Company Profile - One of the Leading Water Pipe Systems ... · PDF fileSaudi Pipe Systems Company has successfully ... AWWA C950-95 Standard for Glass-Fiber-Reinforced Thermosetting-Resin

In the pursuance to establish the main infrastructure industries with top of the line water system production lines and technology, The Saudi Pipe Systems Company has successfully established its manufacturing plants in Phase 4, Jeddah Industrial Zone, Jeddah, Saudi Arabia. SPS is one of the leading manufacturer of all kinds and sizes of Ductile Iron (D.I.) and Cast Iron (C.I.), Epoxy Powder Coated Valves, Fittings, Fiber Glass (GRP/FRP) Pipes, Pre-Insulated Pipes and Fittings and HDPE Pipes as well. Valves include: Gate, Butterfly, Check, Globe, Air Release, Float, Pressure Reducing Valves and several other types of valves, Fire Hydrants, Strainers, Flanges and other industrial materials related to Water sector. Beside D.I. Valves and Fittings, SPS manufactures wide ranges of Fiber Glass (GRP/FRP) and Pre-insulated Pipes and Fittings. The production ranges from 100mm to 3000mm with pressure rating from 6 Bars to 24 Bars. The annual production capacity is 87,000 L/M.

Moreover, SPS has also established a most advanced plant with fully automated extrusion lines for the manufacture of High Density Polyethylene (HDPE) Pipes with a minimum capacity of 8,500 tons / year approximately, covering the size ranges from 16mm – 630mm with pressure rating from 5 bars to 16 bars. SPS has full technical support from leading Companies namely: DUKER OVENTROP (Germany), and CLA-VAL (Switzerland). All SPS product are being tested at every stage of production by its highly qualified, competent and most experienced Quality Assurance Engineers prior to dispatch within and outside the Kingdom. All SPS products are being tested at every stage of production by its highly qualified, competent and most experienced Quality Assurance Engineers prior to dispatch within and outside the kingdom. SPS products are not only used by all renowned customer of the Kingdom of Saudi Arabia, but its products are being exported throughout the GCC countries and many other countries like: Egypt, Yemen, Sudan, etc.

Company Profile

1 P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925

Email: [email protected] Website: www.saudivalve.com

Specializes in producing GRP Pipes and Fittings from small to big ranges with standard specifications, through filament helical winding and continuous filament winding processes.

HDPE (HIGH DENSITY POLYETHELENE) PIPES FACTORY

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FOUNDRY AND VALVES FACTORY

Specializes in the processing and production of all types of Valves, Pipes Fittings, Pipe Clamps, and Flanges, which are essential for Water Sewage, Fire Fighting Systems, and Central Air Condition Systems. The factory also produces engineered castings of variety of metals (Ferrous and Non-Ferrous, e.g. Cast Iron, Ductile Iron, Aluminum, and Copper).

GRP ( FIBER GLASS POLYESTER ) PIPES AND FITTINGS

Specializes in producing HDPE Pipes through small to big sizes. The factory uses most advanced Machinery and Equipment which are operated by well qualified engineers and technicians.

Saudi Pipe Systems Division

P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925


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UNI9032 Pipes in glass-reinforced thermosetting resin (GRP)

UNI9033 and/or mortar pipes used in any application.

ASTM D 2996-88 Filament-Wound Reinforced Thermosetting Resin Pipe.

ASTM D3262-88 Reinforced Plastic Mortar Sewer Pipe

ASTM D3754-88 Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin Sewer and Industrial Pressure Pipe

ASTM D3517-88 Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin Pressure Pipe

AWWA C950-95 Standard for Glass-Fiber-Reinforced Thermosetting-Resin Pressure Pipe.

BS 5480-90 Specification for Glass fiber reinforced plastics (GRP) pipes and fitting to use for water supply or sewerage

ASTM D3262 Gravity Sewer

AWWA C950 Fiberglass Pressure Pipe

AWWA M45 Fiberglass Pipe Design Manual

SASO-1577 Gravity Sewer

SASO-1578 Pressure Sewer ASTM D3839 and Appendix AWWA C950-95 in relation to the inspection standards buried pipes.

GRP Pipe Characteristic Unit of Measurement Filament Winding

Traction Resistance Circ. direct

Kg/cm² 2500-3000

Axial Direct 800-1300

Elasticity Young Modules

Circumferential direct. Kg/cm²

240-3000

Axial direct. 105-125

Density Kg/cm³ 1.9

Barcol Hardness 35-45

Thermal Conductivity Kcal/mh˚C 0.22

Coefficient of Linear Thermal Expansion

cm/cm˚C 1.6*10¯⁵

Electrical Resistivity ohm/cm 10^14

Dielectric Constant F/cm 3-4

Three Base Materials Are Used For The Pipes Having Distinct Characteristic. •Polyster thermosetting resin being of three types : Isophtalic, Bisphenolic, and Vinylester •Continuous fiberglass roving. •Silica sand (optional)

Standards The SPS pipes produced in our plant are manufactured in glass reinforced thermosetting resin (GRP) by the Filament and Continuous Winding system. Reference is made to the following international standards.

GRP Pipe Component



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GRP PIPE PRESSURE Vs. DIAMETER CHART

RTRP (REINFORCED THERMOSETTING RESIN PIPE) A fiberglass pipe without aggregate. Manufactured by the filament winding process up to 24 in. nominal size.

RESIN USED IN SPS RTR PIPES

1.ISOPHTHALIC POLYESTER RESIN

Used for moderate corrosion resistance to water, acids, weak bases, and hydrocarbons such as gasoline and oil. 2.VINYL ESTER RESIN

Offers maximum corrosion and temperature resistance to acid, alkalis, hypochlorite, and many solvents. These products have been formulated for maximum performance with methyl ethyl ketone peroxides. It is well documented that these catalysts provide optimal cure and thus maximum corrosion resistance. PRODUCT USAGE OF VINYL ESTER RESIN

1.Flame retardant / Heat resistance

2.Chemical resistance

3.Ultra Violet Rays 4.High strength to weight ratio

5.Electrical and thermal insulation.

Characteristic of Pipes



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HYDROSTATIC LEAK TEST

PRESSURE REQUIREMENTS

PRESSURE CLASS, Kpa

HYDROSTATIC PRESSURE TEST, Kpa

345 689

689 1034

1034 1379

1379 2068

2068 1724

1724 3447

MINIMUM PIPE STIFFNESS REQUIREMENTS

FOR 5% DEFLECTION

DN STIFFNESS CLASS

62 124 248 496

mm MIN. PIPE STIFFNESS REQUIRED, Kpa

25-200 NR NR 36 72

250 NR 18 36 72

300-3600 9 18 36 72

DEFLECTION LEVEL STIFFNESS CLASS (SN)

2500 5000 1000

A 15% 12% 9%

B 25% 20% 15%

HYDRAULIC FAILURE TEST

ASTM D1599

Every pipe must be tested to two times the nominal pressure for two minutes or as long as a specific standard requires. To reduce the risk of making scrap, there should never be more than 4 untested pipes.

HYDROSTATIC DESIGN BASIS – HDB

ASTM D2992

Requires pipe to withstand a constant pressure of 1.8 times the maximum operating condition. Considering internal pressure and external soil loads, Hydrostatic pressure testing to failure (leakage) of pipe sample at variety of very high constant pressure level is applied.

INITIAL RING DEFLECTION

LEVEL A - No visual evidence of cracking. LEVEL B - No structural damage to the pipe wall. GRP pipe’s long term (50 year) Ring deflection/bending (strain) capability when

exposed to an aqueous environment and under a

constant load must meet level A deflection level.

PARALLEL PLATE LOADING TEST ASTM D2412-02 Parallel Plate Stiffness testing machine is designed to determine the load deflection characteristics of GRP pipe under parallel-plate loading. The characteristics determined by this method are pipe stiffness, stiffness factor, and load at specific deflections

Long Term Material Properties Testing



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UNI9032 Pipes in glass-reinforced thermosetting resin (GRP)

UNI9033 and/or mortar pipes used in any application.

ASTM D 2996-88 Filament-Wound Reinforced Thermosetting Resin Pipe.

