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AMIPOX Piping SystemInstallation Manual
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Table of contents
1 Introductory Information ...............................................................................................................................41.1 Foreword .........................................................................................................................................................41.2 Field Technician ...............................................................................................................................................4
2 Product Information ......................................................................................................................................5
3 Shipping, Handling and Storage ..................................................................................................................63.1 Inspecting Pipe ................................................................................................................................................63.2 Repairing Pipe .................................................................................................................................................63.3 Unloading and Handling Pipe ..........................................................................................................................63.4 Site Pipe Storage .............................................................................................................................................73.5 Storing Gaskets, Lubricants and Adhesives ...................................................................................................73.6 Transporting Pipe ............................................................................................................................................8
4 Joint Types .....................................................................................................................................................84.1 Typer Adhesive bonded Joint ..........................................................................................................................84.2 Seal-Lock Mechanical Joint ............................................................................................................................84.3 Butt & Wrap - Lamination Joint .......................................................................................................................94.4 Flange Joint .....................................................................................................................................................94.5 Mechanical Coupling .......................................................................................................................................9
5 Adhesive bonded Taper Joint, AT - Jointing procedure ..........................................................................105.1 Tools for adhesive bonded Joints .................................................................................................................105.2 Machining ......................................................................................................................................................105.3 Cutting and Shaving of Pipe ..........................................................................................................................105.4 Preparing for Bonding ...................................................................................................................................145.5 Applying the Adhesive ...................................................................................................................................155.6 Curing of the Adhesive ..................................................................................................................................16
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6 AMIPOX Seal-Lock Joints ASL - Jointing Procedures ............................................................................186.1 Tools for Rubber Seal-Lock Joints ................................................................................................................186.2 Joint Assembly ..............................................................................................................................................186.3 Seal-Lock Jointing .........................................................................................................................................196.4 Types of Rubber Ring and Locking Strip ......................................................................................................21
7 Flanged Joints..............................................................................................................................................227.1 Tools for Flanged Joints ................................................................................................................................227.2 Flanged Joint Description ..............................................................................................................................227.3 Gaskets .........................................................................................................................................................237.4 Bolts ..............................................................................................................................................................237.5 Trouble Shooting ...........................................................................................................................................23
8 Butt and Wrap Lamination Joint ................................................................................................................238.1 Tools for Butt and Wrap Lamination Joint .....................................................................................................238.2 Lamination Procedure ...................................................................................................................................248.3 Butt & Wrap Lamination Jointing ...................................................................................................................26
9 Mechanical Couplers ..................................................................................................................................309.1 Tools for Mechanical Couplers ......................................................................................................................30
10 Installation of Underground Pipe Systems ...............................................................................................3110.1 Procedure ......................................................................................................................................................3110.2 Trench Construction ......................................................................................................................................3110.3 Pipe Bedding .................................................................................................................................................3110.4 Backfill Materials ...........................................................................................................................................3210.5 Backfilling Pipe ..............................................................................................................................................3210.6 Burial Depth ...................................................................................................................................................3310.7 Thrust Blocking .............................................................................................................................................3410.8 Thrust Blocks-Design Construction ..............................................................................................................3410.9 Settlement .....................................................................................................................................................3510.10 Pipe Cast in Concrete ...................................................................................................................................3510.11 Concrete Wall Penetrations and Connections ..............................................................................................3510.12 Multiple Pipes in same Trench ......................................................................................................................36
11 Aboveground Pipe Installation ...................................................................................................................3711.1 General ..........................................................................................................................................................3711.2 Support Types ...............................................................................................................................................3711.3 Protective Methods .......................................................................................................................................3911.4 Valve Support ................................................................................................................................................3911.5 Joining with other Materials ..........................................................................................................................3911.6 UV - Resistance .............................................................................................................................................39
12 Field Hydro Testing .....................................................................................................................................40
13 Repair Work .................................................................................................................................................42
13 Safety Precautions ......................................................................................................................................4213.1 Resin, Hardener and Adhesive Kits ...............................................................................................................4213.2 Cutting, Shaving and Sanding .......................................................................................................................4213.3 Hydro Testing ................................................................................................................................................43
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1 Introductory Information
1.1 Foreword
This manual is designed to assist supervisors and field engineers in the installation procedures of the AMIPOX GRE Pipes system. It provides suggestions to avoid/solve problems during installation and mainly addresses the usual circumstances that may be encountered in the field. Unique situations requiring special considerations are not addressed and should be resolved in cooperation with the supplier.Most importantly, this installation guide is not meant to replace common sense, good engineering practices and judgment, applicable laws, safety, environmental or other regulations or local ordinances, nor the specifications and instructions of the owner’s engineers, who are the final authority on each job. Should any conflicting information in this manual create doubts how to proceed properly, please consult the supplier and the owner’s engineers to obtain assistance. These instructions are to be used as a reference only.The installation procedures outlined in this installation manual and the suggestions of the field technicians, when carefully followed, will help in the thorough execution of a proper, long-lasting installation.
Specifications written for a particular project would have priority over the general guidelines mentioned here. Varying circumstances may require deviations from the procedures described. Please consult the supplier with any questions or when variations from this installation manual are being considered.
1.2 Field Technician
The supplier can, at the request of the purchaser and within the terms of the agreement between the purchaser and the supplier, provide a Field Technician. The Field Technician can advise the purchaser and/or the installer to help him achieve a satisfactory pipe installation. It is recommended that “on the job” field service be engaged in the initial stage of installation and it may continue periodically throughout the project. The service may range from continuous (essentially full time) to intermittent depending on the agreement between purchaser and supplier.
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2 Product Information
AMIPOX pipe systems are produced by the filament winding method. In this numerically controlled mechanical process, a continuous glassfiber roving is impregnated with epoxy resin system.
The production of GRE starts with the preparation of the steel mandrel. The steel mandrel is a cylindrical mould. A loose part (head stack) is attached to the mandrel end. This mandrel head stack is determining the shape of the socket (female) and thus the connection type. There are three connection (jointing) types: Taper/Taper, Seal- lock and plain ends.
During the next process step, the glassfibers are pulled through a bath filled with epoxy resin. After impregnation the glassfibers are filament wound around the polished mandrel under constant tension applied at a helix angle of 54 +/- 2 degree. The filament winding process continues until the pipe has come to the desired wall thickness. The wall thickness of the pipe depends on the project requirements and pressure class. In general the higher the pressure the thicker the wall will be.The winding is finished with a resin rich topcoat for weather and UV radiation protection.
After the filament winding process is completed, the mandrel with the pipe will be cured in an oven at about 150°C. After curing the mandrel will be removed from the new formed GRE pipe by means of water pressure. The new formed GRE pipe will be cut at desired length, males (male ends) will be machined, dimensionally and visually checked and hydrostatic tested witness by the quality department.
Figure 2-1 Flow chart AMIPOX winding process
Figure 2-2 AMIPOX pipe wall structure
0.3mm RESIN RICH 0 %
70 % E- GLASS
15 % C- GLASS
Resin Glass
PIPE DIA.WALL THICKNESS COMPOSITION
STRUCTURAL WALL
0.5mm RESIN RICH LINER
100 %
30 %
85 %
0.3mm(APPROX)
Ts0.5
mmMIN
. WT.
± 2°
54
Glass fibre Roving
Epoxy Resin Impregnation
Laying carriage moves in both direction
Rotating mandrel
Length adjustment
Dimension Control& hydrotest
End machining
Curing oven
MandrelExtraction
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Figure 3-2 Lifting pipe at two support points
3.1 Inspecting Pipe
All pipes should be inspected upon receipt at the job site to ensure that no damage has occurred in transit. Depending on the length of storage, the amount of job site handling and other factors that may influence the pipes condition, it is recommended that the pipe be re-inspected just prior to installation.Inspect the shipment upon delivery, as follows:
• Make an overall inspection of the load. If the load is intact, ordinary inspection while unloading is normally sufficient to make sure the pipe has arrived without damage. • If the load has shifted or indicates rough treatment, carefully inspect each pipe section for damage. Generally, an exterior inspection will be sufficient to detect any damage. When pipe size permits, an interior inspection of the pipe surface at the location of an exterior scrape may be helpful to determine if the pipe is damaged.• Check the quantity of each item against the bill of lading.• Note on the bill of lading any transit damage or loss and have the carrier representative sign your copy of the receipt. Claims against the carrier should be in accordance with their instructions.• If any imperfection or damage is found, segregate the affected pipes and contact the supplier.• Do not use pipe that appears damaged or defective.
3.2 Repairing Pipe
Normally, pipes with minor damage can be repaired quickly and easily at the job site by a qualified individual. If in doubt about the condition of a pipe, do not use it.
The Field Technician can help you determine whether repair is required and whether it is possible and practical. Repair designs can vary greatly due to pipe thickness, wall composition, application and the type and extent of the damage. Therefore do not attempt to repair a damaged pipe without consulting the supplier first. Repairs must be made by a trained repair technician. Improperly repaired pipes may not perform as intended.
3.3 Unloading and Handling Pipe
Unloading the pipe is the responsibility of the customer.Be sure to maintain control of the pipe during unloading. Guide ropes attached to pipes or packages will enable easy manual control when lifting and handling. Spreader bars may be used when multiple support locations are necessary. Do not drop impact or bump the pipe, particularly at pipe ends.
3.3.1 Single pipes When handling single pipes, use pliable straps, slings or rope to lift. Do not use steel cables or chains to lift or transport the pipe. Pipe sections can be lifted with only one support point Figure 3-1, although two support points placed as in Figure 3-2 is the preferred method for safety reasons, as it makes the pipe easier to control. Do not lift the pipe using hooks at the pipe ends or by passing a rope, chain or cable through the section end to end.
