Elastopipe System Manual Revision

7/21/2019 Elastopipe System Manual Revision

http://slidepdf.com/reader/full/elastopipe-system-manual-revision 1/60



System Manual

2



System Manual

3

CONTENTS

1 INTRODUCTION 4

1.1 PURPOSE OF MANUAL 4

2 GENERAL INFORMATION 52.1 SYMBOLS AND CONVENTIONS 5

2.2 SAFETY NOTES 5

2.3 ABBREVIATIONS 5

3 TECHNICAL DESCRIPTION 6

3.1 6

4 TRANSPORT AND HANDLING 8

4.1 TRANSPORT 8

4.2 HANDLING 9

5 PREPARATION AND INSTALLATION OF 10

5.1 WORK PROCESS 10

5.1.1 Unpacking and preparation 11

5.2 SUPPORT 12

5.2.1 Denitions 12

5.2.2 Design Criteria - Dimensioning Loads 13

5.2.3 Fastening to Structure 14

5.2.4 Primary Support 15

5.2.4.1 Design Models for UNO-proles for primary Supports 15

5.2.5 Secondary Support 17

5.2.6 Design of Supports 20

5.2.7 Design Example 1 22

5.2.8 Design Example 2 25

5.2.9 Max Span for UNO-proles 28

5.2.10 Primary Support Bracket Design 34

5.3 INSTALLING 40

5.3.1 Cutting 40

5.3.1.1 Cutting using an air driven, slow moving band saw with water ushing 40

5.3.1.2 Cutting using Tiger saw/Bayonet saw 41

5.3.1.3 Cutting using a hacksaw 415.3.2 Jointing 42

5.3.2.1 Preparation of passive Fire Protection for joints 42

5.3.2.2 Installing Pipe Fittings 43

5.3.2.3 Fitting a nozzle clamp on 48

5.3.2.4 Operating the Band-It Machine 50

5.3.2.5 Mounting ConNect Clamps 54

5.3.2.6 Heat Tracing 56

5.3.4 Mounting 57

5.4 CHECKING 58

5.4.1 Pressure Testing 585.4.2 Full scale function testing 58

6 MAINTENANCE, REPAIRS AND MODIFICATION 59



System Manual

4

1 INTRODUCTION

1.1 PURPOSE OF MANUAL

The purpose of this manual is to provide installation guidance for the System,

as supplied by Trelleborg Offshore.

The manual is intended to give the user sufcient technical information and data to be able to

understand the functions and features of the System, together with the neces-

sary transport,

handling, commissioning, maintenance and installation information.

The manual shall also be used as a textbook for training of installation crew.



System Manual

5

2 GENERAL INFORMATION

2.1 SYMBOLS AND CONVENTIONS

The following words and symbols found throughout this manual mark special messages to alert

the operator of specic information concerning of the PERSONNEL, the EQUIPMENT or the

PROCESS.

The WARNING symbol draws attention to potential danger for personnel

(including possible loss of life) and considerable damage to equipment if the

instructions are not followed correctly.

The CAUTION symbol draws attention to potential danger of damage to equipment,

if the instructions are not followed correctly.

The NOTE symbol draws attention to additional clarifying information or special

instructions which are also crucial for equipment or to the installation performed.

The QUALITY symbol draws attention to operations where quality inspections

must be performed.

2.2 SAFETY NOTES

The WARNING symbol as a Safety Note draws attention to installer’s responsibili ty

to identify any possib le danger and take necessary precautions to avoid serious

personal injury or equipment damage.

2.3 ABBREVIATIONS

Abbreviation Explanation

mm - millimetres

" - inches

kg - kilogram

TM - Trade Mark

TO - Trelleborg Offshore



System Manual

6

3 TECHNICAL DESCRIPTION

3.1

is made of synthetic rubber and replaces rigid steel, titanium and glass-bre

reinforced plastic piping. is delivered in pipe sizes from 1" to 8" and in lengths of

up to 15 metres. All sleeves and tees for extensions are supplied in titanium. is a

exible piping system, which is easy and safe to t, and has the following unique properties:

• No corrosion

• Jet re resistant

• Impact resistant

• Minimizes water hammer effects

• Explosion resistant• Frost resistant

• Maintenance free

• No welding or hot work necessary

These properties make ideal for the piping of deluge and sprinkler systems for

offshore oil and gas installations, ships, industrial plants, buildings, mines, etc.

