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System Manual
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System Manual
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CONTENTS
1 INTRODUCTION 4
1.1 PURPOSE OF MANUAL 4
2 GENERAL INFORMATION 52.1 SYMBOLS AND CONVENTIONS 5
2.2 SAFETY NOTES 5
2.3 ABBREVIATIONS 5
3 TECHNICAL DESCRIPTION 6
3.1 6
4 TRANSPORT AND HANDLING 8
4.1 TRANSPORT 8
4.2 HANDLING 9
5 PREPARATION AND INSTALLATION OF 10
5.1 WORK PROCESS 10
5.1.1 Unpacking and preparation 11
5.2 SUPPORT 12
5.2.1 Denitions 12
5.2.2 Design Criteria - Dimensioning Loads 13
5.2.3 Fastening to Structure 14
5.2.4 Primary Support 15
5.2.4.1 Design Models for UNO-proles for primary Supports 15
5.2.5 Secondary Support 17
5.2.6 Design of Supports 20
5.2.7 Design Example 1 22
5.2.8 Design Example 2 25
5.2.9 Max Span for UNO-proles 28
5.2.10 Primary Support Bracket Design 34
5.3 INSTALLING 40
5.3.1 Cutting 40
5.3.1.1 Cutting using an air driven, slow moving band saw with water ushing 40
5.3.1.2 Cutting using Tiger saw/Bayonet saw 41
5.3.1.3 Cutting using a hacksaw 415.3.2 Jointing 42
5.3.2.1 Preparation of passive Fire Protection for joints 42
5.3.2.2 Installing Pipe Fittings 43
5.3.2.3 Fitting a nozzle clamp on 48
5.3.2.4 Operating the Band-It Machine 50
5.3.2.5 Mounting ConNect Clamps 54
5.3.2.6 Heat Tracing 56
5.3.4 Mounting 57
5.4 CHECKING 58
5.4.1 Pressure Testing 585.4.2 Full scale function testing 58
6 MAINTENANCE, REPAIRS AND MODIFICATION 59
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1 INTRODUCTION
1.1 PURPOSE OF MANUAL
The purpose of this manual is to provide installation guidance for the System,
as supplied by Trelleborg Offshore.
The manual is intended to give the user sufcient technical information and data to be able to
understand the functions and features of the System, together with the neces-
sary transport,
handling, commissioning, maintenance and installation information.
The manual shall also be used as a textbook for training of installation crew.
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2 GENERAL INFORMATION
2.1 SYMBOLS AND CONVENTIONS
The following words and symbols found throughout this manual mark special messages to alert
the operator of specic information concerning of the PERSONNEL, the EQUIPMENT or the
PROCESS.
The WARNING symbol draws attention to potential danger for personnel
(including possible loss of life) and considerable damage to equipment if the
instructions are not followed correctly.
The CAUTION symbol draws attention to potential danger of damage to equipment,
if the instructions are not followed correctly.
The NOTE symbol draws attention to additional clarifying information or special
instructions which are also crucial for equipment or to the installation performed.
The QUALITY symbol draws attention to operations where quality inspections
must be performed.
2.2 SAFETY NOTES
The WARNING symbol as a Safety Note draws attention to installer’s responsibili ty
to identify any possib le danger and take necessary precautions to avoid serious
personal injury or equipment damage.
2.3 ABBREVIATIONS
Abbreviation Explanation
mm - millimetres
" - inches
kg - kilogram
TM - Trade Mark
TO - Trelleborg Offshore
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3 TECHNICAL DESCRIPTION
3.1
is made of synthetic rubber and replaces rigid steel, titanium and glass-bre
reinforced plastic piping. is delivered in pipe sizes from 1" to 8" and in lengths of
up to 15 metres. All sleeves and tees for extensions are supplied in titanium. is a
exible piping system, which is easy and safe to t, and has the following unique properties:
• No corrosion
• Jet re resistant
• Impact resistant
• Minimizes water hammer effects
• Explosion resistant• Frost resistant
• Maintenance free
• No welding or hot work necessary
These properties make ideal for the piping of deluge and sprinkler systems for
offshore oil and gas installations, ships, industrial plants, buildings, mines, etc.
There are different ways to support . The most common methods are:
• UNO Channels• Cable trays
• Duo Clamps (when using existing pipes for support)
is a unique piping system and can therefore be put into use in a variety of
unconventional surroundings where exibility is necessary.
The system has many unique joint and connection solutions. Examples of an
system with joints and connections are shown on the following page.
For detailed technical information see chapter 7 in addition to the following documents:
• 89101-001 “Specic Requirements – ELASTOPIPE™ FR “.
• 89101-006 “Specic Requirements – ELASTOPIPE™ FOR”.