Figure 3-1 Lifting pipe at one support point
0.2 x L 0.6 x L 0.2 x L
Control Rope
3 Shipping, Handling and Storage
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3.5 Storing Gaskets, Lubricants and Adhesives
• Rubber ring gaskets, for the seal lock joints, should be stored in the shade in their original packing and should not be exposed to sunlight except during the pipe joining. Also, the gaskets must be protected from exposure to greases and oils which are petroleum derivatives and from solvents and other harmful substances
3.4 Site Pipe Storage
It is generally advantageous to store pipe on flat timber to facilitate placement and removal of lifting slings around the pipe.
When storing pipe directly on the ground, be sure that the area is relatively flat and free of rocks and other potentially damaging debris. Placing the pipe on mounds of backfill material has been found to be an effective way of storing the pipe on site. All pipes should be chocked to prevent rolling in high winds.
If it is necessary to stack pipes, it is best to stack on flat timber supports (minimum width of 75 mm) at quarter point with chocks (see Figure 3-4). If available, use the original shipping dunnage.
Ensure that the stack will be stable in conditions such as high winds, uneven storage surface or other horizontal loads. If strong winds are anticipated, consider using ropes or slings to tie pipes down. Maximum stack height is approximately 1.5 meters, or two layers, whichever is higher.
Figure 3-4 Storing pipe
Pipe storage at construction site
3.3.2 Unitised loads
Unitised loads may be handled using a pair of slings as shown in Figure 3-3. Do not lift a non-unitised stack of pipes as a single bundle. Non-unitised pipes must be unloaded and handled separately (one at a time).
If at any time during handling or installation of the pipe any damage such as a gouge, crack or facture occurs, the pipe should be repaired before the section is installed.
Contact the supplier for inspection of the damage and for the recommended method of repair or disposalSee Chapter 3.2 .
Figure 3-3 Lifting unitised package
0.2 x L 0.6 x L 0.2 x L
Ensure suitable supports such as clean, nail free wooden beams. Supports must be spaced at a maximum interval of 3m and around 1m from each pipe end.
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AMIPOX offer a comprehensive selection of adhesive-bonded and mechanical joining systems for RTR / GRE piping.
4.1 Taper Adhesive bonded Joint
Adhesive bonded Taper/Taper joint with matching taper male and taper female ends, uses adhesive for jointing and offers superior joint strength by controlled adhesive thickness. Available in sizes 50 – 1000 mm (2 – 40 in), pressure rated up to 100 bar.
4.2 Seal-Lock Mechanical Joint
Self-restraint, easy to install, Seal- Lock Mechanical joint uses nylon key and rubber “o”-ring for jointing. Available in sizes 50 – 1000 mm (2 – 40 in), pressure rated up to 70 bar.
3.6 Transporting Pipe
Support all pipe sections on flat timbers, spaced at a maximum of 4 meters with a maximum overhang of 1 meter. Chock the pipes to maintain stability and separation. Avoid abrasion.
Maximum stack height is approximately 1.5 meters. Strap pipe to the vehicle over the support points using pliable straps or rope. Never use steel cables or chains without adequate padding to protect the pipe from abrasion. Bulges, flat areas or other abrupt changes of curvature are not permitted. Transport of pipes outside of these limitations may result in damage to the pipes.
Figure 3–5 Transporting pipe
4 Joint Types
Figure 4-1 Tapered adhesive joint
• Gasket lubricant should be carefully stored to prevent damage. Partially used buckets should be resealed to prevent contamination of the lubricant. If temperatures during installation are below 5° C, gaskets and lubricant should be sheltered until used.
• Adhesives must be stored indoors at temperatures below 38° C. Extended storage at higher temperatures will degrade the catalyst and the resin and reduce adhesive strength. Each adhesive Kit is stamped with an expiry date. They should be removed from shipping cartons and stacked upright so that the expiry dates are visible.
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4.3 Butt & Wrap - Lamination Joint
Butt-And-Wrap (or Lamination) joint for Plain Ends used generally for field adjustments and for large diameter pipes that other types of joints are not available. Butt & Wrap Joint is available for all sizes.
4.5 Mechanical Coupling
Mechanical joint offers quick assembly between plain ends. This joining method, done by means of mechanical coupling (supply by others) like Viking Johnson, Dresser, etc., normally used to connecting different piping material (low pressure application only).
4.4 Flange Joint
Filament-wound fiberglass flanges are used for jointing AMIPOX or AMIPOX RTR / GRE piping to existing steel pipes, valves, pumps and tank nozzles. These are provided with drilling patterns to mate with metal flanges conforming to worldwide standards. Flanged joint uses rubber flat gasket or ‘O’ ring (depending size and pressure rating), bolts, nuts & washers for jointing. Flange Joint is available for all sizes.
4 Joint Types
Figure 4-4 Flanged joint
Figure 4-5 Mechanical coupling joint
Type A: with flat gasket Type B: With O-ring
Figure 4-3 Butt & wrap joint
Figure 4-2 Seal-lock joint
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Before starting adhesive bonding, all safety precautions need to be checked. Ensure that all necessary tools and materials are available.
Adhesive bonded jointing can only be carried out by fully trained and certified personnel
5.1 Tools for adhesive bonded Joints
For the assembly of adhesive bonded joints the following is needed:
• AMIPOX shaving tool(s). Electrical power drive (available from AMIPOX). Hacksaw, disc grinder or power jigsaw. Small electrical or air hand drilling machine (6 mm drive and 1700-2000 rpm). Flapper wheel sanders (available from AMIPOX) and / or coarse emery cloth; grid 60. Pairs of winches or come-alongs (available from AMIPOX). Pairs of band clamps with puller rings (available from AMIPOX). Measuring tape and / or folding rule. Pi-tape with venire division (available from AMIPOX). Clean cloth or clean brush. Pipe fitter’s wrap around, level and white paint pencil. AMIPOX heating blanket and possibly hot air blower. Insulation blankets. Pipe vice or stable supports (brackets) with pipe holding or clamping device of 6 mm. Elastomeric pads. Gloves, dust masks and goggles.
For adhesive bonding: see instructions provided with the cement kit.For machining: see shaver instructions supplied with shaver.
5.2 Machining
After the pipe has been cut to the exact length, the end must be machined to the right diameter to ensure a proper joint. The surface has to be cleaned with clean cloth. If the surface has been in contact with oil or grease, it should be cleaned with a clean cloth soaked in pure acetone, or M.E.K. (methyl ethyl ketone) (free of water). Do not use thinners, petrol or alcohol for cleaning. After drying, machining can start. Wastage of adhesive can be reduced by good planning and the best use of adhesive kits. Too much adhesive applied to the female will reduce diameter and result in restricted flow. Remove excess adhesive with the aid of a spatula and finish the seam properly and smoothly. This can be also done inside the pipe, for example, by pulling a plug threw the pipe. This will prevent problems using foam pigs later.
5.3 Cutting and Shaving of Pipe
1 Determine the cutting length as shown by subtracting the laying lengths of the fittings from the required overall length.
5 Adhesive bonded Taper Joint, AT - Jointing procedure
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Figure 5-1 Different type of tools
Come-along installation tool
Power drive
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Figure 5-2 Cutting length
Figure 5-3 Marking the pipe
Figure 5-5 Supporting and holding the pipe firmly
Figure 5-4 Cutting squareness
2 Mark the pipe using a pipe fitter’s wrap-around. When holding the pipe in a vice, use rubber padding or similar to protect the pipe from damage.
3 Cut the pipe
• Use a hacksaw or an abrasive wheel. • Ensure that cut ends remain within the tolerances as shown in Table A. • These tolerances can be checked by using, for example, the arbour of the shaver flush with the cut end of the pipe.
4 Shaving the pipe
• Support and hold the pipe in position firmly
- Contaminated pipe surfaces should be cleaned prior to shaving the pipe ends. - When holding the pipe in a vice, use rubber padding or similar to protect the pipe from damage.
Pipe size range Tolerance (X)
(mm) (inch) (mm)
80-100 3-4 ±1.5
150-600 6-24 ±3.0
700-900 28-36 ±5.0
1000-1200 40-48 ±6.0
Table A: Maximum tolerance on squareness of cut male ends
ND
XOVERLL LENGTH
CUTTING LENGTH LAYING LENGTH
LAYING
LENGTH
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• Carefully insert the arbour into the pipe. • Fix the arbour to the inside of the pipe by turning the central tensioning bolt clockwise.
Figure 5-6 Fixing the arbour inside the pipe
Figure 5-7 Taper joint details
Table B: Shaving Dimensions per Pipe Series
Pipe size Taper angle Nose thick Male diameter Nose thick Male
diameter Nose thick Male diameter
mm inch degrees mm mm mm mm mm mm
Series AT 10 Series AT 12 Series AT 14
80 3 1.2 2.0 84.0 2.0 84.0 2.0 84.0
100 4 1.2 2.0 104.0 2.0 104.0 2.0 104.0
150 6 1.2 2.0 154.0 2.0 154.0 2.0 154.0
200 8 1.2 2.0 204.0 2.0 204.0 2.0 204.0
250 10 1.5 2.0 254.0 2.0 254.0 2.0 254.0
300 12 1.5 2.0 304.0 2.0 304.0 2.0 304.0
350 14 1.5 2.1 354.2 2.1 354.2 2.1 354.2
400 16 1.5 2.1 404.2 2.1 404.2 2.2 404.4
500 20 2.0 2.3 504.6 2.3 504.6 2.3 504.6
600 24 2.0 2.5 605.0 2.5 605.0 2.5 605.0
700 28 1.75 4.0 708.0 4.0 708.0 4.0 708.0
750 30 1.75 4.0 758.0 4.0 758.0 4.0 758.0
800 32 1.75 4.0 808.0 4.0 808.0 5.5 811.0
900 36 1.75 4.0 908.0 4.0 908.0 6.0 912.0
1000 40 1.75 4.5 1009.0 4.5 1009.0 6.5 1013.0
• Adjust the shaver to the required male diameter.
- Be sure to use the correct taper angle. - Take care when shaving the first layer, because the pipe wall may not be equally thick on all sides. - For shaver information and operation instructions refer to the applicable “AMIPOX Pipe Shaver Operation Instructions”. - Refer to Figure 5-7 and Table B below.
