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INSTALLATION MANUAL FOR

ABOVE GROUND PIPING SYSTEM

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1.0 Introduction

This manual deals with the handling, laying of advanced composites pipes. Pipe diameter

ranges from 80 mm up to 2000 mm with pressure classes of 6,10,16,20 and 25 bar. The

following table (table 1) shows pipe standard lengths.

Table 1

Above ground pipe systems can be roughly divided into categories

a) Lines which are laid on the ground.

b) Lines which are installed on pipe supports.

The manual should be carefully read by the Contractor responsible for laying the pipe, as well

as by the design Engineer. This information should be considered only as a guide. The

Engineers or others involved in pipeline design or installation should establish for themselves

the procedure suited to the site conditions.

Our site service representatives are at the disposal of the Contractor/ end user in order to

advise on the handling and installation of the pipes.

1.1 Responsibilities of site supervisors

The responsibilities of our site supervisors are:

Periodic visits to the job site throughout the duration of pipe installation to advise the

contractor on the proper and applicable handling, storage, laying, jointing and site

testing procedures necessary to achieve a satisfactory pipe installation. These

procedures are detailed in this manual.

It is the responsibility of the Contractor to make available the advanced composites

pipe installation manual to his installation crew, and to ensure that they are familiar

with, and understand the procedures described therein.

Nominal Pipe

Diameter (mm)

Standard Pipe Length

(m)

80 6

100 - 150 9

200 – 600 12

700 – 800 12

900 -1200 12

1300 and above 6

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It is the responsibility of the Contractor to strictly follow and implement the

installation procedures published in this installation manual, as well as any additional

advise given by our field representative.

The manufacturer shall not be liable for any failures related to installation arising from

failure of the Contractor to follow and implement our written installation instructions

and any additional advise or recommendation made by our field representative.

2.0 Handling

2.1 Receiving

Generally pipes will be handed over to Contractor or his representative at the factory or at the

job site as agreed upon in the Contractor’s purchase order. In the case of an Ex-works

delivery, the pipes and fittings shall be loaded on the Contractor’s trucks by the factory

loading staff. If the loading staff considers the transport unsuitable, they will advise the

contractor or his representative accordingly. Inspection is thoroughly made by the factory

loading staff of the goods being loaded. Nevertheless the Contractor or his representative

should make their own inspection of the goods during dispatch.

The Contractor should make the following inspection at the time of the reception of the

goods:

a- Each item should be inspected with care upon its arrival.

b- Total quantity of pipes, fittings & lamination kits, etc…. should be carefully checked

against our delivery notes.

c- Any damaged or missing item must be pointed out to the dispatcher or driver and

noted on the delivery note.

Materials that have been damaged during transportation should be isolated and stored

separately on site, until the material is checked by our site representative and repaired or

replaced.

Note: Damaged material must not be used before it is repaired.

2.2 Unloading pipes

Unloading at the site must be carried out carefully under the control and responsibility of the

Contractor. Care should be taken to avoid impact with any solid object (i.e. other pipes,

ground stones, truck side etc.).

2.2.1 Unloading by hand

Unloading by hand with two men is only allowed for small diameter pipes, not exceeding 60

kg.

2.2.2 Mechanical unloading

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Mechanical unloading is required for pipes heavier than 60 kg. Flexible slings or straps

should be used combined with a mobile crane. When unloading is done with a mobile crane,

care must be taken that the pipes do not slide off the slings. Therefore it is recommended to

use two slings or nylon lifting straps to hold and lift the pipes. Steel cables must not be used

for lifting or handling of pipes. Pipes can also be lifted with one sling or strap balanced in the

middle with the aid of a guide rope.

Caution: Hooks must not be used at the pipe ends to lift the pipes, nor should the pipe be

lifted by passing a rope or sling through the pipe.

2.3 Storing pipes on site

2.3.1 Storing in stock piles

Care must be taken that the storage surface has the same level, as firm as possible, and clear

of rocks or solid objects that might damage the pipes. Store the pipes in separate stock-piles

according to their class and nominal diameter. Pipes are to be placed on wooden timber at a

maximum spacing of 6 meters. Any extraneous materials are to be removed from the area.

Stock piles should not exceed the heights shown in table 2. This height is limited for safety

purpose and to avoid excessive loads on the pipes during storage.

DN 80 - 400 450 - 600 700 - 800 900 - 1400 > 1500

Layers in stock pile 5 4 3 2 1

Maximum height < 2 m < 2.4 m < 2.4 m < 2.8 m 1 D

Table 2: Storing/stacking height

Wooden wedges, which are used in order to prevent the pipe stack from sliding, should be

placed on both sides of the stack on the timber bearers, as shown in figure 1.

