CONSORTIUM OF :

Methode Installation FRP Pipes and Fitting

Document No : Origin Rev No. Contract No :
ML-PR001-COW-CPRO-0042 RS 0 L-30030-00
PT. JURONG ENGINEERING LESTARI

PROJECT : MUARA LABOH GEOTHERMAL POWER PROJECT - EPC

CONTRACT FOR STAGE 1 DEVELOPMENT
EMPLOYER : PT.SUPREME ENERGY MUARA LABOH (SEML)
LOCATION : MUARA LABOH, SOUTH SOLOK, WEST SUMATERA

0 03/08/2018 Issue for Information BA AK AK

Rev Date Description PREP CHECK APPROVED
JEL
 Methode Installation FRP Pipes and Fitting

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TABLE OF CONTENTS
1. INTRODUCTION .......................................................................................................................................3
1.1. SCOPE ............................................................................................................................................3
2. PRODUCT INTRODUCTION .................................................................................................................3
3. MATERIAL HANDLING, STORAGE, LIFTING AND TRANSPORTATION .............................4
4. JOINING SYSTEM .....................................................................................................................................9
5. TOOLS AND EQUIPMENTS ............................................................................................................... 14
6. INSTALLATION OF UNDERGROUND PIPE ................................................................................. 15
7. ABOVEGROUND INSTALLATION OF GRP PIPE ........................................................................ 22
8. HARDNESS CHECK............................................................................................................................... 24
9. HYDROTESTING( LEAK TEST )....................................................................................................... 24
10. QUALITY CONTROL ............................................................................................................................. 25
11. REPAIR ..................................................................................................................................................... 25
12. SAFETY RECOMMENDATION .......................................................................................................... 28
13. ATTACHMENT ....................................................................................................................................... 32
13.1. TOOL AND EQUIPMENT FOR BUTT AND WRAP JOINT GRP PIPE ..................... 32

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1. INTRODUCTION
1.1. SCOPE
This specification cover filament wound (FW) fiberglass reinforced pipe (FRP) and
contactMold/mitered fittings with vinylester resin system.
SPECIFICATIONS AND STANDARDS
Reference is made in this specification to the latest edition, revision or addendum of the
following standards:
ASTM D2996 Specification for Filament Wound Reinforced Thermosetting resin
Pipe
ASME B31.1 Fiberglass Pressure Pipe
ASME RTP‐1 Reinforced Thermoset Plastic Corrosion – Resistant Equipment
BS 7159 Design and Construction of glass reinfoeced plastics (GRP) piping
systems for individual plants or sites
BS 4994 Design and Construction of vessels and tanks in reinfoeced plastics
ISO 14692 Petroleum And Natural Gas Industries ‐Glass Reinforced Plastic
(GRP) piping‐ Parts 1, 2, 3 & 4
2. PRODUCT INTRODUCTION
2.1. DESIGN & CONDITION
a. Service : Geothermal Condensate and River Water Mixture
b. Design Pressure : 5,5 Bar & Full Vacum
c. Installation : Above ground and Under ground
2.2. FABRICATION METHODS
Pipe furnished to this specification shall be produced by the filament winding (FW)
method and fittings shall be produced by contact molding, mitering or filament winding.
2.3. PRODUCT CONFIGURATION
a. The pipe, fittings and flanges shall consist of fiberglass reinforced thermosetting
vinylester resin (FRP). No flexible resin will be used.
b. The fiberglass reinforced vinylester resin material combined in a composite structure
shall meet the performance requirements of this specification.
c. Pipe corrosion ressistant liner : vinylester Resin with C‐glass

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d. Top Coating : contain anti UV protection which shall be maintained every five years of
application or manufacturers recommended

e. Pipes
All pipes shall have plain ends for butt and wrap joint. The corrosion resistant liner of
2,3 mm and Anti‐UV top coat layer is included in the minimum pipe wall thickness, as
described in thickness calculation and product drawing.
f. Fittings
Fittings will bemitered or contact molded with following end configurations:
 Elbow – PE X PE
 Tee - PE X PE X PE
 Tee Branch – PE
 Reducer - PE X PE
 Tee Reducer - PE X PE X PE
 Stub Flange – FF X PE
Where : PE = Plain End
FF = Flat Face

3. MATERIAL HANDLING, STORAGE, LIFTING AND TRANSPORTATION

3.1. HANDLING

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ORI PIPE is a high performance product and must be handled with care. Improper
handling may cause damage to the product that may not be necessarily be visible to the
naked eye.
The following recommendations are made to protect the FRP pipe and fittings against
damage:
 End protection of piping components shall remain in place during handling and
transportation.