ASTM D3262-88 Reinforced Plastic Mortar Sewer Pipe

ASTM D3754-88 Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin Sewer and Industrial Pressure Pipe

ASTM D3517-88 Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin Pressure Pipe

AWWA C950-95 Standard for Glass-Fiber-Reinforced Thermosetting-Resin Pressure Pipe.

BS 5480-90 Specification for Glass fiber reinforced plastics (GRP) pipes and fitting to use for water supply or sewerage

ASTM D3262 Gravity Sewer

AWWA C950 Fiberglass Pressure Pipe

AWWA M45 Fiberglass Pipe Design Manual

SASO-1577 Gravity Sewer

SASO-1578 Pressure Sewer ASTM D3839 and Appendix AWWA C950-95 in relation to the inspection standards buried pipes.

GRP Pipe Characteristic

Unit of Measurement Filament Winding

Traction Resistance Circ. direct

Kg/cm² 2500-3000

Axial Direct 800-1300

Elasticity Young Modules

Circumferential direct. Kg/cm²

240-3000

Axial direct. 105-125

Density Kg/cm³ 1.9

Barcol Hardness 35-45

Thermal Conductivity Kcal/mh˚C 0.22

Coefficient of Linear Thermal Expansion

cm/cm˚C 1.6*10¯⁵

Electrical Resistivity ohm/cm 10^14

Dielectric Constant F/cm 3-4

Base Materials Used For The Pipes Having Distinct Characteristic. •Polyster thermosetting resin being of three types : Isophtalic, Bisphenolic, and Vinylester •Continuous fiberglass roving. •Silica sand (optional)

Standards The SPS pipes produced in our plant are manufactured in glass reinforced thermosetting resin (GRP) by the Filament and Continuous Winding system. Reference is made to the following international standards.

GRP Pipe Component



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STRAIN CORROSION TEST Covers the procedure for determining the chemical - resistant properties of fiberglass pipe in a deflected condition.

Quality Control



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APPLICABLE PROCEDURES / DOCUMENTS INSPECTION / TESTING

ASTM D2563 Visual Inspection

ASTM D3567 Dimension Control

ASTM D2583-87 Barcol Hardness

ASTM D2105-90 Longitudinal (Axial) Tensile Strength

ASTM 2290-00 Hoop (Circumferential Tensile Strength

ASTM D1599 Hydrostatic Leak Test (Hydraulic)

ASTM D2412-02 Stiffness Test

ASTM D2584-68 Glass Reinforcement Content (Loss of Ignition)

QUALITY CONTROL ON PRODUCTS The test, which the products undergo during the manufacturing stages and before dispatching ensures that they fully comply with the international specifications and that they suitable for the usage which they have been made for.

SPS STANDARD SPECIFICATION FOR FIBER GLASS PIPE

Quality Control

BASIN WITH CORROSIVE SOLUTION

DEFLECTED PIPE



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LABORATORY SPS has made the effort to have state of the art laboratory of testing department. This department supervise and issue certificate on all test perform or according to project consulting required.

TESTING SPS-GRP PIPES undergo a series of tests to assure quality standards, these tests are performed on each pipe/batch. • Testing starts on raw materials by making sure of choosing the highest quality raw material we can assure top quality final product. • By inspecting-dimensions and visual/weight throughout production line. • Step by step: follow up checking of materials as they advance throughout the production line. All the way to finished products. • All raw materials undergo extensive testing to assure and confirm that it meets technical specifications and standard of products.

RESINS Density at 25˚C ASTM D 792 Viscosity at 25˚C ASTM D2393-86 Gel Time at 25˚C ASTM D2471-94 Exothermic Peak ASTM D2471 Acid Number - ASTM D1639 H.D.T. ( 264 psi) ASTM D648 Color(Gardener Scale) ASTM D1544 Volumetric Shrinkage UNICHEM2–1969 GLASS MASS PER UNIT AREA ISO 3374-2000 PERCENT HUMIDITY ISO 3344-1997 LOSS OF IGNITION ISO 1887-1995

TEST FOR THE APPROVAL OF RAW MATERIALS Besides test based on workability and test based on verification of the chemicals inertness for resins, for the approval of new raw materials the tests listed in the former paragraph shall be completed with the following tests.

RESIN -Tensile Strength ASTM D 638 M 87 b -Flexural Strength ASTM D 790 M 86

GLASS -Split Disk ASTM D 2290 / 76

Quality Assurance and Testing

PROPERTIES OF SPS GRP PIPES •SERVICE LIFE OF 50 YEARS. •ENVIRONMENTALLY FRIENDLY. •CAN BE TRANSPORTED AS NESTED. •CORROSION RESISTANCE. Resistant to corrosion in a wide range of fluid handling applications. •STRENGTH TO WEIGHT Pipe strength per unit weight surpasses iron, carbon, and stainless steels. •LIGHTWEIGHT 1/6 the weight of other steel with similar properties and 1/10 the weight of similar concrete product. •NON-CONDUCTIVE not necessary to dissipate static electricity build-up when transporting certain fluids such as jet fuel. •DIMENSIONAL STABILITY meet the most stringent material stiffness, dimensional tolerance, weight and cost criteria. •LOW MAINTENANCE COST Resistant to rust and require minimal protection from the environment.



RESIN -Polyester resins based on bisphenol or bisphenol A. -Polyester resins based on Isophthalic acid. -Vinyl Ester resins based on urethane modified or epoxy based. In all cases the resins are taken as a solution of 45 to 50% of styrene monomer.

MAT -A fibrous material consisting of random-oriented, chopped, or swirled filaments loosely held together with a binder.

SURFACING MAT -A thin mat of fine fibers used primarily to produce a smooth surface on a reinforced plastic.

HOOP DIRECT ROOVING -A collection of parallel glass strand or filaments, coated with a finished or coupling agent, to improve compatibility with resins, gathered without mechanical twist. (Fig. 1)

WOVEN ROOVING -A glass-fiber fabric reinforcing material made by the weaving of glass-fiber roving.

CATALYST -MEKP (Methyl Ethyl Ketone Peroxide) in phthalate plasticizer with 9% active oxygen and 33% peroxide content used on an average of 1.5% in the resin.

PROMOTERS -Cobalt octoate in phthalate plasticizer with 6% metal used on an average of 0.4% in the resin.

INHIBITORS -Pera-t-butyl-catechol, 10%, in phthalate plasticizer used on an average of 0.1% in the resin.

SILICA SAND -Siliceous sand conforming to ASTM C33, except that the requirements for gradation need not apply.

Material Used In Production Process



HELICAL FILAMENT WINDING MACHINE Pipes are manufactured using the Filament Winding process on computer controlled machines (CAM), by adjusting the relative speed of mandrel rotation and glass distribution head movement, helical reinforced layer with different angles can be wound. The inside diameter of the finished pipe is defined by the mandrel outside diameter and the designed wall thickness is achieved by repeated passes. Therefore the outside diameter of pipe (OD) is determined by the wall thickness. In order to increase pipe stiffness, specially on large diameter pipe, silica sand can be added to parallel layers of the mechanical wall.

MAIN CHARACTERISTIC OF FILAMENT WINDING PROCESS •Bell and Spigot ends are monolithic with the pipe wall. •Optimization of axial and hoop characteristic can be obtained by changing the winding angles. •Axial strength normally higher than pipe produced with other processes. •Pipe stiffness is not related to joint stiffness that is in any case higher than pipe stiffness. Pipes are manufactured using the filament winding process are used either for above ground and underground installation, with gravity flow, medium and high internal pressure.

GRP Manufacturing Method

MANDREL

RESIN BATH TRANSLATE

ROTATION



PIPE WALL STRUCTURE GRP pipe wall consist of three layers perfectly adherent one to the other and each having different characteristic and properties in relation to their function.

LINER Liner or chemically resistant layer is the internal layer of the pipe, it is in direct contact with the conveyed fluid. This layer has the function to guarantee the resistance to the chemical corrosion and the impermeability of the whole pipe. Liner has the internal surface namely the one in contact with the conveyed fluid, particularly smooth. This characteristic of smoothness reduces to minimum the fluid head losses and pumping heads and opposes to the growth of mineral deposits and algae. Liner is made of two monolithic sub-layers (1) Inner, in direct contact with the fluid, is reinforced with glass veil “C” 30 g/m2, with ratio resin content in a range 80% - 90%by weight (2) Outer, reinforced with plies of glass mat “E” of 450 g/m2, with a resin content in a range of 60% - 70% by weight.

