8th Ameron Asia Piping Workshop

Quality ServiceOn-Time DeliverySuperior Product Value

IntroA d

stem

August, 2009Senai

All rights reservein any form or

8th Ameron Asia Piping Workshop:

Training ManualCopyright Ameron (Pte) Ltd

d. No part of this publication may be produced, stored in a retrieval system, or transmittedby any means, electronic, mechanical, photocopying, recording or otherwise without priorduction tomerons Bondstran

GRE Piping Sywritten permission.

Page 1 of 285


AGENDA8th Ameron Asia Piping Workshop,

Senai August, 2009

Time / Event Presenter

- 0930 Registration

- 1000 Introduction - Company Organization Cheong Chi Keong

- 1030 Product Introduction Cheong Chi Keong

- 1115 Ameron Engineering Services Cheong Chi Keong

- 1130 Piping Design Shoba Sekaran

- 1230 Lunch at Sofitel Resort

- 1330 Plant Tour

- 1400 Project Workflow Irene Teh

- 1445 Piping Surge and Stress Analysis Lu Fang Fang

- 1530 Repair and Installation Oliver Ong

- 1600 Q & A Session

- 1630 Adjourn

Page 2 of 285


CONTENTS

PageIntroduction Company OrganizationSpeaker Biography :

- Cheong Chi Keong............................................................................ 5Reference :

- Long Term Test Per ASTM D2992.................................................... 11

I. Product IntroductionSpeaker Biography :

- Cheong Chi Keong............................................................................ 12Reference :

- Bondstrand Pipe Systems for Marine Applications............................ 27- Bondstrand Fiberglass Pipe and Fittings for offshore

drilling and production application ..................................................... 33

II. Ameron Engineering ServicesSpeaker Biography :

- Cheong Chi Keong............................................................................ 39

III. Piping DesignSpeaker Biography :

- Shoba Sekaran ................................................................................. 43Reference :

- Installation Manual Marine ............................................................. 61- Installation of Suspended Bondstrand Pipe....................................... 100- Bondstrand Series 2000M & 7000M fitted with Double

O-Ring expansion couplings ............................................................. 124- Product Dimension Table 2000M................................................... 130- Product Dimension Table 7000M................................................... 158

IV. Project WorkflowSpeaker Biography :

- Irene Teh........................................................................................... 189Reference :

- Spool Drawings Preparation Requirements ...................................... 209

Page 3 of 285


CONTENTS

PageV. Ameron Piping Surge and Stress Analysis

Introduction & GuidelinesSpeaker Biography :

- Lu Fang Fang.................................................................................... 211Reference :

- Information Request Lists.................................................................. 236- Sample Piping Stress Analysis Report.............................................. 241

VI. Repair and InstallationSpeaker Biography :

- Oliver Ong......................................................................................... 259Reference :

- Modification and Repair Recommendation........................................ 277

Page 4 of 285

Introduction Company Organization

By

Mr. Cheong Chi Keong

Page 5 of 285

Quality ServiceOn-Time Delivery

Superior Product Value

Asia Pacific

Singapore Malaysia Shanghai Middle East

8th Piping Workshop

Speaker biographiesAugust 2009

Cheong Chi KeongSales Engineer, OffshoreE-mail : [email protected] : +65-6865 6825

Chi Keong joined Ameron Singapore since 2005. His primary dutyinclude developing and managing offshore sales and agents inAsia Pacific regions such as Malaysia and India, and alsocoordinates for projects in terms of planning, pricing andexecution. As part of the companys effort in developingemployees, Chi Keong was sent to Hong Kong to attend thecourse on Effective Sales Management conducted by theUniversity of Michigan.

He holds a Degree in Mechanical Engineering, specializing in BioChemistry from Nanyang Technological University.

Page 6 of 285

AMERON ASIABONDSTRAND PIPING

WORKSHOP

AMERON ASIABONDSTRAND PIPING

WORKSHOP

Ameron Pte LtdNo.7A Tuas Ave 3Singapore 639407Company Reg. No. 198200413HCheong Chi [email protected]: +65-68656825, Mobile Ph: +65-9830-9605August, 2009

Objectives of Ameron Piping WorkshopObjectives of Ameron Piping Workshop

Provide Piping Engineers with basicknowledge on the concept and design ofAmeron Piping.

Offer a common platform on executing:- Stress and Surge Analysis- Ameron pipe spool fabrication

Page 7 of 285

ScopeScope Introduce Basic Ameron Product Knowledge Ameron Piping Design Concept Concept and Execution of Ameron Piping Stress

and Surge Analysis Ameron Pipe Support Design Recommendation Execution process of Prefab Spool Order Handling and Installation of Ameron Piping

Three Pillars of Good GRE SystemThree Pillars of Good GRE System PRODUCT QUALIFICATION1. Long-Term Test Per ASTM D29922. Mid Term 1000 HR Survival Test3. Short Term Burst Test Per ASTM D1599

Page 8 of 285

Three Pillars of Good GRE SystemThree Pillars of Good GRE System

ENGINEERING DESIGN

1. Pipe Support Design2. Stress Analysis3. Surge Analysis

Three Pillars of Good GRE SystemThree Pillars of Good GRE System

FIELD INSTALLATION

1. Bonder Qualification and Certification2. Training for QC engineer and Installers.3. Field Supervisor from Manufacturer

Page 9 of 285

VIDEO ON AMERON OPERATIONSVIDEO ON AMERON OPERATIONS

Page 10 of 285

Calculation for Long Term Hydrostatic StrengthASTM D2992 (96e1) Procedure A e1 NOTE: Editorial corrections were made to Eq A1.17 & A1.19 in Sept 1999

Pipe Description: 4" epoxy pipe, hexlical wound at 55. Test temperature @ 66CAve. ID of Pipe: 105.2 mm Ave. Pipe Thickness: 4.5 mmNo. of Data Pts: 21 Pipe design for: 1.50E+08 Cycles Test Date: Jun-90Student's "t" Value: 2.093 Service Design Factor: 1

Failure Stress FailureData Pt Cycles (MPa) Cycles

1 1112 103.52 1.00E+022 2006 102.39 1.00E+033 2145 100.74 1.00E+044 9640 86.26 1.00E+055 9810 83.95 1.00E+066 11122 83.95 LTHS at 1.00E+077 14270 87.23 Specified Cycles 1.00E+088 35924 86.26 1.50E+089 132391 63.18

10 224421 65.46 HDB Category = 43.4 MPa HDS = 41.3 MPa11 359740 59.7312 420271 63.5513 478203 62.4514 625350 63.5515 951773 59.0816 1245014 58.4517 1855349 60.3018 3296040 65.1319 4529594 60.6420 5385506 60.6421 8904332 47.622223242526272829303132

37.0002581841.31510303 37.58060605 35.7349288142.64527986

77.6789373765.2121678154.3411259144.96624538

113.628484797.5172136783.4438649570.7010891958.6231466847.9091616

38.97843813

87.5960509373.1696769861.1192122651.05336337

95% Lower PredictionLimit (MPa)

125.5426544104.8667762

108.229322291.92207423

Stress (MPa)(Regression Line)

95% Lower ConfidenceLimit (MPa)

Regression Line

1.00E+01

1.00E+03

1.00E+02 1.00E+04 1.00E+06 1.00E+08Failure Cycles

Stre

ss(M

Pa)

Data Pts Regression Line 95% Lower Prediction Limit 95% Lower Confidence Limit

01A, ASTM-D2992(Cyclic)-Y96E1-66C Prepared by Goh Boon Hong, Test Engineer Page 1

Page 11 of 285

Product Introduction

By


Page 12 of 285

PRODUCT INTRODUCTIONPRODUCT INTRODUCTIONGlassfiber Reinforced Epoxy/Vinylester


(Pipe Systems Application for Marine / Offshore)

Worldwide ManufacturingWorldwide Manufacturing

Brazil

9 Manufacturing Plants Worldwide operation Representation in more than 100 countries

Page 13 of 285

Fiberglass Pipe Features and BenefitsFiberglass Pipe Features and Benefits Corrosion Resistant Light weight Reliable Safe against fire Low smoke and Toxicity No painting required Life cycle cost saving compared to steel Better Flow characteristics than steel (low

pressure loss) More

Ballast / Stripping / Tank Cleaning Inert Gas Seawater / Brine / Drillwater / Firewater Fresh water / Potable water Cargo Oil Lines Produced water Water Injection Drain More(Governed by rules and regulations)

Piping System ApplicationsPiping System Applications

Page 14 of 285

Lloyds Register of Shipping Det Norske Veritas Registro Italiano Navale Germanischer Lloyd Bureau Veritas Nippon Kaji Kyokai Korean Register of Shipping United States Coast Guard American Bureau of Shipping

Marine Class Society ApprovalsMarine Class Society Approvals

Fiberglass Piping AbbreviationFiberglass Piping AbbreviationRTRP - Reinforced Thermosetting Resin PipeGRP(*) Glass Reinforced PipeFRP - Fiberglass Reinforced PipeGRE - Glass Reinforced EpoxyGRV - Glass Reinforced VinylesterGRP(*) - Glass Reinforced PolyesterPSX PolySiloxane (Glass Reinforced Phenolics)

Page 15 of 285

Type of ResinType of Resin

EpoxyVinylesterPolyesterPhenolic RTRP / FRP / GRP

GRE PSX

GRP GRV

Filament Winding (Pipe) Reciprocal Helical Winding Continuous Winding

Compression Mould Centrifugal Casting Hand Lay Up

Production Methods

Page 16 of 285

JointingMethods

Type of JointsType of Joints Adhesive Bonded Joints

Quick Lock Joint Taper / Taper Joint

Mechanical Joints Key Lock Joint Double O-ring Joint

Butt and Wrap joint Flanged Joint

Page 17 of 285

Bondstrand

Composite - Quick Lock JointFeaturesPipe StopTaper Bell ( taper)Straight Spigot

PIPE STOP

Bondstrand

Composite Taper/Taper JointFeaturesTaper Bell (1 to 2 taper depending on size)Taper SpigotThin Glue Line