INSERT.DEPTH
SPIGOTDIAMETER
NOSETHICKNESS
TAPER ANGLE
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• Shave the taper male.
- Maximum shaving depth /feed is 2mm. - Repeat the shaving action until the required male diameter/male nose thickness is achieved (Table B) - Due to possible tolerance spreading, it is recommended that a nominal sized dummy female end is used. This may avoid too long or too short assembly lengths. If the insertion depth in the dummy is too small, the male end to be shaved has to be adjusted.
Figure 5-8 Shaving the male end
Figure 5-9 Sanding the male (left) and female (right) ends
Table B (continued): Shaving Dimensions per Pipe Series
Pipe size Taper angle Nose thick Male diameter Nose thick Male
diameter Nose thick Male diameter
mm inch degrees mm mm mm mm mm mm
Series AT 16 Series AT 20 Series AT 25
80 3 1.2 2.0 84.0 2.0 84.0 2.0 84.0
100 4 1.2 2.0 104.0 2.0 104.0 2.0 104.0
150 6 1.2 2.0 154.0 2.0 154.0 2.0 154.0
200 8 1.2 2.0 204.0 2.0 204.0 2.0 204.0
250 10 1.5 2.0 254.0 2.0 254.0 2.0 254.0
300 12 1.5 2.4 304.8 2.4 304.8 2.4 304.8
350 14 1.5 2.6 355.2 2.6 355.2 - -
400 16 1.5 2.6 405.2 - - - -
500 20 2.0 2.6 505.2 - - - -
600 24 2.0 2.6 605.2 - - - -
700 28 1.75 5.5 711.0 - - - -
750 30 1.75 6.0 762.0 - - - -
800 32 1.75 5.5 811.0 - - - -
900 36 1.75 6.0 912.0 - - - -
1000 40 1.75 8.0 1016.0 - - - -
Note: For values specified as (-), consult Amipox Engineering
• Sand all bonding surfaces.
- Thoroughly sand within 2 hours of assembly. - Use flapper wheel sanders with a small drilling machine (1700-2000 rpm) or emery cloth with a grid of 60. - Bonding surfaces must be dry and clean before sanding. - Sanded surfaces must have a dull, fresh finish, not a polished look.
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• Dry fit and mark the joint.
- Check the assembly length and mark pipe and fitting for alignment of elbows, flanges, etc. - Measure back from the edge of the male the required insertion depth plus 50 mm and scribe a line. - After assembly by pulling the joint together, the scribe on the pipe should be 50 mm from the end of the female.
5.4 Preparing for Bonding
1 Install the band clamps on both components keeping sufficient space for the winches when pulling the joint together. Normally 2 winches will suffice. If needed, more winches can be used.
2 Dry the bonding surfaces.
• If the relative humidity is higher than 75%, or if the bonding surfaces are wet, they should be dried. • AMIPOX heating blanket can be used in drying the surfaces.
3 Pre-heat or cool down the bonding surfaces.
• It is recommended to keep the bonding surfaces between 15° C and 40° C. • For warming up, AMIPOX heating blankets can be used. • If the sun will heat the bonding surfaces to above 40° C keep them in the shade if possible.
- During final assembly the male may slip approximately 5 mm further into the female, therefore the dry fitted assembly should be approximately 5 mm longer per joint.
Figure 5-9 Dry fit and length marking
Figure 5-10 Position after assembly
Figure 5-11 Fixing band clamps
POSITION IN DRY CONDITION
POSITION AFTERFINAL ASSEMBLY
WITH ADHESIVEUSING WINCHES
55mm
50mm SCRIBEA MARK
HERE
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5.5 Applying the Adhesive
1 Select the proper size adhesive kit.
• Table C, below shows the quantity of adhesive needed for one joint. • More joints may be assembled at the same time. • Make sure the adhesive is not out of date. Refer to the date stamp on the package. • Never split a package, always prepare complete kits. • Do not use damaged or leaking adhesive kits.
4 Re-sand.
If the sanded surfaces have been contaminated, or if initial sanding took place more than 2 hours before assembling, the surfaces should be re-sanded.
5 Clean the sanded surfaces.
• Use a clean dry cloth or brush to remove sanding dust etc. • Do not touch the sanded surfaces after sanding and cleaning.
2 Prepare the adhesive.
• Add the curing agent to the resin. • Stir thoroughly until the mixture has an even colour (after 2 to 3 minutes) • The recommended storing and mixing temperatures of the adhesive are shown below. Storage and usage of adhesive: - Storing temperature: Below 30° C - Recommended mixing temperature: 20-35° C - Below 15° C, the adhesive will not mix well and the adhesive mix cannot be easily spread. - The mixture will cure too fast above 40° C. - Minimum curing temperature of the adhesive: 80° C. • Make sure that before mixing the adhesive, all preparations have been done and all parts to be bonded are ready for assembly, as mixed adhesive has a limited pot life subject to the ambient temperature (Table E) • Apply the adhesive immediately after mixing.
Figure 5-12 Adhesive kit
Size 10 12 14 16 20 25
inch mm bar bar bar bar bar bar
3 80 0.1 0.1 0.1 0.1 0.1 0.2
4 100 0.2 0.2 0.2 0.2 0.2 0.3
6 150 0.2 0.2 0.2 0.2 0.3 0.4
8 200 0.3 0.5 0.5 0.5 1.0 1.0
10 250 1.0 1.0 1.0 1.0 1.0 2.0
12 300 1.0 1.0 2.0 2.0 2.0 2.0
14 350 1.0 1.0 2.0 2.0 2.0 2.0
16 400 2.0 2.0 2.0 2.0 3.0 3.0
18 450 2.0 2.0 2.0 2.0 3.0 3.0
20 500 2.0 2.0 2.0 2.0 3.0 4.0
24 600 2.0 3.0 3.0 3.0 5.0 5.0
28 700 3.0 3.0 4.0 4.0 5.0 6.0
30 750 3.0 4.0 5.0 5.0 6.0 7.0
32 800 4.0 4.0 5.0 6.0 7.0 8.0
36 900 4.0 6.0 6.0 7.0 8.0 -
40 1000 5.0 6.0 7.0 7.0 - -
Note: For values specified as (-), consult Amipox Engineering
Table C: Adhesive kits per joint (250 gram kit)
Temp. oC 20 25 30 35 40
Setting Time 30min 25min 20min 15min 10min
Table E: Pot life of mixed adhesive in minutes
Never use adhesive that has started to gel. This is the case when the mixture gets clotted and toughens.
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• It may be necessary to set a bridge (pieces of wood between winch cables and pipe outside) to simplify placing of the heating blanket. • Do not remove the winches until the adhesive has fully cured. • Remove excess adhesive A spatula may be used to remove excessive adhesive, when possible also from the inside, as in the flanges.
• Insert the male in the female. • When inserting the male, pay attention to the marks and position and keep the joint together. Letting the male slip back or turning the male after complete insertion may result in a bad joint. • Hook the 2 winches in the band clamps and start pulling the joint further together in a smooth movement until the joint is firmly fixed together and there is 50 mm between the female and the mark.
5.6 Curing of the Adhesive
1 Apply the heating blanket.
• Wrap the required sized AMIPOX heating blanket around the joint keeping the power supply cable free from the blanket. • Make sure the voltage is correct. • The blanket should be applied as indicated in the appropriate AMIPOX Heating Blanket Data sheet. • The blanket should be tied down using heat resistant wire.
• Apply a thin layer of adhesive. • Use a spatula or an adhesive scraper for applying the adhesive.
• All surfaces to be bonded (sanded areas) must be completely covered with adhesive, approximately 0.5 mm in the female side and 1 mm on the male side. • A too thick layer of adhesive may result in flow restrictions. • Also make sure that sufficient adhesive is applied on the cylindrical end of the male that will be covered by the female.
Figure 5-13 Applying thin layer of adhesive in female side
Figure 5-15 Removal of excess adhesive by spatula
Figure 5-14 Incorrect application
Figure 5-16 Correct application and assembly
NOT ENOUGH ADHESIVE USED
TOO MUCH ADHESIVE USED
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• Firm blanket to pipe surface contact is essential for proper curing of the adhesive. • When the temperature is below 10°C or the wind has a cooling effect, it is recommended to cover the heating blanket with insulation material and it should not cover the thermostat.
2 Determine the curing time.
• Write starting time • Curing time is mainly dependent to the distance (= wall thickness) between blanket and adhesive. • Table F and G show the recommended curing time (hours) for each pipe and Fitting joints respectively.
Table F: Curing time for taper pipe joints in hours
Table G: Curing time for fitting joints in hoursFigure 5-17 Apply heating blanket
3 Activate the heating blanket.
• Apply electrical power to the heating blanket and check that it heats up. • Write down on the pipe next to the heating blanket the starting time. • During the time of curing, the heating blanket function should be checked regularly; if a cold heating blanket is found, correct the problem and start the complete curing cycle again. • During curing the joint should not be moved, vibrated or otherwise disturbed
Health and safety
• For health and safety data refer to appropriate AMIPOX Adhesive Product Data sheet. • Wear at all time suitable protective clothing, gloves and eye protection. Dust masks should be used during machining and sanding. • Use gloves when working with adhesive, the wet adhesive may cause irritation by skin contact.