• 89101-002 “AP01EP Piping Specications – ELASTOPIPE™ FR “.
• 89101-002 “AP02EP Piping Specications – ELASTOPIPE™ FOR “.
• 89106-003 “Test Spec ELASTOPIPE™ FR”
• 89106-007 “Test Programme ELASTOPIPE™ FOR”
• 89101-008 “ELASTOPIPE FOR - Test Summary”
• 89106-085 “Support manual”
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End Cap
End Cap
Support
4”
Reducing or
straight Tee
6”
Flange Connec-
tion
Commonly used Fit-
tings and Couplings
Straight Connection
with Band-It
(shown enlarged with-
out re protection).
Straight Connector
with Nozzle Adapter
2”
Reduced or straight
X-Connector
2”
1”
Nozzle Adaptor
(shown enlarged with-
out re protection).
4”
End Connection with Nozzle
adapter and inspection Plug
(shown enlarged without re
protection).
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4 TRANSPORT AND HANDLING
4.1 TRANSPORT
Al l ti tanium parts must be stored dry and NOT together wi th other materials.
can be bent to 5D, but avoid breaking and buckling.
Preassembled is
transported and stored in baskets.Fittings and mounting materials are
transported and stored on pallets.The protection on preassembled
ttings should be kept on during all
transport and handling.
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4.2 HANDLING
Al l li fting operat ions shal l be done according to local lif ting procedures, surveyedby certied operators.
Both single pipes and bundles of pipes can be lifted positioned horizontally using soft slings.
Maximum distance between soft slings are 3 metres.
Straps in the end of pipes can lift both single
and bundles of pre-assembled
pipes positioned vertically.
During lifting of vertically positioned pipes,
the strap must be secured by lashing the strap
around the pipes twice,
and with double strapping.
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5 PREPARATION AND INSTALLATION OF
5.1 WORK PROCESS
1. Brieng installation crew
in actual project
2. Supporting methods,
Chapter 5.2
3. Cutting ,
Chapter 5.3.1
4. Applying sealant,
Chapter 5.3.2.2
5. Preparation of passive
re protection,
Chapter 5.3.2.1
6. Installation of pipe ttings,
Chapter 5.3.2.2
7. Installing Band-It bands,
Chapter 5.3.2.4
8. Control
Chapter 5.3.2.4
9. Mounting ConNect Clamps
Chapter 5.4.2.5
10. Installation of nozzleclamps,
Chapter 5.3.2.3
11. Fitting ends to 12. Mounting ,
Chapter 5.3.4
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5.1.1 Unpacking and preparation
This section provides guidelines for unpacking and preparation of once it has
arrived at the installation site.
The following instructions apply when is removed from its storage and transpor-
tation protection:
If possible, keep in its packed condition prior to installation.
Packaging material is the customer’s property and should be disposed of in an
environmentally safe manner.
1. Remove the packing that covers .
The pipes are stable so there is no danger of uncontro lled movement during
removal of packing materials.
2. Remove packing material from installation parts and tools.
Make sure that the content of the package tally with the packing list , which is included.
Conduct a thorough visual inspection of every component and tool. Be particularly
aware of loose or broken components. Make sure that mechanical/electrical tools
function as expected.
Report any damage or discrepancies, enclosing a copy of the packing list.
is made of exible composite materials and can be installed in a different man-
ner than other conventional piping systems.
The pipes are not subject to thermal expansion so expansion loops are not necessary.
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5.2 SUPPORT
NO HOT WORK: Since all installation of can be done without hot
work, welding of supports should be avoided. Only installation requiring cold
work are recommended.
Support systems for both replacement of existing pipes and installation on new
builds are included. For replacement work the reuse of existing support is
favourable, and should be the preferred choice.
To reduce the consumption of support materials, and to make installation in
narrow areas easier, the use of support should be reduced to a minimum by
fastening directly to the structure or primary support.
5.2.1 Denitions
Primary Support is dened as
existing pipe supports, angle iron,
UNO-channels (mainly for diago-
nal struts) or Multigrid.
Fastening to structural steel with
beam clamps, bolts in drilled holes or
direct fastening with nails or studs.
is fastened to the second-
ary support with pipe rings, bow clamps,
straps or Duo-clamps.
Secondary support is made of
UNO-channels, cable ladders or
by using existing piping.
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5.2.2 Design Criteria - Dimensioning Loads
is exible and the elastic material dampens the effect of explosion,
impacts and water hammer. The support should be designed to allow the
dampening, but also to allow draining and avoid sagging.
h
F
F
Span
Secondary
supportPrimarysupport
Structural Steel
F
In most cases explosion is the dimensioning load in support cal-
culation. Typical Design Accidental Load (DAL) of 0,25 - 0,6 bar
is normally dominating compared to the load contributions from
weight, wind and water hammer.