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2.4 Handling of nested pipes

For some projects, pipes may be delivered nested (i.e. one or more small pipes inside a larger

pipe). Special handling procedures must be followed when handling and de-nesting such pipe

loads.

When handling nested pipes, never use only one sling or strap. Nested pipes must always be

lifted using at least two straps or slings. A spreader bar will help to insure that the load is

lifted at one level. Mobile lifting equipment should move slowly when handling nested pipes

and all such movements should be kept to a minimum to insure the safety of site personnel.

The Contractor should insure that the crane operator realizes that the smaller pipes inside the

larger nested pipes may slip out and fall during movement. All necessary precautions should

be taken.

De-nesting a load is easily accomplished by inserting a forklift fork into a padded boom. The

forklift lifting capacity should be appropriate enough to handle the weight and length of the

pipes being de-nested. Figure 2 shows how this is accomplished. Proper padding is essential.

Rubber, several wraps of corrugated cardboard sheets, or a PVC or PE pipe slipped over the

boom are all suitable options to avoid damaging the inside of the pipes.

The forklift operator should lift the innermost pipe above the pipe around it sufficiently so the

pipes do not touch each other when the inner pipe is being pulled out.

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3.0 Expansion Joint Design

Expansion joints may be used to absorb thermal expansion in long , straight pipe runs.

Various types of expansion joints are available and suitable for use with fiberglass piping

systems. Because the forces developed during the a temperature change are relatively low

compared with metallic systems , it is essential to specify an expansion joint that activates

with low force. Remember that fiberglass pipe will expand more than most metallic systems.

The required movement per expansion joint and the number of expansion joints may be

greater for fiberglass systems.

The allowable activation force for expansion joints depend on both the thermal forces

developed in the pipe and the support and guide spacing. Guide spacing at the entry of an

expansion joint is typically 4 pipe diameters (first guide) and 14 pipe diameters (second

guide) from the inlet of the expansion joint ( Figure 3.1). These guides and locations give

proper alignment. The spacing of the remaining supports should remain within the maximum

calculated interval.

Figure 3.1: Typical expansion joint installation

Note : The pressure thrust must be considered. Pressure thrust is the design pressure times the

area of the expansion joint.

In all applications, the activation force of the expansion joint must not exceed the thermal end

loads developed by the pipe. The cost and the limited motion capability of expansion joints

makes them impractical to use in many applications. In these cases, loops, guide spacing, or

short lengths of flexible hose can handle thermal expansion. The expansion joint needs an

anchor on both sides for proper operation.

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Figure 3.2: Expansion Loop Dimensions

3.2 Expansion Loop Design

Expansion loops flex to accommodate changes in length (Figure 3.2). The design method is

used to calculate the stress developed in a cantilevered beam with a concentrated load at the

free end and ignores flexibility of the loop leg, the leg parallel to the line.

Two guides on both sides of each expansion loop ensure proper alignment. The recommended

guide spacing is 4 and 14 nominal pipe diameters. Additional guides or supports should be

located so the maximum spacing interval is not exceeded.

To design an expansion loop, use the following equation:

Note: In some cases, the manufacturer may require anchors at all fittings. For example,

mitered fittings and /or large diameter fittings may have allowable bending stresses below

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that of the pipe. In these cases, thermal expansion procedures may be limited to the use of

anchors and guides or expansion joints if the bending moment is not available.

3.3 Direction Changes

In some installations, system directional changes can perform the same function as expansion

loop. Directional changes that involve some types of fittings, such as saddles, should not be

used to absorb expansion or contraction. The bending stresses may cause fitting failure. Stress

in the pipe at a given directional change depends on the total change in length and the

distance to the first secure hanger or guide past the directional change. In other words, the

required flexible leg length is based on the maximum change in length.

Recommended support or guide spacing cannot be disregarded. However, flexible or movable

supports, such as strap hangers, can provide support while allowing the pipe to move and

absorb the changes in length. Supports must prevent lateral movement or pipe buckling.

Figure 3.3: Directional Change

The equation for calculating the length of the flexible pipe leg (i.e., the distance to the first

restraining support or guide) is:

This type of analysis usually neglects torsional stresses. Allowable bending stress is much

lower than the allowable torsional stress. Therefore, bending of the pipe leg as shown in

Figure 3.3 will typically absorb pipe movement.

3.4 Supports , Anchors, And Guides

Six basic rules control design and positioning for supports, anchors and guides.