There are different ways to support . The most common methods are:

• UNO Channels• Cable trays

• Duo Clamps (when using existing pipes for support)

is a unique piping system and can therefore be put into use in a variety of

unconventional surroundings where exibility is necessary.

The system has many unique joint and connection solutions. Examples of an

system with joints and connections are shown on the following page.

For detailed technical information see chapter 7 in addition to the following documents:

• 89101-001 “Specic Requirements – ELASTOPIPE™ FR “.

• 89101-006 “Specic Requirements – ELASTOPIPE™ FOR”.

• 89101-002 “AP01EP Piping Specications – ELASTOPIPE™ FR “.

• 89101-002 “AP02EP Piping Specications – ELASTOPIPE™ FOR “.

• 89106-003 “Test Spec ELASTOPIPE™ FR”

• 89106-007 “Test Programme ELASTOPIPE™ FOR”

• 89101-008 “ELASTOPIPE FOR - Test Summary”

• 89106-085 “Support manual”



System Manual

7

End Cap

End Cap

Support

4”

Reducing or

straight Tee

6”

Flange Connec-

tion

Commonly used Fit-

tings and Couplings

Straight Connection

with Band-It

(shown enlarged with-

out re protection).

Straight Connector

with Nozzle Adapter

2”

Reduced or straight

X-Connector

2”

1”

Nozzle Adaptor

(shown enlarged with-

out re protection).

4”

End Connection with Nozzle

adapter and inspection Plug

(shown enlarged without re

protection).



System Manual

8

4 TRANSPORT AND HANDLING

4.1 TRANSPORT

Al l ti tanium parts must be stored dry and NOT together wi th other materials.

can be bent to 5D, but avoid breaking and buckling.

Preassembled is

transported and stored in baskets.Fittings and mounting materials are

transported and stored on pallets.The protection on preassembled

ttings should be kept on during all

transport and handling.



System Manual

9

4.2 HANDLING

Al l li fting operat ions shal l be done according to local lif ting procedures, surveyedby certied operators.

Both single pipes and bundles of pipes can be lifted positioned horizontally using soft slings.

Maximum distance between soft slings are 3 metres.

Straps in the end of pipes can lift both single

and bundles of pre-assembled

pipes positioned vertically.

During lifting of vertically positioned pipes,

the strap must be secured by lashing the strap

around the pipes twice,

and with double strapping.



System Manual

10

5 PREPARATION AND INSTALLATION OF

5.1 WORK PROCESS

1. Brieng installation crew

in actual project

2. Supporting methods,

Chapter 5.2

3. Cutting ,

Chapter 5.3.1

4. Applying sealant,

Chapter 5.3.2.2

5. Preparation of passive

re protection,

Chapter 5.3.2.1

6. Installation of pipe ttings,

Chapter 5.3.2.2

7. Installing Band-It bands,

Chapter 5.3.2.4

8. Control

Chapter 5.3.2.4

9. Mounting ConNect Clamps

Chapter 5.4.2.5

10. Installation of nozzleclamps,

Chapter 5.3.2.3

11. Fitting ends to 12. Mounting ,

Chapter 5.3.4



System Manual

11

5.1.1 Unpacking and preparation

This section provides guidelines for unpacking and preparation of once it has

arrived at the installation site.

The following instructions apply when is removed from its storage and transpor-

tation protection:

If possible, keep in its packed condition prior to installation.

Packaging material is the customer’s property and should be disposed of in an

environmentally safe manner.

1. Remove the packing that covers .

The pipes are stable so there is no danger of uncontro lled movement during

removal of packing materials.

2. Remove packing material from installation parts and tools.

Make sure that the content of the package tally with the packing list , which is included.

Conduct a thorough visual inspection of every component and tool. Be particularly

aware of loose or broken components. Make sure that mechanical/electrical tools

function as expected.

Report any damage or discrepancies, enclosing a copy of the packing list.

is made of exible composite materials and can be installed in a different man-

ner than other conventional piping systems.

The pipes are not subject to thermal expansion so expansion loops are not necessary.



System Manual

12

5.2 SUPPORT

NO HOT WORK: Since all installation of can be done without hot

work, welding of supports should be avoided. Only installation requiring cold

work are recommended.

Support systems for both replacement of existing pipes and installation on new

builds are included. For replacement work the reuse of existing support is

favourable, and should be the preferred choice.

To reduce the consumption of support materials, and to make installation in

narrow areas easier, the use of support should be reduced to a minimum by

fastening directly to the structure or primary support.

