89937730-method-statement-ug-gre-r-3.pdf

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METHOD STATEMENT FOR

INSTALLATION OF GRE PIPING

Document No. E09335-43-00-4S-014

Project Name BTIP- Onshore Facilities I Offshore Pipelines

Contract No. E-09335

Client Shell Petroleum Development Company of Nigeria Limited

-- --=-------- -- --- - ~ /--1 [r. · .. ~~ EPIC CONTRACTOR

<

Description Prepared Reviewed

Date by by 09. Mar. 2004 Revised Akerele. J J.Y.Lee

Reflected hydrostatic test 06.Jun.2004 procedure recommended I.T.Koh I.T.Koh

by Ameron Change the order of Ai~ ~~oh 07 July 2004 Hydro-Test & Water Flushing

AHYUNDAI HEAVY INDUSTRIES CO., LTD. 1, Cheonha-Dong, Dong-Ku, Ulsan, Korea, 682-792, http//:www.hhi.co.kr Tel: 82-52-230-3370, Fax: 82-52-230-3447, E-mail: [email protected]

Approved by

Dl P ali<

J.K.Lee /)

J. K. Letl'

CONTRACT NO E-09335 Doc. No : E09335-43-00-.HYUNDBI BTIP- ONSHORE FACILITIES I OFFSHORE PIPELINES 48-014

IEMY .DIISTRES CD. LTD. METHOD STATEMENT FOR REV. NO 3

INSTALLATION OF GRE PIPING PAGE 2 of 10

REVISION HISTORY

EPIC CONTRACTOR SPDC

Rev Date Prepared Reviewed Approved Validity

by by by Period Date Reviewed Approved

by by

0 19. Feb, S.Y.Kim J.Y.Lee Dl Park 6 Years

2004

1 09. Mar. Akerele. J J.Y.Lee 01 Park 6

2004 Years

2 06. Jun. I.T.Koh I.T.Koh J.Klee 6

2004 Years

3 07. July AkereleA. I.T.Koh J.Klee 6

2004 Years ~

CONTRACT NO E~9335 Doc. No : E09335-43-00-.HYlJMJBI BTIP- ONSHORE FACILITIES I OFFSHORE PIPELINES 48~14

I£MY IIIUSIRIES CD., LTD. METHOD STATEMENT FOR REV. NO 3


TABLE OF CONTENTS

1.0 PURPOSE

2.0 SCOPE

3.0 DEFINITIONS

4.0 REFERENCE DOCUMENT

5.0 SAFETY

6.0 RESPONSIBILITIES

7.0 HANDLING, STORAGE AND TRANSPORTATION

8.0 WORK SEQUENCE FOR GRP PIPE INSTALLATION

9.0 DOCUMENTATION

10.0 ATTACHMENTS

·,' .

CONTRACT NO E-09335 Doc. No : E09335-43-00-

_.HYUNDBI BTIP -ONSHORE FACILITIES I OFFSHORE PIPELINES 48-014 lEAVY INDUS111ES CD. LTD. METHOD STATEMENT FOR REV. NO 3


1.0 PURPOSE

The purpose of this method is to assign responsibility for the installation of the underground piping systems. It serves to define the methods and processes to be adopted to ensure all GRE pipe of underground piping systems are installed in accordance with the appropriate project specifications

2.0 SCOPE

This method covers the installation, jointing and backfilling of GRE pipe systems for fire water pipe spool on under ground. Erection of GRE pipe spool is described in procedure SCS-16. Pressure testing of all piping systems will be conducted in accordance with the pressure test procedure ..

3.0 DEFINITIONS

1) PDC 2) HHI 3)SCS 4)GRE 5) U/G

Shell Petroleum Development Company. Hyundai Heavy Industries Co., Ltd. Standard Construction Specification Glass-Fiber Fiber Reinforced Epoxy Underground

4.0 REFERENCE DOCUMENT

1) SCS-S-35: Contractor Safety

2) DEP 31.38.70.2 Design and Installation Of Glass-Fiber Fiber Reinforced Epoxy and Polyester Piping.

3) DEP 31.38. 70.37 Requirement for Glass-Fiber Fiber Reinforced Epoxy and Polyester Pipes and Fittings

4) DEP 31.40.10.31 Glass-Fiber Fiber Reinforced Epoxy and Polyester Pipes and Fittings

5) GRE Vendor Specification & Installation Manual and hydrostatic test

procedure supplied by AMERON)

6) DEP 31.40.1 0.19-Gen. GRE PIPELINES AND PIPING SYSTEMS

5.0 SAFETY

5.1 SITE SAFETY

All safety procedures as covered by Standard Construction Specification SCS-S-35 (Contractor Safety) shall be strictly adhered to.

1) All workers shall wear appropriate personnel protective equipment while executing the project.

CONTRACT NO E-09335 Doc. No : E09335-43-00-.HYUNDBI BTIP -ONSHORE FACILITIES I OFFSHORE PIPEUNES 45-014 lEAVY INIIUS1liiES CO., Llll. METHOD STATEMENT FOR REV. NO 3


2) Electrical cables shall be properly arranged to avoid damage and possible current leakage.

5.2 LIFTING I RIGGING WORKS

1 ) Mechanical I manual lifting shall be applied in the lifting operation using quality and experience riggers.

2) All lifting operations including movement of GRE pipes and fittings, -valve boxes etc shall be carried out by experienced riggers.

3) All lifting equipments including slings, shackles, lifting beam etc, shall be prepared I inspected and color coded prior to being used.

5.3 SAFETY PRECAUTIONS

The following safety precautions shall be observed when using GRE products. When cutting or grinding GRE materials the following personal protection is necessary to prevent dust irritating the skin:

1 ) A dust mask covering nose and mouth 2) A pair of safety glasses 3) Gloves and coveralls

Using resin and hardener of adhesives or lamination sets. In case of irritation of the respiratory system care shall be taken that satisfactory ventilation is provided.

If a system is pressure tested, adequate safety precautions shall be taken as a " safe test pressure "does not exist. Any pressure in itself is dangerous.

The test equipment shall be operated by experienced personnel. Personnel not involved in the test or inspection, shall be excluded from the immediate area.

A testing supervisor shall be in charge, and hislherinstructions shall be final. No on line work shall be carried out during a pressure test.

Leaking joints shall only be repaired after the pressure has been fully released. The test equipment shall be installed at a sufficient distance (determined by the safety dept.) from the connection to the pipe system.

All Safety Precaution shall be kept in accordance with the job hazard analysis for the UIG GRE piping as attached documents.


6. 1 The piping manager shall be responsible for the following:

1) Preparation and implementation of this method statement 2) Control of Material , Handling, Storage 3) Establishment and execution of Installation schedule and sequence 4) Control of construction documents and drawing

CONTRACT NO E-09335 Doc. No : E09335-43-00-.HYUNDBI BTIP- ONSHORE FACILITIES I OFFSHORE PIPELINES 45..014

l£lriY 1111USn1ES CO. LTU. METHOD STATEMENT FOR REV. NO 3


5) Overall site safety management 6) Ensures that all installation tasks are carried out as per specification

6.2 The QA/QC manager shall be responsible for the following:

1 ) Reviewing of this method statement 2) Performance of all inspection works as required 3) Check and monitor the use of latest version/revision of applicable design

documents and drawing in GRE pipe installation. 4) Review and approval of Inspection and Test Plan. 5) Performing inspection on Mechanical/Civil Work relative in method

statement

6.3 The HSE Manager has the overall responsibility regarding development, implementation and monitoring of HSE program capable of achieving lowest exposure to hazards and accidents on the site.

6.4 Design department of Project Control Team

The design department of the project control team shall be responsible for

the composition and distribution of Isometric piping drawings, As-Built

drawings and the compilation of piping test packages.

6.5 Manager

Site manager is ultimately responsible for the execution of method statement.

6.6 Clivil Construction Manager

Civil construction manager is responsible for the excavation and back filling

of piping trenches all associated survey work.

7.0 HANDLING, STORAGE AND TRANSPORTATION

7. 1 Materials control

End protection of piping components shall remain in place during handling and transportation.

Pipes and fittings shall be handled with care and protected from impact.

Throwing, dropping, bumping or hitting the pipes and the fittings are prohibited. Pipes shall not be dragged or pushed over sharp objects.

Forklift trucks may only be used for transporting pipes, provided that the forks

are padded with carpeting or some other suitable soft material.

Do not let the pipe rest on the floor of the container where nails, studs or other

CONTRACT NO E-09335 Doc. No : E09335-43-00-.HYUND41 BTIP -ONSHORE FACILITIES I OFFSHORE PIPELINES 48-014

IEA'IY lfDUSlRIES CO. LTD. METHOD STATEMENT FOR REV. NO 3


sharp objects might damage it. Pipes shall be laid on wooden sleepers.

The pipe should be securely fastened directly over the timbers with tie downs

such as nylon straps or ropes. Do not use steel wire ropes or others sharp

material which might cause damage.

No other materials should be loaded on the top of the pipes.

Do not drop the pipe or walk or stand on it.

When loading 12m lengths of pipes, a minimum of 4 wooden supports must

be used to separate each length.

7.2 Loading

Pipes, fittings and prefabricated spools shall be transported by suitable trucks. These trucks shall have flat floors. The materials manager or his staff shall check for and remove any projection or nails etc. before each load. Materials shall be secured by using wooden supports. These supports shall have a minimum width of 1 0 em, GRE pipe shall be tied in place using soft straps.

Chains or steel cables shall not be used. The support distances shall not exceed 2.5 m. The width of the supports shall be a minimum of 10 em. When pipes are inserted (one inside the other), the support distance shall not exceed 3m. Flanges shall be secured against sliding. Flanges shall only be loaded on their sealing face if they are sufficiently protected against damage.

Pipe ends, machine part, fittings shall be protected without damage. Pipe ends and machined parts shall be protected, for example, by means of straw mats, covered by polyethylene sheet or polyethylene netting. pipes and spools shall be lifted by using cloth belts with a minimum 2 times of lifting weight and shall be lifted at two points, using the largest diameter of the prefabricated spool, in such a way that the weight is well balanced.

The truck bottom shall be covered with wood or thick matting to protect the GRE pipe from damage. Side loading trucks shall be the preferred type of vehicle for transportation. If pipes are handled by a forklift truck, the forks shall be padded or covered with suitable materials (plastic ).

7.3 Unloading

The unloading of material is the responsibility of the materials control team unless agreed otherwise

The following handling points are mandatory:

1) Do not use chains, steel cables or clamps during lifting.