 FRP pipe and fittings shall be handled with care and protected from impact. Throwing,
dropping, bumping or hitting the FRP pipe and the fittings is prohibited. FRP pipes shall
not be dragged or pushed over sharp objects that may scratch or damage the pipe.
 Forks of forklift trucks used in the handling of FRP products must be padded with
adequate cushion material such as rubber sheet, nylon pad or its equivalent

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 Use PP or PE handling sling to lift the Pipe, as the steel sling or other sharp material may
damage the pipe surface. Check the centre of gravity of pipe or package prior lifting.
3.2. TRANSPORTATION
In case of transportation in containers, FRP products are packed in a manner that damage
during transportation will be prevented.
Where FRP products are taken out of the containers, the following should be observed:
 Do not let the FRP pipe rest on floor of the container where nails, studs or other sharp
object might damage it.
 The FRP pipe shall be securely fastened directly over the timbers with tie‐downs
such steel slings with PE hose protection.
 No foreign materials shall be loaded in the FRP pipe or on the top of pipes that will
damage the pipe.
 Do not drop the FRP product, walk or stand on it
 When stacking 12 m length pipe, a minimum of 4 wooden supports must be used to
separate each length.

 Do not allow the FRP pipe to extend more than 4 meters from surface level to prevent
excessive bowing (according to local transport regulation).

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3.3. LIFTING
When the FRPpipe has to be lifted, e.g. during assembling, the following has to be taken
in to account:
When the FRP pipe is withdrawn from stock it shall either be lifted carefully by hand or
where mechanical lifting is required, canvas or nylon slings are to be used.
No steel chain or wire ropes shall be used for lifting FRP components.
Short FRP pipe sections up to three (3) meter in length may be lifted with crane using
one sling. Longer sections may be lifted with a three (3) meter spreader bar using two
slings.Twelve (12) meter long sections may be lifted with a six (6) meter spreader bar
with two slings.

One pointsling lifting for pipe not more than three (3) meter length pipe.

Caution: each row of pipes shall be tied down properly to make sure the pipe in firm condition.

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Lifting in a group
Cartons can be lifted by hand or in case of palette cartons, a forklift truck may be used.
Dothrow or dropthe cartons.
3.4. STORAGE
Storage of piping components may be required prior to fabrication and installation.
Special precautions to avoid damage to any piping components shall be taken.
Consideration shall be given to the state of the storage surface (no weaving of sharp
projection objects).
a. Storage of FRP pipes
FRP pipe may be safely stored outside for extended periods provided the following
recommended storage procedure be observed:
 Support shall be spaced at three (3) meter intervals and approximately not more
than 1½ meter from each end.
 The supports should have a minimum 100 mm wide bearing surface. The supports
(timbers) used in the container can be used for this purpose at the storage area.
 Pipe should not be stacked exceeding three (3) meter height and should have side
supports or blocks to prevent rolling or slipping in the stack.
 It is not recommended to place pipes directly on the ground
b. Storage of FRP Fittings
Fittings shall be removed from shipping cartons, closely inspected and stored on
shelves. For large fittings that require forklift for handling, the fitting shall be stored
and properly secured on wooden pallet. Storage inside a warehouse is preferred.
c. Storage of FRP pipe spools

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Pipe spools shall be stored with temporary protection in place. If possible, pipe spools
shall be stored in the original packing and shipping skid. When spools are stacked
after receiving inspection, sufficient wood spacers shall be placed in between layer.
Pipe spools shall be stored in such a way that spools can be easily identified, located
and taken away when the specific spool is required for installation.
d. Handling and Storage Glass Material
Cartons containing of glass fiber material should be storage on pallets. Stowing
material must have smooth surface without sharp edges. Cartons should be handled
with care and with the appropriate equipment in order to prevent any damage. It is
recommended that the material is storage in a cool, dry area in which the
temperature should not exceed 35°C and the relative humidity should be maintained
below 75%. Material should remain in its original packaging until immediately before
use.
It is advise that stock rotation of the material is exercised. However, if the above
conditions are respected, the material is guaranteed against significant deterioration
for a period of three years. A Material Safety Data Sheet is Attach.
e. Handling and Storage Resin Material.
This resin contains ingredients which could be harmful if mishandle. Contact with
skin and eyes should be avoided and necessary protective equipment and clothing
should be worn. Material Safety Data Sheets contains health and safety information
for your development of appropriate product handling procedures to protect
employees and customers. Material Safety Data Sheets should be read and
understood by all of supervisory personnel and employees before using resin
material.
f. Recommended Storage.
Drums – storage at temperature below 25°C. Storage life decreases with increasing
storage temperature. Avoid exposure to heat sources such as direct sunlight or steam
pipes. To avoid contamination of product with water, do not storage outdoors. Keeps
sealed to prevent moisture pick‐up and monomer loss. Rotate stock.
4. JOINING SYSTEM
4.1. BUTT & WRAP JOINTS