Normally the weight of and
support only contribute to the dimensioning
of the support when the pipes are lled with
water.
An installationshall have a nice, robust ap-
pearance without sagging and
water pockets. The principle of
free hanging pipe with minimum
support to allow dampening often
contradicts this.
Water hammer effects (transient)
can be damaging to pipes and sup-
port, but are dampened consider-
ably by .
The loads from water hammer
effects are only considered in spe-
cic project and design cases.
Wind loads are nor-
mally negligible.
If climbing is performed in the area
with installed, and
any risk that the pipes may be
stepped on or hanged in, the sup-
ports can be designed and installed
to allow this without sagging.
Normally
withstands impacts and
rough physical handling bet-
ter than the support.
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5.2.3 Fastening to Structure
All installation of can be made without hot work. Fastening
methods which do not include welding or other hot work are recommended.
Using bolts is the common way to fasten
supports.
Bolts should always be secured.
Supports can also be fastened directly
to structure with nails or studs.
Fastening should always be made ac-
cording to local requirements.
Fastening with beam clamps.
Beam clamps must always be secured
against sliding and twisting by use of
double bolts, lock nuts and clamps on
both sides.
.
Use isolation in joints to to avoid galvanic corrosion!
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5.2.4 Primary Support
Traditional pipe supports made of angle iron are suitable as primary support for
, but stainless systems (e.g. UNO channels) with standard
prefabricated components are available and recommended.
In retrot projects it is recommended to use the
existing support and bolt holes.
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5.2.4.1 Design Models for UNO-proles for primary Supports
● Fixed - Fixed
● Fixed - Hinged
● Hinged - Hinged
● Fixed - Free (Cantilever)
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5.2.5 Secondary Support
Max 100 mm
Locking nut
The clamp bolts must be secured with lock
nuts.
Do not tighten the clamp bolts more than necessary to
obtain a rm grip around the pipe without deforming,
leaving a gap between the two clamp halves.
For self draining, always
mount pipes slooping (2%).
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When ladders are used as
secondary support, and the ex-
plosion load is the dimensioning
force, pipe clamps are used for
every 4th stage.
Ladders are fastened with brack-
ets for every 3rd meter.
When the dimensioning force is
stronger than the explosion load,i.e. loads from water hammer,
clamps on every second stage of
the ladder is recommended.
Around corners max distance be-
tween clamps should not exceed
1300 mm.
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Typical use of cable ladders for sup-port of piping.
In retrot projects the existing
pipe can be used as secondary
support, and isfastened with Duo-clamps.
Existing cable ladders are suitable
for support of piping.
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5.2.6 Design of Supports
The owchart describes how to design the support:
Blast load F ........ bar
Pipe dim. (inches) .............
Input from customer
Max load on primary support ........... kg
Design Model .....................
Max span for seondary support ............. mm
Input from Table 5.1 - 5.11
Select typeof primary support
Height of primary support ........... m
Input from tables
5.12 - 5.17
Within limits Outside limits
Construct a primary support
based on figures in
table 5.12 - 5.17
A special designed primary
support has to be constructed
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5.2.7 Example 1
h 1,0 m
F
F
Max span
Pipe dimension 4”
F = 0,3 bar
Support
to be
designed
The routing for a 4” is 1,0 meter below the deck structure, and we are informed
that blast load is 0,3 bar in the area. This information is lled into the owchart:
Blast load F ........ bar
Pipe dim. (inches) .............
Input from customer
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This information is used to nd the max load (kg) allowed on the primary support, in the right
hand column of table 5.2. Single or double UNO can be used. In this example the simplest to be
allowed is single UNO, and the corresponding load (876 kg) is lled into the owchart. The “De-
sign Model” (Fixed-xed, Fixed-hinged, Hinged-hinged or Fixed-free (cantilever)) and the corre-
sponding “Max span for secondary support” are also lled into the owchart. In our example the
max span for a xed-xed is 3300 mm:
Example from table 5.2
Secondary SupportPrimarySupport
Max span for UNO-proleDistance center to center [mm]
Blast load = 0,30 bar
UNOProle
IDFixed-xed Fixed-
hingedHinged-hinged Cantilever
Max load on pri-mary support (kg)
U-41-1-PSingle
1 6000 3500 2000 500
1,5 5200 3000 1700 400
2 4700 2800 1500 300
3 3900 2300 1300 300
4 3300 1900 1100 200
U-41-2-PDouble
1 7400 4300 2400 600
1,5 6600 3900 2200 500
2 6200 3600 2000 500
3 5300 3100 1700 400
4 4700 2800 1500 300
6 3900 2300 1300 300
8 3300 1900 1100 200
Max load onprimary support........... kg
Design Model .....................Max span for seondarysupport .............. mm
Input from Table ..........