Page 18 of 285

Bondstrand

Composite Butt & Wrap JointFeaturesSkill Required to Make JointVersatile

Products

Page 19 of 285

Bondstrand

Composite ProductsStandard filament-wound

and fabricated fittings

Such as : Flange Elbows Tees, reducing tees Reducers, etc. Saddle reducing Grounding Saddle Blank Saddle

Bondstrand

Pipe and Grounding Saddle

Grounding saddle will bebonded onto conductivepipe surface

Page 20 of 285

Bondstrand

Tee, Fab Tee, Cross and Lateral

Mitered Tee Lateral Fitting

Cross Fitting Tee Equal Fabricate Tee

Bondstrand

Deluge Coupling / SaddleReducing

Bushing materials shall be specified in detail Saddle Reducing is applicable to low pressure rating

20bar or below depending on outlet size

Page 21 of 285

Bondstrand

Flange, Blind Flange, OrificeFlange

Drilling pattern to be specified (CL150, JIS5K,DIN10)

Bush size and materials to be specified in detail

Adhesive Types

Page 22 of 285

Kit sizes- 3oz- 6oz

Bondstrand

Composite Adhesives

Product Series Marine & Offshore Application

RP-34, RP-48QL, TT, DOR*0.5GRE2000MFP-FV

RP-48TT0.5GRE2400

RP-60TT0GRE2400C

GRE

GRE

GRE

Resin

RP-60QL, TT, DOR*07000MFP-FV

RP-60QL, TT, DOR*07000M

RP-34, RP-48QL, TT, DOR*0.52000M

AdhesiveJoint TypeLiner(mm)Product

Note: * Double O-Ring Joint - Not an adhesive joint.

Page 23 of 285

Product Series Marine & Offshore Application

PSX

PSX

PSX

PSX

GRV

GRV

Resin

RP-105QL1.35000

RP-106QL1.35000C

PSX-60QL, TT0PSX-JFC

PSX-34QL, TT0.5PSX-JF

PSX-60QL, TT0PSX.L3C-16 Bar

PSX-34QL, TT0.5PSX.L3-16 Bar

AdhesiveJointTypeLiner(mm)Product

Product Series Marine & Offshore ApplicationM Marine applicationC ConductiveFP Fire proofingFV Favuseal (Fire protection material)L3 IMO L3JF Jet fire

Page 24 of 285

Question and Answer

??List down JointTypes??

??? and AnswerFRP is lighter in weight, but how much

less compare with steel pipe?25%

50%

75%

90%

Page 25 of 285

??? and AnswerWhat is the limitation of Fiberglass Piping

application???

Page 26 of 285

BALLAST LINESBILGE WATERINERT GAS EFFLUENTCOOLING WATERVENT PIPES

GLASSFIBER REINFORCED EPOXYPIPE SYSTEMS FOR MARINE APPLICATIONS

BONDSTRAND

Page 27 of 285

n FAST AND EASY INSTALLATION

n LIGHT WEIGHT

n TOTAL INSTALLED COST EQUALSTRADITIONAL STEEL PIPING

n LITTLE, OR NO MAINTENANCE

n LONG SERVICE LIFE

Bondstrand piping systems provide

a long service life in the harsh

marine environment. During the

typical life of the vessel, metal pipe

will need replacement two or three

times. Bondstrand GRE pipe

systems can last the life of a vessel.

Glassfiber Reinforced Epoxy (GRE)

is highly resistant to both internal

and external corrosion without

surface preparation or special

coatings.

Glassfiber Reinforced Epoxy (GRE)

pipe can be installed for less of the

cost than Schedule 80 Carbon Steel

piping systems. The adhesive

joining system eliminates the need

for certified welders, or special

welding techniques. The light

weight of the pipe also eliminates

the need of expensive lifting

equipment.

Bondstrand can be installed much

faster than steel or alloy systems.

Bondstrand marine pipes are easy

to install, maintenance personnel

can be quickly trained to cut and

complete a joint. Proper

installation procedures are

described in Ameron literature and

Ameron field technicians are

available if required.

BONDSTRAND GLASSFIBERREINFORCED EPOXY PIPE SYSTEMS FORMARINE APPLICATIONS

BONDSTRANDREINFORCED EMARINE APPL

OUTSTANDING BENEFITS

Custom built bell mouths areavailable in various designs

Page 28 of 285

TOTAL INSTALLED COST EQUALSTRADITIONAL STEEL PIPINGA comparison of costs clearly shows thesavings during the service life of the vessel.

COST COMPARISON WITH CONVENTIONALSTEEL MECHANICAL SYSTEMS

PREFABBondstrand GRE systems are assembled using standard components.This enables the yard, or (subcontracted) installer to make prefabspools at the yard, eliminating the need for adhesive-bonded joiningon board. Major advantage is, that by using standard fittings andavoiding lamination, adjustments can be made on-site, if required.Once the installer is trained and certified by Ameron according toIMO standards, they can handle the complete installation.Amerons scope of supply may vary from material supply to completeturn-key projects.Ameron can be of assistance every step of the way, based onindividual customer requirements.

The Ameron Fiberglass-Composite Pipe Group hasworldwide engineering services available, which areperformed by professional, experienced and qualifiedpersonnel using internationally accepted analysismethods. Main activities of our engineering servicesinclude:

l Pipe stresses and flexibility analysis (Ceasar II)l Isometric and spool drawings (Autocad)l Head loss calculationsl Special spool designsl Support spacings etc.l Detailed installation designl Field Service

Bondstrand Glassfiber Reinforced Epoxy (GRE) pipe isavailable for piping systems with the followingrequirements:External Pressure Bondstrand 2000MExternal Pressure/Conductivity Bondstrand 7000MNo External Pressure Bondstrand 3400/2400Page 29 of 285

CARGO (flammable cargoes f.p 60C)Cargo lines

l l l l l l l l l l l

Fuel oill l l l l l l l l l l

Lubricatingl l l l l l l l l l l

Hydraulic oill l l l l l l l l l l

SEAWATER

Bilge main and branchesl l l l l l l l l l l

Fire main and water sprayl l l l l l l l l l l

Foam systeml l l l l l l l l l l

Sprinkler systeml l l l l l l l l l l

Ballastl l l l l l l l l l l

Cooling water, essential servicesl l l l l l l l l l l

Tank cleaning services fixed machinesl l l l l l l l l l l

Non essential systemsl l l l l l l l l l l

FRESH WATER

Cooling water, essential servicesl l l l l l l l l l l

Condensate returnl l l l l l l l l l l

Non essential systemsl l l l l l l l l l l

SANITARY / DRAINS / SCUPPERS

Deck drains (internal)l l l l l l l l l l l

Sanitary drains (internal)l l l l l l l l l l l

Scuppers and dischargers (overboard)l l l l l l l l l l l

SOUNDING / AIR

Water tanks / dry spacesl l l l l l l l l l l

Oil tanks (f.p. > 60C)l l l l l l l l l l l

MISCELLANEOUS

Control airl l l l l l l l l l l

Service air (non essential)l l l l l l l l l l l

Brinel l l l l l l l l l l

Auxiliary low pressure steam ( 7 bar)l l l l l l l l l l l

Fire endurance requirementsmatrix according to IMO 753regulations

l

Bondstrand approved systemsl

Not applicablel

Not allowed

Mac

hine

ry sp

aces

of C

ateg

ory A

Othe

r mac

hine

ry sp

aces

and

pum

p ro

oms

Carg

o pu

mp

room

s

Ro-ro

carg

o ho

lds

Othe

r dry

carg

o ho

lds

Carg

o ta

nks

Fuel

oil t

anks

Balla

st w

ater

tank

s

Coffe

rdam

s voi

d sp

aces

pip

e tu

nnel

and

duct

s

Acco

mod

atio

n se

rvice

and

cont

rol s

pace

s

Open

dec

ks

9

9

9

1

1

1

1

111

1 1

6

93

3

9

2

4 4 4

5 5 55 5 5 5

888 8 8

1-7 1-7 1-7 1-7 1-7 1-7

1 Where non-metallic piping is used, remotely controlled valves to be proved at ships side (valve is to be controlled from outsidespace).

2 Remote closing valves to be provided at the cargo tanks.3 When cargo tanks contain flammable liquids with f.p. >60C, l may replace l or l .4 For drains serving only the space concerned, l may replace l .5 When controlling functions are not required by statutory requirements or guidelines, l may replace l .6 For pipe between machinery space and deck water seal, l may replace l .7 Scuppers serving open decks in positions 1 and 2, as defined in regulation 13 of the International Convention on Load Lines,

1966, should be l throughout unless fitted at the upper end with the means of closing capable of being operated from aposition above the freeboard deck in order to prevent downflooding.

8 For essential services, such as fuel oil tank heating and ships whistle, l is to replace l .9 For tankers where compliance with paragraph 3(f) of regulation 13F of Annex I of MARPOL 73/78 is required, l is to replace l .

9

3 9

3

Page 30 of 285

The Bondstrand 7000M conductive piping system has been developed toprevent accumulation of potentially dangerous levels of static electricalcharges. Pipe and flanges contain high strength conductive filaments;fittings include a conductive liner. Together with a conductive adhesive thisprovides an electrically continuous system. If required, grounding saddlesmay be installed on the pipe once the piping system is installed. Integralgrounding cables are then bolted to the ships structure to drainaccumulated charges.