Pipe Size Series
mm inch AT10 AT12 AT14 AT16 AT20 AT25
80 3 1.0 1.0 1.0 1.0 1.0 1.0
100 4 1.0 1.0 1.0 1.0 1.0 1.0
150 6 1.0 1.0 1.0 1.0 1.0 1.0
200 8 1.0 1.0 1.0 1.0 1.0 1.0
250 10 1.0 1.0 1.0 1.0 1.0 1.0
300 12 1.0 1.0 1.0 1.0 1.0 1.0
350 14 1.0 1.0 1.0 1.0 1.0 1.0
400 16 1.0 1.0 1.0 1.0 1.0 1.0
450 18 1.0 1.0 1.0 1.0 1.5 1.5
500 20 1.0 1.0 1.5 1.5 1.5 1.5
600 24 1.0 1.5 1.5 1.5 2.0 2.0
700 28 1.0 1.5 2.0 2.0 3.0 3.0
750 30 1.5 1.5 2.0 2.0 3.0 3.0
800 32 1.5 2.0 2.0 2.0 3.0 3.0
900 36 1.5 2.0 3.0 3.0 4.0 4.0
1000 40 2.0 3.0 4.0 4.0 4.0 4.0
Pipe Size Series
mm inch AT10 AT12 AT14 AT16 AT20 AT25
80 3 1.0 1.0 1.0 1.0 1.0 1.0
100 4 1.0 1.0 1.0 1.0 1.0 1.0
150 6 1.0 1.0 1.0 1.0 1.0 1.0
200 8 1.0 1.0 1.0 1.0 1.0 1.0
250 10 1.0 1.0 1.0 1.0 1.5 1.5
300 12 1.0 1.0 1.5 1.5 1.5 1.5
350 14 1.0 1.0 1.5 1.5 1.5 1.5
400 16 1.0 1.5 1.5 1.5 2.0 2.0
450 18 1.5 1.5 2.0 2.0 2.0 2.0
500 20 1.5 1.5 2.0 2.0 3.0 3.0
600 24 1.5 2.0 3.0 3.0 4.0 4.0
700 28 2.0 3.0 4.0 4.0 4.0 4.0
750 30 2.0 3.0 4.0 4.0 4.0 4.0
800 32 2.0 4.0 4.0 4.0 4.0 4.0
900 36 3.0 4.0 4.0 4.0 4.0 4.0
1000 40 4.0 4.0 4.0 4.0 4.0 4.0
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6 AMIPOX Seal-Lock Joints ASL - Jointing Procedures
• Before assembling the rubber Seal-Lock Joints, all safety precautions need to be checked. • Ensure that all necessary tools and materials are available.
6.1 Tools for Rubber Seal-Lock Joints
For assembly of rubber seal-Lock joints the following is needed:• Lubricant for O-ring and locking strip• A rod or stick• Two (2) pipe clamps• Come along (2) with pulling force 750 kg for Diameter ≤500 mm and 1500 kg for larger diameters • Plastic or wooden mallet to drive the locking strip into the rubber seal lock joint• Non fluffy cleaning-rags
1: Come along set of 2 pcs.2: Lubricant3: Pipe clamps set of 2 pcs.4: D Rings set of 4 pcs.5: Rubber O ring.6: Water bucket7: Screwdriver8: Mallet9: Nylon key
6.2 Joint Assembly
1 Preparation of seal lock joining surfaces
• When ready to join the pipe, remove the end protection from the male pipe end. Loosen and remove dirt and debris from the grooves using compressed air, a clean, dry rag or a paint brush . • Clean the grooves and sealing surface of the female end or coupling. Sand off any projections or rough edges on the entry ramps which compress the O-ring during insertion.
• Now brush or rub a layer of lubricant into the O-ring groove of the male end and all inside surfaces of the female end or coupling. • Apply lubricant only when you are ready to complete the joint. Keep lubricated surfaces clean and free of sand and dirt, as contamination is likely to interfere with joining and sealing. Proper lubrication of the O-ring and joint surfaces is important to avoid cutting the O-ring or rolling it out of place during assembly.
2 O-ring placement
• Lubricate the entire surface of the O-ring and slip it into the first groove on the male end. • Distribute the O-ring evenly in the groove by slipping a screwdriver under it and sliding the screwdriver around the joint. • As an alternative for distributing the O-ring in pipe sizes to 400mm, use a screwdriver to lift the lubricated O-ring at top centre a distance of about 20 per cent of the pipe diameter and let it snap back into the groove.
Do not gouge or abrade the O-ring. A sound O-ring is the key to a water tight joint.
3 Pipe male insertion
• Place the band clamps on either side of the joint. • Rotate the new pipe so its keyholes are in the proper position for driving the key(s) for the next joint. • Align the male end against the female end or coupling already in place for straight concentric entry. Proper alignment is essential for joining. • Deflect the joint to conform to the actual horizontal and vertical alignment of the trench only after the joint is fully assembled in the straight position. An AMIPOX joint puller is recommended for joint assembly. • Connect the ratchet winches to pulling rings attached to the band clamps on either side of the pipe. It is often convenient to place one band clamp just behind the female end or coupling and the other about 1.5m from the male end. • Tighten the winches evenly on both sides so that the O-ring enters smoothly and without being pushed or rolled out of its groove. • Insert the male end until the scribed line is about 6mm from the leading edge of the female end or coupling. To reduce slippage you may elect to use rubber pads under the band clamps. Straightness of entry adds significantly to the ease of assembly. Sight along the pipe and carefully observe concentricity and uniformity of entry.
Figure 6-1 Seal-lock joint assembly tools
6
8
9
5
2
1
4
3
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4 Driving the keys:
• Place lubricated locking keys into the insertion holes, and slowly close the joint until the keys slip into the keyways. • Check the straightness of the entry again by sighting along the pipe and by aligning the scribe mark on the male end with the edge of the female end or coupling. • Use a hammer or mallet to drive the locking keys through the insertion holes and into the keyways until the leading end can be seen in the insertion hole and approximately 75 to 100 mm remain projecting. ! Note! Drive the key only until you can see its leading end through the insertion hole. If the key is driven too far, heat may elongate it and cause it to stick, making later removal impossible. Protect the projecting keys of piping exposed to sunlight or other ultraviolet radiation from embitterment. Within several days of installation, spray all exposed key surfaces with a black acrylic coating, or wrap them with duct tape. Also, fill keyholes with caulking compound to prevent intrusion of sand and dirt which may make later key removal difficult.
5 Positioning and aligning the joined pipe:
• After driving the keys, deflect the joint to fit the hanger supports or trench bottom. With the pipe fully supported in its final position, release the lifting straps: for buried pipe in sag curves, it may be necessary to leave the lead lifting strap in position to align the next joint during assembly. • To avoid excessive movement and bending at turns and branches during the hydrostatic test, pull straight sections of joined pipe forward as assembly progresses, using a ratchet winch or other means to remove play in the joints.
STEP 2 Lubricate inside the female end and locking key groove with ample amounts of lubricant (available on order from AMIPOX). Note that the pipe already in place has been properly rotated so that the key-hole of the next joint is conveniently positioned.
6.3 Seal-Lock Jointing
The Seal-Lock jointing is demonstrated step by step in the subsequent pictures.
STEP 1 End protection (supplied by AMIPOX) should be removed just prior to assembly to keep joining surfaces and grooves clean.
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STEP 6 Align the pipe for straight concentric entry. Proper alignment is essential to ease joining.
STEP 7 Tighten the come-a-longs (provided by user) on both sides so that the O-ring enters smoothly without being pushed out of its groove.
STEP 8 Insert the male end until the scribe line is about ¼ inch (6mm) from the leading edge of the female end or coupling.
STEP 5 Mount the band clamps (available on order from AMIPOX) a convenient distance on each side of the joint, making certain that the pipe going in is properly positioned to allow access to the keyhole of the following joint.
STEP 4 After coating the O-ring (supplied by AMIPOX) with lubricant, mount it in the end most groove in the male pipe end. Insert a screwdriver under the mounted O-ring and run it around the pipe to distribute the O-ring in the groove.
STEP 3 The male end of the pipe going in should also be generously lubricated. Again, make sure that the keyway is well lubricated.
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STEP 9 Lubricate the locking key (supplied by AMIPOX) before insertion.
STEP 10 Place the lubricated locking key into the keyhole and slowly close the joint until the key slips easily into the keyway. Check the pipe alignment. Drive the locking key only until you can see its leading end through the keyhole. If the key is driven in too far, it may bind, making later removal difficult or impossible.
Joint completely assembled.
Nominal Pipe Size Maximum joint deflection
inch mm Male x Female Coupling
2-16 50-400 1/2° 1°
18-48 450-1200 1/4° 1/2°
Table 6-1: Permissible angular deflection at seal lock joints
6.4 Types of Rubber Ring and Locking Strip
• The commonly used rubber ring is made of NBR (Nitrile Butadiene Rubber).Other types of rubber can be supplied depending on the medium and/or the temperature.• Locking Keys are normally plastic nylon material but metallic can also be used depending project requirement.
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AMIPOX flanges are normally used for joining RTRP to existing steel pipes, valves or pumps; rubber gaskets are used for hydrostatic sealing. AMIPOX flanges meet the dimensional requirements. Drilling patterns of all common standards such as ANSI, API, and ISO etc.Before assembling flanged joints, all safety precautions need to be checked. Ensure that all necessary tools and materials are available.
7.1 Tools for Flanged Joints
Tools necessary for assembly of flanges:• Ring spanner with required bolt head size.• Torque wrench with required socket size.
7.2 Flanged Joint Description
• AMIPOX flanges are usually flat faced. These flanges must always be accurately aligned and not subject to any stress.• The bolts and nuts must have washers to avoid exceeding the permitted surface pressure. As an alternative, a stub-end type flange with steel backing ring centre can be installed.• Pipe must not be pulled together by tightening the bolts. If an R.T.R.P. pipeline is connected to a metal pipe, this metal pipe must be anchored to prevent any movement or loads being transmitted to the R.T.R.P. line.
• First, finger tighten all nuts. Bolt threads must be clean and lubricated to attain proper torque. Use lubricated washers under both nuts and bolt heads to protect flange back faces.• Tighten all nuts following the sequences shown in Figure 7-2 below• Do not exceed the torque increments given in Table 7-1 below• After all bolts have been tightened to the recommended torque, recheck the torque on each bolt in the same sequence, as previously tightened bolts may have relaxed.
! Note! Excess torque can prevent sealing and can damage flanges.