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The next step is to select the type of primary support from tables 5.12-5.17. The principle is to
choose the simplest conguration that the height of the primary support (h) and “max load” al-
lows. In our example this is conguration 5.1B, a single UNO prole with one bracing:
Example from table 5.12
All bracing single UNO or similar Part no.
Name of member Height h (m) Max. Load F (kg)
B
K10-400-P-SS
or similar
1,0 2629
1,4 1341
1,8 811
Select typeof primary support
Height of primary support ........... m
Input from tables
5.12 - 5.17
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5.2.8 Example 2
h 1.4 m
F
F
Max span
Pipe dimension 6”
F = 0,6 bar
Supportto bedesigned
The routing for a 6” is 1,4 meter below the deck structure, and we are informed
that blast load is 0,6 bar in the area. This information is lled into the owchart:
Blast load F ........ bar
Elastopipe ID ............. inches
Input from customer
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Example from table 5.8
Secondary SupportPrimarySupport
Max span for UNO-proleDistance center to center [mm]
Blast load = 0,60 bar
UNOProle
IDFixed-xed Fixed-
hingedHinged-hinged Cantilever
Max load on pri-mary support (kg)
U-41-1-P
Single
1 4200 2500 1400 300
1,5 3600 2100 1200 300
2 3300 2000 1100 200
3 2700 1600 900 200
4 2300 1400 700 100
U-41-2-P
Double
1 5200 3100 1700 400
1,5 4700 2700 1500 300
2 4400 2600 1400 300
3 3800 2200 1200 300
4 3300 1900 1100 200
6 2800 1600 900 200
8 2300 1400 700 100
Max load onprimary support........... kg
Design Model .....................
Max span for seondarysupport .............. mm
Input from Table ..........
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Example from Table 5.12
All bracing single UNO or similar Part no.
Name of member Height h (m) Max. Load F (kg)
C
K10-400-P-SS
or similar
1,4 2683
2,0 1315
2,5 841
Select typeof primary support
Height of primary support ........... m
Input from tables5.12 - 5.17
This means that this primary support can be a 1,4 m single UNO prole with double bracings,
mounted with minimum distance of 1600 mm from the next primary support.
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5.2.9 Max span for UNO-proles
The tables below documents the max span that can be achieved using UNO-proles as primary
support.
Table 5.1
Secondary SupportPrimarySupport
Max span for UNO-proleDistance center to center [mm]
Blast load = 0,25 bar
UNOProle
IDFixed-xed Fixed-
hingedHinged-hinged Cantilever
Max load on pri-mary support (kg)
U-41-1-P
Single
1 6600 3900 2200 5001,5 5700 3300 1900 400
2 5200 3100 1700 400
3 4300 2500 1400 300
4 3600 2100 1200 300
U-41-2-P
Double
1 8100 4800 2700 600
1,5 7200 4300 2400 600
2 6800 4000 2200 500
3 5900 3400 1900 400
4 5200 3000 1700 4006 4300 2500 1400 300
8 3600 2100 1200 300
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Table 5.2
Secondary SupportPrimarySupport
Max span for UNO-proleDistance center to center [mm]
Blast load = 0,30 bar
UNOProle
IDFixed-xed Fixed-
hingedHinged-hinged Cantilever
Max load on pri-mary support (kg)
U-41-1-PSingle
1 6000 3500 2000 500
1,5 5200 3000 1700 400
2 4700 2800 1500 300
3 3900 2300 1300 300
4 3900 1900 1100 200
U-41-2-PDouble
1 7400 4300 2400 600
1,5 6600 3900 2200 500
2 6200 3600 2000 500
3 5300 3100 1700 400
4 4700 2800 1500 300
6 3900 2300 1300 300
8 3300 1900 1100 200
Table 5.3
Secondary SupportPrimarySupport
Max span for UNO-proleDistance center to center [mm]
Blast load = 0,35 bar
UNOProle
IDFixed-xed Fixed-
hingedHinged-hinged Cantilever
Max load on pri-mary support (kg)
U-41-1-P
Single
1 5600 3300 1800 4001,5 4800 2800 1600 400
2 4400 2600 1400 300
3 3600 2100 1200 300
4 3100 1800 1000 200
U-41-2-P
Double
1 6800 4000 2200 500
1,5 6100 3600 2000 500
2 5700 3400 1900 400
3 4900 2900 1600 400
4 4300 2600 1400 3006 3600 2100 1200 300
8 3100 1800 1000 200
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Table 5.4
Secondary SupportPrimarySupport
Max span for UNO-proleDistance center to center [mm]
Blast load = 0,40 bar
UNOProle
IDFixed-xed Fixed-
hingedHinged-hinged Cantilever
Max load on pri-mary support (kg)
U-41-1-P
