Total Sheet 253

Vendor’s name : NOV FGS SINGAPORE (PTE.) LTD

Company 's name : Nghi Son Refinery and Petrochemical LLC.
Purchaser : JGCS Consortium
Responsible OC : JVD
Plant Location : Nghi Son, Vietnam
Project name : NSRP Complex Project
P / Order No. : 0-6495-PV216A-109-A
Equipment/Material name : GRP Pipes and Piping Components
Item number : Common

Document title : Installation, Operation and Maintenance Manual

NSRP Complex Project (JOB No.: 0-6495-20)

DOCUMENT CLASS: Others
ISSUE PURPOSE: FI
RESULT CODE: A, B, R, F A
( by purchaser )
NEXT STATUS: FA, FR, FI, FC, AB ( by purchaser
- )
RESUBMISSION DATE: -
( by purchaser )
RESPONSIBLE DEPT./PERSON: ( Construction/J.Shirota
by purchaser )
Review Date: ( 14-Mar-2014
by purchaser )
A: Approved without Comment; B: Approved with Minor Comment
R: Not Approved; F: Not Subject to Review
Approval or review hereunder shall not be construed to relieve Vendor/ Subcontractor of his responsibilities and
liability under the Contract

Purchaser ORIG. PURCHASE ORDER NO. SERIAL REV.

DOC. No.
V V216A-109-A- 801 1

This procedure contains duplicated subject with other documents such as storage, handling, field assembly, repair,

hydrotest etc. " If there are any deviation or conflict with other specific procedure for NSRP Project, specific procedure shall be

followed.

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 FIELD INSTALLATION MANUAL OF
GRE PIPING

NGHI SON REFINERY COMPLEX PROJECT

(JV-JGC, TECHNIP, CHIYODA, SKEC & GS)

BONDSTRAND
SERIES

S2410 & S2420FM

( UP TO 40” )

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 CONTENTS
1. RECEIVING & INSPECTION
 Shipping, Handling, Storage & Inspection of Bondstrand Fiberglass pipe
2. PRODUCT DATA
 Bondstrand Series S2400 Fiberglass pipe & fittings Product Data
 Dimension Table

3. TYPE OF ADHESIVES
 Bondstrand RP 48 Adhesive Kit

4. TOOLS & ACCESSORIES

 Bondstrand M 86 Pipe Shaver Operating Instructions
 Bondstrand M 87 Pipe Shaver Operating Instructions
 Bondstrand M 87XL Pipe Shaver Operating Instructions
 Bondstrand M 88 Pipe Shaver Operating Instructions
 Heating Blankets

5. ASSEMBLY
 Taper / taper assembly procedure.
 Key Lock Assembly Instruction

6. INSTALLATION MANUALS
 Bondstrand Engineering Guide For Suspended Pipe
 Bondstrand Engineering Guide for Buried Pipe.
 Saddle Installation.

7. MISALIGNMENT TOLERANCE AND ASSEMBLY FLANGES

 Assembly Instructions for Bondstrand fiberglass flanges
 Flange Mounting Misalignment Tolerance
 Fiberglass Pipe – Maximum Allowable Misalignment

8. TESTING
 Flushing Procedure
 Hydro-testing Procedure

9. REPAIR
 Maintenance & Repair Procedure (MOD-01, 02, 03 )
 Butt & Wrap Joint ( LAM-01 & 03 )

10. Others
 Safety Recommendations
 Weathering & UV
 Estimated Man-hour
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 Bondstrand® 2400
Glassfiber Reinforced Epoxy (GRE) pipe systems

Uses and applications

• Potable water • Crude oil & gas
• Cooling water • Brine solutions
• Produced water • Drainage
• Fire water (FM approved) • Sewage
• Waste water • CO2
• Salt water • General service for mildly corrosive liquids

Characteristics
• Laminate meets requirements of API specification 15LR and ISO 14692;
• Pipe wall design based on hydrostatic design basis (procedure B) with a 0.5 service factor;
• Maximum operating temperature: 93 °C. Temperatures up to 121 °C are possible. Please consult NOV Fiber Glass
Systems;
• Pipe sizes: 50 - 1000 mm (2” - 40”);
• Standard pressure rating up to 50 bar. Higher pressure ratings are possible. Please consult NOV Fiber Glass Systems;
• ASTM D-2310 classification: RTRP-11AW.

Description
Pipe
Filament wound Glassfiber Reinforced epoxy (GRE) pipe with an integral Taper female x shaved spigot adhesive bonded joint
or Key-Lock integral female x male mechanical joint.

Fittings
Filament wound Glassfiber Reinforced epoxy (GRE) fittings with integral Taper female bell ends. A wide range of fittings, such
as elbows, tees and reducers are available.

Flanges
Filament wound GRE heavy duty and stub end flanges with integral Taper female bell end. Standard flange drilling pattern as
per ASME B16.5 and B16.47A class 150. Other drilling patterns such as class 300, DIN and JIS are also available.

For dimensional data and standard configurations for fittings, please refer to the respective fitting guides. Optionally, the
system can be supplied conductive (Bondstrand 2400C) or with fireproofing (Bondstrand 2400FP).

Note: pipe nipples, saddles and flanged fittings have different end configurations.

Pipe sizes
From 50 - 100 mm (2”- 4”): 5.8 - 6.2 m or 9 m random length
For 150 mm (6”): 5.8 - 6.2 m, 9 m or 11.6 - 11.9 m random length
From 200 - 1000 mm (8” - 40”): 11.6 - 11.9 m random length

Note: Overall pipe length depends on size, end configuration and production location.

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 Typical physical properties
Pipe property Units Value Method
Thermal conductivity pipe wall W/m°K 0.33 NOV FGS
Thermal expansion @ 21 °C mm/mm °C 18x10-6 ASTM D696
Thermal expansion @ 93 °C mm/mm °C 24x10-6 ASTM D696
Flow coefficient Hazen-Williams 150 -
Absolute roughness m 5.3x10-6 -
Density kg/m3 1800 -
Specific gravity 1.8 ASTM D792
Specific heat J/kg°K 910 -
Grounding resistance @500 Volt - pipe Ohm/m < 1x10-6 ASTM D257
Grounding resistance @500 Volt - fitting Ohm/ea < 1x10-6 ASTM D257
Shielding capability Volt 100 -

Typical mechanical properties

Pipe property Units Value Value Method
21°C 93°C
Hydrostatic design basis N/mm2 161* 124 ASTM D2992 proc. B
Ultimate hoop stress at weeping N/mm2 280 ASTM D1599
Circumferential
Hoop tensile strength N/mm2 380 ASTM D2290
Hoop tensile modulus N/mm2 26500 16800 ASTM D2290
Poisson's ratio axial/hoop 0.61 0.79 NOV FGS
Longitudinal
Aial tensile strength N/mm2 80 65 ASTM D2105
Axial tensile modulus N/mm2 15500 9900 ASTM D2105
Poisson's ratio hoop/axial 0.35 0.40 NOV FGS
Axial bending strength N/mm2 85
Axial bending modulus N/mm2 15500 9900 ASTM D2925
Shear modulus N/mm2 15500 9900 NOV FGS

* at 65°C

Typical pipe dimensions

Minimum structural wall thickness
Nominal pipe size Pipe ID Bondstrand series

2410 2412 2414 2416 2420 2425 2432 2440 2450

(mm) (in) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)
50 2 53.2 1.8 1.8 1.8 1.8 1.8 1.8 1.8 2.3 2.8
80 3 81.8 1.8 1.8 1.8 1.8 1.8 2.2 2.6 3.4 4.2
100 4 105.2 1.8 1.8 1.8 2.0 2.2 2.8 3.4 4.4 5.4
150 6 159.0 2.0 2.2 2.5 2.9 3.3 4.1 5.1 6.5 8.2
200 8 208.8 2.6 2.7 3.2 3.7 4.3 5.3 6.7 8.6 10.7
250 10 262.9 3.0 3.4 4.0 4.6 5.3 6.7 8.3 10.7 13.5
300 12 313.7 3.4 4.0 4.8 5.5 6.3 7.9 9.9 12.9 16.1
350 14 344.4 3.6 4.3 5.2 6.1 6.9 8.7 10.9 14.1 17.7
400 16 393.7 4.0 5.0 5.9 6.9 7.9 10.0 12.4 15.1
450 18 433.8 4.4 5.5 6.5 7.6 8.7 11.0 13.7 17.7
500 20 482.1 4.9 6.1 7.2 8.4 9.6 12.2 15.2 19.6
600 24 578.6 5.8 7.2 8.8 10.1 11.6 14.6 18.3 23.5
700 28 700.0 6.9 8.6 10.3 12.1 13.8 17.4 21.8
750 30 750.0 7.4 9.2 11.1 13.0 14.8 18.6 23.4
800 32 800.0 7.9 9.8 11.8 13.8 15.8 19.9 25.0
900 36 900.0 8.8 11.0 13.2 15.5 17.7 22.3 28.0
1000 40 1000.0 9.8 12.3 14.8 17.3 19.8

Note:
D
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Pipe wall thickness measured according to NOV Fiber Glass System procedure.

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 External pressure
Ultimate Collapse pressure at 21 °C
Nominal pipe size Bondstrand series

2410 2412 2414 2416 2420 2425 2432 2440 2450

(mm) (in) (bar) (bar) (bar) (bar) (bar) (bar) (bar) (bar) (bar)
50 2 18.6 18.6 18.6 18.6 18.6 18.6 18.6 37.7 66.3
80 3 5.3 5.3 5.3 5.3 5.3 9.5 15.5 33.7 61.7
100 4 2.5 2.5 2.5 3.4 4.6 9.2 16.3 34.3 61.7
150 6 1.0 1.3 2.0 3.0 4.5 8.4 15.9 32.1 62.5
200 8 1.0 1.1 1.8 2.8 4.4 8.0 15.9 32.8 61.4
250 10 0.8 1.1 1.8 2.7 4.1 8.1 15.2 31.7 61.8
300 12 0.7 1.1 1.8 2.7 4.0 7.9 15.2 32.7 61.7
350 14 0.6 1.0 1.7 2.8 4.0 7.9 15.3 32.2 61.9
400 16 0.5 1.0 1.7 2.7 4.0 8.1 15.1 26.7
450 18 0.5 1.0 1.7 2.7 4.0 8.0 15.2 31.9
500 20 0.5 1.0 1.7 2.7 3.9 8.0 15.1 31.6
600 24 0.5 1.0 1.8 2.7 4.0 7.9 15.3
700 28 0.5 0.9 1.6 2.6 3.8 7.6 14.6
750 30 0.5 0.9 1.6 2.6 3.8 7.5 14.7
800 32 0.5 0.9 1.6 2.6 3.9 7.6 14.7
900 36 0.5 0.9 1.6 2.6 3.8 7.5 14.6
1000 40 0.5 1.0 1.6 2.6 3.9

Note: At 93°C. the values for collapse pressure are approximately 37% lower.

Stiffness
Specific Tangential Initial Stiffness (STIS) per NEN 7037 at 21 ºC
Nominal pipe size Bondstrand series

2410 2412 2414 2416 2420 2425 2432 2440 2450

(mm) (in) (kN/m2) (kN/m2) (kN/m2) (kN/m2) (kN/m2) (kN/m2) (kN/m2) (kN/m2) (kN/m2)
50 2 77.4 77.4 77.4 77.4 77.4 77.4 77.4 157.2 276.0
80 3 22.0 22.0 22.0 22.0 22.0 39.7 64.6 140.3 257.2
100 4 10.5 10.5 10.5 14.3 19.0 38.5 67.8 142.9 257.0
150 6 4.2 5.6 8.2 12.7 18.6 35.1 66.3 133.8 260.5
200 8 4.1 4.6 7.6 11.7 18.1 33.5 66.4 136.7 255.8
250 10 3.2 4.6 7.4 11.2 17.0 33.9 63.3 132.1 257.3
300 12 2.7 4.4 7.6 11.3 16.9 32.7 63.2 136.1 256.9
350 14 2.4 4.1 7.3 11.6 16.7 33.0 63.8 134.4 257.9
400 16 2.2 4.4 7.1 11.3 16.8 33.6 62.9 111.3
450 18 2.2 4.3 7.1 11.3 16.8 33.4 63.4 133.0
500 20 2.2 4.3 7.0 11.1 16.4 33.2 63.1 131.7
600 24 2.2 4.1 7.4 11.2 16.8 32.9 63.6
700 28 2.1 3.9 6.7 10.8 16.0 31.5 60.8
750 30 2.1 3.9 6.9 10.9 16.0 31.3 61.2
800 32 2.1 3.9 6.8 10.8 16.0 31.6 61.5
900 36 2.0 3.9 6.7 10.7 15.8 31.2 60.7
1000 40 2.0 4.0 6.9 10.9 16.2

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 Stiffness (C’tnd)
Stiffness Factor (SF) per ASTM D-2412 at 21°C
Nominal pipe size Bondstrand series

2410 2412 2414 2416 2420 2425 2432 2440 2450

(mm) (in) (lb in) (lb in) (lb in) (lb in) (lb in) (lb in) (lb in) (lb in) (lb in)
50 2 114 114 114 114 114 114 114 238 429
80 3 114 114 114 114 114 208 344 768 1448
100 4 114 114 114 156 208 429 768 1665 3078
150 6 156 208 305 477 702 1347 2593 5368 10777
200 8 344 385 640 990 1554 2910 5879 12432 23944
250 10 528 768 1251 1902 2910 5879 11176 23944 48089
300 12 768 1251 2162 3252 4887 9637 18965 41958 81568
350 14 912 1554 2748 4436 6421 12871 25312 54790 108384
400 16 1251 2443 4014 6421 9637 19545 37266 67294
450 18 1665 3252 5368 8580 12871 26015 50258 108384
500 20 2299 4436 7295 11585 17293 35491 68640 147168
600 24 3814 7295 13320 20138 30508 60828 119784
700 28 6421 12432 21358 34626 51367 102966 202495
750 30 7920 15220 26731 42941 63362 125772 250433
800 32 9637 18396 32114 51367 77093 154029 305397
900 36 13320 26015 44954 72785 108384 216750 429060
1000 40 18396 36371 63362 101200 151719

Pipe Stiffness (PS) per ASTM D-2412 at 21°C

Nominal pipe size Bondstrand series

2410 2412 2414 2416 2420 2425 2432 2440 2450

(mm) (in) (psi) (psi) (psi) (psi) (psi) (psi) (psi) (psi) (psi)
50 2 602.8 602.8 602.8 602.8 602.8 602.8 602.8 1223.8 2149.5
80 3 171.6 171.6 171.6 171.6 171.6 308.9 502.7 1092.8 2003.0
100 4 81.9 81.9 81.9 111.7 147.8 299.7 527.7 1112.6 2001.4
150 6 33.0 43.7 63.8 98.8 144.5 273.2 516.2 1041.8 2028.4
200 8 32.0 35.8 59.1 90.8 141.3 260.9 516.8 1064.5 1991.9
250 10 24.7 35.8 57.9 87.4 132.7 263.9 492.9 1028.6 2003.6
300 12 21.2 34.3 58.9 88.0 131.2 254.9 492.4 1059.6 2000.5
350 14 19.0 32.2 56.6 90.6 130.3 257.2 496.5 1046.2 2008.4
400 16 17.5 33.9 55.3 87.9 130.9 261.4 489.5 866.6
450 18 17.4 33.7 55.3 87.8 130.7 260.1 493.4 1036.0
500 20 17.5 33.5 54.8 86.4 128.0 258.5 491.0 1025.3
600 24 16.8 31.9 57.8 86.8 130.6 256.4 495.5
700 28 16.0 30.7 52.4 84.4 124.3 245.4 473.7
750 30 16.0 30.6 53.3 85.1 124.6 243.7 476.3
800 32 16.1 30.5 52.8 83.9 124.9 245.9 478.5
900 36 15.6 30.3 51.9 83.5 123.4 243.1 472.3
1000 40 15.7 30.8 53.3 84.6 125.9

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 Span lengths
Single span recommendations at 21°C
Nominal pipe size Bondstrand series

2410 2412 2414 2416 2420 2425 2432 2440 2450

(mm) (in) (m) (m) (m) (m) (m) (m) (m) (m) (m)
50 2 2.8 2.8 2.8 2.8 2.8 2.8 2.8 3.0 3.1
80 3 3.2 3.2 3.2 3.2 3.2 3.3 3.5 3.7 3.9
100 4 3.4 3.4 3.4 3.5 3.6 3.8 4.0 4.2 4.4
150 6 3.9 4.0 4.1 4.3 4.4 4.6 4.9 5.1 5.4
200 8 4.5 4.4 4.7 4.9 5.0 5.3 5.6 5.9 6.2
250 10 4.7 4.9 5.3 5.4 5.6 5.9 6.2 6.6 6.9
300 12 4.9 5.3 5.7 5.9 6.1 6.5 6.8 7.2 7.6
350 14 5.0 5.4 6.0 6.2 6.4 6.8 7.1 7.5 7.9
400 16 5.2 5.9 6.4 6.6 6.9 7.2 7.6 7.9
450 18 5.4 6.2 6.7 7.0 7.2 7.6 8.0 8.5
500 20 5.8 6.5 7.1 7.3 7.6 8.0 8.4 8.9
600 24 6.2 7.0 7.8 8.1 8.3 8.8 9.2 9.8
700 28 6.7 7.6 8.4 8.8 9.1 9.6 10.1
750 30 7.0 7.9 8.7 9.2 9.4 9.9 10.5
800 32 7.2 8.1 9.0 9.4 9.7 10.3 10.8
900 36 7.6 8.6 9.5 10.0 10.3 10.9 11.5
1000 40 8.0 9.1 10.1 10.6 10.9

Continuous span recommendations at 21 °C

Nominal pipe size Bondstrand series

2410 2412 2414 2416 2420 2425 2432 2440 2450

(mm) (in) (m) (m) (m) (m) (m) (m) (m) (m) (m)
50 2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.5 4.7
80 3 4.8 4.8 4.8 4.8 4.8 5.0 5.2 5.5 5.8
100 4 5.1 5.1 5.1 5.2 5.4 5.7 5.9 6.3 6.5
150 6 5.8 6.0 6.2 6.4 6.6 6.9 7.3 7.7 8.1
200 8 6.7 6.7 7.0 7.3 7.5 7.9 8.3 8.8 9.2
250 10 7.3 7.6 7.9 8.1 8.4 8.9 9.3 9.8 10.3
300 12 7.9 8.2 8.6 8.9 9.2 9.7 10.2 10.8 11.3
350 14 8.2 8.6 9.0 9.3 9.6 10.1 10.7 11.3 11.8
400 16 8.7 9.2 9.6 9.9 10.3 10.8 11.4 11.9
450 18 9.2 9.7 10.1 10.4 10.8 11.4 11.9 12.6
500 20 9.7 10.2 10.6 11.0 11.3 12.0 12.6 13.3
600 24 10.6 11.1 11.7 12.0 12.4 13.1 13.8 14.6
700 28 11.6 12.2 12.7 13.2 13.6 14.4 15.1
750 30 12.0 12.6 13.2 13.7 14.1 14.9 15.7
800 32 12.4 13.0 13.6 14.1 14.6 15.4 16.2
900 36 13.1 13.8 14.4 15.0 15.4 16.3 17.2
1000 40 13.8 14.6 15.2 15.8 16.3

Notes: 1. Span lengths are based on 12.7 mm (1/2 inch) mid span deflection.
2. Span lengths are based on pipes filled with water having a density of 1000 kg/m3 and include no provisions for weight caused by
insulation material, valves, flanges or other heavy objects.
3. At 93 °C, span lengths are approximately 10% lower.
4. Span lengths do not include provisions for occasional loads like, snow, ice, wind etc.

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 Conversions
1 psi = 6895 Pa = 0.07031 kg/cm2
1 bar = 105Pa = 14.5 psi = 1.02 kg/cm2
1 MPa = 1 N/mm2 = 145 psi = 10.2 kg/cm2
1 inch = 25.4 mm
1 Btu•in/(h•ft2 • °F) = 0.1442 W/(m•K)
°C = 5/9 (°F-32)

National Oilwell Varco has produced this brochure for general information only. and it
is not intended for design purposes. Although every effort has been made to maintain
the accuracy and reliability of its contents. National Oilwell Varco in no way assumes
responsibility for liability for any loss. damage or injury resulting from the use of information
and data herein nor is any warranty expressed or implied. Always cross-reference the
bulletin date with the most current version listed at the website noted in this literature.

North America South America Europe Asia Pacific Middle East

2425 SW 36th Street Avenida Fernando Simoes P.O. Box 6. 4190 CA No. 7A. Tuas Avenue 3 P.O. Box 17324
San Antonio. TX 78237 USA Recife. Brazil 51020-390 Geldermalsen. The Netherlands Jurong. Singapore 639407 Dubai. UAE
Phone: +1 210 434 5043 Phone: +55 31 3326 6900 Phone: +31 345 587 587 Phone: +65 6861 6118 Phone: +971 4881 3566

www.fgspipe.com • [email protected]

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© 2012. NATIONAL OILWELL VARCO
® Trademark of NATIONAL OILWELL VARCO
FP 158 B 05/12
 BONDSTRAND PRODUCT DIMENSION - SERIES 2"-24" (S2420FM), 26"-40" (S2410) - NGHI SON REFINERY

PIPE (Taper Joint Data) SOCKET DEPTH 90º ELBOW TF 45º ELBOW TF 22.5º ELBOW TF

OL
OL OL
TF LL Ds LL DS
TM Taper x Taper LL Ds

°
90
OD
ID
Ds

45°

.5
22
DS
DS L
L : LAYING LENGTH

DN OD ID Wt. #CC DIM "Ds" LL OL Wt. #CC LL OL Wt. #CC LL OL Wt. #CC
(mm) (in) (mm) (mm) (Kg/m) (mm) (mm) (mm) (Kg) (mm) (mm) (Kg) (mm) (mm) (Kg)
INSERT. DEPTH INSERT. DEPTH
FOR FITTING FOR PIPE &
(ref.) (ref.) EXCEPT FLG. FLANGE

50 2" 59.3 53.4 0.7 229N37G9 50 50 87 137 0.6 229N20J8 45 95 0.5 229N14J8 29 79 0.4 229N12J8
80 3" 87.9 82 1 339N37G9 50 50 126 176 1.1 339N20J8 61 111 0.9 339N14J8 37 87 0.6 339N12J8
100 4" 112.1 105.4 1.5 449N37G9 50 50 155 205 2.1 449N20J8 73 123 1.3 449N14J8 43 93 0.9 449N12J8
150 6" 168.1 159.2 3.4 669N37G9 80 80 240 320 5.8 669N20J8 106 186 3.9 669N14J8 60 140 1.4 669N12J8
200 8" 219.9 209 5.6 889N37G9 80 80 315 395 12 889N20J8 137 217 7.4 889N14J8 76 156 5.1 889N12J8
250 10" 276 263.1 8.6 AA9N37G9 110 110 391 501 16.1 AA9N20J8 169 279 12.4 AA9N14J8 68 178 9.7 AA9N12J8
300 12" 328.8 313.9 12 BB9N37G9 140 140 463 603 26 BB9N20J8 196 336 22 BB9N14J8 77 217 15.5 BB9N12J8
350 14" 360.7 344.6 14.4 CC9N37G9 140 140 364 504 37 CC9N20J8 125 265 29 CC9N14J8 71 211 21 CC9N12J8
400 16" 412 393.9 18.7 DD9N37G9 170 170 402 572 53 DD9N20J8 142 312 41 DD9N14J8 85 255 24 DD9N12J8
450 18" 453.7 434 22.6 EE9N37G9 170 170 472 642 76 EE9N20J8 204 374 54 EE9N14J8 106 276 39 EE9N12J8
500 20" 503.8 482.3 27.7 FF9N37G9 200 200 523 723 125 FF9N20J8 225 425 75 FF9N14J8 116 316 56 FF9N12J8
550 22" 554.1 530 33.5 GG9N37G9 200 200 584 784 163 GG9N20J8 257 457 98 GG9N27J8 136 336 69 GG9N12J8
600 24" 604.3 578.8 39.9 HH9N37G9 230 230 625 855 228 HH9N20J8 268 498 130 HH9N14J8 136 366 93 HH9N12J8
650 26" 667.8 650.3 -- JJ9037G9SP4777 110 110 675 785 120 JJ9020J8 289 399 67 JJ9014J8 146 256 52 JJ9012J8
700 28" 718.7 700.2 -- KK9037G9SP4778 140 140 726 866 123 KK9020J8 310 450 90 KK9014J8 157 297 60 KK9012J8
750 30" 769.9 750.2 -- LL9037G9SP4779 140 140 777 917 196 LL9020J8 331 471 107 LL9014J8 167 307 70 LL9012J8
800 32" 821.1 800.2 -- ZZ9037G9SP4780 170 170 828 998 252 ZZ9020J8 352 522 139 ZZ9014J8 177 347 94 ZZ9012J8
900 36" 923.1 900 -- MM9037G9SP4781 200 200 929 1129 348 MM9020J8 394 594 193 MM9014J8 197 397 137 MM9012J8
1000 40" 1025.5 1000 -- WW9037G9SP4782 200 200 1023 1223 480 WW9020J8 433 633 257 WW9014J8 216 416 171 WW9012J8

Note. 1) Pipe OD is for reference only and for use on support clamp design.