PRODUCT OVERVIEW

EXTERNAL DESIGN PRESSURE*

Bar PSI PSIBar

*at 21C

Nominalpipe size

(mm) (in) 2410 2412 2414 2416 2420 2425 2410 2412 2414 2416 2420 2425 2000M 7000M 2000M 7000M

50 2 20.78 20.78 20.78 20.78 20.78 20.78 301 301 301 301 301 301 34.11 52.02 495 75480 3 5.72 5.72 5.72 5.72 5.72 10.44 83 83 83 83 83 151 9.95 15.31 144 222

100 4 2.69 2.69 2.69 3.69 4.91 10.12 39 39 39 53 71 147 10.78 15.02 156 218125 5 5.61 7.84 81 114150 6 1.07 1.42 2.09 3.25 4.80 9.20 15 21 30 47 70 133 3.48 4.54 50 66200 8 1.04 1.16 1.93 2.99 4.69 8.77 15 17 28 43 68 127 3.64 3.83 53 56250 10 0.80 1.16 1.89 2.87 4.40 8.88 12 17 27 42 64 129 3.56 3.72 52 54300 12 0.68 1.11 1.92 2.89 4.35 8.57 10 16 28 42 63 124 3.75 3.62 54 53350 14 0.65 1.11 1.96 3.16 4.58 9.18 9 16 28 46 66 133 3.49 3.60 51 52400 16 0.60 1.17 1.92 3.07 4.61 9.34 9 17 28 45 67 135 3.48 3.48 50 50450 18 0.56 1.09 1.80 2.88 4.33 8.75 8 16 26 42 63 127 3.70 3.70 54 54500 20 0.56 1.09 1.79 2.84 4.24 8.69 8 16 26 41 61 126 3.70 3.70 54 54600 24 0.54 1.03 1.84 2.89 4.28 8.66 8 15 27 42 62 126 3.63 3.84 53 56700 28 0.54 1.03 1.89 2.85 4.32 8.62 8 15 27 41 63 125 3.66 3.66 53 53750 30 0.51 1.00 1.73 2.74 4.19 8.15 7 15 25 40 61 118 3.63 3.63 53 53800 32 0.51 0.99 1.71 2.77 4.11 8.24 7 14 25 40 60 119 3.66 3.66 53 53900 36 0.52 0.99 1.74 2.79 4.12 8.18 7 14 25 41 60 119 3.62 3.62 53 53

1000 40 0.52 0.99 1.72 2.75 4.13 8.26 7 14 25 40 60 120

Based on Safety Factor 3,according to IMO Regulations

Bondstrand Characteristics Joining Max. Max. Nominalseries system operating operating pipe size

temperature pressure(C) (F) (bar) (PSI) (mm) (in)

2000M A standard epoxy system for applications Quick-Lock 93 200 16 230 50-400 2-16where corrosion resistance and external Taper/Taper 93 200 16 230 450-600 18-24pressures are of paramount importanceExternal Pressure Rating according to IMO Regulations

2410*/3410* An epoxy system for applications where Taper/Taper 93 200 10 145 50-1000 2-402412*/3412* corrosion resistance and light weight are of Taper/Taper 93 200 12 175 50-1000 2-402414*/3414* paramount importance. Taper/Taper 93 200 14 200 50-1000 2-402416*/3416* Pressure class determined by internal Taper/Taper 93 200 16 230 50-1000 2-402420*/3420* pressure requirements Taper/Taper 93 200 20 300 50-1000 2-402425*/3425* No External Pressure Requirements Taper/Taper 93 200 25 350 50-1000 2-40

7000M** An epoxy system with high strength conductive Quick-Lock 93 200 16 230 50-400 2-16filaments incorporated in the wall of the pipes Taper/Taper 93 200 16 230 450-600 18-24to prevent accumulation of static electricityproduced by the flow of liquids insideExternal Pressure Rating according to IMO Regulations

* Also available as a conductive version** Conductive version of Bondstrand 2000M

Ultimate Collapse Pressure

Page 31 of 285

AMERON OFFERS THE WORLDS MOST COMPREHENSIVESELECTION OF JOINING SYSTEMS FOR MARINE PIPE SYSTEMS

QUICK-LOCK

An adhesive-bonded joint with straight spigot and taperedbell. The integral pipe stop in the Quick-Lock bellensures accurate laying lengths in close tolerancepiping.Available in sizes 50-400 mm (2-16 in).

TAPER-TAPERAn adhesive-bonded joint with matching taperedmale and female ends offering superior jointstrength by controlled adhesive thickness.Available in sizes 50-1000 mm (2-40 in).

DOUBLE O-RINGA mechanical joint offering quick assembly betweenmale and female ends. Two O rings are employedto provide sealing.Available in sizes 50-900 mm (2-36 in).

FLANGESOne-piece flanges and Van Stone-type flanges withmovable rings.Available in sizes 50-1000 mm (2-40 in).

AmeronFiberglass-Composite PipeGroupHeadquartersP.O. Box 801148Houston, TX 77280USAPhone (+1) 713 690 7777Fax (+1) 713 690 2842www.ameron.comE-mail: [email protected]

AmeronFiberglass-CompositePipe GroupEuropeAmeron B.V.P.O. Box 64190 CA GeldermalsenThe NetherlandsPhone (+31) 345 587 587Fax (+31) 345 587 561E-mail: [email protected]

AmeronFiberglass-CompositePipe GroupAsiaAmeron (Pte) Ltd.N0. 7A, Tuas Avenue 3JurongSingapore 639407Phone (+65) 8616118Fax (+65) 8621302/861 7834E-mail: [email protected]

AmeronFiberglass-CompositePipe GroupThe AmericasP.O. Box 878Burkburnett, TX 76364USAPhone (+1) 940 569 1471Fax (+1) 940 569 2764

Ameron 2001 FP 845 05/01 SING. Printed in The Netherlands

LEADING PRODUCERAmeron is a leadingproducer of glassfiber-reinforced epoxy (GRE) pipesystems with manufacturingfacilities in the Americas,Europe and Asia-Pacific.Ameron offers the worldsmost comprehensive line ofGRE pipe products forindustry, oil & gas, offshore,marine and fuel handlingapplications.

CUSTOMER SUPPORTAmeron provides a highdegree of customer supportthrough a network of salesoffices, supply houses,stocking distributors andsales representatives inmore than 100 countries.This is supported by centralresearch and developmentfacilities, to meet customerrequirements.

ADVICE AT EVERY STAGEAmeron offers advice atevery stage, from projectplanning to installation.With advanced software,Ameron can offer assistancein design, calculations andengineering.

WORLDWIDE APPROVALSAmeron is committed toTotal Quality Managementand conforms to theinternational ISO 9001standard and holds manytype approvals such asLloyds, DNV, ABS and BV.

WORLDWIDEOP E RAT IONWithmanufacturingfacilities in theUSA, Europe andAsia-Pacific,Ameron offers

the worlds most comprehensive line ofGRE pipe products for industry, oil & gas,offshore, marine and fuel handling.

FITTINGSStandard filament-wound Couplings; 30,45, 60, and 90 Elbows; Tees and ReducingTees; Concentric Reducers; Flanges andNipples.Standard Flanges are available with thefollowing drilling: ANSI B16.5 Class 150 &300, DIN, ISO and JIS. Other drilling patternsare available on request.Available in sizes 50-1000 mm (2-40 inch)

This literature and the information and recommen-dations it contains are based on data reasonablybelieved to be reliable. However, such factors asvariations in environment, application or installa-tion, changes in operating procedures, or extrapo-lation of data may cause different results. Ameronmakes no representation or warranty, express orimplied, including warranties of merchantabilityor fitness for purpose, as to the accuracy, adequacyor completeness of the recommendations or in-formation contained herein. Ameron assumes noliability whatsoever in connection with this litera-ture or the information or recommendations itcontains.

Page 32 of 285

of 285

BONDSTRAND GLASSFIBER REINFORCEDEPOXY AND PHENOLIC PIPE SYSTEMSFOR OFFSHORE APPLICATIONS

BONDSTRANDEPOXY AND PHFOR OFFSHOR

SPECIFICATIONS

UKOOAIn 1994, the United Kingdom Offshore OperatorsAssociation (UKOOA) issued a Document Suite onbehalf of and under the guidance of the FibreReinforced Plastic (FRP) workgroup of the UKOOA.This Document Suite provides the offshore oil & gasindustry with mutually agreed specifications andrecommended practices for the design, purchase,manufacturing, qualification testing, handling,storage, installation, commissioning and operationof Glass Reinforced Epoxy (GRE) piping systemsoffshore.Ameron was a member of the advisory group thatwas formed to review the documents during theirdevelopment.

ISOThis Document Suite formed the basis of the ISO14692 Standard.Although, the ISO 14692 Standard is primarilyintended for offshore applications on both fixed andfloating topsides facilities, it may also be used asguidance for the specification, manufacture, testingand installation of GRE piping systems in othersimilar applications found onshore, e.g. produced-water and firewater systems.

IMOIn 1993, the International Maritime Organisation(IMO) issued a resolution (A.18/ Res. 753) coveringacceptance criteria for plastic materials in pipingsystems, appropriate design and installationrequirements and fire test performance criteria forassuring ship safety. Major certifying bodies (such asLloyds Registre, Bureau Veritas, Det Norske Veritas,American Bureau of Shipping and United StatesCoast Guard) have adopted and implemented theseGuidelines in their respective Rules and Regulationsfor the Classification of Ships.All Bondstrand pipe series that are used in themarine/offshore industry are type-approved by thesemajor certifying bodies.

Historically, offshore productionplatform, drilling rig and FPSO ownersand operators have had to face the grimreality of replacing most metal piping.This has resulted in piping systems costingtwo or three times the originalinvestment.Bondstrand Glassfiber Reinforced Epoxy(GRE) pipe systems offer the cost-effective, maintenance-free andlightweight solution that providesproblem-free operation during theservice life of the installation.

The many advantages of AmeronGlassfiber Reinforced Epoxy (GRE)pipe systems

Durable and corrosion resistantBondstrand GRE piping is inert to internalcorrosion caused by (salt) water,chemicals, residues and bacteria.Similarly, it resists exterior corrosion evenin aggressive environments. Cathodicprotection is not required.