Single
1 5200 3100 1700 400
1,5 4500 2600 1500 300
2 4100 2400 1300 300
3 3400 2000 1100 200
4 2900 1700 900 200
U-41-2-P
Double
1 6400 3700 2100 600
1,5 5700 3400 1900 500
2 5400 3200 1800 500
3 4600 2700 1500 400
4 4100 2400 1300 300
6 3400 2000 1100 300
8 2900 1700 900 200
Table 5.5
Secondary SupportPrimarySupport
Max span for UNO-proleDistance center to center [mm]
Blast load = 0,45 bar
UNOProle
IDFixed-xed Fixed-
hingedHinged-hinged Cantilever
Max load on pri-mary support (kg)
U-41-1-P
Single
1 4900 2900 1600 4001,5 4200 2500 1400 300
2 3900 2300 1300 300
3 3200 1900 1000 200
4 2700 1600 900 200
U-41-2-P
Double
1 6000 3500 2000 500
1,5 5400 3200 1800 400
2 5000 3000 1600 400
3 4300 2600 1400 300
4 3800 2200 1200 3006 3200 1900 1000 200
8 2700 1600 900 200
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Table 5.6
Secondary SupportPrimarySupport
Max span for UNO-proleDistance center to center [mm]
Blast load = 0,50 bar
UNOProle
IDFixed-xed Fixed-
hingedHinged-hinged Cantilever
Max load on pri-mary support (kg)
U-41-1-P
Single
1 4600 2700 1500 300
1,5 4000 2300 1300 300
2 3700 2100 1200 300
3 3000 1800 1000 200
4 2600 1500 800 200
U-41-2-P
Double
1 5700 3300 1900 600
1,5 5100 3000 1700 500
2 4800 2800 1600 500
3 4100 2400 1300 400
4 3600 2100 1200 300
6 3000 1800 1000 300
8 2600 1500 800 200
Table 5.7
Secondary SupportPrimarySupport
Max span for UNO-proleDistance center to center [mm]
Blast load = 0,55 bar
UNOProle
IDFixed-xed Fixed-
hingedHinged-hinged Cantilever
Max load on pri-mary support (kg)
U-41-1-P
Single
1 4400 2600 1400 3001,5 3800 2200 1200 300
2 3500 2000 1100 200
3 2900 1700 900 200
4 2400 1400 800 200
U-41-2-P
Double
1 5400 3200 1800 400
1,5 4900 2900 1600 400
2 4600 2700 1500 300
3 3900 2300 1300 300
4 3500 2000 1100 200
6 2900 1700 900 200
8 2400 1400 800 200
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Table 5.8
Secondary SupportPrimarySupport
Max span for UNO-proleDistance center to center [mm]
Blast load = 0,60 bar
UNOProle
IDFixed-xed Fixed-
hingedHinged-hinged Cantilever
Max load on pri-mary support (kg)
U-41-1-P
Single
1 4200 2500 1400 300
1,5 3600 2100 1200 300
2 3300 2000 1100 200
3 2700 1600 900 200
4 2300 1400 700 100
U-41-2-P
Double
1 5200 3300 1700 400
1,5 4700 3000 1500 300
2 4400 2800 1400 300
3 3800 2400 1200 300
4 3300 2100 1100 200
6 2800 1800 900 200
8 2300 1500 700 100
Table 5.9
Secondary SupportPrimarySupport
Max span for UNO-proleDistance center to center [mm]
Blast load = 0,65 bar
UNOProle
IDFixed-xed Fixed-
hingedHinged-hinged Cantilever
Max load on pri-mary support (kg)
U-41-1-P
Single
1 4100 2400 1300 3001,5 3500 2100 1100 200
2 3200 1900 1000 200
3 2600 1500 800 200
4 2200 1300 700 100
U-41-2-P
Double
1 5000 2900 1600 400
1,5 4500 2600 1500 300
2 4200 2500 1400 300
3 3600 2100 1200 300
4 3200 1900 1000 2006 2700 1600 900 200
8 2200 1300 700 100
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Table 5.10
Secondary SupportPrimarySupport
Max span for UNO-proleDistance center to center [mm]
Blast load = 0,70 bar
UNOProle
IDFixed-xed Fixed-
hingedHinged-hinged Cantilever
Max load on pri-mary support (kg)
U-41-1-P
Single
1 3900 2300 1300 300
1,5 3400 2000 1100 200
2 3100 1800 1000 200
3 2500 1500 800 200
4 2100 1300 700 100
U-41-2-P
Double
1 4800 2800 1600 400
1,5 4300 2500 1400 300
2 4000 2400 1300 300
3 3500 2000 1100 200
4 3100 1800 1000 200
6 2600 1500 800 200
8 2100 1300 700 100
Table 5.11
Secondary SupportPrimarySupport
Max span for UNO-proleDistance center to center [mm]
Blast load = 0,75 bar
UNOProle
IDFixed-xed Fixed-
hingedHinged-hinged Cantilever
Max load on pri-mary support (kg)
U-41-1-P
Single
1 3800 2200 1200 3001,5 3300 1900 1100 200
2 3000 1700 1000 200
3 2400 1400 800 200
4 2100 1200 700 100
U-41-2-P
Double
1 4600 2800 1600 300
1,5 4200 2400 1400 300
2 3900 2300 1300 300
3 3400 2000 1100 200
4 3000 1700 1000 2006 2500 1400 800 200
8 2100 1200 700 100
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5.2.10 Primary Support Bracket Design
The primary support brackets can be constructed in the following congurations:
Table 5.12 Primary Support Bracket Designs, Single UNO-prole
All bracing single UNO or similar Part no.
