bond strand bonder training

Fiberglass Pipe

Bondstrand Bonder Training

Bondstrand Bonder Training for PTSC M&C - 2009 2

Contents Part-1: General Part-2: AMERON’s Bondstrand Products Part-3: HSE & Product handling Part-4: Fabrication & Installation Part-5: Hydro-testing


Part-1 : General

Training Purpose To provide knowledge of AMERON’s

Bondstrand Products To qualify bonder for bonding

certification required for fabrication and installation of AMERON’s Bondstrand Products


Part-1 : General

Understanding AMERON’s Bondstrand Products

Understanding product data and QC form Pass hydrotest on practice

Achievements : Trainee must complete below points to get certificate


Part-1 : General

Issued by AMERON to trainee who pass hydrotest on spool practice

2-year validity

Bonding certificate


RTRP - Reinforced Thermosetting Resin Pipe FRP - Fiberglass Reinforced Pipe GRE - Glass Reinforced Epoxy GRV - Glass Reinforced Vinylester GRP - Glass Reinforced Polyester (in some

specifications it means Glass Reinforced Pipe)

Part-2 : AMERON’s Bondstrand Products

Abbreviations


QLF - Quick Lock Female QLM - Quick Lock Male TF - Taper Female TM - Taper Male B&W - Butt & Wrap Spigot - Bondstrand Male Pipe End Bell - Bondstrand Female Pipe End


Abbreviations



Epoxy (GRE) Vinylester (GRV)

Filament-wound pipe & fittings with advanced resins

Bondstrand Product Lines Bondstrand 2000/2000M Bondstrand 7000/7000M Bondstrand 2400/3400 series


Bondstrand 2000A lined epoxy system for applications where corrosion resistance and light weight are of paramount importance.



A lined epoxy system for applications where corrosion resistance and external pressure are of paramount importance.


Bondstrand 2000M


Bondstrand 7000/7000MAn epoxy system with conductive elements incorporated in the wall of the pipe to prevent accumulation of static electricity produced by the flow of liquids inside, and external effects outside the pipe.

Design equal to Bondstrand 2000/2000M

Unique patented pipe saddle drains off static charge build-up



Bondstrand Series 2400/3400 An epoxy system where corrosion

resistance and light weight are of paramount importance.

Pressure class determined by internal pressure requirements.

No external pressure requirements. Internal pressure class : 10, 12, 14,

16, 20 and 25 bar.* Also conductive



Joining SystemQuick-Lock Joint An adhesive-bonded joint with

straight spigot and tapered bell. The integral pipe stop in the Quick-Lock bell ensures accurate laying lengths in close tolerance piping.

Sizes : 25-400 mm (1”-16”) Sizes : 450-600 mm (18”-24”)



Taper/Taper Joint An adhesive-bonded joint with

matching tapered male and female ends offering superior strength by controlled adhesive thickness. Available in sizes : 50-1000 mm (2”- 40“).

Internal pressure class : 10, 12, 14, 16, 20, 25 bar.


Joining System


Flanged Joint A mechanical joint. Available

in sizes: 25-1000 mm (1”- 40“).

Various drilling patterns available (e.g. CL150, JIS 10K, DIN 10, etc.) - Compatible to Steel flanges.


Joining System


Joining SystemButt & Wrap Joint A lamination joint. Available

in sizes: 25-1000 mm (1”- 40“).

Time costly. Versatile. Most use on repair.



Adhesive SystemRP-34C A two-part amine cured

epoxy resin system Non-conductive Use on Quick-Lock joint Available in 3 oz. kit and 6

oz. kit



Adhesive SystemRP-60B A two-part thermosetting,

electrically conductive epoxy resin system

Conductive Use on Quick-Lock joint and

Taper/Taper joint Available in 3 oz. kit and 6

oz. kit



Adhesive SystemRP-48 A two-part amine cured

epoxy resin system Non-conductive Use on Taper/Taper joint Available in 3 oz. kit and 6

oz. kit



Special Tools Pipe Shaver & Power Drive Heating Blanket

Other Accessories Band Clamp Lever Hoist Bore Polisher (Flapper Wheel)

Common Pipe Tools


Tools & Equipment


!!! Pipe Shaver: Machine of pipe end to obtain appropriate spigot end for bonding, shaver shall be selected based on type of joint, pipe diameter, with consideration of total project scope.

B-1F Shaver: ½”, ¾”, 1”, 1 ½”, 2”, 3”, 4”, 5” & 6”

Cutting Insert

For detail guide, See FP376F, ‘Ameron B-1F Pipe End Preparation Tool’

To individual size only; Straight Spigot (For Quick-

Lock Joint) only. Driven by common electrical

tools or air tools, such as hand drill.

Special Tools – Pipe Shaver & Power Drive


M-74 Shaver

For detail guide, See FP696A, ‘M-74 Pipe Shaver’

For 2” – 16” pipes Use with arbor set Straight Spigot (For

Quick-Lock Joint) only. Driven by hand or

electrical tools (RIDGID-700).



