bondstrand bonder training

8/10/2019 Bondstrand Bonder Training

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Fiberglass Pipe

Bondstrand Bonder Training


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Bondstrand Bonder Training for PTSC M&C - 2009 2

Contents

Part-1: General

Part-2: AMERONs Bondstrand Products

Part-3: HSE & Product handling

Part-4: Fabrication & Installation

Part-5: Hydro-testing


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Part-1 : General

Training Purpose

To provide knowledge of AMERONs

Bondstrand Products To qualify bonder for bonding certification

required for fabrication and installation of

AMERONs Bondstrand Products


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Part-1 : General

Understanding AMERONs BondstrandProducts

Understanding product data and QC form

Pass hydrotest on practice

Achievements : Trainee must complete

below points to get certi f icate


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Part-1 : General

Issued by AMERON to trainee who passhydrotest on spool practice

2-year validity

Bonding certif icate


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RTRP - Reinforced Thermosetting Resin Pipe

FRP - Fiberglass Reinforced Pipe

GRE - Glass Reinforced Epoxy

GRV - Glass Reinforced Vinylester

GRP - Glass Reinforced Polyester (in some

specifications it means Glass Reinforced Pipe)

Part-2 : AMERONs Bondstrand Products

Abbreviations


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QLF - Quick Lock Female

QLM - Quick Lock Male

TF - Taper Female

TM - Taper Male

B&W - Butt & Wrap

Spigot - Bondstrand Male Pipe End

Bell - Bondstrand Female Pipe End


Abbreviations


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Epoxy (GRE)

Vinylester (GRV)

F ilament-wound pipe & fittings withadvanced resins

Bondstrand Product L ines

Bondstrand 2000/2000M

Bondstrand 7000/7000M Bondstrand 2400/3400 series


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Bondstrand 2000

A lined epoxy system

for applications where

corrosion resistance

and light weight are of

paramount

importance.



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A lined epoxy systemfor applications where

corrosion resistanceandexternal pressureare of paramountimportance.


Bondstrand 2000M


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Bondstrand 7000/7000MAn epoxy system with

conductiveelements

incorporated in the wall

of the pipe to prevent

accumulation of static

electricity produced by

the flow of liquids inside,and external effects

outside the pipe.

Design equal to B onds trand

2000/2000M

Unique patented pipe saddle drains

off static charge build-up



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Bondstrand Series 2400/3400An epoxy system where corrosion

resistance and light weight are of

paramount importance.

Pressure class determined by

internal pressurerequirements.

No external pressure requirements.

Internal pressure class : 10, 12, 14,16, 20 and 25 bar.

* Also con duct ive



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Joining SystemQuick-Lock Joint

An adhesive-bonded joint with

straight spigot and tapered bell.The integral pipe stop in theQuick-Lock bell ensuresaccurate laying lengths in closetolerance piping.

Sizes : 25-400 mm (1-16)

Sizes : 450-600 mm (18-24)



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Taper/Taper Joint

An adhesive-bonded joint with

matching tapered male andfemale ends offering superiorstrength by controlled adhesivethickness. Available in sizes :50-1000 mm (2- 40).

Internal pressure class : 10, 12,14, 16, 20, 25 bar.


Joining System


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Flanged Joint

A mechanical joint. Available

in sizes: 25-1000 mm (1-40).

Various drilling patternsavailable (e.g. CL150, JIS10K, DIN 10, etc.) -Compatible to Steel flanges.


Joining System


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Joining SystemButt & Wrap Joint

A lamination joint. Available

in sizes: 25-1000 mm (1-40).

Time costly.

Versatile. Most use on repair.