Name of member Height h (m) Max. Load F (kg)
A
K10-400-P-SSor similar
0,2 1000
0,4 500
B
K10-400-P-SS
or similar
1,0 2629
1,4 1341
1,8 811
C
K10-400-P-SS
or similar
1,4 2683
2,0 1315
2,5 841
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Table 5.13 Primary Support Bracket Designs, Double UNO-prole
All bracing single UNO or similar Part no.
Name of member Height h (m) Max. Load F (kg)
A
K20-600-P-SS
or similar
0,35 1500
0.67 750
B
K20-600-P-SS
or similar
1,0 2629
1,4 1341
1,8 811
C
K20-600-P-SS
or similar
1,4 2683
1,8 1623
2,5 841
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Table 5.14 Primary Support Bracket Cradle Design, Single UNO-prole
All bracing single UNO or similar Part no.
Name of member Height h (m) Max. Load F (kg)
A
K10-400-P-SS
or similar
0,2 2000
0,4 1000
B
K10-400-P-SS
or similar
1,0 2629
1,4 1341
1,8 811
C
K10-400-P-SS
or similar
1,4 2683
1,8 1623
2,5 841
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Table 5.15 Primary Support Bracket Ladder Design, Single UNO-prole
All bracing single UNO or similar Part no.
Name of member Height h (m) Max. Load F (kg)
A
K10-400-P-SS
or similar
0,2 2000
0,4 1000
B
K10-400-P-SS
or similar
1,0 2629
1,4 1341
1,8 811
C
K10-400-P-SS
or similar
1,4 2683
1,8 1623
2,5 841
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Table 5.16 Primary Support Cradle Designs, Double UNO-prole
All bracing single UNO or similar Part no.
Name of member Height h (m) Max. Load F (kg)
K20-600-P-SS
or similar
0,33 2000
0.67 1500
K20-600-P-SS
or similar
1,0 2629
1,4 1341
1,8 811
K20-600-P-SS
or similar
1,4 2683
1,8 1623
2,5 841
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Table 5.17 Primary Support Ladder Designs, Double UNO-prole
All bracing single UNO or similar Part no.
Name of member Height h (m) Max. Load F (kg)
K20-600-P-SS
or similar
0,33 2000
0.67 1500
K20-600-P-SS
or similar
1,0 2629
1,4 1341
1,8 811
K20-600-P-SS
or similar
1,4 2683
1,8 1623
2,5 841
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5.3 INSTALLING
5.3.1 Cutting
Protective wear must be worn and safety precautions observed, as dened by the
manufacturer of the cutting tool. This applies to all cutting methods described in
the following instructions.
Some of the methods shown below may require “ Hot Work” permits.
A ne-toothed blade is always recommended for a clean cut.
5.3.1.1 Cutting using an air driven, slow moving band saw with water ushing
This method entails no risk of sparks.
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5.3.1.2 Cutting using Tiger saw/Bayonet saw
This cutting method may cause sparks and must therefore only be performed in
suitable areas. Will require a work permit for “Hot-Work”.
Fasten the saw to the pipe withequipment suitable for the saw.
Let the saw work through the pipe
without using excessive force.
The cut should be perpendicular
to the pipe.
This method is also suitable for cutting in installed systems.
5.3.1.3 Cutting using a hacksaw
This cutting method may cause sparks and must therefore only be performed in
suitable areas. Will require a work permit for “Hot-Work”.
