Bondstrand bonder training, rev 0 (ptsc m&c)

Bondstrand Bonder Training

Fiberglass Pipe

Contents

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

Bondstrand Bonder Training for
PTSC M&C - 2009 2

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
PTSC M&C - 2009 3

Part-1 : General

Achievements : Trainee must complete
below points to get certificate
 Understanding AMERON’s Bondstrand
Products
 Understanding product data and QC form
 Pass hydrotest on practice

PTSC M&C - 2009 4

Part-1 : General

Bonding certificate
 Issued by AMERON to trainee who pass
hydrotest on spool practice
 2-year validity

PTSC M&C - 2009 5

Part-2 : AMERON’s Bondstrand Products
Abbreviations
 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)
PTSC M&C - 2009 6

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
PTSC M&C - 2009 7

Filament-wound pipe & fittings with
advanced resins
 Epoxy (GRE)
 Vinylester (GRV)

Bondstrand Product Lines
 Bondstrand 2000/2000M
 Bondstrand 7000/7000M
 Bondstrand 2400/3400 series
PTSC M&C - 2009 8


Bondstrand 2000
A lined epoxy system
for applications where
corrosion resistance
and light weight are of
paramount
importance.
PTSC M&C - 2009 9


Bondstrand 2000M
A lined epoxy system
for applications where
corrosion resistance
and external pressure
are of paramount
importance.

PTSC M&C - 2009 10


Bondstrand 7000/7000M
An epoxy system with
conductive elements
Unique patented pipe saddle drains
incorporated in the wall
off static charge build-up
of the pipe to prevent
accumulation of static
electricity produced by
the flow of liquids inside,
Design equal to Bondstrand and external effects
2000/2000M
outside the pipe.
PTSC M&C - 2009 11


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
PTSC M&C - 2009 12


PTSC M&C - 2009 13


Joining System
Quick-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”)
PTSC M&C - 2009 14


Joining System
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.
PTSC M&C - 2009 15


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.
PTSC M&C - 2009 16


Joining System
Butt & Wrap Joint
A lamination joint. Available
in sizes: 25-1000 mm (1”-
40“).
 Time costly.
 Versatile. Most use on repair.

PTSC M&C - 2009 17


Adhesive System
RP-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

PTSC M&C - 2009 18


Adhesive System
RP-60B
A two-part thermosetting,
electrically conductive epoxy
resin system
 Conductive
 Use on Quick-Lock joint and
Taper/Taper joint

Bondstrand Bonder Training for oz. kit
PTSC M&C - 2009 19


Adhesive System
RP-48
A two-part amine cured
epoxy resin system
 Non-conductive
 Use on Taper/Taper joint
oz. kit

PTSC M&C - 2009 20


Tools & Equipment
 Special Tools
 Pipe Shaver & Power Drive
 Heating Blanket
 Other Accessories
 Band Clamp
 Lever Hoist
 Bore Polisher (Flapper Wheel)
 Common Pipe Tools
PTSC M&C - 2009 21

Special Tools – Pipe Shaver & Power Drive
!!! 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”

 To individual size only;
 Straight Spigot (For Quick-
Lock Joint) only.
 Driven by common electrical
tools or air tools, such as hand Cutting Insert
drill.
For detail guide, See FP376F, ‘Ameron B-1F Pipe End Preparation Tool’
PTSC M&C - 2009 22


 M-74 Shaver
 For 2” – 16” pipes
 Use with arbor set
 Straight Spigot (For
Quick-Lock Joint) only.
 Driven by hand or
electrical tools
(RIDGID-700).

For detail guide, See FP696A, ‘M-74 Pipe Shaver’
PTSC M&C - 2009 23


 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.

PTSC M&C - 2009 24

Special Tools – Heating Blanket
!!! 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
PTSC M&C - 2009 25


 Description of Heating Blanket

PTSC M&C - 2009 26


 Using Heating Blanket
 Wrap the pipe using the
end with thermostat;
 Tie down accessory
shall be used;
 Do NOT pull the cable;

PTSC M&C - 2009 27

 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;

PTSC M&C - 2009 28

Other Accessories
 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

PTSC M&C - 2009 29

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
PTSC M&C - 2009 30

Common Piping Tools
There are many other common piping tools might be
required for fiberglass piping fabrication and installation
work, such as:
 Hacksaw or abrasive wheel;  Cotton Roller;
 Paint marker;  Adjustable Pipe Stands;
 Pipe wraparound;  Sanding Disc;
 Baby grinder;  Screw Driver;
 Electric or Air drill;  Scissors;
 Level Gauge;  Air Release Roller;
 Paint Brush;  ……
 Nylon/Rubber Mallet;
PTSC M&C - 2009 31

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

PTSC M&C - 2009 32

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
PTSC M&C - 2009 33

Chemical and Dust Hazards
!!! 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;
PTSC M&C - 2009 34

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.
PTSC M&C - 2009 35

Receiving and Handling

!!! 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
PTSC M&C - 2009 36

Good Receiving Inspection
 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.
PTSC M&C - 2009 37

Handling and Transportation
 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.
PTSC M&C - 2009 38

Handling and Transportation

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

PTSC M&C - 2009 39

Storage
!!! 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.

PTSC M&C - 2009 40

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.
PTSC M&C - 2009 41

Part-4 : Fabrication and Installation

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

PTSC M&C - 2009 42

Drawings
 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
Bondstrandinformation, materials specification.
Bonder Training for
PTSC M&C - 2009 43

Sample Drawing – Spool 1

PTSC M&C - 2009 44


PTSC M&C - 2009 45


PTSC M&C - 2009 46

Sample Drawing – ISO

PTSC M&C - 2009 47

Sample Drawing – Layout

PTSC M&C - 2009 48

Product data & Pipe length Calculation

 Product data
 Assembling dimension of fittings

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

Exercise : calculate pipe length.

PTSC M&C - 2009 49

QC Form : Log sheet

 To record bonding history for fabrication and site
installation
 Part of QC documentation

PTSC M&C - 2009 50

Fabrication and Installation Tolerances

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

PTSC M&C - 2009 51

Recommended Fabrication Tolerances

1. Face/center to face/center
dimension, or location of
attachment
2. Lateral translation of branch or
connection
3. Rotation of flange
4. End preparation
5. Alignment of flange face
6. Angular deflection
7. Reference: ISO14692-4:2002

PTSC M&C - 2009 52

Recommended Fabrication Tolerances

DN Tolerances / Dimension Number
(Inch) 1 (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.
PTSC M&C - 2009 53

Hook-up to Equipment / Other Material

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.
PTSC M&C - 2009 54

Part-5 : Hydro-testing

 Fabricated Spool Testing
 System Hydro-testing

PTSC M&C - 2009 55

Fabricated Spool 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”
 …….

PTSC M&C - 2009 56

System Hydro-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;

PTSC M&C - 2009 57

 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;

PTSC M&C - 2009 58

 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
PTSC M&C - 2009 59

 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”
PTSC M&C - 2009 60

Bondstrand bonder training, rev 0 (ptsc m&c)

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Bondstrand bonder training, rev 0 (ptsc m&c)