5.2.1 Denitions

Primary Support is dened as

existing pipe supports, angle iron,

UNO-channels (mainly for diago-

nal struts) or Multigrid.

Fastening to structural steel with

beam clamps, bolts in drilled holes or

direct fastening with nails or studs.

is fastened to the second-

ary support with pipe rings, bow clamps,

straps or Duo-clamps.

Secondary support is made of

UNO-channels, cable ladders or

by using existing piping.



System Manual

13

5.2.2 Design Criteria - Dimensioning Loads

is exible and the elastic material dampens the effect of explosion,

impacts and water hammer. The support should be designed to allow the

dampening, but also to allow draining and avoid sagging.

h

F

F

Span

Secondary

supportPrimarysupport

Structural Steel

F

In most cases explosion is the dimensioning load in support cal-

culation. Typical Design Accidental Load (DAL) of 0,25 - 0,6 bar

is normally dominating compared to the load contributions from

weight, wind and water hammer.

Normally the weight of and

support only contribute to the dimensioning

of the support when the pipes are lled with

water.

An installationshall have a nice, robust ap-

pearance without sagging and

water pockets. The principle of

free hanging pipe with minimum

support to allow dampening often

contradicts this.

Water hammer effects (transient)

can be damaging to pipes and sup-

port, but are dampened consider-

ably by .

The loads from water hammer

effects are only considered in spe-

cic project and design cases.

Wind loads are nor-

mally negligible.

If climbing is performed in the area

with installed, and

any risk that the pipes may be

stepped on or hanged in, the sup-

ports can be designed and installed

to allow this without sagging.

Normally

withstands impacts and

rough physical handling bet-

ter than the support.



System Manual

14

5.2.3 Fastening to Structure

All installation of can be made without hot work. Fastening

methods which do not include welding or other hot work are recommended.

Using bolts is the common way to fasten

supports.

Bolts should always be secured.

Supports can also be fastened directly

to structure with nails or studs.

Fastening should always be made ac-

cording to local requirements.

Fastening with beam clamps.

Beam clamps must always be secured

against sliding and twisting by use of

double bolts, lock nuts and clamps on

both sides.

.

Use isolation in joints to to avoid galvanic corrosion!



System Manual

15

5.2.4 Primary Support

Traditional pipe supports made of angle iron are suitable as primary support for

, but stainless systems (e.g. UNO channels) with standard

prefabricated components are available and recommended.

In retrot projects it is recommended to use the

existing support and bolt holes.



System Manual

16

5.2.4.1 Design Models for UNO-proles for primary Supports

● Fixed - Fixed

● Fixed - Hinged

● Hinged - Hinged

● Fixed - Free (Cantilever)



System Manual

17

5.2.5 Secondary Support

Max 100 mm

Locking nut

The clamp bolts must be secured with lock

nuts.

Do not tighten the clamp bolts more than necessary to

obtain a rm grip around the pipe without deforming,

leaving a gap between the two clamp halves.

For self draining, always

mount pipes slooping (2%).



System Manual

18

When ladders are used as

secondary support, and the ex-

plosion load is the dimensioning

force, pipe clamps are used for

every 4th stage.

Ladders are fastened with brack-

ets for every 3rd meter.

When the dimensioning force is

stronger than the explosion load,i.e. loads from water hammer,

clamps on every second stage of

the ladder is recommended.

Around corners max distance be-

tween clamps should not exceed

1300 mm.



System Manual

19

Typical use of cable ladders for sup-port of piping.

In retrot projects the existing

pipe can be used as secondary

support, and isfastened with Duo-clamps.

Existing cable ladders are suitable

for support of piping.



System Manual

20

5.2.6 Design of Supports

The owchart describes how to design the support:

Blast load F ........ bar

Pipe dim. (inches) .............

Input from customer

Max load on primary support ........... kg

Design Model .....................

Max span for seondary support ............. mm

Input from Table 5.1 - 5.11

Select typeof primary support

Height of primary support ........... m

Input from tables

5.12 - 5.17

Within limits Outside limits

Construct a primary support

based on figures in

table 5.12 - 5.17

A special designed primary

support has to be constructed



System Manual

22

5.2.7 Example 1

h 1,0 m

F

F

Max span

Pipe dimension 4”

F = 0,3 bar

Support

to be

designed

The routing for a 4” is 1,0 meter below the deck structure, and we are informed

that blast load is 0,3 bar in the area. This information is lled into the owchart:


Pipe dim. (inches) .............