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 BONDSTRAND PRODUCT DIMENSION - SERIES 2"-24" (S2420FM), 26"-40" (S2410) - NGHI SON REFINERY
EQUAL TEE TF EQUAL LATERAL 45º TF COUPLING TF NIPPLE TMxTM
OL

s
Ds LL Ds

D
L2
O
L2

H
RUN

OD
N
A
BR
LL1
RUN Ds Ds

OL1
GAP

BRANCH
Ds LL Ds LL
Ds L1 L2 Ds

DS
OL1 OL2
OL

DN Branch Total run Wt. #CC L1 OL1 L2 OL2 Wt. #CC LL OL Wt. #CC LL Wt.. #CC
(mm) (in) LL1 OL1 LL OL (Kg) (mm) (mm) (mm) (mm) (Kg) (mm) (mm) (Kg) (mm) (Kg)
(mm) (mm) (mm) (mm)
50 2" 74 124 148 248 1.3 229N80J8 74 124 209 259 2.3 229N26J8 70 170 0.4 229N07J8 125 0.1 229N28G8
80 3" 96 146 192 292 2.9 339N80J8 86 136 264 314 4.1 339N26J8 70 170 0.7 339N07J8 125 0.1 339N28G8
100 4" 115 165 230 330 4 449N80J8 86 136 315 365 6.3 449N26J8 70 170 0.9 449N07J8 125 0.1 449N28G8
150 6" 153 233 306 466 11.9 669N80J8 99 179 378 458 12.3 669N26J8 70 230 1.9 669N07J8 185 0.5 669N28G8
200 8" 188 268 376 536 21 889N80J8 N.A. N.A. N.A. N.A. N.A. N.A. 70 230 2.5 889N07J8 190 0.7 889N28G8
250 10" 226 336 452 672 21 AA9N80J8 N.A. N.A. N.A. N.A. N.A. N.A. 70 290 4 AA9N07J8 250 1.4 AA9N28G8
300 12" 264 404 528 808 50 BB9N80J8 N.A. N.A. N.A. N.A. N.A. N.A. 70 350 9.8 BB9N07J8 320 2.5 BB9N28G8
350 14" 272 412 544 824 55 CC9N80J8 N.A. N.A. N.A. N.A. N.A. N.A. 70 350 10.5 CC9N07J8 320 3.1 CC9N28G8
400 16" 295 465 590 930 87 DD9N80J8 N.A. N.A. N.A. N.A. N.A. N.A. 70 410 13.2 DD9N07J8 380 4.8 DD9N28G8
450 18" 339 509 678 1018 103 EE9N80J8 N.A. N.A. N.A. N.A. N.A. N.A. 70 410 9 EE9N07J8 400 5.8 EE9N28G8
500 20" 370 570 740 1140 209 FF9N80J8 N.A. N.A. N.A. N.A. N.A. N.A. 70 470 21 FF9N07J8 460 8.7 FF9N28G8
550 22" 412 612 824 1224 271 GG9N80J8 N.A. N.A. N.A. N.A. N.A. N.A. 70 470 22 GG9N07J8 460 10.4 GG9N28G8
600 24" 434 664 868 1328 351 HH9N80J8 N.A. N.A. N.A. N.A. N.A. N.A. 70 530 24 HH9N07J8 520 13.9 HH9N28G8
650 26" 457 567 914 1134 180 JJ9080J8 -- -- -- -- -- -- 70 290 20.3 JJ9007J8 280 6.1 JJ9028G8
700 28" 497 637 994 1274 240 KK9080J8 -- -- -- -- -- -- 70 350 23.5 KK9007J8 340 8.5 KK9028G8
750 30" 523 663 1046 1326 285 LL9080J8 -- -- -- -- -- -- 70 350 25.3 LL9007J8 340 9.4 LL9028G8
800 32" 559 729 1118 1458 363 ZZ9080J8 -- -- -- -- -- -- 70 410 28.6 ZZ9007J8 400 12.4 ZZ9028G8
900 36" 624 824 1248 1648 518 MM9080J8 -- -- -- -- -- -- 70 470 30.5 MM9007J8 460 17.2 MM9028G8
1000 40" 691 891 1382 1782 683 WW9080J8 70 470 33 WW9007J8 460 21 WW9020G8

D R A
PD2420FM/2410 - TAB2 2 of 14 Rev. ( 0 ) - 10.01.14
IN8-MAR 14
1
- 2 0
 BONDSTRAND PRODUCT DIMENSION - SERIES 2"-24"
(S2420FM), 26"-40" (S2410) - NGHI SON REFINERY

HEAVY DUTY FLANGE BLIND FLANGE

THK/OL
THK/OL

LL Ds

DN LL THK/OL Wt. #CC THK/OL Wt. #CC

(mm) (in) (mm) (mm) (Kg) (mm) (Kg)
(CL 150) (CL150)
50 2" 5 55 1.5 229N53J8A 30 0.7 22945700A
80 3" 5 55 2.2 339N53J8A 30 1.1 33945700A
100 4" 5 55 2.9 449N53J8A 40 1.4 44945700A

150 6" 5 85 5.8 669N53J8A 48 5.03 66945700A

200 8" 6 86 8.4 889N53J8A 51 8.05 88945700A

250 10" 6 116 14.3 AA9N53J8A 60 13.4 AA945700A

300 12" 6 146 26 BB9N53J8A 68 21.4 BB945700A

350 14" 6 146 33 CC9N53J8A 76 29.2 CC945700A

400 16" 6 176 46 DD9N53J8A 80 38.8 DD945700A

450 18" 6 176 49 EE9N53J8A 81 43.9 EE945700A

500 20" 6 206 54 FF9N53J8A 82 54.2 FF945700A

550 22" 6 206 GG9N53J8A 85 67.3 GG945700A

600 24" 6 236 98.1 HH9N53J8A 90 80.3 HH945700A

650 26" 6 116 58 JJ9053J8A 70 78 JJ905700A

700 28" 6 146 67 KK9053J8A 70 90.7 KK905700A

750 30" 6 146 73 LL9053J8A 75 110 LL905700A

800 32" 6 176 117 ZZ9053J8A 80 121 ZZ905700A

900 36" 6 206 148 MM9053J8A 85 175 MM905700A

1000 40" 6 206 175 WW9053J8A 110 238 WW905700A

D R A
IN8-MAR 14
1
- 2 0
PD2420FM/2410 - TAB3 3 of 14 Rev. ( 0 ) - 10.01.14
 BONDSTRAND PRODUCT DIMENSION - SERIES 2"-24" (S2420FM), 26"-40"
(S2410) - NGHI SON REFINERY

REDUCING TEE TF CONC. REDUCER TF

OL
OL1
L1 Ds1

RUN

L2
OL2
BRANCH
Ds1 LL Ds2
OL

Ds2
NOMINAL
PIPE SIZE
L1 OL1 L2 OL2 Wt. #CC LL OL Wt. #CC
(mm) (in) (mm) (mm) (mm) (mm) (Kg) (mm) (mm) (Kg)

80x50 3"x2" TFxTF 96 146 86 136 2.7 329N83J8 74 174 0.8 329N76J8
100x50 4"x2 TFxTF 115 165 99 149 3.8 429N83J8 96 196 1.1 429N76J8
100x80 4"x3" TFxTF 115 165 108 158 4 439N83J8 94 194 1.3 439N76J8
150x50 6"x2" TFxTF 153 233 124 174 11 629N83J8 -- -- -- --
150x80 6"x3" TFxTF 153 233 134 184 12 639N83J8 117 247 2.2 639N76J8
150x100 6"x4" TFxTF 153 233 140 190 12 649N83J8 124 254 2.4 649N76J8
200x80 8"x3" TFxTF 188 268 159 209 16 839N83J8 -- -- -- --
200x100 8"x4" TFxTF 188 268 172 222 17 849N83J8 163 293 4.3 849N76J8
200x150 8"x6" TFxTF 188 268 178 258 18 869N83J8 129 289 5.1 869N76J8
250x100 10"x4" TFxTF 226 336 194 244 29 A49N83J8 -- -- -- --
250x150 10"x6" TFxTF 226 336 204 284 32 A69N83J8 148 338 6.8 A69N76J8
250x200 10"x8" TFxTF 226 336 213 293 34 A89N83J8 135 325 6.9 A89N76J8
300x100 12"x4" TFxTF 264 404 216 266 43 B49N83J8 -- -- -- --
300x150 12"x6" TFxTF 264 404 229 309 44 B69N83J8 -- -- -- --
300x200 12"x8" TFxTF 264 404 239 319 45 B89N83J8 180 400 9.9 B89N76J8
300x250 12"x10" TFxTF 264 404 251 361 51 BA9N83J8 167 417 10.8 BA9N76J8

D R A
IN8-MAR 14
1
- 2 0
PD2420FM/2410 - TAB4 Page 4 of 14 Rev. ( 0 ) - 10.01.14
 BONDSTRAND PRODUCT DIMENSION - SERIES 2"-24" (S2420FM), 26"-40"
(S2410) - NGHI SON REFINERY

REDUCING TEE TF CONC. REDUCER TF

OL
OL1
L1 Ds1

RUN

L2
OL2
BRANCH
Ds1 LL Ds2
OL

Ds2
NOMINAL
PIPE SIZE
L1 OL1 L2 OL2 Wt. #CC LL OL Wt. #CC
(mm) (in) (mm) (mm) (mm) (mm) (Kg) (mm) (mm) (Kg)

350x150 14"x6" TFxTF 272 412 254 334 41 C69N83J8 -- -- -- --

350x200 14"x8" TFxTF 272 412 264 344 54 C89N83J8 -- -- -- --
350x250 14"x10" TFxTF 272 412 277 387 62 CA9N83J8 214 464 17 CA9N76J8
350x300 14"x12" TFxTF 272 412 289 429 66 CB9N83J8 208 488 16.8 CB9N76J8
400x150 16"x6" TFxTF 295 465 274 354 51 D69N83J8 -- -- -- --
400x200 16"x8" TFxTF 295 465 283 363 56 D89N83J8 -- -- -- --
400x250 16"x10" TFxTF 295 465 293 403 63 DA9N83J8 -- -- -- --
400x300 16"x12" TFxTF 295 465 305 445 67 DB9N83J8 195 505 22 DB9N76J8
400x350 16"x14" TFxTF 295 465 315 455 71 DC9N83J8 183 493 23 DC9N76J8
450x200 18"x8" TFxTF 339 509 316 396 100 E89N83J8 -- -- -- --
450x250 18"x10" TFxTF 339 509 329 439 104 EA9N83J8 -- -- -- --
450x300 18"x12" TFxTF 339 509 329 469 107 EB9N83J8 -- -- -- --
450x350 18"x14" TFxTF 339 509 330 470 137 EC9N83J8 -- -- -- --
450x400 18"x16" TFxTF 339 509 330 500 143 ED9N83J8 128 468 27 ED9N76J8

D R A
IN8-MAR 14
1
- 2 0
PD2420FM/2410 - TAB4 Page 5 of 14 Rev. ( 0 ) - 10.01.14
 BONDSTRAND PRODUCT DIMENSION - SERIES 2"-24" (S2420FM), 26"-40"
(S2410) - NGHI SON REFINERY

REDUCING TEE TF CONC. REDUCER TF

OL
OL1
L1 Ds1

RUN

L2
OL2
BRANCH
Ds1 LL Ds2
OL

Ds2
NOMINAL
PIPE SIZE
L1 OL1 L2 OL2 Wt. #CC LL OL Wt. #CC
(mm) (in) (mm) (mm) (mm) (mm) (Kg) (mm) (mm) (Kg)

500x200 20"x8" TFxTF 370 570 350 430 175 F89N83J8 -- -- -- --

500x250 20"x10" TFxTF 370 570 355 465 180 FA9N83J8 -- -- -- --
500x300 20"x12" TFxTF 370 570 355 495 188 FB9N83J8 -- -- -- --
500x350 20"x14" TFxTF 370 570 356 496 188 FC9N83J8 -- -- -- --
500x400 20"x16" TFxTF 370 570 356 526 195 FD9N83J8 249 619 36 FD9N76J8
500x450 20"x18" TFxTF 370 570 365 535 200 FE9N83J8 151 521 35 FE9N76J8
550x300 22"x12" TFxTF 412 612 380 520 238 GB9N83J8 -- -- -- --
550x350 22"x14" TFxTF 412 612 381 521 240 GC9N83J8 -- -- -- --
550x400 22"x16" TFxTF 412 612 381 551 248 GD9N83J8 378 748 53 GD9N76J8
550x450 22"x18" TFxTF 412 612 390 560 253 GE9N83J8 280 650 53 GE9N76J8
550x500 22"x20" TFxTF 412 612 396 596 263 GF9N83J8 159 559 53 GF9N76J8
600x300 24"x12" TFxTF 434 664 405 545 211 HB9N83J8 -- -- -- --
600x350 24"x14" TFxTF 434 664 406 546 281 HC9N83J8 -- -- -- --
600x400 24"x16" TFxTF 434 664 406 576 220 HD9N83J8 486 886 70 HD9N76J8
600x450 24"x18" TFxTF 434 664 428 598 239 HE9N83J8 388 788 70 HE9N76J8
600x500 24"x20" TFxTF 434 664 428 628 279 HF9N83J8 267 697 70 HF9N76J8
600x550 24"x22" TFxTF 434 664 440 640 340 HG9N83J8 158 588 71 HG9N76J8
650x350 26"x14" TFxTF 457 567 444 584 -- -- -- -- -- --
650x400 26"x16" TFxTF 457 567 444 614 -- -- 673 953 -- --
650x450 26"x18" TFxTF 457 567 460 630 -- -- 575 855 -- --
650x500 26"x20" TFxTF 457 567 460 660 -- -- 454 764 -- --
650x600 26"x24" TFxTF 457 567 468 698 -- -- 217 557 -- --

D R A
IN8-MAR 14
1
- 2 0
PD2420FM/2410 - TAB4 Page 6 of 14 Rev. ( 0 ) - 10.01.14
 BONDSTRAND PRODUCT DIMENSION - SERIES 2"-24" (S2420FM), 26"-40"
(S2410) - NGHI SON REFINERY

REDUCING TEE TF CONC. REDUCER TF

OL
OL1
L1 Ds1

RUN

L2
OL2
BRANCH
Ds1 LL Ds2
OL

Ds2
NOMINAL
PIPE SIZE
L1 OL1 L2 OL2 Wt. #CC LL OL Wt. #CC
(mm) (in) (mm) (mm) (mm) (mm) (Kg) (mm) (mm) (Kg)

700x350 28"x14" TFXTF 497 637 475 615 202 -- -- -- -- --

700x400 28"x16" TFXTF 497 637 483 653 207 -- 796 1106 62 --
700x450 28"x18" TFXTF 497 637 483 653 209 -- 698 1008 60 --
700x500 28"x20" TFXTF 497 637 491 691 212 -- 577 917 58 --
700x550 28"x22" TFXTF 497 637 501 701 215 -- 468 808 55 --
700x600 28"x24" TFXTF 497 637 491 721 217 -- 340 710 52 --
700x650 28"x26" TFXTF 497 637 491 601 221 KJ9083J8 153 403 49 KJ9076J8
750x350 30"x14" TFXTF 523 663 501 641 243 -- -- -- -- --
750x400 30"x16" TFXTF 523 663 501 671 245 -- 915 1225 74 --
750x450 30"x18" TFXTF 523 663 509 679 247 -- 817 1127 73 --
750x500 30"x20" TFXTF 523 663 509 709 250 -- 696 1036 70 --
750x550 30"x22" TFXTF 523 663 519 719 253 -- 587 927 67 --
750x600 30"x24" TFXTF 523 663 517 747 256 -- 459 829 64 --
750x650 30"x26" TFXTF 523 663 517 627 260 LJ9083J8 272 522 58 LJ9076J8
750x700 30"x28" TFXTF 523 663 517 657 268 LK9083J8 149 429 58 LK9076J8
800x350 32"x14" TFXTF 559 729 529 669 300 -- -- -- -- --
800x400 32"x16" TFXTF 559 729 537 707 303 -- 1038 1348 94 --
800x450 32"x18" TFXTF 559 729 537 707 306 -- 940 1280 94 --
800x500 32"x20" TFXTF 559 729 545 745 309 -- 819 1189 90 --
800x550 32"x22" TFXTF 559 729 555 755 312 -- 710 1080 87 --
800x600 32"x24" TFXTF 559 729 545 775 315 -- 982 862 83 --
800x650 32"x26" TFXTF 559 729 553 663 321 ZJ9083J8 395 675 77 ZJ9076J8
800x700 32"x28" TFXTF 559 729 553 693 329 ZK9083J8 272 582 77 ZK9076J8
800x750 32"x30" TFXTF 559 729 553 693 332 ZL9083J8 153 463 72 ZL9076J8

D R A 900x400 36"x16" TFXTF -- -- -- -- -- -- 1284 1654 -- --

IN AR 14
18-M
- 2 0
PD2420FM/2410 - TAB4 Page 7 of 14 Rev. ( 0 ) - 10.01.14
 BONDSTRAND PRODUCT DIMENSION - SERIES 2"-24" (S2420FM), 26"-40"
(S2410) - NGHI SON REFINERY

REDUCING TEE TF CONC. REDUCER TF

OL
OL1
L1 Ds1

RUN

L2
OL2
BRANCH
Ds1 LL Ds2
OL

Ds2
NOMINAL
PIPE SIZE
L1 OL1 L2 OL2 Wt. #CC LL OL Wt. #CC
(mm) (in) (mm) (mm) (mm) (mm) (Kg) (mm) (mm) (Kg)

900x450 36"x18" TFXTF 624 824 603 773 427 -- 1186 1556 133 --
900x500 36"x20" TFXTF 624 824 603 803 430 -- 1065 1465 130 --
900x550 36"x22" TFXTF 624 824 613 813 433 -- 956 1356 126 --
900x600 36"x24" TFXTF 624 824 611 841 437 -- 828 1258 122 --
900x650 36"x26" TFXTF 624 824 611 721 443 MJ9083J8 641 951 115 MJ9076J8
900x700 36"x28" TFXTF 624 824 611 751 452 MK9083J8 518 858 116 MK9076J8
900x750 36"x30" TFXTF 624 824 618 758 458 ML9083J8 399 739 111 ML9076J8
900x800 36"x32" TFXTF 624 824 618 788 468 MZ9083J8 276 646 111 MZ9076J8
1000x400 40"x16" TFXTF -- -- -- -- -- -- 1532 1902 -- --
1000x450 40"x18" TFXTF -- -- -- -- -- -- 1434 1804 -- --
1000x500 40"x20" TFXTF 691 891 669 869 570 -- 1313 1713 173 --
1000x550 40"x22" TFXTF 691 891 679 879 574 -- 1204 1604 169 --
1000x600 40"x24" TFXTF 691 891 669 899 578 -- 1076 1506 165 --
1000x650 40"x26" TFXTF 691 891 677 787 586 WJ9083J8 889 1199 157 WJ9076J8
1000x700 40"x28" TFXTF 691 891 677 817 596 WK9083J8 766 1106 157 WK9076J8
1000x750 40"x30" TFXTF 691 891 677 817 601 WL9083J8 647 987 152 WL9076J8
1000x800 40"x32" TFXTF 691 891 685 855 614 WZ9083J8 524 894 152 WZ9076J8
1000x900 40"x36" TFXTF 691 891 685 885 632 WM9083J8 278 678 146 WM9076J8

D R A
IN8-MAR 14
1
- 2 0
PD2420FM/2410 - TAB4 Page 8 of 14 Rev. ( 0 ) - 10.01.14
 BONDSTRAND PRODUCT DIMENSION - SERIES 2"-24" (S2420FM), 26"-40" (S2410) - NGHI SON
REFINERY

FABRICATED RDC TEE FABRICATED RDC TEE

TFxTFxFLG(HD)
HD FLG

OL2

L2
L2
Ds L1 Ds Ds L1 Ds

OL1
OL1
NOMINAL OL (TOTAL RUN)
OL (TOTAL RUN)
PIPE SIZE
L1 OL1 L2 OL2 Wt. #CC L1 OL1 L2 Wt. #CC
(mm) (in) (mm) (mm) (mm) (mm) (Kg) (mm) (mm) (mm) (Kg) (CL 150)