CONTRACT NO E-09335 Doc. No : E09335-43-00-.HYI.INDBI BTIP- ONSHORE FACILITIES I OFFSHORE PIPELINES 48-014

I£JtiY INDIJSTIIES CD. LTtl. METHOD STATEMENT FOR REV. NO 3


2) Nylon or cloth hoisting belts with a minimum 2 times of safety load shall be used.

3) Standard pipe lengths shall be picked up at two supporting points.

4) Ensure that nylon or cloth hoisting belts are always put round the widest part.

5) Pipes shall be unloaded one at a time when sling belts are used.

6) Each part is carefully loaded and shall be inspected on site in order to ensure that no damage has occurred during transportation.

7.4 Handling

For pipe and components supplied with machined parts, the Manufacturer shall apply external and internal closed end machined parts protectors to protect the ends and all exposed machined parts of the pipe, coupling and fittings from damage under normal handling and transportation. For machined parts connections, the end protectors shall also protect the end face and the outer surface of the bell-end to prevent chipping and impact damage. Machined parts protectors shall exclude foreign matter such as dirt from the ends. Protector material shall be plastic and contain no compounds capable of damaging the machined parts or making the protectors adhere to the machined parts.

7.5 Storage

7.5.1 Pipe

Pipes with bell-ends shall be stored with the bell-ends in alternate directions to avoid contact with and damage to the ends, mating surfaces or machined parts.

Wooden or plastic spacers shall be used and shall be of sufficient size and strength to prevent contact between pipes. Spacers shall be located clear of the bell-ends. It is recommended that all pipes and fittings be supplied complete with end protection (both inside and outside) of the pipe wall and shall be transported either packed in a container or strapped onto pallets, suitable for site storage for up to two years.

7.5.2 Storage of materials

In order to avoid damage to the stacked pipes, the following rules are mandatory:

a) Do not lay the pipes directly on the ground, onto rails or concrete floors. Provide a flat surface.

b) Suitable supports shall be used with wooden support. To avoid damage to machined pipe ends, stacking shall be undertaken with care. The machined ends shall be protected by polyethylene covered straw mats or

' \.., ..

CONTRACT NO E-09335 Doc. No : E0933543-00-.HYUNillll BTIP- ONSHORE FACILITIES I OFFSHORE PIPELINES 48-014

I£MYIIIIUSTIIIEll CD., LTD. METHOD STATEMENT FOR REV. NO 3


polyethylene netting. The bell/socket and spigot ends shall not come in contact with each other.

c) The pipes can be stacked economically by alternating the spigot and the socket/bell ends.

d) To avoid bending of the pipes supports shall be spaced at a maximum of 3 meters intervals and 1 meter from each end.

e) The width of the supports shall be at least 10 em. The maximum allowable stack height is 1.5 meters. However, for diameters of 800 mm and above, a maximum of 2 pipes shall be stacked one on top the other.

f) If the product is stacked too high for long storage periods (6-12 months) and subjected to high temperatures, the supports shall cause flattening. The product (in particular machined parts) shall be stored under tarpaulins or white polyethylene sheeting.

g) Pipe stacks shall have side supports or blocks to prevent rolling or slipping of the stack during stormy weather.

h) Store rubber a-rings, gaskets, plastic locking strips, adhesive kits, resins, hardeners, woven roving and lubricants in their original packages, below 35° C. Keep dry, avoid direct sunlight and ozone.

i) Observe the shelf life of the adhesives and resins. Order these as required.

j) Unprotected flange faces shall never be placed directly on the ground or on concrete floors.

k) If any damage during transportation or installation is observed such as scratches, cracks or pits, repair or replace. Do not install any damaged material even if the intent is to repair it later.

8.0 WORK SEQUENCE FOR GRP PIPE INSTALLATION

8. 1 All GRE pipe installation sequence shall be performed in accordance with

the GRP bondstrand installation manual supplied by Ameron.

Inspection for civil work, excavation, compaction , GRE pipe installation shall be executed in accordance with the relevant ITP. (Doc.no. ITP-C-002, ITP-C-01 0, ITP-P-003)

8.2 Hydrostatic pressure test

Hydrostatic Pressure test shall be conducted in accordance with HydroTesting Procedure for GRE I GRV Pipe (Doc. No.: AME/INS-004) by Ameron. But, Test pressure shall be held for a minimum period of 60 minutes and leak test shall be maintained at design pressure for at least 60 minutes , Operating pressure shall be use for integrity test for 24hrs and all joints, connections shall be examined for leak

Tighten the come-a-longs (provided by user) on both sides so that the 0-ring

enters smoothly without being pushed out of its groove

Insert the male end until the scnbe One is about ~ inch (6mm) from the leading

edge of the female end or coupHng.

Lubricate the locking key (supplied by Ameron) before insertion. Depending on

the project requirements, metallic or plastic locking keys may be used.

7

8

Place lubricated locking key into the keyhole and slowly close the joint until the

key will slip easily into the keyway Check the pipe alignment.

Drive the locking key only until you can see its leading end through the keyhole. If

the key is driven in too far, it may bind, making later removal difficult or

impossible

Thanks to the reusability of the Key-Lock mechanical joint, this slurry water pipeline

can be readt7y extended or relocated as required at some future time.

CONTRACT NO E-09335 Doc. No : E09335-43..00-.HYUNDill BTIP- ONSHORE FACILITIES I OFFSHORE PIPELINES 45..014

lEAVY INIIUITRIEI CO. LTD. METHOD STATEMENT FOR REV. NO 3


Inspection for hydrostatic Pressure test shall be executed in accordance with the relevant ITP. (Doc. no. ITP-P-007)

8.3 Water flushing

Flushing shall be in accordance with Flushing Procedure for Bondstrand Pipe by Ameron (Doc. no.: AMEIINS-005).

8.4 Back filling, Compacting and Final back fillirig shall be performed in

accordance with the GRP bondstrand installation manual supplied by

Ameron.

Inspection for back filling, compacting and final back filling shall be executed in accordance with the relevant ITP. (Doc. no. ITP-C-002)

8.5 Final inspection

Inspection and Test Plan (Doc. no. ITP-P-003) shall apply and be

monitored by the responsible QA/QC Personnel. Also all reports and

other documents resulting from the Inspections and other checks as

may apply during the process of this work shall be dully prepared,

controlled maintained and afterwards submitted to SPDC at sign-off of this work

9.0 DOCUMENTATION

All relevant documents shall be applied the latest version

All relevant documents such as AFC drawing, method statement, ITP,

JHA and HSE presentation shall be maintained at the work site office.

The inspection and test record or check list verified by QA/QC inspector shall

be maintained in QA/QC office.

10.0 ATTACHED DOCUMENTS

1) Job Hazard Analysis for the U/G GRE Piping

2) Hydro-Testing Procedure for Bondstrand GRE I GRV Pipe (Doc. No.: AME/INS-004).

3) Flushing Procedure for Bondstrand Pipe (Doc. No.: AME/INS-005).

/

JOB HAZARD ANALYSIS FOR THE U/G GRE PIPING

RISK ASSESSMENT

NO TASK HAZARD EXPOSED ·coNSEQUENCES Seve Likely Riskl CONTROL RECOVERY ACTION STEP DESCRIPTION SUBJI;:CT rity hood MEASURE MEASURES PARTY

Task Name: Site Preparation 1 Preparation of work - Sharp objects -Personnel Injury to personnel M L M - Watch out for sharp - First aid kit -Workers

site including - Debris, scraps Potential fatality or materials. - Medevac contractor temporary & waste. multiple fatality - Use proper PPE's always procedure - Supervisor & facilities - Community dis- - Use specified uitility safety officer

burtance. detector - Supervisor & Waste magt system safety officer

- unpremmobed -Personnel - Damage to ex- Premob of equipment is - First aid kit vehicle, eqpts -Property isting surface & M M M mandatory - Medevac

Inexperienced - Environment underground utilities Equipment maintanance procedure

personnel schedule

Use PTW

Third parties Personnel M L M Hold tool box meetings - First aid kit

activities - Follow guidelines on - Medevac

community/client relations procedure

Seek guidance from SPDC

on community issues ' provide day/ night security

Post warningg signs in the

area 2 Site measuremenU Harmful insects -Workers Trip or fall L M L - Watch out for open - First aid kit - Supervisors &

surveying - High noise near involved Injury to personnel drains - Medevac pro workers. running plants. Potential fatality Barricade work sites

Sharp objects M M L - Use ear muff - Supervisor & safety

Third party activities near running plants.

' Open ditches - Wear correct PPE -Foreman

I Use PTW -Foreman

Hold tool box meetings I

- Guide assistant(s) -Foreman

- '---·~-~-----~-~--· ---L_~ iproperl~

r-·,.,


RISK ASSESSMENT

NO TASK HAZARD EXPOSED CONSEQUENCES Seve Likely Risk! CONTROL RECOVERY ACTION STEP DESCRIPTION SUBJECT rity hood MEASURE MEASURES PARTY

Task Name:Transportation of Materials by Road 3 Transportation of Unpremmobed -Personnel Injury to personnel M L L - Check a pre-journey - First Aid & Ki -Driver

personnel and vehicles - Pedestrian -Damage to property vehicle. -Emergency materials to site damage -Ensure load is properly procedure -Rigger

Weak pipe support other personnel Pipe falling out of truck secured. MEDIVAC improper stacking in the area Injury to personnel H L M - Check vehicle is not -Foreman

Damage to other fac. overload. Vehicle overspeed -Vehicle Collision with other - Obey all road safety - Safety Officer

-Driver vehicles rules. M L L - Check fire extin- -Driver

guishers before each journey to see

I that they are serv-

~~

iceable. -------- --- ------ --

Task N - ~ ~ M ---- I Handli ------.:__v__

I 4 Move load materials - Personnel ob- - Loading crew - Injury to personnel M L L - Supervise closely First Aid office - Rigger Foreman, from one point to structing move- follow approved routes on site Safety officer another by hand ment of load/ - Materials & -Damage to - Wear correct PPE MEDIVAC - Rigger Foreman,

personnel equipment equipment, materials (e.g. hand gloves, Safety officer - Load slipping coverall etc.)

from hand. -Riggers - Fall/ tripping -Foreman

Bad lifting position Personnel Injury to the back of M L L - Follow safe lifting personnel procedure/position back strain, pains Maintain good housekeeping

HSE induction for all personnel to include ergonomics - Keep access to load

destination clear from I

all obstructions

r· \


RISK ASSESSMENT

NO TASK HAZARD EXPOSED ·coNSEQUENCES Seve Likely Risk CONTROL RECOVERY ACTION STEP DESCRIPTION SUBJECT rity hood MEASURE MEASURES PARTY

Task Name: Mechanical Lifting 5 Lift load (materials) Unpremmobed operators -Damage to H M M - Check and conform site First Aid - Rigger foreman and

from one point to equipment other personnel equipment, integrity of lifting office safety officer. another by use of Inexperienced cargo, and equipment. MEDIVAC crane and low bed operator workers Select experienced persons

Riggers Wear correct PPES Safety Officer Uncertified lifting personnel Heavy object falling H M M Check to confirm integrity

I slings and gears operators Impact on immediate of lifting rope/shackle uncertified riggers environment and sling correctly. Safety Officer

- Use tag rope when necessary.