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Joints will be butt & wrap joints. This procedure cover the butt and wrap joint system
for GRV pipe and fittings with vinylester resin system only. The butt joints are made in
accordance with this process description containing pipe segments and fittings.
4.2. REFERENCE DOCUMENT
Document Title
 Resin Mixing Procedure
 Butt & Wrap Joint Check Sheet
 Product Drawing
 Inspection and Test Procedure
4.3. MATERIALS FOR CONSTRUCTION
a. Glass
Material Weight
C‐Veil, C‐glass 30 g/m2
Woven Roving, 600 and/or 800 g/m2
CSM, 300 and/or 450 g/m2
b. Typical Resin Formulation & Gel time
For Putty:
Resin type : Vinylester
Thixotropic : 1% CSM + 12% Rhodoline
Hardener type : MEKP
For Lamination Lay‐up :
Resin type : Vinylester
Hardener type : MEKP
For Top Coating :
Resin type : Vinylester Anti‐oxidant : Wax Solution
UV Retardant : Tinuvin® P Hardener type : MEKP

Note: *)
To simplify the application on site, resin sent to the site usually
already promoted. Simply add catalyst / hardener and mix prior to
use.

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For this inquiry and more detail in resin formulation, please see our Resin Mixing
Procedure.
4.4. MIXING PROCEDURE
a. All tools and container for mixing must be clean and dry.
b. For preparation of Putty, Hand Lay‐up Lamination resin and UV Top Coating resin,
refer to Resin Mixing Procedure.
4.5. HAND LAY‐UP LAMINATION PROCEDURE
a. Prepare all tools and glass materials required for the lamination including Resin,
Hardener and glass material. The pipe section to be cut shall be marked using a
marker or masking tape. Ensure that the squareness of the cut has been properly
made. Prior to commencement of butt and wrap, the parts to be connected must be
dried thoroughly.

b. Grind and clean the external area in way of the lamination surface covering its
entire lamination length. Ensure that the pipe ends are also grinded.

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c. Two reference points at each side (taken from centre of joints) shall be marked to
ensure that the laminator can locate the centre of the joint during laying of glass
materials.
d. Outer surface of the pipe to be joined must be completely cleaned and the grinding to
a layer of top coat removed 1). The tolerances on gap between cut ends and
misalignment

Tabel.1 Reference for Length of external grinding area for lamination

1. Top coat approximately ± 0.2 mm shall be removed before apply joint
lamination.
2. Dimension refer to Butt & Wrap Product Drawing
3. Length of B&W grinding area for lamination (Le/Li) should be minimum 50
mm wider for pipe and fittings diameter up to DN300 (25 mm both side) than
B&W lamination width (We/Wi). Length of B&W grinding area for lamination
(Le/Li) should be minimum 100 mm wider for pipe and fittings diameter
above DN300 (50 mm both side) than B&W lamination width (We/Wi).
4. Internal Lamination only applied DN 600 ≥, for Nominal Diameter under
600mm no need to be applied internal lamination due to no access for
lamination work, no space available inside pipe.
e. To prevent any movement during setting, pipes and/or fittings can be joined to
temporary support fixing equipment. Check the flanges bolt, holes orientation,
levelness, etc. prior to tacking by resin putty. Extruded putty must not exceed 10mm
or 5% of the pipe diameter. This ensures that putty is not extruded into the pipe’s

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bore until the extend that significant blockage is created. Tacking is done by adding
resin putty around the circumference and allowing it to cure at ambient temperature.

All glass material shall be checked to ensure it cleanliness with no evidence of

moisture contamination, the correct width, density, temperature, etc shall also be
recorded.
f. Prepare resin mix with correct mixing ratio (take note of the pot‐life after mixing).
For environmental controls refer to Resin Mixing Procedure. The quantity of mix
depends on the diameter. Be sure that the curing agent is carefully mixed in the resin.
Then wet the pipe ends over the entire length of the sanded surface with mixed resin.
g. Temperature of materials and laminate surface during field operations shall be
maintained above 15°C and a minimum of 2.8°C above Dew point. Maximum Relative
Humidity for lamination is 90%. In extreme conditions beyond those situations,
consult with the manufacturer prior to lamination.
h. Apply layers of Chopped Strand Mat and woven roving with working laminate resin
circumferentially on the pipe joint ends as outlined in the attached Butt & Wrap Joint
in Process Check Sheet. Each layer should overlap in circumferential 25 to 75mm and
offset between layers (see Fig. 1). When an internal overlay is not called out. Install
an internal overlay minimum 1.3 mm thick x 150mm wide, where possible. It is a
must to protect the joint during lamination process from direct sunlight, water, rain,
dust and even workers sweat. Use adequate protective equipment.
i. Cure the laminate for 24 hours at ambient temperature before proceeding with spool
lifting. To avoid air (bubbles) into the lamination, use air relief rollers (bristle roller)

