings and joints are repaired by replacing
the defective part. In some cases, especially for buried
systems, insufficient space and/or difficult accessibility to
pipes and fittings may occur.
Each application of a GRE pipe system and each type
of product or design requires a different repair and/or
replacement procedure.
For further details, reference is made to manufacturers
documentation.
11. Tolerances
It is recommended to consider and use the dimensional
tolerances illustrated and figured below.
Internal diameter mm
25 - 200
250 - 300
350 - 400
450 - 600
700 - 900
1000 - 1200
5 mm
5 mm
5 mm
10 mm
10 mm
10 mm
3 mm
3 mm
3 mm
5 mm
5 mm
5 mm
0,5
0,3
0,3
0,3
0,2
0,15
3 mm
3 mm
3 mm
3 mm
4 mm
6 mm
1 mm
1 mm
2 mm
2 mm
3 mm
3 mm
0,5
0,5
0,5
0,5
0,5
0,5
Dimension A
a) Face to face dimensions
b)
c)
Location of attachments
d)
Dimension B
Lateral translation of branches or
connections
Dimension C
Rotation of flanges, from the indicated position
Dimension D
End preparations
Dimension E
Cut of alignment of flanges from the
indicated position, measured across
the full gasket face
Dimension F
Angular deflection