Lightweight easy to installBondstrand GRE pipe systems, being justa quarter to an eighth the weight ofcomparable steel pipes, are easy to installwithout the need of heavy installationequipment, welding or protectivecoating. For installation of GRE pipingsystems no hot work is required.

Low installation and operating costsThe installation cost of Bondstrand GREpipe systems is typically 80% of the costof carbon steel. The smooth internalsurface reduces the head loss resulting inlower pump energy consumption.

Wide range of pipe systemsAmeron offers a complete range of pipesystems in a variety of diameters andpressure classes for many differentapplications. Pipe systems are available indiameters up to 1000 mm (40 inch),pressure classes up to 245 bar (3500 PSI)and standard lengths up to12 m (40-feet).

No contaminationBondstrand GRE does not produce rust orscale, which could foul steam traps, valvesand other components. Page 34 of 285

ENGINEERING CAPABILITIES

PREFABRICATION

The Ameron Fiberglass-Composite Pipe Group canassist in converting layout- or isometric drawingsinto spool drawings, which in turn are used byAmeron for the manufacture of the spools .Amerons Engineering Service can include:

l General engineering calculations such as supportspan, thrust loads, joint strength, collapsepressure and internal pressure ratings, etc.

l Design drawings, stress- and hydraulic analyses

l Pipe Spool drawings from piping isometrics

l Pipe support detailing

l Material take offs (MTO)

l Supervision and/or survey of installation

l Project Management

l Special product design for custom made parts

l Expertise on international specification worktowards approval authorities

l Field service

l Training to certify installers.

Ameron has highly skilled and trained pipespool fabricators to provide spoolprefabrication services to our customers.These spools are fabricated based on spooldrawings issued by the Ameron Fiberglass-Composite Pipe Group.

Where pipe spacing is a constraint, Ameron canoffer custom made spools to meet specificdimensions.Amerons team of piping engineers andfabricators can assist to ensure that custom-madespools are designed and fabricated to meet thedesign requirements.

Supply of pre-fabricated spools by Ameron isrecommended as it will reduce the number offield joints and provide greater reliabilitybecause of the high quality joints and testing ofjoints made at the Ameron factory.

Page 35 of 285

TESTING

FIRE ENDURANCE

Bondstrand fittings are tested to 1.5 times theirpressure rating before they leave the factory or areused in spools. Small diameter fittings, to150 mm (6 inch) are air tested, when possible. Allothers and the large diameter fittings arehydrotested. Ameron is the only manufacturer toconduct unrestrained hydro-test of fittings above500 mm (20 inch) in diameter using self-energizingtest plugs. Unrestrained testing is a morerepresentative test as it simulates the actualcondition the pipeline is subjected to in mostoffshore installations.

Ameron has extensive testing capabilities to meetspecial testing requirements. Comprehensivequalification testing is done on representative sizesbefore manufacturing. Qualification test includeslong-term hydrostatic test in accordance withASTM D-2992, medium term survival test(1000-hour survival test) and short time burst test inaccordance with ASTM D-1599. Mechanical andphysical property tests of Bondstrand pipe can alsobe conducted.

Epoxy pipeBondstrand epoxy offshore products can be used for systemswhich are normally water filled without additional passive fireprotection. Fire exposure will cause the outer surface of the pipeto char, but the inner piping is able to perform, stabilized by thewater.

Epoxy pipe with intumescent coatingFor dry services where epoxy pipe is preferred, an outer layer ofpassive fire protection can be used.Intumescent coatings can be applied in the field (unreinforced)or in the factory (reinforced or unreinforced) to provide the fireendurance needed.The coating also provides very high resistance to damage andmay be considered for areas where the piping is vulnerable toimpact.

Phenolic pipeBondstrand PSX-L3 pipe can also be used in normally wet serviceand in those locations where smoke density and toxicity are ofconcern. The PSX-JF pipe is used in normally dry service (such asdeluge lines). Both products include an exterior jacket for impactresistance and enhanced fire performance.

Page 36 of 285

Our corrosion-resistant piping systems can beused in a wide range of applications.

Typical application areas are:

WIDE RANGE OFAPPLICATIONS

l Ballast water

l Caissons

l Cooling water

l Disposal

l Drains

l Drilling mud

l Fresh water

l Potable water

l Produced water

l Fire mains

l Saltwater / seawater

l Sanitary / sewage

l Column piping

l Vent lines

WIDE RANGE OFSYSTEMS*

As a leading producer Ameron offersthe worlds most comprehensiverange of glassfiber reinforced epoxyand phenolic pipe systems. Whetheryou need corrosion protection, fireprotection, or a conductive system,Ameron offers the right choice.

Bondstrand Glassfiber ReinforcedEpoxy (GRE) and Phenolic pipe seriesSizes: 25-1000 mm (140 inch)

Pressure classes: up to 25 bar (365 psi)

Internal liners: available if needed

Conductive systems: available ifneeded

Joining systems: Quick-Lock and

Taper/Taper adhesive bonded joints.

* Depending on requirements

COST COMPARISONWITH CONVENTIONALSTEEL MECHANICALSYSTEMS

BONDSTRAND CONDUCTIVE PIPING SYSTEMSBondstrand conductive piping

systems have been developed to

prevent accumulation of potentially

dangerous levels of static electrical

charges. Pipe and flanges contain

high strength conductive filaments;

fittings include a conductive liner.

Together with a conductive adhesive this

provides an electrically continuous system. If

required, grounding saddles may be installed

on the pipe once the piping system is installed.

Integral grounding cables are then bolted to

the ships structure to drain accumulated

charges.

TOTAL INSTALLED COSTEQUALSTRADITIONAL STEEL PIPINGA comparison of costsclearly shows the typicalsavings during the servicelife of the piping system.

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WO RLD WID EO P E RAT IO NWithmanufacturingfacilities in theUSA, Europe andAsia-Pacific,Ameron offers

the worlds most comprehensive line ofGRE pipe products for industry, oil & gas,offshore, marine and fuel handling.

AmeronFiberglass-Composite PipeGroupHeadquartersP.O. Box 801148Houston, TX 77280USAPhone (+1) 713 690 7777Fax (+1) 713 690 2842www.ameron.comE-mail: [email protected]

AmeronFiberglass-CompositePipe GroupEuropeAmeron B.V.P.O. Box 64190 CA GeldermalsenThe NetherlandsPhone (+31) 345 587 587Fax (+31) 345 587 561www.ameron-fpg.nlE-mail: [email protected]

AmeronFiberglass-CompositePipe GroupAsiaAmeron (Pte) Ltd.N0. 7A, Tuas Avenue 3JurongSingapore 639407Phone (+65) 8616118Fax (+65) 8621302/861 7834www.ameron.com.sgE-mail: [email protected]

AmeronFiberglass-CompositePipe GroupThe AmericasP.O. Box 878Burkburnett, TX 76364USAPhone (+1) 940 569 1471Fax (+1) 940 569 2764

This literature and the information and recommen-dations it contains are based on data reasonablybelieved to be reliable. However, such factors asvariations in environment, application or installa-tion, changes in operating procedures, or extrapo-lation of data may cause different results. Ameronmakes no representation or warranty, express orimplied, including warranties of merchantabilityor fitness for purpose, as to the accuracy, adequacyor completeness of the recommendations or in-formation contained herein. Ameron assumes noliability whatsoever in connection with this litera-ture or the information or recommendations itcontains.

LEADING PRODUCER AMERON OFFERS THE WORLDS MOST COMPREHENSIVESELECTION OF JOINING SYSTEMS FOR OFFSHORE PIPESYSTEMS

FITTINGSStandard filament-wound Couplings; 30,45, 60, and 90 Elbows; Tees and ReducingTees; Concentric Reducers; Flanges andNipples.Standard Flanges are available with thefollowing drilling: ANSI B16.5 Class 150 &300, DIN, ISO and JIS. Other drilling patternsare available on request.Available in sizes 50-1000 mm (2-40 inch)

Ameron is a leadingproducer of glassfiber-reinforced epoxy (GRE) pipesystems with manufacturingfacilities in the Americas,Europe and Asia-Pacific.Ameron offers the worldsmost comprehensive line ofGRE pipe products forindustry, oil & gas, offshore,marine and fuel handlingapplications.

CUSTOMER SUPPORTAmeron provides a highdegree of customer supportthrough a network of salesoffices, supply houses,stocking distributors andsales representatives inmore than 100 countries.This is supported by centralresearch and developmentfacilities, to meet customerrequirements.

EXPERTISE AT EVERYSTAGEAmeron offers advice atevery stage, from projectplanning to installation.With advanced software,Ameron can offer assistancein design, calculations andengineering.

WORLDWIDE APPROVALSAmeron is committed toTotal Quality Managementand conforms to theinternational ISO 9001standard and holds manytype approvals such asLloyds, DNV, ABS, BV,United States Coast Guardand UKOOA.

Ameron 2003 FP 287 D 04/03 supersedes FP 287 C 11/95. Printed in The Netherlands.

QUICK-LOCK

An adhesive-bonded joint with straight spigot and taperedbell. The integral pipe stop in the Quick-Lock bellprovides accurate laying lengths in closetolerance piping.Available in sizes 50-400 mm (2-16 in).

TAPER-TAPERAn adhesive-bonded joint with matching taperedmale and female ends offering superior jointstrength by controlled adhesive thickness.Available in sizes 50-1000 mm (2-40 in).

DOUBLE O-RINGA mechanical joint offering quick assembly betweenmale and female ends. Two O rings areemployed to provide sealing.Available in sizes 50-900 mm (2-36 in).

FLANGESOne-piece flanges and Stub-end flanges withmovable rings.Available in sizes 50-1000 mm (2-40 in).