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continuously. It is a must to protect the curing of lamination joint from rain. Use
plastic wrap immediately to cover lamination joint if sudden rain during cure process.
4.6. TOP COATING PROCEDURE
The surface pipe or fitting that want to top coating must be clean from dust, water,
other debris, and follow next step instructions :
a. Prepare and clean the tools prior to use.
b. Roughly sand the outer surface with fiber disc attached to hand grinder, care must
be taken in order not to break the roving totally.
c. Clean the surface with acetone damped cloth completely
d. Weight resin, tinuvin, and chloroform in correct ratio.
e. Dilute the Tinuvin with choloroform
f. Mix the resin with cobalt, pigment, Tinuvin, and wax solution. Each component
must be mixed completely.
g. Take small amount of resin mixture (about 10 cc) and mix with MEKP in correct
ratio and spread it to clean and dry surface to test the gel time for reference.
h. Mix a bowl of resin or amount that will suit to working time with MEKP. Note should
betaken that the resin in thick condition (in bowl) will gel faster than in thin coat
condition.
i. Apply the coating resin on the prepared surface with brush
j. Let the coating cures in room temperature about 1 to 2 hours
k. Hot air blower may be used to expedite curing process if possible or when the
temperature drop to below 28 deg C.
l. Clean the tools after use.
4.7. FINISHING
After all stage of lamination joint installed, sand rough edges and generally sand the
external lamination surface. Clean the surface with brush or dry clean cloth. Do not
use pressurized air to clean the surface. Prepare amount of topcoat resin and apply a
thin coat of topcoat resin onto grinded surface after initiated with curing agent
(catalyst/hardener).
5. TOOLS AND EQUIPMENTS
For tools & equipment for lamination see attachment.

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6. INSTALLATION OF UNDERGROUND PIPE
Underground GRP piping is supported by the bedding soil. Consequently, bedding and
backfilling of the trench need attention to provide the required lateral support. To ensure long
life and trouble free service from a GRP piping system, proper adherence to the principles of
excavation, laying, jointing, bedding, backfilling and field testing is required. All civil works
such as trench, bedding, backfill, and so on, shall be carried out in accordance with civil design
document and civil work instructions.
The recommended practices presented in this guide for the installation of buried GRP pipe is
developed from the two basic concepts outlined below:
 The manufacturer’s recommendation for assembling GRP pipe section and curing the joint
shall be carefully followed.
 These instructions are intended to be used as a guide, and may be amended and expanded
to meet specific job requirements.
6.1. TRENCH
The trench shall be regular and free from rocks or any other hard objects, which may
damage the GRP pipe. GRP pipe may be placed in a curved alignment provided the
curvature in the installed GRP pipe is uniform and does not exceed the recommended
bending radius. The trench shall have no sudden changes in direction or slope unless at
the location of fittings.
a. TRENCH WIDTH
The width of trench at the top of pipe need not be greater than necessary to provide
adequate room for jointing the pipe in trench and compacting the pipe zone backfill at
the haunches. The standard trench clearance for this andFor lamination joint
space/area (see figure 01)

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Figure 01. Show the standard trench width and clearance area.

Figure 02. Show the trench width at the joint area.

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Pipe Line Joint Pipe
DIAMETER
NO Position Position
(MM)
Width Deep Width Deep
1 250 850 1850 2250 2550
2 600 1200 2200 2600 2900
3 650 1250 2250 2650 2950
4 900 1500 2500 2900 3200
5 1150 1750 2750 3150 3450
6 1400 2000 3000 3400 3700
7 1800 2400 3400 3800 4100
8 2000 2600 3600 4000 4300

Table 01. Show the trench width& backfill (pipe line & joint pipa position)
Note : if necessary sandbag during pipe laying on direct contact to ground (sand).
b. MULTIPLE PIPE IN ONE TRENCH
When more than one pipe is installed in one trench a minimum distance should be keep to
provide sufficient to ensure good compactors of the backfill material under the pipe
hunches for pipes of the same diameter. The suggested minimum distance between pipe as
follow :

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c. TRENCH DEPTH
Determine the trench depth by considering the pipe line design, intended service, pipe
properties, and local conditions such as the properties of soil and combination of static and
dynamic loading.
When the ground water table is high and in order to prevent pipes from floating a minimum
burial depth equal to one diameter should be kept. The cover layer should be placed before
the dewatering system are turned off.
A minimum depth of cover above the pipe should be always observed.
 0.6 m with no traffic loads
 1.0 m AASHTO H‐ 20 truck loading.
 1.5 m with BS 153 HA or ISO H I 60 loading and when compactor equipments are
used above the pipe.
d. MIGRATION
Where ground water conditions are such that running or standing water occurs in the
bottom of trench, or are such that the soil in the bottom of the trench exhibits a quicksand
tendency, remove the water by suitable means, such as well points or under drains, until
the pipe has been installed and the trench back‐filled to a height great enough to prevent
floating of the pipe line.
The gradation of the pipe zone backfill, bedding and foundation material shall be such that,
under saturated conditions, fines from these areas will not migrate into the adjacent soil of
the trench bottom or walls and material from the trench bottom walls will not migrate into
the pipe zone material. Any migration or movement of soil particles from one area to other
can result in the loss of the necessary foundation or side support of the pipe, or both. The
migration of material can prevented by use of filter fabric.
Significant hydraulic gradients may arrive in the trench during installation when water
level is controlled by various pumping or well pointing methods. Gradients may be also
arise after construction when permeable under chain pipes or when the age graded
bedding and backfill material acts as a chain under high ground water levels in general
gravel and crushes stone backfill material should be avoided when the native soil in a fine
type unless geotextile filter fabric in used in the trench bottom sides.

