Pioneer in GRP Pipe Installations Email:[email protected] Web:.

Pioneer in GRP Pipe Installations

Email:[email protected] Web:www.cesl.in

About Organization

GRP Pipes

Transportation and handling of GRP Pipes

Storage of GRP Pipes

GRP Pipe Joining Systems

Joint Methods

Testing

General Safety Recommendations

Personal Hygiene

Field Hydro Testing of Above Ground Pipes

Causes for pressure drop – Hydro Testing

Statutory Documents

Client Details

Agenda


AMIBITION

1. Goal / Vision 2. About partners3. Experience4. Achievements – in few lines5. Market Share


About Organization


About Organization

Aravindan Sivakumar.C. P Hari Natarajan

Site Managers&

Site Engineers

Supervisors

Technicians

Quality Team&

Additional Technicians

Supervisors

Technicians

Safety EngineerStores

&Maintenance Team


GRP piping systems are time tested and it’s proven their durability and value in stony environments and brutal applications for decades

Long life:

It has a minimum life of 50 years. The smooth inner surface is maintained

throughout the entire life of the pipe.

Cost effective:

10 % -15 % cheaper than steel pipes & 20% - 30% percent cheaper than pre-

stressed cement concrete pipes.

Light weight:

GRP pipes weights only 25 % as much as similar steel pipe and 10 % as much

as similar concrete product. GRP pipes are light weighted, hence easier

handling, faster installation and low transportation costs. The use of heavy

equipment is practically eliminated.

GRP Pipes


Dimension stability:

GRP piping system can maintain the required critical tolerances of the most

demanding structural and piping application. The materials need the most

stringent material stiffness and dimensional tolerance.

Strength to weight ratio: The GRP pipe has excellent strength to weight properties. When the ratio of strength per unit of weight is considered, GRP composites surpass iron, mild steel, HDPE (High-density polyethylene) and PVC (Poly Vinyl Chloride).

Very low friction factor: Value of 'C' in Hazen Williams equation for calculation head loss due to friction in pipes is 150-160 for GRP pipes against 120-130 for steel pipes. Thus, the low friction coefficient and the hydraulic characteristics of GRP pipes lead to significant saving in pumping costs.

Low maintenance cost: No maintenance cost due to absence of corrosion, zero replacement.

GRP Pipes


GRP Pipes Corrosion resistance:

GRP piping is having anti-corrosion system in both inside & outside. These pipes has been used for handling dilute acids, saturated brine, organic solvents and other corrosive chemical but there is a zero corrosion as result additional lining and exterior coating are not required.

Low thermal conductivity:

Low thermal conductivity of GRP pipe not only causes low temperature losses but also in many cases eliminates condensation or the need for additional thermal insulation.

Installation benefits:

GRP pipes are light weight, hence it is easy for installation. These can be manufactured up to 12m long to speed up the installation and eliminates up to 75% of the joints compare to any other materials, hence handling & installation is easier than any other products. GRP pipes are meager heaviness hence it’s reduce the expensive installation, labor and machinery expenditures..


Transportation and handling

Prior to unloading of pipes from trailers, all items shall be inspected for any visual/transportation damages.

From the lay-down area to the trench site, the pipes shall be transported through trailers or by using of Hydra.

Single pipe must be unloaded and handled separately (one at a time) by using pliable straps, wide fabric straps, slings or ropes to lift single pipe. (Not using Steel Cables or Chains).

Individual pipe can usually be lifted with a single sling.

At any time during handling or installation of the pipe, any damage such as cracks, de-lamination or fracture occurs, the pipe should be repaired before the section is installed.


Transportation and handling of GRP Pipes

Transporting Pipe Lifting pipe at two support points Lifting pipe at one support point



Pipe is generally stored on flat timbers to facilitate placement and removal of

lifting slings.

The support timbers should have sufficient width to prevent point loads.

The maximum stack height is typically 8 ft.

When stored directly on the ground, the pipe weight should not be

supported by the bell, coupling, or any other joint surface.

The pipe should rest on plane ground and should not rest on rocks, boulders,

or other hard debris that may cause a point load sufficient to gouge,

crack, puncture.

The pipe interior and all joining surfaces should be kept free of dirt and foreign

particles.



Storing Pipes



Unrestrained Pipe Joints

Fiberglass Couplings or Bell and Spigot Joints

Mechanical Coupling Joint

Restrained Pipe Joints

Coupling, or bell and spigot with a restraining device

Flange

Butt and wrap

Wrapped bell and spigot

Bonded bell and spigot



3. Lubricant Gasket

1. Cleaning Coupling 2.Installing Gasket

4.Cleaning Spigot


Tools for Butt & Wrap Lamination Joints Measuring tape + pipe fitter's wrap-a-round + marker pen

Cleaning-rags

Angle grinder with diagrit or carborundum cutting disc (grain 24), a

handsaw 24 teeth/inch, jig saw with a 14 teeth/inch blade

Angle grinder + sanding disc + flexible support disc

Resin, hardener and glass reinforcement + a pair of scissors

Gloves, brushes, rollers, dust masks in quantities as mentioned in the

fit and laminating sets, a pair of safety glasses

Shelter (depending on the weather circumstances)

Hot air gun (paint stripper gun), digital temperature gauge, gas burner,

field oven, heating blanket, variable energy control (rheostat)

Pipe clamp, bench and rubber strips (under chain clamp).