The cut should be perpendicular
to the pipe
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5.3.2 Jointing
Equipment • Pipe tting
required: • Band-It band (quantity in accordance with the Band-It chart)
• Sealant (Superx and re sealant) • Band-It machine
• Chain block
• Rubber mallet / bre mallet
5.3.2.1 Preparation of passive Fire Protection for joints
All Fire protection material andclamps must be slided onto each
pipe end before it is assembled with
the tting.
Band-It clamps for the re protec-
tion material
If the is used in
classied areas, all joints must be re
protected. The re protection material
and clamps must be slided over one
end of the pipe before the other end isassembled onto the joint connection.
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5.3.2.2 Installing Pipe Fittings
For cutting , see chapter 5.3.1.
Use a chain block and slings to
ease the installation of ttings into
pipes.
Position the tting into the pipe
against the stop marking.
If it is difcult to insert the tting use a rubber mallet or similar which will not
damage the tting.
Do not use any metal tools.
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Slide Band-It bands in correct number and suitable dimension according to
the chart below onto the pipes.
Inspect and remove loose objects
Inspect the pipe tting visually for
damages or other defects
Mark the pipe for correct position-
ing of Band-It bands and tighten in
order 1 - 2
1 2
Table 5.18 Band-It Specications
dimension
Outsidediameter
No. of Band-Itbands per end
Type Band-It band Type Band-Itlock
ID 25 1” 53 mm 2 ULC, 0,030”X3” INCONEL 625
ID 40 1 ½” 68 mm 2 ULC, 0,030”X3” INCONEL 625
ID 50 2” 78 mm 2 ULC, 0,030”X31/2” INCONEL 625
ID 75* 3” 103.5 mm 3 ULC, 0,030”X41/2” INCONEL 625
ID 100* 4” 128.5 mm
ID 150* 6” 184 mm
ID 200* 8” 234 mm
All dimensions use Band-It lock type INCONEL 625
* Dimensions marked in “italic” normally are secured with ConNect clamps not Band-It,
refer to 5.3.2.5
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Insert the connector into the rst
pipe, check for correct location.
Likewise insert rest of pipes.
Apply Superx sealant evenly to
the end surfaces with the aid of a
putty knife or similar.
This is made easier if the tool is
coated with dishwashing soap
before use.
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When the tting and pipes are in
place, t the Band-It bands accord-
ing to Chapter 5.3.2.4
Apply Jet Fire Tape to line up with
the length of the re protection,
and min. 30mm from the outer
Band-It band.
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Fit the Tee Fire Protection and
secure with Band-It. Pry open and
slide the in-line Fire Protection in
position around the Tee.
The split in the In-line Protection
must be covered with a piece of
Band-It band, secured with clamps.
Apply re sealant to all joints
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5.3.2.3 Fitting a nozzle clamp on
Equipment • Cutting tool
required: • Nozzle clamp
• Loctite thread lock
• Band-It bands (quantity according to the Band-It chart)
• “Superx” sealant (in the hole)
• Band-It machine UL 9000
Place the two halves of the nozzle
in the desired position and secure it
with Band-It bands.
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Enter the cutting tool in the threaded
opening and drill a hole in the pipe.
The cutting tool is designed to cut only
as far into the pipe as is necessary.
¾″Band-It
Remove the inner rubber with a sharpknife and check that no rubber pieces
are left in the pipe. Apply Superx
sealant, making sure that the rein-
forcement area is covered.
Apply re tape on each side of the
nozzle mount.
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Pull the re protection over the nozzle
clamp and fasten it with Band-It bands
Screw the nozzle into the hole in the
clamp (hand¬tight + 1 ½ turn) and
mount the nozzle.
Af ter instal lation, check the system according to chapter 5.4
5.3.2.4 Operating the Band-It Machine
The following details are important and must be observed when tting
Band-It bands:
• Location of bands according to the markings.
• The machine’s angle in relation to the band.
• Sufcient space to operate the Band-It machine and the locking handle.
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Start the machine and the band will
gradually tighten. A rattling sound
indicates that the tightening mecha-
nism has reached the end position,but not that the band is rm. The
machine must be reversed to en-
gage a new grip before any further
tightening can be made.
Lock the band by pushing the han-
dle up to the locking position.
Reverse the machine to release the
band.
Band-It machine.
90°
Keep settings to match the calibration certicate. Electrically and pneumatically
operated machines have different and individual settings.
Please note the following when using pneumatically operated Band-It machine:
• Daily lubrication of the tool is necessary. Lubricate the thightening screw with
molybdenum grease.
• Run the machine until it stops completely. Then release the clamp and repeat the
process, making sure the clamp is tight.
• Trelleborg Offshore must carry out all repair and calibration onshore.