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 D15/d85 Where D 15 is the sieve opening size passing 15% by weight of the
coarser material and d85 is the sieve opening size passing 85 % by weight of the
finer material
 D50/d50 < 25 where D50 is the sieve passing 50 % by weight of the coarser
material and d 50 is the sieve opening size passing 50 % by weight of the finer
material.This criterion need not apply if the coarser material is well graded (see
ASTM D2487 )
If the liner material ia a medium to highly plastic clay (CL or CH)then the following
criterion may be used in the lieu of the D15/d85 criteria D15<0.02 in. (0.5mm) where D15
is the sieve opening size passing 15 % by weight of the coaser.
The aforementioned criteria may need to be modified if one of the material is gap
graded. Material selected for use based on filter gradation criteria should be handled and
place in the manner that will minimize segregation.
e. BEDDING AND BACKFILLING SELECTION
The Installation type, bedding and backfill material is based on stiffness of pipe,
maximum burial depth, vacuum and native soil.
Soil stiffness category 1 (SC1). SC1 materials provide maximum pipe support for
a given percent compaction due to low content of sand and fines. With minimum effort
these materials can be installed at relatively high soil stiffnesses over a wide range of
moisture contents. In addition, the high permeability of SC1 materials may aid in the
control of water, making them desirable for embedment in rock cuts where water is
frequently encountered. However, when groundwater flow is anticipated, consideration
should be given to the potential for migration of fines from adjacent materials into the
open‐graded SC1 material (see Sec. 6.5.2).
Soil stiffness category 2 (SC2). When compacted, SC2 materials provide a
relatively highlevel of pipe support. However, open‐graded groups may allow migration
and the sizes should be checked for compatibility with adjacent material (see Sec. 6.5.2).
Soil stiffness category 3 (SC3). SC3 materials provide less support for a given
density than SC1 or SC2 materials. Higher levels of compactive effort are required and
moisture content must be near optimum to minimize compactive effort and achieve the

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requireddensity. These materials provide reasonable levels of pipe support once proper
density is achieved.
Soil stiffness category 4 (SC4).SC4 materials require a geotechnical evaluation
prior to use. The moisture content must be near optimum to minimize compactive.
The bedding under GRP pipe shall be free of sharp objects. Thickness of the bedding under
GRP pipe shall be minimum 100mm however, in rocky trenches at least 150 mm
in`thickness.
Padding material shall be soft clean sand, free of rocks, metal part, roots, etc. And
without sharp edges. To ensure fine, clean sand padding material at a mobile screening
plant is recommended (sieve size 5x5mm recommended).
f. PLACING AND JOINTING PIPE
a. Placing Pipe
Place pipe and fittings in the trench with the invert conforming to the required
elevations, slopes, and alignment. Provide bell holes in pipe bedding, no larger than
necessary, in order to ensure uniform pipe support. Fill all voids under the bell by
working in bedding material. In special cases, where the pipe is to be installed to a
curved alignment, maintain angular “joint deflection” (Axial alignment) and pipe
bending radius within acceptable design limits.
Pipe should be laid on flat uniform material that is at the appropriate grade. Do not
bring pipe to grade by using mounds of soils or other material at discreet points along
the length of the pipe. When pipe laying is interrupted, secure piping against
movement and seal open ends to prevent the entrance of water, mud, or foreign
material.
g. TYPICAL COMPACTION METHOD
The following compacting suggestions will enable to achieve the maximum practical
material density. Excessive compacting or compaction with inappropriate equipment can
result in pipe deformation or pipe lifting off the bedding. Care must be used when
compacting the pipe zone backfilling with frequent checks of pipe shape.
Coarse grained soils – 5% fines. For coarse grained soils with less than 5% fines, the
maximum density successive lifts of backfill must be limited to the penetrating depth of the
vibrator. The backfilling is placed in lifts of 0.15 to 0.3m. pipeline flotation has to be avoided

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when saturating the pipe zone backfill over the pipe must be avoided while the pipe zone
material is saturated. That would load the pipe before the proper support can develop.
Coarse grained soils – 5 ‐ 12% fines. Compacting of coarse grained soils containing
between 5 and 12% fines, is carried out such as by tamping or saturation and vibration.
The method used should result in the maximum density of the backfill
Coarse grained soils ‐ > 12% fines. Coarse grained soils containing more than 12% fines,
compact best by mechanical tamping in lifts of 0.1 to 0.15m. In particular for fined grained
soils, the soil modulus (passive soil resistance) is density sensitive and a greater compact
effort will be required to obtain the necessary protector density dictated by design.