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3.4.1 Rule 1 – Avoid Point Loads

Use curved supports fitted to contact the bottom 120 degrees of the pipe and that have a

maximum bearing stress of 85 psi (586 kPa). Do not allow unprotected pipe to press against

roller supports, flat supports, such as angle iron or I-beams, or U- bolts.

Table 3: Typical support width (minimum) for 120° contact supports

Pipe Size Minimum Support Width

in. mm in. mm

1 25 0.88 22.4

1.5 40 0.88 22.4

2 50 0.88 22.4

3 80 1.25 31.8

4 100 1.25 31.8

6 150 1.50 38.1

8 200 1.75 44.5

10 250 1.75 44.5

12 300 2.00 50.8

14 350 2.00 50.8

16 400 2.50 63.5

Note: Table is based on maximum liquid specific gravity of 1.25.

Do not allow pipe to bear against ridges or points on support surfaces. Use metal or fiberglass

sleeves to protect pipe if these conditions exist.

3.4.2 Rule 2 – Meet Minimum Support Dimensions

Standard pipe supports designed for steel pipe can support fiberglass pipe if the minimum

support widths provided in Table 3 are met. Supports failing to meet the minimum must be

augmented with a protective sleeve of split fiberglass pipe or metal. In all cases, the support

must be wide enough so that the bearing stress does not exceed 85 psi ( 586 kPa).

Sleeves augmenting supports must be bonded in place using adhesives stable at the system’s

maximum operating temperature.

Prepare all pipe and sleeve bonding surfaces by sanding the contacting surfaces.

3.4.3 Rule 3 – Protect Against External Abrasion

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If vibrations or pulsations are possible, protect contacting surfaces from wear (Figure 3.4).

When frequent thermal cycles, vibrations or pulsating loadings affect the pipe, all contact

points must be protected. This is typically accomplished by bonding to the wall a wear saddle

made of fiberglass, steel or one half of a section of the same pipe.

3.4.4 Rule 4 – Support Heavy Equipment Independently

Valves and other heavy equipment, must be supported independently in both horizontal and

vertical directions (Figure 3.5).

3.4.5 Rule 5 – Avoid Excessive Bending

When laying lines directly on the surface, take care to ensure there are no excessive bends

that would impose undue stress on the pipe.

Figure 3.4: Fiberglass wear protection cradle Figure 3.5: Steel wear protection cradle

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3.4.6 Rule 6 – Avoid Excessive Loading in Vertical Runs

Support vertical pipe runs as shown in Figure 3.6. The preferred method is to design for ˝

pipe in compression ˝. If the ˝ pipe in tension ˝ method cannot be avoided, take care to limit

the tensile loadings below the recommended maximum tensile rating of the pipe. Install guide

collars using the same spacing intervals used for horizontal lines (Figure 3.6).

3.4.7 Guides

The guiding mechanism must be loose to allow free axial movement of the pipe. However,

the guides must be attached rigidly to the supporting structure so that the pipe moves only in

the axial direction (Figure 3.7).

All guides act as supports as supports and must meet the minimum requirements for supports.

Figure 3.6: Vertical Support

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Figure 3.7: Guide Support Figure 3.8: Anchor Support

3.4.8 Anchors

An anchor must restrain the movement of the pipe against all applied forces. Pipe anchors

divide a pipe system into sections. They attach to structural material capable of with standing

the applied forces. In some cases, pumps, tanks and other similar equipment function as

anchors. However, most installations require additional anchors where pipe sizes change and

fiberglass pipe joins another material or a product from another manufacturer. Additional

anchors usually occur at valve locations, changes in direction of piping runs and at major

branch connections. Saddles and laterals are particularly sensitive to bending stresses. To

minimize stresses on saddles and laterals, anchor the pipe on either side of the saddle or

anchor the side run.

Figure 3.8 shows a typical anchor. Operating experience with piping systems indicates that it

is a good practice to anchor long, straight runs of aboveground piping at approximately 300 ft

(91m) intervals. These anchors prevent pipe movement due to vibration or water hammer.

One anchoring method features a clamp placed between anchor sleeves or a set of anchor

sleeves and a fitting. The sleeves bonded on the pipe prevent movement in either direction.

Sleeve thickness must equal or exceed the clamp thickness. To achieve this, it often is

necessary to bond two sleeves on each side of the clamp. Anchor sleeves are usually one pipe

diameter in length and cover 180° of circumference. Anchors act as supports and guides and

must meet minimum requirements for supports.

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3.4.9 Supports

To prevent excessive pipe deflection due to the pipe and fluid weight, support horizontal pipe

(see Figure 3.9) at intervals determined by one of the following methods.