- Dedicate a signal man - All lifting equipment

to be colour coded Use PTW Hold tool box meetings

Maintain SWL of eqpt. -Personnel under -Riggers, - Riggers,helpers M L L - Ensure "no rider" - Safety officer suspended load helpers Other personnel sign is written on

equipment due to model, all load to be lifted must be identi-

fied by its weight. - High noise level Crane operator L L L - Operator to use ear muff - Operator foreman

i other personnel I third parties I

6 Pre- fabricate GRE Body contact with Personnel Body irritation from M L L Use complete PPEs to First Aid kit Supervisor I piping spools GRE materials contact with GRE include Coverall, hand Sfety officer

I Exposure to material Burn susta- gloves nose muff adhesive jointing ined from Ill health Select experienced persons

I materials USE MSDS

----- ---- ----- ----- ----- -- --

~

~-


RISK ASSESSMENT

NO TASK HAZARD EXPOSED -CONSEQUENCES Seve Likely Risk CONTROL RECOVERY ACTION STEP DESCRIPTION SUBJE;CT rity hood MEASURE MEASURES PARTY

Task Name: Workshop Pre-fabrication of GRE spools

6 Exposure to hot Personnel Burn sustained from M L L Use PTW First Aid kit

surface epoure to hot surfaces Hod toolbox meetings

Wear complete PPEs

GRE particles personnel Maintain good house- M L L Train workers on GRE

Poor housekeeping keeping handling

provide SHOC for all matls ~--- ---- --------- ---~-----

Task Name:Excavatlon and road crossings

7 Excavation and road Underground - Third party Damage to under- M L L - Keep off human traffic First Aid - Supervisor &

crossings facilities personnel ground facilities at work. MEDIVAC safety officer

Sharp objects Environment Injury to personnel - Dedicate flagmen/

open ditch signal men to control

limited work space human traffic.

Road closed for a - Probe work area so

long period as to safeguard existing First Aid

Other road users utilities I third part property MEDIVAC

stone and splinters Wear complete PPEs

from road breakage Use PTW

Hold tool box meetings

Unstable excavated personnel M L L Use well point where

wall excavation is> 3.0m

water logged ditch personnel provide shoring for excavated

Environment wall> 3.0m

Cordon off open excavation 1

Post warning signs at

- L__ excavated areas

- - --····- ----·· --~-----

/''


RISK ASSESSMENT

NO TASK HAZARD EXPOSED CONSEQUENCES Seve I Likel~~ Risk! CONTROL RECOVERY ACTION STEP DESCRIPTION SUBJECT rity hood MEASURE MEASURES PARTY

' Task Name: Demobilisatlon

8 Remove equipment Inexperienced -All personnel - Body injury, L L L - Use correct PPE - Safety officer

materials & per- personnel - Client site rep

sonnel from site Use of faulty or - Site Supervisor

unpremobbed eqpt

Clean up of work Sharp objects - All personnel - Environmental M L L - Use journey mana he-

site, reinstate site excess, left over pollution men! slip

to original condition materials Damage to materials - Liaise with HSE

third party property

.a Bondstrand · Installation 1\~FRO:-.; .................. ,.

Introduction

Receiving piping materials

Series 2400 and Series 3400 -piping systems

using the Key-Lock® mechanical joint

This guide provides recommendations for the installation of Bondstrand piping systems using the Key-Lock mechanical joint. Many of the skills, techniques and principles of steel pipe installation also apply to fiberglass piping. As you work with Bondstrand fiberglass piping, you will find that it weighs much loss than steel and that it is more flexible, but it must be handled more carefully than uncoated and unlined carbon steel pipe. In addition, fiberglass pipe often needs protection against abrasion at points of support.

To accommodate these characteristics of Bondstrand fiberglass piping, the following installation recommendations should be followed. You are encouraged to contact Ameron or your Bondstrand distributor for more help on specific problems or questions.

Inventory and inspect all incoming shipments of Bondstrand pipe and fittings.

If the inventory does not exactly match the delivery receipt, recount the materials in the presence of the truck driver Any discrepancy in the inventory and any obvious shipping damage must be noted on the receipt. Insist that the receipt be signed by the truck driver. If it is evident that materials have been lost or abused, damage claims must be initiated before accepting the shipment. Under customary shipping procedures, title and risk of loss pass to buyer upon delivery of material to carrier Ameron's Standard Terms and Conditions of Sale require that the buyer promptly notify both seller and carrier of any damages or shortages. Examine pipe and fittings carefully for shipping damage. In particular examine (a) key and 0-ring grooves on pipe ends with damaged or missing end protection, and (b) fittings received in damaged containers. Pads which are damaged or suspected of being damaged should beset aside and reported as stated above

Unloading and handling Pipe, except when crated, is normally unloaded as single lengths or bundles. To prevent damage to grooved pipe ends, do not drag or slide pipe in any way that abrades or dislodges the end protection. Do not bump pipe or grooved pipe ends. Pipe maybe moved either by hand or by lifting equipment using nonmetallic ropes or straps. Single-point pickup is permissible for pipe 8 inches (200 mm) and larger in diameter in 20-foot (6 m) lengths. Two-point pickup using a spreader bar is recommended for all other sizes and lengths. Caution: Do not throw or drop pipe or fittings. Bondstrand product packaging is not designed to withstand dropping from a truck onto the ground. Do not use a f0f1<1ift to handle pipe unless forks are padded with carpeting or some other suitable material. liners can be damaged to the point of allowing leakage even though the outside surface shows no signs of mishandling. Handle all material carefully at all times.

'C Anwron 1916 FP111 0 DS/93 Printed in Holland

2

Storage

Preparing for installation

Pipe or pipe bundles may be stored for extended periods in stacks up to four feet (1.25 m) high. Pipe stacks must have side supports or blocks to prevent! them from rolling or slipping. Pipe stored in stacks should be supported using bearing boards and spacer boards as shown in Table 1 on a level surface'. free of rocks and other hard or sharp objects. Bearing boards under the stack and spacer boards between the pipe layers must ensure that bell and spigot ends remain round. not distorted by stack loads. Bearing and spacer boards should be at least three inches (75 mm) wide and cushioned with a suitable foamed plastic or other material. More supports may be required for telescoped (nested) pipe. Contact Ameron or your Bondstrand distributor for advice regarding this special case.

Table 1 Sueeort SQacing for PiQe Storage

Pipe Pipe Support Distance Length Diameter from End of Stack

(ft) (m) (in) (mm) (ft) (mm)

20 6.1 all sizes 4 1.2 30 9.1 all sizes 6 1.8

40* 12.2. 2-4 50-100 5 1.5 40 12.2 6+ 150+ 8 2.4

*Add third support in center of stack or 40-foot pipe in 2-4 inch sizes.

Fittings should be removed from cartons, closely inspected and stored on shelves, preferably inside a warehouse Extended outdoor storage may impair the exterior appearance of fittings but will not affect their physical strength. Outdoor storage of cartons is not recommended since they are not weatherproof. Caution: 0-ring grooves on ends of stored pipe and fittings must be protected from direct sun. Locking keys and 0-rings are often shipped to the jobsite in cartons with the 0-rings separately packaged. Locking keys and 0-rings are to be stored indoors. Adhesives must be stored indoors at temperatures below 1 00 •F (38 "C). Extended storage at higher temperatures will degrade the catalyst and the resin and reduce adhesive strength. Each adhesive kit is stamped with an expiration date. In order to monitor the storage life remaining and to rotate the stock so that older kits are used first, all kits should be removed from shipping cartons and stacked upright so that the expiration dates are visible.

Pipe in trenches: Trench construction,. bedding preparation and backfill must

conform to the project plans and specifications. If no requirements are given. refer to ASTM D3839 and the Ameron publication, "Guide for Installing Buried Pipe,· for basic guidelines.

This guide gives permissible bending radii which may be used for either horizontal or vertical curvature of the trench bottom (that is, the pipeline). A small deflection at Key-Lock joints is also permissible provided that pipe-to-trench support is maintained. The angle between adjacent pipe at keyed joints must not exceed the values in Table 2.

Once the trench has been prepared and the sand bedding brought to grade and compacted. the pipe sections may be lowered into place. Remove enough sand from the graded bottom at joint locations to maintain a working clearance while assembling the joint Additional clearance can be obtained by placing a temporary wooden block support under the joint during assembly. Dig block out after assembly without lifting pipe.

Table2 Permissible Angular Deflection

at Key-Lock Joints Nominal Pipe Size Maximum Joint Deflection

(in) (mm) Male x Female CouQiing 2-16 50-400 }4° 1 °

18-24 450-600 y.• y,•

Suspended pipe: Refer to ltle project plans and specifications for details and locations of supports and anchors. The Ameron publication, "Bondstrand Engineering Guide for Suspended Pipe," BEG-13. outlines general design principles for' suspended fiberglass piping systems including hanger detailing. The guide also contains information on rates of expansion and contraction and on the design of systems restrained against movement.

If span lengths are not shown on the plans, consult Ameron or your Bond-strand representative for span recommendations at the operating temperature of the system.

Bondstrand pipe should not be point supported. Place supports under pipe rather than fittings. All shields and hangers in contact with the pipe should be free of burrs. Provide abrasion protection for the pipe where it slides through fixed supports or guides. Firm attachment of abrasion protection is necessary where movement is possible between pipe and support.

Use a material compatible with service environment such as those listed below:

Bondstrand support saddles provide a clean, corrosion-free surface and act as a stiffening saddle for the pipe. Support saddles are adhesive bonded to the pipe.

A half section of the same size pipe may be bonded to the line pipe to provide light-duty abrasion protection for pipe eight inches (200 mm) and larger in diameter.