Do not cover pipe joint until all pressure test have been performed.

h. DEFLECTION MEASUREMENT
In order rest to exceed the allowable long term deflection of GRP pipe, the initial deflection
should be checked. Pipe deflection is the % reduction in the vertical diameter after the
installation.

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As it is difficult to measure the long term deflection, (long term deflection are
reached within 6 months from the completion of installation and removal of all denaturing
system), it is useful to measure the initial deflection immediately after backfilling reaches
the final grade and systems are turned off for at least 3 days.
It is useful to have the deflection measurement parallel to the pipe layer so that
corrective actions can be quickly and reduce term and expenses related to the faulty
installation.

7. ABOVEGROUND INSTALLATION OF GRP PIPE

Aboveground GRP piping is supported by elevated supports. Temporary stagger supports or
scaffolding shall install to prevent the piping from movement during installation. To ensure
long life and trouble free service from a GRP piping system, the GRP piping system installation
shall properly adhere to the well‐engineered piping system design.
7.1. SUPPORTING OF ABOVE GROUND GRP PIPE
Suspended pipe often required to carry loads (self weight and fluid weight) in certain
specific gravity. The table below provided is based on fluid specific gravity of 1.0 that is
common in condensed water for power piping. RECOMMENDED SUPPORT PIPE LENGTH

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7.2. ASSEMBLY INSTRUCTION FOR GRP FLANGES
These instructions show general recommendation for the use and installation of GRP
flanges. It may be amended and expanded to meet specific job requirements.
First finger tighten the all the nuts. All Bolt thread must be clean and lubricated to attain
proper torque. Mount lubricated washers under both nuts and bolt heads t avoid damage
of the flange back‐face. Tighten all nuts following the “Tightening sequence” as follows:
TYPICAL BOLT TIGHTENING SEQUENCE

RECOMMENDED BOLT TORQUE

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8. HARDNESS CHECK
8.1. BARCOL HARDNESS
Confirm Hardness Requirement @barcol Min 31,5
8.2. ACETONE SENSITIVITY TEST
9. HYDROTESTING (LEAK TEST)
9.1. EQUIPMENT
 Electrical Pump.
 Hand Pump
 Pressure gauges
 Blind Flange
 Flow nozzles
 Pressure control valves
 Hose
9.2. PROCEDURE.
It is advised not exceed pipe testing with Installation by more than approximately 1000
meters
1. Prior to the test the following should be checked :
 Initial pipe deflection within the acceptable limit
 System restrained in place
 Flange bolt are torqued per instructions
 Backfilling completed for underground
 Valves and pumps anchored
 Backfill and compaction near structures and at closure pieces has been properly
carried out.
 Temporary support may be required for hydrotest.
 Pipe support and pipe clamp shall be done
 Consult and inform about condition to pipe manufacturer before hydrotest.
2. The line should be filled with water – The valves and vents should be opened, so that
all air is expelled from the line during filling and pressure surges should be avoided”.

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3. The line should be pressurized slowly. Considerable energy is stored in a pipeline
under pressure and this power should be respected.
4. It should be ensured that the gauge location will read the highest line pressure or
adjust accordingly. Locations lower in the line will higher pressure due to additional
head.
5. Is should be ensured that test pressure does not exceed 1.5 x Design Pressure.
Normally the field test pressure is either a multiple of the operating pressure plus a
small incremental amount. However in no case should the maximum field test pressure
exceed 1.5 x Design Pressure and minimum test pressure is design pressure.
6. If after a brief period for stabilization the line does not hold constant pressure it should
be ensured that thermal effect (a temperature change), system expansion or entrapped
air is not the cause. If the pipe determined to be leaking and the location is not readily
apparent, the following methods may aid discovery of the problem source:”
 Checking flange and valve areas
 Checking line tap locations
 Using sonic detection equipment
 Testing the line in smaller segments to isolate the leak
7. During a pressure test conducted above design pressure, expansion of the pipe and
pressure drop indication may be observed but, if there is no leak at the lamination
joints, test result shall be acceptable.
10. QUALITY CONTROL
For Quality control refer to:
Inspection and Test Procedure
11. REPAIR
Quality control officer at site work, have responsibility to check and make sure each
layerlamination is in conformity with the Butt & Wrap In Process Check Sheet and general
visual acceptance. Lamination process shall meet the minimum requirements to perform.
If the laminate results in each layer are not in accordance with the above specifications
and criteria that have been defined, butt & wrap join can be repair. But in case when pipe