80x25 3"x1" TFxQLF 88 138 162 189 5.3 319N79K1 88 138 192 5.8 319N79N8A
80X40 3"x1.5" TFxQLF 88 138 162 194 5.4 3Q9N79K1 88 138 197 6.5 3Q9N79N8A
100x25 4"x1" TFxQLF 88 138 194 221 12.1 419N79K1 88 138 224 12.6 419N79N8A
100x40 4"x1.5" TFxQLF 88 138 194 226 12.2 4Q9N79K1 88 138 229 13.3 4Q9N79N8A
150x25 6"x1" TFxQLF 88 168 221 248 16.3 619N79K1 88 168 251 17.8 619N79N8A
150x40 6"x1.5" TFxQLF 88 168 221 253 21.9 6Q9N79K1 88 168 256 23 6Q9N79N8A
200x25 8"x1" TFxQLF 88 168 245 272 24.6 819N79K1 88 168 275 25.1 819N79N8A
200x40 8"x1.5" TFxQLF 88 168 246 278 24.7 8Q9N79K1 88 168 281 25.8 8Q9N79N8A
200x50 8"x2" TFxTF 88 168 179 229 24.6 829N79J8 88 168 316 26.1 829N79K7A
250x25 10"x1" TFxQLF 88 198 272 299 29.7 A19N79K1 88 198 302 30.2 A19N79N8A
250x40 10"x1.5" TFxQLF 88 198 273 305 29.8 AQ9N79K1 88 198 308 30.8 AQ9N79N8A
250x50 10"x2" TFxTF 88 198 206 256 29.8 A29N79J8 88 198 343 31.3 A29N79K7A
250x80 10"x3" TFxTF 100 210 206 256 32 A39N79J8 100 210 343 34.2 A39N79K7A
300x25 12"x1" TFxQLF 88 228 298 325 34.6 B19N79K1 88 228 328 35.1 B19N79N8A
300x40 12"x1.5" TFxQLF 88 228 298 330 34.7 BQ9N79K1 88 228 333 35.8 BQ9N79N8A
300x50 12"x2" TFxTF 88 228 232 282 34.6 B29N79J8 88 228 369 36.1 B29N79K7A
300x80 12"x3" TFxTF 100 240 232 282 37.2 B39N79J8 100 240 369 39.4 B39N79K7A
350x25 14"x1" TFxQLF 88 228 313 340 37.3 C19N79K1 88 228 343 37.8 C19N79N8A
350x40 14"x1.5" TFxQLF 88 228 313 345 37.3 CQ9N79K1 88 228 348 38.4 CQ9N79N8A
350x50 14"x2" TFxTF 88 228 247 297 37.2 C29N79J8 88 228 384 38.7 C29N79K7A
350x80 14"x3" TFxTF 100 240 247 297 40 C39N79J8 100 240 384 42.2 C39N79K7A
350x100 14"x4" TFxTF 113 253 247 297 42.8 C49N79J8 113 253 384 45.7 C49N79K7A
400x25 16"x1" TFxQLF 88 258 338 365 49.8 D19N79K1 88 258 368 50.3 D19N79N8A
400x40 16"x1.5" TFxQLF 88 258 338 370 49.8 DQ9N79K1 88 258 373 50.9 DQ9N79N8A
400x50 16"x2" TFxTF 88 258 272 322 49.8 D29N79J8 88 258 409 51.3 D29N79K7A
400x80 16"x3" TFxTF 100 270 272 322 52.9 D39N79J8 100 270 409 55.1 D39N79K7A
400x100 16"x4" TFxTF 113 283 272 322 56.1 D49N79J8 113 283 409 59 D49N79K7A
450x25 18"x1" TFxQLF 88 258 358 385 54.2 E19N79K1 88 258 388 54.7 E19N79N8A
450x40 18"x1.5" TFxQLF 88 258 358 390 54.36 EQ9N79K1 88 258 393 55.4 EQ9N79N8A
450x50 18"x2" TFxTF 88 258 292 342 54.2 E29N79J8 88 258 429 55.7 E29N79K7A
450x80 18"x3" TFxTF 100 270 292 342 57.7 E39N79J8 100 270 429 60 E39N79K7A
450x100 18"x4" TFxTF 113 283 292 342 61.1 E49N79J8 113 283 429 64 E49N79K7A
450x150 18"x6" TFxTF 138 308 292 372 65 E69N79J8 138 308 489 161.5 E69N79K7A
450x200 18"x8" TFxTF 163 333 292 372 70 E89N79J8 163 333 492 180 E89N79K7A
500x25 20"x1" TFxQLF 88 288 382 409 59.4 F19N79K1 88 288 412 60 F19N79N8A
500x40 20"x1.5" TFxQLF 88 288 382 414 59.8 FQ9N79K1 88 288 417 60.6 FQ9N79N8A
500x50 20"x2" TFxTF 88 288 316 366 59.4 F29N79J8 88 288 453 60.9 F29N79K7A
500x80 20"x3" TFxTF 100 300 316 366 63.2 F39N79J8 100 300 453 65.4 F39N79K7A
500x100 20"x4" TFxTF 113 313 316 366 67 F49N79J8 113 313 453 69.9 F49N79K7A
500x150 20"x6" TFxTF 138 338 316 396 - F69N79J8 138 338 513 - F69N79K7A
500x200 20"x8" TFxTF 163 363 316 396 - F89N79J8 163 363 516 - F89N79K7A
550x25 22"x1" TFxQLF 88 288 406 433 G19N79K1 88 288 436 G19N79N8A
550x40 22"x1.5" TFxQLF 88 288 406 438 GQ9N79K1 88 288 442 GQ9N79N8A
550x50 22"x2" TFxTF 88 288 340 390 G29N79J8 88 288 477 G29N79K7A
550x80 22"x3" TFxTF 100 300 340 390 G39N79J8 100 300 477 G39N79K7A
550x100 22"x4" TFxTF 113 313 340 390 G49N79J8 113 313 477 G49N79K7A
550x150 22"x6" TFxTF 138 338 340 420 G69N79J8 138 338 537 G69N79K7A
550x200 22"x8" TFxTF 163 363 340 420 G89N79J8 163 363 540 G89N79K7A

D R A
IN8-MAR 14
1
- 2 0
PD2420FM/2410 - TAB5 Page 9 of 14
Rev. ( 0 ) - 10.01.14.
 BONDSTRAND PRODUCT DIMENSION - SERIES 2"-24" (S2420FM), 26"-40" (S2410) - NGHI SON
REFINERY

FABRICATED RDC TEE FABRICATED RDC TEE

TFxTFxFLG(HD)
HD FLG

OL2

L2
L2
Ds L1 Ds Ds L1 Ds

OL1
OL1
NOMINAL OL (TOTAL RUN)
OL (TOTAL RUN)
PIPE SIZE
L1 OL1 L2 OL2 Wt. #CC L1 OL1 L2 Wt. #CC
(mm) (in) (mm) (mm) (mm) (mm) (Kg) (mm) (mm) (mm) (Kg) (CL 150)

600x25 24"x1" TFxQLF 88 318 430 457 70.6 H19N79K1 88 318 460 71.1 H19N79N8A
600x40 24"x1.5" TFxQLF 88 318 431 463 70.6 HQ9N79K1 88 318 466 71.7 HQ9N79N8A
600x50 24"x2" TFxTF 88 318 364 414 70.6 H29N79J8 88 318 501 72.3 H29N79K7A
600x80 24"x3" TFxTF 100 330 364 414 75 H39N79J8 100 330 501 77.3 H39N79K7A
600x100 24"x4" TFxTF 113 343 364 414 79.5 H49N79J8 113 343 501 82.4 H49N79K7A
600x150 24"x6" TFxTF 138 368 364 444 - H69N79J8 138 368 561 H69N79K7A
600x200 24"x8" TFxTF 163 393 364 444 H89N79J8 163 393 564 H89N79K7A
650x100 26"x4" TFxTF 113 223 400 450 113 223 537
650x150 26"x6" TFxTF 138 248 400 480 138 248 597
650x200 26"x8" TFxTF 163 273 400 480 163 273 600
700x100 28"x4" TFxTF 113 253 425 475 107.2 113 253 562 110.1
700x150 28"x6" TFxTF 138 278 425 505 138 278 622
700x200 28"x8" TFxTF 163 303 425 505 163 303 625
750x100 30"x4" TFxTF 113 253 450 500 114.3 113 253 587 117
750x150 30"x6" TFxTF 138 278 450 530 138 278 647
750x200 30"x8" TFxTF 163 303 450 530 163 303 650
800x100 32"x4" TFxTF 113 283 475 525 135.9 113 283 612 139
800x150 32"x6" TFxTF 138 308 475 555 138 308 672
800x200 32"x8" TFxTF 163 333 475 555 163 333 675
900x100 36"x4" TFxTF 113 313 525 575 168 113 313 662 170.1
900x150 36"x6" TFxTF 138 338 525 605 138 338 722
900x200 36"x8" TFxTF 163 363 525 605 163 363 725
1000x100 40"x4" TFxTF 113 313 575 625 113 313 712
1000x150 40"x6" TFxTF 138 338 575 655 138 338 772
1000x200 40"x8" TFxTF 163 363 575 655 163 363 775

Note: Reinforcement required for 6" and 8" branch

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 BONDSTRAND PRODUCT DIMENSION - SERIES 2"-24" (S2420FM), 26"-40" (S2410) - NGHI SON REFINERY
RDC SADDLE QLF/TF RDC SADDLE FLG(HD)
6mm THK
Ds

REINFORCE
WEDGE
Ds

4PCS(90°
OL

APART)
L

OL

180°
L

T
180°
B = SADDLE LENGTH
µ = SADDLE ANGLE T
2" outlet and below B = SADDLE LENGTH 2" outlet and below
NOMINAL 1& 1.5" OUTLET IS QLF.
2",3",4" & 6" OUTLET IS TF.
µ = SADDLE ANGLE
PIPE SIZE
(runxbranch) L OL B α Τ Wt. #CC L B α Τ Wt. #CC
(mm) (in) (mm) (mm) (mm) (deg) (mm) (Kg) (mm) (mm) (deg) (mm) (kg) (CL150)
Note. Note.
650x25 26"x1" 450 477 152 90 33.3 5.0 J1197103 443 152 90 33.3 5.6 J1197126A
650x40 26"x1.5" 449 481 152 90 33.3 5.0 JQ197103 443 152 90 33.3 5.6 JQ197126A
650x50 26"x2" 520 570 152 90 33.3 5.0 J2947103 487 152 90 33.3 6.2 J2947126A
650x80 26"x3" 520 570 241 90 33.3 7.6 J3947103 487 241 90 33.3 9.4 J3947126A
700x25 28"x1" 477 504 152 90 33.3 5.2 K1197103 461 152 90 33.3 5.8 K1197126A
700x40 28"x1.5" 477 509 152 90 33.3 5.2 KQ197103 461 152 90 33.3 5.8 KQ197126A
700x50 28"x2" 547 597 152 90 33.3 5.2 K2947103 513 152 90 33.3 6.4 K2947126A
700x80 28"x3" 547 597 241 90 33.3 7.8 K3947103 513 241 90 33.3 9.6 K3947126A
750x25 30"x1" 502 529 152 90 33.3 5.8 L1197103 495 152 90 33.3 6.2 L1197126A
750x40 30"x1.5" 502 534 152 90 33.3 5.6 LQ197103 495 152 90 33.3 6.2 LQ197126A
750x50 30"x2" 577 627 152 90 33.3 5.6 L2947103 540 152 90 33.3 6.8 L2947126A
750x80 30"x3" 577 627 241 90 33.3 8.4 L3947103 540 241 90 33.3 10.2 L3947126A
800x25 32"x1" 528 555 152 90 33.3 -- Z1197103 521 152 90 33.3 -- Z1197126A
800x40 32"x1.5" 528 560 152 90 33.3 -- ZQ197103 521 152 90 33.3 -- ZQ197126A
800x50 32"x2" 600 650 152 90 33.3 -- Z2947103 566 152 90 33.3 -- Z2947126A
800x80 32"x3" 600 650 241 90 33.3 -- Z3947103 566 241 90 33.3 -- Z3947126A
900x25 36"x1" 581 608 152 90 33.3 6.9 M1197103 572 152 90 33.3 7.3 M1197126A
900x40 36"x1.5" 581 613 152 90 33.3 6.7 MQ197103 572 152 90 33.3 7.3 MQ197126A
900x50 36"x2" 651 701 152 90 33.3 6.7 M2947103 617 152 90 33.3 7.9 M2947126A
900x80 36"x3" 651 701 241 90 33.3 10.1 M3947103 617 241 90 33.3 11.9 M3947126A
1000x25 40"x1" 647 674 152 90 33.3 7.9 W1197103 640 152 90 33.3 -- W1197126A
1000x40 40"x1.5" 647 679 152 90 33.3 7.9 WQ197103 640 152 90 33.3 -- WQ197126A
1000x50 40"x2" 706 756 152 90 33.3 -- W2947103 672 152 90 33.3 -- W2947126A
1000x80 40"x3" 706 756 241 90 33.3 -- W3947103 672 241 90 33.3 -- W3947126A

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 BONDSTRAND PRODUCT DIMENSION - SERIES 2"-24"
(S2420FM), 26"-40" (S2410) - NGHI SON REFINERY
Laminated Tee
NOMINAL
PIPE SIZE
L1 OL1 L2 OL2 Wt. #CC
(mm) (in) (mm) (mm) (mm) (mm) (Kg)
550x250 22"x10" TFxTF 412 612 372 482
600x250 24"x10" TFxTF 434 664 400 510
650x250 26"x10" TFxTF 457 567 430 540
650x300 26"x12" TFxTF 457 567 425 565
700x250 28"x10" TFxTF 497 637 459 569
700x300 28"x12" TFxTF 497 637 454 594
750x250 30"x10" TFxTF 523 663 484 594
750x300 30"x12" TFxTF 523 663 479 619
800x250 32"x10" TFxTF 559 729 510 620
800x300 32"x12" TFxTF 559 729 505 645
900x250 36"x10" TFxTF 624 824 562 672
900x300 36"x12" TFxTF 624 824 557 697
900x350 36"x14" TFxTF 624 824 582 722
900x400 36"x16" TFxTF 624 824 577 747
1000x250 40"x10" TFxTF 691 891 609 719
1000x300 40"x12" TFxTF 691 891 604 744
1000x350 40"x14" TFxTF 691 891 629 769
1000x400 40"x16" TFxTF 691 891 624 794
1000x450 40"x18" TFxTF 691 891 649 819
Note: Reinforcement required for 6" and 8" branch

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 BONDSTRAND PRODUCT DIMENSION - SERIES 2"-24"
(S2420FM), 26"-40" (S2410) - NGHI SON REFINERY

BONDED CONC. REDUCER TF

NOMINAL
PIPE SIZE
LL OL #CC
(mm) (in) (mm) (mm)

150x50 6"x2" TFxTF 316 446 629N76J87

200x80 8"x3" TFxTF 382 512 839N76J87
250x100 10"x4" TFxTF 457 617 A49N76J87
300x100 12"x4" TFxTF 533 723 B49N76J87
300x150 12"x6" TFxTF 499 719 B69N79J87
350x150 14"x6" TFxTF 612 832 C69N76J87
350x200 14"x8" TFxTF 599 819 C89N76J87
400x200 16"x8" TFxTF 695 945 D89N76J87
400x250 16"x10" TFxTF 682 962 DA9N76J87

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 BONDSTRAND PRODUCT DIMENSION - SERIES 2"-24"
(S2420FM), 26"-40" (S2410) - NGHI SON REFINERY

BONDED CONC. REDUCER TF

NOMINAL
PIPE SIZE
LL OL #CC
(mm) (in) (mm) (mm)

450x300 18"x12" TFxTF 703 1013 EB9N76J87

450x350 18"x14" TFxTF 691 1001 EC9N76J87
500x300 20"x12" TFxTF 824 1164 FB9N76J87
500x350 20"x14" TFxTF 812 1152 FC9N76J87
550x300 22"x12" TFxTF 953 1293 GB9N76J87
550x350 22"x14" TFxTF 941 1281 GC9N76J87
600x300 24"x12" TFxTF 1062 1432 HB9N76J87
600x350 24"x14" TFxTF 1049 1419 HC9N76J87
650x300 26"x12" TFxTF 1248 1498 --
650x350 26"x14" TFxTF 1236 1486
700x300 28"x12" TFXTF 1371 1651 --
700x350 28"x14" TFXTF 1359 1639 --
750x300 30"x12" TFXTF 1490 1770 --
750x350 30"x14" TFXTF 1478 1758 --
800x300 32"x12" TFXTF 1613 1923 --
800x350 32"x14" TFXTF 1601 1911 --

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 Bondstrand RP-48 Epoxy Adhesive
for bonding Glassfiber Reinforced Epoxy (GRE) Taper/Taper pipe and fittings

Description
The RP-48 adhesive kit contains an adhesive resin, hardener and mixing spatula.
The adhesive resin is a white paste. The adhesive hardener is a brown to orange paste.
The mixed adhesive is medium orange. RP-48 is a two component amine-cured epoxy resin
system, formulated for bonding Taper/Taper joints on NOV Fiber Glass Systems Glassfiber
Reinforced Epoxy (GRE) pipe and fittings.

Instructions
Before mixing, make sure that the bonding surfaces are clean and dry. Completely mix all of the hardener with the resin.
Never split a kit ! Apply a uniform layer to both bonding surfaces and draw both parts firmly together. A heat cure is
required before joints are tested or put in to service. Required cure times must be observed. Detailed joint assembly
instructions can be found in the Taper/Taper Assembly Instructions (FP 1043).

Pot life
The pot life (working time) of adhesives is measured from the time the hardener and resin are first mixed until the
adhesive starts to thicken and harden and can no longer be used. The table indicates the pot life of 3 and 6 Oz adhesive
kits at various temperatures.

°C 21 27 32 38
°F 70 80 90 100
3 Oz Kit 25 15 11 8
6 Oz Kit 18 11 7 6
Table A: Pot life in minutes

Curing time
An NOV Fiber Glass Systems approved heating blanket must be used to force cure the
adhesive. The curing time is mainly subject to the distance (= wall thickness) between the
blanket and the adhesive layer. Joint surfaces should be pre-heated when the ambient
temperature is below 15°C (59°F) or when relative humidity is higher than 75%. Curing times
can be found in the Taper/Taper Assembly Instructions (FP 1043).
Heating blanket

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I 18-MA R - 2 014
 Adhesive kit size and bonds per joint
RP-48 Adhesive kits are available in 3 and 6 fluid ounce sizes.

Table B shows the quantity of adhesive needed for one joint. Multiple joints may be assembled at the same time.
Do not use damaged or leaking adhesive kits.

Adhesive Size 10 12 14 16 20 25 32 40 50
Kit Size Inch Bar Bar Bar Bar Bar Bar Bar Bar Bar
3 Oz 2 1/3 1/3 1/3 1/3 1/3 1/3 1/3 1/3 1/3

3 1/3 1/3 1/3 1/3 1/3 ½ ½ ½ 1

4 ½ ½ ½ ½ ½ ½ ½ 1 1
6 ½ ½ ½ ½ 1 1 1 2 2
8 1 1 1 1 1 2 2 2 2
6 Oz 10 ½ 1 1 1 1 1 1 2 2
12 1 1 1 1 1 2 2 2 3
14 1 1 2 2 2 2 2 3 3
16 1 1 2 2 2 2 2 3 3-4
18 2 2 2 2 2 2 3 4 4-5
20 2 2 2 3 3 3 4 4-5 5-6
24 2 3 3 3 3 4 5 5-7
28 3 3 4 4 5 4-6
30 3 4 5 5 4-6 5-7
32 3 4 4 6 6 6-8
36 4 6 6 6-7 6-7
40 5 5-7 7 5-7
Table B: Adhesive kits per joint

** Where 3-4, 4-6, 6-8 etc. is shown, the first figure is valid for series Bondstrand 3400 and the s econd figure for series Bondstrand 2400.

Storage
Adhesive Kits should be stored indoors, at room temperatures between 10°C (50°F) and 30°C (86°F).
At lower temperatures the adhesive will be difficult to mix and to process. At higher temperatures, the potlife will be too
short for proper processing. Do not use adhesive past its expiry date. Refer to date stamp on the package.

Toxity and precautions

Resin:
R20/21/22 Harmful by inhalation, in contact with skin and if swallowed.
R36/38 Irritating to eyes and skin.
R40 Limited evidence of a carcinogenic effect.
R43 May cause sensitization by skin contact.
R51/53 Toxic to aquatic organisms, may cause long-term adverse effects
in the aquatic environment.
R68 Possible risk of irreversible effects.
S36/37 Wear suitable protective clothing and gloves.
S53 Avoid exposure - obtain special instructions before use.
S61 Avoid release to the environment. Refer to special
instructions / safety data sheets.

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 Toxicity and precautions C’tnd
Hardener
R23/24/25 Toxic by inhalation, in contact with skin and if swallowed.
R34 Causes burns.
R43 May cause sensitization by skin contact.
R50/53 Very toxic to aquatic organisms, may cause long-term adverse effects in the aquatic
environment.
R68 Possible risk of irreversible effects.
S26 In case of contact with eyes, rinse immediately with plenty of water and seek medical advice.
S36/37/39 Wear suitable protective clothing, gloves and eye/face protection.
S45 In case of accident or if you feel unwell, seek medical advice
immediately (show label where possible).
S53 Avoid exposure - obtain special instructions before use.
S61 Avoid release to the environment. Refer to special
instructions / safety data sheets.

First Aid
Inhalation: Keep at rest. Move to fresh air. Oxygen or artificial respiration if needed. In the case of accident or if
you feel unwell, seek medical advice immediately (show the label where possible).
Skin contact: Take off contaminated clothing and shoes immediately. Wash off immediately with soap and plenty
of water. Do not use solvents or thinners If skin irritation persists, call a physician. Wash
contaminated clothing before re-use.
Eye contact: Rinse immediately with plenty of water, also under the eyelids, for at least 15 minutes. Call a
physician immediately.
Ingestion: Do NOT induce vomiting. Drink plenty of water. Obtain medical attention.
Additional advice: Never give anything by mouth to an unconscious person. Show the safety data sheet to the doctor
in attendance. Treat symptomatically.

Important notice
This literature and the information and recommendations it contains are based on data reasonably believed to be
reliable. However, such factors as variations in environment, application or installation, changes in operating procedures,
or extrapolation of data may cause different results. This literature is intended to be used by personnel having
specialized training in accordance with currently acceptable industry practice and for normal operating conditions.

D R A
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3
 National Oilwell Varco has produced this brochure for general information only, and it
is not intended for design purposes. Although every effort has been made to maintain
the accuracy and reliability of its contents, National Oilwell Varco in no way assumes
responsibility for liability for any loss, damage or injury resulting from the use of information
and data herein nor is any warranty expressed or implied. Always cross-reference the
bulletin date with the most current version listed at the website noted in this literature.

North America South America Europe Asia Pacific Middle East

2425 SW 36th Street Avenida Fernando Simoes P.O. Box 6, 4190 CA No. 7A, Tuas Avenue 3 P.O. Box 17324
San Antonio, TX 78237 USA Recife, Brazil 51020-390 Geldermalsen, The Netherlands Jurong, Singapore 639407 Dubai, UAE
Phone: +1 210 434 5043 Phone: +55 31 3326 6900 Phone: +31 345 587 587 Phone: +65 6861 6118 Phone: +971 4881 3566

www.fgspipe.com • [email protected]

D R A
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® Trademark of NATIONAL OILWELL VARCO
FP 459 B 07/12
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 Installation guide for GRE pipe systems

1. Introduction
1.1. Scope
This manual gives general information about various
aspects that are relevant for the installation of Glassfiber
Reinforced Epoxy (GRE) pipe systems. Respect for the
requirements, methods and recommendations given in
this guide will contribute to a successful operating pipeline
system.