Elastomeric materials such as rubber, neoprene or even cut-up tire casings may be held in place by pipe clamps or pipe insulation straps.

Fiberglass shields such as manufactured by Glas Mesh Co. •

Galvanized sheet metal may be banded to the pipe in environments where it is expected to have a suitable service life. Recommended minimum metal gauge is given in Table 3.

Important: Hangers and supports which clamp around saddles, shields or pads must be sized properly and must be flexible enough to fit and grip without damage. Check outside diameter of pipe in the appropriate Bondstrand product literature as th~·varies with pressure class.

(in) 2-6 8-16

Table 3 Recommended Thickness

for Galvanized Sheet Metal Protective Wrappers Pipe Size

(mm) 50-150 20().400

Gauge 46 10

Thickness (in) 0.0598 0.1345

*A division of Rubco Products, Inc., West Chester, Pennsylvania 19380.

(mm) 1.5 3.4

Lines which are emptied and filled during the cycle of operations may require anchoring at changes in direction. Bondstrand pipe weighs approximately 1

/ 6 as much as Schedule 40 steel pipe, therefore, thrust generated at turns may move or lift the line when it is filled rapidly.

- 3

Joint assembly

4

It is sometimes advantageous to use restrained supports, especially in tunnels or areas where space is restricted- In such cases, guides will be required at spacings as indicated in the adjoining chart.

9 30 8 7 6 20

5 15

4

01 10 c: 3 ·;:; ., §:a c.-CJ)g

G> 2 "0 6 ·:; 0

4 , 3

I I ! I

.......... r" ~'r---........... j'-...

~' ~ -........... r--~'r-

\'-.-. ['..

!"-r-.. ~

....... r:::,. ~ r...

~ !'

f' f"r---

I

~I !-............

r--... \'--., ..........

f".. ~

~

..........

" ~ ~

~ ~ .....

Pipe Size {in)

12

10

a

6

4

3

2

20 30 40 50 60 80 100 150 200

10 20 30 40 50 60 80 100

Temperature Change

Figure 1 Guide spacing vs. temperature change for Key-Lock joined fiberglass pipefines with blocked (restrained) ends. Solution shown assumes an initial temperature of 60 °F and a water-filled line.

Preparation of Key-Lock joining surfaces: When ready to join the pipe, remove the end protection from the male pipe end. Loosen and remove dirt and debris from the grooves using compressed air, a clean, dry rag or a paint brush.

Clean the grooves and sealing surface of the female end or coupling. Sand oft any projections or rough edges on the entry ramps which compress the 0-ring during insertion.

Now brush or rub a layer of Ameron lubricant into the 0-ring groove of the male end and all inside surfaces of the female end or coupling. Apply lubricant only when you are ready to complete the joint Keep lubricated surfaces clean and free of sand and dirt as contamination is likely to interfere with joining and sealing. Proper lubrication of the 0-ring and joint surfaces is important to avoid cutting the 0-ring or rolling it out of place during assembly.

()o.rtng placement: Lubricate entire surface of the 0-ring and slip it into the first groove on the male end. Distribute the 0-ring evenly in the groove by slipping a screwdriver under it and sliding the screwdriver around the joint As an alternative for distributing the 0-ring in pipe in sizes through 16 inches (400 mm), uses screwdriver to Jilt the lubricated 0-ring at top center a distance of about 20 percent of the pipe diameter and let it snap back into the groove.

Do not gouge or abrade the 0-ring. A sound 0-ring is the key to a watertight joint. Pipe spigot insertion: Place the band clamps on either side of the joint Rotate the new pipe so its keyhole(s) are in proper position for driving the key(s) for the next joint

End protection (supplied by Ameron should be removed just prior to assembly

to keep joining surfaces and grooves clean.

Lubricate inside of female end and locking key groove wfth ample amounts of lubricant (available on order from Ameron). Note that the pipe already

in place has been properly rotated so that the key-hole of the next joint

is conveniently positioned.

The male end of the pipe going in should 8/so be generously lubricated. Again, make sure that the keyway is

wei/lubricated.

5

... __

6

Affer coating the G-ring (supplied by Ameron) with lubricant, mount it in the endmost groove in the male pipe end

Insert a screwdriver under the mounted 0-ring and run it around the pipe to

distribute the 0-ring in the groove

Mount the band clamps (available on order from Ameron) a convenient dis

tance on each side of the joint, making certain that the pipe going in is properly

positioned to allow access to the keyhOle of the foiiO'Mng joint.

Align the pipe for a straight concentric entry Proper alignment is essential for

joining ease.

Align the male end against the female end or coupling already in place for a straight concentric entry. Proper alignment is essential for joining. Deflect the joint to conform to the actual horizontal and vertical alignment of the trench only after the joint is fully asSembled in the straight position.

An Ameron joint puller is recommended for joint assembly. Connect the ratchet winches to pulling rings attached to the band damps on either side of the pipe and ease the joint together It is often convenient to place one band damp just behind the female end or coupling and the other about 4.5 feet (1.5 m) from the male end.

Tighten the winches evenly on both sides so that the D-ring enters smoothly and without being pushed or rolled out of its groove Insert the male end until the scribed line is about %inch (6 mm) from the leading edge of the female end or coupling. To reduce slippage you may elect to use rubber pads under the band damps.

Straightness of entry adds significantly to the ease of assembly. Sight along the pipe and carefully observe concentricity and uniformity of entry.

Driving the keys: Place lubricated locking keys into the insertion holes and slowly dose the joint until the keys will slip into the keyways. Check the straightness of the entry again by sighting along the pipe and by aligning the scribe mark on the male end with the edge of the female end or coupling.

Use a hammer or mallet to drive the locking keys through the insertion holes and into the keyways until the leading end can be seen in the insertion hole and approximately 3 to 4 inches (75 to 100 mm} remain projecting.

Caution: Drive the key only until you can see its leading end through the insertion hole. If the key is driven too far. heat may elongate it and cause it to stick, making later removal impossible.

Protect the projecting keys of piping exposed to sunlight or other ultraviolet radiation from embrittlement Within several days after installation, spray all exposed key surfaces with a black acrylic coating or wrap them with duct tape. Also, fill keyholes with caulking compound to prevent intrusion of sand and dirt which may make later key removal difficult

Positioning and aligning the joined pipe: After driving the keys, deflect the joint to fit the hanger supports or trench bottom. With the pipe fully supported in its final position, release the lifting straps: for buried pipe, extract them carefully from under the pipe.

Note: When installing buried pipe in sag curves, it may be necessary to leave the lead lifting strap in position to align the next joint during assembly.

To avoid excessive movement and bending at turns and branches during the hydrostatic test, pull straight sections of joined pipe forward as assembly progresses, using a ratchet winch or other means to remove play in the joints.

Anchoring-and blocking Suspended pipe is anchored against forces tending to move the pipe by supports which grip the pipe barrel or preferably the female end or coupling. The magnitude and direction of these forces depend on system pressure, temperature, layout geometry and other factors. Refer to the "Bondstrand Engineering Guide for Suspended Pipe)' BEG-13, for guidance. It is sometimes necessary to block buried pipe especially for high pressure or high temperature services. Refer to the Ameron publication, "The Need for Blocking of Buried Pipe; EB-24. Blocks on buried lines which experience temperature changes greater than 90"F (SO"C) should encase the fitting so that the block resists the compression or tension in the line. Alternatively, blocks may be placed on each pipe leg adjacent to the fitting, thereby leaving the joints and fitting open to inspection. When blocking in this fashion, bond saddles to the pipe or use special anchor pipe from Ameron.

9

Cutting pipe to length

Connections to other piping

Field testing

10

Special pipe lengths are frequently required for fit-up. When pipe is shortened by cutting off factory-prepared ends, new male ends must be furnished by bonding on end adaptors. Cutting and bonding often can be avoided by using factory-made short lengths (pups) with male ends. Special tools, equipment and assembly instructions are available from your Bondstrand distributor

Bondstrand fiberglass piping maybe connected to either metallic or thermo-

plastic piping using flanges drilled to ANSI Standard 816.5, Class 150. Other flange drillings are available on special order Bondstrand filament-wound flanges may be bolted directly against raised-face steel flanges provided a torque wrench is used. These flanges also seal well against lined steel configurations. Use a full-faced 1/.,..inch (3 mm} thick elastomeric gasket with a Shore A hardness of 60 ± 5 for best results. Consult Ameron literature for complete flange assembly instructions.

For working pressures above 300 psi (20 bar), a special machined steel adaptor is used to form a matching male end which is then welded to the steel line. Join the Bondstrand Key-Lock .end to the steel adaptor using normal Key-Lock joining techniques.

Important: Where Bondstrand piping is connected to metallic pipe, anchor the metallic pipe securely at the point of connection so that expansion and contraction of the metal line is not transferred to the Bondstrand line.

Field testing is best and most safely accomplished using a noncompressible fluid -usually water Provide taps for air and vapor removal stall high points in the system. Trapped gases may creates hazard during test and operation of the system and may also restrict flow or drainage. Avoid rapid filling of long lines. A rapidly moving column of fluid has high inertia and can build explosive pressures in trapped sir pockets. Recognize that at 150 psi (10 bar}, air will be compressed to 1/1o of its original volume and will stores considerable amount of energy.

Caution: Before testing with compressible fluids such as air or gases, contact Ameron or your Bondstrand representative for special recommendations.

Closures for test can be made using blind flanges or valves. A Swei-Piug positive

grip end closure. Model4031*, is a reusable alternative.

For systems intended for noncompressibte fluids. test the piping hydrostatically at the test pressure cited in the appropriate Bondstrand product data publication for a period of four hours. Although a drop in the gauge pressure will reveal larger leaks, a visual surface check of pipe, fittings and joints at the end of the hydrostatic test period will provide the best evidence of satisfactory installation.

Key-Lock joints Installed with good wol1cmanship will normally be leak-free. However, small amounts of sand or grit, cut 0-rings or excessive joint deflection may cause some leakage. For the field test, a leakage allowance of ~ gallon per hour (1.89 liter per hour} per 1 00 joints irrespective of pipe diameter is suggested as permitted by NFPA 24 for private fire service mains.

Temperature has a significant influence on test pressure. Direct sun and the heat of the day may cause pressures to rise well above the intended test pressure, possibly overstressing piping, valves and equipment Avoid this by bleeding off excess pressure. Conversely failing test pressures may indicate cooling of the line; pressure should be boosted until the cause of the pressure drop has been established.