MECHANICAL RESISTANT LAYER Glass reinforced layers guarantee the mechanical resistance of the whole pipe against stresses due to internal and/or external pressure, external load due to handling and installation, and thermal loads. The layer is obtained by applying on the previous partly curved liner, continuous roving of glass wetted with resin, under controlled tensioning. This layer can contain aggregates (inert granular material such as silica) in order to increase the stiffness of the whole pipe. Thickness of mechanical resistant layer depends on the design condition.

TOP COAT Top coat or Gel coat is the outer layer of the pipe which consist of pure resin added with UV protectors to protect the pipe from sun exposure. In case of severe exposure conditions, i.e. aggressive soils or very corrosive environment, the gel coat can be reinforcement with a surfacing veil or added with fillers or pigments.

MECHANICAL RESISTANT

LAYER

TOP COAT

LINER

GRP Pipe Helical Filament Winding



NOMINAL DIAMETER INSIDE DIAMETER

mm in mm in

100 4 100 4

150 6 150 6

200 8 200 8

250 10 250 10

300 12 300 12

350 14 350 14

400 16 400 16

450 18 450 18

500 20 500 20

600 24 600 24

700 27 700 27

800 30 800 30

900 36 900 36

1000 39 1000 39

1100 42 1100 42

1200 48 1200 48

1300 51 1300 51

1400 54 1400 54

1500 60 1500 60

1700 66 1700 66

1800 72 1800 72

2000 78 2000 78

2200 84 2200 84

2300 90 2300 90

2400 96 2400 96

2600 102 2600 102

NOMINAL DIAMETER ASTM D3567

INSIDE DIAMETER SERIES

SPS pipes manufactured in Helical Filament Winding are ranging from diameters 100mm to 2600mm. Nominal diameter coincides with the internal diameter. Any nominal diameter can be manufactured. Larger diameters can be manufactured at site by means of special equipment.

DIMENSION OF PIPE

DN

Dimension Control



GRP Pipe Continuous Filament Winding Machine

The Continuous Filament Winding Machine is designed for the continuous production of GRP pipes. Similar to Helical Filament Winding, but continuous, this process allows to produce only cylindrical parts like pipes, based on a special continuous mandrel design. In this process, both single-end roving and chop (multi-end) roving are necessary. It is designed for very high production capacity. It is ideal choice when the GRP pipes are used for water transmission and distribution, desalination plants, cooling systems in power plants, irrigation projects and sewage systems.

Using this technology and developed by material specialist, a very dense laminate is created that maximizes the contribution from the three basic raw materials. Both the continuous glass fiber roving and chop able roving are incorporated for high hoop strength and axial reinforcement. A sand as fortifier is used to increased the stiffness with placement near the neutral axis in the pipe wall core.

The basic machine for manufacturing (winder) is composed of a continuous steel band supported by beans which form a cylindrically shaped mandrel. The beans rotate, friction pulls the band around and roller bearings allow the band to move longitudinally so that the entire mandrel continuously moves in a spiral path toward the end of the machine. As the mandrel moves fine graded filler, glass fibers and resins and surface materials are metered on in precise amount under the direction of a programmable logic controller (PLC) and computer (PC). The PLC-PC modules provide integrated process control based on the recipes encoded. Only basic pipe such as diameter pressure and stiffness class need to be entered and the computer calculates the settings.



GRP Pipe Wall Structure

The wall of the pipe manufactured on continuous filament winding machine is made of several layers.

OIOU OUTER LINER

OUTER SKIN

MORTAR CORE

INTERNAL SKIN HOOP ROVING AND CHOP REINFORCEMENT

ANTI-DIFFUSION BARRIER CHOP MATERIAL REINFORCEMENT

INTERNAL LINER – RESIN RICH SURFACING VEIL REINFORCEMENT

TOTA

L TH

ICK

NES

S

INTERNAL LAYER Layer directly contact with the internal fluid, and is resin rich (approx.90% by weight), reinforced with a surfacing veil made of C glass (chemical resistant very light fiberglass mat), or polyester veil. Thickness ≈ 0.2mm for 1 only surfacing veil, but can be doubled.

ANTI DIFFUSION BARRIER Part of the internal layer, is resin rich (approx.70% by weight) and is reinforced with chopped roving of E glass. The function is to stop the propagation of micro-cracks from the mechanical layer (inner skin) to the internal layer. Thickness ≈ 0.8 mm to 2 mm or more according to project-specification. The standard is 0.8 mm.

INNER HIGH STRENGTH SKIN Forms the mechanical resistant layer together with the core and the outer skin. Reinforced with high strength hoop wound fiberglass roving (50-60% by weight), and chopped roving (10-20% by weight). The resin content is 25-30% by weight.

MORTAR CORE To increase the thickness and the stiffness of the pipe without using a lot of valuable raw materials. the main constituent of the mortar core is silica sand, with a few hoop and chop roving and as low as possible resin.

OUTER HIGH STRENGTH SKIN As the inner skin. Generally it has the same thickness of the inner skin, but can be different.

OUTER LINER The outer liner can be simply pure resin, but can be also reinforced with a surfacing veil, in order to increase the finishing and the chemical resistance to the environment.

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Outside Diameter Series

SPS pipes manufactured in Continuous Filament Winding are standardized on the basis of the outside diameter in order to use standard coupling. Nominal Diameter (DN) and outside Diameter (OD) are taken from the International Standards, basically the AWWA C-950.

DIMENSION OF PIPE FOR CONTINUOUS FILAMENT WINDING

z DN

OUTSIDE DIAMETER SERIES OUTSIDE DIAMETER SERIES

NOMINAL DIAMETER OUTSIDE DIAMETER NOMINAL DIAMETER OUTSIDE DIAMETER

mm mm mm mm

300 310 1300 1332

350 361 1400 1434

400 412 1500 1536

450 463 1600 1638

500 514 1700 1740

600 616 1800 1842

700 718 1900 1944

800 820 2000 2046

900 924 2100 2148

1000 1026 2200 2250

1100 1128 2300 2351

1200 1229 2400 2453

2500 2556



DN PN1 PN6 PN10 PN16 PN20 PN25 PN32

80 N/A 89 178 238 269 N/A N/A

100 N/A 119 238 318 358 N/A N/A

150 N/A 178 357 477 538 N/A N/A

200 N/A 238 476 636 717 N/A N/A

250 N/A 297 595 795 896 N/A N/A

300 N/A 357 714 95 1076 N/A N/A

350 70 420 400 1120 1400 1750 2240

400 80 480 800 1280 1600 2000 2560

450 90 540 900 1440 1800 2250 2880

500 100 600 1000 1600 2000 2500 3200

600 120 720 1200 1920 2400 3000 3840

700 140 840 1400 2240 2800 3500 4480

800 160 960 1600 2560 3200 4000 5120

900 180 1080 1800 2880 3600 4500 5760

1000 200 1200 2000 3200 4000 5000 6400

1200 240 1440 2400 3840 4800 6000 7680

1400 280 1680 2800 4480 5600 7600 8960

1600 320 1920 3200 5120 N/A N/A N/A

1800 360 2160 3600 5760 N/A N/A N/A

2000 400 2400 4000 6400 N/A N/A N/A

2400 480 2880 4800 7680 N/A N/A N/A

2500 500 3000 5000 8000 N/A N/A N/A

LENGTH

The standard length of SPS Pipe is normally 12 meters for DN150 and above. DN100 are only available in 9 meter standard lengths.

LOAD CAPACITY VALUES

The following values can be applied for axial tensile and hoop tensile for design objectives.

