PPT on GRP pipes manufacturing and testing

GRP pipes

1. Prepared by : Anoop Manoharan GRP Pipe Manufacturing, Inspection, Testing and Installation at site

2. Course Outline Design a n d B uild Utili t ies Ch emi c als Objective : To provide awareness on GRP pipe Manufacturing Processes, Inspection, Testing and installation at site. By the end of the programme, participants will be able to : Understand the manufacturing process Understand the minimum Inspection and Testing requirements at shop Understand the installation and testing requirements at site Course intended for: All Employees Duration: 30 minutes Location: Microsoft Team Training Provider: Anoop Manoharan & Basha Mujib (QA/QC Engineers)

3. Content Design a n d B uild Utili t ies Ch emi c als 1. Introduction about GRP 2. Characteristics and Advantages 3. References 4. Types of GRP 5. Material used in GRP 6. Manufacturing Process 7. Types of Joints 8. Classification of GRP 9. Shop Inspection and Testing 10. Common Defects 11. Marking & Identification Packing, Handling , Storage & Transportation HSE checks and controls at shop 14. Site receipt inspection and Preliminary Checks 15. Storage of GRP Pipes at site 16. Handling of Nested Pipes at site 17. Pipes laying in Trench 18. Pipes Jointing at site 19. Backfilling 20. Underground and above ground installations 21. Field Tests 22. Gel Coating 23. Quality Requirements 24. Safety Precautions 25. Conclusion 26. Q&A Shop Activities Site Activities

4. Introduction Design a n d B uild Utili t ies Ch emi c als What is GRP? GRP ( Glass Reinforced Plastics) - Composite of Polymer matrix + reinforced with glass fibers. GRP belongs to the family of products known as FRP ( Fibre Reinfornced Plastics )

5. Why GRP ? Design a n d B uild Utili t ies Ch emi c als Characteristics and advantages : Long life; highly durable. Low maintenance cost. High Corrosion resistance. Low lifecycle cost. No need for cathodic protection. Less transportation and handling cost. Environmentally friendly. Economic when compared with DSS pipe

6. REFERENCES CODES & STANDARDS Design a n d B uild Utili t ies Ch emi c als International standards ASTM Standards - (ASTM D 2992, 2996, 2310, 3262, 3517, 3754, etc.,) AWWA - (AWWA C 950 & AWWA M 45) BS - (BS 5480, BS 7159, BS 4994, etc.,) UKOOA DIN. Legal Local legislative documents and specific sections (As applicable) Metito & Project specific Project Specification, Applicable Drawings and Data Sheets QA/QC Plan, ITP and Testing Procedures Method Statements and Risk Assessments Metito Standard checklist forms for Site Activities

7. Types of GRP Design a n d B uild Utili t ies Ch emi c als Classification based on Raw material composition Types Raw material used Application GRUP: Glass reinforced unsaturated polyester Isophthalic resin / Polyester resin + Fiber Glass Temperature up to 60 º C. Irrigation, potable water, Sewerage, Waster water, RO plants GRV: Glass – fiber reinforced vinyl ester. Vinyl Ester Resin + Fiber Glass Better mechanical and chemical properties when compared to GRP Pipes. Used for temperature up to 90 º C GRE: Glass – fiber reinforced epoxy. Amine Cured Epoxy resin + Fiber Glass Temperature up to 110 º C Better properties than GRP/GRV Chemical resistance and anticorrosive Offshore application, Acid transportation

8. Raw materials used Design a n d B uild Utili t ies Ch emi c als Vinyl ester Resin Chopped strand Mat Woven Roving Mat Direct Roving Surface Tissue / Veil UV inhibitor

9. Pipe Wall Structure Design a n d B uild Utili t ies Ch emi c als

10. Manufacturing Process Design a n d B uild Utili t ies Ch emi c als Manufacturing processes : 1. Discontinuous Filament Winding process (DFW) 2. Continuous Filament Winding process (CFW) 3. Centrifugal casting (CC)