Input from customer



System Manual

23

This information is used to nd the max load (kg) allowed on the primary support, in the right

hand column of table 5.2. Single or double UNO can be used. In this example the simplest to be

allowed is single UNO, and the corresponding load (876 kg) is lled into the owchart. The “De-

sign Model” (Fixed-xed, Fixed-hinged, Hinged-hinged or Fixed-free (cantilever)) and the corre-

sponding “Max span for secondary support” are also lled into the owchart. In our example the

max span for a xed-xed is 3300 mm:

Example from table 5.2

Secondary SupportPrimarySupport

Max span for UNO-proleDistance center to center [mm]

Blast load = 0,30 bar

UNOProle

IDFixed-xed Fixed-

hingedHinged-hinged Cantilever

Max load on pri-mary support (kg)

U-41-1-PSingle

1 6000 3500 2000 500

1,5 5200 3000 1700 400

2 4700 2800 1500 300

3 3900 2300 1300 300

4 3300 1900 1100 200

U-41-2-PDouble

1 7400 4300 2400 600

1,5 6600 3900 2200 500

2 6200 3600 2000 500

3 5300 3100 1700 400

4 4700 2800 1500 300

6 3900 2300 1300 300

8 3300 1900 1100 200

Max load onprimary support........... kg

Design Model .....................Max span for seondarysupport .............. mm

Input from Table ..........



System Manual

24

The next step is to select the type of primary support from tables 5.12-5.17. The principle is to

choose the simplest conguration that the height of the primary support (h) and “max load” al-

lows. In our example this is conguration 5.1B, a single UNO prole with one bracing:


All bracing single UNO or similar Part no.

Name of member Height h (m) Max. Load F (kg)

B

K10-400-P-SS

or similar

1,0 2629

1,4 1341

1,8 811



Input from tables

5.12 - 5.17



System Manual

25

5.2.8 Example 2

h 1.4 m

F

F

Max span

Pipe dimension 6”

F = 0,6 bar

Supportto bedesigned

The routing for a 6” is 1,4 meter below the deck structure, and we are informed

that blast load is 0,6 bar in the area. This information is lled into the owchart:


Elastopipe ID ............. inches

Input from customer



System Manual

26





UNOProle

IDFixed-xed Fixed-



U-41-1-P

Single

1 4200 2500 1400 300

1,5 3600 2100 1200 300

2 3300 2000 1100 200

3 2700 1600 900 200

4 2300 1400 700 100

U-41-2-P

Double

1 5200 3100 1700 400

1,5 4700 2700 1500 300

2 4400 2600 1400 300

3 3800 2200 1200 300

4 3300 1900 1100 200

6 2800 1600 900 200

8 2300 1400 700 100

Max load onprimary support........... kg

Design Model .....................

Max span for seondarysupport .............. mm

Input from Table ..........



System Manual

27

Example from Table 5.12



C

K10-400-P-SS

or similar

1,4 2683

2,0 1315

2,5 841



Input from tables5.12 - 5.17

This means that this primary support can be a 1,4 m single UNO prole with double bracings,

mounted with minimum distance of 1600 mm from the next primary support.



System Manual

28

5.2.9 Max span for UNO-proles

The tables below documents the max span that can be achieved using UNO-proles as primary

support.