Authorized, trained and certified personnel can only

contribute to a reliable pipeline system. Note that the
remarks about the various joints in this document are for
guidance only.

More specific and detailed information about underground

and aboveground installations, as well as various joining Fig. 1.1. Offshore unit
methods, is given in manufacturers’ referenced documents.

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 Table of contents

1. Introduction 1
1.1. Scope 1
1.2. References 4
1.3. Notification 5

2. Product introduction 6
2.1. Systems 6
2.2. Pipe fabrication process 6
2.3. Advantages and disadvantages of GRE compared with steel 6
2.3.1. Advantages 6
2.3.2. Disadvantages 7
2.4. Product identifcation 7

3. Material handling, storage and transportation 7

3.1. Handling 7
3.1.1. Loading 7
3.1.2. Unloading 8
3.2. Storage 9

4. Joining systems and preparation methods 10

4.1. Conical-Cylindrical bonded joint 10
4.2. Taper-Taper bonded joint 10
4.3. Laminate Joint 11
4.4. Flange Joint 11
4.5. Mechanical O-Ring Lock Joint 12
4.6. Mechanical O-Ring Joint 12
4.7. Mechanical Coupler 12

5. Tools and materials 13

5.1. Tools 13
5.1.1. Non-consumables 13
5.1.1.2. Heating blanket 13
5.1.1.3. Pullers and band clamps 14
5.1.1.4. Others 14
5.1.2. Consumables 14
5.2. Materials 15
5.2.1. Adhesive 15
5.2.2. O-ring 15
5.2.3. Locking key 15
5.3. Check of incoming material 15
5.3.1. Quality check 15
5.3.2. Quantity check 15

6. Installation of underground pipe systems 16

6.1. Trench construction 16
6.2. System assembly 16
6.2.1. Positioning components in the plant 16
6.2.2. Joining of components 17
6.3. Backfilling 17
6.3.1. Procedure and requirements 17
6.3.2. Backfill material specification 18
6.3.3. Other backfilling methods 18
6.4. Special underground installations 18
6.4.1. Road crossing 18
6.4.1.1. Jacket pipe 18
6.4.1.2. Relief plates 18
6.4.1.3. Burial depth 18
6.4.1.4. Pipe stifness 18
6.4.2. Channel crossing 19
6.5. Alignment 19
6.6. Settlement 19
6.7.
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 7. Installation of aboveground pipe systems 20
7.1. Supports 20
7.1.1. General 20
7.1.2. Fixed support points 20
7.2. Pipe clamps 21
7.3. Valves 21
7.4. Bellows 22
7.5. Pipe connections through walls 22
7.5.1. GRE pipe with sealing puddle flange 22
7.5.2. Sand coated GRE pipe 22
7.5.3. Link seal 22
7.5.4. Special sealing shape 23
7.5.5. Plain wall passing 23
7.6. Joining with other materials 23
7.7. UV-resistance 23

8. Quality Control/Quality Assurance 24

8.1. General 24
8.2. Joint traceability 24
8.3. Possible installation defects 24

9. Field Test Procedure 25

9.1. General 25
9.2. Preparation 26
9.3. Filling, stabilizing, testing and depressurizing 26
9.3.1. Filling and stabilizing 26
9.3.2. Testing 26 - 27
9.3.3. Depressurising 27

10. Repair 27

11. Tolerances 28

12. Safety precautions 29

12.1. Resin, hardener, adhesive and lamination sets 29
12.2. Cutting, shaving and sanding 29
12.3. Environment 29

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 1.2. References
Following documentation gives additional and detailed information about various subjects, which are described in this
manual

Chapter Subject Reference number

2.4 Product Identification ---

3.1 Packing and handling instructions FP 167

4.1 Assembly instructions for Quick-Lock adhesive bonded joints FP 170

4.2 Assembly instructions for Taper-Taper adhesive bonded joints FP 564

4.3 Jointing Instructions Laminate ---

4.4 Assembly instructions for Flanges FP 196

4.5 - 4.6 Assembly instructions for Key-Lock mechanical joints FP 161

5.1.1 Operating instructions M74 Pipe Shaver FP 696

5.1.1 Operating instructions M86 Pipe Shaver FP 453

5.1.1 Operating instructions M86 XL Pipe Shaver FP 919

5.1.1 Operating instructions M87 Pipe Shaver FP 454

5.1.1 Operating instructions M87 XL Pipe Shaver FP 455

5.1.1 Operating instructions M88 Pipe Shaver FP 1022

5.1.1 Operating instructions M95 Pipe Shaver FP 925

5.1.1 Operating instructions B1-Tool FP 810

5.1.1.3 Operating instructions for NOV FGS Heating Blankets FP 730

It is the user’s responsibility to ensure that he has the latest revision of the listed documents.
Documents can be obtained via [email protected]

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 1.3. Notification
This manual provides the following information:
• A general overview on tooling and materials for
pipe system installation
• A description of joining methods and systems
• Handling, storage and transporting materials
• Installation systems and procedures
• System control and safety measures

Please note that the instructions in this manual are for

guidance only. Specifications written for a particular project
will be normative.

We cannot describe all possible circumstances met in the

field. For this reason, our experienced supervisors may
deviate from given descriptions in order to achieve the
optimum solution for the particular situation, using the latest Fig. 1.2. Water injection
techniques and methods.

Fig. 1.3. Mine application

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 2. Product introduction
2.1. Systems
GRE pipeline systems are made from glass fibers, which
are impregnated with an aromatic- or cyclo-aliphatic amine
cured epoxy resin.
This thermoset resin system offers superior corrosion
resistance together with excellent mechanical, physical and
thermal properties.

The glass fiber reinforced epoxy pipeline is resistant to the

corrosive effects of mixtures with a low concentration of
acids, neutral or nearly neutral salts, solvents and caustic
substances, both under internal and external pressure. Fig. 2.1. Filament winding process
A reinforced resin liner can protect the helical wound
continuous glass fibers of the reinforced wall of the pipes
and the structural reinforcement of the fittings internally.

2.2. Pipe fabrication process THETHE

WALL STRUCTURE
WALL STRUCTURE
GRE pipes are manufactured using the filament winding
method. In this mechanical process, continuous glass fiber
RESIN GLASS
rovings are impregnated with epoxy resin.
0,3mm EPOXY COATING ...... 100% 0%
The production of GRE starts with the preparation of a steel
mandrel, which may be completed with a socket mould. E-GLASS WALL .......... 30% 70% E-GLASS

The dimensions of these tools determine the inner 0,5mm RESIN RICH LINER ... 70% 30% C-GLASS

dimensions of the pipe, fitting and joint system.

Glass fibers are guided through a resin bath, which is filled
with epoxy resin and are wound under constant tension in a
specific pattern around the polished mandrel.
This process continues until the required wall thickness W
is reached. Generally, the higher the pressure class, the AXIAL
greater the wall thickness of the product will be.
The winding process ends with curing the epoxy resin in an
oven, extraction of the mandrel/ mould from the product,
finishing the product by cutting to length and machining the
ends. The products are subjected to visual and dimensional
controls as well as a hydro test. Fig.2.2. GRE pipe wall build-up

2.3. Advantages and disadvantages of GRE

compared with steel

2.3.1. Advantages
Glass Reinforced Epoxy pipe systems have a number of
advantages over conventional pipe systems, of which the
most important are:
• Durable/corrosion resistant
GRE piping is resistant, both internally and externally,
to the corrosive effects of water, oil and many
chemicals.
Cathodic protection or coating is not required.
• Low weight/easy to install
The specific weight of GRE is only 25 % of steel; due
to the low weight, GRE pipeline components are Fig.2.3. Spool manufacturing
easier to handle without the need of heavy (lifting)
equipment.
• No initial painting or conservation
The epoxy topcoat on the outer surface of GRE pipe
components is resistant to the influences of
the installation environment and an additional external
conservation is initially not required.

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 2.3.2. Disadvantages
Attention should be paid to the following disadvantages of
GRE when comparing with conventional pipe systems, such
as:
• Impact resistance
The pipe system is more susceptible to impact
damage due to the brittle nature of the thermoset resin
system.
• Handling
GRE installations require more and careful preparation
due to other joining methods, handling- and
transportation requirements and installation
techniques.
• Flexibility Fig. 3.1. Vacuum lifting device
The flexible GRE piping system requires specific
support design.

2.4. Product identification

Products are marked with labels, which contain relevant
product information.
For specific and detailed information, reference is made to
manufacturers’ documentation.

3. Material handling, storage

and transportation
3.1. Handling
GRE products must be handled carefully to avoid any Fig. 3.2. Spool handling
damage. Handling and transportation of GRE is not
restricted by temperature. This section lists the most
important requirements for handling materials before and
after shipment and for storage.

3.1.1. Loading
Mind following requirements:
• Pipes, fittings and prefabricated parts (spools) must be
transported by suitable trucks having flat bed floors
• Forklifts may be used for handling provided that the
forks are padded with a protective material such as
rubber or plastic
• Check for and remove any projections, nails or other
sharp edges from the supporting floor before each load
• Any contact of the truck or steel container with the
GRE products shall be separated by wood or rubber Fig. 3.3. Pipe handling (unloading)
• Avoid direct contact between individual GRE products
during transportation
• Pipes and spools shall be lifted at least at two points
by using nylon or canvas sling belts with a minimum
width of 100 mm. Use the largest spool diameter to
balance the load during the lift
• Secure materials by wooden wedges and supports
having a minimum width of 100 mm
• Pipe supports shall be spaced at ≈3 m intervals,
minimal 1 m from the ends; the support distance of
nested pipes shall not exceed ≈2 m
• Tie the products in place by using either nylon or
canvas sling belts
• Chains and steel cables may never be used for lifting
or fixation Fig. 3.4. Pipe handling (loading)

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 • Avoid support on sharp edges
• Fittings can be properly transported in crates or on
pallets
• Flanges must be secured against sliding when stored
on the sealing face
• Pipe ends and machined surfaces must be protected
(e.g. with PE-foil)

3.1.2. Unloading
The client is responsible for unloading ordered material,
unless agreed otherwise.
Mind following:
• Use nylon or canvas sling belts with a minimum width
of 100 mm
• Standard pipe lengths shall be lifted at minimal two Fig. 3.5. Crate handling
supporting points
• Fix at least one sling belt around the section with the
greatest diameter
• Unload one (packed) item at a time

Fig. 3.6. Crate handling

Fig. 3.7. Spool handling

Fig. 3.8. Stacked pipe in stock

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 3.2. Storage
In order to avoid damage to GRE products, the following
recommendations shall be respected:
• Provide a flat and horizontal supporting surface
• Do not store the pipes directly on the ground, onto
rails or concrete floors
• Ensure suitable supports such as clean, nail free
wooden beams
• Machined ends must be protected (e.g. with PE-foil)
• Bell and/or spigot ends may not touch each other
Fig. 3.9. Pipe stacking
• Pipes can be stacked economically by alternating the
orientation of spigot- and socket end
• Avoid pipe bending by locating supports between the
layers of stacked pipe vertically above each other
• Supports must be spaced at a maximum interval of
3 m and ≈1 m from each pipe end
• The allowable stacking height is 1.5 m or 2 layers,
whichever is higher
• Product diameters may flatten when stacked too high
and/or too long, specially at elevated temperature
• Long term storage is recommended under tarpaulins
or PE-sheets
• Pipe stacks must have side supports (e.g. wooden
wedges) to prevent rolling or slipping
• Unprotected flange sealing faces shall not be placed
directly on the ground or on supporting floors
Fig. 3.10. Wooden wedge
• Spools shall not be stacked
• No other materials shall be loaded on top of GRE
products
• Do not drop, walk, or stand on GRE products
• Avoid point loading due to careless stacking

Raw materials such as O-rings, gaskets, locking keys,

adhesive kits, resin, hardener, woven roving and lubricants
shall be stored in the original packaging, in a dry
environment, at recommended temperatures.

The shelf life of adhesives and resins must be respected.

If any damage is observed due to transportation or during

installation (e.g. excessive scratches, cracks) contact the
supplier.
Fig. 3.11. Storage of fittings
Never use damaged materials.

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 4. Joining systems and preparation methods
For the joining of GRE pipe components, various types of
joints can be used. This section details the characteristics of
each of these joints.

4.1. Conical-Cylindrical bonded joint

This type of adhesive bonded joint consists of a slightly
conical socket and a cylindrical spigot. This joint allows for
an accurate assembly length with narrow tolerance and may
be used for above- and underground pipe systems.

For this adhesive joint the following tools and materials are
required:
• Gloves, dust mask, safety glasses
• Measuring tape, marker, bench, pipe fitters wrap-a
round
• Angle cutter, hand saw or jig saw
• Shaver, grinding tools
• Rubber scraper, pulling equipment, adhesive kit
• Heating blanket or air gun, insulation blanket,
digital temperature gauge
• Cleaning brush, non-fluffy cleaning rags, cleaning
fluids

Summarized, the bonding procedure consists of cutting,

cleaning, machining, and application of adhesive, joining
and curing. The installation time depends on proper
Fig. 4.1. Conical-Cylindrical bonded joint
preparation, diameter and personnel.
For specific and detailed information, reference is made to
manufacturers’ documentation.

4.2. Taper/Taper bonded joint

This adhesive bonded joint consists of a conical socket and
conical spigot.

When comparing with the conical-cylindrical adhesive

bonded joint this type of joint is also available in
higher-pressure classes.

For specific dimensions, specific instructions are required.

The tools, materials, joining procedure and installation time
for the taper-taper bonded joint are similar to those of the
conical-cylindrical adhesive bonded joint.

Fig. 4.2. Taper/Taper bonded joint

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4.3. Laminate Joint
The laminate joint is used to join plain-ended pipe sections.
After preparation of the pipe surfaces, a specific thickness
of resin impregnated glass reinforcement is wrapped over a
certain length around the pipes to be joined; the thickness
and the length of the laminate are related to diameter and
pressure.

This joint requires following tools/materials:

• Gloves, dust mask and safety glasses
• Measuring tape, marker and pipe fitters wrap around
• Angle cutter, jig saw or hand saw
• Grinding tools and flexible support disc
• Rubber scraper, scissors, brushes, resin, hardener and
glass reinforcement
• Air gun, gas burner or field oven with insulation Fig. 4.3. Scheme laminate joint
blanket and digital temperature gauge
• Cleaning brush, non-fluffy cleaning rags and cleaning
fluids

The successive activities for a laminate joint are cutting,

sanding, cleaning, mixing, fitting, laminating and curing.
For specific and detailed information, reference is made to
manufacturers’ documentation.

4.4. Flange Joint

The flange joint connects appendages and equipment
as well as other lines of different materials. Based on the
application and pressure, several types are available.

For a flange joint following tools and materials are required:

Fig. 4.4. Laminate joint
• Ring spanner, torque wrench
• Bolts, nuts and washers
• Gasket

It is of major importance that GRE flanges are aligned with

the counter flange. Excessive misalignment may cause high
stresses, which lead to premature material failure.
Generally, flange joints facilitate connections with steel
piping and allow easy assembly and disassembly of piping
systems.

For specific and detailed information, reference is made to

manufacturers’ documentation.

Fig. 4.5. Flanged joint

D R A Fig. 4.6. Flange detail

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 4.5. Mechanical O-Ring Lock Joint
The mechanical O-ring lock joint is a tensile resistant
type of joint. This restrained type of joint can be used in
unrestrained environments, e.g. aboveground.

The following tools and materials are required to make

such a joint:
• Pipe clamps and pulling equipment
• Lubricant, O-ring, locking key(s) and plastic or wooden
mallet to drive the locking key in position
• Non-fluffy cleaning rags and cleaning fluids

The assembly procedure starts with cleaning and lubricating

surfaces, then mounting clamps, aligning, pulling the spigot
in the socket and mounting the locking key(s). The joint can
be disassembled, but is not designed as such. Fig. 4.7. Mechanical O-Ring lock joint (2-key)
For specific and detailed information, reference is made to
manufacturers’ documentation.

4.6. Mechanical O-Ring Joint

The mechanical O-ring joint is a non-tensile resistant type
of joint. This unrestrained type of joint can be used in a
restrained environment, e.g. underground.

This type of joint is made with the following tools and

materials:
• Pipe clamps and pulling equipment
• Lubricant, O-ring
• Non-fluffy cleaning rags and cleaning fluids

Joining starts with cleaning and lubricating surfaces; then

mounting clamps, aligning and pulling of the spigot in the
socket. For specific and detailed information, reference is
made to manufacturers’ documentation. Fig. 4.8. Mechanical O-Ring lock joint (1-key)

4.7. Mechanical Coupler

Generally, mechanical couplers are used for joining plain-
ended GRE 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.

Specific information can be obtained from the supplier of

the coupler.

Fig. 4.9. Scheme mechanical coupler

D R A Fig. 4.10. Various mechanical couplers

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 5. Tools and material
For details on tooling and materials, reference is made to
manufacturers’ detailed documentation.

5.1. Tools
Tools are divided in two main categories:
non-consumables and consumables.

5.1.1. Non-consumables
Non-consumable tools can be used multiple times.

5.1.1.1. Shaver
A GRE pipe shaver is a custom designed tool, which is
used to prepare a spigot end for an adhesive bonded joint Fig. 5.1. M95 shaver type
on a pipe. Pipes are standard supplied with the appropriate
end figuration, but an adjustment to length at site requires
shaving of a spigot in the field.

The shaver is mounted on an arbor. The arbor is mounted

and centred in the pipe and fixed against the inner surface
of the pipe by expanding the diameter.

The shaver arm rotates around the central shaft of the arbor;
the machining tool shapes the spigot end.

5.1.1.2. Heating blanket

Heating blankets are designed to cure adhesive bonded
and laminate joints.
Fig. 5.2. Mounted shaver (M87 type)
Blankets are made from a coiled resistance wire, which is
sandwiched between two layers of silicon rubber.

To control the temperature, each blanket is furnished with a

thermostat.

It is important to store the heating blanket properly in order

to keep this tool in an optimal condition.

Heating blankets shall never be folded; these blankets may

only be stored flat or rolled.

Fig. 5.3. Arbor

Fig. 5.4. Heating blanket

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 5.1.1.3. Pullers and band clamps
Pullers and band clamps are used to make Taper-Taper
adhesive bonded joints, large diameter Conical-Cylindrical
bonded joints and mechanical O-ring (lock) joints.

Band-clamps with pulling lugs must be applied at both pipe

ends to be joined. The positions of the pulling lugs shall
face each other.

The Taper-Taper joint must be kept under tension until

curing of the adhesive is completed to avoid joint
detachment.

Rubber protection pads are placed underneath the ratchets

before tightening the band clamps. Put a wooden wedge
between the pipe and the pulling lug to create a gap for
mounting of the heating blanket.
Fig. 5.5. Pulled adhesive joint
For bonding of large diameters 3 to 4 pullers are required.
Check the pullers on defects on a regular base.

5.1.1.4 Others
Other non-consumables may be required such as:

• Air gun, gas burner or field oven

• Angle cutter, hand saw or jig saw
• Pipe fitters wrap-a-round
• Pi Tape
• Grinding tool
• Insulation blankets
• Digital temperature gauge
• Generator
Fig. 5.6. Pull mechanism
5.1.2. Consumables
Consumable tools can only be used once.
Following tools are supposed to be consumable:

• Measuring tape
• Pair of scissors
• Marker
• Sand paper/grinding discs P40 – P60
• Brushes
• Rubber scrappers, bucket
• Cleaning fluids, joint lubricant
• Dust masks, gloves and safety glasses
Fig. 5.7. Wedge between pipe and pulling lug

 Powerpull (2x)
 Joint lubricant

 Band clamps (2x) 
 Pulling rings (4x)
 O-ring
 Bucket with water

 Screw driver
 Hammer 
 Key  
 



Fig. 5.8. Tools for joint assembly

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 5.2. Materials

5.2.1. Adhesive
Different types of adhesive are available depending on the
application. Adhesive can be conductive or non-conductive.

An adhesive kit contains resin, hardener, mixing spatula and

bonding instructions.
Adhesive kits contain chemicals that are sensitive to
temperature and moisture.

It is important to check the expiry date of the adhesive,

which is printed on the package.
Do not use adhesive or resin after indicated expiry date.

5.2.2. O-ring
A rubber O-Ring provides sealing of the mechanical O-ring Fig. 5.9. Adhesive kit
(lock) joint. Standard O-rings are made of Nitryl Butadiene
Rubber (NBR).

Depending on the medium and/or temperature, other types

of rubber can be supplied.

O-rings must be stored properly and flat, in a dry, cool and

dark environment, free from dust and chemicals, which may
attack the material.

Direct sunlight must be avoided.

5.2.3. Locking key

Locking keys block the longitudinal displacement of the
spigot in the socket of a mechanical O-ring lock joint.
Locking keys must be stored in a dry and cool location Fig. 5.10. O-rings
without direct exposure of sunlight. Improper storage may
affect the mechanical properties negatively. For further
details, reference is made to manufacturers’ detailed
documentation.

5.3. Check of incoming material

5.3.1. Quality check

The condition of containers, crates, boxes and pallets must
be checked on possible damage upon arrival. If damage
has occurred to any material package, the contents might
be damaged too. Check pipes and fittings on impact
damage. Materials and tooling must be dry at arrival.

The damaged state of materials and/or products when

delivered must be reported and documented (e.g. clarified
with pictures). Damaged materials shall be separated
and quarantined from undamaged materials to avoid Fig. 5.11. Locking keys
unintentional use.

5.3.2. Quantity check

Check the delivered quantities and the reported quantities
on the packaging list. The recipient is advised to check the
contents of the deliveries.

Quantity, size and configuration of materials and products

should be physically checked against the data on the
packing list.

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 6. Installation of underground pipe systems
GRE pipes are used for various applications in various soils
conditions. Underground pipeline systems require accurate
trench structuring, product assembly and installation.
For detailed information about underground installation,
reference is made to manufacturers’ documentation.

6.1. 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 recommendations:
• The trench shape is determined by the classification of
the soil, which can be unstable or stable
• Top sides of the trench must be cleared from rocks or
any other sharp/heavy materials Fig. 6.1. Trench in unstable soil
• 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
• 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, operating conditions, soil
characteristics and wheel load the minimum burial depth
is 0.8 m
• The crown of the pipe must be installed below frost level
Fig. 6.2. Trench in stable soil
6.2. System assembly
The assembly procedure of a piping system may vary per
project. Generally, this procedure deals with positioning and
joining of components in the plant.