Figure 3.9: Typical Support

3.4.9.1 – Type I

Pipe analyzed as simply supported single spans (two supports per span length) with the run

attached to a fitting at one end or any other section of less than three span lengths. Beam

analysis for other types of spans such as a section adjacent to an anchor is sometimes used to

obtain a more accurate span length. However, the following equation is more conservative.

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5.6 Flanged joint

Flanged pipes and fittings can be provided for the valve chambers. Calculation for the flange

thickness is based on the project specifications. Confirm flange thickness before ordering

flange bolts as they are thicker than steel flanges.

Before assembling the flanged Joints, all safety precautions will need to be checked. Ensure

that all necessary tools are available.

5.10.a Tools for several types of joints

Flanges

Tools necessary for assembly of flanges:

1. Ring Spanner with required bolt head size

2. Torque wrench with required socket size

5.10.b Flanged joints

F.R.P.flanges are flat faced. These flanges must always be accurately aligned and not subject

to any stress. On the F.R.P.side of the flanged joint the bolts and nuts must have washers to

avoid exceeding the permitted surface pressure. As an alternative, a steel-backing ring can be

installed.

Pipes must not be pulled together by tightening the bolts. If an F.R.P.pipeline is connected to

a metal pipe, this metal pipe must be anchored to prevent any movement or loads being

transmitted to the F.R.P.line.

Fig. 5.10.b (1)

Fig. 5.10.b (2)

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When assembling a wafer – type butterfly valve, the bolts should be tightened first by hand. If

leakage occurs during the pressure tests, the bolts can be tightened up to the max. values

according to table 5c.

To prevent damage of the flanges when tightening, spacers may be placed between the

F.R.P.flanges.

Tightening of the bolts of a flange connection must be done diagonally according to the

sequence as shown in figure Fig. 5.10.b (4)

Bolts in flanges must be placed on either side of the centre line unless otherwise specified.

Fig. 5.10.b (3)

Fig. 5.10.b (4)

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The flange must be connected perpendicular to the axis of the pipe. In practice minor

deviations might occur. Ifthis happens, a gasket with an O-ring seal or a profiled gasket with

vulcanized steel ring (Kroll & Ziller) should be used.

5.10.c Gaskets and torques

For F.R.P.flanges several gaskets may be used, depending on the diameter, system pressure or

specific requirements of the client. To prevent excessive bending on F.R.P.flanges the max.

bolt torques are specified. In order to determine the right torque value, it is necessary to

lubricate the bolt with, for example, molykote.

5.10.c (1) Torques for gaskets with plastic collar

When assembling F.R.P.flanges the bolt should be tightened by hand up to 30% of the max.

torque value. If leakage occurs, increase the torque value upto 60% of the maximum value

according to the sequence shown in Fig. 5.10.b (4). The torques listed are maximum values.

Table 5a

ID (mm) Torque (Nm)

Max. 16 bar Max. 32 bar

25 t/m 300 50 50

350 t/m 600 100 200

700 t/m 800 300

900 t/m 1200 400

Type/ thickness : Full-face. Thickness depends on the diameter.

Trade name : Kempchen

Application : All diameter and pressure ratings.

Canvas reinforced rubber gasket

This gasket can be used for pressure up to 10 bar.

The kind of rubber depends on the medium to be transported.

Type/ thickness : Full-face. Thickness = 5mm.

Trade name : Eriks, Reinz

Application : All diameters, upto 10 bar.

Fig. 5.10.b (5)

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5.10.c (2) Torques for canvas reinforced rubber gasket

Table 5b

ID (mm) Torque (Nm)

25 - 300 300

350, 450 400

500,600 500

700 -1200 700

5.10.c (3) Torques for metal reinforced rubber gaskets

This gasket is located on the inside of the bolt circle.

Type/ thickness : The kind of rubber depends on the medium to be transported.

The thickness depends on the diameter.

Application : All diameters and pressure ratings.

Table 5c

ID (mm) Torque (Nm)

Max. 16 bar Max. 32 bar

25 t/m 300 50 50

350 t/m 600 100 200

700 t/m 800 300

900 t/m 1200 400

Note: Above mentioned values are also valid for butterfly valves located inside the bolt circle.

Fig. 5.10.b (6)

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Fiberglass flanges must always be installed tension free, therefore flanges must be accurately

aligned. Pipelines must never be pulled by means of the flange bolts. If a Fiberglass pipeline

is connected to a metal line, this metal line must be anchored to prevent any movements or

loads being transmitted to the Fiberglass line.