7 Flanged Joints
Figure 7-2 Bolts tightening sequence
Table 7-1: Recommended bolt torques
Figure 7-1 Flange assembly
Nominal Pipe Size TorqueIncrements Final Torque
mm inch (N-m) (N-m)
80 3 15 56
100 4 15 56
125 5 20 82
150 6 20 82
200 8 20 82
250 10 30 150
300 12 30 150
350 14 30 150
400 16 50 250
450 18 80 400
500 20 80 400
600 24 100 500
700-750 28-30 100 500
800 32 100 500
900 36 100 500
1000-1200 40-48 100 500
800 32 100 500
900 36 100 500
1000-1200 40-48 100 500
1
2
3
4
5
6 7
8
9
10
11
12 13
14
15
16
17
18
19
28
21
22
23
2420 25
26
27
1
1
1
2
2
2
3
3
34
4
4
5
5
5
6
6
7
7
8
8
9
9
9
10
10
11
11
12
13
13
14
14
15
15
16
16
17
17
17
18
18
19
19
21
22
23
24
20
20
2
3
4
67
8
10
11
13
14
15
16
12
1
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3 4
5
6
78
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7.3 Gaskets
For AMIPOX fiberglass flanges assembly, use full-face gaskets of an elastomeric suitable for the service pressure and temperature and fluids in the system. Gaskets should be 1/8 inch (3mm) thick with shore durometer hardness between 60 and 75. Refer to ASTM D1330 specification for sheet rubber gaskets, grade 1 or 2, to establish minimum physical property requirements for use with water, Rubber gasket with steel inlay or compressed fiber is used for high pressure AMIPOX flanges and Rubber “O Ring” sealing is also used for higher pressure and diameters.
7.4 Bolts
AMIPOX flanges are thicker than metal flanges and require washers. This should be taken into account when calculating the bolt length. For flange thickness see the appropriate AMIPOX product datasheet for dimension data.
7.5 Trouble Shooting
If the assembled joint leaks:
• Loosen it and remove all bolts, nuts, washers and gaskets.• Check for alignment of assembly. Rebuild to correct alignment as required.• Check the gasket for damage. If damaged, discard and replace it with new, undamaged, gasket.• Check flanges for seal ring damage. In particular, check the condition of the inner seal rings. Flanges with damaged inner seal rings must be removed and new, undamaged, flanges installed• If leaks occur as a result of deficiencies in non- fibreglass components of the piping system, consult the manufacturer of the defective components for recommended corrective procedures.• Clean and re-lubricate old threads and washers before re-joining.• Repeat the joining procedure outlined above.• After corrective action has been taken, retest the joint to make sure proper sealing is achieved.
8 Butt and Wrap Lamination Joint
This lamination method is used to join plain-end pipe sections through overlapping layers of fiberglass reinforcement (woven roving and boat tape) thoroughly impregnated with a resin system, it is generally intended for field adjustments works where adhesive bonded joints cannot be accommodated. This jointing method needs to be performed only by experienced and trained pipe technicians under AMIPOX field engineer supervision. Before starting a butt and wrap (lamination) joint, all safety precautions need to be checked. Ensure that all necessary tools and materials are available.
8.1 Tools for Butt and Wrap Lamination Joint
For butt and wrap lamination joint the following tools/equipment are needed:• Measuring tape + pipe fitter’s wrap-a-round + marker pen and a pair of scissors• Cleaning-rags• Abrasive cutting disc (diamond grid or carborundum)• Flapper wheel sander or grinding disc• Air Relive Rollers, Paint Brush and Rubber Scraper Plate• Gloves, dust masks sets, and safety glasses.• Shelter (depending on the weather circumstances)• Infra-Red Burners or Hot Air Guns and Heating blankets• Electric Power Source• Materials: Glass Reinforcement (Woven Roving and Boat Tape), Resin & Hardener and Adhesive Kits.
! Note! Quantity and specification refer to the instructions supplied with butt & wrap kits).
Figure 8-1 Tools and accessories for butt & wrap lamination joints
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8.2 Lamination Procedure
1 Preparation • Qualification of the installation staff by means of installation and material knowledge. • Information about safety regulation and measures. • Account of special working conditions; jobsite, weather, influence, etc. • Installation equipment and materials. • Check the pipes and fittings for visible damage. If necessary, clean the parts to be connected.
2 Process A Cutting the pipe • Determine the length of the pipe sections, taking into account the dimensions of the fittings see Figure 8-2 below. • Mark the pipe sections with the aid of a marking template. • Clamp the pipe in a vice; plies of rubber or similar material should be used to protect the pipe. • Cut the pipe with a hack saw, grinding wheel, etc. Make sure the cut is straight and right-angled. • Cut right through, do not break off. Support the free end of the pipe. Use a fine-tooth saw. The liner must not to be damaged.
B Prepare pipe ands and fittings • Prepare pipe and fitting ends by means of grinding and leveling. Which angle about which length. • Secure and prepare the pipe end. • The prescribed lamination length must be maintained and checked. • The resin coat on the surface must be completely removed by sand blasting or grinding till the glass fibers are exposed. • Remove dirt and chips with a clean rags and dry brush.
• Centre the parts to be laminated and block/fix them firmly, so they cannot slip. • Start the lamination of the fitted sections within two hours after sanding or grinding; re-sanding of lamination area shall be required if the waiting period exceeds two hours.
C Adhesive fit layer • Check whether the sections to be joined together are dry, clean and at the right temperature. • Position the pipe sections for joining. • Prepare the adhesive mixture according to given instructions. The two components must be stirred (e.g. 1 minute) until there is a uniform color. • When fixing by bonding the front edges together; first, a thin coat of adhesive is applied thoroughly onto the front edges. Subsequently, a second thicker coat is applied external surfaces of the pipe ends approximately 100 mm in width, then the sections are connected and their alignment is checked. • Wet out boat tape with adhesive and apply a minimum of three layers circumferentially onto the joined pipe ends. • Use a heating blanket to force cure the initial laminate for one hour.
D Lamination sequence • Start the lamination of the fitted section (see point C above) within two hours after sanding; re-sanding of lamination area shall be required if the waiting period exceeds two hours. • Remove dirt using clean rags and dry brush and also remove any possible moisture by slightly heating the surfaces by means of heating blankets. • Prepare the resin mix using the correct mixing ratio – Resin = 100 parts by weight; Hardener = 24 parts by weight. Take note of the pot life after mixing. The amount of the mixture depends on the diameter. Several batches could be used depending on the weather, temperature and gelling time.
Figure 8-2 Fit layer schematic sketch
Material Description Specifications Remarks
Epoxy ResinAMIANTIT approved
commercial grade such as: Araldite GY6010, DER
330 and Epikote 827
Mixing Ratio Resin to Hardener is 100:24 ppwHardener IPD
Boat Tape 150 grams per Sq. meter 2” and 4” wide
Woven Roving 500 grams per Sq. meter 4” and 6” wide
Adhesive 250 grams kits Two components
Note! Store all fiberglass components in a dry, clean, cool and covered area. IPD is hygroscopic, keep it stored in close containers when not in use. Prepare IPD batches shortly before mixing with resin component.
Table 8-1: Raw materials used in butt & wrap lamination joints
BOATTAPE 50% OVERLAP, 2 LAYERSL
WOVEN ROVING 50% OVERLAP, 5 LAYERS
BOATTAPE 50% OVERLAP, 1 LAYER
1
2
3
BOATTAPE WITH ADHESIVECIRCUMFERENTIAL, 3 LAYERS
MAX. 5mm (FILL GAP WITH ADHESIVE)
FIT LAYER
REPEAT THIS SEQUENCE UNTIL THE MINIMUMREQUIRED LAMINATE THICKNESS IS ACHIEVED
*
NOTE:. SIZE 150 ND AND BELOW USE ONLY BOATTAPE
250mm OD USE 50mm width boat tape
LAMINATION SEQUENCE
250mm OD USE 100mm width boat tape≥<
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For pipes 150 ND or smaller:• For the hand lay-up of the laminate structure, use boat tape with 50% overlap.• Be sure to obtain the minimum required lamination thickness, see Figure 8-4.
For pipes larger than 150 ND:• For the hand lay-up of the laminate structure, use boat tape and woven roving in the sequence as shown in Figure 8-3 and with 50% overlap until the minimum required laminated thickness is achieved, see Figure 8-4.• Make sure that each applied layer of boat tape or woven roving is thoroughly impregnated with resin mixture.• Apply the layers in the circumferential direction onto the pipe – joint ends. • During the wrapping process, tension must be applied so that the resin under the layer being laid could be pressed out.• Avoid air getting into the laminate by using the air- relieve rollers continuously.• To give the finishing touch, apply one final layer of boat tape spirally wrapped onto the whole surface of the laminate. Use air relieve rollers to avoid air enclosures.• After the final boat tape layer, smooth out the resin from the exterior of the laminate using a rubber scraper to leave a resin – rich surface.
E Curing and finishing • The lamination will harden at ambient temperatures. This can be speeded up by applying heat, for example using an infrared device or hot air gun. • The hardening process needs to be carried out gradually. • After the lamination is no longer sticky, curing can be continued with the aid of heating blankets, hot air guns or ovens. • Heating up to the curing temperature should also be performed gradually. • Heating blankets are the most appropriate to use for field butt &wrap joining. • Check if the heating blanket is working properly, temperature in excess of 120°C should be easily achieved if the heating blanket works properly. The surface contact between the heating blanket and the laminate should be as large as possible. Fit the blanket as snugly as possible to the joint. • The curing time only starts when the laminate has reached the correct curing temperature. • Cure the laminate for 4 hours minimum. Whenever possible apply a heating blanket on the inside as well and close the pipe ends to avoid air drafts. • After curing, use sandpaper to remove the rough edges of the laminate and to generally smooth out the external surface • The joint is ready and can be tested when the laminate is fully cured and has cooled down.
E Finishing work • Clean up the area. • Dispose waste products in an environment- friendly manner. • Subsequently activities must be performed in accordance with the instructions, e.g. supports, pressure tests, etc.