6.2.1. Positioning components in the plant

After positioning of the pipe system elements next to the
trench, these components have to be handled into final
position in the trench:
• Small diameter pipe sections can be lowered manually
using ropes, slings or light lifting devices
• Large diameter piping requires heavier equipment
during final positioning Fig. 6.3. General scheme of trench construction
• To avoid damage the minimum bending radius of a pipe
shall be respected
• Avoid unwanted objects falling into the trench during
lowering pipe sections
• Use nylon sling belts or special designed equipment
during product handling

Fig. 6.4. Assembly in process

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 6.2.2. Joining of components
Respect next requirements and recommendations for
joining of underground pipe systems:
• Inspect all products before installation
• Components with mechanical O-ring joints shall be
assembled in the trench
• Adhesive bonded and laminated joints can be
assembled either inside or outside the trench
• Never move or disturb a joint during the curing process
• Standard pipe lengths may be doubled in order to
reduce the installation time
• Ensure sufficient space around joints for proper align
ment and joining
• Keep the system centred in the trench
• Respect the allowable joint angular deflection and pipe Fig. 6.5. Main assembly inside the trench
bending radius
• Bending of a joint shall be avoided unless allowable by
system design
• Changes in directions in non-restrained pipeline
systems must be anchored
• Ensure stretching of the O-ring lock joints; this prevents
axial displacement of the pipeline and overloading of
fittings when pressurising the system
• The pipeline can be stretched by pressurizing at 0.8 *
operating pressure. Mechanical stretching is
recommended. Precautions shall be taken to avoid
overloading of fittings
• Branches shall be left free or are installed after
stretching of the header completely
Fig. 6.6. Scheme trench construction stable soil

6.3. Backfilling
Backfilling shall be performed according standard
procedures. Trench filling, proper compaction and
stabilizing of the system shall be performed in accordance
with the requirements.

6.3.1. Procedure and 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
• Dumping large quantities of backfill material at one spot Fig. 6.7. Scheme trench construction unstable soil
on top of the pipe may cause damage; spread the
applied backfill material
• Backfill material shall be compacted in layers of 150
mm. The pipe may not be displaced due to backfilling
• When reaching a compaction 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
GRE-product Fig. 6.8. Pipe assembly in process in prepared trench

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 6.3.2. Backfill material specification
For classification of various backfill materials and types of
embedment, reference is made to AWWA Manual M45 or
ASTM D 3839.

Note that highly plastic and organic soil materials are not
suitable for backfilling and must be excluded from the pipe
zone embedment.

6.3.3. Other backfilling methods

Use of the saturation method does not give any better result
than the above-described method.

The grade of compaction is lost if compaction by saturation

is performed after mechanical compaction. When saturating
the trench, avoid floating of the pipeline as well as erosion
of the side support. Do not backfill if the ground is already
saturated.

The saturation method may only be used for free draining

soils, when the drainage pumps are kept in operation and
the pipe system is completely filled with liquid.

6.4. Special underground installations

Road crossings and channel crossings demand particular
attention and requirements.

6.4.1. Road crossing

Precautions shall be taken to protect pipes, which cross
underneath roads against the possible consequences of
traffic loads.
Possible alternatives are: Fig. 6.9. Compaction of backfill material
• Jacket pipe
• Relief plate
• Burial depth
• Pipe stiffness

6.4.1.1. Jacket pipe

The GRE pipe is nested in a jacket pipe. In order to avoid
direct contact between both pipes, spacers centre the
GRE pipe. These spacers also support the GRE pipe at a
maximum distance of 3 m. The jacket pipe should be longer
than the width of the road.

6.4.1.2. Relief plates Fig. 6.10. Jacket pipe at road crossing

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.
The plate is specially designed and dimensioned to
minimise the transfer of wheel load on the pipe.

6.4.1.3. Burial depth

Generally, the influence of the wheel load of traffic passing a
buried pipe reduces with increasing burial depth.
However, with increasing burial depth the soil load on the
buried pipe increases.
Our engineers may assist to determine an optimal solution.

6.4.1.4. Pipe stiffness

Pipes with higher stiffness are better resistant to external
loads due to traffic loads. Stiffness of pipe can be increased
Fig. 6.11. Relief plate
by increasing the wall thickness.

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 6.4.2. Channel crossing
The common method to install underwater mains is to
assemble the pipe on the bank of the canal or river. The
pipe can be lowered using a floating crane or other lifting
equipment; care should be taken to ensure sufficient pipe
supports.

The process starts by sealing the ends of the pipe and

pulling the system into the water; the pipe keeps floating.
Then, the pipe is filled and carefully sunk into its final
position.

Flexible joints can be used for underwater piping if the

installation is performed using a cofferdam construction;
this makes the installation similar to an onshore assembly.
Fig. 6.12. Lowering underwater main
Note that underwater pipes should be covered sufficiently to
prevent floating and damage (e.g. by anchors).

6.5. Alignment
Undulating land levels with minor difference in height can
be followed by the flexibility of the system.
Joints or pipe bending, if assessed by system design,
ensures no lateral displacement while allowing angular
deflection.

6.6. Settlement
Flexible joints have to be installed in pairs; 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 adding more joints that are Fig. 6.13. Pipe alignment
flexible. Based on the soil parameters, the number of joints
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.

6.7. Pipe cast in concrete

In some cases, pipe systems may be cast in concrete. Such
applications require following:
Fig. 6.14. Settlement

• Do not pour concrete directly onto pipe

• The vibrating poker 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 pressure is not exceeded by using pressure relief
valves.

D R A Fig. 6.15. Pipe cast in concrete

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 7. Installation of aboveground pipe systems
Aboveground pipe systems may be subjected to various
loadings resulting from operation of the system.
Next to the information in this section, reference is made to
specific manufacturer’s documentation.

7.1. Supports
Supports not only provide system fixation, loading relief and
clinching but also protection. Prior to installation, supports
are checked for location, type and span as detailed in
drawings and specifications of the project. Supports can
be differentiated as fixed, guided sliding and free sliding
supports.

7.1.1. General
Functional pipe supporting can be obtained with the aid of
system design analysis. Fig. 7.1. Aboveground pipe system
Following aspects need to be respected:
• Pipes resting on sleepers are supplied with 180°
saddles, which are bonded to the pipe at the support
location to protect the pipe against wear damage from
possible pipe movements
• The length of the wear saddle must be 50 mm longer
than the calculated pipe displacement plus the support
width
• Allow pipe expansion within a clamp
• In vertical pipe assemblies, the sockets of O-ring joints
shall point downwards, so water cannot be trapped in
the socket. Entrapped water in the socket may cause
joint damage when freezing
• For clamp dimensions, reference is made to
manufacturers’ detailed documentation Fig. 7.2. Pipe supports
• Mechanical O-ring joints require minimal one support
per pipe length
The distance of the support to the joint is maximal 20 %
of the pipe length

7.1.2. Fixed support points

Fixed points may never be realized by tightening the bolts
of the pipe clamps. This may lead to pipe deformations and
excessive wall stresses.

Mind the following requirements for fixed points:

• Fixation saddles shall be positioned on both sides,
at the shoe side of the clamp
• Laminated fixation saddles shall be applied on both
sides of the clamp Fig. 7.3. Sliding support
• When using non-restrained jointing systems each pipe
shall be fixed
• Each change of direction in a non-restrained pipeline
shall be anchored to prevent pipe joints coming apart
• Check whether the positions of pipe supports are still in
accordance with the installation requirements after
testing. The supporting elements might be
dislocated due to test pressure

Note that the mechanical O-ring lock joints must be

fully stretched to avoid movement of pipe sections and
consequently possible overloading. For further details
on this type of joint, reference is made to manufacturers’
documentation.

D R A Fig. 7.4. Support with fixed point

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 7.2. Pipe clamps
Various types of pipe supports are available.
Following considerations must be respected:
• Avoid point loads by using clamps made of flat strips
instead of U-bolts. The width of the strip is related to the
pipe diameter. For large diameter pipe double clamps
may be applied
• The inside of the clamp is furnished with a rubber or
cork liner to compensate the uneven pipe outer surface
and to minimise abrasion due to pipe movement and
vibration
• Longitudinal movement in the clamps is not advised.
Generally, movement between the clamp shoe and
the support structure shall realize sliding of supports

For detailed information on clamps, reference is made to

manufacturers’ documentation.

7.3. Valves
To avoid overstressing of pipes by the weight of valves
or other heavy equipment it is advised to support pipe
accessories on the flange bolts.

The load on the pipeline by operating the valve shall be

carried by the support of the pipe structure. In case of a
GRE flange mounted against a steel flange, the support is
preferably fixed to the steel flange.

Fig. 7.6. Fixed point with bonded saddles

Fig. 7.8. Valve

D R A
Fig. 7.5. Collars on both sides of the pipe clamp Fig. 7.7. Pipe clamp
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 7.4. Bellows
GRE products can absorb low amplitude vibrations due to
the flexible properties of the composite material.

To eliminate high amplitude vibrations caused by e.g.

pumps and to compensate soil settlement or expansion of
e.g. tanks joined with pipes, bellows can be applied.

Bellows facilitate dismantling of pipe sections, valves, orifice

flanges and gaskets. This equipment also absorbs pipe
movements due to cyclic pressure and/or temperature in
pipe systems that are joined with relatively stiff adhesive
bonded joints.

In many cases, bellows are directly joined to the vibrating

item by means of flanges. Note that the pipe section next to
the bellow shall be supported separately to absorb the pipe Fig. 7.9. Bellow
loads.

7.5. Pipe connections through walls

Several alternatives are available for passing pipes through
walls. In case of anticipated settlement of the wall or
pipeline, flexible couplings must be installed on both sides
of the wall.
The joints shall be positioned as close as possible outside
the wall.

7.5.1. GRE pipe with sealing puddle flange

The factory made puddle flange consists of a GRE ring,
which is laminated on the pipe.
Fig. 7.10. Puddle flange
7.5.2. Sand coated GRE pipe
A sand coating on a GRE pipe offers an excellent adhesion
between concrete and GRE.

7.5.3. Link seal

This type of wall penetration consists of several linked
rubber parts, which fit in the circular space between the
outer surface of a GRE pipe and the diameter of a hole in a
wall. A sufficiently smooth inner surface of the wall can be
obtained by:
• Mounting a steel pipe section with water seal before
pouring mortar
• Drilling a hole with a crown drill having diamond inlays
• Fixing a removable plastic casing pipe section before
pouring mortar

The rubber parts are linked together with bolts and form Fig. 7.11. Sand coated GRE pipe casted in concrete
a rubber chain. The rubber sections are compressed by
tightening the bolts.
All components of the link seal can be made of various
material qualities.

Link seals allow for some angular deflection and lateral

movement. After having mounted the GRE pipe in the
link seal the rubber elements are compressed by tightening
the bolts evenly. The expanded rubber sections seal the
room between GRE and concrete.

D R A Fig. 7.12. Sketch link seal

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 7.5.4. Special sealing shape
This wall penetration consists of a steel pipe, which is
provided with flanges. One of the flanges is profiled to
fit a sealing element. By tightening the nuts, the seal is
compressed in the annular space between the flange and
the pipe and provides an excellent seal.

7.5.5. Plain wall passing

When passing a pipe through a wall, the outer surface of
the pipe must be protected with a flexible material, e.g. a 5
mm thick rubber layer, protruding 100 mm at both sides of
the wall.
Fig. 7.13. Link seal

7.6. 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 sections.

Instrument connections can be made using a saddle and a

bushing.

7.7. UV-resistance
The topcoat of GRE pipes and fittings consist of a resin rich
layer. This layer offers sufficient protection against
UV-radiation.

When exposed to weather conditions the epoxy topcoat

may be attacked on the long term; this may result in a
chalked outer surface.

After several years of operation, the chalked layer may

be removed and replaced by a resistant, protective
polyurethane paint coating. Contact the manufacturer for Fig. 7.15. Plain wall passing
advice.

D R A Fig. 7.16. Joining to other materials

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 8. Quality Control / Quality Assurance
8.1. General
To assure good workmanship, only qualified and certified personnel shall be allowed to work on the installation of GRE
pipeline systems.

Always strictly follow the installation manuals next to the necessary instruction guidelines. When making joints, it is
necessary to execute the required steps in the correct sequence.

Never compromise on work quality and follow the instructions assigned from handling and storing through joining and
installing GRE materials.

8.2. Joint traceability

As part of the quality control and on behalf of the traceability of adhesive bonded joint data, the following information
should be registered during installation for each joint:
1. Name or registration info of the pipe-fitter
2. Joint identification (number)
3. Start/end of the curing process
4. Heat blanket identification (number)
5. Identification (number) of adhesive batch
6. Temperature of heating blanket (optional)

8.3. Possible installation defects

Following table lists a number of defect types along with acceptance criteria and recommended corrective actions:

Defect Inspection Cause Acceptance criterion Corrective action

method

Incorrect spool Visual Incorrect prefabrication Can difference be compensated Accept

dimensions elsewhere in the system?
Can system not be Reject
compensated?
Misaligned spools Visual Misaligned components Can difference be compensated Accept
e.g. flanges elsewhere in the system?
Can system not be Reject
compensated?
Misaligned joint Visual Movement during Not permitted Reject
cure. Incorrect shave
dimensions

Diameter restriction Visual Application of too much Maximum height (h) of adhesive If accessible, remove
adhesive seam is 0.05 * ID or 10 mm, by grinding
whichever is smaller

Impact, wear, or Visual Incorrect transport or According to ISO 14692, Annex Major defect: replace
abrasive damage handling A, Table A1
Minor defect: repair

Leaking joint Hydro test Joining not properly Not permitted Reject
performed

Table 8.1. Defect, acceptance criterion, corrective action

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 9. Field Test Procedure
9.1. General
Before the installed pipeline system is operational, the
system has to be hydro tested to ensure the integrity and
leak tightness. Hydro testing of the pipeline system will be
performed in two steps:

1. Integrity test
The test pressure shall be increased over an agreed
duration at an agreed pressure level in order to prove
the maximum pressure resistance of the system.
2. Leak tightness test
The test pressure shall be increased to an agreed
pressure level at which the joints can be inspected
visually

Pressure level and test duration can be stated in an

Inspection and Test section of the Site Quality Plan.

All safety precautions must be applied. It is important to test

the integrity of the system first, to avoid the risk of injury
during visual inspection. All pressure gauges and pumps
must be suitable and calibrated. Ensure that the pipeline
can be vented and drained.
The pressure gauge must be mounted between a valve and
the pipeline system in order to indicate the test pressure
in the GRE system after having closed the valve, which
is mounted after the pump. Due to the head of water, the
pressure gauge should be located at the lowest point in the
system. The pressure gauge should have a maximum scale
reading of approximately twice the test pressure.

If the system is not designed to withstand any negative

pressure, which might occur during testing, then the system
needs to be protected by an air release valve. Trapped air
should be released by using vent(s).

The application of GRE pipeline systems may vary from

long, (buried) line pipe applications to small skid piping
systems.

Joint types might vary from laminate joints to mechanical

joints with O-ring seal, with or without locking strip.

Each system requires its specific testing method. For each

system, the test procedure has to be described in the
Inspection and Testing Section of the Site Quality Plan. This
Inspection and Test Plan (ITP) must be established before
the project starts.

The advices for testing mentioned in the following

paragraphs are for guidance only and are not mandatory.

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 9.2. Preparation
Prior to hydro testing, the following issues shall be checked:
• All material that should not be on the inside of the
pipeline system shall be removed
• All joining procedures shall be completed
• Trenches should be partially backfilled and compacted;
the joints should be left exposed
• All supports, guides, and (temporary) anchors shall be
in place and functional before pressurizing the system
• All temporary supports and installation aids shall be
removed
• Unless stated otherwise, all valves should be through-
body tested
• All check valves shall be removed to enable monitoring
of the full line Fig. 9.1. Various pipe pigs
• Flange bolts shall be made up to the correct torque
• Buried pipe systems must be backfilled sufficiently to
restrain the system

9.3. Filling, stabilizing, testing and depressurizing

9.3.1. Filling and stabilizing

Fill the pipeline at the lowest point with water using a small
diameter branch connection and vent the trapped air at the
highest point(s) of the system. Long straight sections may
be vented using an inflatable ball or foam pig to expel any
air and impurities.

After filling, the line is pressurized gradually up to 0.8 *

Design Pressure; the pressure shall be maintained for 24
hours in order to allow the system to set and the pressure
to stabilise. For small above ground systems, it is allowed to
reduce the stabilising time.
Fig. 9.2. Field test unit
9.3.2. Testing
Once the pressure is stabilised, the integrity of the pipe
system is tested first in accordance with agreements.

Depending on the system a pressure drop might occur. In

all cases, leakage of joints, pipes or fittings is not allowed.
For safety reasons, an inspection of the system because
of a possible leakage is not permitted when the pipeline
is loaded at integrity test pressure level. This has to be
mentioned in the ITP.

When the integrity test has been completed successfully,

depressurise the system to leak tightness test pressure
level. Duration of the leak tightness test normally depends
on the time needed to inspect all joints, pipes and fittings
visually.

It is preferable to test the line in sections, for example the

length of one-day installation. The line is temporarily closed
using, e.g. a test plug and a flange at the end. The blind
flange should be provided with an air release valve.

After testing of the installed section the test plug, needs to

be pushed back about 2 meters by pressuring air via the air
release valve. The excess water is released by opening the
valve at the begin of the line. After securing of the test plug,
e.g. by inflation, the temporary flange connection can be
removed and the assembly may proceed.

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 The advantage of this method is that the test medium stays
in the tested section and does not need to be re-filled for
hydro testing of the next section.

Any leak caused by incorrect assembly of the joint can be

detected easily. Extreme movements can be prevented by
partially filling and compacting of the trench.
Note that temperature changes over a 24 hours period will
affect the pressure in a closed system.

A drop in pressure during the night does not always indicate

that there is a leak in the system. When testing a system the
ambient temperature should be measured.

GRE material behaves different from steel due to the low

weight, the flexibility of the joint and elasticity of the material.
Fig. 9.3. Test pressure recording
In case of a failure during hydro testing, the line will move
due to the sudden release of stored energy; there might be
a risk of injury to personnel.
Note that testing with air or gas is extremely dangerous and
should be avoided. Systems shall never be tested with an
inflammable fluid or gas.
The manufacturer of GRE pipe systems does not take any
responsibility for any damage resulting from the use of
these methods.
The following causes may affect pressure drop and
consequently result in hydro test failures:

• Leakage of pipeline accessories

• Leakage of gaskets
• Leaking joints
• Leakage of pipes

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.

9.3.3. Depressurising
Depressurisation of the system must be carried out carefully
to avoid a negative pressure.

In the unlikely event, GRE pipes, joints and/or fittings may

have to be repaired. Repair on the pipeline system shall be
performed according described instructions.

10. Repair
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.

For further details, reference is made to manufacturer’s

R A
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 11. Tolerances
It is recommended to consider and use the dimensional tolerances illustrated and figured below.

Tolerances to dimensional reference
Internal diameter A B C D E F
mm
25 - 200 ±5 mm ±3 mm ±0,5° ±3 mm ±1 mm ±0,5°
250 - 300 ±5 mm ±3 mm ±0,3° ±3 mm ±1 mm ±0,5°
350 - 400 ±5 mm ±3 mm ±0,3° ±3 mm ±2 mm ±0,5°
450 - 600 ±10 mm ±5 mm ±0,3° ±3 mm ±2 mm ±0,5°
700 - 900 ±10 mm ±5 mm ±0,2° ±4 mm ±3 mm ±0,5°
1000 - 1200 ±10 mm ±5 mm ±0,15° ±6 mm ±3 mm ±0,5°

A Dimension A
F a) Face to face dimensions

b) Center to face dimensions

c) Location of attachments
F
d) Center to center dimensions
F

Dimension B
Lateral translation of branches or
connections

Dimension C
B C Rotation of flanges, from the indi-
cated position

A Dimension D
End preparations

D
A Dimension E
Cut of alignment of flanges from the
indicated position, measured across
F A A the full gasket face

A Dimension F
Angular deflection
E
A

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 12. Safety precautions
The following safety precautions should be respected
when using GRE products. The required rescue and safety
measures when using resin and hardener for adhesive
or lamination sets are shown under the R- and S- code
numbers which are listed in manufacturer’s documentation.

12.1. Resin, hardener, adhesive and lamination sets

In order to avoid irritation of the respiratory system,
satisfactory ventilation should be provided. If a system is
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.

Persons not involved in the test or inspection are not
allowed in the immediate area of the tested system.
Only one person should be in charge and everyone else
must follow his/her instructions.

Do not change anything on the pipe 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.

12.2. Cutting, shaving and sanding

When cutting or grinding GRE materials the following
personal 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

12.3. Environment
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.

This literature should only be used by personnel having

This literature should only be used by personnel having

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 National Oilwell Varco has produced this brochure for general information only, and it
is not intended for design purposes. Although every effort has been made to maintain
the accuracy and reliability of its contents, National Oilwell Varco in no way assumes
responsibility for liability for any loss, damage or injury resulting from the use of information
and data herein nor is any warranty expressed or implied. Always cross-reference the
bulletin date with the most current version listed at the website noted in this literature.

North America South America Europe Asia Pacific Middle East

2425 SW 36th Street Avenida Fernando Simoes P.O. Box 6, 4190 CA No. 7A, Tuas Avenue 3 P.O. Box 17324
San Antonio, TX 78237 USA Recife, Brazil 51020-390 Geldermalsen, The Netherlands Jurong, Singapore 639407 Dubai, UAE
Phone: +1 210 434 5043 Phone: +55 31 3326 6900 Phone: +31 345 587 587 Phone: +65 6861 6118 Phone: +971 4881 3566

www.fgspipe.com • [email protected]

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© 2012, NATIONAL OILWELL VARCO
® Trademark of NATIONAL OILWELL VARCO
FP 1040 A 04/12
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 DOCUMENT TITLE

HYDRO-TESTING PROCEDURE FOR

BONDSTRAND GRE AND GRV PIPE

REVISION HISTORY
REV DESCRIPTION DATE ENGRG ENGRG QA
0 Originated 26-Jun-00 - YK Tan HC Fou
1 Revision on Para.8 28-Sep-04 - YK Tan HC Fou
2 Revision on 4.3, 4.4, 5.0, 6.2, 6.14, 14-Jul-06 Allen Zong YK Tan HC Fou
7.0 & 8.9
3 Revision on 7.8 (Not officially issued) 29-Mar-10 Oliver Ong YK Tan HC Fou
4 Revision on 7.6 & to officially approve 2-Sep-10 WH Leong YK Tan HC Fou
together with Rev. 3.
5 Revised company logo & name 12-Feb-12 WH Leong YK Tan HC Fou

PROPRIETARY NOTE SPECIFICATION NO. REV

This document contains information proprietary to NOV FGS
Singapore.
INS-004 5
Any disclosure, or use is expressly prohibited, except upon
explicit written permission by NOV FGS Singapore. Page 1 of 8

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 DOCUMENT TITLE

HYDRO-TESTING PROCEDURE FOR

BONDSTRAND GRE AND GRV PIPE
SPECIFICATION NO. REV.
INS-004 5

Prepared by Approved Approved

WH Leong YK Tan HC Fou

ENGRG ENGRG QA

1.0 SCOPE

This procedure covers the minimum requirement for the pressure testing of
NOV FGS piping system at site.

2.0 RESPONSIBILITIES

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

the owner representative.