Maintenance and Store Shall be kept in original tool box after use; Keep it in dry location, away from rain and

moisture; Do not use oil and/or grease as dust will

accumulate on oil and grease; Remove of dust/dirt using brush.



!!! Heating Blanket: For accelerating joint curing, as well as preheat of jointing surface Available in 115V and 230V, to be specified; Size depends on pipe size; Equipped with thermostat;

For 1” to 28” Pipe For 30” to 40” Pipe

Special Tools – Heating Blanket


Description of Heating Blanket



Using Heating Blanket Wrap the pipe using the

end with thermostat; Tie down accessory

shall be used; Do NOT pull the cable;



Packing, Storage and Transporting Always roll up the heating blanket when not in used; Do NOT pack and transport heating blanket in

folded form; Any heavy object fall on it may damage the heating

blanket;



Band Clamp with D-Rings Shall be used when making joints, Quick-Lock,

Taper, Mechanical O-Ring, … Available in 2” width x 6’ length, and Available in 2” width x 13’ length, and Available in 3” width x 13’ length

Other Accessories


Lever Hoist Shall be used when making joints,

Quick-Lock, Taper, Mechanical O-Ring, ……

Available in ½ Ton and 1 Ton, ……

Alternatively, ratchet puller (chain block) can be used

Bore Polisher (Flapper Wheel) Sanding bonding surface Grid 40~60 Driven by electrical drill or air tool

Other Accessories


Hacksaw or abrasive wheel; Paint marker; Pipe wraparound; Baby grinder; Electric or Air drill; Level Gauge; Paint Brush; Nylon/Rubber Mallet;

Cotton Roller; Adjustable Pipe Stands; Sanding Disc; Screw Driver; Scissors; Air Release Roller; ……

There are many other common piping tools might be required for fiberglass piping fabrication and installation work, such as:

Common Piping Tools


Part-3 : HSE & Product handling

!!! To prevent injuries & occupational diseases, property damages through needless industrial accidents and inefficient environment via waste management.

Personal Protection Equipment (PPE) Chemical and Dust Hazards


Personal Protection Equipment (PPE)

!!! PPE is any device or appliance designed to be worn by an individual when exposed to one or more health and safety hazards.

Overall Safety Helmet Safety Boots Safety Glasses Gloves Dust Mask Etc


!!! Resin, curing agent, catalyst, adhesive and other chemical products could cause irritation, some could be harmful to eyes.

Quick access to water in case of chemical contact !! No eating, drinking and smoking during handling of

above products; Maintain personal hygiene at all time; Safe glasses during handling above products; Dust mask to prevent inhalation of glass-fiber dust; Long sleeve shirts with long pants, or overall to

prevent skin irritation due to fiber dust;

Chemical and Dust Hazards


Maintain personal hygiene at all time; Do not rub or scratch irritated area if occurred; Shower in lukewarm water with soap and a

washcloth at day’s end to remove loose fiber; Wash work clothes separately; Good ventilation in workplace to keep dust

concentration below the MAC value (10mg/m3); Rinsing workplace with water or sweeping with

brushes or brooms; Refer to relevant MSDS and product literature for

unfamiliar products.

Chemical and Dust Hazards


!!! GRP piping components can be susceptible to mechanical damage from impact, sharp edges or scratching. Special consideration should be given to protecting components and to ensuring that all personnel involved are given training in the relevant procedures. ISO14692-4:2002

Goods Receiving Inspection Handling and Transportation Storage

Receiving and Handling


Verify goods receiving conform to shipping and packing document and compliance to purchase order.

Packing condition. Spools and components condition. Adhesive Kits condition including shelf life, visible

damage and/or leaking, completeness of kit packing. Reporting of any deviation and/or issue. FP167D, Shipping, Handling, Storage and Inspection

of Bondstrand Fiberglass Pipe.

Good Receiving Inspection


Handling and Transportation Proper support and protection with protection pad. Securely fastened. Forklifts should have at least a 6-foot carriage,

spacer of at least 2-inch thickness are located. Fittings shall be loaded onto pallets, crates or

baskets with sufficient protection. 3m or less pipe and spool could be lifted by single

4” wide canvas or suitable plastic. Pipe and spool greater than 3m (in length) shall be

lifted in using two or more canvas or suitable plastic.

Handling and Transportation


Prohibitions Being thrown or dropped from any height. Using chains, wire ropes or clamps for lifting

Handling and Transportation


!!! Carrying out inspection for good storage preparation and carrying out periodical inspection.

Fiberglass Pipe Well supported (side support and spacer support), not more

than 10-ft Interval, 6-ft from each end, the support should have 4-in wide bearing surface.

Side supports; not exceed 5-ft height; proper tie down. Protective end cover must be in place.

Storage


Fiberglass Fitting and Accessories Shall be kept in shipping box/pallet. Protective end cover must be in placed. Accessories such as Nylon Key and O-Ring, shall be kept in

shed store. Fiberglass Fabricated Spools

Shall be kept in shipping pallet or skid. End cover / protection shall not be removed until installation.

Adhesive Kit, Resin and Curing Agent Shall be kept in original packing. Shall be kept in specified control condition. Shall be used before expiry date.