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Adhesive SystemRP-34C

A two-part amine cured

epoxy resin systemNon-conductive

Use on Quick-Lock joint

Available in 3 oz. kit and 6

oz. kit



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Adhesive SystemRP-60B

A two-part thermosetting,

electrically conductive epoxyresin system

Conductive

Use on Quick-Lock joint and

Taper/Taper jointAvailable in 3 oz. kit and 6

oz. kit



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Adhesive SystemRP-48

A two-part amine cured

epoxy resin systemNon-conductive

Use on Taper/Taper joint

Available in 3 oz. kit and 6

oz. kit



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Special Tools Pipe Shaver & Power Drive

Heating Blanket

Other Accessories Band Clamp

Lever Hoist

Bore Polisher (Flapper Wheel)

Common Pipe Tools


Tools & Equipment


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!!! Pipe Shaver: Machine of pipe end to obtain

appropriate spigot end for bonding, shaver shall beselected based on type of joint, pipe diameter, withconsideration of total project scope.

B-1F Shaver: , , 1, 1 , 2, 3, 4, 5 & 6

Cutting Insert

For detail guide, See FP376F, Ameron B-1F Pipe End Preparation Tool

To individual size only;

Straight Spigot (For Quick-Lock Joint) only.

Driven by common electricaltools or air tools, such as hand

drill.

Special ToolsPipe Shaver & Power Drive


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M-74 Shaver

For detail guide, See FP696A, M-74 Pipe Shaver

For 2 16 pipes

Use with arbor set

Straight Spigot (For

Quick-Lock Joint) only. Driven by hand or

electrical tools (RIDGID-700).



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Maintenance and Store

Shall be kept in original tool box after use;

Keep it in dry location, away from rain and

moisture; Do not use oil and/or grease as dust will

accumulate on oil and grease;

Remove of dust/dirt using brush.



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!!! Heating Blanket: For accelerating joint curing, as

well as preheat of jointing surface

Available in 115V and 230V, to be specified;

Size depends on pipe size;

Equipped with thermostat;

For 1 to 28 Pipe For 30 to 40 Pipe

Special ToolsHeating Blanket


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Description of Heating Blanket



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Using Heating Blanket Wrap the pipe using the

end with thermostat;

Tie down accessoryshall be used;

Do NOTpull the cable;



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Packing, Storage and Transporting Always roll up the heating blanket when not in used;

Do NOTpack and transport heating blanket in foldedform;

Any heavy object fall on it may damage the heatingblanket;



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Band Clamp with D-Rings Shall be used when making joints, Quick-Lock,

Taper, Mechanical O-Ring,

Available in 2 width x 6 length, and

Available in 2 width x 13 length, and

Available in 3 width x 13 length

Other Accessories


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Lever Hoist Shall be used when making joints,

Quick-Lock, Taper, Mechanical O-Ring,

Available in Ton and 1 Ton,

Alternatively, ratchet puller (chainblock) can be used

Bore Polisher (Flapper Wheel) Sanding bonding surface

Grid 40~60 Driven by electrical drill or air tool

Other Accessories


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Hacksaw or abrasive wheel;

Paint marker; Pipe wraparound;

Baby grinder;

Electric or Air drill;

Level Gauge;

Paint Brush;

Nylon/Rubber Mallet;

Cotton Roller;

Adjustable Pipe Stands; Sanding Disc;

Screw Driver;

Scissors;

Air Release Roller;

There are many other common piping tools might be

required for fiberglass piping fabrication and installation

work, such as:

Common Piping Tools


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Part-3 : HSE & Product handling

!!! To prevent injuries & occupational diseases,

property damages through needless industrial

accidents and inefficient environment via waste

management.

Personal Protection Equipment (PPE)

Chemical and Dust Hazards


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Personal Protection Equipment (PPE)

!!! PPE is any device or appliance designed to be wornby an individual when exposed to one or more healthand safety hazards.

Overall

Safety Helmet Safety Boots

Safety Glasses

Gloves

Dust Mask Etc


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!!! Resin, curing agent, catalyst, adhesive and other

chemical products could cause irritation, some couldbe harmful to eyes.

Quick access to water in case of chemical contact !!