•A product of the Tube Tums Division of Chemetron Corp., Louisville. Kentucky 40201.

Leak repair Leaks in pipe and joints are repaired by replacing the faulty part. The following procedure describes disassembly of a coupled Key-Lock joint but applies equally for male x female joints when the pipe can be moved axially in either direction. If the pipe cannot be moved, the female end must be cut off and replaced by insertion of an adapter, a length of pipe (pup) and two coupled joints.

When disassembling a Key-Lock joint.. be aware of the effects of temperature on restrained or buried lines. Disassembly will be far easier if the joint is relatively free of tension or compression. The warmest time of the day may be best for a joint under tension, and the coolest time best for one under compression.

Before disassembly, it may not be obvious whether the joint is in tension or compression. Assume tension in a normally hot system after cooling and compression in a pressurized system after dropping the pressure.

Caution: Pipeline contents may be at unexpected temperatures o,:. pressures. Pipelines may even contain fluids other than water. Open the line slowly and carefully to avoid injury to personnel. Before disassembly, depressurize the line and allow it to cool .. if necessary. The keys can sometimes be removed more easily when the pipe is relatively cool. Attach an Ameron key e)(!ractor to the projecting keys and e)(!ract them one at a time. Next, slide the coupling to the side until the 0-ring can be seen through the keyhole. Using

. a special 0-ring retractor tool, grip the 0-ring firmly and pull a loop out of the hole.

Next. grip the o-rtng firmly using a vise-grip wrench or pliers and remove the retractor tool, Cut the 0-ring on the short side of the loop. The keyhole is tangental to the surface of the pipe. Thus, when the 0-ring is pulled straight out of the hole, the short side is that half of the loop nearest the female end or coupling surface. Push the short cut end back into the keyhole. Now pull the gripped end to remove the 0-ring.

Now slide the coupling further to the side until the second 0-ring appears and repeat this process to e)(!ract that 0-ring. In most cases it will be necessary to remove the coupling using this procedure at the other end of the pipe section as well.

If a locking key or an 0-ring cannot be e)(!racted-. the joint can be disassembled by making two or more longitudinal sawcuts through the coupling with a portable circular saw.

Caution: When cutting a coupling, avoid cutting into the pipe surface.

After removing the damaged or faulty pipe section, determine the average distance between the open ends of the in-line pipe. Note that once the joints of a restrained or buried line are opened and tension or compression in the line released, the distance between the open ends may change somewhat because of temperature changes in the piping. In some buried systems under axial stress. the line will continue to shorten or lengthen for a time as the pipe slowly moves through its soil envelope. Therefore, make this measurement just before you are ready to proceed with the replacement

Using this average distance and allowing for joining dimensions, select an appropriate pipe length from stock. Insertion of replacement pipe maybe facilitated by taking advantage of temperature change during the day. One may expect a correction of 0.025 inches in a 20-toot length for each 10 •F of temperature change (1.1 mm/6 mm/10 "C).

Use new 0-rings and keys for reassembly. Slip the coupling onto one of the pipe ends at each joint, far enough to expose the 0-ring grooves. Clean and lubricate the joining surfaces and replace the o-rtngs. Use the Arneron joint puller to ease the first coupling back over the two spigot ends and insert the keys to complete the joint Repeat this process at the other end of the pipe to complete the repair.

11

Important notice

FlbeFJius Pipe GI"OIIp Headq .. nen P.O. Box 801148 HOUIIOn,TXm80 U.S.A. Phone: {+I) 713 690 7777 Fax: (+1)7136902842 lntemec www.ameron-intl.com

This literature and the information and recommendations it contains are based on data reasonably believed to be reliable. However, such factors as variations in erwironment, application or installation, changes in operating procedures, or extrapolation of data may cause different results. Ameron makes no representation or warranty, express or implied, including warranties of merchantability or fitness for purpose, as to the accuracy, adequacy or completeness of the recommendations or information contained herein. Ameron assumes no liability whatsoever in connection with this literature or the information or recommendations it contains.

Written comments regarding this document are invited. Please write Engineering Manager, Ameron Fiberglass Pipe Division

A\ A ME RON ..................

Flberpus Pipe Dlvilfoo Tile Americas P.O. Box878 Burkburnett. TX 76364 U.S.A. Pbonc: (+I) 940 569 1471 Fax:(+I~S692764

Fiberglas Pipe Division Europe AmeronB.V. RO.Box6 4 I 90 CA Ocldennalscn The Nc:therl&Dds Phone: (+31)34SS87S87 Fax: (•31) 345 S87 S61

Flberpua Pipe DMsloa Alia Amcroa {Pte) Ltd No. 7A. TuuAvenuc:3 Jwtlll& Sinppore 639407 Phoac: (+65)8616118 Fax: ( +65) 862 13021861-7834

II -=---Bondslrand pipe is also manufactured in Japan and Saudi Arabia

;

'······

FIBERGlASS PIPE GROUP

Introduction

1

2

Receiving, storing and handling fiberglass pipe

Trench design and excavation

IS0-9001

II! .. --

Installation of Buried Bondstrand Pipe

To ensure long life and trouble-free service from a Bondstrand piping system, the principles of excavation, joint make-up, bedding, backfilling and field testing must be property applied. These principles must be reflected in the phrasing of contract documents and must be enforced through inspection. Be sure that contractor personnel have been thoroughly trained In Bondstrand assembly procedures by a

cer1lfted Arneron field "'f-W 1tat1ve.

These recommendations for installing buried 8ondstrand pipe are based on two principles:

• Follow Ameron's recommendations for assembling pipe sections and curing the joints carefully.

• Provide evenly distributed support for each section of pipe rather than concentrating the support at points or short stretches of the pipe bottom. Evenly distributed support is achieved through proper bedding.

Bondstrand pipe is manufactured from fiberglass reinforced epoxy or vinyl ester resins. When property handled and installed, fiberglass pipe and fittings will provide a

maintenance-free, hi~performance piping system. Fiberglass rWiforced pipe and fittings are impact sensitive and must be handled with a reasonable amount of care. Refer to the Ameron publication SHPPING, HNo.ING, ST'oRAGE 1>HJ INSPECTlON OF 8oNDs'rJwc FtseRc3lASS PIPE, FP167 for pertinent guide6nes and a table of pipe weights.

1) The excavation must allow the pipe to be laid to the grades and alignments shown on the plans.

2) Provide the narrowest practical trench width that will allow proper compaction of the pipe zone backfil. The trench must have vertical sidewalls from the foundation to at least the top of the pipe. Maintain a minimum trench width equal to the inside diameter of the pipe plus 12 inches (300 mm). The maximum trench width from the foundation to the top of the pipe must not exceed the inside diameter of the pipe plus 24 inches (600mm}.

3} Beneath vehicular traffic, the height of earth cover over the top of the installed pipe must be no less than 3 feet (.91 m} unless suitable methods are used to protect the pipe. See ROADWAY CRossiNGS below.

4} Provide firm. but not hard foundations consisting of sound earth 1 or granular soi!2, and free from stones or lumps exceeding one inch (25 mm) In greatest dimension that might bear against the pipe. Prepare suitable foundations by overexcavating the trench for not less than 4 inches {1 00 mm) and backfilling

FP278C (1 0196)

•;

2 Trench design and excavation

Rg.2. Pipe ZOIIe backfill should ccnsist of sound 88lfll or gnn~lllr material free of

stones or lumps exceecing 1 inch (25 mm) in diameter. The material should not contain

wgetation or debris that could Ieiwe I'Oids upon decon'rPOSitiof GranuiBr matarial:l

St.JCh as sand, gravel orCIIIshed rock yield high densities with a ll1inirnlln of

compaction effrxt and have {JfOVflfl iciNJ for the pipe ZDnfl backfilL GrarXJJar malerials

should PBSS a 'IHnch screen and no more than 15% should passa No. 200 sieve.

3 Assembling pipe and fittings

aoo-2~~ Bending l'lldius

4 Placing pipe in trench

2

2 inches (50 mm) to subgrade with loose bank run material, graded uniformly in one plane for the full length of the pipe. Overexcavate at each bell so that the pipe barrel rests on the bottom of the trench. Foundations must provide uniform support under the haunches of the pipe along the full length of each pipe section.

5) When the excavation is in soft or wet. unstable soils that will not provide sufficient support for the pipe, overexcavated the trench at least 6 inches (150 mm} and backfill to 2 inches (50 mm) below subgrade with solid granular soil compacted to at least 85-95% Proctor (40-70% relative density). Then complete the subgrade as described in section 5. The method described in NFPA No. 24 section 8-4.3 under ·exception• is not acceptable for fiberglass pipe.

6) When solid rock, hardpan or other hard foundation is

All units in • inclleS(mm)

Min Bidding • 2•(50mm)

I 1

1 Trench Width ;

~In ·10. 12" (300mmll Max • 10 + 2.a•(!CIOmm)t

I I I

encountered during excavation, overexcavate the trench at least 6 inches (150 mm) and backfill to 2 inches (50 mm) below subgrade with solid granular soil compacted to at least 85-95% Proctor (40-70% relative density). Then complete the subgrade as described in section 5.

1) Moat nativ .. oils. with the ucaption of highly Olg8nic, spongy aoilsiW!d fat, tighly plastic _..;.e clays. 2) Send with a maximu'n particle size of 1A inch (6 rnm) or gnMII with a minimum grain siZit of '14 inct1 (6 mm). or

paa gnMII or CNihad rock milced with 8W1CI.

1) Prepare and assemble Bondstrand Quick-Lock joints in accordance with the rt!COm

mendations contained in Ameron publk:ation, FP170. For taper/taper joints to 6 inches (150 mm), consult Ameron publication FP1 04.

2) Position pipe on 4 x 4 timbers across the trench. Block pipe to hold alignment and prevent lateral movement during cure. For larger diameters, use of come-afongs for joint assembly.

Pipe Mid-ordinate to 1QO-ft Chord Bending Radius Diameter 2000Series 3000Series 2000Series 3000Series Qn) (mm) (ft) (m) (ft) (m) (ft) (m) (ft) (m) 2 50 16.5 5.0 19.1 6.0 85 25 75 231 3 80 10.5 3.2 13.4 4.7 125 38 100 30 4 100 8.1 2.5 8.6 2.7 160 48 150 46 6 150 5.3 1.6 6.4 2.0 235 71 200 60 8 200 4.1 12 4.0 1.3 305 93 320 98

10 250 3.2 0.9 3.3 1.0 380 116 375 114 12 300 2.7 0.8 2.8 0.9 450 138 450 138 14 350 2.5 0.8 2.2 0.7 495 150 560 170 16 400 2.2 0.7 1.7 0.5 565 172 750 230

1) Cutvann may be .wtical, horizontal. ora cornbO>alion. ~if~ for llllgrftWII conlnll. shill -=tl-lllong a! least 4 ~ (100 mm) of pipe surface.