3.0 EXCLUSION

3.1 The following piping accessories and equipment shall be excluded or

isolated from pressure testing of piping.
- Rotating machinery, pumps, compressors, etc.
- Filter elements of strainers.
- Pressure relieving devices such as rupture discs and pressure relief
valves.
- Vessels that would be overstressed at piping test pressures;
- All instruments, including level controllers and gauge glasses;
- Pressure gauges;
- Metallic expansion joint / bellow;
- Orifice plates;
- Flow nozzles;
- Pressure control valves;
- Corrosion probes;
- Deluge nozzles;
- Any other piping or equipment designated by owner representative
(packaged units/ Equipment shall be isolated or by-passed as
required)
3.2 All the elements that are not to be tested along with the piping shall
either be blanked off during testing or spool pieces inserted during
testing.

4.0 TEST PRESSURE, EQUIPMENT AND INSTRUMENT

4.1 For pressure testing of piping system, the test pressure indicated in the
construction drawings shall be strictly followed. The recommended test

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 DOCUMENT TITLE

HYDRO-TESTING PROCEDURE FOR

BONDSTRAND GRE AND GRV PIPE
SPECIFICATION NO. REV.
INS-004 5
pressure is 1.5 times the anticipated design operating pressure. When
higher test pressures are desired, the test pressure should not exceed
1.5 times the maximum rated operating pressure of the lowest rated
element in the system. Therefore it is important to check the pressure
rating of all components of the system, because fittings, tanks, or
hoses may carry a pressure rating lower than that of the pipe.

4.2 Sudden pressure surge or “water hammer” should be avoided during

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

4.3 Equipment required for hydrostatic testing – such as caps, valves, blind
flanges, manual or automatic air release devices, pumps, pressure
regulating devices, temperature & pressure recorders and indicators,
as a minimum, should be available at site before the start of
hydrostatic test.

a. Safety valves(s) with appropriate setting shall be installed on the

piping system to avoid overpressure and pipe damage;

b. The end closure(s) and other component(s) intended for the test
section shall have equal or higher pressure ratings than the test
pressure;

c. All air release devices should be located at the highest points along
the test section.

4.4 All test recorders/indicators used for field-testing shall have a suitable
range and shall be used for test purposes only.

a. Pressure gauges shall be selected so that the test pressure of the

system falls between 30% to 75% scale range of the gauge;

b. Recorders/indicators shall be new, of good quality, and in good

working condition;

c. The date of calibration shall be certified on the recorders/indicators.

5.0 TEST MEDIUM

5.1 All NOV FGS pipe shall be hydrostatically tested with the following
provisions:

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 DOCUMENT TITLE

HYDRO-TESTING PROCEDURE FOR

BONDSTRAND GRE AND GRV PIPE
SPECIFICATION NO. REV.
INS-004 5
- Water used for testing shall be clean and free from filth or
undissolved solids of any description;

- Unless otherwise specified, all piping shall be hydrostatically tested

with fresh industrial water;

- The test water temperature intended for hydrastatic testing should

be ambient condition, but shall not be below 5°C (41°F).

6.0 PRECAUTIONS AND SAFETY

6.1 Qualified and experienced personnel should operate pressurizing

equipment. Untrained or unauthorized personnel should not be around
the pressurizing equipment.

6.2 Threaded connections and the bolts of flanged joints shall be tight to
correct torque prior to testing. Do not make any adjustments on
pressurized fittings under pressure. For example, if an adapter or
flange joint is leaking, take the pressure off the line before attempting
to tighten.

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

6.4 Testing with air or gaseous media is particularly dangerous and should
be avoided. Gas or air pipelines shall be hydraulically tested then “de-
watered”. Never test with flammable fluids or gases.

6.5 The effect of hydrostatic head shall be considered when determining

correct test pressure from gauge reading.

6.6 Caution shall be exercised in system hydrostatic testing to ensure that

simultaneous testing of large sized adjacent equipment and piping
does not overload supporting structures and foundations.

6.7 Any system under hydrostatic test shall be carefully observed, to

prevent overpressure of lines and any connected equipment.

6.8 The pressure generator shall be disconnected if the operator leaves

the equipment for any reason.

6.9 The testing operations shall be conducted diligently, thoroughly, and in

a safe workman like manner in accordance with accepted piping
testing practices.

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HYDRO-TESTING PROCEDURE FOR

BONDSTRAND GRE AND GRV PIPE
SPECIFICATION NO. REV.
INS-004 5
6.10 During testing, safety standards shall be observed at all times.
a) Barrier distance per pressure test values.
b) Signs and Notices
c) Toolbox talks etc.
6.11 The working area shall be roped off and sign positioned.

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

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

6.14 All adhesive bonded joints shall be fully cured prior to flushing and
pressure testing.

7.0 PREPARATION FOR TESTING

7.1 Before filling of water, the piping system should be thoroughly cleaned
and flushed to get-rid-of the dirt and debris to avoid damaging of
valves, regulators, and other such things.

7.2 All vent and other connections, which can serve as pressure test vents
shall be open during filling so that all air can be vented prior to applying
test pressure to the system.
7.3 Lines that are spring or counterweight supported shall be temporary
blocked up during test in order to sustain the hydrostatic load.
7.4 Before pressure testing, all lines or systems shall be inspected to
ensure that all connected parts to be excluded from the test are
isolated by blinds.

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

7.6 Before filling of water and commence testing, check to ensure

that all pipe supports are installed in accordance with approved
construction drawings. Adequate temporary supports should be
erected, if found required.

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

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HYDRO-TESTING PROCEDURE FOR

BONDSTRAND GRE AND GRV PIPE
SPECIFICATION NO. REV.
INS-004 5
7.8 Calibrated/ certified gauges and recorders should be used for all
hydrostatic tests. Pressure recorders are optional for hydrostatic
tests less than 4 hours in duration. The pressure shall be shown
in kg/ cm2 or KPa. Pressure gauges or recorders used to indicate and
record test pressure shall be dead weight tested for accuracy
according to a procedure, dependent of type of equipment. The
validity of calibration for all gauge and recorder shall be one (1) year.

7.9 Where required piping and equipment may be insulated or coated

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

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

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

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

7.13 When testing underground systems, the line should be partially

backfilled and temporarily blocked at directional changes to prevent
excessive movement during the test.

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

8.0 HYDROSTATIC PRESSURE TESTING

8.1 Test pressure shall be in accordance to paragraph 4.0 of this

procedure.

8.2 Care shall be exercised to avoid increase in pressure due to

temperature variation during the test.

8.3 Hydrostatic testing shall not be done against closed valves.

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HYDRO-TESTING PROCEDURE FOR

BONDSTRAND GRE AND GRV PIPE
SPECIFICATION NO. REV.
INS-004 5
8.4 Vents shall be open during filling of water so that air is vented prior to
applying pressure to the system. Vents will then be closed to permit
pressurization to commence.

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

8.6 Hydrostatic pressure tests on each major section of piping shall be

carried out with all pressure relief valves removed and their respective
nozzles or connections blanked off or plugged.

8.7 Hydrostatic test pressure connections shall be on the upstream side of

check valves.

8.8 The pressure shall be brought up slowly and gradually to allow for
equalizing for strain during the test, and in stages to allow checking for
leaks and inspection of the system. (Pressure shall first be brought up
to 10 bar and hold for 30 minutes. After that increase in stages of 3
bars and hold for 10 minutes before proceed to next stage). In any
case, the test pressure shall be raised over a period of 30 minutes or
longer to 1.5 times the design pressure.

8.9 Once attained, the test pressure shall be held for a period of two hours
or such time as required for a full visual inspection of the system to be
made. During the first half hour of hydro-test, if pressure drops it is
necessary to bring up to test pressure and test for two hours or such
time as required for a full visual inspection of the system. A ±4%
pressure change during hydro-test is acceptable. No leakage
allowance shall be permitted for fiberglass piping.

8.10 Temperature changes have a definitive effect on the pressure in the

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

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

9.0 POST-HYDROSTATIC TEST MEASURES.

9.1 After completion of hydrostatic test, the pressure shall be released

gradually in steps. All the vents and drains shall be kept open until the

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HYDRO-TESTING PROCEDURE FOR

BONDSTRAND GRE AND GRV PIPE
SPECIFICATION NO. REV.
INS-004 5
lines are fully drained. All temporary facilities installed to facilitate
pressure test shall be removed.

9.2 Where permanent or temporary strainers have remained in place for

the hydrostatic pressure test they shall be removed following the test
and thoroughly cleaned before reinstalling.

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

9.4 These records shall be prepared in tabulated forms and shall include,
but not limited to:
- Date of test;
- Identification of piping system and Package number;
- Test medium & Pressure;
- Test duration;
- Inspector’s name and signature;
- Reference P & ID’s and Isometrics;
- Acceptance of test results by installer and owner representative

10.0 CORRECTIVE ACTIONS

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

10.2 All joints and/or components failing to pass the pressure test shall be
repaired in accordance with the relevant specification, and the relevant
sections shall be retested to the applicable test pressure.

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 Doc No.: AME/INS-005
Rev. : 1
Page : 1 of 3

FLUSHING

PROCEDURE

FOR

BONDSTRAND PIPE

1 W H LEONG K S CHONG Y K TAN 13 JAN ‘12

0 W H LEONG K S CHONG Y K TAN 26 JUN ’00

REV. PREPARED BY CHECKED BY APPROVED BY DATE

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 Doc No.: AME/INS-005
Rev. : 1
Page : 2 of 3

FLUSHING PROCEDURE FOR BONDSTRAND GRE PIPE

1.0 SCOPE

This procedure covers the minimum requirement for the flushing of NOV FGS
piping system at site.

2.0 RESPONBILITIES

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

3.0 PRECAUTIONS

3.1 All equipment and instrument along piping system to be disconnected

during flushing.

3.2 Provision shall be made for discharge of water.

4.0 FLUSHING MEDIA

All NOV FGS pipes shall be flushed with the following provisions:

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

b) Industrial fresh water shall be used for flushing.

5.0 PROCEDURE

5.1 Flushing to be conducted by “end to end” method and carried out after
hydro-test.

5.2 Flushing shall be performed with the maximum combination of different

test loops to minimize any inconveniences at site. The maximum
combined test loops for each flushing shall be discussed and agreed upon.

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 Doc No.: AME/INS-005
Rev. : 1
Page : 3 of 3

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

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

5.5 All instrument leads shall be disconnected prior to flushing. Soft-seated

valves should be removed before flushing.

5.6 At end point of flushing (discharge), the pipe bore area shall be reduced to
25% - 35% of system bore area. This is to increase backpressure to flush
out residual particle in pipe. The minimum flushing velocity is 2.5m/sec.

5.7 Water shall run through the piping for 15 minutes.

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

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

6.0 POST FLUSHING

6.1 All temporary blinds shall be removed and system drained completely.

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

6.3 Temporary pipe supports shall be removed.

6.4 Blind off all pipe ends if for some reasons they are not connected. This is
to prevent ingression of debris or foreign materials.

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 DOCUMENT TITLE

MODIFICATION AND REPAIR

RECOMMENDATION

REVISION HISTORY
REV DESCRIPTION DATE ENGRG ENGRG ENGRG
0 New Issue 31-Mar-06 Leong AZ YKTan
1 Revised on Company Logo & name 13-Mar-12 Leong AZ YKTan

PROPRIETARY NOTE SPECIFICATION NO. REV

This document contains information proprietary to NOV-FGS
Singapore.
MOD-01 1
Any disclosure or use is expressly prohibited, except upon
explicit written permission by NOV-FGS Singapore. Page 1 of 7

D R A
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 DOCUMENT TITLE

MODIFICATION AND REPAIR

RECOMMENDATION
SPECIFICATION NO. REV.
MOD-01 1

Prepared by Approved Approved

WH Leong Allen Zong YK Tan

ENGRG ENGRG ENGRG

1. SCOPE

This document provides recommendations and guidelines on the modification

and repair of fiberglass piping system. The recommendations and guidelines
here are based on the philosophy that the work shall be permanent and last as
long as original design of the fiberglass piping system life.

All components used must be approved by manufacturer.

2. DESCRIPTION

Modification and repair works made in accordance with this process description
are generally for installed fiberglass piping system including new installation and
operating system. It covers issues on pipes, fittings, as well as joints. The
recommendation and guidelines provide an appropriate rectification method
corresponding to the nature and the extent of the issue.

3. GENERAL

The modification and repair work shall be carried out by qualified fiberglass
bonder/fitter.

If any sign of leaking is observed during hydro-testing or operation, the repair

work shall only be carried out after the relevant piping section is depressurized
and fully drained. Heat shall be applied onto all repair surfaces to dry out
entrapped water before repair work.

It is recommended to carry out modification work when system is isolated or

shutdown and dry.

After repair and modification, the piping section containing the repaired or
replaced piping shall be re-certified by performing a pressure test. The test
pressure shall be same as the initial system test pressure.

4. TYPICAL DAMAGES

Fiberglass pipe is susceptible to the following typical types of damages:

 Impact Damage;

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 DOCUMENT TITLE

MODIFICATION AND REPAIR

RECOMMENDATION
SPECIFICATION NO. REV.
MOD-01 1
 Outer surface damage due to weld splatter and abrasion;

 Ruptured joint due to excessive movement, water hammer and so on;

 Outer surface fiber blooming;

 Cracks in flanges;

Guidance, criteria and corresponding rectification methods that concern

damages are given in Table-I.

5. COMMON MODIFICATION AND REPAIR METHODS

5.1. Partial Replacement:

Partial replacement is to replace pipe and fitting (Including flange) which

has problem on the body and at the bonding joint. The new pipe and fitting
shall be jointed with existing pipe in accordance with appropriate jointing
procedure. It is recommended to assemble the existing pipe and new pipe
with coupling, lamination (Butt & Wrap) is the alternative for product with
pressure rating 25bar and below.

Alternative: Lamination
Adhesive (Butt & Wrap) Joint
Bonding
Coupling

When partial replacement is applicable:

- Careful inspection should be made to ensure that all

imperfections/leaks etc. are identified;
- Cut out damaged section with consideration of extension of the
damage, sufficient left-over pipe length for shaving or lamination,
sufficient length to accommodate new pipe and fitting;
5.2. Over-wrap (For product with pressure rating 25bar and below):

Over-wrap can be applied to minor damage pipe and fitting, and minor
leaking adhesive bonding joint. It is not recommended to apply it onto
leaking lamination joint. The Over-wrap is good to use in places where it is

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MODIFICATION AND REPAIR

RECOMMENDATION
SPECIFICATION NO. REV.
MOD-01 1
not practical to partial renew due to space constraint, insufficient time
schedule, lack of replacement pipe/fittings, and so on.

When Over-wrap is applicable:

- The sharp corner of bell of pipe or bell of fitting shall be chamfered to

obtain a smooth transition area;
- All loose fiber must be removed, and the damage part must be coated
with adhesive or resin prior to lamination;

- Lamination length and number of layers depends on system design

pressure;

- Refer to appropriate procedure for Over-wrap and lamination work.

5.3. Surface Repair:

Corrosion resistant Bondstrand products do not require any special

coatings to withstand environmental effect. If desired, however, the pipe
may be coated for cosmetic or identification purpose with the appropriate
adhesive or paint.

- Lightly sand down the affected area (Such as minor scratch, surface
crack);
- Apply a thin coat of adhesive, or spray paint, the paint shall be
compatible with product material;
- Leave the coating for self-curing at ambient temperature.

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MODIFICATION AND REPAIR

RECOMMENDATION
SPECIFICATION NO. REV.
MOD-01 1

5.4. Other Methods:

Other methods might be applied depending on type of damage and/or type

of modification, and site situation. Please consult NOV-FGS engineering for
case-to-case solution.

6. TEMPORARY REPAIR

A temporary repair should be utilized when it is not feasible to shut down the pipe
system to install a permanent repair. Temporary repair may be carried out as
agreed by owner, repair kit manufacturer and NOV-FGS.

A range of techniques are available which include, but are not limited to,
overwrap with water activated resin-glass tape, self-sealing clamps.

It must be recognized that NOV-FGS does not endorse the long-tem

performance of the temporary repair, and it is recommended to install a
permanent repair as soon as circumstances permit.

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MODIFICATION AND REPAIR

RECOMMENDATION
SPECIFICATION NO. REV.
MOD-01 1

Table-I: Damage, Acceptance Criteria and Rectification Method

Rectification
Type Description Criteria
Method
Flange Crack Cracks along bolt No sign of leakage; The Grind and fill the
holes depth of the crack is not cracks with adhesive
more than 5% of the or adhesive with
flange thickness chopped glass
The depth of the crack is Partial replacement
greater than 5% of with new flange;
thickness; Leakage at Further investigation
flange body; Joint not is required
sealed
Body Impact Damage Crack / de-lamination Patch with Blank
Damage limited to ring areas of Saddle; Over-Wrap
diameter less than 10mm,
no leaking
Crack / de-lamination Patch with Blank
extension limited to Saddle (Rated 20bar
diameter 50mm whereby Max), Over-Wrap
weeping or minor leakage
Extensive damage and Partial Replacement
leakage
Cutting/grinding Circular or ellipsoidal For pipe 3” and
damage diameter not greater than above, patch with
50mm on pipe body, no blank saddle, the
crack extension and no blank saddle shall be
de-lamination not thinner than pipe
wall. Limited to
20bar.
Other than above criteria Partial replacement
Scratch Pipe and fitting Line scratch with damaged Surface repair
body scratch, fibre less than 1mm or
flange scratch 10% of total wall thickness
(except sealing (Whichever is lower), less
ring) than 6” in length
Undamaged fibre are Surface repair
exposed over any area, or
no fibers are exposed but
an area equal to or greater
than 10x10mm lacks resin
No fibers are exposed and Repair is not
area lacking resin is less required.
than 10x10mm

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MODIFICATION AND REPAIR

RECOMMENDATION
SPECIFICATION NO. REV.
MOD-01 1

Rectification
Type Description Criteria
Method
Weeping Fitting-Pipe / Pipe- Weeping Over-Wrap; Partial
Pipe Bonding Joint Replacement
Lamination Joint None Permitted Remove lamination,
rework the joint
Flange Joint None Permitted Partial Replacement
Burning Surface Burning Depth limited to surface Surface repair
Damage resin rich layer, no loose
fiber
Minor Structure Loose fiber depth limited Surface Repair
Burning to 10% of structural wall
and area is not greater
than 150mm in diameter
Serious Structure Worse than above criteria Over-wrap, partial
Burning replacement
Adhesive Crack lines appear Depth of crack is limited to Repair is not
Crack at adhesive fillet adhesive fillet only, no required; Surface
sign of leaking and repair
weeping
Crack extension to joint, Partial Replacement;
weeping Over-Wrap; Further
investigation is
required
Earthing Earthing cable None permitted Install new grounding
Cable broken; dislodged saddle
Damage from earthing
saddle
Surface Fiber blooming on Depth limited to surface Surface painting for
Blooming outer surface of resin layer HSE concern, but not
pipe and fitting compulsory
Joint Failure Joint dislodged; None permitted Partial replacement;
continuous leaking Further investigation
at joint is required

Note: Table-I shows typical issues and general rectification recommendation.

However, method used might be different from case to case. Consult NOV-
FGS engineering if damages and/or its corresponding rectification method are
not given in the table.

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 DOCUMENT TITLE

RE-CONDITION OF ADHESIVE
BONDING SOCKET

REVISION HISTORY
REV DESCRIPTION DATE ENGRG ENGRG ENGRG
0 Issued for Use 10-May-06 Jose Allen Z YK Tan
1 Revised 9-April-09 Jose Allen Z YK Tan
2 Revised on Company Logo & name 13-Mar-12 WHL Allen Z YK Tan

PROPRIETARY NOTE SPECIFICATION NO. REV

This document contains information proprietary to NOV FGS
Singapore.
MOD-02 2
Any disclosure, or use is expressly prohibited, except upon
explicit written permission by NOV FGS Singapore. Page 1 of 5

D R A
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 DOCUMENT TITLE

PROCEDURE FOR THE RE-

CONDITIONING OF ADHESIVE BONDING
SOCKET
SPECIFICATION NO. REV.
MOD-02 2
Prepared by Approved Approved

WH Leong Allen Zong YK Tan

ENGRG ENGRG ENGRG

1. SCOPE

This process description covers the removal/extraction of pipe from socket end of
adhesive bonding joint, and re-condition of the socket end of pipe, fittings and
flange.

All components used must be approved by manufacturer. This procedure is

applicable in fabrication shop and construction field. The extraction and re-
condition work shall only be carried out by NOV FGS Representative or NOV
FGS certified personnel.

2. DESCRIPTION

Pipe, fittings and flanges re-conditioned in accordance with this procedure are of
filament-wound product with adhesive bonding socket. The procedure is
applicable to pipe, fittings and flanges in good condition but subjected to re-
bonding and modification, the procedure is also applicable to rework of failed
(Leaking and Weeping Only) adhesive joint.

3. TOOLS

Following tools are recommended, but not limited to:

- Electric grinder c/w cutting disc;
- Electric drill;
- Pneumatic grinder;
- Flapper Wheel, grit 40~60;
- White Marker;
- Measuring tape, 50’ (15m);
- Chisel;
- Flat screw driver;
- Hammer;

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PROCEDURE FOR THE RE-

CONDITIONING OF ADHESIVE BONDING
SOCKET
SPECIFICATION NO. REV.
MOD-02 2
4. GENERAL

The procedure is not applicable to pipe, fittings and flange with body and/or bell
leakage; the procedure is also NOT applicable to pipe, fittings and flange with
structural damage (such as de-lamination, fiber tear) at its socket.

In the case of repair work for leaking joint, the work shall only be carried out after
the relevant piping section is depressurized and fully drained.

Prior to extraction work, relevant product information shall be ready for reference,
such as insertion depth, nose thickness, taper angle, pipe wall thickness, etc.

5. EXTRACTION & RE-CONDITION

5.1. Mark up & cut the pipe approximately 2 inches from the socket edge;

5.2. (For pipe size 5” (DN125) and Above) Cut into the longitudinal section of the
bonded pipe left in the socket. The cutting shall be carried out carefully so
that the socket will not be cut and/or damaged.

For Quick-Lock Joint:

INSERTION DEPTH
Socket Body Spigot OD
Pipe Body Socket Body
Longitudinal cuts

Pipe OD
Less than 4"

 The cut length shall be equal to insertion depth;

 The cut depth shall be nose thickness;

For Taper/Taper Joint:

 The cut length shall be approximately equal to ¾ of insertion depth;

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PROCEDURE FOR THE RE-

CONDITIONING OF ADHESIVE BONDING
SOCKET
SPECIFICATION NO. REV.
MOD-02 2
 The cut depth shall be generally reduced towards inside, the
approximate cut depth and its variance shall be worked out in
accordance with socket taper angle and design nose thickness.
Insertion Depth
Pipe Body Socket Body
3/4 Inertion Depth Longitudinal cuts

Less than 4"

Cutting Depth

Pipe OD

Socket Body

It is recommended to have longitudinal cuts in intervals of less than 4”.