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crack occur or when hydro test the lamination is not able to withstand the pressure, please
contact / consult the pipe manufacturer immediately to get advice.
Following is the typical guide to repair defects in the butt and wrap joint for example
when dry spot or air bubbles occur:
a. Prepare all tools and glass materials required for the lamination including Resin,Hardener
and glass material. The surface section to be repaired shall be marked using a marker or
masking tape.
b. Grind and clean the area in entire defect area until all defect removed. Make sure grind
area clean, dried and free from dust and other foreign material. All glass material shall be
checked to ensure it cleanliness with no evidence of moisture contamination, the correct
width, density, temperature, etc shall also be recorded.
c. Prepare resin mix with correct mixing ratio (take note of the pot‐life after mixing). For
environmental controls refer to Resin Mixing Procedure. The quantity of mix depends on
the grinded area. Be sure that the curing agent is carefully mixed in the resin. Then wet
the sanded surface with mixed resin.
d. Temperature of materials and laminate surface during field operations shall be
maintained above 15°C and a minimum of 2.8°C above Dew point. Maximum Relative
Humidity for lamination is 90%. In extreme conditions beyond those situations, consult
with the manufacturer prior to lamination.
e. Apply layers of Chopped Strand Mat and Woven Roving with working laminate resin to
cover grinded area until approximately parallel to the surrounding surface.
f. After cured, grind the additional lamination surface again to remove excessive resin, and
continue to next lamination stage or if the repair stage is for last stage of butt & wrap joint,
the apply top coat for outer with mixed UV protection resin.
g. To protect the joint during lamination process from direct sunlight, water, rain, dust and
even workers sweat. Use adequate protective equipment.
h. Cure the laminate for 24 hours at ambient temperature before proceeding with spool
lifting. To avoid air (bubbles) into the repaired lamination, use air relief rollers (bristle
roller) continuously. It is a must to protect the curing of lamination joint from rain. Use
plastic wrap immediately to cover lamination joint if sudden rain during cure process.
11.1. MAJOR DEFECT REPAIR PROCEDURE

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Following this typical to repair major defects in the butt and wrap joint for example
when joint leak occurred and water come out from joint.
NOTE : Major defect shall be replace
 Joint leak shall be removed then re‐apply Butt & Wrap Joint.
 Fitting leak shall be replaced with same fitting, and re‐apply joint end.
 Pipe leak shall be replaced by cut pipe then replace with new pipe and re‐apply joint
both ends.

a. Prepare all tools and glass materials joint kid required for the lamination including
Resin, Hardener and glass material. The surface section to be repaired shall be
marked using a marker or masking tape. Please refer to In Process Check Sheet for
glass sequence.
b. Grind and remove the area in entire joint area untill all existing joint removed.
c. Look closely for the existing putty, if it is crack in circum then shall be removed all
existing putty. If putty have only hole then only grid on the putty near hole area.

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d. Make sure grind area clean, dried and free from dust and other foreign material. All
glass material shall be checked to ensure it cleanliness with no evidenceof moisture
contamination, the correct width, density, temperature, etc shall also be recorded.
e. Prepared mixed putty and hardener, put amount refer to existing removed. Quantity
of mix depends on the grinded area. Prepare resin mix with correct mixing ratio (take
note of the potlife after mixing). For environmental controls refer to Resin Mixing
Procedure. Be sure that the curing agent is carefully mixed in the resin. The wet the
sanded existing putty surface with mixed resin.
f. Mix putty with hardener and then apply putty, wait until cure.
g. Grind cure putty in order to have smooth surface before apply Butt & Wrap joint
repair.
h. Apply layers of Chopped Strand Mat and Woven Roving with working laminate resin
to cover grinded area untill approximately parallel to the surrounding surface. See
detail Butt & Wrap in process checksheet.
i. After cured, grinded the additional lamination surface again to remove excessive
resin and continue to next lamination stage or if the repair stage is for last stage of
butt and wrap joint, the apply top coat for outer with mixed UV protection resin.
j. To protect the joint during lamination process from direct sunlight, water, rain, dust,
and even workers sweat. Use adequate protective resin.
k. To Protect the joint during lamination process from direct sunlight, water, rain, dust,
and even workers sweat. Use adequate protection equipment.
l. Cure the laminate for 24 hours at ambient temperature before procceding with spool
lifting. To avoid air (bubbles) into the repaired lamination, use air relief rollers
(bristle roller) continuosly. It is a must to protect the curing of lamination joint from
rain. Use plastic wrap immediately to cover lamination joint if sudden rain during
cure process.
LAMINATION JOINT SEQUENCES
Refer to Butt & Wrap Joint In‐process Check sheet
LAMINATION SADDLE FOR ANCHOR SEQUENCES (IF ANY)
Refer to Butt & Wrap Joint In‐process Check sheet
12. SAFETY RECOMMENDATION