11. Manufacturing Process Design a n d B uild Utili t ies Ch emi c als 1. Discontinuous Filament Winding process (DFW) Flexible, High Strength performance, High corrosion resistance, Good Pressure Withstanding hydraulic performance Helical winding Polar winding

12. Manufacturing Process Design a n d B uild Utili t ies Ch emi c als 2. Continuous Filament Winding process (CFW) Medium Mechanical performance Allows use of high percentages of fillers, siliceous aggregates and additives Application of the band in parallel direction (winding angle about 90 °) on a rotating collapsible mold

13. Manufacturing Process Design a n d B uild Utili t ies Ch emi c als 3. Centrifugal casting Process (CC) Spraying of aggregates and reinforcing cut fibers inside a rotating drum. Used for Higher pipe thicknesses

14. Types of Joints Design a n d B uild Utili t ies Ch emi c als F langed Joint Lamination Joint Rubber seal lock Joint Adhesive Joint

15. Types of Joints Design a n d B uild Utili t ies Ch emi c als Bell and Spigot Joint Double Bell Coupling Click here for more details regarding application of different joints

16. Classification of GRP Pipes Design a n d B uild Utili t ies Ch emi c als GRP Pipes are mainly classified as, 1. Pressure class (PN): represents pipe’s design pressure in Bar 2. Stiffness class (SN) : represents pipe's minimum initial specific stiffness in N/m² (Pa) NB : Other pressure class and stiffness class are also available

17. Inspection and Testing of GRP Pipes Design a n d B uild Utili t ies Ch emi c als The most common testing used in GRP are, 1. Testing of Raw Materials Viscosity (cps or Pa-s) - the resistance to flow of a liquid Specific Density (kg/m 3 ) - the mass per unit volume of a material Curing / Gel time (sec) - to determine the curing characteristics / t he time taken to gel on a surface at a specified temperature Gel Time test Viscometer Specific density test

18. Inspection and Testing of GRP Pipes Design a n d B uild Utili t ies Ch emi c als 2. Testing on samples for physical properties Stiffness Test (N/m 2 )- Resistance to Deflection and Creep Axial Tensile Test (N/mm 2 ) – Resistance to axial tensile load. Burst Test (psi or bar) - to determine the ultimate pressure resistance Loss on Ignition test (%) - determine the ignition loss of a cured reinforced resin sample Stiffness Testing Axial Tensile test **Sample Lab test Report **Sample ITP Burst Test Loss on ignition test

19. Testing of GRP Pipes Design a n d B uild Utili t ies Ch emi c als 3. Testing on Finished products Visual Inspection Dimensional Inspection UT Thickness check (mm) Barcol Hardness Test (B) - measure the degree of cure. Acetone Sensitivity Test - to determine solubility or chemical resistance Hydrotest - to check pipe integrity under pressure conditions Hydrotest UT Thickness Check Barcol Hardness Test Acetone sensitivity Test ** Sample Hydrotest report Note: During hydrotest care must be taken to detect the seepage/ sweating through minute pores. Thorough visual inspection with increased holding time (minimum 30 mins) shall be considered. Dimensional check

20. Defects in GRP Pipes Design a n d B uild Utili t ies Ch emi c als 1. Visual Defects Wrinkling Pinhole Poor adhesion of the Gel Coat Blister's Star crazing / cracking The most found visual defects on GRP pipes are, ** Refer Acceptance as per ASTM D 2563

21. Defects in GRP Pipes Design a n d B uild Utili t ies Ch emi c als 2. Defect observed during manufacturing Seepage / sweating noticed on pipe surface through minute pores during hydrotest Root Cause: Uneven polymerization due to higher speed of production of pipe Correction done: Defective pipes rejected and replaced with new ones Corrective action: Calibration of machine done Speed chart is pasted near to machine for ready reference. Continuous Monitoring required by Production and QC Engineer