Table 5.1




UNOProle

IDFixed-xed Fixed-



U-41-1-P

Single

1 6600 3900 2200 5001,5 5700 3300 1900 400

2 5200 3100 1700 400

3 4300 2500 1400 300

4 3600 2100 1200 300

U-41-2-P

Double

1 8100 4800 2700 600

1,5 7200 4300 2400 600

2 6800 4000 2200 500

3 5900 3400 1900 400

4 5200 3000 1700 4006 4300 2500 1400 300

8 3600 2100 1200 300



System Manual

29

Table 5.2




UNOProle

IDFixed-xed Fixed-



U-41-1-PSingle

1 6000 3500 2000 500

1,5 5200 3000 1700 400

2 4700 2800 1500 300

3 3900 2300 1300 300

4 3900 1900 1100 200

U-41-2-PDouble

1 7400 4300 2400 600

1,5 6600 3900 2200 500

2 6200 3600 2000 500

3 5300 3100 1700 400

4 4700 2800 1500 300

6 3900 2300 1300 300

8 3300 1900 1100 200

Table 5.3




UNOProle

IDFixed-xed Fixed-



U-41-1-P

Single

1 5600 3300 1800 4001,5 4800 2800 1600 400

2 4400 2600 1400 300

3 3600 2100 1200 300

4 3100 1800 1000 200

U-41-2-P

Double

1 6800 4000 2200 500

1,5 6100 3600 2000 500

2 5700 3400 1900 400

3 4900 2900 1600 400

4 4300 2600 1400 3006 3600 2100 1200 300

8 3100 1800 1000 200



System Manual

30

Table 5.4




UNOProle

IDFixed-xed Fixed-



U-41-1-P

Single

1 5200 3100 1700 400

1,5 4500 2600 1500 300

2 4100 2400 1300 300

3 3400 2000 1100 200

4 2900 1700 900 200

U-41-2-P

Double

1 6400 3700 2100 600

1,5 5700 3400 1900 500

2 5400 3200 1800 500

3 4600 2700 1500 400

4 4100 2400 1300 300

6 3400 2000 1100 300

8 2900 1700 900 200

Table 5.5




UNOProle

IDFixed-xed Fixed-



U-41-1-P

Single

1 4900 2900 1600 4001,5 4200 2500 1400 300

2 3900 2300 1300 300

3 3200 1900 1000 200

4 2700 1600 900 200

U-41-2-P

Double

1 6000 3500 2000 500

1,5 5400 3200 1800 400

2 5000 3000 1600 400

3 4300 2600 1400 300

4 3800 2200 1200 3006 3200 1900 1000 200

8 2700 1600 900 200



System Manual

31

Table 5.6




UNOProle

IDFixed-xed Fixed-



U-41-1-P

Single

1 4600 2700 1500 300

1,5 4000 2300 1300 300

2 3700 2100 1200 300

3 3000 1800 1000 200

4 2600 1500 800 200

U-41-2-P

Double

1 5700 3300 1900 600

1,5 5100 3000 1700 500

2 4800 2800 1600 500

3 4100 2400 1300 400

4 3600 2100 1200 300

6 3000 1800 1000 300

8 2600 1500 800 200

Table 5.7




UNOProle

IDFixed-xed Fixed-



U-41-1-P

Single

1 4400 2600 1400 3001,5 3800 2200 1200 300

2 3500 2000 1100 200

3 2900 1700 900 200

4 2400 1400 800 200

U-41-2-P

Double

1 5400 3200 1800 400

1,5 4900 2900 1600 400

2 4600 2700 1500 300

3 3900 2300 1300 300

4 3500 2000 1100 200

6 2900 1700 900 200

8 2400 1400 800 200



System Manual

32

Table 5.8




UNOProle

IDFixed-xed Fixed-



U-41-1-P

Single

1 4200 2500 1400 300

1,5 3600 2100 1200 300

2 3300 2000 1100 200

3 2700 1600 900 200

4 2300 1400 700 100

U-41-2-P

Double

1 5200 3300 1700 400

1,5 4700 3000 1500 300

2 4400 2800 1400 300

3 3800 2400 1200 300

4 3300 2100 1100 200

6 2800 1800 900 200

8 2300 1500 700 100

Table 5.9




UNOProle

IDFixed-xed Fixed-



U-41-1-P

Single

1 4100 2400 1300 3001,5 3500 2100 1100 200

2 3200 1900 1000 200

3 2600 1500 800 200

4 2200 1300 700 100

U-41-2-P

Double

1 5000 2900 1600 400

1,5 4500 2600 1500 300

2 4200 2500 1400 300

3 3600 2100 1200 300

4 3200 1900 1000 2006 2700 1600 900 200

8 2200 1300 700 100



System Manual

33

Table 5.10




UNOProle

IDFixed-xed Fixed-



U-41-1-P

Single

1 3900 2300 1300 300

1,5 3400 2000 1100 200

2 3100 1800 1000 200

3 2500 1500 800 200

4 2100 1300 700 100

U-41-2-P

Double

1 4800 2800 1600 400

1,5 4300 2500 1400 300

2 4000 2400 1300 300

3 3500 2000 1100 200

4 3100 1800 1000 200

6 2600 1500 800 200

8 2100 1300 700 100

Table 5.11




UNOProle

IDFixed-xed Fixed-



U-41-1-P

Single

1 3800 2200 1200 3001,5 3300 1900 1100 200

2 3000 1700 1000 200

3 2400 1400 800 200

4 2100 1200 700 100

U-41-2-P

Double

1 4600 2800 1600 300

1,5 4200 2400 1400 300

2 3900 2300 1300 300

3 3400 2000 1100 200

4 3000 1700 1000 2006 2500 1400 800 200

8 2100 1200 700 100



System Manual

34

5.2.10 Primary Support Bracket Design

The primary support brackets can be constructed in the following congurations:

Table 5.12 Primary Support Bracket Designs, Single UNO-prole



A

K10-400-P-SSor similar

0,2 1000

0,4 500

B

K10-400-P-SS

or similar

1,0 2629

1,4 1341

1,8 811

C

K10-400-P-SS

or similar

1,4 2683

2,0 1315

2,5 841



System Manual

35

Table 5.13 Primary Support Bracket Designs, Double UNO-prole



A

K20-600-P-SS

or similar

0,35 1500

0.67 750

B

K20-600-P-SS

or similar

1,0 2629

1,4 1341

1,8 811

C

K20-600-P-SS

or similar

1,4 2683

1,8 1623

2,5 841



System Manual

36

Table 5.14 Primary Support Bracket Cradle Design, Single UNO-prole



A

K10-400-P-SS

or similar

0,2 2000

0,4 1000

B

K10-400-P-SS

or similar

1,0 2629

1,4 1341

1,8 811

C

K10-400-P-SS

or similar

1,4 2683

1,8 1623

2,5 841



System Manual

37

Table 5.15 Primary Support Bracket Ladder Design, Single UNO-prole



A

K10-400-P-SS

or similar

0,2 2000

0,4 1000

B

K10-400-P-SS

or similar

1,0 2629

1,4 1341

1,8 811

C

K10-400-P-SS

or similar

1,4 2683

1,8 1623

2,5 841



System Manual

38

Table 5.16 Primary Support Cradle Designs, Double UNO-prole



K20-600-P-SS

or similar

0,33 2000

0.67 1500

K20-600-P-SS

or similar

1,0 2629

1,4 1341

1,8 811

K20-600-P-SS

or similar

1,4 2683

1,8 1623

2,5 841



System Manual

39

Table 5.17 Primary Support Ladder Designs, Double UNO-prole



K20-600-P-SS

or similar

0,33 2000

0.67 1500

K20-600-P-SS

or similar

1,0 2629

1,4 1341

1,8 811

K20-600-P-SS

or similar

1,4 2683

1,8 1623

2,5 841



System Manual

40

5.3 INSTALLING

5.3.1 Cutting

Protective wear must be worn and safety precautions observed, as dened by the

manufacturer of the cutting tool. This applies to all cutting methods described in

the following instructions.

Some of the methods shown below may require “ Hot Work” permits.

A ne-toothed blade is always recommended for a clean cut.

5.3.1.1 Cutting using an air driven, slow moving band saw with water ushing

This method entails no risk of sparks.



System Manual

41

5.3.1.2 Cutting using Tiger saw/Bayonet saw

This cutting method may cause sparks and must therefore only be performed in

suitable areas. Will require a work permit for “Hot-Work”.

Fasten the saw to the pipe withequipment suitable for the saw.

Let the saw work through the pipe

without using excessive force.

The cut should be perpendicular

to the pipe.

This method is also suitable for cutting in installed systems.

5.3.1.3 Cutting using a hacksaw

This cutting method may cause sparks and must therefore only be performed in

suitable areas. Will require a work permit for “Hot-Work”.

The cut should be perpendicular

to the pipe



System Manual

42

5.3.2 Jointing

Equipment • Pipe tting

required: • Band-It band (quantity in accordance with the Band-It chart)

• Sealant (Superx and re sealant) • Band-It machine

• Chain block

• Rubber mallet / bre mallet

5.3.2.1 Preparation of passive Fire Protection for joints

All Fire protection material andclamps must be slided onto each

pipe end before it is assembled with

the tting.

Band-It clamps for the re protec-

tion material

If the is used in

classied areas, all joints must be re

protected. The re protection material

and clamps must be slided over one

end of the pipe before the other end isassembled onto the joint connection.



System Manual

43

5.3.2.2 Installing Pipe Fittings

For cutting , see chapter 5.3.1.

Use a chain block and slings to

ease the installation of ttings into

pipes.

Position the tting into the pipe

against the stop marking.

If it is difcult to insert the tting use a rubber mallet or similar which will not

damage the tting.