5.10.d Gaskets and Torques

As sealing for Fiberglass flanges, several gaskets types may be used, depending on the

diameter, system pressure or specific requirements of the clients.

When assembling Fiberglass flanges, bolts should be tightened by hand first, then using a

torque wrench up to 30 % of the max. torque value shown below and on the following pages.

If flanges are not leak tight, torques should be increased upto 60% of the max. torque value

shown. After all bolts have been tightened to the recommended torque, recheck the torque on

each soil in the same sequence, since previously tightened bolts may be relaxed. Max. torque

values shown are ‘Ultimate’ and should be avoided under normal site conditions. Always

follow the correct torqueing sequence specified. Consult the manufacturer for further

assistance. Excess torque can prevent sealing and can damage flanges.

CAF (Compressed Asbestos Fibres)

Recommended quality IT-c (acc. DIN 3754)

Type Size : Full-face. Thickness = 3mm.

Trade name : Frenzelit-chemie, Reinz Universal, Walkerlite

Application : Diam. 25mm to 300mm

Torques if assembled against flat faced flanges

Table 5d

+

ID (mm) Max torque (Nm)

DIN1882

DIN 2501 ND 10

Max torque (Nm)

DIN 2502 ND 16

ASA 150

Max torque (Nm)

DIN2501 ND 25

ASA 300

25 70 70 100

40 100 100 150

50 100 100 150

80 100 100 150

100 100 100 250

150 150 150 250

200 150 150 300

250 150 300 500

300 150 300 550

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Torques if assembled against raised-face flanges

Table 5e

ID (mm) Torque (Nm)

25-80 25

100,150 50

200,250 75

300 100

Note: The above values are valid for pressure upto 25 bar and for all mentioned bores.

CAF with O-ring Seal.

This is a CAF gasket with an o-ring seen placed at the innerside.

The material of this o-ring depends on the medium to be transported.

Type size : Full face, t = 5

O Ring size : The dia. Of the ‘O’ Ring is 8m.

Application : Diameters 350mm through 800mm, pressure upto 16 bar

Diameters 900mm through 1200mm, pressure upto 10 bar

Torques if assembled against flat faced flanges

Table 5f

ID (mm) Torque (Nm)

350-450 400

500-600 500

700-1400 700

Note: The above mentioned values are valid for above mentioned classes and all bores.

Rubber gasket with Inner Layer.

The kind of rubber depends on the medium to be transported.

Type size : Full face, t = 5

Trade name : Eriks, Reinz

Application : All diameters, pressure class up to 10 bar.

Torques if assembled against flat faced flanges

Table 5g

ID (mm) Max Torque (Nm)

350-450 400

500-600 500

700-1400 700

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Rubber Gasket with Steel Inner Layer.

This gasket is located on the inside of the bolt circle.

Type size : The kind of rubber depends on the medium to be transported. The

Thickness depends on the diameter.

Trade name : Kroll & Ziller

Application : Diameters 25mm to 300mm, pressure class upto 25 bar

Diameters 350mm to 1400mm, pressure class upto 8 bar

Table 5h

ID (mm) Max Torque (Nm)

25-80 25

100,150 50

200,250 75

300 100

350-1400 150

Note: The above mentioned values are also valid for butterfly valves with integral rubber

sealing gaskets located inside the bolt circle. For this type of butterfly valves no other gasket

is required.

Neoprene rubber gasket with ‘O’ Ring Seal

This gasket can be used for pressure up to 10 bars (150 psi)

Type size : Full face (t=5mm with shore ‘A’ durometer_hardness of 60 5 for

sizes Larger than 300mm OR t = 3mm for other sizes. ‘O’ Ring size:

8mm (for sizes larger than 300mm).

Trade name : Neoprene sheet rubber gasket.

Application : Diameters up to 1400mm pressure class up to 10 bars.

Torques in Nm.

Table 5i

ID (mm) Max Torque (Nm)

25-100 55

150 55

200 100

250 110

300 125

350-450 300

500-600 400

700-1400 500

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Flanges 1500mm and Larger

These flanges are low torque flanges. The sealing is by an ‘O’ Ring contained in a groove

molded into the flange damage.

Note: Two flanges with an ‘O’ ring cannot be jointed to each other. In this case one of the

flanges must be made without a groove.

The ‘O’ Ring used for the sealing may be made of EPDM or natural rubber with a shore

hardness of 60.

Figure 5.10.b (7)

Maximum Torque value is 100 N m

Flange O.D. ( F.O.D.)

(B.C.D.)

Bolt Circle Diameter

Flange thickness

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List of References

BS 7159 : 1989

BS 8010 : 1989

AWWA Manual