Page 38 of 285

Ameron Engineering Services

By


Page 39 of 285

AMERONEngineering Services

AMERONAMERONEngineering ServicesEngineering Services


ApplicationEngineering

StressAnalysis

TechnicalSupportGroup

Field Service

Page 40 of 285

Application Engineering

Colin Shi+65-68656872

[email protected]

Engineering Calculations Product application advisory Preliminary MTO Preliminary design review

Application engineers+65-686568871

Stress Analysis

Allen Zong+65-68656898

[email protected]

Piping stress analysis Piping system surge analysis Piping supporting review

Dr. Lu FangFang+65-68656654

[email protected]. Alister Lok

[email protected]

Stress AnalysisPiping Engineers

+65-686568871

Page 41 of 285

Technical Support Group

KS Chong+65-68656666; +60-7-5975259

[email protected]

Pipe Spool Drawing Design (Drawing) review Material Take Off

Ms. Shoba+60-7-5975272

[email protected]. Irene Teh

[email protected]

Mr. Farid+60-7-5975244

[email protected]. Siti

[email protected]

Field Service

Oliver Ong / WH Leong+65-68656873 & 874

[email protected][email protected]

Training of bonder Construction site advisory Installation advisory Installation inspection Modification / Repair advisoryField Service Engineers

+65-686568871

Page 42 of 285

Piping Design

By

Ms. Shoba Sekaran

Page 43 of 285

Quality ServiceOn-Time Delivery

Superior Product Value

8th Piping Workshop

Speaker biographiesAugust 2009

Shoba SekaranPiping Engineer, Technical Support GroupE-mail : [email protected] : +60-7-5975 272

Shoba joined Ameron Malaysia since 21st August 2006 starting asa management trainee with Technical Support Group. She wasconverted to the position of Piping Engineer on 21st February2007. Shoba is responsible for project coordination, spool drawingchecking, MTO and calculation etc. As part of the companys effortin developing employees, Shoba is sent to Hong Kong to attendthe course on Developing Manager in You conducted by theUniversity of Michigan.

Prior to joining Ameron Malaysia, Shoba completed her bachelordegree in Chemical Gas Engineering from University TechnologyMalaysia.

Page 44 of 285

PIPING DESIGN GRE Piping & Supports

PIPING DESIGN GRE Piping & Supports

Shoba Sekaran(TSG, Manufacturing)

ObjectivesObjectives Learn the differences between GRE and

metallic piping system Proper GRE pipe support design Share and exchange experiences

Page 45 of 285

Part 1GRE Piping Design

Part 1GRE Piping Design

Key for A Success GRE Piping DesignKey for A Success GRE Piping Design Piping stress analysis Proper pipe support design

Define support span Select support type Design support structure (secondary pipe support)

Other design philosophy identical withsteel pipe

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General GuidanceGeneral Guidance Supports shall be arranged to avoid sag due to

weight of: Pipe Fluid Insulation materials Fire protection materials

Supports shall be arranged to avoid vibration: Vertical pipe Near vibration source Expose to vibration environment

General GuidanceGeneral Guidance Independent support for valves & heavy in-line

items: Weight of valve(or in-line items), flanges and bolting

materials, actuator, and so on; Prevent excessive bending moment to piping when valve is

forced to open/close

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General GuidanceGeneral Guidance Independent anchor support for hose

connection, utility station, loading stations: To avoid excessive bending stress when hose is connected

and pulled; To avoid damage caused by re-action force when sudden

release in pressure

Axial stopper for long run pipe: Potential piping movements are within control; If there is surge effect in long run pipe; Two axial stoppers (anchor) on the same straight line is not

recommended;

General GuidanceGeneral Guidance Fiberglass pipe shall NOT be used to support

other piping

Steel Pipe

GRE Pipe

Pipe Support

Page 48 of 285

Enough space is provided between support andfittings: To ensure that pipe movement is not obstructed either

axially or laterally

General GuidanceGeneral Guidance

General GuidanceGeneral Guidance Supports shall be located at common point and

location where there is strong structure, such asmain beam; To reduce construction cost. However, it might not be appropriate where few number of

lines running parallel and impose strong force to thecommon support structure

Page 49 of 285

XX

X

20

20

20

Anchor Support

Can main beam withstand anchor loads?

Main Beam

If not, what is the solution?

General GuidanceGeneral Guidance Supports shall be located at convenient and

accessible location: Shall not be exact elevation of deck penetration. Shall not be exact location of non-tight structural.

Supports shall be preferably located on plainpipe rather than at fittings or joints, as: OD of fittings/joints are greater

than pipe, special clamp designwill be required;

OD of fittings/joints arenot even;

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Change of flow direction, support span shall bereduced:L1+L2=0.6xL, where: L Partial support span (refer Ameron catalogue); L1 & L2 Support distance from support 1 and support 2 to tee or

elbow; In any case, L and L1+L2 shall not exceed 6m

LL2 L L1+L2 L

L1L L

L1


Which is the correct design? Why?

A B

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Vertical pipe loop To eliminate air trapping in the loop, vent is required at

high point. Pressure release/dump line

A guide support near the end shall be installed if there iselbow at the end of pressure release/dump line

Safety relief valve shall be properly anchored To avoid damage caused by re-action force due to

sudden pressure release.


General GuidanceGeneral Guidance End of blind end of free end shall be

supported to avoid cantilever for fiberglass piping

Supporting shall not restraint theflexibility of piping that is designed toaccommodate structural displacement

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General GuidanceGeneral Guidance Fiberglass piping will sometimes require

additional supports to minimize: bending moments. excessive stress caused by pressure surges excessive stress caused by external factors, such

as wind, acceleration, wave load, blast load, andso on.

dynamic forces caused by fluid flow

Part 2GRE Pipe Support Design

Part 2GRE Pipe Support Design

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Key for A Success GRE Pipe SupportDesignKey for A Success GRE Pipe SupportDesign Avoid direct contact between GRE

pipe and harder surface. Protection between GRE pipe and

steel clamp. Proper secondary pipe support

(support structure) design

Pipe Support DesignPipe Support Design1. Guide/Sliding Support

Protection between pipe and clamp; Maintain a gap between pipe and clamp The sample shown here is NOT suitable for strong lateral force

GAP 0-5 MM

CLAMP C/W LINING

SLIDING SHOEPOLYETHYLENE/PVC

LININGSTEELCLAMP

SECTION VIEW - CLAMPLateral Force

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Pipe Support DesignPipe Support Design2. Guide/Sliding Support

Protection between pipe and clamp; Maintain a small gap between pipe and clamp to allow axial

movement between pipe and clamp; Lining material shall be permanently fixed to clamp or restrained

by clamp

CLAMP

SPACERIF REQUIRED

0~3mm GAP

PIPE

CLAMP

LINING

LINING

Pipe Support DesignPipe Support Design3. Anchor Support

Protection between pipe and clamp; Double nuts installation, locking and preventing excessive

clamping force Gap between clamp and stopper shall not be greater than 3mm,

unless specially specified Strength of the support is IMPORTANT

SUPPORTBRACING

CLAMP0~3mm GAP

BLANKSADDLE

CLAMP C/W LINING

Secondary Support

Primary Support

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Pipe Support DesignPipe Support Design4. Flange Frame

Sufficient coverage of number of bolts; Flange frame shall be as short as possible; Reinforcement wedge plate if necessary; Bolted to flange prior to final secure to structure; It can be ANCHOR, GUIDE or REST

SUPPORTBRACING

FLANGE FRAMEC/W WEDGE PLWELDING

OR BOLTING

PIPE BODY

CLEARANCE

FLANGEFRAME

Pipe Support DesignPipe Support Design5. Rest Support

Advantage: Simple, high degree of flexibility Designed for:

Weight taking; Allow for movement / displacement

Not recommended for marine/offshore application unless it isspecially designed for allow of movement / displacement.

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Pipe Support DesignPipe Support Design6. Thrust Stopper

Thrust stopper shall be avoided.Appropriate axial stop type supportshall be designed and installed,unless there is difficulty to have axialstop type support.

The steel element must be rigid andstrong

Poor SupportsPoor Supports

FlangeFrame Anchor??

Valve??Poor

Poor

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In Summary.In Summary.1. Shorter support span to avoid sagging

due to weight.

2. Do not use GRE pipe to support otherpiping material.

3. Proper anchored at locations subject toreaction forces.

4. Protect GRE pipe against harder surface.

Q & A

Page 58 of 285

Can we place 2 anchor supports alongstraight pipe?

How to decide grounding saddle location?

Page 59 of 285

THANK YOUTHANK YOU

Page 60 of 285

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BONDSTRAND FIBERGLASS PIPING

MARINE INSTALLATION MANUAL

PROJECT REFERENCE NO.:

DOCUMENT NO.:

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Content List1 Introduction....................................................................................................................... 5

2 Reference .......................................................................................................................... 5

3 Pipe Arrangement ............................................................................................................. 6

3.1 Layout ................................................................................................................... 6

3.2 Spool breaking ...................................................................................................... 6

3.3 Conductivity and Grounding (Applicable on conductive system only)................ 6

4 Supports ............................................................................................................................ 7

4.1 General guidance .................................................................................................. 7

4.2 Support span.......................................................................................................... 8

4.2.1 Maximum Support Span ............................................................................... 8

4.2.2 Support span at Double O-Ring Expansion Joint ......................................... 8

4.2.3 Support Span at Mechanical Expansion Joint............................................. 10

4.3 Axial load on anchor support .............................................................................. 11

4.4 Support type and detail ....................................................................................... 12

4.4.1 Guide support.............................................................................................. 12

4.4.2 Fixed support (Light anchor) ...................................................................... 13

4.4.3 Anchor support............................................................................................ 13

4.4.4 Flange Frame .............................................................................................. 14

5 Receiving, Handling, Storage ......................................................................................... 15

5.1 Receiving ............................................................................................................ 15

5.2 Handling.............................................................................................................. 15

5.3 Transportation ..................................................................................................... 15

5.4 Lifting ................................................................................................................. 16