HOOP TENSILE LOAD CAPACITY Minimum hoop or circumferential load, N per length (mm)

HOOP TENSILE LOAD CAPACITY

SPS Pipe Technical Data



DN PN1 PN6 PN10 PN16 PN20 PN25 PN32

80 N/A 89 178 238 269 N/A N/A

100 N/A 119 238 318 358 N/A N/A

150 N/A 178 357 477 538 N/A N/A

200 N/A 238 476 636 717 N/A N/A

250 N/A 297 595 795 896 N/A N/A

300 N/A 357 714 95 1076 N/A N/A

350 70 420 400 1120 1400 1750 2240

400 80 480 800 1280 1600 2000 2560

450 90 540 900 1440 1800 2250 2880

500 100 600 1000 1600 2000 2500 3200

600 120 720 1200 1920 2400 3000 3840

700 140 840 1400 2240 2800 3500 4480

800 160 960 1600 2560 3200 4000 5120

900 180 1080 1800 2880 3600 4500 5760

1000 200 1200 2000 3200 4000 5000 6400

1200 240 1440 2400 3840 4800 6000 7680

1400 280 1680 2800 4480 5600 7600 8960

1600 320 1920 3200 5120 N/A N/A N/A

1800 360 2160 3600 5760 N/A N/A N/A

2000 400 2400 4000 6400 N/A N/A N/A

2400 480 2880 4800 7680 N/A N/A N/A

2500 500 3000 5000 8000 N/A N/A N/A

Nominal Pressure (PN) Pressure Rating (Bar) Diameter Limit (mm)

1 1 3700

6 6 3700

10 10 2500

16 16 2000

20 20 1400

25 25 1400

32 32 1400

AXIAL TENSILE LOAD CAPACITY Minimum axial or longitudinal load, N per circumference (mm)

PRESSURE Nominal Pressure of SPS pipes are listed below. Some nominal pressures are not available in all diameter and stiffness’s.




STIFFNESS CLASS N/ m3

SN 2500 2500

SN 5000 5000

SN10000 10000

HYDROTESTING

Standard Factory Test Pressure 1.5 x PN

Maximum Field 1.5 x PN (Nominal Pressure)

Maximum Pressure 1.4 X PN (Nominal Pressure)

SURGE

STIFFNESS CLASS GRP pipe can be supplied to the following stiffness

FLOW VELOCITY The flow velocity for clean water and contains no abrasive material are up to 4m/sec. The recommended maximum flow velocity is 3m/sec.

ULTRA VIOLET DEGRADATION EFFECT Discoloration in the outermost of the SPS pipe may be occurred due to exposure from sunlight or by ultra violet degradation. However, it cannot affect to the long term service of SPS pipe. Proper maintenance is also required to make the service of the pipe longer.

POISON’S RATIO In any pipe constructions the Poison’s ratio is required. The Poison’s ratio of SPS pipe is slightly less by using the following hoop tensile and axial loading ranging 0.22 to 0.29.

THERMAL COEFFICIENT The SPS pipe thermal coefficient of axial expansion and contraction is between 24 to 30 x 104 cm/cm/°C




Steel, Ductile and Iron pipes 50%

SPS Pipe surge pressure allowance 40% of Nominal Pressure

DN 350-400 450-800 900-2500

SN 2500 meter/sec

PN6 365 350 340

PN10 435 420 405

PN16 500 490 480

DN 350-400 450-800 900-2500

SN 10000 meter/sec

PN6 420 415 410

PN10 435 425 415

PN16 500 465 485

PN25 580 570 560

PN32 620 615 615

DN 80 100 150 200 250

SN 10000 meter/sec

PN6 580 560 540 520 500

PN10 590 570 560 50 520

PN16 640 620 610 600 590

DN 350-400 450-800 900-2500

SN 5000 meter/sec

PN6 405 380 370

PN10 435 420 410

PN16 505 95 480

PN25 575 570560

SURGE AND WATER HAMMER

WATER HAMMER Water hammer or pressure surge is the sudden rise or fall in pressure caused by abrupt change in the fluid velocity within the pipe system.

THE CAUSE OF WATER HAMMER PRESSURE IN THE PIPE: 1. Rapid closing or opening of valves. 2. Sudden starting or stopping of pumps such as during power failure. 3. Change in velocity of the fluid. 4. Rate of change of velocity (valve closing time). 5. Compressibility of the fluid 6. Stiffness of the pipe in the “hoop” direction and physical lay-out of pipe system.

SPS PIPE WATER HAMMER PRESSURE APPROXIMATION AND ALLOWANCE:

An approximate relationship for the maximum pressure variation at a given point in a straight pipeline with negligible friction loss can be calculated from the formula:

ΔH = (w∆v) / g Where: ΔH = change in pressure (m) Δv = change in liquid velocity (m/s) w = surge wave celerity (m/s) g = acceleration due to gravity (m/s) SPS PIPE SURGE WAVE CELERITY

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SPS -GRP Pipe Hydraulic Characteristics

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Saudi Pipe Systems Co. (SPS) produces GRP pipes by continuous filament winding machines, by reproducible processes. All these pipes are provided with rich interior layers, providing very smooth inner surfaces. This smooth interior surfaces results in very low fluid resistance.

For hydraulic analysis of the every piping system, pipe roughness is the concern. One of the FAQ by the Hydraulic Engineers / Consultants / Contractors / Clients is what the value of GRP pipe toughness is.

This roughness is being used in various forms in various equations of hydraulic analysis. Find below the summary of the mean value based on the experimental studies.

These values are based on the experimental studies carried out by Owens Corning and SINTEFF from Norway. Complete report is available upon request.

In fact AWWA C-950 also recommends for the usage of similar values. This confirms that above values are in good agreement even with the international standards.

Apart from above, the interior pipe surfaces, typically remains smooth overtime, in most fluid services . Therefore, fluid resistance will not increase with age. This has been demonstrated, when few GRP pipes under operation over the decade were inspected and evaluated. Certificate from respective authorities is available upon request confirming no deterioration.

Roughness Parameters (Means Values)

Flow Rate Cole Brook-White Manning Hazen-Williams

(m3/hr) Є or K (mm) M (m1/3/s) C (10-1.38m0.37/s)

150 N/A 178 357

For any additional hydraulic requirements and clarifications do not hesitate to approach SPS. We are willing to assist you anytime.

ABRASION RESISTANCE Abrasion resistance can be related to the effects that sands or other similar material may have on the interior surface of the pipe. While there is no widely standardized testing procedure or ranking method. SPS-GRP Pipe has been evaluated by using the Darmstadt Rocker method. Results will be highly influenced by the type of abrasive material used in the test. Using gravel which was obtained from the same source as that used at Darmstadt University, the average abrasion loss of SPS Pipe is 0.84mm at 100,000 cycles.



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Head loss chart



The Engineering department of SPS can assist the costumers in all stages of their projects and is able to issue (but not limited to) the following documentation: STRESS ANALYSIS ON AERIAL / BURIED GRP PIPING SYSTEM BY MEANS OF CEASAR II PROGRAM

Calculation of buried pipes according to AWWA M-45. Calculation of aerial pipes, installed on supports according to AWWA M-45. Hydraulic calculations according to usual formula. Standards and Specifications. Design – Technical and shop drawings in Autocad format. Field assistance.

SPS EXPERTS ARE ABLE TO PROVIDE ASSISTANCE DURING THE FOLLOWING FIELD ACTIVITIES

• Installation

• Laminations

• Hydro-Testing

GRP pipe installation needs special attention if the contractor engaged in laying the pipes has no knowledge or experience with this product. In this case the SPS /GRP by means of its technical team can offer assistance by sending a qualified person to the customer who will train and assist the contractor.

Engineering Services

FIELD OF APPLICATION

•Water transmission and distribution on both civil and industrial (Potable and Raw Water). •Sewer system on both urban and industrial. •Irrigation networks.

•Water intakes for cooling water system. •Waste water outfalls to sea. •Sea lines and river crossings. •Process lines for industrial plants. •Corrosive fluids and verity gas tanks. •Wells casing and wells pump riser. •Penstock. •Flue gas desulphurization. •Gasoline handling and distribution networks. •Flue gas stacks. •Gravity & pressure sewer lines. •Storm sewers. •Circulating water for power plants.



24

• Prior to unloading of pipes from trailer, all items shall be inspected for any visual transportation damages. • Single pipe must be unloaded and handled separately (one at a time). Use pliable straps, slings or ropes to lift single pipe. • Do not use steel cables or chains to lift or transport the pipe. • Care shall be taken to prevent pipes from rolling or falling from flat bed trailer and this shall be attained by using proper supports.