22. Handling, Transportation & Storage of GRP Pipes Design a n d B uild Utili t ies Ch emi c als Not only for protection of pipes but also for the safety of the personnel handling them. Avoid direct contact of Lifting accessories ( Metal chains, Metallic slings, hooks) with GRP items. Use Wide band webbed slings of polypropylene, nylon or similar material. Obtain Lifting permits (if required) Onload / Offload one pipe at a time Do not drop or drag or rolled on the ground Handling:

23. Handling, Transportation & Storage of GRP Pipes Design a n d B uild Utili t ies Ch emi c als Use Flat bed Trailers. Use supports (free of sharp edges or projection) Evenly support over their full length Do not overhang the vehicle Transportation :

24. Handling, Transportation & Storage of GRP Pipes Design a n d B uild Utili t ies Ch emi c als Only on flat even grounds Away from sharp projections Adequate space for movement of lifting equipment Protected from direct sunlight for long period of storage. Never place in contact with lubricating oil, gasoline and solvents. Away from exhaust outlet and other high temp. sources Storage :

25. HSE Hazards and Controls at Manufacturer Shop Design a n d B uild Utili t ies Ch emi c als Common Hazards Resins are highly flammable and explosive Irritation to skin, eyes, nose and throat Excessive inhalation may cause dizziness, drowsiness, loss of consciousness, cardiac irregularities. Control Measures Use Proper PPEs (dust / vapor mask, safety glass, rubber gloves, long sleeved shirt, long pants, safety hat, shoes, etc..) First Aid measures If inhaled take victim to fresh air Flush eye with flowing water Wash skin with soap Take medical aid in case of severity

26. Site Receipt Inspection & Preliminary Checks Design a n d B uild Ch emi c als Utili t ies Site receipt Inspections Ensure no damages occurred during transit Check the quantity Verify the spool numbers against the Delivery Note. Verify inspection reports. Preliminary Checks Approved documents are available (Piping and trench backfilling Material submittal, Method Statement, Drawings & RA, EA, PQP, HSEP, ITP) Piping route is clear of obstructions, existing services (if any) are well protected. Approved subcontractor and competent Engineers, HSE team are available Obtain permit to work

27. Storage of GRP Pipes at Site Design a n d B uild Ch emi c als Utili t ies The pipes shall be stored on an even surface. T he stacking height depends on the soil conditions as well as the loading and safety equipment on site as below table

28. Handling of Nested Pipes at Site Design a n d B uild Ch emi c als Utili t ies GRP pipes may be delivered nested (i.e., one or more small pipes inside a larger pipe).  Nested pipes must always be lifted using at least two straps or slings . De-nesting is accomplished by inserting a forklift/mobile crane boom. Proper padding is essential on the boom.

29. Pipe Laying Trench Requirements Design a n d B uild Ch emi c als Utili t ies Standard Trench The trench preparation must comply to approved drawing. Foundation & Bedding (soil/gravel or any other forms) as per project specification. Side support must provide with shoring or trench box in case excavated soil is not intact but loose. Multiple Pipes Pipes must be laid in the same bottom level. The clear spacing between adjacent pipes must be as per below given table.

30. Pipe Laying Trench Requirements Design a n d B uild Ch emi c als Utili t ies Trench Excavation Below Water Table Dewatering process must be carried out to ensure trench is dry prior laying the pipeline. Trench supported with Trench Box Side support must provide with shoring or trench box in case excavated soil is not intact but loose.

31. Various Underground Installations-Road Crossings Design a n d B uild Ch emi c als Utili t ies Pipe Laying Trench preparation

32. Various Underground Installations Design a n d B uild Ch emi c als Utili t ies

33. Pipes Joining at Site Design a n d B uild Ch emi c als Utili t ies Coupling Cleaning Gasket Installation & Lubricating Spigots Cleaning and Lubrication Fixing of Clamps Coupling Joining Pipe Misalignment

34. Pipes Joining at Site-Lamination Method Design a n d B uild Ch emi c als Utili t ies Grinding & Sanding Alignment Resin+Woven Ring application After curing

35. Pipes Joining at Site Design a n d B uild Ch emi c als Utili t ies Fast Curing of Pipe joints using Heating Blanket @130 C or as per specs