Do not use any metal tools.



System Manual

44

Slide Band-It bands in correct number and suitable dimension according to

the chart below onto the pipes.

Inspect and remove loose objects

Inspect the pipe tting visually for

damages or other defects

Mark the pipe for correct position-

ing of Band-It bands and tighten in

order 1 - 2

1 2

Table 5.18 Band-It Specications

dimension

Outsidediameter

No. of Band-Itbands per end

Type Band-It band Type Band-Itlock

ID 25 1” 53 mm 2 ULC, 0,030”X3” INCONEL 625

ID 40 1 ½” 68 mm 2 ULC, 0,030”X3” INCONEL 625

ID 50 2” 78 mm 2 ULC, 0,030”X31/2” INCONEL 625

ID 75* 3” 103.5 mm 3 ULC, 0,030”X41/2” INCONEL 625

ID 100* 4” 128.5 mm

ID 150* 6” 184 mm

ID 200* 8” 234 mm

All dimensions use Band-It lock type INCONEL 625

* Dimensions marked in “italic” normally are secured with ConNect clamps not Band-It,

refer to 5.3.2.5



System Manual

45

Insert the connector into the rst

pipe, check for correct location.

Likewise insert rest of pipes.

Apply Superx sealant evenly to

the end surfaces with the aid of a

putty knife or similar.

This is made easier if the tool is

coated with dishwashing soap

before use.



System Manual

46

When the tting and pipes are in

place, t the Band-It bands accord-

ing to Chapter 5.3.2.4

Apply Jet Fire Tape to line up with

the length of the re protection,

and min. 30mm from the outer

Band-It band.



System Manual

47

Fit the Tee Fire Protection and

secure with Band-It. Pry open and

slide the in-line Fire Protection in

position around the Tee.

The split in the In-line Protection

must be covered with a piece of

Band-It band, secured with clamps.

Apply re sealant to all joints



System Manual

48

5.3.2.3 Fitting a nozzle clamp on

Equipment • Cutting tool

required: • Nozzle clamp

• Loctite thread lock

• Band-It bands (quantity according to the Band-It chart)

• “Superx” sealant (in the hole)

• Band-It machine UL 9000

Place the two halves of the nozzle

in the desired position and secure it

with Band-It bands.



System Manual

49

Enter the cutting tool in the threaded

opening and drill a hole in the pipe.

The cutting tool is designed to cut only

as far into the pipe as is necessary.

¾″Band-It

Remove the inner rubber with a sharpknife and check that no rubber pieces

are left in the pipe. Apply Superx

sealant, making sure that the rein-

forcement area is covered.

Apply re tape on each side of the

nozzle mount.



System Manual

50

Pull the re protection over the nozzle

clamp and fasten it with Band-It bands

Screw the nozzle into the hole in the

clamp (hand¬tight + 1 ½ turn) and

mount the nozzle.

Af ter instal lation, check the system according to chapter 5.4

5.3.2.4 Operating the Band-It Machine

The following details are important and must be observed when tting

Band-It bands:

• Location of bands according to the markings.

• The machine’s angle in relation to the band.

• Sufcient space to operate the Band-It machine and the locking handle.



System Manual

51

Start the machine and the band will

gradually tighten. A rattling sound

indicates that the tightening mecha-

nism has reached the end position,but not that the band is rm. The

machine must be reversed to en-

gage a new grip before any further

tightening can be made.

Lock the band by pushing the han-

dle up to the locking position.

Reverse the machine to release the

band.

Band-It machine.

90°

Keep settings to match the calibration certicate. Electrically and pneumatically

operated machines have different and individual settings.

Please note the following when using pneumatically operated Band-It machine:

• Daily lubrication of the tool is necessary. Lubricate the thightening screw with

molybdenum grease.

• Run the machine until it stops completely. Then release the clamp and repeat the

process, making sure the clamp is tight.

• Trelleborg Offshore must carry out all repair and calibration onshore.



System Manual

52

Use of the pneumatic Band-It machine:

• Apply a few drops of oil in the pneumatic tool (via the air connector).

• The machine must only be used with an approved air regulator.

• The pressure setting must be set according to the machine’s calibration certicate.

Check the air pressure each time the machine is connected to compressed air.