HANDLING OF NESTED PIPES We propose to nest various diameter pipes during transportation. Always lift nested bundles using at least two pliable ropes. Always keep nested pipes on site in the original transportation package only. Stacking of these pipes is not advisable. De-nesting of pipes should be done carefully at pre allocated station. Inside pipe may be removed by lifting slightly with an inserted padded boom to suspend the section and carefully move it out without damaging the outer pipe.

Transportation and Handling



25

AVAILABLE METHODS IN PIPE SYSTEM INSTALLATION AND ADJUSTMENT OF JOINT:

•Double O-ring Bell and Spigot Joint •Double O-ring Bell and Spigot with locking key joint. •Mechanical Coupling. •Butt and Strap Joint. •Flanged Joint. •Reka Coupling.

METHODS FOR INSTALLATION OF PIPE AND FITTINGS

1.STANDARD COMPONENTS Adjustment should be made in the field by means of Butt and Strap joining system. 2.PRE-FABRICATED PIPES For quick and easy mounting, narrow tolerances less field joints, and lower installation cost.

CATEGORIES OF ABOVE GROUND INSTALLATION 1. Lines which laid directly on the surface of the ground. 2. Lines which are hung or supported as in typical plant. -Tensile Resistance Couplings should be used. In well-supported pipelines for non-pressure application, a non-tensile resistant system can be used. -- Horizontal pipe should be supported at intervals suggested by support spacing data. - For the supporting of pipes systems, several types of pipe clips can be used. Between pipe and steel collar, a PVC saddle or protective rubber layer should be provided to minimize abrasion.

Installation

GRP OVERLAY

F

F SUPPORT

SUP

PO

RT



UNDERGROUND INSTALLATION CLASSIFICATION OF NATIVE SOILS

The external loads (soil and traffic) above a GRP buried pipe cause a decrease in the vertical diameter and an increase in the horizontal diameter (deflection), that is indicate of stain(stress) levels in the pipe wall. Native soils according to AWWA 950/95 are classified in 4 soil stiffness category. Native soil groups depend both on soil types (classification) and soil density, which together determine the soil modulus. The symbols GW, GP,SW,SP,GM,SM,SC,ML,CL etc… are in accordance to ASTM-D2488.

SOIL STIFFNESS CATEGORY 1

Crushed Rock and Gravel with <15% Sand and 5% Fines - Provide maximum pipe support for a given density due to low contents of sand and fines. -Can be installed at relatively high soil stiffness over a wide range of moisture contents.


Course Grained Soils with Little or no Fines -When compacted, provide a relatively high level of pipe support. However, open-graded groups may allow migration and sizes should be checked for compatibility with adjacent material.

SOIL STIFFNESS CATEGORY 3 Course Grained Soils with Fines -Provide less support for a given density SC1 and SC2 material.


Fine Grained Soils with Medium to no Plasticity - The moisture content must be near optimum to minimize compactness effort and achieve the required density. - Can provide reasonable levels of pipe support.

SOIL PIPE SYSTEM

The external loads (soil and traffic) above a GRP buried pipe cause a decrease in the vertical diameter and an increase in the horizontal diameter (deflection), that is indicative of strain (stress) levels in the pipe wall.

The horizontal movement develops a passive soil resistance that enhances pipe support.

The amount of deflection depends on soil load, live load, native soil characteristics, pipe backfill material, trench width, hunching and pipe stiffness.

Buried fiberglass pipes generally accommodate 4-5% long term deformation without structural damage.

26

Installation



INSTALLATION TYPE 1 -Carefully constructed bed. -Backfill 70% relative Density Gravel. -Backfill compacted gravel to 300mm over pipe crown.

INSTALLATION TYPE 2

-Carefully constructed bed. -Backfill 90% standard proctor Sand. -Backfill compacted sand to 300mm over pipe crown.

INSTALLATION TYPE 3 -Backfill to 70% of pipe diameter with gravel or sand (primary pipe zone) -Backfill from 70% to pipe crown with compatible native compacted to 90% standard Proctor.

INSTALLATION TYPE 4 -Prepare pipe bed and haunch with sand or gravel compacted to 90% standard Proctor or 70% Relative Density. -Backfill from 30% of pipe diameter to pipe crown with compactable native compacted to 90% standard Proctor.

INSTALLATION TYPE

GROUND LEVEL

NATIVE SOIL

INIT

IAL

BA

CK

FILL

BEDDING -MIN. 150mm

FIN

AL

BA

CK

FILL

30

0m

m

EXCAVATED TRENCH WIDTH

F F

Where: • F = 200 for pipe DN300 to 500 mm. • F = 300 for pipe DN600 to 900 mm. • F = 450 for pipe DN1000 to 1600 mm. • F = 600 for pipe above DN1600 mm.

27

Installation



FABRICATION METHODS

Fitting are manufactured by the hand lay-up, contact molding and spray-up process. In hand lay-up and contact molding, previous veil and alternate layers of mat and woven roving saturated with resin are applied on the mold. The operation is repeated to reach the required thickness. To fit the special needs of the costumers a study and development can be performed for making non-standards products. Before supplying such products, SPS/GRP needs to be sure that the product is made according the relevant standards and that is tested and proven as a good one.

WALL STRUCTURE

GRP fitting wall such as the pipe wall consist of three layers perfectly adherent one to the other in order to have monolithic structure, each having different characteristics and properties in relation to their function. Liner and top coat are the same as the pipe. The difference consists in the mechanical resistant layer due to the type of reinforcement used.

Fittings

FITTINGS AND ACCESSORIES Supply the following fittings such as Flanges, Elbows, Wyes, Tees, Couplings, and reducers. Large Diameter Fittings are available upon request.



FLANGE – CALIBRATED END

FLANGE – FLANGE FLANGE –

LAMINATION JOINT END

CALIBRATED END LAMINATION JOINT

L L L

FLANGES

29

Fittings

FL/CAL. END FL/FL FL/ LAM. JOINT END

100 105 340 170

150 120 470 235

200 125 540 270

250 135 620 310

300 160 720 360

350 170 800 400

400 195 910 455

450 210 1000 500

500 230 1100 550

600 270 1290 645

700 315 1500 750

800 360 1710 855

900 400 1900 950

1000 430 2060 1030

1100 480 2160 1080

1200 520 2240 1120

1300 550 2300 1150

1400 580 2360 1180

1500 620 2440 1220

DN OVER-ALL LENGTH, L (mm)



DN

DRILLING

PN10 PN16

T OD PCD HOLE

DIA.

No. OF

HOLES T OD PCD

HOLE

DIA.