Generator


General Safety Recommendations

The practical or possible fabrication area is to be setup to perform as much of

the fabrication work.

Local exhaust ventilation should be provided at areas of cutting and

tapering to remove airborne dust and fibers. General dilution ventilation

should be provided as necessary to keep airborne dust and fibers below

the applicable exposure limits and guidelines.

Work area should be kept clean, including floor or other horizontal surfaces.

Rinsing with water or sweeping with brushes or brooms (using floor sweep) is

recommended. Brushes should be used to remove residue from shaved

surfaces.

Always refer to the Material Safety Data Sheet (MSDS) prior to working with

unfamiliar materials or if there are questions concerning the contents of the

fiberglass pipe. Email:[email protected]

Web:www.cesl.in

General Safety Recommendations Barrier creme may be applied to the skin in areas, which may be

exposed to shavings prior to beginning work.

Clean clothes should be worn each day. Do not wear clothing that has not

been laundered to begin a work shift. More frequent changing may be required

by conditions.

Long sleeved shirts or work suits should be used.

Gloves with elastic cuffs should be worn at all times. Replace worn or

contaminated gloves as necessary. Gloves with flared, stiff cuffs act as a

gathering funnel for shavings.

Pant legs should be worn outside work boots. If necessary for safety

purposes, the pant legs can be taped to fit closely to the boot. Over-the-calf

socks can be used to prevent chafing of the boot on the skin.


Personal Hygiene

Wash exposed skin with soap solution (liquid soap preferred) and cool

water.

Use washcloth with “brushing” motion to remove dust or fibers. Do not scrub

the Skin. This could result in the fibers being imbedded into the skin.

Rinse thoroughly with clean, cold water.

Apply lotion or cream to skin (non-detergent formulas such as baby

lotion) to soothe Irritation or prevent further immediate irritation.


Field Hydro Testing of Above Ground Pipes Fill with water at the lowest point in the line using a small diameter branch

connection and vent the trapped air at the highest points.

Long straight sections may be vented using an inflatable ball or foam pig to

expel any air and impurities.

After filling, the line must be pressurized gradually at 0.8 times working

pressure dependent.

on the system and must be maintained for 24 hours allowing the pipe system

to set. After the system is stabilized, the pressure must be raised gradually to

the agreed field test pressure.


Causes for pressure drop Temperature change - day as well as night

Leakage of valves, fittings, hydrants, etc…

Leakage of gaskets

Dirt at sealing ring

Wrong installation of O-ring (slip ring)

Pipes or fittings insufficiently blocked in the trench resulting in displacement

Air lock

Leaking test equipment

Leaking joint (adhesive bonded, rubber seal or laminated joint)

Leakage in fittings

Leakage of the pipe as result of damage (cracks)

Settlement of the pipe system


Statutory Documents


Client Details – Industrial Pipe Lines

Gujarat Electricity Board/ BSES – Dhuvaran (Various Dia up to 1200 mm).

Reliance Industries Silvassa–(Water intakes system & Fire Hydrant 80 mm to 30 mm) -

7800Mtrs.

Shell LNG/Petron (Erection of 13500 Mtrs of Pipes of various dia up to 1450 mm from Sea

water intake & reject, Potable water, DM water & Fire Hydrant).

Cairn Energy Pty Ltd. (Sea water bore well header injection line – onshore)- 900 Mtrs.

Hindalco Industries – 600 mm to1800 mm dia (Condenser to Cooling tower System) -

1500 Mtrs.

HPCL Project, SALPG Vizag with L&T Chennai (100 mm to 450 mm dia for condenser

cooling & Fire Hydrant server)- 1200Mtrs.

IVRCL Infrastructure & Projects Ltd- (100MLD Desalination Plant, Chennai – 80mm to

1600 dia)- 2100 Mtrs.

Reliance Energy Tech Engineers ltd, Dahanu Project-(Fuel Gas Disaffirmation sea water

lines, from 50 mm to 1800 mm dia)- 3300 Mtrs.


Client Details – Cross Country Lines

Bharuch Eco Aqua Industries ltd with Aban Engineering ltd-(Engineering, Logistics &

erection of 800 mm dia GRP pipes of 45 Kms).

Hindustan Construction Co Ltd, Pune -(80mm to 400mm dia GRP pipes for 56.94 Kms).

Tata Hydro Power Ltd, Pune- (900mm dia GRP pipes for 1.8 Kms for Rain Water

Harvesting System).

Navayuga Engineering Co Ltd Chennai for Chennai Petroleum Corporation ltd for

Desalination project-(700 mm to 900 mm dia pipes – 28 kms).

Karnataka Urabn Water Supply & Drainage Board – 350 mm dia pipes for 1.6 Kms.


Technical Comparison among Different types of pipes for Sewage Application

Water Proofing


Technical Comparison among Different types of pipes for Sewage Application

Speed of Installation


Pioneer in GRP Pipe Installations Email:[email protected] Web:.

Documents

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