1) Cure the joints fully before lowering the pipe into the trench. Any vibration or movement of partialy cured joints wiU increase the risk of joint failure.

2) When the joints have and, raise the pipe slightly to remove the timber supports, using rope or webbed sling to lift the pipe. Do not use chains. Lower the pipe into the trench gradually. Do not drop the pipe. When wof1<ing manually, use at least two men for 6-inch (150 mm) pipe and four men for 8 and 1 Q-inch (200 and 250 mm) pipe. Install larger pipe with lifting equipment. Do not lift pipe C1l/ef' 10 inches (250 mm) in diameter or 30 feet {9 m) in length at a single point use a spreader bar.

4 Placing pipe in trench

5 Bedding and backfill

Fill the pipeline with water or use other appropriate means to prevent

buried pipe from floating during compaction with water in

cohesionless soils.

6 Roadway crossings

3} Should the depth of the trench measured from the top of the supports upon which the pipe is assembled to the trench bottom exceed 5 feet (1.5 m), do not lower the pipe by the method outlined in section 4 as it may overstress the pipe. It is the customer's responsibility to submit specific laying conditions (trench depth, handling equipment,

pipe diameter, etc.) to Ameron for recommendations for trench depths in excess of

5 feet(1.5 m).

4} Pipe may be installed in curved trenches provided the curvature is uniform and does not exceed the tabulated values.

1) Grade the trench bottom accurately and bed with sand to provide uniform bearing and support along the entire length of each pipe section. Provide a shallow depression

for bells and couplings. The grade should not exhibit abrupt changes in di~on or slope except at fittings.

2) Do not cover· pipe joints until all pressure tests have been performed.

3) Compact the backfill uniformly around the pipe giving particular care to the bedding beneath the haunches of the pipe. Compaction may be done with water if the native soil is free draining. If the native soil is not free draining, bedding with damp sand will facilitate compaction. Extend backfill at least 6 inches (150 mm) above the pipe.

4) Place backfill in 6-inch (1 SO mm) maximum lifts to a point at feast 2 feet (.6 m) above the top of the pipe. Do not use mechanical compactorS directly over the pipe until at least 12 inches (300 mm)offill have been placed over the pipe, or at least24inches (600 rrm) if heavy compaction equipment is used. Compact each lift to 85% at maximum density as determined in accordance with ASTM 01557 for cohesive soils, or to 70% relative density in accordance with ASTM 02049 for cohesionless soils which fail to produce a well-defined, moisture-density relationship when tested in accordance with ASTM 01557. Avoid damage to pipe wall during compaction. Place the remaining backfill as directed by the engineer. Make in-place tests at soil density in accordance with ASTM 01556 or ASTM 02167. Contact Ameron Applications Engineemg for specific information on ASTM specffications.

Mechanical compactors may be used provided harmful shock loads are not transmitted to the pipe. Maintain at least 121nches (300 mm) between tamping feet

and pipe wall to avoid damage to the pipe.

Where Hve loads are less than the conventional H20-S161oading, the burial depth

ITl88SUred from the top of pipe should be at feast 3 feet (.91 m) for all diameters. At road crossings where the loading exceeds H2D-S16, bury the pipe deeper or use casing pipe and coBars or sleeves to protect the pipe. Ameron will make recorTVT181'1dations on increased depth at burial upon request provided complete loading and soil conditions

are submitted tor an engineering analysis.

H-20 load

+f Roadway surface

~. ••• • • • •• • •• • •• •• 0 • •• • •• • ....... • •• • •• • •• •• ••• • ••••• • •• • •• • •• • •• • •• • •• • •• • ••••• • •• • •• • •• • •• •••• • •• • •• • •• ', ••• • ••••••••••••••• • •• • ••• 0 ••

Ext- cuing 2 II I (50 """' tMyond foo .. __ _

comPCtlon zone 10ft(3 m) tnDJmum speang

·'

7 Hydrostatic thrust

8

4

Thrust due to thennal expansion

1) It is the responsibility of the engineer to evaluate the need for thrust blocks. A

complete evaluation must consider singly and in combination the effects of temperature changes, intennal pressure surges and pipeline geometry.

2) Temperature changes produce stress in buried pipe that is restrained by (1) friction of the surrounding bedding, (2) passive soil pressure at fittings, or (3) thrust blocks.

Forces developed at fittings in fully restrained pipe are tabulated in Section 8 below.

3) Hydrostatic thrust at fittings is a function of the degree of restraint of the ad;acent

pipe. The magnitude of the hydrostatic thrust experienced by a Bondstrand piping

system is also a function of the method of construction of the pipe: different values must be used for systems employing reciprocally wound pipe (Series 2000, 2400, 3400, 4000, 5000, 5700 and 7000) and pipe made by the continuous winding process

(Series 3000, 3000A. 3200, 3300 and adhesjve-bonded oilfteld line pipe such<§ Bondstrand 200, 300, etc). In a fully restrained reciprocally wound Bondstrand fiberplass pipe (i.e.; blocked against movement at both ends) wfth all joints bonded, the Poisson effect produces considerable tension in the pipe wall: as the internal pressure

increases, the pipe expands circumferentia/fy and at the same time tries to contract

longitudinally. The resulting tensile fon:e in the pipe wall acts to reduce the axial hydrostatic thrust on the fitting by about 50% compared to the thrust experienced in a system using continuously wound Bondstrand pipe.

The ttvust forces acting on a bend are defined as follows:

T = 2PA sin~ where T = Thrust at fitting (I~) P = Hydrostatic pressure (ps~ A = FlowareaofpipeOn2) 9 Angle of bend (deg)

Use this formula for determining thrust in systems employing Series 3000 and related continuously-wound products. To determine hydrostatic thrust in pipe using Series 2000 and related reciprocally-wound piping, use one half the value given by the

above formula. HydrtlStatic thrusts at fitmgs in fully restrained systems at 1 00 psi (7 bar} are tabulated in Appendix A. Thrusts at other pressure may be determined by ratio.

4) Valves should normally be blocked as indicated in section 9.8 (fig. 9.2) to support their own weight, resist thrust and to prevent excessive torque loads on the pipe

connections.

5} Thrust blocksae required at hydrants and atfH1Ch (150 mm) orlagertfanetertees and

elbows for firewater mai'lsregulated by Fac:tcry MltuaJ Research Caporaticn.

Thrus1 forces arising from thermal expansion of the pipe wall in Series 2000 and related products are tabulated below. The effects of thermal expansion will generally be less in systems employi"lg Series 3000 and related piping since the pipe wall thickness of these latter systems is less than for Series 2000 products.

Pipe Ola

On)(mm) 2 50 3 eo 4 100 6 150 8 200

10 250 12 300 14 350 16 400

Thrust at Rttings for a 1 40" ~Tin 2000 Series Pipi'lg Tees or 90" 45" Ends Elbows Elbows

Qbrl (kN) QbJ (kN) ObJ (kN) 1,880 8.4 2,660 11.9 1,440 6.4 2,830 . 12.6 4,000 17.8 2,170 9.7 4,550 20.3 6,430 28.7 3,480 15.5 6,760 30.2 9,560 42.6 5,170 23.1 9,710 43.3 13,700 61.1 7,430 33.1

12.200 54.4 17,300 n.2 9,340 28.3 14,500 64.7 20,500 91.4 11, 100 49.5 17,400 n.6 24,200 1oa.o 13.200 58.9 22,000 98.1 27,800 123.6 15,100 67.4

1) Inial '*"perature • 60"F (15'C) Oper.ling ternpenllurw - 200"F(93'C)

; ........ '

9 Thrust block design and construction

F~g. 9-7 Thtvst blocks should be cast wffh the beaiing area against

uncjjsturbecJ native soil.

A Cross sectional area of pipe ~n') At, Bloclc bearing area (tt') b Widlh of block bearing area (ft) C, Soil cohesion factor D = PipeOO(ft) f, = Safety factor F" Sail thrust ~bt) h = Height of block bearing area (ft) H Depth ot cc:NfK (It) He = Buial depth of pipe (ft) Hb Depth of block base (ft) p Opetating plus SLI"Q8 pressure (psi) P" Passive soil pressure ~b,'ft') R Soil weig.t reduction factor T = Thrust force on bend Qbt) w Unit soil weight Oblft') w 5011 weig1tlft of pipe (lb,'fl:) 9 Pipe bend (deg) • Soil friction angle (deg)

Formulas: T = 2PA sin! (lb,l

Existing Condition General construction

Reduction Factor, A

backfill soils compacted to critical void ratio

Well-compacted backfill ~

and select backfill to critical void ratio

1) Once the anticipated thrusts have been deterTTiined, thrust block design must consider soil strength. so a stability and location of the water table. Blocks must (a) have adequate bearing area to resist the soil thrust, (b) bear against undisturbed soil and (c) be so designed that the resultant thrust vector passes perpendicularly through the

center of the bearing surface (exceptfor valves as in section 9.8). Should the soil be unstable or th9 installation below the water table, the engineer must make provisions to ensure stability such as driving piles to anchor to deeper layers of soil. Note that any

connecting metaluc pipe must be anchored at the point of connection to the fiberglass

pipe to prevent transfer of excessive stress.

Section A-A

2) Safe bearing pressures for common soil type are tabulated below.

Allowable Soil Bearing Pressure P 0

Soil Description Qb,~ MPa Rock, hard thick layers 400,000 19.2 Rock, • good masonry 50,000 2.39 Rock,. best brick 30,000 1.44 Rock.. poor brick 1 0,000 0.48 Clay, always dry 8,000 0.38 Clay, fairtydry 4,000 0.19 Clay, soft 2.000 0.1 o Gravel,coarsesand, firm 16,000 o.n Sand, compact. firm 8,000 0.38 Sand,clean,dry 4,000 0.19 Quicksand, aUuvial soiJ1 - -

11) =-==may betaqUftd in loose orsolhals, pattic:ua.1y when below I 3) The required bearing area is computed using the fOITTlula:

T Ab= Pp

Ao = Bearing area of thrust block (ft2) T = llvust (Jbd

P P = Alowable soH bearing pressure O~!ft2)

5

'·-~·

9 Thrust block design and construction

Rg. 9-2. l4IMts must beb ldepetldenlly supporledto ,_,rlnlnsfsroftotqueloads

to the fibetglass piping.