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Use of the pneumatic Band-It machine:
• Apply a few drops of oil in the pneumatic tool (via the air connector).
• The machine must only be used with an approved air regulator.
• The pressure setting must be set according to the machine’s calibration certicate.
Check the air pressure each time the machine is connected to compressed air.
Tightening Screw
Air Connector
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Bend excessive end up and down
until it breaks off
A correctly tted Band-It should look as illustrated below. The band must follow
the contour the lock, and must not sl ide back more than 1mm
Tap the buckle down with a ham-
mer to complete the lock
CORRECTWRONG
If the band is not correctly tted, it
must be retted with a new
After installation all connections with Band-It shall be controlled, approved anddocumented in accordance with procedure ID31785: “ Procedure for check of pipe
couplings,
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5.3.2.5 Mounting ConNect Clamps
Equipment • Pipe Fitting
required: • ConNect Clamps
• Sealant (Superx and re sealant)
• Molycoat
• Torque Wrench
Fire Protection
Sleeve
ConNect Clamp
Inboard Bolt
Outboard Bolt
Strap
Pipe Fitting
Rod
Strap
Installation sequence:
1. Slide the re protection sleeve and the ConNect clamp onto the before
the tting is inserted.
2. Insert the tting into the by hand, and push until the pipe contacts the
stop ring on the tting.
3. Lubricate the bolts and tighten sequencially to obtain a snug t. The rods should be
parallel, and the gaps should be equal on both sides, check by measuring.
4. Position the clamp.
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Strap
Fire Protection
Sleeve
ConNect Clamps
5. Tighten the inboard bolts (against the joint) sequentially to 50% of the labelled torque.
Each bolt maximum 2 turns at a time,using a torque wrench.
6. Tighten the inboard bolts to full labelled torque. Tighten the outboard bolts likewise.
7. Slide the second ConNect clamp onto the other before it is mounted onto
the tting.
8. Position the second clamp in line with the rst one, and repeat the steps 3 - 6.
9. Slide the re protection sleeve over the clamps, fasten with straps and seal the exposed
gaps with re sealant compound.
Af ter instal lation all connect ions wi th ConNect shall be control led, approved anddocumented in accordance with procedure ID31785: “ Procedure for check of pipe
couplings,
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5.3.2.6 Heat Tracing
1. In the heat tracing cable is drawn inside the pipe, exposed to the medium.
Max. 15 m Max. 15 m
Heat tracing Cable
Sealing kit
2. A ag line should be pulled through the pipe before connecting pipe and ttings to help
installing the heat tracing cable. The cable must be pulled carefully.
Lubricate cable with soap before installation.
Termination seals are supplied in plastic bags together with a mounting instruction that
should be followed thoroughly. The seal must be tightened rmly, without squeezing the
teon.
3. Install re protection according to chapter 5.3.2.1
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5.3.4 Mounting
Secure pipe and tighten the end
clamps. When appropriate support is installed,
place pipe clamps with max. spacing of
1.3m (tighten to avoid sagging).
Use a chain hoist and “soft-sling” to
lift and support the pipe during instal-
lation.
Minimum bend radius for
is 5D
See Table below
Table 5.19 Dimensions
Tubing Dimension D Bending Radius Weight
1” (ND25) 53 mm 265 mm 2,8 kg/m
1 1/2” (ND40) 68 mm 340 mm 3,5 kg/m
2” (ND50) 78 mm 390 mm 4,4 kg/m
3” (ND75) 103,5 mm 518 mm 6,6 kg/m
4” (ND100) 128,5 mm 643 mm 8,4 kg/m6” (ND150) 184 mm 920 mm 15,0 kg/m
8” (ND200) 234 mm 1170 mm 20,0 kg/m
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5.4 CHECKING
When the installation of the system is completed, and before anymounting of re protection, all supports, clamps and Band-It bands (locks,
position and quantity) must be inspected by a Trelleborg Offshore supervisor.
Use a check list for the inspection.
Flushing, pressure testing and full scale testing may be required and faults must be rectied
after the installation and testing procedure is completed.
Each system/project will require a unique set of tests.
5.4.1 Pressure Testing
5.4.2 Full scale function testing
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6 MAINTENANCE, REPAIRS AND MODIFICATION
has an expected life time of more than 20 years without maintenance, but
inspection of joints, nozzles, and end caps, etc. should be performed at regular intervals accord-
ing to inspection procedure 89104-005.
is well suited for modication as it is an easy system to expand.
Minor damages (< 4 cm² ) on the
pipe surface can be repaired by
applying a re protection section
over the damaged area.
Damages to larger areas of pipe
are replaced by cutting out the
damaged section and replacing it
by jointing in a new section.
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