Tightening Screw

Air Connector



System Manual

53

Bend excessive end up and down

until it breaks off

A correctly tted Band-It should look as illustrated below. The band must follow

the contour the lock, and must not sl ide back more than 1mm

Tap the buckle down with a ham-

mer to complete the lock

CORRECTWRONG

If the band is not correctly tted, it

must be retted with a new

After installation all connections with Band-It shall be controlled, approved anddocumented in accordance with procedure ID31785: “ Procedure for check of pipe

couplings,



System Manual

54

5.3.2.5 Mounting ConNect Clamps

Equipment • Pipe Fitting

required: • ConNect Clamps

• Sealant (Superx and re sealant)

• Molycoat

• Torque Wrench

Fire Protection

Sleeve

ConNect Clamp

Inboard Bolt

Outboard Bolt

Strap

Pipe Fitting

Rod

Strap

Installation sequence:

1. Slide the re protection sleeve and the ConNect clamp onto the before

the tting is inserted.

2. Insert the tting into the by hand, and push until the pipe contacts the

stop ring on the tting.

3. Lubricate the bolts and tighten sequencially to obtain a snug t. The rods should be

parallel, and the gaps should be equal on both sides, check by measuring.

4. Position the clamp.



System Manual

55

Strap

Fire Protection

Sleeve

ConNect Clamps

5. Tighten the inboard bolts (against the joint) sequentially to 50% of the labelled torque.

Each bolt maximum 2 turns at a time,using a torque wrench.

6. Tighten the inboard bolts to full labelled torque. Tighten the outboard bolts likewise.

7. Slide the second ConNect clamp onto the other before it is mounted onto

the tting.

8. Position the second clamp in line with the rst one, and repeat the steps 3 - 6.

9. Slide the re protection sleeve over the clamps, fasten with straps and seal the exposed

gaps with re sealant compound.

Af ter instal lation all connect ions wi th ConNect shall be control led, approved anddocumented in accordance with procedure ID31785: “ Procedure for check of pipe

couplings,



System Manual

56

5.3.2.6 Heat Tracing

1. In the heat tracing cable is drawn inside the pipe, exposed to the medium.

Max. 15 m Max. 15 m

Heat tracing Cable

Sealing kit

2. A ag line should be pulled through the pipe before connecting pipe and ttings to help

installing the heat tracing cable. The cable must be pulled carefully.

Lubricate cable with soap before installation.

Termination seals are supplied in plastic bags together with a mounting instruction that

should be followed thoroughly. The seal must be tightened rmly, without squeezing the

teon.

3. Install re protection according to chapter 5.3.2.1



System Manual

57

5.3.4 Mounting

Secure pipe and tighten the end

clamps. When appropriate support is installed,

place pipe clamps with max. spacing of

1.3m (tighten to avoid sagging).

Use a chain hoist and “soft-sling” to

lift and support the pipe during instal-

lation.

Minimum bend radius for

is 5D

See Table below

Table 5.19 Dimensions

Tubing Dimension D Bending Radius Weight

1” (ND25) 53 mm 265 mm 2,8 kg/m

1 1/2” (ND40) 68 mm 340 mm 3,5 kg/m

2” (ND50) 78 mm 390 mm 4,4 kg/m

3” (ND75) 103,5 mm 518 mm 6,6 kg/m

4” (ND100) 128,5 mm 643 mm 8,4 kg/m6” (ND150) 184 mm 920 mm 15,0 kg/m

8” (ND200) 234 mm 1170 mm 20,0 kg/m



System Manual

58

5.4 CHECKING

When the installation of the system is completed, and before anymounting of re protection, all supports, clamps and Band-It bands (locks,

position and quantity) must be inspected by a Trelleborg Offshore supervisor.

Use a check list for the inspection.

Flushing, pressure testing and full scale testing may be required and faults must be rectied

after the installation and testing procedure is completed.

Each system/project will require a unique set of tests.

5.4.1 Pressure Testing

5.4.2 Full scale function testing



System Manual

59

6 MAINTENANCE, REPAIRS AND MODIFICATION

has an expected life time of more than 20 years without maintenance, but

inspection of joints, nozzles, and end caps, etc. should be performed at regular intervals accord-

ing to inspection procedure 89104-005.

is well suited for modication as it is an easy system to expand.

Minor damages (< 4 cm² ) on the

pipe surface can be repaired by

applying a re protection section

over the damaged area.

Damages to larger areas of pipe

are replaced by cutting out the

damaged section and replacing it

by jointing in a new section.



System Manual

60

Elastopipe System Manual Revision

Documents

Transcript of Elastopipe System Manual Revision