No. OF

HOLES

100 23 220 180 16 8 28 220 180 16 8

150 25 285 240 20 8 31 285 240 20 8

200 30 340 295 20 8 36 340 295 20 12

250 35 395 350 20 12 41 405 355 22 12

300 40 445 400 20 12 48 460 410 22 12

350 41 505 460 20 16 50 520 470 22 16

400 41 565 515 22 16 52 580 525 27 16

450 45 615 565 22 20 57 585 640 27 20

500 47 670 620 22 20 60 715 650 30 20

600 53 780 725 27 20 66 840 770 33 20

700 61 895 840 27 24 76 910 840 33 24

800 67 1015 950 30 24 85 1025 950 36 24

900 73 1115 1050 30 28 90 1125 1050 36 28

1000 85 1230 1160 33 28 105 1255 1170 39 28

1100 90 1340 1270 33 32 105 1355 1270 39 32

1200 90 1455 1380 36 32 105 1485 1390 45 32

1300 95 1575 1490 39 32 110 1585 1490 45 32

1400 95 1675 1590 39 36 110 1685 1590 45 36

1500 100 1785 1700 39 36 110 1820 1710 52 36

FLANGES

DXN

OD

PCD

T

30

Fittings



FLANGE COUPLING

REDUCER

CONCENTRIC REDUCER ECCENTRIC REDUCER

1. Length of A and B = Length of Lamination according to DN and pressure. 2.Length of L = ( D1 - D2 ) x 2.5

FLANGE – CALIBRATED END

FLANGE-BELL END

FLANGE – SPIGOT END

REKA COUPLING

A A L B L B

D1

D1

D2

D2

31

Fittings



ELBOW - MITERED

90 DEGREE 60 DEGREE 45 DEGREE 30 DEGREE

L

L L L

32

Fittings

90° 60° 45° 30° 90° 60° 45° 30°

100 223 160 142 113 283 220 202 173

150 345 250 223 180 415 320 293 250

200 446 320 284 227 536 410 374 317

250 548 390 346 273 658 500 456 383

300 640 449 397 310 770 579 527 440

350 736 514 453 352 886 664 603 502

400 798 544 474 359 968 714 644 529

450 884 599 520 390 1084 799 720 590

500 986 669 581 437 1216 899 811 667

600 1144 764 658 567 1404 1024 918 827

700 1302 859 736 534 1607 1164 1014 839

800 1466 958 818 587 1816 1308 1168 937

900 1624 1053 895 636 2014 1443 1285 1026

1000 1782 1148 972 684 2202 1568 1392 1104

1100 1940 1243 1050 732 2290 1593 1400 1082

1200 2103 1343 1132 930 2373 1613 1402 1200

1300 2262 1437 1209 834 2462 1637 1409 1034

1400 2420 1532 1286 883 2550 1662 1416 1013

1500 2578 1627 1364 931 2638 1687 1424 991

DN L (PN10) L (PN16)



D1 D2 CALIBRATED

JOINT LAMINATION D1 D2

CALIBRATED JOINT

LAMINATION

L H L H L H L H

100 100 240 120 370 185 700

100-300 1400 700 2270 1135

150 100-150 300 145 520 260 350-700 1400 780 2270 1215

200 100 380 210 690 355

800 100-350 1600 800 2590 1295

150-200 400 210 690 355 400-800 1600 900 2590 1395

250 100 470 260 840 440

900 100-400 1840 900 2900 1450

150-250 490 260 840 440 450-900 1840 1020 2900 1570

300 100-150 580 330 1000 530

1000 100-450 2000 1000 3200 1600

200-300 600 330 1000 530 500-1000 2000 1140 3200 1740

350 100-150 680 385 1150 615

1100 100-500 2200 1100 3400 1750

200-350 690 385 1150 615 550-1100 2200 1240 3400 1840

400 100-200 800 400 1320 660

1200 100-500 2400 1200 3600 1900

250-400 800 450 1320 710 600-1200 2400 1340 3600 1940

450 100-200 910 445 1470 735

1300 100-600 2600 1300 3800 1900

250-450 910 505 1470 795 700-1300 2600 1400 3800 2040

500 100-250 1000 500 1640 820

1400 100-600 2800 1400 4000 2100

300-500 1020 570 1640 890 700-1400 2800 1540 4000 2140

600 100-250 1200 600 1950 975

1500 100-700 3000 1500 4200 2200

300-600 1200 660 1950 1035 800-1500 3000 1640 4200 2240

TEE – EQUAL AND UNEQUAL

D2

L

D1

H

33

Fittings



The joint is a double O-ring bell and spigot type with a locking device that is inserted through a bell opening into a hoop groove. Both metallic and shear resistant plastic materials are used for this device. This joint is a non-destructive, separable joint. Higher pressure can be supplied on request. The axial forces have to be sustained by external devices.

SLEEVE COUPLING DOUBLE O-RING BELL AND SPIGOT WITH LOCKING KEY

GRP pipes manufactured by the continuous filament winding machine and cross winding machine are joined with sleeve coupling made of lip-type elastomeric profile (REKA RRA-69) inserted into the grooves of the GRP sleeve and covering the pipe spigot ends. •the pressure of the conveyed fluid against the profile lips •the compression of the elastomeric profile between the pipe external surface.

Maximum Recommended Angular Deflection of Bell and Spigot joint

DN Angular Deflection, Degree

< 500 3

>= 500 to < 900 2

>= 900 to < 1800 1

> 1800 0.5

Application

Diameters Pressure

25 - 500mm up to 30 Bar

600 - 1200mm up to 20 Bar

1300 and above up to 16 bar

BELL END

SPIGOT END

PRESSURE TEST NIPPLE LOCKING KEY

DOUBLE O-RING

REKA GASKET RUBBER

REKA COUPLING

PIPE 1 PIPE 2

Joints

34

PRESSURE TEST NIPPLE

PIPE 1

PIPE 1 ANGLE

BELL SPIGOT JOINT



BUTT AND STRAP

This permanent joint consist of a hardening of impregnated glass, mats and tissues laminated according to specified with and thickness. The laminated joint provides continuity in both hoop and axial directions.

COUPLING AND EXPANSION JOINT

DN PN10 PN16

T L T L 100 4 100 5 130 150 5 160 7 230 200 6 200 9 290 250 7 240 11 350 300 8.5 270 13 400 350 10 310 14.5 460 400 11 350 16 520 450 12 380 18 580 500 13 420 20 640 600 15 490 23.5 750 700 18 560 27 870 800 20 640 31 990 900 22 710 34.5 1100

1000 24.5 780 38 1220 1100 26 850 41.5 1220 1200 27.5 920 45 1300 1300 29 990 49 1300 1400 32 1060 52 1340 1500 35 1100 56 1340

DN COUPLING EXPANSION JOINT

L NL BL

100 393 1172 672

150 467 1208 708

200 467 1208 708

250 467 1208 708

300 592 1208 756

350 592 1256 756

400 592 1256 756

450 704 1315 815

500 704 1315 815

600 704 1315 815

700 704 1315 815

800 704 1315 815

900 750 1336 836

L

T

DN

NL

NL

NL

L

NL

COUPLING

EXPANSION JOINT

T = P ( ID+2T)/(2H-P) L = P ( ID+2T)/2S

T = THICKNESS OF LAMINATION, Mpa P = DESIGN PRESSURE, Mpa ID = INSIDE DIA., mm T = PIPE THICKNESS, mm H = ALLOWABLE HOOP STRESS, Mpa S = ALLOWABLE SHEAR STRESS, Mpa

The application field of butt and strap joint is related to diameter and pressure classes of pipes to diameter and pressure classes of pipes and fittings to be joint. The dimensions of butt and strap joint are calculated according to the following formulae :

35

Joints



36

SPS GRP pipe sections are typically joined using GRP double bell couplings or bell and spigot joints. Pipe and couplings may be supplied separately or the pipe may be supplied with a coupling installed on one end.

Other joining systems such as flanges, mechanical couplings and butt and strap lamination joints may also be used with SPS GRP pipe.

JOINING PIPES

DOUBLE BELL COUPLING Cleaning and Gasket Installation the following steps (1 to 4) apply to all double bell coupling-joining procedures.

STEP 1: CLEAN COUPLING Thoroughly clean double bell coupling grooves and rubber gasket rings to make sure no dirt or oil is present.

STEP 2: INSTALL GASKETS Insert the gasket into the grooves, leaving two or more uniform loops of rubber (depending on diameter) extending out of the groove. Do not put any lubricant in the grooves or on the gasket at this stage. There should be a minimum of one loop for each 450mm of gasket ring circumference.

With uniform pressure, push each loop of the rubber gasket into the gasket groove.

When installed, pull carefully on the gasket in the radial direction around the whole circumference to check for well-distributed compression of the gasket.

Check also that both sides of the gasket protrude equally above the top of the groove around the whole circumference.

Tapping with a rubber hammer will be helpful to accomplish the above.

STEP 1

STEP 2

STEP 3

STEP 3: LUBRICATE GASKETS Next, using a clean cloth, apply a thin film of lubricant to the rubber gaskets.

Pipe Joining



37

STEP 4: CLEAN AND LUBRICATE SPIGOTS Thoroughly clean pipe spigots to remove any dirt, grit, grease, etc. Using a clean cloth, apply a thin film if lubricant to the spigots from the end of the pipe to the black positioning stripe. After lubricating, take care to keep the coupling and spigot clean.

Caution: It is very important to use only the correct lubricant thin film of lubricants to the spigots from the end of the pipe to the black positioning stripe. After lubricating, take care to keep the coupling and spigot clean.

Caution: It is very important to use only the correct lubricant. STEP 4

STEP 5: FIXING OF CLAMP Clamp A is fixed anywhere on first pipe or left in position from previous joint. Fix clamp B on the pipe to be connected in the correct position relative to the alignment stripe on the spigot-end (home line) so as to act as a stopper.