Figure 8-3 Lamination sequence
Figure 8-4 Minimum lamination length and thickness
LAMINATE OVERLAY
FIT LAYER
L
2L
L
W.T.
LT = LAMINATION THICKNESS = 2 x PIPE WALLTHICKNESS
L.T.
NOTE:
L = 120mm FOR PIPE SIZES 50mm ND TO 200mm ND
L = ND FOR PIPE SIZES 250mm ND AND ABOVE
BOATTAPE 50% OVERLAP, 2 LAYERSL
WOVEN ROVING 50% OVERLAP, 5 LAYERS
BOATTAPE 50% OVERLAP, 1 LAYER
1
2
3
BOATTAPE WITH ADHESIVECIRCUMFERENTIAL, 3 LAYERS
MAX. 5mm (FILL GAP WITH ADHESIVE)
FIT LAYER
REPEAT THIS SEQUENCE UNTIL THE MINIMUMREQUIRED LAMINATE THICKNESS IS ACHIEVED
*
NOTE:. SIZE 150 ND AND BELOW USE ONLY BOATTAPE
250mm OD USE 50mm width boat tape
LAMINATION SEQUENCE
250mm OD USE 100mm width boat tape≥<
• Be sure that the curing agent is carefully mixed with the resin. The temperature of the resin and curing agent mixture should not exceed 25°C.
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8.3 Butt & Wrap Lamination Jointing
The butt & wrap lamination jointing is demonstrated step by step in the subsequent pictures.
STEP 1 Pipe cutting, aligning and initial grinding. STEP 2 Initial fit-up layer with adhesive and boat tape.
↑ ↑
↑↑
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STEP 3 Heat cure of the initial fit-up. STEP 4 Marking lamination length and surface grinding.
↑ ↑
↑↑
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STEP 6 Mixing of resin and hardener and start of application to the surface for lamination.
STEP 5 Cleaning of surface for lamination, preparation of working area and check of materials for lamination.
↑ ↑
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STEP 7 First layers of boat tape impregnated with the resin mixture.
STEP 8 Layers of woven roving to be impregnated with resin mixture as well and air removal using air relieve rollers.
↑ ↑
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STEP 9 Final layers of boat tape and woven roving, allowing the laminate to gel and dry and finally heat cure for 4 hours.
9 Mechanical Couplers
Generally, mechanical couplers are used for joining plain ended GRE / RTR pipes to pipes made from other materials. A step coupler can join pipes with different outer diameters. This type of joint is unrestrained. These couplers can also be used for preliminary repairs. However, restraining couplers should not be used as these may damage the AMIPOX pipes.Specific information can be obtained from the supplier of the coupler.
Before starting the assembly of a mechanical coupler, check that all safety precautions have been taken and that all necessary tools and materials are available
9.1 Tools for Mechanical Couplers
For Straub and Taylor Kerr: Allen key and torque wrench For Dresser, Viking Johnson and inland couplers: - ring spannerAMIPOX pipes have lower torques than steel pipes, depending on the wall thickness
Figure 9-1 Mechanical couplers
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To ensure long life and trouble-free service from underground piping systems, proper application of the principles of excavation is essential.Laying and jointing, bedding, backfilling and field testing is required. If pipe is installed by a contractor it is equally essential that these principles be reflected in the phrasing of contract documents and that the customer enforce them through inspection. The recommended practices presented in this guide for the installation of buried AMIPOX pipe are developed from the two basic concepts outlined below. Both should be rigorously maintained to obtain best results. Firstly, the manufacturer’s recommendations for assembling pipe sections and curing the joints should be carefully followed. Secondly, each section of pipe should have its support well distributed under the pipe rather than concentrated at points or along a narrow portion of the pipe bottom. This is accomplished by providing proper bedding. These instructions are intended to be used as a guide only and should be amended for a specific job. Because any specification should be properly applied and adapted to meet the requirements in force, there is no specific or implied assurance that inclusion of these paragraphs in a specification will insure a successful job. However, they should assist materially in accomplishing this objective.
10.1 Procedure
The type of installation procedure appropriate for AMIPOX pipe varies with pipe, cover depth, width, native soil characteristics, surcharge loads and backfill materials.The native material must adequately confine the pipe zone backfill to achieve proper pipe support. The following installation procedures are intended to assist the installer in achieving a proper pipe installation.
10.2 Trench Construction
The trench construction highly depends on the soil parameters, such as type, density and moisture content. The construction of the trench should comply with following requirements and recommendation:
• The trench shape is determined by the classification on the soil, which can be unstable or stable.• Top sides of the trench must be cleared from rocks or any other sharp/heavy materials.• The trench foundation shall consist of a compacted sand layer without stones or sharp objects.• Loosen a hard and uneven trench foundation in order to prevent point loading.• Keep the trench dry during installation; if necessary use of a pumping system and drainage.
10.3 Pipe Bedding
The bedding should be placed over a firm, stable trench bottom so as to provide proper support. The finished bed must provide a firm, stable and uniform support for the pipe barrel and any protruding feature of its joint.The common practice is to provide 150 mm of bedding below the barrel and 75 mm below the joint. For soft or unstable trench bottoms, an additional foundation may be needed to achieve firm support for the bedding.
10 Installation of Underground Pipe Systems
• The minimum width (W) at the bottom of the trench for a single pipe shall be: W = 1.25* OD + 300 mm.• The space between the pipe and the trench wall must be 150 mm wider than the used compaction equipment.• Respecting pipe stiffness, operation conditions, soil characteristics and wheel load the minimum recommended burial depth is 0.9 m.• Refer Figure 10-1 and Figure 10-2 below for stable and unstable standard trench construction details.
Figure 10-1 Standard trench construction stable soils
Figure 10-2 Standard trench construction unstable soils
W
15 cm Bedding15 cm Foundation
Secondary back�llzone compacted inlayers of 30 cm
Final back�llexcavated soilcompacted inlayers of 30 cm
0.7 x D
30 cm
Primary back�llzone compacted inlayers of 15 cm
D
15 cm Bedding15 cm Foundation
W
D0.7 x D
30 cm
Primary back�llzone compacted inlayers of 15 cm
Final back�llexcavated soilcompacted inlayers of 30 cm
Secondary back�llzone compacted inlayers of 30 cm
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• The limits for the maximum particle size and stone size given in Table 3-2 must be adhered to.• No soil clumps greater than two times the maximum particle size.• No frozen material• No organic material• No debris (tires, bottles, metals, etc.)
The backfill above the pipe zone may be made with excavated material with a maximum particle size of up to 300 mm providing there is at least 300 mm cover over the pipe. Stones larger than 200 mm should not be dropped on the 300 mm layer covering the pipe crown from a height greater than 2 meters.
10.5 Backfilling Pipe
Immediate backfilling after joining is recommended as it will prevent two hazards, i.e. floating of pipe due to heavy rain and thermal movements due to large differences between day and night temperatures. Floating of pipe can damage the pipe and create unnecessary reinstallation costs. Thermal expansion and contraction can cause loss of seal due to movement of several pipe lengths accumulated at one joint.
If sections of pipe are placed into the trench and backfilling is delayed, each pipe should have the centre section backfilled to the crown to help minimize movements at the joint.
Proper selection, placement and compaction of pipe zone backfill are important for controlling the vertical deflection and are critical for pipe performance. Care must be taken so that the backfill material is not contaminated with debris or other foreign materials that could damage the pipe or cause loss of support. The hunching material in the area between the bedding and the underside of the pipe should be worked in and compacted before placing the remainder of the backfill (see Figure 10-4 and Figure 10-5)
The bedding material may need to be imported to provide proper gradation and pipe support. The recommended materials for bedding are SC1 or SC2. To determine if the native material is acceptable as a bedding material, it should meet all of the requirements of the pipe zone backfill. This determination must be made constantly during the pipe installation process because native soil conditions may vary and change suddenly along the length of a pipeline. The bed must be over-excavated at each joint location to ensure that the pipe has a continuous support and does not rest on the couplings. The coupling area must be properly bedded and backfilled after joint assembly is completed. See Figure 9-3 for proper and improper bedding support.
10.4 Backfill Materials
For classification of various backfill materials and types of embedment, reference is made to AWWA Manual M45 or ASTM D 3839, the following general restrictions apply:
Figure 10-3 Assembly inside trenchTable 10-1: Maximum particle size
Figure 10-4 Pipe bedding
DN Max. Size (mm)
≤ 450 13
500-1200 19
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Figure 10-4 Proper haunch backfill
Figure 10-5 Improper haunch
Procedure & requirements
The procedure and the requirements comprise:
• Temporary installation devices must be removed prior to backfilling.• The maximum particle size for pipe zone embedment is related to the pipe diameter and is described in the backfill material specification (see Table 9-1).• Dumping large quantities of backfill material at one spot on top of the pipe may cause damage; spread the applied backfill material.• Backfill material shall be compacted in layers of 150 mm. make sure pipe is not be displaced due to backfilling.• When reaching a compactions, height of 0.3 * ID below the crown of the pipe, compaction may be continued in layers of 300 mm.• Each layer of backfill shall have a compaction grade of at least 85% Standard Proctor Density (SPD).• Compaction is performed on both sides of the pipe, never across the pipe. A vibrating plate with an impact force of 3000 N is used.• Do not use heavy pneumatic hammers or vibrating equipment until having reached a backfill level of 500 mm over the crown of the pipe.
• Avoid any contact between compaction tools and RTR products.• Use hand – camping only method of compacting within 150 mm envelop around the pipe circumference there after hand operation vibratory – plate compactors can be used.
10.6 Burial Depth
When live loads are less than the conventional H20-S16 loading, the burial depth measured from the top of pipe should be at least 3 feet (0.91 m) for all diameters. At road crossings where the loading exceeds H20-S16, use one of the following methods:• Bury the pipe deeper; AMIPOX will make recommendation on increased depth of burial upon request provided complete loading and soil conditions are submitted for an engineering analysis.• Use casing pipe and collars to protect the pipe; when casings/sleeves are used, take care that the pipe is properly bedded at the points of entry and exit of the casing pipe, pad the pipe to prevent rubbing against the steel casing and spacers to support the pipe inside the casing (see Fig. 10-6).