No eating, drinking and smoking during handling of

above products; Maintain personal hygiene at all time;

Safe glasses during handling above products;

Dust mask to prevent inhalation of glass-fiber dust;

Long sleeve shirts with long pants, or overall toprevent skin irritation due to fiber dust;



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Maintain personal hygiene at all time;

Do not rub or scratch irritated area if occurred;

Shower in lukewarm water with soap and awashcloth at days end to remove loose fiber;

Wash work clothes separately;

Good ventilation in workplace to keep dustconcentration below the MAC value (10mg/m3);

Rinsing workplace with water or sweeping withbrushes or brooms;

Refer to relevant MSDS and product literature forunfamiliar products.



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!!! GRP piping components can be susceptible tomechanical damage from impact, sharp edges or

scratching. Special consideration should be given to

protecting components and to ensuring that all

personnel involved are given training in the relevantprocedures. ISO14692-4:2002

Goods Receiving Inspection

Handling and Transportation Storage

Receiving and Handling


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Verify goods receiving conform to shipping andpacking document and compliance to purchase order.

Packing condition.

Spools and components condition.

Adhesive Kits condition including shelf life, visibledamage and/or leaking, completeness of kit packing.

Reporting of any deviation and/or issue.

FP167D, Shipping, Handling, Storage and Inspection

of Bondstrand Fiberglass Pipe.

Good Receiving Inspection


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Handling and Transportation Proper support and protection with protection pad.

Securely fastened.

Forklifts should have at least a 6-foot carriage,spacer of at least 2-inch thickness are located.

Fittings shall be loaded onto pallets, crates orbaskets with sufficient protection.

3m or less pipe and spool could be lifted by single4 wide canvas or suitable plastic.

Pipe and spool greater than 3m (in length) shall belifted in using two or more canvas or suitableplastic.

Handling and Transportation


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Prohibitions Being thrown or dropped from any height.

Using chains, wire ropes or clamps for lifting

Handling and Transportation

S


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!!! Carrying out inspection for good storage preparation and

carrying out periodical inspection.

Fiberglass Pipe Well supported (side support and spacer support), not more

than 10-ft Interval, 6-ft from each end, the support shouldhave 4-in wide bearing surface.

Side supports; not exceed 5-ft height; proper tie down. Protective end cover must be in place.

Storage

S


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Fiberglass Fitting and Accessories

Shall be kept in shipping box/pallet. Protective end cover must be in placed.

Accessories such as Nylon Key and O-Ring, shall be keptin shed store.

Fiberglass Fabricated Spools Shall be kept in shipping pallet or skid.

End cover / protection shall not be removed untilinstallation.

Adhesive Kit, Resin and Curing Agent Shall be kept in original packing.

Shall be kept in specified control condition.

Shall be used before expiry date.

Storage

P 4 F b i i d I ll i


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Drawings

Product data & Pipe length calculation

QC form : Log sheet

Fabrication and Installation Tolerances

Hook-up to Equipment / Other Material

Part-4 : Fabrication and Installation

D i


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Spool Drawing Contain detail dimensions, fabrication materials, and

erection materials.

Isometric Drawing Contain all details of design (Pressure, fluid, system,

temperature,..), fabrication and erection (Materials),installation (Coordinates, connections) and testing.

Layout Drawing Background, surrounding, piping routing, supporting,

interface, equipment, etc.

Piping and Instrument Diagram Principle such as size, flow direction, design

information, materials specification.

Drawings

S l D i S l 1


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Sample DrawingSpool 1

S l D i S l 2


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Sample Drawing Spool 3


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Sample Drawing ISO


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Sample DrawingISO

Sample Drawing Layout


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Sample DrawingLayout

Product data & Pipe length Calculation


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Product data Assembling dimension of fittings

Pipe length calculation

To produce pipe cutting table To calculate pipe length for spool adjustment

To verify installation

Product data & Pipe length Calculation

Exercise : calculate pipe length.