Storage


Drawings Product data & Pipe length calculation QC form : Log sheet Fabrication and Installation Tolerances Hook-up to Equipment / Other Material

Part-4 : Fabrication and Installation


Spool Drawing Contain detail dimensions, fabrication materials, and

erection materials. Isometric Drawing

Contain all details of design (Pressure, fluid, system, temperature,…..), fabrication and erection (Materials), installation (Coordinates, connections) and testing.

Layout Drawing Background, surrounding, piping routing, supporting,

interface, equipment, etc. Piping and Instrument Diagram

Principle such as size, flow direction, design information, materials specification.

Drawings


Sample Drawing – Spool 1


Sample Drawing – ISO


Sample Drawing – Layout


Product data Assembling dimension of fittings

Pipe length calculation To produce pipe cutting table To calculate pipe length for spool adjustment To verify installation

Product data & Pipe length Calculation

Exercise : calculate pipe length.


To record bonding history for fabrication and site installation

Part of QC documentation

QC Form : Log sheet


Good tolerances control could ensure success in installation; reduce the possibility of leak at field joint; reduce the possibility of damage due to force on mismatched pipes; reduce/eliminate modification work, …

Recommended Fabrication Tolerances Installation Dimensional Tolerances

Refer to tolerance of different type of joints such as flange joint, mechanical o-ring joint.

Project specification

Fabrication and Installation Tolerances


1. Face/center to face/center dimension, or location of attachment

2. Lateral translation of branch or connection

3. Rotation of flange4. End preparation5. Alignment of flange face6. Angular deflection7. Reference: ISO14692-4:2002

Recommended Fabrication Tolerances


DN (Inch)

Tolerances / Dimension Number1 (mm) 2 (mm) 3 (Degree) 4 (mm) 5 (mm) 6 (Degree)

½”-8” ±5 ±3 ±0.5 ±3 ±1 ±0.5

10”-12” ±5 ±3 ±0.3 ±3 ±1 ±0.5

14”-16” ±5 ±3 ±0.3 ±3 ±1.6 ±0.5

18”-24” ±6 ±5 ±0.3 ±3 ±2.0 ±0.5

26”-36” ±6 ±5 ±0.2 ±4 ±2.4 ±0.5

40”-48” ±6 ±5 ±0.15 ±5 ±2.4 ±0.5

Reference: ISO 14692-4:2002 and Ameron PF-01.

Recommended Fabrication Tolerances


To prevent damage to both equipment and fiberglass piping system, attention shall be given when fiberglass piping is hooked up to equipment and other piping materials.

Hook-up to Equipment Equipment (Including fire hydrant, ballast eductor,

….) shall be independently anchored, Allowable alignment to avoid excessive stress, Control torque value strictly if equipment connection

is cast iron material, Dismantle piece is recommended for testing and

equipment maintenance.

Hook-up to Equipment / Other Material


Fabricated Spool Testing System Hydro-testing

Part-5 : Hydro-testing


Spool Testing is normally used to verify quality of fabrication joints (if applicable). Test pressure determination: 1.5 times of design pressure of

the weakest component on the spool. Recommended Test Duration: 10 minutes Special end blind/plug required for variety of spool end

configuration Limitation: Some fabricated spools could not be tested due

to end configuration and size : Spool with “Taper Male” end, Spool with QL Female and Taper Female and greater than 16” …….

Fabricated Spool Testing


System Hydrotesting is carried out on installed piping system to verify fabricated joints, site joints, as well as the integrity of the installed piping system. Prior to Hydro-Testing

All piping supports must be completed; For underground piping, sufficient partial backfill and

temporary block must be in place to prevent excessive movement;

High point vents / low point drains in place; Removing/isolating components that shall be

excluded from hydro-testing;

System Hydro-testing


Test Pressure 1.5 times of design pressure 1 hour holding minimum, or sufficient time to carry out

line check, or project specification whichever is longer Testing Equipment

Quick closing valve and booster pump without suitable control shall not be used, to avoid surge;

Pressure gauges and instrument must be calibrated; Appropriate pressure gauges shall be selected, the test

pressure shall be between 30% to 75% of reading range If possible, pressure recorder shall be used;



Hydro-Testing Pressure build up process:

The test pressure shall be raised over a period of 30minutes of longer.

Slowly and gradually to allow for equalizing for strain, and also in stages to allow for inspection.

Inspection Instrument reading Visual inspection of joints, pipes and fittings

24 hour holding @ 1.1 design pressure (ISO14692:4) Acceptance criteria

No sign of leaking or weeping No significant pressure lost



Possible causes of pressure change Effect of joint expansion and material creep; Effect of temperature (Morning, afternoon, night, under

sun, and so on), take precaution to prevent over-pressure Other Concerns

Glycol antifreeze shall be added when test is carry out in subzero temperature.

Instrument to prevent from buckling in case of sudden depressurization

Safety aspects, such as qualified operator, signs and notices, operation procedures …. Shall be in placed.

Reference: AME/INS-004 – “Hydro-Testing Procedure for Bondstrand GRE / GRV Pipe”


bond strand bonder training

Documents