Figure 9-3. Provide flfiCIJPSlJ/lft lhlust blocks for crtiSSOWIIS.

1 0 Manhole penetrations and connections

Rg. 10. 7yPieal wall penetration. The ~pipe,_ thoughsmetalsi!Mwe n.o pipe simsWgerthan the pipe diamet8r.

7he~be'-'pipeMdalelweia aalrld Mttl an fllastomer1c caulking

compound.

6

· 4) Thrust blocks for Bondstrand pipe systems should be poured after hydrostatic testing to allow for clear visual inspection of all fitting joints during the test. To retain

pipe in proper alignment while testing, placement of sand bedding and backfill per section 5 may be required. Joints should be left exposed for observation during testing.

5) Thrust blocks should be shaped with the "designed bearing area• against native

soil of the trench wall. Smaller blocks using a dry mix may be shaped by hand but larger blocks (2 ft2 or greater) require formwork.

6) Unless otherwise specified by the engineer, use a concrete mix consisting of 1 part Portland cement, 2 parts washed sand and 3 parts washed gravel with enough water for a relatively a

Soil Description Friction Angle.$

(deg)

Well-graded sand dry saturated

Silt (passing 200 sieve)

dry saturated

Cohesive granular soil

wet to moist Clay

wet to moist at

44.5

39.0

40 32

13-22

max compaction 11.5-16.5

0

0 ll

385-920

460-1175

dry mix. A dry mix is stronger and is easier to shape.

7) Work the concrete thoroughly around the fittings to maximize surface contact. The entire area between the fittings and the freshly cut trench wall must be filled with concrete and be void free. Maintain at least a 2-inch (50 mm) space between concrete

vibrators and pipe or fittings as even indirect contact through the concrete aggregate may produce excessive impact loads on the fiberglass pipe.

8) Valve blocks should incorporate the steel necessary to support the weight of the valve and resist any torque loads caused by opening and dosing the valve.

9) Thrust blocks should encapsulate aossovers with at least six inches (150 mm) of concrete between fittings and native soil.

1) When making penetrations through concrete walls, run Bondstrand pipe through metal pipe sleeves at least two sizes larger In diameter than the pipe. Caulk the space between the sleeve and the pipe with a waterproof compound that dries to a firm but plable mass.

2) Assemble flanged connections in accordance with the recommendations in Assaa.Y INs'mUCOONS FOR

BoNt:lsrRANo AEIERGLASS FLANGES,

FP196.

3) When connecting fiberglass piping to metallic piping, anchor the metanic line to avoid stress transfer to the fiberglass.

4) Support valves indepen

dently of fiberglass piping.

St ..... pipe-

Elatorr.ric caulking ! 2-;n(SOmml m1t1. I ~~~~

11 Field testing

A Appendix

."

1) Pneumatic testing is not recommended fer reasons of safety.

3) Displace all free air in the Bondstrand piping system with the tes: ~uid. Provide taps tor air and vapor release at all high points in the system.

Hydrostatic Thrust at Reducers at 1 00 psi1 in 2000 Series Piping Svstems2

Reducer Size Thrust Reducer Size Thrust (in x in) (mm x mm) (ib.) (kNl (in x in) (mm x mm) ~1?4 lkNl 3 X 11h 80X40 10 X 6 250 X 150 2,650 11.8 3x2 SOxSO 240 1.0. 10x8 250x200 1,550 _ 6.9 4x2 100x50 510 2.3 12x8 300x200 3,.35J 15.i.l 4x3 100x80 270 12 12x10 300x250 1,800 8.0 6x3 150x80 1,150 5.1 14x 10 350x250 6,COO 26.8 6 x4 150 x 100 880 3.9 14x 12 350 x 300 2.5LJ 1 ~ .2 8x4 200x100 1,980 8.8 16x12 400x300 7,SOO 31.2 8x6 200x150 1,100 4.9 16x14 400x350 4,~\:0 2" 1

_;;..;.;..;;___;;;.;~~..;;.____;~;_____;..;..__;__ ___ ___;;__;,..;..;;._.:..;..;;..:_.___;;~-- . -· .... ---·1) lnaflllly-...ed....,_ · • -~· •·- . 2) lnca.dea s.n-2000,2400, 3400, 4000,5000,5100and7000..

Hydrostatio:: Thrus~ at Red•Jr:')rs at 1 (10 os:' in 3000Series ~~?~-~·;_":_:·":~.:?"2 __ .

ReducerSize Thrust ReducerSize Thrust (in x in) (mm x mm) (lb.) (N) On x in) (mm x mm) (ib.; {N) 3x11h 80x40 10x6 250x150 5,300 23.6 3x2 80x50 470 2.1 10x8 250x200 3,1CO 13.5 4x2 100x50 1,010 4.5 12x8 300x200 6,700 29.9 4x3 100x80 54C 2.4 12x10 300:-:250 :3."":::: 113_1

6x3 150x80 2,300 10.3 14x10 350x250 12,CCC 53.5 6x4 150x100 1,750 7.8 14x12 350x300 5,000 22.3 8x4 200x100 3,950 17.6 16x12 400x300 14,000 62.4 8x6 200x150 2200 9.8 16x14 400x350 9.:::oc 40.1

1) Ina fully IWinlined ~-2) ~ Seria3000, 3000A, 3200. 3300, Bondslr3nd 150.200, 300. 450 and eoo.

Thrust at Frttin~ at 100 ~i' in 2000Series Pioing Svst~ o;-, """:' ... -.- ,... .. C::'"':o •':'"

Oia 45" Laterals Elbows Eibows (in)(mm) (ibr) (kN) (ibJ (kN) (ibr) (k~j)

2 50 170 .8 245 1.1 130 .e 3 80 405 1.8 575 2.6 310 1.~

4 100 675 3.0 950 4.3 515 2.3 6 150 1,550 6.9 2.200 9.8 1,200 5.4 8 200 2,650 11.8 3,750 16.7 2.050 S.1

10 250 4,200 18.7 5,950 26.5 3,300 37.0 12 300 6,000 26.8 8,450 37.7 4,600 20.5 14 350 7,300 32.6 10,200 45.5 5,500 24.5 16 400 9,500 42.4 13,300 59.3 7.200 32.~

1) In aiiAiy ,_..ined S)'Stem. 2) lncUiea SenM 2000, 2400, 3400, 4000, 5000. 5 I 00 anc17000..

Thrust at Fltti!];!s at 1 00 ~i 1 in 3000 Series Pieing Svs!ems2

Pipe Tees or 90" 45. Oia 45• Laterals Sbows Elbows

(ln)(mm) Qb.) (kN) (lb.) (kN) (ib,) (kN}

2 50 340 1.5 490 2.2 260 1.2 3 80 810 3.6 1.150 5.1 620 2.8 4 100 1,350 6.0 1,900 8.5 1,030 4.6 6 150 3,100 13.8 4,400 19.6 2,400 1C.7 8 200 5,300 23.6 7,500 33.5 4,100 18.3

10 250 8,400 37.5 11,900 53.1 6,600 29.4 12 300 12,000 53.5 16,900 75.4 9200 41.~ 14 350 14,600 65.1 20,400 91.0 11,0CO <!9. ~ 16 400 19,000 84.7 26,600 118.6 14.400 64.:

1) In • itAly -ined 3)IStern. 2) lndudes s.n. 3000. 3000A. 3200. 3300, ~ 1so. zx. 3CO. ~.5c arxJ ecc.

7

Important notice This rrtararure and the information and recorrvnendations it contains are based on data reasonably beliewd to be reliable. ~such tac:1ors as varialians in environment, applic:ation or installation, changes in optnt;ng procedo.ns. or ex1rapolalion of data may c:au. dilfwant results. Ameron makes no reptWa1tation orwana-rty.

e><pniSS8d or implied, induding wananttes of marchantability or fitness lor purpose, as to the aca.racy.

adequacy or~ ot the oiiCOITIII'Iel odations or inlormlltion c:ontared herein. AmMin assumes no

&ability ~in CDrYiedion with this i-or the infcrmation orrecorrrTWidatio it contains.

A\ AMERON INTERNATIONAL

Doc No. : AME/INS-004 Rev 0 Page 1 of 8

HYDRO-TESTING

PROCEDURE FOR

BOND STRAND

GRE I GRV PIPE

0 WHLEONG KSCHONG YKTAN 26 JUN '00

REV. PREPARED BY CHECKED BY APPROVED BY DATE

I

\ ..


Doc No. Rev Page

AME/INS-004 0 2 of 8

HYDRO-TESTING PROCEDURE FOR BONDSTRAND GRE I GRV PIPE

1.0 SCOPE

This procedure covers the m1mmum requirement for the pressure testing of AMERON piping system at site.


The execution is under the responsibility of the installer in co-ordination with the owner representative.

3.0 EXCLUSION

3.1 The following piping accessories and equipment shall be excluded or isolated from pressure testing of piping.

• • •

• • • • • • • • • •

Rotating machinery, pumps, compressors, etc . Filter elements of strainers . Pressure relieving devices such as rupture discs and pressure relief valves. Vessels that would be overstressed at piping test pressures . All instruments, including level controllers and gauge glasses . Pressure gauges . Steel expansion joints I bellows Orifice plates . Flow nozzles . Pressure control valves . Corrosion probes Deluge nozzles Any other piping or equipment designated by owner representative (packaged units/ Equipment shall be isolated or by-passed as required)

3.2 All the elements that are not to be tested along with the piping shall either be blanked off during testing or spool pieces inserted during testing.

A\ Doc No. Rev Page

AME/INS-004 0 AMERON 3 of 8 INTERNATIONAL

4.0 TEST PRESSURE

5.0

4.1 For pressure testing of piping systems, the test pressure indicated in the construction drawings shall be strictly followed. The recommended test pressure is 1.5 times the anticipated design operating pressure. When higher test pressures are desired, the test pressure should not exceed 1 .5 times the maximum rated operating pressure of the lowest rated element in the system. Therefore it is important to check the pressure rating of all components of the system, because fittings, tanks, or hoses may carry a pressure rating lower that that of the pipe.

4.2 Sudden pressure surges or "water hammer" should be avoided during test. In some instances, surge and hammer can produce pressures of several times the rating of the pipe and fittings. In order to prevent water hammer or over pressurization, quick closing valves and booster pumps without suitable controls must not be used.