QC Form : Log sheet


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To record bonding history for fabrication and siteinstallation

Part of QC documentation

QC Form : Log sheet



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Good tolerances control could ensure success in installation;reduce the possibility of leak at field joint; reduce the

possibility of damage due to force on mismatched pipes;

reduce/eliminate modification work,

Recommended Fabrication Tolerances

Installation Dimensional Tolerances Refer to tolerance of different type of joints such as

flange joint, mechanical o-ring joint.

Project specification




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1. Face/center to face/centerdimension, or location of

attachment

2. Lateral translation of branch or

connection

3. Rotation of flange

4. End preparation

5. Alignment of flange face

6. Angular deflection

7. Reference: ISO14692-4:2002




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DN(Inch)

Tolerances / Dimension Number

1 (mm) 2 (mm) 3 (Degree) 4 (mm) 5 (mm) 6 (Degree)

-8 5 3 0.5 3 1 0.5

10-12 5 3 0.3 3 1 0.5

14-16 5 3 0.3 3 1.6 0.5

18-24 6 5 0.3 3 2.0 0.5

26-36 6 5 0.2 4 2.4 0.5

40-48 6 5 0.15 5 2.4 0.5

Reference: ISO 14692-4:2002 and Ameron PF-01.


Hook-up to Equipment / Other Material


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To prevent damage to both equipment and fiberglass pipingsystem, attention shall be given when fiberglass piping is

hooked up to equipment and other piping materials.

Hook-up to Equipment

Equipment (Including fire hydrant, ballast eductor, .)shall be independently anchored,

Allowable alignment to avoid excessive stress,

Control torque value strictly if equipment connection iscast iron material,

Dismantle piece is recommended for testing andequipment maintenance.

Hook up to Equipment / Other Material

Part-5 : Hydro-testing


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Fabricated Spool Testing

System Hydro-testing

Part 5 : Hydro testing



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Spool Testing is normally used to verify quality of

fabrication joints (if applicable).

Test pressure determination: 1.5 times of design pressure ofthe weakest component on the spool.

Recommended Test Duration: 10 minutes

Special end blind/plug required for variety of spool endconfiguration

Limitation: Some fabricated spools could not be tested dueto end configuration and size : Spool with Taper Male end,

Spool with QL Female and Taper Female and greater than 16

.




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System Hydrotesting is carried out on installed

piping system to verify fabricated joints, site joints,as well as the integrity of the installed piping system.

Prior to Hydro-Testing All piping supports must be completed;

For underground piping, sufficient partial backfill andtemporary block must be in place to prevent excessivemovement;

High point vents / low point drains in place;

Removing/isolating components that shall be excluded

from hydro-testing;

System Hydro testing



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Test Pressure 1.5 times of design pressure

1 hour holding minimum, or sufficient time to carry outline check, or project specification whichever is longer

Testing Equipment

Quick closing valve and booster pump without suitablecontrol shall not be used, to avoid surge;

Pressure gauges and instrument must be calibrated;

Appropriate pressure gauges shall be selected, the testpressure shall be between 30% to 75% of reading range

If possible, pressure recorder shall be used;

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Hydro-Testing

Pressure build up process: The test pressure shall be raised over a period of

30minutes of longer.

Slowly and gradually to allow for equalizing forstrain, and also in stages to allow for inspection.

Inspection Instrument reading

Visual inspection of joints, pipes and fittings

24 hour holding @ 1.1 design pressure (ISO14692:4)

Acceptance criteria

No sign of leaking or weepingNo significant pressure lost

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Possible causes of pressure change

Effect of joint expansion and material creep; Effect of temperature (Morning, afternoon, night, under

sun, and so on), take precaution to prevent over-pressure

Other Concerns Glycol antifreeze shall be added when test is carry out

in subzero temperature. Instrument to prevent from buckling in case of sudden

depressurization

Safety aspects, such as qualified operator, signs andnotices, operation procedures . Shall be in placed.

Reference: AME/INS-004Hydro-Testing Procedure for

Bondstrand GRE / GRV Pipe

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