5.5 Storage ................................................................................................................ 16

5.5.1 Pipe ............................................................................................................. 16

5.5.2 Fittings ........................................................................................................ 16

5.5.3 Fabricated Spools........................................................................................ 16

5.5.4 Adhesives.................................................................................................... 17

5.5.5 Accessories ................................................................................................. 17

5.5.6 Tools ........................................................................................................... 17

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6 Installation of Fiberglass Pipe......................................................................................... 17

6.1 Adhesive bonding joint ....................................................................................... 17

6.1.1 Special Tools for adhesive bonding joint.................................................... 17

6.1.2 Bonding Procedure...................................................................................... 18

6.2 Flange assembly.................................................................................................. 18

6.2.1 Gaskets........................................................................................................ 18

6.2.2 Bolts ............................................................................................................ 18

6.2.3 Assembly..................................................................................................... 19

6.2.4 Flange mounting misalignment tolerances ................................................. 19

6.2.5 Recommended bolt torque .......................................................................... 20

6.2.6 Tightening Sequence................................................................................... 21

6.3 Double O-Ring Joint Assembly.......................................................................... 21

6.3.1 Preparation and preset................................................................................. 21

6.3.2 Insertion depth and Accessories.................................................................. 22

6.3.3 Inspection prior to assembly ....................................................................... 23

6.3.4 Assembly integral DOF DOM Joint ........................................................ 24

6.3.5 Assembly Double o-ring expansion coupling............................................. 24

6.4 Mechanical Coupling Joint Assembly ................................................................ 25

6.4.1 Preparation and preset................................................................................. 26

6.4.2 Inspection.................................................................................................... 27

6.4.3 Assembly..................................................................................................... 27

6.5 Connection to Other Materials............................................................................ 28

6.6 Connections to equipment, tanks, pressure vessels ............................................ 28

6.7 Maximum allowable misalignment tolerances ................................................... 29

6.8 Installation in Hull Block.................................................................................... 30

7 Test of Fiberglass Pipe System ....................................................................................... 31

7.1 Hydro-test ........................................................................................................... 31

7.1.1 Test general recommendations ................................................................... 31

7.1.2 Test medium and test pressure.................................................................... 31

7.1.3 Inspection, acceptance criteria, and approval ............................................. 31

7.1.4 Effect of temperature .................................................................................. 32

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7.1.5 Reinstatement.............................................................................................. 32

7.1.6 Safety .......................................................................................................... 32

7.2 Conductivity test (For Conductive System Only)............................................... 32

7.2.1 Test methods ............................................................................................... 32

7.2.2 Acceptance criteria...................................................................................... 33

8 Field Modification and Repair ........................................................................................ 34

8.1 Modification and repair procedure...................................................................... 34

8.2 Modification and repair general concerns........................................................... 34

8.3 Common modification and repair methods......................................................... 34

8.3.1 Partial replacement...................................................................................... 34

8.3.2 Over-wrap ................................................................................................... 35

8.3.3 Surface repair .............................................................................................. 36

8.4 Temporary repair ................................................................................................ 36

8.5 Other methods and solutions............................................................................... 36

9 Safety Recommendation ................................................................................................. 37

9.1 Dust Hazards....................................................................................................... 37

9.2 Chemical Hazards ............................................................................................... 37

9.3 Spill and Disposal ............................................................................................... 38

Important Notice ..................................................................................................................... 38

Copyright ................................................................................................................................ 38

Revision Notes ........................................................................................................................ 39

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1 IntroductionThis installation manual is to provide installers a comprehensive overview for installationof Ameron fiberglass pipe systems, on marine projects, such as, ships, FPSOs, DrillingUnits, Etc.

Characteristics for marine installations are, piping is arranged in confined space; and theinstallation work is significantly affected by hull structure design, fabrication anderection. Therefore it is necessary to take special precaution and follow the includedrecommendations for installation.

This manual contains material on receiving and handling, piping layout and supportprinciples. The manual also covers various types of joint assembly, followed by hydrotest and conductivity test procedures.

In case any site modification is required, or any damage on fiberglass piping systemoccurs, modification and repair recommendation are provided.

General health and safety recommendations are given in the last chapter of the manual.

2 ReferenceAME/INS-004 Hydro-testing procedure for bondstrand GRE/GRV pipeAME/INS-003 Procedure for conductivity and grounding of GRE pipeMOD-01 Modification and Repair Recommendation

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3 Pipe Arrangement3.1 Layout

Fiberglass piping shall be routed in such a way that:

- It is in accordance with specification and piping diagram;

- The number of direction change are minimized to reduce the surge effect on thefiberglass piping system;

- It allows sufficient expansion joints in appropriate locations for ship sagging andhogging effect, and also be able to accommodate minimal fabrication, erectionand installation deviation of hull structure and piping work;

- It provides for ease of installation;

- Ease of supporting. Supports can be easily located and fabricated;

- Certain flexibility is provided in the system to enable joint assembled to thecorrect dimensions without the need to pull/push a spool into position.

3.2 Spool breakingThe use of prefabricated spools shall be maximized to minimize the amount of siteadhesive jointing work. Fiberglass piping shall be broken for spooling in such a way:

- To avoid/minimize site adhesive bonding joint;

- To not exceed handling capacity of installation, and transportation equipment orfacilities;

- To make it feasible to bring the spool into position after hull-block erection;

- That no spool will protrude through the hull block after installation in block;

- That the breaking point shall be located at accessible location.

3.3 Conductivity and Grounding (Applicable on conductive system only)Ameron conductive fiberglass pipe, fittings and flanges incorporate high strengthconductive filaments to prevent accumulation of potentially dangerous levels of staticelectrical charges by the flow of liquids or other environmental causes.

Accumulated charges are harmlessly drained from the fiberglass pipe system into themetallic hull structure by means of:

- Flange connection to metallic flange of metallic piping, equipment, tanks,bulkhead penetration and so on;

- Flange frame support at fiberglass flange. The flange frame is bolted at the backof fiberglass flange, and the base of flange frame will be connected to steelstructure.

- Grounding saddle with embedded stainless steel cable, one end is bonded ontopipe surface, and the other end is bolted to steel structure.

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Sufficient electrical drainage points shall be installed to enable a completely conductivesystem.

Grounding saddles shall be mounted on the pipe section that is isolated from othermeans of electrical drainage. Mechanical coupling joints and double o-ring joints areconsidered as isolating points or conductivity breaking points.

In general, the grounding saddle shall be positioned near a support, so that theextension cable of the grounding saddle can be fixed on the support structure,avoidinig disruption to the primary hull structure.

4 Supports4.1 General guidance

Piping supports shall be arranged in such a way that:

- Supports shall be arranged to avoid sag and/or excessive vibration;

- Valves, and other heavy in line items shall be independently supported;

- Hose connections, utility or loading stations shall be supported to avoidexcessive bending stress;

- Fiberglass pipe shall not be used to support other piping;

- Enough space is provided between support and fittings to ensure that pipemovement is not obstructed either axially or laterally;

- Supports shall be located at convenient and accessible location;

- Supports shall be preferably located on plain-pipe sections rather than atfittings or joints;

- A fixed support must be located along the length of the straight pipe/spool ifits both ends are connected with unrestrained mechanical joints;

- An anchor support shall be installed between an unrestrained mechanical jointand an elbow, a tee or a reducer.

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4.2 Support span

4.2.1 Maximum Support SpanRecommended maximum spans for Ameron pipe at operating temperatures66C and below are listed below. These spans are intended for normalhorizontal piping arrangements. The tabular values are for partial span thatrepresent a compromise between continuous and simple spans.

Product Series: 2000M & 7000M

Size (mm) Span(m) Size (mm)Span(m) Size (mm)

Span(m)

1 (DN25) 3.0 10 (DN250) 6.0 26 (DN650) 6.01- (DN40) 3.5 12 (DN300) 6.0 28 (DN700) 6.0

2 (DN50) 3.8 14 (DN350) 6.0 30 (DN750) 6.03 (DN80) 4.3 16 (DN400) 6.0 32 (DN800) 6.04 (DN100) 4.9 18 (DN450) 6.0 36 (DN900) 6.05 (DN125) 5.2 20 (DN500) 6.0 40 (DN1000) 6.06 (DN150) 5.5 22 (DN550) 6.0 - -8 (DN200) 6.0 24 (DN600) 6.0 - -

Note: Consult Ameron for product series others than 2000M & 7000M.

4.2.2 Support span at Double O-Ring Expansion JointSupports shall be arranged at both sides of Double O-Ring Expansion Joint.The support shall be positioned in such a way that it will not cause obstructionto dismantling/assembly of the joint, and it provides good support for theweight effect of the joint assembly.

Double O-ringExpansion Coupling

Support Clamp

Neylon Key

Product Series: 2000M & 7000MSize A-min (m) A&B-Max (m) C-min (m)

2 (DN50) 0.23 1.0 0.303 (DN80) 0.23 1.0 0.30

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Size A-min (m) A&B-Max (m) C-min (m)4 (DN100) 0.23 1.0 0.305 (DN125) 0.25 1.0 0.366 (DN150) 0.25 1.5 0.368 (DN200) 0.30 1.5 0.4410 (DN250) 0.33 1.5 0.4612 (DN300) 0.38 1.5 0.5314 (DN350) 0.40 1.5 0.5516 (DN400) 0.43 1.5 0.5818 (DN450) 0.45 2.0 0.5420 (DN500) 0.49 2.0 0.5622 (DN550) 0.53 2.0 0.6224 (DN600) 0.55 2.0 0.6226(DN650) 0.60 2.0 0.7028 (DN700) 0.63 2.0 0.7230 (DN750) 0.63 2.0 0.7332 (DN800) 0.68 2.0 0.8236 (DN900) 0.68 2.0 0.9540 (DN1000) 1.00 2.0 0.95

Note:

A-min denotes the recommended minimum distance for Double O-ringMale (DOM) end to avoid interference between clamp and fiberglasscomponent;

A&B-max denotes the recommended maximum distance of the support;C-min denotes the minimum clearance for assembly/dismantling ofDouble O-ring Expansion Coupling;

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4.2.3 Support Span at Mechanical Expansion JointSupports shall be arranged at both sides of Mechanical Expansion Joint. Thesupport shall be positioned in such a way that it will not cause obstruction todismantling/assembly of the mechanical expansion coupling, and it providesgood support for the weight effect of the joint assembly.