4.3 All test gauges used for field-testing shall have a suitable range and shall be used for test purposes only.

4.4 Pressure gauges shall be selected so that the test pressure of the system falls between 30% to 75% scale range of the gauge.

4.5 Gauge shall be new, of good quality, and in good working condition.

4.6 The date of calibration shall be certified on the gauges.

TEST MEDIUM

5.1 All AMERON pipe shall be tested hydrostatically with the following prOVISIOnS:

•

•

Water used for testing shall be clean and free from filth or undissolved solids of any description.

Unless otherwise specified, all piping shall be hydrostatically tested with fresh industrial water

' '


6.0 PRECAUTIONS/ SAFETY

Doc No. Rev Page


6.1 Qualified and experienced personnel should operate pressunzmg equipment. Untrained or unauthorized personnel should not be around the pressurizing equipment.

6.2 Do not make any adjustments on pressurized fittings under pressure. For example, if an adapter or flange joint is leaking, take the pressure off the line before attempting to tighten.

6.3 The test operation should be well planned and carried out with all due precautions. It is always best for one man to be in charge of the operation so that all other persons on the job take their direction from him.

6.4 Testing with air or gaseous media is particularly dangerous and should be avoided. Gas or air pipelines shall be hydraulically tested then "dewatered". Never test with flammable fluids or gases.

6.5 The effect of hydrostatic head shall be considered when determining correct test pressure from gauge reading.

6.6 Caution shall be exercised in system hydrostatic testing to ensure that simultaneous testing of large sized adjacent equipment and piping does not overload supporting structures and foundations.

6. 7 Any system under hydrostatic test shall be carefully observed, to prevent overpressure of lines and any connected equipment.

6.8 The pressure generator shall be disconnected if the operator leaves the equipment for any reason.

6.9 The testing operations shall be conducted diligently, thoroughly, and in a safe workman like manner in accordance with accepted piping testing practices.

6.10 During flushing and testing, safety standards shall be observed at all times. a) Barrier distance per pressure test values. b) Signs and Notices c) Toolbox talks etc.

6.11 The working area shall be roped off and sign positioned.

6.12 This work shall be carried out in open space or shelter with sufficient ventilation.

6.13 The installer's supervisor shall be responsible for safety provisions.

A\ Doc No. Rev Page

AME/INS-004 0

AMERON 5 of 8 INTERNATIONAL

7.0 PREPARATION FOR TESTING

7.1 All vent and other connections, which can serve as pressure test vents shall be open during filling so that all air can be vented prior to applying test pressure to the system.

7.2 Lines that are spring or counterweight supported shall be temporary blocked up during test in order to sustain the hydrostatic load.

7.3 Before pressure testing, all lines or systems shall be inspected to ensure that all connected parts to be excluded from the test are isolated by blinds.

7.4 Instruments shall be excluded from hydro-test of piping system.

7.5 Adequate temporary supports should be used where volume and weight of water may cause line deflection.

7.6 Hydrostatic test loops shall have all high points in the piping with a vent and all low points with a drain, regardless of whether or not they are specifically shown on the drawings. When filling, the test fluid shall be introduced at the lowest point of the system to minimize the risk of entrapped air and all vents shall be opened. Vents and drains shall be closed once a continuous flow of fluid is obtained through the vent or drain.

7.7 Calibrated/ certified gauges and recorders should be used for all hydrostatic tests. The pressure shall be shown in kg/ cm2 or K.Pa. Pressure gauges or recorders used to indicate and record test pressure shall be dead weight tested for accuracy according to a procedure, dependent of type of equipment. The validity of calibration for all gauge and recorder shall be one (1) year.

7.8 Where required piping and equipment may be insulated or coated before testing, but all joints shall be left un-insulated or un-coated and exposed until suitable test acceptance by owner representative. This is applicable to insulated piping or GRE pipe with fire coating.

7.9 Hydro testing shall be performed via a manifold. The test pump shall be isolatable from the system with its own pressure gauge. Valves, hoses used in tests shall be suitably rated (preferably use rating of max. test on line list throughout to avoid any confusion)

7.10 Lines containing check valves shall have the sources of pressure upstream of the check valve so that the pressure is applied under the seat. The point of draining shall be downstream of check valve. If this is not possible, the check valve disc shall be removed or jacked open.


Doc No. Rev Page


7.11 At least 2 gauges and recorders shall be installed in the test system, one near the pressure generator (at the lowest point) and the other at the highest point, both of which to be positioned so that they can be easily reached and observed.

7.12 When testing underground systems, the line should be partially backfilled and temporarily blocked at directional changes to prevent excessive movement during the test.

7.13 Care should be taken to prevent above ground systems from buckling or moving excessively during test or in case of sudden depressurization.

8.0 HYDROSTATIC PRESSURE TESTING

8.1 Test pressure shall be in accordance to paragraph 4.0 ofthis procedure.

8.2 Care shall be exercised to a void increase in pressure duet o temperature variation during the test.

8.3 Hydrostatic testing shall not be done against closed valves.

8.4 Vents shall be open duringfillingofwatersothatairisventedpriorto applying pressure to the system. Vents will then be closed to permit pressurization to commence.

8.5 Suitably rated spectacle blinds, spades, skillets, blank inset chokes, blind flanges or other means of positive closure shall be used for each section of pipeline tested.

8.6 Hydrostatic pressure tests on each major section of piping shall be carried out with all pressure relief valves removed and their respective nozzles or connections blanked off or plugged.

8. 7 Hydrostatic test pressure connections shall be on the upstream side of check valves.

8.8 The pressure shall be brought up slowly and gradually to allow for equalizing for strain during the test, and in stages to allow checking for leaks and inspection of the system. (Pressure shall first be brought up to 10 bar and hold till it stabilizes. After that raise in stages of 2 bars and hold for 1 0 minutes before proceed to next stage)


Doc No. Rev Page


8.9 Once attained, the test pressure shall be held for a period of two hours or such time as required for a full visual inspection of the system to be made. During the first half hour of hydro-test, if pressure drops it is necessary to bring up to test pressure and test for two hours or such time as required for a full visual inspection of the system. A ±4% pressure change during hydro-test is acceptable.

8.10 Temperature changes have a definitive effect on the pressure in the line. In closed systems, where a pipe is directly exposed to the sun, pressure increases up to 25% may occur. Take necessary precautions to prevent over pressurization. An overnight decrease in pressure from afternoon to early morning is normal due to temperature changes and does not necessarily indicate a leak.

8.11 Any lines changed or modified after they had been tested shall be retested unless waived by the owner representative in writing.

9.0 POST-HYDROSTATIC TEST MEASURES.

9.1 After completion of hydrostatic test, the pressure shall be released gradually in steps. All the vents and drains shall be kept open until the lines are fully drained. All temporary facilities installed to facilitate pressure test shall be removed.

9.2 Where permanent or temporary strainers have remained in place for the hydrostatic pressure test they shall be removed following the test and thoroughly cleaned before reinstalling.

9.3 Records are made on each piping system when test is completed. These records shall be retained in the installer's quality document, as a permanent record and a copy will be given to owner's representative.

9.4 These records shall be prepared in tabulated forms and shall include: i) Date of test ii) Identification of piping system and Package number iii) Test medium & Pressure iv) Test duration v) Inspector's name and signature vi) Reference P & ID's and Isometrics vii) Acceptance of test results by installer and owner representative


10.0 CORRECTIVE ACTIONS

Doc No. Rev Page


10.1 Ifthe pressure drop is found during the test due to leakage at somejoint(s), the system shall be depressurized, repaired and re-testing shall be done at pressure originally specified for the test.

10.2 All joints failing to pass the pressure test ~hall be repaired in accosdance with the relevant specification and the relevant sections shall be retested to the applicable test pressure.

. . . ~

A\ AMERON !NTERNAT!O:'\AL

.)

0 W H LEONG

REV. PREPARED BY

Doc No.: Rev. Page

FLUSHING

PROCEDURE

FOR

BONDSTRAND PIPE

:

K S CHONG Y K TAN I

CHECKED BY I APPROVED BY

I

I

I


:26 .JUN ·oo

DATE

. ,

A\ AMERON INTERN ATIO NA L

Doc No.: Rev. Page

FLUSHING PROCEDURE FOR BONDSTRAND GRE PIPE

1.0 SCOPE

AMEIINS-005 0 2 of 3

This procedure covers the nummum requirement for the tlushing of Ameron piping system at site.

2.0 RESPONBILITIES

The execution is under the responsibility of the installer in co-ordination with the owner's representative.

3.0 PRECAUTIONS

3.1

..., ')

.)._

All equipment and instrument along piping system to be disconnected during flushing.

Provision shall be made for discharge of water .

4.0 FLUSHING MEDIA

All Arneron pipes shall be flushed with the following provisions:

a) Water used for flushing shall be clean and free from filth or un-dissolved solids of any description.

b) Industrial fresh water shall be used for flushing.


5.0 PROCEDURE

Doc No.: Rev. Page

AMEIINS-005 0 3 of 3

5. 1 Flushing to be conducted by .. end to end" method and carried out after hvdro-test.

5.2 Flushing shall be performed with the maximum combination of ditTerent test loops to minimize any inconveniences at site. The maximum combined test loops for each flushing shall be discussed and agreed ~pon.

5.3 Items of equipment that ·would be sensitive to damage during flushing shall be removed, blocked off or isolated.

5.4 All in line valves and ball valves (including actuated onioff valves) shall be flushed in fully open position.

5.5 All instrument leads shall be disconnected prior to t1ushing. Soft-seated valves should be removed before tlushing.

5.6 At end point of flushing (discharge), the pipe bore area shall be reduced to 25% - 35% of system bore area. This is to increase backpressure to flush out residual particle in pipe.

5.7 Water shall run through the piping for 15 minutes.

5.8 Discharged water shall be drained to the nearest drainage by flexible hose. Location shall be discussed and agreed upon.

5.9 After flushing, all lines shall be drained completely. The system shall be vented while draining" to avoid vacuum.

6.0 POST FLUSHING

6. I All temporary blinds shall be removed and system drained completely.

6.2 All valves. orifice plates. expansion joints. instruments. short pieces of piping and other excluded components shall be reinstalled

6.3 Temporary pipe supports shall be removed.

6.4 Blir!_d off all pipe ends if for some reasons they are not connt!cted. This is to prevent ingression of debris or foreign materials.

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