Note: The mechanical installation clamp is to act both as a stop to position the coupling and as a device on which to attach the pulling (come-along jacks) equipment. Clamp contact with the pipe.

Shall be padded or otherwise protected to prevent damage to the pipe and to have high friction resistance with the pipe surface. If clamps are not available, nylon slings or rope may be used as in Figure 3.6, but care must be taken in the alignment of the acting as a stopper. However, if not available, insert the pipe spigots until the home-line (alignment stripe) aligns with the coupling edge.

STEP 6: PIPE PLACEMENT The pipe to be connected is placed on the bed with sufficient distance from previously joined pipe to allow lowering the coupling into position.

SPS GRP provides sufficient lubricant with each delivery of coupling. If for some reason you run out, please contact SPS GRP for additional supply or advice on alternative lubricants. Never use a petroleum based lubricant.

CLAMP B CLAMP A

STEPS 5 & 6

“COME-ALONG JACK” (one on each side)

PLANK ON BOTH SIDES TO PREVENT PIPE DAMAGE

NYLON OR ROPE SWING



38

STEP 7: JOIN COUPLING Come-along jacks are installed to connect the pipe clamps and two 10 cm x 10 cm timbers or similar (large diameters require a bulkhead) are placed between the pipe previously connected and the coupling. While these are held in position the new pipe is entered into the coupling until it rests against the pipe is entered into the coupling until it rests against the pipe.

Note: Approximate joining force 1 kg/mm of diameter.

Note: For smaller diameter (100mm to 300mm) it might be possible to joint pipe and coupling without the use of come-along jacks. The use of levers is common to join small diameters.

STEP 8: JOIN PIPES Come-along jacks are loosened and timbers removed before re-tightening the jacks for entering the coupling onto the previously connected pipe. Check the correct position of the edge of the coupling to the alignment stripe.

Note: When step 8 has been completed, clamp-B is left in position while Clamp A is moved on to the next pipe to be joined.

WOOD (10cm x 10cm)

STEP 7 A

WOOD (10cm X 10cm)

B

STEP 8

B

A

A

B



39

Maximum angular deflection (turn at each coupling joint must not exceed the amounts given in table. The pipes should be joined in straight alignment and thereafter deflected angularly as required

Angular Deflection at Double Bell Coupling Joint

The bending radius depends on the section length of the pipe. In the above table it is shown for the standard section length of 6m to 12 m, but it can be easily calculated since it is inverse relation to the section length (for 3m section length will be half of the radius for 6m section length).

PIPE DIAMETER PIPE TO PIPE ANGULAR

DEFLECTION

BENDING RADIUS

L = 6m L = 12m

300 ≤ DN ≤ 600 4.0° 86 172

600 ≤ DN ≤ 750 3.5° 98 196

750 ≤ DN ≤ 900 3.0° 115 229

900 ≤ DN ≤ 1100 2.5° 138 275

1100 ≤ DN ≤ 1400 2.0° 172 344

1400 ≤ DN ≤ 1900 1.5° 229 458

1900 ≤ DN ≤ 2800 1.0° 344 688

2800 ≤ DN ≤ 3800 0.75° 458 917

3800 ≤ DN ≤ 4000 0.5° 688 1375

COUPLING

PIPE

RADIUS OF CURVATURE

DEFLECTION OF ANGLE

OFFSET

Angular Deflection of Double Bell Couplings



40

FRP Flange Joining Procedure

GRP flanges with diameter 350mm and larger should be jointed according to the following procedure:

1. Thoroughly clean the flange face and the ‘O’ ring groove with any clean rags and avoid any oil contact for both the groove and the ‘O’ ring.

2. Ensure the ‘O’ ring gasket is clean and undamaged. Do not use defective gasket.

3. Position the ‘O’ ring in the groove and secure in position, if necessary, with small strips of adhesive tape at intermittent locations.

4. Make sure that the two flanges or connecting flange with valve or expansion joint is well aligned with GRP flanges. Any misalignment could lead to high stress at flange neck and could cause damage.

5. Insert bolts, washers and nuts. All hardware must be clean and lubricated to avoid incorrect tightening. Washers must be used on all GRP flanges.

1. Using a torque wrench, tighten all bolts to 35 N-m torque, following standard flange bolt tightening sequences shown in Fig. SPS-2.

2. Repeat this procedure, raising the bolt until the flanges almost touch at their inside edges with a gap of 2-3mm or maximum bolt torque of 100 N-m. Do not exceed this torque without consulting SPS for advice. If done so, this may cause permanent damage to the GRP flange.

3. Uniform pressure should be established over the flange face by tightening bolts in 7 N-m (5 lb-ft) increment according to the sequence shown in Fig. SPS-2. For flanges with more than 20 bolts, similar alternating bolt tightening sequences shall be used, ( As per ASTM D4024-00).

4. Check bolt torque one hour later and adjust as seen necessary to 100 N-m.

5. The maximum torque, in any case, should not be more than 110 to 130 N-m. Care should be exercised while increasing the torque uniformly.

6. The above procedure is applicable for all diameters.

FIG. SPS-2

FIG. SPS-1

METAL FLANGE

GRP FLANGE

“O” RING GASKET



41

Note: When connecting two GRP flanges, only one flange should have a gasket groove in the face.

OTHER JOINING METHODS

1. Flexible Steel Couplings: (Straub, Tee Kay, etc – See Fig. SPS-3) These couplings can be used for joining as well for repair. The coupling consist of a steel mantle with an interior rubber-sealing sleeve.

Three grades are available: • Epoxy or PVC-coated steel mantle. • Stainless steel mantle. • Hot dip galvanized steel mantle.

Control of bolting torque with these couplings is most important. After initial bolt up, the coupling should be rapped with a rubber mallet to help seat and flow the gasket. Bolt torque should then be adjusted up to proper levels. Depending on coupling size, this procedure may need to be repeated several times. Do not over torque as this may. Over stress the bolts. Follow the manufacturer’s recommended assembly instructions.

2. Mechanical Steel Couplings: (Viking Johnson, Dresser etc. – See Fig. SPS-4) These couplings can be used for joining, typically to other types of pipe or to rigid items. Bolting torque must be controlled not to exceed the manufacturer’s maximum recommended values. Excess torque could damage the pipe.

FLANGE SLEEVE

GASKET

FLANGE

FIG. SPS-4

FIG. SPS-3



42

Site Hydrotest – GRP Piping

UNDER GROUND PIPING SYSTEM- COUPLING JOINTS

Field hydrotest could be conducted in segments or as a complete piping system.

SEGMENT HYDROTESTINGS Certain lengths shall be chosen according to site conditions to test the installed piping system in segments. A clearance of 4 meters minimum shall be maintained between the segments which could be later installed as Make-up pipe piece with double spigot calibration to facilitate the jointing on existing piping segment.

FIXING TEST PLUGS: There are more than one methods to close temporarily the pipe ends for hydrotest purposes:

1.USING BLIND END CAPS: Blind end cap is FRP coupling with one end lamination, while the other end is with groove for rubber gasket to work as sealing the end.

Fix the end cap with the last pipe end to be tested after placing the rubber gasket into end cap groove.

Joint with the spigot pipe end through pullers/come-along jacks.

Necessary openings could be provided to the end caps for ventilation/pressure gauge. After segment test, these end caps could be removed through pullers & could be reused for other segments after rubber gasket replacement. Adequate concrete block supports shall be provided to the end cap to prevent the pipe movement during hydrotest.

2.FLANGED BLIND END: Flanged blind end is a spool consist of flange with pipe piece & blind through a blind flange with bolts at one end while the other end is a spigot calibrated pipe shall be joined with the existing end coupling.

* Further details of above options is available upon request.)

CHECK LIST PRIOR TO PIPE ENDS BLIND:

To check each coupling joint is connected correctly and the clearance between the pipe end is uniform all around. (Field joints testing equipment is available for pipe diameters ranging from 700 mm to 2600 mm ). This test ensures the rubber gasket’s correct positioning inside the double bell coupling groove. The test shall be conducted prior to start backfill. For details, contact SPS field representative.