• Relief plates are used if pipes are installed at shallow depth in well compacted sandy soils or in case the soil – and traffic load cause an excessive loading or deformation of the GRE pipe. The plate is specially designed and dimensioned to minimise the transfer of wheel load on the pipe.
Figure 10-6 Road crossing pipe protection with casing pipe
Figure 10-7 Relief plate
Rubber pad
Road surfaceShrinkingsleeve
Spport3 mCasing pipe
45
OD
Relief plateTop load free spacePolystyrene foam
Spread0.5 x OD
correct: pipe firmly supported
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Bearing area required is computed using the formula
10.7 Thrust Blocking
AMIPOX adhesive bonded tapered joints and seal-lock mechanical joints are fully restrained thrust blocks are not needed. Unless recommended as per below points
• Evaluation of the need for thrust blocks is the responsibility of the engineering agency designing the system. The decision will depend on the exposure to temperature change, surges of internal pressure and the geometry of the pipeline layout. For each of these factors, singly or in combination, the effect of movement and thrusts on the pipe joints and fittings must be evaluated.• Temperature changes produce stress in buried pipe which is restrained by friction of the surrounding bedding, by passive soil pressure at fittings, or by thrust blocks.• Hydrostatic thrusts at fittings depend on the degree of restraint on the pipe bonded to those fittings. In a fully restrained pipe (blocked against movement at both ends) with all joints bonded, the Poisson effect produces considerable tension in the pipe wall; that is as internal pressure is applied, the pipe expands circumferentially and at the same time tries to shorten longitudinally. This tensile force in the AMIPOX pipe wall acts to reduce the hydrostatic thrust on a fitting by about 50%.
10.8 Thrust Blocks-Design and Construction
• Once the applied thrusts are determined, the designer of thrust blocks must consider soil strength, soil stability and location of the water table. • Blocks must have: - Adequate bearing area to resist the soil thrust. - Bearing surface against undisturbed soil. - The resultant thrust vector passing perpendicularly through the centre of the bearing surface (except for valves). Should the soil be unstable or the installation below the water table, the engineer will have to make special provision to ensure stability. ! Note! It is important that any connecting metallic pipe must be anchored at the point of connection to prevent excessive stresses being transferred to the pipe.
where:At = Bearing area of thrust blockR = ReactionSP = Allowable soil bearing pressure
• Thrust blocks for AMIPOX pipe systems should be poured after hydrostatic testing of the pipe. This will allow for clear visual inspection of all fitting joints during the test. To retain pipe in proper alignment while testing, the placement of sand bags and or partial backfilling may be required. Joints may be left exposed for observation during test.• Thrust blocks should be shaped with the “designed bearing area” against virgin earth of the trench wall. Smaller blocks using a dry mix may be shaped by hands but larger blocks will require forms
Figure 10-8 Typical AMIPOX pipe system with thrust blocks
Table 10-2: Safe bearing pressure of soils
Soil Type Description Safe Bearing Pressure (Sp) kg/m2
Rock, hard thick layers 195
Rock, equal to good masonry 24.5
Rock equal to best brick 14.64
Rock equal to poor brick 4.8
Clay, always dry 3.9
Clay, fairly dry 1.95
Clay soft 0.97
Gravel, coarse sand, firm 7.8
Sand, compact, firm 3.9
Sand, clean, dry 1.95
At = RSp
+
+
++
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Figure 10-9 Settlement
• The trench should be undercut beneath the pipes at least 6 inches to give additional thrust resistance and to provide for an adequate concrete envelope around the fittings. At least 6 inches of concrete should be over the top of the pipe.• The centre of the thrust block should coincide with the horizontal centreline of the pipe.• Unless otherwise specified by the engineer, acceptable concrete is 1 part Portland cement, 2 parts washed sand and 3-parts washed gravel with enough water for a relatively dry mix. The dry mix is easier to shape and offers higher strength.• It is important that the concrete be “worked” thoroughly around the elbows for maximum surface contact. Take care that entire area between the fittings and the freshly cut trench wall is filled with concrete and free of voids.
10.9 Settlement
Flexible rubber seal lock joints have to be installed in pairs (ASL); one joint is placed at the beginning of the deviation while the other is located at the end of this area, in order to create a rocker pipe. The rocker pipe will act as a hinge.
The longer the rocker pipe, the higher the loads on the joints. This can be avoided by using more rocker pipes. Based on the soil parameters, the number of rocker pipes is determined.
Note that the length of the sections shall be limited in order to avoid excessive bending which may result in failure of pipe or joint.The section length = ID + minimal 0.5 m. Mechanical O-ring joints shall be installed at both ends to accommodate further settlements.
10.10 Pipe Cast in Concrete
Concrete can be poured around AMIPOX piping system.
• Do not pour concrete directly onto pipe.• The vibrating equipment must be kept at least 300 mm away from the pipe.• The pipe system must be pressure tested prior to casting.• Cradles are provided with steel clamps and rubber lining in order to prevent floating.• Buckling of the pipe during casting can be prevented by pressurizing the system.
Note that concrete shrinks when setting; this may result in extra loading of the GRE pipe system. Ensure that the allowable external pressure is not exceeded by using pressure relief valves.
10.11 Concrete Wall Penetrations and Connections
Several methods are used for AMIPOX pipe connections through concrete walls.
1 Puddle flange
Factory made puddle flange consists of a GRE ring which is directly laminated on a pipe piece (exact location by client) with standard dimensions of approximate 50 mm thickness and a diameter of 50 mm greater than the diameter of the pipe to be installed. A rubber pad wrap is recommended to protect the surrounding pipe portions.
Figure 10-10 Pipe cast in concrete
Original position
Sag
Settled pro�leofter subsidence
Flexible joint
Location of pipeafter subsidence
Flexiblejoint
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10.12 Multiple Pipes in same Trench
When two or more pipes are installed parallel or cross over in the same trench, there should be clear spacing between the pipes, as shown in Figure 9-14.It is advisable, when laying pipes of different diameters in the same trench, to lay them with the same invert level. When this is not possible, use backfill material type SC1 or SC2 to fill all the space from the trench bottom to the invert of the higher pipe. Proper compaction must be achieved (min 90%SPD)
2 Support saddles
Two 180 degree support saddles are bounded on the pipe for tie where it fits in the wall and slightly protruding outside the wall.
3 Metal pipe sleeve
This type of wall penetration pipe should be fitted into a metal pipe sleeve a minimum is 50mm larger in diameter than the AMIPOX pipe size. The opening between the metal pipe sleeve and the AMIPOX should be caulked with a waterproof compound which will dry to a firm but pliable mass.
Figure 10-11 Pipe passing through wall with puddle flange
Figure 10-12 Pipe passing through wall with support saddle
Figure 10-14 Spacing between pipes in the same trench
Figure 10-13 Wall penetration with metal pipe sleeve
RTR pipe
Puddle Flange
Rubber pad wraparound pipe
Concrete wall
100 (typ)
RTR pipe
Concrete wall
2 - RTR support saddle 180^bonded on pipe
Sand bedding
RTR pipe Packing seal
R1 D R2
R2
R1F
F (R1+R2) 2 BUT NOT LESS THAN 300MM
D (R1+R2) /2 BUT NOT LESS THAN 300MM
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11.1 General
This section gives guidelines for proper installation of AMIPOX pipe systems installed above the surface of the ground.
Those who know how to install steel pipe will find that most of the same skills and techniques apply but there are some important differences. AMIPOX pipe requires protection against potential external abrasion or crushing at points where supports are located. In general, the objective of any above ground installation is to provide supports, guides and anchors points in such a way that deflection of unsupported span lengths are maintained within acceptable limits over the long-term.
11.2 Support Types
There are three main types of supports• Simple support • Guide support• Anchor support
Following is set of rules to be followed when designing and positioning supports anchors and guides.• Avoid point loads.• Meet minimum support dimensions.• Protect against abrasion.• Support valves and other heavy equipment independently of the pipe in both vertical and horizontal installations.• Avoid excessive bending.• Avoid excessive loading in vertical runs.
A Simple supports:To prevent excessive pipe deflection due to the weight of the pipe and the fluid, horizontal pipe should be supported at intervals recommended in the support spacing tables provided by AMIPOX Typical for simple support are shown in Figure 11-1
11 Aboveground Pipe Installation
Aboveground piping system
Type A Wall type support
Type A Pipe clamp loose fit Type B U bolt loose fit
Type B Sitting on pipe sleeper
Type C Floor type support
Figure 11-1 Typical Simple Supports
Figure 11-2 Typical guide supports
B Guide supports:Support vertical loads and restrain lateral movement. The main use of guides is to avoid buckling and maintain alignment when axial compressive loads exist in a pipe. Typical, for guide support are shown in Figure 11.2 below
180^ GRE SADDLE PERMITTINGAFFIXED TO PIPE
180º GRE saddle permittinga�xed to pipe
Type C Guide support vertical pipe run
U-bolt with 3-mm thickrubber protection to pipe
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Valve support arrangement
Type A Straight pipe
Type B Anchor support on flange
Type D Anchor support on valve – vertical line
Type C Anchor support on valve –horizontal line
Figure 11-3 Typical anchor supports
C Anchor supports:Anchors supports must positively, restrain the movement of the pipe against all applied forces. The low modulus and light weight of AMIPOX pipe cause these pipes to move easily when emptied and filled rapidly during the cycle of operation and under water hammer conditions. If the movement causes excessive bending stresses, it must be controlled by anchoring at changes in direction. Pipe anchors divide a pipe system into sections or runs and must be attached in structural material capable of withstanding any applied forces. In some case pumps, tanks and other similar equipment functions as anchors.