5.3. Using a hammer and chisel, knock off the adhesive fillet at the joint, thus to
expose the socket edge and pipe wall;

5.4. Hammer the protruding pipe all around from outside to develop crack on the
pipe wall and loosen the adhesion;

5.5. Using chisel, chip and extract pipe layer by layer. The work shall be done
taking extra care to prevent damage during this process;

5.6. Remove residual pipe element as much as possible until the adhesive is
visible;

5.7. Use a sanding disc (For 5”dia pipe and above) or flapper wheel (For 4”dia
pipe and below) to clean adhesive in the socket. Ensure that the core
roundness of the socket is not deformed when sanding; use flapper wheel to
finalize the surface preparation of refurbished socket;

5.8. Insert a standard spigot end or nipple into the socket to check the diameter,
angle and uniform roundness of the socket; pull out the test piece and
inspect the socket, use flapper wheel to rectify significant uneven surface of
the socket if any; repeat this process till the correct insertion and uniform
roundness is achieved.

6. ACCEPTANCE CRITERIA

The socket diameter, taper angle and roundness shall be verified with standard
spigot or nipple as described in Para. 5.8;

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PROCEDURE FOR THE RE-

CONDITIONING OF ADHESIVE BONDING
SOCKET
SPECIFICATION NO. REV.
MOD-02 2
Crack on re-conditioned socket surface is not allowed;

7. OTHERS

In the case of re-condition of leaking joint, the re-conditioned socket shall be

heated to disperse water content if any.

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 DOCUMENT TITLE

RE-CONDITION OF PIPE SPIGOT

REVISION HISTORY
REV DESCRIPTION DATE ENGRG ENGRG ENGRG
0 New Issue 10-May-06 Jose Allen Z YK Tan
1 Revised on Company Logo & name 13-Mar-12 WHL Allen Z YK Tan

PROPRIETARY NOTE SPECIFICATION NO. REV

This document contains information proprietary to NOV FGS MOD-03 1

Singapore.
Any disclosure, or use is expressly prohibited, except upon
explicit written permission by NOV FGS Singapore. Page 1 of 5

D R A
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 DOCUMENT TITLE

RE-CONDITION OF PIPE SPIGOT

SPECIFICATION NO. REV.

MOD-03 1

Prepared by Approved Approved

WH Leong Allen Zong YK Tan

ENGRG ENGRG ENGRG

1. SCOPE

This process description covers the removal of female pipe, fitting and flange
from pipe spigot end, and re-condition of the pipe spigot end.

All components used must be approved by manufacturer. This procedure is

applicable in fabrication shop and construction field. Manual removal and re-
condition work shall only be carried out by NOV FGS Representative.

2. DESCRIPTION

Pipe re-conditioned in accordance with this procedure are of filament-wound

product. The procedure is applicable to joint in good condition but subjected to
modification, the procedure is also applicable to rework of failed adhesive joint
without structural damage on the pipe end.

3. TOOLS

Following tools are recommended, but not limited to:

- Pipe Shaver c/w power drive and pipe arbor (Except B1F Shaver);
- Electric grinder c/w cutting disc;
- Electric drill;
- Pneumatic grinder;
- Flapper Wheel, grit 40~60;
- White Marker;
- Measuring tape, 50’ (15m);
- Chisel;
- Flat screw driver;
- Hammer;

4. GENERAL

In the case of repair work for leaking joint, the work shall only be carried out after
the relevant piping section is depressurized and fully drained.

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 DOCUMENT TITLE

RE-CONDITION OF PIPE SPIGOT

SPECIFICATION NO. REV.

MOD-03 1
Prior to re-condition work, relevant product information shall be ready for
reference, such as insertion depth, nose thickness, taper angle, pipe wall
thickness, etc.

5. REMOVAL AND RE-CONDITION

5.1. When pipe is bonded with flange:

5.1.1. Cut the flange along the bolt holes;

5.1.2. Knock off the cut sections using hammer and chisel;

Cuts
Knock Off layer
by layer

Subsequent Cuts

5.1.3. Continue the cut and the knock off of the flange; till the flange
thickness is suitable for the pipe shaver;

5.1.4. When the flange thickness is suitable for the pipe shaver, using
shaver, remove leftover element of the flange and shave the pipe to
required dimension;

If the pipe shaver is not available, continue the cut and knock off layer
by layer till the adhesive of the joint is exposed, remove adhesive
using sanding disc or flapper wheel. Check the core roundness and
dimension of the spigot using a standard socket (Such as flange,
coupling and other fittings) by trial and error, and make necessary
touch-up to achieve required dimension.

5.1.5. Square the pipe end with a grinder;

5.1.6. Remove and Refine the pipe spigot surface using flapper wheel;

5.2. When pipe is bonded with pipe and fittings (Elbow, Tee, Coupling, etc.):

D R A Page 3 of 5
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 DOCUMENT TITLE

RE-CONDITION OF PIPE SPIGOT

SPECIFICATION NO. REV.

MOD-03 1
5.2.1. Measure and mark the cut line on the female of the pipe or fitting, the
cut line shall be socket depth (or insertion depth) plus 20mm;

20mm INSERTION DEPTH

First Cut Second Cut Socket Body

Pipe Body

5.2.2. Cut the pipe or fitting along marking line;

5.2.3. Using flapper wheel, sand off adhesive bead inside the bonding joint;

5.2.4. Measure the length (Inside the pipe, from pipe spigot end to the edge
of earlier cut, and cut the pipe or fitting further to obtain a cut end that
is flush with pipe end;

5.2.5. Cut the female part in longitudinal direction. It is recommended to

have cut not more than 4” apart;
4"

Longitudinal Cuts
an
Th
e
or

Socket Body
tM
No

Pipe Body

5.2.6. Knock off of cut section using hammer and chisel, it is recommended
to have each knock-off layer not more than 3mm thickness; till the
fitting thickness is suitable for the pipe shaver;

5.2.7. Continue the cut and the knock off, till the outside diameter is suitable
for the pipe shaver;

5.2.8. Using pipe shaver, remove leftover element of female part and shave
the pipe to required dimension;

D R A Page 4 of 5
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 DOCUMENT TITLE

RE-CONDITION OF PIPE SPIGOT

SPECIFICATION NO. REV.

MOD-03 1
If the pipe shaver is not available, continue the cut and knock off layer
by layer till the adhesive of the joint is exposed, remove adhesive
using sanding disc or flapper wheel. Check the core roundness and
dimension of the spigot using a standard socket (Such as flange,
coupling and other fittings) by trial and error, and make necessary
touch-up to achieve required dimension.

5.2.9. Square the pipe end with a grinder;

6. ACCEPTANCE CRITERIAS

The nose diameter, taper angle (For Taper Male Only) and roundness of the re-
conditioned pipe spigot shall be within the allowable tolerance of design
requirement;

Crack on re-conditioned pipe spigot is not allowed;

De-lamination on re-conditioned pipe spigot is not allowed.

7. OTHERS

In the case of re-condition of leaking joint, the re-conditioned pipe spigot shall be
heated to disperse water content if any.

D R A Page 5 of 5
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 DOCUMENT TITLE

LAMINATION (BUTT AND WRAP)

WITH EPOXY RESIN (10 BAR)

REVISION HISTORY
REV DESCRIPTION DATE ENGRG ENGRG QA
0 Transfer from MP-22 & general revision 25-Nov-05 - YK Tan HC Fou
1 Revised Company Logo & name 12-Mar-12 WH LEONG YK Tan HC Fou

PROPRIETARY NOTE SPECIFICATION NO. REV

This document contains information proprietary to NOV FGS

LAM-01 1
Singapore.
Any disclosure, or use is expressly prohibited, except upon
explicit written permission by NOV FGS Singapore. Page 1 of 8

D R A
N
I 18-MA R - 2 014
 DOCUMENT TITLE

LAMINATION (BUTT AND WRAP) WITH

EPOXY RESIN (10 BAR)
SPECIFICATION NO. REV.
LAM-01 1

Prepared by Approved Approved

WH LEONG YK Tan HC Fou

ENGRG ENGRG QA

1. SCOPE

This process description covers the butt and wrap joint system for NOV FGS
epoxy based fiberglass pipe. The butt and wrap joint outlined in this procedure
may be used under factory and site condition. This procedure covers pipe sizes
1” to 40” with a maximum pressure rating of 150psi (10 bar) at 200 oF (93oC).

This process description is recommend to used in the environmental condition

that temperature is not greater than 40oC and humidity is not greater than 99%.
To consult NOV FGS if site condition is harsher than specified above.

All components used must be approved by manufacturer. Included in this

description is a general description of the product, a list of raw materials, and a
description of the lamination process.

2. DESCRIPTION

Joints made in accordance with this process description is made with Epoxy
based pipes. The pipes are filament wound at helical angle of 55. The
lamination (Butt & Wrap) consists of resin impregnated multiple layers of woven
roving and boat tape.

3. MATERIALS AND TOOLS

3.1 Reinforcement-Glass
Woven Roving : 100 mm (4”) width, 500-610 gr/m2 or
60 mm (6¼”) width, 500-610 gr/m2
Boat Tape : 50 mm (2”) width, 150 gr/m2 or
100 mm (4”) width, 150 gr/m2

3.2 Resin

Epikote-827 or DOW-330 : 100 pbw

Curing Agent, I.P.D. : 24 pbw
Adhesive for Jointing : RP-34 or RP-48 Adhesive
RP-60 for Conductive Product
Or other compatible adhesive

D R A Page 2 of 8
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 DOCUMENT TITLE

LAMINATION (BUTT AND WRAP) WITH

EPOXY RESIN (10 BAR)
SPECIFICATION NO. REV.
LAM-01 1
3.3 Tools
- * Heat blanket; - Weighing scale;
- * Band clamps with D-rings; - Ratchet winch;
- Flapper wheel sander (for 1” top 12”); - Scissors or knife;
- Air release roller (3/4” Dia x 3” L); - Disc grinder or file;
- Hack saw, saber saw or abrasive wheel; - Level;
- Pipe fitter’s wraparound; - Dust respirator / mask;
- Measuring tape, 50’ (15m) - Plastic pails;
- White grease pencil or soapstone; - Pipe support;
- Rubber gloves / working gloves; - Folding rule, 10’ (3m);
- Duster brush or clean rag; - Paint brush (4” and 6”);
- Rubber scraper plate;
- Methylene chloride (for cleaning equipment);
- Rubber mallet, 2lb (1kg), shore A Durometer 70-80, 2½” – 3” Diameter;
- Electronic ¼” (6m) drill motor, 1700-2000 rpm (for 1” to 12”);
- Belt sander (for sizes above 14”);
- Nylon strap / lifting block for large diameter pipe.

* Tools are available from NOV FGS.

4. LAMINATION PROCESS

4.1 Preparation

4.1.1 Prepare all tools mentioned in paragraph 3.3, and materials required for
the lamination (see Table-II).

4.1.2 Cutting: The pipe section to be cut shall be marked using a “wrap around”
or other suitable tools and a white marker. Make sure that the squareness
of the cut is properly made. The outer surface of the pipe can be either
lightly abraded leaving a cylindrical surface, or else abraded to provide a
taper not steeper than 1:6, when pipe end is tapered, the nose thickness
shall be around ½ of pipe wall thickness.

4.1.3 Sanding & Cleaning: Sand and clean the total external surface as per
requirement shown on Table-I. Alternatively, sanding and cleaning on area
for process 4.1.5 will be acceptable, however rest of total external surface
must be sanded and cleaned prior to process 4.2. Pipe cutting ends shall
be sanded too.

Start laminating within two hours after sanding; if greater than two hours,
sanding is again required. However, lamination immediately after sanding is
recommended.

D R A Page 3 of 8
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 DOCUMENT TITLE

LAMINATION (BUTT AND WRAP) WITH

EPOXY RESIN (10 BAR)
SPECIFICATION NO. REV.
LAM-01 1
4.1.4 The cross section of the pipes (cut ends) should be coated with adhesive
or working resin to protect against penetration of the medium. Continue the
procedure as per paragraph 4.1.5 immediately.

4.1.5 After the pipe sections are positioned, prepared the adhesive and coat the
external surfaces of the pipe ends approximate 50-150mm width. Wet out
the boat tape with adhesive and apply two layers circumferentially on the
pipe ends (Figure-I). A rubber squeegee or small spatula can be used to
smooth the adhesive. Use a heating blanket for 30 minutes curing. Sand
the surface after curing before continuing with structural wall building
process.

4.2 Structural Wall Building

4.2.1 Prepare resin mix with correct mixing ratio. Ensure that the curing agent is
carefully mixed in the resin. The mixed resin shall not be used after 30
minutes. The amount of mix depends on the diameter and speed of usage;
refer to Table-II for recommendation. Resin and curing agent should not
exceed temperature of 27oC.

4.2.2 For pipes equal to or smaller than 3”: Use boat tape as in Table-I with 50%
overlap.

For pipes greater than 3”: Use boat tape and woven roving as in Table-I
with 50% overlap.

4.2.3 Apply the required number of layers of boat tape (BT) with tension and with
50% overlap individually in circumferential direction on the pipe ends.
Simultaneously impregnate the boat tape with the resin mix. To avoid air
getting into the laminate, use air relieve/cotton roller continuously.

Apply the required number of layers of woven roving (WR) (50% overlap)
individually in circumferential direction on the pipe joint ends;
simultaneously impregnate the woven roving with resin mix. To avoid air
getting into the laminate, woven roving shall be wrapped under tension, and
use air-relieve/cotton roller continuously.

4.2.4 Tie down woven roving, using boat tape on the complete external joint
surface (spirally). Simultaneously impregnate the boat taper with resin. The
boat tape has to be wrapped around under tension and with an overlap
50%. To avoid air getting into the laminate, use air relieve roller / cotton
roller continuously.

4.2.5 Before curing, the laminate can be left in ambient to gel (Hand touch dry),
the ambient gel might take 4~12 hours depending on environmental

D R A Page 4 of 8
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 DOCUMENT TITLE

LAMINATION (BUTT AND WRAP) WITH

EPOXY RESIN (10 BAR)
SPECIFICATION NO. REV.
LAM-01 1
condition. If possible, use a heat gun to accelerate the laminate to gel; the
heat gun shall be use when laminate surface is dry.

4.3 Cure

Use infrared burners when applicable, or heating blanket. Curing

temperatures at 150C (300F) for 2.5 hours; 4 hours when heating blankets
are used. If possible, apply heating blankets on the inside as well to shorten
curing process to 3 hours.

4.4 Finishing

Sand rough edges and generally smooth external surface. Coat the sanded
area with working resin or adhesive for appearance and protection.

5. COLD WEATHER APPLICATION

If ambient temperature is below 18C, bonding and lamination surface shall be

warmed up in using heating blanket, hot air gun and so on.

If the ambient temperature is below 5C, during heat curing, the heating blanket
should be insulated.

6. FIRE PROTECTION PRODUCT APPLICATION

Fire protection layer should be removed prior lamination work.

6.1. Before start work, please check the exact thickness of fire protection layer.

6.2. Cut fire protection layers all around pipe by using disc grinder. Repeat pipe
cutting all around at location 100mm to 150mm from initial cut.

6.3. Cut a straight line along the surface from first cut to the second.

6.4. Remove the fire protection layer by using a screwdriver and hammer. Be
extra caution when removing the protective layer to avoid damage to pipe
body.

6.5. Repeat 6.2~6.4 till required pipe length is exposed.

After lamination process, fire protection layer shall be reinstated in accordance

with NOV FGS ’s recommendation of fire protection layer installation.

D R A Page 5 of 8
N
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 DOCUMENT TITLE

LAMINATION (BUTT AND WRAP) WITH

EPOXY RESIN (10 BAR)
SPECIFICATION NO. REV.
LAM-01 1

Table-I: Structural Wall Building Layers

LAYERS FOR BUTT AND WRAP JOINTS
 1”-3” 4" 6" 8" 10" 12" 14" 16" 18" 20" 22" 24" 26" 28" 30" 32" 36" 40"
L
120 120 120 120 125 150 175 200 225 250 275 300 325 350 375 400 450 500
(mm)
Sequence No. of Layers
1 BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT
2 BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT
3 BT WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR
4 BT WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR
5 BT BT WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR
6 BT BT WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR
7 BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT
8 BT WR WR WR WR WR WR WR WR WR WR WR WR WR
9 BT BT WR WR WR WR WR WR WR WR WR WR WR
10 BT WR WR WR WR WR WR WR WR WR WR
11 BT WR WR WR WR WR WR WR WR WR
12 BT BT BT BT BT BT BT BT BT
13 WR WR WR WR WR WR WR WR
14 WR WR WR WR WR WR WR WR
15 BT BT WR WR WR WR WR WR
16 BT BT WR WR WR WR
17 BT BT BT BT
18 WR WR WR
19 BT WR WR
20 BT WR
21 WR
22 BT
23 WR
24 WR
25 BT
26
27
28
29
30

Note: Overlap is 50% of each layer. For non-listed pipe size, lamination layers and
lamination length shall be referred to nearest upper size.

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 DOCUMENT TITLE

LAMINATION (BUTT AND WRAP) WITH

EPOXY RESIN (10 BAR)
SPECIFICATION NO. REV.
LAM-01 1

Table-II: Material Requirement

Woven Recommended
Adhesive Boat Tape Resin Curing
mm) Roving Mixing Quantity
– 6oz Kit (Kg) (Kg) Agent (Kg)
(Kg) (Resin in Kg)
25 1/2 0.15 - 0.15 0.04 0.15
40 1/2 0.20 - 0.20 0.05 0.20
50 1/2 0.25 - 0.22 0.06 0.22
80 1/2 0.30 - 0.30 0.08 0.30
100 1/2 0.15 0.25 0.40 0.11 0.40
150 1/2 0.20 0.50 0.70 0.19 0.70
200 1 0.30 1.00 1.20 0.33 1.20
250 1 0.40 1.20 1.30 0.35 1.30
300 1 0.60 2.10 2.20 0.60 2.20
350 2 0.80 2.70 2.90 0.79 2.90
400 2 1.00 4.50 4.50 1.23 4.50
450 2 1.20 6.00 6.00 1.65 4.00
500 3 1.50 8.50 8.50 2.30 4.00
550 3 2.20 12.50 12.50 3.40 4.00
600 3 2.60 15.00 14.80 4.00 4.00
650 3 3.20 20.00 19.50 5.30 4.00
700 3 3.70 23.00 22.50 6.00 4.00
750 3 4.30 29.00 28.00 7.70 4.00
800 3 5.80 36.00 35.00 9.50 4.00
900 4 7.50 50.00 48.00 13.00 4.00
1000 5 11.00 80.00 75.00 20.50 4.00

Note: Above materials estimated including wastage (allow wastage of 15% to 20%)

Mixing quantity shall be decided by working crew in accordance with working environment
and crew size.

D R A Page 7 of 8
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 DOCUMENT TITLE

LAMINATION (BUTT AND WRAP) WITH

EPOXY RESIN (10 BAR)
SPECIFICATION NO. REV.
LAM-01 1

Figure-I: Process Sketch

D R A Page 8 of 8
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 DOCUMENT TITLE

LAMINATION (BUTT AND WRAP)

WITH EPOXY RESIN (16 BAR)

REVISION HISTORY
REV DESCRIPTION DATE ENGRG ENGRG QA
0 Transfer from MP-19 & general 25-Nov-05 - YK Tan HC Fou
revision
1 Revised on Company Logo & name 12-Mar-12 WHL YK Tan HC Fou

PROPRIETARY NOTE SPECIFICATION NO. REV

LAM-02 1
This document contains information proprietary to NOV
FGS Singapore.
Any disclosure, or use is expressly prohibited, except upon
explicit written permission by NOV FGS Singapore. Page 1 of 10

D R A
N
I 18-MA R - 2 014
 DOCUMENT TITLE

LAMINATION (BUTT AND WRAP) WITH

EPOXY RESIN (16 BAR)
SPECIFICATION NO. REV.
LAM-02 1

Prepared by Approved Approved

WH Leong YK Tan HC Fou

ENGRG ENGRG QA

1. SCOPE

This process description covers the butt and wrap joint system for NOV FGS
epoxy based fiberglass pipe. The butt and wrap joint outlined in this procedure
may be used under factory and site condition. This procedure covers pipe sizes
1” to 40” with a maximum pressure rating of 232psi (16 bar) at 200 oF (93oC).

This process description is recommend to used in the environmental condition

that temperature is not greater than 40oC and humidity is not greater than 99%.
To consult NOV FGS if site condition is harsher than specified above.

All components used must be approved by manufacturer. Included in this

description is a general description of the product, a list of raw materials, and a
description of the lamination process.

2. DESCRIPTION

Joints made in accordance with this process description is made with Epoxy
based pipes. The pipes are filament wound at helical angle of 55. The
lamination (Butt & Wrap) consists of resin impregnated multiple layers of woven
roving and boat tape.

3. MATERIALS AND TOOLS

3.1 Reinforcement-Glass
Woven Roving : 100 mm (4”) width, 500-610 gr/m2 or
60 mm (6¼”) width, 500-610 gr/m2
Boat Tape : 50 mm (2”) width, 150 gr/m2 or
100 mm (4”) width, 150 gr/m2

3.2 Resin

NanYa NPEL 127 Epoxy Resin or Equivalent : 100 pbw

Curing Agent, I.P.D. : 24 pbw
Adhesive for Jointing : RP-34 or RP-48
RP-60 for Conductive Product

D R A Page 2 of 8
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 DOCUMENT TITLE

LAMINATION (BUTT AND WRAP) WITH

EPOXY RESIN (16 BAR)
SPECIFICATION NO. REV.
LAM-02 1
3.3 Tools
- * Heat blanket; - Weighing scale;
- * Band clamps with D-rings; - Ratchet winch;
- Flapper wheel sander (for 1” top 12”); - Scissors or knife;
- Air release roller (3/4” Dia x 3” L); - Disc grinder or file;
- Hack saw, saber saw or abrasive wheel; - Level;
- Pipe fitter’s wraparound; - Dust respirator / mask;
- Measuring tape, 50’ (15m) - Plastic pails;
- White grease pencil or soapstone; - Pipe support;
- Rubber gloves / working gloves; - Folding rule, 10’ (3m);
- Duster brush or clean rag; - Paint brush (4” and 6”);
- Rubber scraper plate;
- Methylene chloride (for cleaning equipment);
- Rubber mallet, 2lb (1kg), shore A Durometer 70-80, 2½” – 3” Diameter;
- Electronic ¼” (6m) drill motor, 1700-2000 rpm (for 1” to 12”);
- Belt sander (for sizes above 14”);
- Nylon strap / lifting block for large diameter pipe.

* Tools are available from NOV FGS.

4. LAMINATION PROCESS

4.1 Preparation

4.1.1 Prepare all tools mentioned in paragraph 3.3, and materials required for
the lamination (see Table-II).

4.1.2 Cutting: The pipe section to be cut shall be marked using a “wrap around”
or other suitable tools and a white marker. Make sure that the squareness
of the cut is properly made. The outer surface of the pipe can be either
lightly abraded leaving a cylindrical surface, or else abraded to provide a
taper not steeper than 1:6, when pipe end is tapered, the nose thickness
shall be around ½ of pipe wall thickness.