Internal visual inspection shall be carried out for accessible pipe diameters for any possible damage during installation/backfilling.

In no case, shall a single person be allowed to get inside of the piping for inspection.

Vertical deflection measurements shall be taken to observe the pipe behavior after the backfill. (Refer to underground installation manual for details).

Make sure that the pipes are backfilled to the minimum cover depth requirements of hydrotest.

For 100mm to 300 mm diameters (Min. 600 mm cover over the pipe crown)

For 350mm diameters and above (Min. 1000mm cover over the pipe crown)

Double bell coupling joints could be exposed in case of the client requirements.

Make sure that the backfilling slope at the joints location is maintained with minimum pipe exposure.

PREPARATION PRIOR TO HYDROTEST:

Make sure that the test method statement is available with full understanding of implementation to the testing team.

Allowance for each branch/manhole to move freely, within limits during the hydrotest.

Fixing ventilation at highest points, minimum two pressure gauges and filling points with valves.



43

The values and reading at the pressure shall be calculated taking into account the static head between the lowest pipe invert level along the complete line and the level of the pressure gauge.

All flanges are tightened to the specified torque bolt sequence. Make sure that the values are anchored and the above ground piping, if any is supported as specified.

In no case, shall a single person be allowed to get inside of the piping for inspection.

Upon verification of the inspection, when the finding are all judged acceptable & recorded, manhole covers shall be closed. Prior to start water filling, temporarily piping & blinds shall be installed checked & verified by the client/consultant/contractor/representatives.

WATER FILLING & PRESSURIZING THE SYSTEM:

(It shall be confirmed that all vent points are fully opened to atmosphere, prior to start water filling).

Introduce water filling through temporary hosing & pump at lowest point. Pump capacity shall be chosen according to the pipe diameter and segment/system linear length. (Pump having 100m3 capacity/hour are generally used for large diameter pipes).

The sign of complete water filling is when the water starts coming through higher point ventilation opened valves.

Stop water pumps at this stage & check the flanges, valves and connected accessories for any webpage/leakage while keeping the vents open.

PRESSURIZING:

Start pressurizing the segment/system through pump. Once the water starts coming out through vent opening, close the valves at low elevation. Later on the high elevation end the vent valves shall be closed as well after water starts coming.

The pressure increment shall be maintained approximately as 0.5 bar/10minutes at this stage. When the pressure reaches to 2 bar, the pumps shall be stopped.

Keep this stoppage for 15-20 minutes. During this time, following checks shall be made:

• Pressure at each test gauge shall be checked & recorded on inspection sheet. • Watch the pressure at the water feed point for any decrease in pressure. • Walk through along with the underground lines to observe any traces of wet soil. Check the coupling joints if exposed.

The inspection sheet shall be maintained for the observations & findings.

Anything unusual shall be immediately reported to the team leader.

Unless there is no findings which prevent the test from continuing, the segment/system shall be further pressurized.

Connect the hose with the pressure pump and start pressurizing the line. At this stage, slightly open the vent. Valve should be fixed at a higher elevation to ensure that no entrapped air is present.

Upon confirmation of water coming out of the vent, valve shall be closed. The system is now totally closed and under pressure. Continue the pressure pump until it reaches to 5.0 Bar. During this operation, the pump shall be constantly attended for pressure control.

Stop the pressure pump once it reaches to 5.0 Bar and let it stabilize.

There could be a drop in pressure due to the thermal expansion, which could be resolved by restarting the pump or keep it as is & record it on the inspection sheet.

Keep this stoppage for about 30 minutes. During this period, repeat the same sequence of inspection as described earlier. The findings & observations shall be recorded on inspection sheets.

Any unusual findings shall be reported immediately to the team leader.



Unless there are no findings which prevent the test from continuing, the segment/system shall be further pressurized to the requirement.

The test pressure should not exceed 1.5 times the maximum rated operating pressure. The test pressure shall be maintained for a minimum period of time.

(It is recommended to maintain the test hold time to a maximum of 15 minutes after pressure stabilization).

A thorough inspection shall be made as Final Inspection.

Fill up the inspection sheets accordingly. The test shall be considered as “PASS” if no signs of leakage is observed. The inspection sheets shall be signed by the authorities.

POST HYDROTEST: After completion the test, drain or flush out the filled water from the pipe segment/system through drain valves & vents shall be opened. This pressure release shall be made slowly @ 2 bar/5 minutes.

1. Remove the end cap from the segment as per procedure.

2. Prepare the pipe end to be ready for next installation.

3. Exposed joints may be backfilled using the specified backfill material.

4. Connect the adjacent segment ends with closure pipe piece.

5. Continue the installation for the other segments & conduct the hydrotest in the similar manner as described earlier, keep connecting the segments through closure spools.

6. Complete system hydrotest/Final hydrotest.

The purpose of this hydrotest is to test the pipe closure spools joints.

Following arrangements shall be made: • All branch connections shall be kept free to move. • Separate the line from all connections equipments. • Exposure of joints at closure pipe piece shall be done manually in order to prevent the pipe from any damage.

The procedure described for the segment testing is applicable to the final hydrotest.

For final hydrotest, it is recommended to maintain the test hold pressure for minimum period of time (one is enough to inspect the joint / fittings) and the pressure shall be equal to the maximum rated operating pressure.



SPS - GRP Manholes are made of a chemical resistant thermosetting isophthalic polyester resin and fiberglass reinforcement with silica sand or calcium carbonate additives. The standard diameter (DN) of manholes are usually 1000 mm or 1200 mm cylinder with a concentric reducer on top of it to form a 600 mm man way. The concentric reducer (cone) is manufactured separately by hand lay - up process will then be factory jointed with the manhole body to form one piece manhole. GRP manholes conform to the ASTM for GRP manhole Specification D 3753.

•Ultimate Compressive strength in the axial direction, when measured •according to ASTM D695 is 985 Kg/ cm. Cylinder Stiffness ( ASTM D2412)

MANHOLE HEIGHT,

H(mm) MINIMUM STIFFNESS,

KN/m²

1000 – 1800 4.96

2000 - 3600 8.69

3800 - 7600 20.82

USE AND APPLICATION

•The product is applicable to use in corrosive environment such as sanitary sewers, storm and sewers including cooling water lines with a temperature from - 40 to 70 deg. C. •The ring and cover must rest on a course of bricks or a concrete ring, not the fiberglass support ledge. All surcharge load must be applied to the ring and cover. •GRP manholes must be installed in accordance with SPS installation instruction. Holes or arches must be cut in the cylindrical portion of the manhole using a circular cutting diamant disc or similar equipment with a masonry type blade. Axes, hammers, chisels or similar tools are not advisable to use to make cuts on the manhole. Maximum single cutout hole diameter is 750 mm for the 1200 mm manhole and 600 mm for the 1000 mm manhole. Sum of all cutouts must not exceed 1900mm for the 1200 mm manhole and 1500 mm for the 1000 mm manhole.

DIMENSION TOLERANCE

DN 1200 1000 ± 7

H 1000 ~ 7600 ± 50

Wall Thickness

10 10 min

PRODUCT REQUIREMENT AND TOLERANCES Visual Standard SPS-GRP Manhole is to be commercially free from the following defects.

DEFECTS DEFINITION

Fuzz Glass fibers loosely

adhering to the pipe which are not wet out with resin

Protruding Fibers Glass fibers sticking out

from pipe surface that are not wet out with resin

Resin Runs Runs of resin and sand on

surface of pipe

DN

H

Manhole



Main Office : Jeddah Industrial Zone Phase IV P.O. Box 34572 Jeddah 21478 Kingdom of Saudi Arabia Tel. +966 2 608 1100 / +966 2 637 0999 Fax +966 2 636 5925 / +966 2 637 9439 www.saudivalve.com / [email protected]

Sales Office : Takhasussi Street P.O. Box 52408 Riyadh 11563 Kingdom of Saudi Arabia Tel. +966 1 482 6006 Fax +966 1 482 8742

Documents

Company Profile - One of the Leading Water Pipe Systems ... · PDF fileSaudi Pipe Systems Company has successfully ... AWWA C950-95 Standard for Glass-Fiber-Reinforced Thermosetting-Resin