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Recommended practices to minimize exposure and effects of shag from fiberglass pipe
12.1. Engineering Controls
a. A fabrication area should be set up in which to perform as much of the fabrication
work as is practical or possible.
b. Local exhaust ventilation should be provided at areas of cutting and/or lamination
joint to remove airborne dust and fibers. General dilution should be provided as
necessary to keep airborne dust an fibers below the applicable exposure limits and
guidelines.
c. Work area should be kept clean, including floor or other horizontal surfaces. Rinsing
with water or sweeping with brushes or brooms (using floor sweep) is
recommended. Never use compressed air to clean area or to remove dust for
personal cleaning. Brushes should be used to remove residue from shaved surface.
12.2. Personal Protection
a. Always refer to the Material Safety Data Sheet (MSDS) prior to working with
unfamiliar materials or if there are questions concerning the contents of the
fiberglass pipe.
b. OSHA regulates glass wool (fiberglass) under the Hazard Communication Standard
and as chemical hazard in laboratories. OSHA classifies glass wool fiber as a
“Particulate Not Otherwise Regulated.” With a workplace permissible exposure
limit (PEL) of 5.0 mg/m³ forrespirable dust and 15.0 mg/m³ for total dust. These
limits are identical to those OSHA requires for construction workers exposed to
fibrous glass, which were adopted from the 1970 Threshold Limit Values (TLVs) of
the American Conference of Governmental Industrial Hygienists (ACGIH).
c. Barrier crème should be applied to the skin areas which may be exposed to
shavings prior to beginning work.
d. Long sleeved shirt or work suits should be used. Tape should be used at sleeve
opening.
e. Cotton or flannel shirt under work shirts may be worn to prevent rubbing of skin
at opening of work suit.
f. Glove with elastic cuffs should be worn at all times. Replace worn or contaminated
gloves as necessary. Glove with flared.

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g. Pant legs should be worn outside work boots. In necessary for safety purpose, the
pant legs can be taped to fit closely to the boot. Over‐the‐calf socks can be used to
prevent chafing of the boot on the skin.
h. Safety glasses must be worn at all time.
i. Do not smoke in the work area.
j. Wristbands and watches should be removed to prevent rubbing or accumulation
of particles on skin underneath the band.
k. A respirator should be used if ventilation is unavailable. Or is inadequate for
keeping dust and fiber levels below the applicable exposure limits. To protect
against dust and fibers, use a NIOSH‐certified disposable or reusable particulate
respirator with an efficiency rating of N95 or higher (42 CFR 84) when working
with this product. For exposures up to five times the established exposures limits
use a quarter‐mask respirator, rated N95 or higher; and for exposures up to ten
times the established exposure limits use a half‐mask respirator (e.g., MSA’s DM‐
11, Racal’s Delta N95, 3M’s 8210), rated N95 or higher. Operations such as drawing,
blowing, tear out and spraying may generate airborne fiber concentrations
requiring a higher level of respiratory protection. For exposures up to 50 times the
established exposure limits use a full‐face respirator, rated N99 or higher.
12.3. Special Consideration for Inside Lamination Equipment
Use the air blower to supply enough oxygen, make sure enough air in the pipes. Always
use a respirator while working. If you feel dizzy, you should make a quick exit from the
pipe during and after the lamination process, the cleanliness of the pipe must be kept.
12.4. Personal hygiene
a. Wash exposed skin with soap solution (liquid soap preferred) and cool water.
b. Use washcloth with “brushing” motion to remove dust or fibers. Do not scrub the
skin. This could result in the fibers being embedded into the skin.
c. Rinse thoroughly with clean, cold water.
d. Apply lotion or crème to skin (non‐detergent formulas such as baby lotions) to
soothe irritation or prevent further immediate irritation.

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12.5. Standard Personal Protection Equipment for Grinding and Lamination

1. Helmet & Safety Shoes

2. Rubber Gloves & Glasses
3. Half Face Respirator
4. Chemical Pants
5. Full Face Protector (Grinder Man)

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13. ATTACHMENT
A. TOOLS AND EQUIPMENT FOR BUTT AND WRAP JOINT GRP PIPE

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APPENDIX – A RECOMMENDATION SUPPORT PIPE LENGTH

APPENDIX – B WIDTH OF GRINDING AREA FOR BUTT & WRAP JOINT GRP

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APPENDIX – C BOLT TORQUE RECOMMENDATION

APPENDIX – D BUTT & WRAP JOINT IN PROCESS CHECK SHEET

1. In Process Check Sheet B&W DN 250 mm
2. In Process Check Sheet B&W DN 600 mm
3. In Process Check Sheet B&W DN 650 mm
4. In Process Check Sheet B&W DN 900 mm
5. In Process Check Sheet B&W DN 1150 mm
6. In Process Check Sheet B&W DN 1400 mm
7. In Process Check Sheet B&W DN 1800 mm
8. In Process Check Sheet B&W DN 2000 mm

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