• Typical for anchor supports are shown in Figure 11-3
support can be bolteddirectly to the �ange
support to be weldedor anchor to a base
GRE support saddle04 nos. 180º saddle
3-mm thick rubber protectionin between pipe & clamp
support to be weldedor anchor to a base
support can be bolteddirectly to the �ange
support to be weldedor anchor to a base
support can be bolted
directly to the �ange
support to be weldedor anchor to a base
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11.5 Joining with other Materials
The most appropriate method to join objects of different materials is by using a flange. A mechanical coupler might be an alternative. For details about these joints, reference is made to manufacturers’ documentation.
Flanges can be drilled according most of the relevant standards. When a flanged GRE pipe section is joined with a metal pipe section, the metal section must be anchored to avoid transmission of loads and displacements to the GRE pipe section.
Instrument connections can be made using a saddle and a bushing.
11.6 UV - Resistance
To manufacture AMIPOX RTR Products, a pigment is added to the resin system, which improves the resistance to UV Radiation of the finished products. The pigmentation delays the effect of the UV but does not completely eliminate it. Pipes exposed to direct sunlight for long period of time will definitely undergo changes in appearance. The rate of appearance change will depend on the intensity of sunlight and length of exposure.
Although no failures are known to have resulted from this change of appearance, it does cause a dull, grey appearance, which some users wish to avoid. Surface degradation has little effect on piping system performance. However, the mechanical properties or structural integrity of the RTR products are not affected by this surface change of appearance.
One can prevent or control the effect by painting with good quality solvent-based paint. However, it is recommended to delay the application of paint till the weathering has occurred in order to have good paint adhesion.
11.3 Protective Methods
Some recommended protective methods include:
• AMIPOX saddles, which provide a clean, corrosion- free surface acting as stiffening saddle for the pipe. Saddles are bonded to the pipe.• Elastomeric material such as rubber, neoprene or even cut-up tire casings. This material may be held in place by pipe clamps or pipe insulation straps.• When using support styles that clamp the pipe, be sure that clamping forces do not crush the pipe. Local crushing could result from a poor fit, and all- around crushing could result over tightening.
11.4 Valve Support
Valves and pumps in AMIPOX lines must be supported independently. Figure 10-3 C and D shows how supports may be bolted to a flange to support weight, to resist thrust and torque and to provide electrical grounding.
If a GRE flange is connected to a steel flange, the support should preferably be at the side of the steel flange.One suggestion would be concrete supports, with steel connections able to carry the full load of the valve. Also, the bending and torque forces caused by opening and closing of valves should be absorbed. Hand operated butterfly valves can be supported or mounted in a manhole as f shown in Figure 10-4.
Support saddle
Figure 11-5 Reducing saddle with metallic bushing
Figure 11-4 Valve box connections
concrete wall water baffle
butterfly valve
support
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Some job specifications require the completed pipe installation to be hydrostatically tested prior to acceptance and service. This is good practice as it can permit early detection and correction of some installation flaws, damaged products etc. If a field hydro test is specified, it must be done regularly as installation proceeds. Good construction practice would be to not exceed pipe testing with installation by more than approximately 1000 meters in order to properly assess the quality of work. The first field hydro test should ideally include at least one air valve or drainage chamber to assess the total pipeline system. In addition to routine care, normal precautions and typical procedures used in this work, the following suggestions should be noted:
1 Preparations prior to test
Inspect the completed installation to assure that all work has been finished properly. Of critical importance is: • Joints assembled correctly. • System restraints (i.e. thrust blocks and other anchors) in place and properly cured. • Flange bolting torques per instructions. • Backfilling completed to minimum burial. • Valves and pumps anchored. • Backfill and compaction near structures and at closure pieces has been properly carried out
2 Filling the line with water
Open valves and vents, so that all air is expelled from the line during filling and avoid pressure surges. Fill from the lowest point. Long straight sections may be vented using an inflatable ball or foam pig to expel the air.
Field hydro testing unit
Testing manifold
12 Field Hydro Testing
3 Pressurize the line slowly
Considerable energy is stored in a pipeline under pressure, and this power should be respected. Apply 0.8 times the pressure and allow 24 hours to settle.
4 Ensure that the gauge location will show the highest line pressure or adjust accordingly. Locations lower in the line will have higher pressure due to additional head.
5 Ensure that the maximum test pressure does not exceed 1.5x PN. Normally, the field test pressure is either a multiple of the operating pressure or the operating pressure plus a small incremental amount. However, in no case should the maximum field test pressure exceed 1.5 x PN.
6 If, after a brief period for stabilization, the line does not hold constant pressure, ensure that thermal effect (a temperature change), system expansion or entrapped air is not the cause. If the pipe is determined to be leaking and the location is not readily apparent, the following methods may aid in the discovery of the problem source:
• Check flange and valve areas. • Check line tap locations. • Use sonic detection equipment. • Test the line in smaller segments to isolate the leak.
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7 Causes of pressure drop
The following causes may affect pressure and can be used as a check list:
• Temperature change, by day as well as by night. • Leakage of valves, fittings, hydrants, etc. • Leakage of gaskets. • Dirt at sealing ring. • Wrong installation of O-ring (slip ring). • Pipes or fittings insufficiently blocked in the trench resulting in displacement. • Air Lock • Leaking test equipment. • Stabilizing time too short. • Leaking joint. • Leakage in fittings. • Leakage of the pipe as result of damage (cracks). • Settlement of the pipe system.
The system shall be considered to have passed the hydro test if there is no leaking of water from the piping at any location and there is no significant pressure loss that can be accounted for by usual engineering considerations.
8 Depressurising
Depressurising of the system must be carried out carefully to avoid a negative pressure.
13 Repair Work
Below listed are some typical repair methods:
1 General
The repair procedure shall be prepared and qualified by the contractor in accordance with the pipe manufacturer’s recommendations. It shall be demonstrated that the repair method restores the specified properties.
Leaks in pipe, fittings and joints are repaired by replacing the defective part. In some cases, especially for buried systems, insufficient space and/or difficult accessibility to pipes and fittings may occur.
Each application of a GRE pipe system and each type of product or design requires a different repair and/or replacement procedure.
2 Minor surface damage
• Minor damage to the surface of pipes, fittings and laminates (e.g. scratches, scour marks) is sealed with resins or adhesive (respective instruction must be followed). • Reinforced wall not be damaged.
3 Damage to reinforced wall
• Fittings showing damage to the reinforced wall must be replaced. • In the case of pipes with damage to the reinforced wall it is generally necessary to replace part of the pipe. For this the damaged section of the pipe is cut out with sufficient spacing left from the visible damage and replaced by a new section. If this is not possible for operation or other reasons, a necessary recommendation must be obtained from AMIPOX. • A provisional repair of the leak is possible, for example, by means of a supplementary laminate or by bonding a saddle to the pipe (pipe must be drained) or by means of a mechanical coupling (non - tensile resistant).
4 Leakages from joints
• Adhesive bonded joints - The leaking joint must be cut out and replaced (see section “Adhesive Bonded Joints”). - If allowed, the leak can be repaired with a laminate (taking due account of the operating pressure, specification) – See section “Laminated Joints”.Assembled pipe inside trench before backfilling
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14 Safety Precautions
The following safety precautions should be respected when dealing with AMIPOX products.
14.1 Resin, Hardener and Adhesive Kits
• For required rescue and safety measures when using adhesives, resins, hardener and Any other chemicals always refer to safety data sheet supplied with it.• In order to avoid irritation of the respiratory system, satisfactory ventilation should be provided.• Always clean up the work area. GRE and cured adhesive are chemically inert and do not have to be treated as chemical waste. Waste shall always be disposed in an environment friendly manner.
14.2 Cutting, Shaving and Sanding
When cutting or grinding GRE materials the following personnel protection is necessary to protect eyes and skin:
• A dust mask covering nose and mouth.• A pair of safety goggles.• Gloves and overall.• Close overall sleeves with adhesive tape to keep the dust out.• Wear protective clothing to protect the body.• Machining should be carried in a well-ventilated room or in open air.
• Laminated joints - Grind off the entire laminate including the bonding laminate and affix a new laminate – See section “Laminated Joints”.
• Seal-Lock joints - If it is not possible to open the joint, cut it out and replace it (taking due account of the system’s flexibility) – See section “Seal-Lock Joints”. - If you can open the joint, established and correct the causes of the problem (e.g. new O-ring, remove dirt, replace pipe) – See section “Seal-Lock Joints”.
• Flanged joints - Check whether all the bolts have been properly torque. - Check whether the flanges as parallel. - Check the flanges and seals for damage and replace if necessary – See section “Flanged Joints”.
Pipe assembly inside the trench using come-along
14.3 Hydro Testing
If system is to be hydro tested, adequate safety precautions must be taken, as a “safe test pressure” does not exist. Any pressure in itself is dangerous.
Experienced personnel must operate the test equipment. Only persons involved in the test or inspection are allowed in the immediate area of the testing system. Only one person should be in charge and everyone else must follow his/her instructions.
Do not change anything on the pipes system when it is under pressure. Leaking joints may only be repaired after the pressure has been fully released.
The test equipment must be installed at a safe distance from the connection to the pipe system. If welding needs to take place, the GRE material must be protected from hot works.
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This handbook is intended as a guide only. All values listed in the product specifications are nominal. Unsatisfactory product results may occur due to environmental fluctuations, variations in operating procedures, or interpolation of data. We highly recommend that any personnel using this data have specialised training and experience in the application of these products and their normal installation and operating conditions. The engineering staff should always be consulted before any of these products are installed to ensure the suitability of the products for their intended purpose and applications. We hereby state that we do not accept any liability, and will not be held liable, for any losses or damage which may result from the installation or use of any products listed in this handbook as we have not determined the degree of care required for product installation or service. We reserve the right to revise this data, as necessary, without notice. We welcome comments regarding this handbook.
FT-A
MIP
OX
V1
01-1
3-E
NG
Distributed by:
AMIPOX First Industrial CityP.O. Box 589Dammam, 31421Saudi ArabiaTel.: + 966 (3) 847 1500Fax: + 966 92 000 [email protected]
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