Support Clamp AB

Mechined End

Product Series: 2000M & 7000MSize (mm) A-min (m) B-Max (m) Size (mm) A-min (m) B-Max (m)

50 0.35 1.0 450 0.39 2.080 0.35 1.0 500 0.42 2.0100 0.35 1.0 550 0.42 2.0125 0.36 1.0 600 0.42 2.0150 0.36 1.5 650 0.42 2.0200 0.37 1.5 700 0.42 2.0250 0.38 1.5 750 0.42 2.0300 0.38 1.5 800 - 2.0350 0.38 1.5 900 - 2.0400 0.38 1.5 1000 - 2.0

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4.3 Axial load on anchor supportWhen a mechanical joint and/or double o-ring joint is in place together with a bend,the strength of the steel structure of axial stop type support is the essential to thereliability of the piping system. The steel support shall be designed, fabricated andinstalled to withstand the full axial force (thrust) with minimal deflection.

AXIAL

DOUBLE O-RING EXPANSION JOINTOR MECHANICAL EXPANSION JOINT

ANCHORSUPPORT

Estimated Axial Force (Unrestrained Joint + Bend) at 5Bar PressureSize (mm) Axial Force (Kg) Size (mm) Axial Force (Kg)

50 155 450 507580 275 500 6040100 415 550 8200125 620 600 8475150 780 650 10150200 1540 700 11745250 2825 750 13060300 3470 800 15115350 3485 900 18825400 4310 1000 22825

Note: For other pressure ratings, the estimated axial force can be computedlinearly to the pressure. System hydro-test pressure (1.5 times of systemdesign pressure) shall be considered for support design.

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4.4 Support type and detailThe following support types are most common used for fiberglass piping system onthe shipboard and offshore projects.

4.4.1 Guide supportGuide supports permit longitudinal movement of the pipe but restrain lateralmovement. A guide support on horizontal pipe also hold the pipe againstmoving up and down. Guide supports shall be designed, fabricated andinstalled that:

- No direct contact between fiberglass pipe and steel support base/clampoccurs. Protective material such as polyethylene, or PVC, or fiberglassblank saddles shall be installed permanently;

- A gap 0~5mm shall be maintained between pipe clamp and fiberglasspipe.

- Nut locking device (Extra nut, locking washer) is recommended.

GAP 0-5 MM

CLAMP C/W LINING

SLIDING SHOEPOLYETHYLENE/PVC

LININGSTEELCLAMP

SECTION VIEW - CLAMP

Note: Where the support is exposed to strong lateral force, the U-Bolt/Clamptype guide support will NOT be recommended. In such circumstance, thetwo-half clamps shall be installed.

CLAMP

SPACERIF REQUIRED

0~3mm GAP

PIPE

CLAMP

LINING

LINING

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4.4.2 Fixed support (Light anchor)Generally, fixed supports areinstalled on straight fiberglass pipe where bothends are connected to mechanical expansion joint such as MechanicalExpansion Coupling, Mechanical Flange Adaptor, Double O-Ring ExpansionCoupling, Double O-Ring Flange Adaptor, etc. The fixed support providesrestrain to both lateral movement and axial movement. Fiberglass saddles arefixed onto fiberglass pipe as a stopper collar. The fixed support shall bedesigned, fabricated and installed that:

- No direct contact between fiberglass pipe and steel support clamp occurs.Protective material such as rubber, or polyethylene, or PVC, or fiberglassblank saddles shall be installed permanently;

- Double nuts shall be installed for clamp bots to prevent excessiveclamping force on pipe;

- Axial gap between blank saddle and steel clamp shall not be greater than3mm.

CLAMP C/W LININGPIPE CLAMP

0~3mm GAP

BLANKSADDLE

4.4.3 Anchor supportGenerally, anchor supports are installed to provide restrain to both lateralmovement and axial movement. Fiberglass saddles are fixed onto fiberglasspipe as stopper collars. Strong force is expected on an anchor support. Theanchor support shall be designed, fabricated and installed in such a way that:

- No direct contact between fiberglass pipe and steel support clamp,protection material such as rubber, or polyethylene, or PVC, or fiberglassblank saddles shall be installed permanently;

- Double nuts shall be installed for clamp bolts to prevent excessiveclamping force on pipe;

- Axial gap between blank saddle and steel clamp shall not be greater than3mm;

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- Support structure shall be strong enough to stand force caused by internalpressure, separation force generated by free joint such as Double O-RingJoint and Mechanical Expansion Joint, calculated surge and so on.

SUPPORTBRACING

CLAMP0~3mm GAP

BLANKSADDLE

CLAMP C/W LINING

4.4.4 Flange FrameFlange frames are used for supporting flanged valves and flanged heavy inlineitems independently. Flange frames can also be installed to pipe flange forother supporting purpose. The flange frame can be fully welded to structure,thus being a fixed type or anchor type support; also the flange frame can sitloose on a support base with guide bars, thus being a guide type support.

The flange frame is connected to piping with bolts, and it might be exposed tohigh axial force, thus it shall be designed, fabricated and installed that:

- It must provide clearance with pipe body;

- It is of the correct size and covers appropriate number of bolt holes;

- The plate shall not be too high, thus to minimize bending stress on steel;

- It is installed with reinforcement wedge plate if necessary;

- It shall be bolted to flange prior to being fully secured to structure.

SUPPORTBRACING

FLANGE FRAMEC/W WEDGE PLWELDING

OR BOLTING

PIPE BODY

CLEARANCE

FLANGEFRAME

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5 Receiving, Handling, Storage5.1 Receiving

Inspect all shipments of fiberglass materials and accessories and do the following:

- Verify packing list and material

- Check material for any damage

Fiberglass pipe, fittings, fabricated spools, tools, accessories shall be inspectedimmediately upon receiving and shipping agent is to be informed of any deficiency.In the event of damage or missing items, relevant parties shall be informedimmediately.

5.2 HandlingThe following recommendations are made to protect the fiberglass pipe, fittings andfabricated spools against damage:

- End protection shall remain in place during handling and transportation. Endprotection can be removed for receiving inspection, but is shall be put backimmediately.

- Fiberglass components shall be handled with care and protected from impact.Throwing, dropping, bumping or hitting the fiberglass component is prohibited.Fiberglass component shall not be dragged or pushed over sharp objects.

The use of a forklift truck is tolerated, provided that the forks are padded with carpetingor some other suitable soft material.

5.3 TransportationIt is recommended to transport fiberglass materials in their original container andoriginal packing. In case the contents of the containers would be altered, attentionshall be paid to the following:

- Do not let the fiberglass pipe and spools rest on the floor of the container wherenails, studs or other sharp objects might damage them;

- The fiberglass pipe and spools shall be securely fastened directly over thetimbers with tie-downs such as nylon straps or ropes. Do not use steel wire ropesor other sharp material, which might cause damage;

- No other materials shall be loaded on top of the fiberglass components;

- Do not drop the fiberglass products, walk or stand on them;

- When stacking 12m lengths, a minimum of 4 wooden supports must be used toseparate each length;

- Do not allow the fiberglass pipe to extend more than 2 meters beyond the truckor trailer bed to prevent excessive bowing.

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5.4 LiftingWhen the pipe and spool have to be lifted, the following has to be taken in to account:

- When mechanical lifting is required, canvas or nylon slings are to be used. Nosteel chains, wire ropes or clamps shall be used for lifting fiberglass pipecomponents;

- Pipe/spools up to 3m in length may be lifted with a crane using at least onesling. Longer sections, up to 6m in length, may be lifted with a 3m spreaderbar and two slings. Twelve-meter long sections may be lifted with a 6mspreader bar and two slings;

- Cartons can be lifted by hand or, in case of pallet cartons, by using a forklifttruck. Do not throw or drop the cartons.

5.5 Storage

Storage of piping components may be required prior to installation. Special precautionsshall be taken to avoid damage.

5.5.1 PipeFiberglass pipe may be safely stored outside for extended periods provided thefollowing recommended storage procedures be observed.

- Supports shall be spaced at 3-meter intervals and approximately not morethan 1 meter from each end. The supports should have a minimum 100mm(4-inches) wide bearing surface. The supports (timbers) used in the Ameroncontainers can be used for this purpose at the storage area.

- The pipe stack should not exceed 3m in height and should have side supportsor blocks to prevent rolling or slipping in the stack.

- It is not recommended to stack pipes directly on the ground.

- Protective end coverings must be left intact until the time of installation.

5.5.2 FittingsFittings shall be kept in cartons, stored on shelves, preferably inside awarehouse.

5.5.3 Fabricated SpoolsPipe spools are packed by Ameron to avoid damage during transportation.Spools shall be stored with temporary protection in place. If possible, spoolsshall be stored in the original packing and shipping skid. When spools arestacked after receiving inspection, sufficient wood spacers shall be placed inbetween layers.

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5.5.4 AdhesivesAdhesives shall be stored indoors at temperatures between 5C and 35C.Extended storage at higher temperatures will degrade the catalyst and the resin,and reduce adhesive strength. Avoid storage of the adhesive in direct sunlight.

Adhesive shall be kept in original packing; it shall not be stored upside down.Each adhesive kit is stamped with an expiration date. FIFO (First In First Out) isrecommended for adhesive usage.

5.5.5 AccessoriesAccessories such O-Rings, Nylon Keys, etc., shall be stored away from directsunlight and rain. The minimum storage temperature for O-Ring and Nylon Keyis 10C.