36. Pipes & Fittings Joining at Site-Flanged Joints Design a n d B uild Ch emi c als Utili t ies GRP Fixed Flange. Flat Face Bolting: Flange tightening sequence as per pic.1 Torquing depends on Bolt standard or manufacturer recommendation Don’t overdo it to damage base material as well as gaskets Pic.1

37. Backfilling Design a n d B uild Ch emi c als Utili t ies Backfilling shall be performed as per client specification Degree of compaction and FDT Tests shall carry out as per client specification Ensure warning tape installed during backfilling

38. Various Aboveground Installations-Wall Embedded Design a n d B uild Ch emi c als Utili t ies

39. Various Aboveground Installations-Skids Design a n d B uild Ch emi c als Utili t ies A s per approved Isometric, PID or GA supports and clamps are checked for location, type and span GRE flange mounted against a steel valve flange; the support is preferably fixed to the steel flange. All MEICA Items are installed as per PID Pipes shall be identified, tagged, color banded, flow direction marked (if any)

40. Installation of aboveground pipe systems Design a n d B uild Ch emi c als Utili t ies Valve supports Bellow supports

41. Field Tests after jointing Design a n d B uild Ch emi c als Utili t ies Barcol Hardness Test - ASTM D2583 To determine the hardness of site laminated joints. Degree of hardness depends on the resin used or by manufacturer recommendation.

42. Field Tests-Pipe Deflection Test Design a n d B uild Ch emi c als Utili t ies **Deflection test sample report

43. Field Hydrotest Design a n d B uild Ch emi c als Utili t ies Piping Hydrotest Test pre-checks Pipeline system inside shall be clear of foreign particles, debris, grease etc., All joining procedures and client inspections shall be completed. Trenches should be sufficiently backfilled, and joints should be left exposed. All supports, guides, and (temporary) anchors shall be in place Flange bolts shall be made up to the correct torque. Calibrated PG; media filling and disposal area must be agreed from client ITP, Method statement including test packs must be approved HSE requirements shall be respected.

44. Field Tests-Leak Test Design a n d B uild Ch emi c als Utili t ies Piping Leak Tightness Test Piping Hydrotest Test

45. Gel Coating Design a n d B uild Ch emi c als Utili t ies GRP Gel coated to improve UV and chemical resistance, for color coding of piping and vessels, or for aesthetics. 

46. Tolerance Chart Design a n d B uild Ch emi c als Utili t ies Tolerance chart for dimension control these might vary project wise. Ensure only competent workers executing the FRP works Ensure only latest approved drawings are used Check for resins shelf life prior to application

47. Safety precautions Design a n d B uild Ch emi c als Utili t ies Obtain Permit to work Work must be carried out strictly under the supervision of HSE Toolbox talks must be carried out at site. Proper ventilation must be provided to avoid irritation of the respiratory system Safety precautions must be followed during hydrotest GRP material must be protected from hot works Comply to confined space requirements and always check gas detector When cutting or grinding GRE materials proper personal protection is necessary to protect eyes and skin • A dust mask covering nose and mouth. • A pair of safety goggles, Gloves and overall. • Overall sleeves to keep the dust out. • Protective clothing to protect the body.

48. SUMMARY Design a n d B uild Utili t ies Ch emi c als BE Aware of GRP manufacturing process, inspection and tests involved BE Ahead of manufacturer’s knowledge BE Able to identify the defects KNOW the specification and standards KNOW drawing and design requirements KNOW the controls and check points DO Follow Method Statement and Risk Assessment DO not take short cut – Short cut causes rework DO not work hard – WORK SMART In Summary BE…KNOW…DO!

49. CONCLUSION Design a n d B uild Utili t ies Ch emi c als In this training – if this is followed what can we expect to see from attendees? Activities involved in Manufacturing and installation of GRP pipes. Understands HSE Risks involved and control measures to be implemented Monitor and carryout Inspections and Tests

50. QUESTIONS & ANSWERS Design a n d B uild Utili t ies Ch emi c als

51. Design a n d B uild Utili t ies Ch emi c als