4.1.3 Sanding & Cleaning: Sand and clean the total external surface as per
requirement shown on Table-I. Alternatively, sanding and cleaning on area
for process 4.1.5 will be acceptable, however rest of total external surface
must be sanded and cleaned prior to process 4.2. Pipe cutting ends shall
be sanded too.

Start laminating within two hours after sanding; if greater than two hours,
sanding is again required. However, lamination immediately after sanding is
recommended.

D R A Page 3 of 8
N
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 DOCUMENT TITLE

LAMINATION (BUTT AND WRAP) WITH

EPOXY RESIN (16 BAR)
SPECIFICATION NO. REV.
LAM-02 1
4.1.4 The cross section of the pipes (cut ends) should be coated with adhesive
or working resin to protect against penetration of the medium. Continue the
procedure as per paragraph 4.1.5 immediately.

4.1.5 After the pipe sections are positioned, prepared the adhesive and coat the
external surfaces of the pipe ends approximate 50-150mm width. Wet out
the boat tape with adhesive and apply two layers circumferentially on the
pipe ends (Figure-I). A rubber squeegee or small spatula can be used to
smooth the adhesive. Use a heating blanket for 30 minutes curing. Sand
the surface after curing before continuing with structural wall building
process.

4.2 Structural Wall Building

4.2.1 Prepare resin mix with correct mixing ratio. Ensure that the curing agent is
carefully mixed in the resin. The mixed resin shall not be used after 30
minutes. The amount of mix depends on the diameter and speed of usage;
refer to Table-II for recommendation. Resin and curing agent should not
exceed temperature of 27oC.

4.2.2 For pipes equal to or smaller than 3”: Use boat tape as in Table-I with 50%
overlap.

For pipes greater than 3”: Use boat tape and woven roving as in Table-I
with 50% overlap.

4.2.3 Apply the required number of layers of boat tape (BT) with tension and with
50% overlap individually in circumferential direction on the pipe ends.
Simultaneously impregnate the boat tape with the resin mix. To avoid air
getting into the laminate, use air relieve/cotton roller continuously.

Apply the required number of layers of woven roving (WR) (50% overlap)
individually in circumferential direction on the pipe joint ends;
simultaneously impregnate the woven roving with resin mix. To avoid air
getting into the laminate, woven roving shall be wrapped under tension, and
use air-relieve/cotton roller continuously.

4.2.4 Tie down woven roving, using boat tape on the complete external joint
surface (spirally). Simultaneously impregnate the boat taper with resin. The
boat tape has to be wrapped around under tension and with an overlap
50%. To avoid air getting into the laminate, use air relieve roller / cotton
roller continuously.

4.2.5 Before curing, the laminate can be left in ambient to gel (Hand touch dry),
the ambient gel might take 4~12 hours depending on environmental

D R A Page 4 of 8
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 DOCUMENT TITLE

LAMINATION (BUTT AND WRAP) WITH

EPOXY RESIN (16 BAR)
SPECIFICATION NO. REV.
LAM-02 1
condition. If possible, use a heat gun to accelerate the laminate to gel; the
heat gun shall be use when laminate surface is dry.

4.3 Cure

Use infrared burners when applicable, or heating blanket. Curing

temperatures at 150C (300F) for 2.5 hours; 4 hours when heating blankets
are used. If possible, apply heating blankets on the inside as well to shorten
curing process to 3 hours.

4.4 Finishing

Sand rough edges and generally smooth external surface. Coat the sanded
area with working resin or adhesive for appearance and protection.

5. COLD WEATHER APPLICATION

If ambient temperature is below 18C, bonding and lamination surface shall be

warmed up in using heating blanket, hot air gun and so on.

If the ambient temperature is below 5C, during heat curing, the heating blanket
should be insulated.

6. FIRE PROTECTION PRODUCT APPLICATION

Fire protection layer should be removed prior lamination work.

6.1. Before start work, please check the exact thickness of fire protection layer.

6.2. Cut fire protection layers all around pipe by using disc grinder. Repeat pipe
cutting all around at location 100mm to 150mm from initial cut.

6.3. Cut a straight line along the surface from first cut to the second.

6.4. Remove the fire protection layer by using a screwdriver and hammer. Be
extra caution when removing the protective layer to avoid damage to pipe
body.

6.5. Repeat 6.2~6.4 till required pipe length is exposed.

After lamination process, fire protection layer shall be reinstated in accordance

with NOV FGS’s recommendation of fire protection layer installation.

D R A Page 5 of 8
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 DOCUMENT TITLE

LAMINATION (BUTT AND WRAP) WITH

EPOXY RESIN (16 BAR)
SPECIFICATION NO. REV.
LAM-02 1

Table-I: Structural Wall Building Layers

LAYERS FOR BUTT AND WRAP JOINTS
 1”-3” 4" 6" 8" 10" 12" 14" 16" 18" 20" 22" 24" 26" 28" 30" 32" 36" 40"
L
120 120 120 120 125 150 175 200 225 250 275 300 325 350 375 400 450 600
(mm)
Sequence No. of Layers
1 BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT
2 BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT
3 BT WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR
4 BT WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR
5 BT WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR
6 BT WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR
7 BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT BT
8 WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR
9 BT WR WR WR WR WR WR WR WR WR WR WR WR WR WR WR
10 BT WR WR WR WR WR WR WR WR WR WR WR WR WR WR
11 BT WR WR WR WR WR WR WR WR WR WR WR WR WR
12 BT BT BT BT BT BT BT BT BT BT BT BT BT
13 WR WR WR WR WR WR WR WR WR WR WR WR
14 BT WR WR WR WR WR WR WR WR WR WR WR
15 BT WR WR WR WR WR WR WR WR WR WR
16 BT WR WR WR WR WR WR WR WR WR
17 BT BT BT BT BT BT BT BT BT
18 WR WR WR WR WR WR WR WR
19 WR WR WR WR WR WR WR WR
20 BT BT WR WR WR WR WR WR
21 WR WR WR WR WR WR
22 BT BT BT BT BT BT
23 WR WR WR WR WR
24 BT WR WR WR WR
25 BT WR WR WR
26 WR WR WR
27 BT BT BT
28 WR WR
29 WR WR
30 BT WR
31 WR
32 BT
33 WR
34 WR
35 BT
36

Note: Overlap is 50% of each layer. For non-listed pipe size, lamination layers and
lamination length shall be referred to nearest upper size.

D R A Page 6 of 8
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 DOCUMENT TITLE

LAMINATION (BUTT AND WRAP) WITH

EPOXY RESIN (16 BAR)
SPECIFICATION NO. REV.
LAM-02 1

Table-II: Material Requirement

Woven Recommended
Adhesive Boat Tape Resin Curing
mm) Roving Mixing Quantity
– 6oz Kit (Kg) (Kg) Agent (Kg)
(Kg) (Resin in Kg)
25 1/2 0.15 - 0.15 0.04 0.15
40 1/2 0.20 - 0.20 0.05 0.20
50 1/2 0.25 - 0.22 0.06 0.22
80 1/2 0.30 - 0.30 0.08 0.30
100 1/2 0.15 0.50 0.60 0.16 0.60
150 1/2 0.25 0.90 1.00 0.27 1.00
200 1 0.35 1.40 1.50 0.40 1.50
250 1 0.45 2.10 2.20 0.60 2.20
300 1 0.60 3.50 3.40 0.90 3.40
350 2 1.00 5.00 5.00 1.35 5.00
400 2 1.25 7.00 7.00 1.90 4.00
450 2 1.50 9.50 9.00 2.40 4.00
500 3 2.00 13.00 12.00 3.30 4.00
550 3 2.70 18.00 17.00 4.60 4.00
600 3 3.20 21.50 20.00 5.50 4.00
650 3 4.00 30.00 28.00 7.70 4.00
700 3 5.50 37.00 35.00 9.60 4.00
750 3 6.00 45.00 42.00 11.50 4.00
800 3 7.00 57.00 54.00 14.50 4.00
900 4 10.00 80.00 75.00 20.00 4.00
1000 6 17.00 135.00 128.00 35.00 4.00

Note: Above materials estimated including wastage (allow wastage of 15% to 20%)

Mixing quantity shall be decided by working crew in accordance with working environment
and crew size.

D R A Page 7 of 8
N
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 DOCUMENT TITLE

LAMINATION (BUTT AND WRAP) WITH

EPOXY RESIN (16 BAR)
SPECIFICATION NO. REV.
LAM-02 1

Figure-I: Process Sketch

D R A Page 8 of 8
N
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 ®
Bondstrand Marketing Bulletin
FIBERGLASS PIPE GROUP

Safety
Recommendations
Recommended practices to minimize exposure and
effects of shavings from fiberglass pipe.

Engineering Controls • A fabrication area should be set up in which to perform as much of the
fabrication work as is practical or possible.
• Local exhaust ventilation should be provided at areas of cutting and/or
tapering to remove airborne dust and fibers. General dilution ventilation
should be provided as necessary to keep airborne dust and fibers below
the applicable exposure limits and guidelines. The need for ventilation
systems should be evaluated by a professional industrial hygienist.
• Work area should be kept clean, including floor or other horizontal surfaces.
Rinsing with water or sweeping with brushes or brooms (using floor sweep)
is recommended. Never use compressed air to clean area or to remove
dust for personal cleaning. Brushes should be used to remove residue from
shaved surfaces.

Personal Protection • Always refer to the Material Safety Data Sheet (MSDS) prior to working with
unfamiliar materials or if there are questions concerning the contents of the
fiberglass pipe.
• OSHA regulates glasswool (fiberglass) under the Hazard Communication
Standard and as a chemical hazard in laboratories. OSHA classifies
glasswool fiber as a “Particulate Not Otherwise Regulated,” with a
workplace permissible exposure limit (PEL) of 5.0 mg/m3 for respirable dust
and 15.0 mg/m3 for total dust. These limits are identical to those OSHA
requires for construction workers exposed to fibrous glass, which were
adopted from the 1970 Threshold Limit Values (TLVs) of the American
Conference of Governmental Industrial Hygienists (ACGIH).
• Barrier creme should be applied to the skin in areas which may be exposed
to shavings prior to beginning work.
• Clean clothes should be worn each day. Do not wear clothing that has not
been laundered to begin a work shift. More frequent changing may be
Essential safety wear includes required by conditions.
eye protection, dust mask and
clean cotton gloves (right). • Long sleeved shirts or worksuits should be used. Tape should be used at
sleeve opening.
• Cotton or flannel shirts under workshirts may be worn to prevent rubbing of
skin at opening of worksuit.
• Gloves with elastic cuffs should be worn at all times. Replace worn or
contaminated gloves as necessary. Gloves with flared, stiff cuffs act as a
ISO-9001 gathering funnel for shavings.
• Pant legs should be worn outside work boots. If necessary for safety
purposes, the pant legs can be taped to fit closely to the boot. Over-the-calf
socks can be used to prevent chafing of the boot on the skin.

D R A
IN8-MAR 14
1
CERTIFICATED FIRM

- 2 0
FP811 (1/99)
 Personal Protection • Wristbands and watches should be removed to prevent rubbing or
(cont’d) accumulation of particles on skin underneath the band.
• A respirator should be used if ventilation is unavailable, or is inadequate for
keeping dust and fiber levels below the applicable exposure limits. To
protect against dust and fibers, use a NIOSH-certified disposable or
reusable particulate respirator with an efficiency rating of N95 or higher (42
CFR 84) when working with this product. For exposures up to five times the
established exposure limits use a quarter-mask respirator, rated N95 or
higher; and for exposures up to ten times the established exposure limits
use a half-mask respirator (e.g., MSA’s DM-11, Racal’s Delta N95, 3M’s
8210), rated N95 or higher. Operations such as sawing, blowing, tear out
and spraying may generate airborne fiber concentrations requiring a higher
level of respiratory protection. For exposures up to 50 times the
established exposure limits use a full-face respirator, rated N99 or higher.
•Special Consideration for Repair/Maintenance of
Contaminated Equipment: Use personal protective equipment as
discussed above. Where possible, vacuum equipment before
repair/maintenance to remove excessive dust and loose fibers.

Personal Hygiene • Wash exposed skin with soap solution (liquid soap preferred) and
cool water.
• Use washcloth with “brushing” motion to remove dust or fibers. Do
not scrub the skin. This could result in the fibers being imbedded
into the skin.
• Rinse thoroughly with clean, cold water.
• Apply lotion or creme to skin (non-detergent formulas such as baby
lotion) to soothe irritation or prevent further immediate irritation.

For more information, contact:

Ameron International Fiberglass Pipe Division
1004 Ameron Road, Burkburnett, Texas 76354
(940)569-1471 • (940)569-2764

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

GROUP HEADQUARTERS
P.O. Box 801148 • Houston, TX 77280 • Tel: (713) 690-7777 • Fax: (713) 690-2842 • http://www.ameron.com
FIBERGLASS PIPE GROUP
Fiberglass Pipe Division Fiberglass Pipe Division Fiberglass Pipe Division Ameron Composites Fiberglass Pipe Division
Asia Europe Americas P.O. Box 71370 Centron International
Ameron (Pte) Ltd. Ameron B.V. P.O. Box 878 11 McBride Street P.O. Box 490
No. 7A, Tuas Avenue 3 J.F. Kennedylaan 7 Burkburnett, TX 76354 Newnan, Georgia 30263 600 FM 1195 South
Singapore 639407 4191 MZ Geldermalsen Tel: (940) 569-1471 Tel: (770) 253-2000 Mineral Wells, Texas 76068
Tel: 65 861 6118 The Netherlands Fax: (940) 569-2764 Fax: (770) 253-9234 Tel: (940) 325-1341
Fax: 65 862 1302/861 7834 Tel: +31 345 587 587 Fax: (940) 325-9681

D R A Fax: +31 345 587 561

Telex: 40257 bonds nl

IN8-MAR 14
1
- 2 0
©1998 Ameron• FP811 (1/99) • Printed in U.S.A. • 5M[124]
 D R A
IN8-MAR 14
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 D R A
IN8-MAR 14
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 Marketing Bulletin
FIBERGLASS PIPE GROUP
Estimated Man-hours for®
Assembly of Bondstrand Systems
matching taper/taper and Quick-Lock® adhesive joints;
Pronto-Lock®/Pronto-Lock II, and Key-Lock™
mechanical joints
General The information in this bulletin may be helpful in estimating construction costs where
Bondstrand products will be used. The tables estimate man-hours for making various
Bondstrand joints. The estimates are based on timed tests under ideal conditions: an
experienced person with all necessary materials at hand. Times do not include jigging,
measuring, planning, and other activities normally associated with piping joint fabrication.
Actual times may vary due to environmental conditions, skill and experience of the fabri-
cator, and the equipment available. These times are based on the assumption that the
crew received limited training from an Ameron Certified Technician and they are familiar
with basic installation procedures as recommended in standard Ameron literature. Once
the crew gains familiarity with the procedure, total time may be reduced as much as
50%. The estimates are given using tools that are new or in perfect operating condition.
The cutting blades are sharp and suitable for cutting glass fibers and resin materials.
Taper/taper and Table 1 estimates installation of taper/taper adhesive joints and Pronto-Lock/Pronto-Lock
Pronto-Lock/Pronto-Lock II II mechanical joints. (Series 3000A, 3200 and 3300 Series)
Quick-Lock Table 2 estimates installation of Quick-Lock adhesive bonded joints.(Series 2000, 2000M,
2000M-FP, 4000, 5000, 7000 and PSX Series)
Key-Lock and Quick-Lock Table 3 estimates man-hours required for field fabrication of piping using both Quick-Lock
and Key-Lock joints. Key-Lock joint assembly times are based on a single key joining of a
male end of a pipe to a coupling already mounted on a pipe end fitting. For comparison,
man-hours for fabricating welded joints in selected types of metallic piping are included.
Assemblers will be experienced after a few hours of training. This gives the contractor the
option to use less skilled (and less expensive) labor than certified welders. The assembly
of Bondstrand piping generally does not require heavy lifting equipment, reducing the set-
up and assembly time and eliminating the need for skilled equipment operators.

Table 1 Estimated Man-hours to Assemble Taper/Taper or Pronto-Lock/Pronto Lock II Joint

Pipe Diameter (in•mm)
Step # Operation 2•50 3•75 4•100 6•150 8•200 10•250 12•300 14•350 16•400
1 Cutting: 1.1 Hand saw1 0.03 0.05 0.07 0.07 – – – – –
1.2 Power saw1 0.01 0.01 0.02 0.02 0.03 0.03 0.03 0.04 0.05
2 Tapering: 2.1 Hand tool 2 0.08 0.12 0.14 0.20 – – – – –
2.2 Power tool 2 0.05 0.08 0.09 0.12 0.17 0.20 0.25 0.27 0.35
3 Surface preparation 0.05 0.08 0.10 0.14 0.15 0.18 0.22 0.26 0.30
4 Mix & apply adhesive: 0.03 0.03 0.03 0.04 0.05 0.05 0.06 0.07 0.08
5 Joint make-up:
5.1 Adhesive T/T bell x spigot3 0.02 0.03 0.04 0.05 0.06 0.06 0.07 0.08 0.09
5.2 Pronto-Lock/Pronto-Lock II 0.02 0.02 0.03 0.04 0.05 0.06 0.06 0.07 0.08
6 Total joint completion time:
6.1 Field prepared T/T bell x spigot 0.14 0.19 0.23 0.30 0.39 0.43 0.52 0.59 0.72
6.2 Factory prepared T/T bell x spigot 0.10 0.14 0.17 0.23 0.26 0.29 0.35 0.41 0.47
6.3 Pronto-Lock/Pronto-Lock II4 0.02 0.02 0.03 0.04 0.05 0.06 0.06 0.07 0.08
ISO-9001 1 Using a pipe cutting hacksaw blade with 26 or more teeth for 2" through 6"; pipe cutting circular saw has abrasive wheel for 8" through
16" Tripod pipe vise or strap-down fixture is used to hold pipe in place.
2 For 2"-6", using Ameron Unique tool set; for 8"-16", using Taper Tool II set

D R A 3 For 6" diameters and above, a comealong is used to pull the joint together during joint make up.

IN8-MAR 14
1
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CERTIFICATED FIRM
4 Field installation of Pronto-Lock or Pronto-Lock II male assemblies requires approximately 75% of the times shown in Step 6.1.
Note: Recommended minimum number of crew for 2"-4", 6"-12" and 14"-16" is two, three and four respectively.
FP674B (11/99)
 Table 2 Estimated Man-hours to Assemble Quick-Lock Joint
Pipe Diameter (in•mm)
Step # Operation 2•50 3•75 4•100 6•150 8•200 10•250 12•300 14•350 16•400
1 Sand socket1 0.03 0.05 0.06 0.08 0.10 0.12 0.13 0.15 0.17
2 Sand spigot1 0.03 0.05 0.06 0.08 0.10 0.12 0.13 0.15 0.17
3 Mark pipe & cut to length2 0.06 0.06 0.07 0.07 0.11 0.15 0.19 0.23 0.2
4 Shave Spigot3 0.04 0.04 0.04 0.05 0.05 0.05 0.06 0.16 0.18
5 Mix & apply adhesive 0.05 0.06 0.06 0.07 0.08 0.09 0.10 0.16 0.20
6 Assemble joint, remove excess 0.02 0.03 0.03 0.04 0.05 0.05 0.06 0.07 0.08
adhesive and attach heat blanket
7 Total preparation time for socket & 0.13 0.19 0.21 0.27 0.33 0.38 0.42 0.53 0.62
spigot joint with factory-made spigot
(sum of steps 1, 2, 5 & 6)
8 Total for preparing socket & spigot 0.20 0.24 0.26 0.31 0.39 0.46 0.54 0.77 0.89
joint requiring shaving of spigot (sum
of steps 1, 3, 4, 5 & 6)
1 Using a flapper type sanding wheel. Time may be less, depending on length of time pipe has been weathered.
2 Hand hacksaw cutting. Time required may be reduced if an abrasive wheel or sabre saw is used.
3 For sizes 2" through 12" based on using a standard pipe threading drive motor at 20 rpm with an M74 pipe shaver. Shaving can be done
by hand at about the same speed but worker will tire. For 14" and 16" sizes, based on use of large diameter shaver (M80) at 12 rpm.
Time can be reduced on 1" through 8" sizes by using a B1 shaver and 1⁄2" electric drill.

Table 3 Estimated Man-hours Required to Fabricate Piping Assemblies

Pipe Diameter (in•mm)
Operation 2•50 3•75 4•100 6•150 8•200 10•250 12•300 14•350 16•400
1
Quick-Lock:
Assembly of bell & spigot joint with
field shaving of spigot 0.4 0.5 0.7 0.8 0.9 1.1 1.2 1.6 1.9
Key-Lock:2
Joining pipe sections with
Key-Lock male/female ends 0.3 0.3 0.4 0.5 0.6 0.8 1.0 1.1 1.3
3
Metallic Alternatives:
Welded Joints:
Schedule 40 carbon steel 1.0 1.3 1.5 2.0 2.6 3.1 4.1 5.0 6.6
Schedule 80 carbon steel 1.0 1.4 1.8 2.5 3.3 5.1 6.6 9.6 12.4
Schedule 10S stainless steel 1.4 1.9 2.4 3.3 4.5 5.6 6.7 8.3 10.0
Schedule 40 copper-nickel 1.5 2.1 2.4 3.3 4.5 5.7 8.0 10.0 14.2
1 Joining includes operations described in Table 2 plus time for various routine aligning and measuring
operations discussed in text.
2 Joining includes cleaning, lubricating, and placing O-ring and single locking key.
3 Values are from: Page, John,S., and james G. Nation, Estimator's Piping Man Hour Manual, 3rd edition,
Gulf Publishing Co., Houston, 1979. Estimated man-hours do not include cutting and beveling, preheating,
stress relieving, coating, or wrapping the joint.

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

GROUP HEADQUARTERS
P.O. Box 801148 • Houston, TX 77280 • Tel: (713) 690-7777 • Fax: (713) 690-2842 • http://www.ameron.com
FIBERGLASS PIPE GROUP
Fiberglass Pipe Division Fiberglass Pipe Division Fiberglass Pipe Division Ameron Composites Fiberglass Pipe Division
Asia Europe Americas P.O. Box 71370 Centron International
Ameron (Pte) Ltd. Ameron B.V. P.O. Box 878 11 McBride Street P.O. Box 490
No. 7A, Tuas Avenue 3 J.F. Kennedylaan 7 Burkburnett, TX 76354 Newnan, Georgia 30263 600 FM 1195 South
Singapore 639407 4191 MZ Geldermalsen Tel: (940) 569-1471 Tel: (770) 253-2000 Mineral Wells, Texas 76068
Tel: 65 861 6118 The Netherlands Fax: (940) 569-2764 Fax: (770) 253-9234 Tel: (940) 325-1341
Fax: 65 862 1302/861 7834 Tel: +31 345 587 587 Fax: (940) 325-9681

D R A Fax: +31 345 587 561

Telex: 40257 bonds nl

IN8-MAR 14
1
- 2 0 © 1996 Ameron • FP674B (11/99) supercedes FP674A (11/97) • Printed in U.S.A. • 5M [3005]