5.5.6 ToolsPipe shavers, arbors and power drive shall be kept in original toolbox after use.These tools shall be kept in dry location.

Heating blankets shall be rolled up when not in used. Heating blankets shallbe kept in box or on a rack to avoid damage from any heavy objects. Thestorage shall be away from direct sunlight and rain.

6 Installation of Fiberglass Pipe6.1 Adhesive bonding joint

Site adhesive bonding joint shall be minimized so that to facilitate an efficientinstallation. In the situation that adhesive bonding joint is inevitable, the adhesivebonding joint shall be carried out by well-trained and qualified bonder in accordancewith Ameron adhesive bonding joint procedure.

QL JOINT

INSERT

OD

LENGTHINSERT DEPTH

TAPER ANGLE

NOSETHK

TAPER JOINT

6.1.1 Special Tools for adhesive bonding jointPipe shavers to machined pipe end to required dimensions:

- B1F for 1 ~ 6 Quick-Lock Male (QLM);

- M74 for 2~16 Quick-Lock Male (QLM) & Machined End (ME);

- M86 for 2~6 Taper Male (TM);

- M87 for 6~16 QLM, TM & ME;

- M87XL for 16~24 QLM, TM & ME;

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- M88 for 26~40 QLM, TM & ME

Power Drive is the power unit to drive M74, M86, M87, M87XL & M88shavers;

Pipe Arbor is required to fix shaver (M74, M86, M87, M87XL & M88) ontopipe;

Heating Blanket to heat cured adhesive bonding joint.

Note: Refer to relevant product literature for safety and proper use of tools.

6.1.2 Bonding ProcedureBrief adhesive bonding joint procedure is as follows:

- Cut the pipe to required length;

- Shave the pipe end to required dimensions (Diameter and length forQLM; Nose thickness, Taper angle and length for TM)

- Bonding surface preparation to ensure all bonding surfaces are clean,non-glossy, fresh finish without oil and water contamination;

- Dry fit and mark alignment and reference;

- Select and mix adhesive;

- Apply adhesive to all bonding surfaces;

- Assemble the joint and remove excessive adhesive;

- Heat cure with heating blanket

- Complete necessary documentation

Note: Refer to relevant bonding procedure, or adhesive product literature fordetail guidance for adhesive bonding process and concerns, measures andprecautions for making quality bonding joint.

6.2 Flange assembly6.2.1 Gaskets

Use full-face gaskets of an elastomeric (Shore A Hardness 55~65) or othercompatible material, suitable for the service pressure, temperature and fluidsin the system. Gaskets shall be at least 3 mm thick.

6.2.2 BoltsWell-lubricated new bolts shall be used. Bolt material and treatment shall bein accordance with project technical specification. Plain washers shall beinstalled on all fiberglass flanges to prevent damage. Spring washer shall nothave direct contact with fiberglass flange.

In general, stud bolts shall be used. Bolts shall be placed only when they areready to tighten the flange joint. In the situation where it is difficult to placebolt after spool/flange placement, the bolts shall be preset in the flange.

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6.2.3 AssemblyMount lubricated washers under both nuts and bolt heads to avoid damage ofthe flange back-face. Tighten all nuts following the sequences given in"Tightening sequence";

Do not exceed the torque increments given in "Recommended Bolt Torques";

After all bolts have been tightened to the recommended torque, recheck thetorque on each bolt in the same sequence, since previously tightened boltsmay have relaxed;

Excess torque can damage the flange;

6.2.4 Flange mounting misalignment tolerancesThe alignment of the flanges is very important. Force the bolts to align amismatch flange pair will result in damage on fiberglass components and/orleaking at bonding joint. When a flange joint is assembled, the maximummisalignment shall not exceed the recommendation shown below. Otherwise,the pipe work must be rectified to correct the alignment.

Maximum Misalignment AllowanceSize

A B

Up to 16 1/16 1.6 mm 1/8 3.2 mm

18 40 3/32 2.4 mm 3/16 4.8 mm

Flange pair offset results in difficulty of bolt installation. The maximumoffsets are given in table below.

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OFFSET

6.2.5 Recommended bolt torqueTo achieve full pressure seal, bolt tightening shall achieve RecommendedTorque as minimum. To prevent damage, the bolt torque for Heavy Dutytype flange shall not be more than Maximum Torque shown in the table.

Flange size TorqueIncrementsRecommended

TorqueMaximum

TorqueInch mm N.m N.m N.m

1 4 25 100 7 27 566 8 150 200 14 41 82

10 14 250 350 14 68 15016 400 14 68 250

18 20 450 500 27 81 40022 30 550 - 750 34 102 50032 40 800 - 1000 45 210 500

Maximum Offset Allowance (mm)Size

JIS5K JIS10K DIN10 CL150

2 to 22 3.0 3.0 2.0 3.0

24 40 3.0 3.0 3.0 3.0

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6.2.6 Tightening Sequence

6.3 Double O-Ring Joint Assembly6.3.1 Preparation and preset

Inspect all connecting surfaces of fiberglass Double O-Ring to ensure thereare no scratches and damage on Double O-ring Male (DOM) end, Double O-ring Male Key (DOMK) end, and inner surface of Double O-ring Female(DOF). Clean all connecting surfaces so that there are free of oil, dirt, loosescale, and so on.

The Double O-ring Expansion Coupling shall be preset onto DOMK end. Thepreset work shall be done during block installation stage and/or prior toplacement of connection spools.

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Hul

lBlo

ckJo

int

DOMK End Double O-RingExpansion Coupling

KEY GROOVE KEY HOLE

The Double O-ring Expansion Coupling shall be preset in right direction, i.e.the key-hole side of the Double O-ring Expansion Coupling shall be at the farside of the joint.

The Double O-ring Expansion Coupling shall be secured onto pipe, and itshall be wrapped together with DOM end to prevent burning damage andimpact damage, and also to protect against contaminated of dirt and debris.

6.3.2 Insertion depth and AccessoriesRefer to below table for standard insertion depth, O-ring size and Nylon-Keysize.

OSO

NYLON KEY O-RINGS

Size(mm/Inch)

DOMInsertion(Os) mm

DOMKInsertion(O) mm

O-Ring Nylon Key

50 2 81 91 7 x 59.7 6 x 30580 3 81 91 7 x 88.3 6 x 400100 4 81 91 7 x 113.7 6 x 483125 5 102 112 9 x 135 8 x 580150 6 105 115 10 x 161.3 8 x 660200 8 138 149 10 x 225 10 x 840250 10 148 158 12.5 x 302 12 x 1270300 12 175 185 12.5 x 342.3 15 x 1270350 14 185 195 12.5 x 342.3 15 x 1360

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Size(mm/Inch)

DOMInsertion(Os) mm

DOMKInsertion(O) mm

O-Ring Nylon Key

400 16 195 205 12.5 x 393.1 18 x 1585450 18 178 188 15 x 445 15 x 1750500 20 186 197 15 x 490 15 x 1930550 22 210 220 18 x 556 18 x 2100600 24 210 220 18 x 580 18 x 2240650 26 247 257 18 x 622.3 18 x 2510700 28 250 260 20 x 685 20 x 2700750 30 257 267 20 x 740 20 x 2700800 32 292 302 20 x 790 20 x 3065900 36 347 357 25 x 890 25 x 31751000 40 340 350 26 x 987 20 x 3500

6.3.3 Inspection prior to assemblyTo ease installation, to obtain proper assembly, and to avoid unnecessarystress to Double O-ring Joint and its component, following dimensionalcriteria shall be inspected prior to final assembly:

50 20 (FOR 8"-40")

BEFORE INSTALLATION

E

50 10 (FOR 2"-6")

Gap between connecting pipes (For Double O-ring Coupling joint), thegap shall be 50mm for standard design, the tolerance is 10mm forpipe size 6(DN150) and below, and 20mm for pipe size 8(DN200)and above;

Offset between connecting pipes shall be within allowable tolerancespecified in table below;

DOR Joint Allowable OffsetPipe Size Range (mm) Offset (mm)

2-5 (DN50-125) 3.0

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DOR Joint Allowable Offset6-8 (DN150-200) 4.0

10-12 (DN250-300) 5.014-16 (DN350-400) 4.018-20 (DN450-500) 6.022-40 (DN550-1000) 5.0

All connecting surfaces are in good condition without scratches and/orstructural damage;

6.3.4 Assembly integral DOF DOM JointWhen ready to joint the pipe, remove the dirt and debris from o-ring groovesusing compressed air, a clean rag or a paintbrush;

Brush or rub a layer of Vynoleo grease into o-ring grooves, pipe end, andmale end surface, and all inside surfaces of the female end. (Apply lubricantonly when you are ready to assemble the joint) Keep lubricated surfaces cleanand free of sand and dirt.

Lubricate entire surface of o-rings and slip them into both grooves on the maleend, distribute each o-ring evenly in the groove by slipping a screwdriverunder them and sliding the screwdriver around the joint;

Mount band clamps (with D-rings) a convenient distance on each side of thejoint, hook up band clamps with come-a-longs or lever hoists;

Tighten the come-a-longs or lever hoists to pull mating pipe to join togetheruntil the center scribe line is aligned with the leading edge of the female end.

LEADING EDGE

A A

MIN. INSERTTARGET MAX. INSERT

C

AFTER INSTALLATION

6.3.5 Assembly Double o-ring expansion couplingWhen ready to joint the pipe, remove the dirt and debris from o-ring groovesand inner surface of Double o-ring expansion coupling using compressed air,a clean rag or a paintbrush;

Brush or rub a layer of Vynoleo grease into o-ring grooves, key groove, pipeend, and male ends surface, and inner surface of the Double o-ring expansion

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coupling. (Apply lubricant only when you are ready to assemble the joint)Keep lubricated sur

8th Ameron Asia Piping Workshop

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