TR-01Bonder Training Program (Main)

TR‐01 Training and Qualification of Bondstrand® Pipe Bonder

(ISO14692)

21 February 2014NOV Fiber Glass System ‐ <Bondstand® Pipe Bonder Training Program>

Contents• 1:Introduction• 2:Health,Safety and Environment• 3:Responsibilities and Documentation• 4:Receiving and Handling• 5:Fiberglass Pipe Jointing and Repair• 6:Tools and Equipment• 7:Fabrication and installation• 8:Testing• 9:Fire Performance Product

21 February 2014NOV Fiber Glass System - <Bondstand® Pipe Bonder Training Program>

Introduction Video


Product Video


1) Introduction

• NOV FGS – Company Profile• Fiberglass Piping• NOV FGS Products• Approvals

NOV Fiber Glass System - <Bondstand® Pipe Bonder Training Program> 21 February 2014

NOV FGS Fiberglass Pipe Group

• Manufacturing Fiberglass since 1950’s• World-wide marketing, sales, distribution and

services• State-of-the-Art manufacturing equipment• Dedicated Laboratory Facilities• In-House Research, Development, and

Engineering



HollandU.S.A

Middle East

SingaporeMalaysia

Harbin SuZhou

Brazil



• Group Headquarterso Houston, Texas USA

• Worldwide Manufacturing Facilitieso Texas USAo Singapore & Malaysiao Netherlandso MiddleEast:- Suadi Arabia; Oman;

Kuwaito China:- Suzhou; Harbino Brazil



• Major Marketso Industrialo Marineo Offshoreo Oilfieldo Fuel Handling



• Product Rangeso Size: 1-inch to 144-incho Temperature: -40°C to 121°Co Applications: Buried and Suspendedo Media: Industrial Chemicals to Ultra-Pure

Watero Pressure: -3 bar to 200 bar (higher external

and internal pressure available


Fiberglass Piping Terminology

• RTRP - Reinforced Thermosetting Resin Pipe• FRP - Fiberglass Reinforced Pipe• GRE - Glass Reinforced Epoxy• GRV - Glass Reinforced Vinylester• GRP1 - Glass Reinforced Polyester• GRP2 - Glass Reinforced Pipe


Raw Material - ResinProperties Epoxy Vinylester Polyester Modified

PhenolicsRemarks

Tensile Strength (Mpa)

65~80 60~75 50~70

Elongation 2~5% 1.7% 1.5%

Shear Strength (Mpa)

30~50 20~30 10~20

Heat Distortion in oC

180 70~93 60~80

Maximum allowable temp

110~121 70~93 60~80 Continuous / peak in °C

Hydrostatic design (hoop) stress N/mm2

63~80 45~50 15~35 (±55° pipe, biaxal loaded)


Raw Material - ResinProperties Epoxy Vinylester Polyester Modified

PhenolicsRemarks

Reduction of stiffness

10% 20% 40% In 50 years

Shrinkage during curing

1~2% 7% 7%

Chemical Resistance

Good Good Fair


Raw Material - Curing AgentProperties Aromatic

AmineCyclo-

Aliphatic Amine

Anhydride Acid Base / Polysiloxa

ne

BPO/DMA

Tg (ºC) 160 130 110 >250 110Resin

SystemEpoxy Epoxy Epoxy Phenolic Vinylester


Raw Material - Glass• Type of Glass

o E-Glass: “E” denotes electrical resistance• Over 90% of the glass fiber market is held by E-glass• Tensile modulus around 80 Gpa• Tensile Strength around 3.5 Gpa• elongation-to-break is nearly 5%

o S-Glass: “S” denotes High Strength• Generally, 10~15% stronger than E-Glass• Better heat resistance than E-Glass

o C-Glass: “C” denotes chemical resistance


Raw Material - Glass• Glass Roving

o TEX – The weight of the glass fiber roving strand in terms of grams per 1,000 meters

o YIELD – A length per unit weight measure, for example, 250 Yield denote net 250 yards of roving per pound


Raw Material - Glass• Other forms

o Boat Tape

o Woven Roving


Pipe & Fitting Production Methods• Filament Winding

o Helical Windingo Continuous Windingo Custom (Fitting)

• Compression Mold

• Centrifugal Casting

• Hand Lay Up


Mandrel

Resin Bath

Reciprocal Filament Winding

Roving


Continuous Filament Winding

90’s 90’s 90’sPuller

Cut-offsawMandrel

OvenOven

H2O

Long. Head

Long. Head Optional

fillerapplicator

Liner resin


• Corrosion Resistant• Light weight, easy handling• Reliable• Safe against fire• Low smoke and Toxicity• Eliminates scale buildup which can clog

spray nozzles• Better Flow characteristics than steel (low pressure

loss)• Life cycle cost saving compared to steel• Less expensive than Stainless Steel & Cu Ni

Fiberglass Pipe Features and Benefits


• Marine Piping SystemsBallast; Seawater Cooling; Bilge; Stripping; Vent; Firewater; Cargo; Intert-Gas; Sanitary; etc.

• Industry ApplicationFirewater; High Grade Industrial Water; Brine; Drainage; Seawater; Corrosive liquid; Chemical processing; etc.

• Offshore Piping SystemsSeawater; Firewater; Drainage; Sewerage; Caissons; Potable water; Produced water; etc.

• Oil and Gas, Fuel HandlingFlow line; Oil, gas, water Gathering and transmission; Jet Fuel line; Saltwater; Tubing & Casing; etc.

Fiberglass Pipe Application


Common Jointing Methods• Adhesive Bonded Joints

o Quick Lock® Jointo Taper / Taper Joint

• Mechanical Jointso Key Lock® Jointo Double O-ring Jointo Coil Lock® Jointo Threaded Joint

• Lamination joint• Flange Joint• Metallic Couplings (e.g. Dressor, Straub)


Bondstrand®

Quick Lock Joint• Features

o Pipe Stopo Taper Female Bell (1/2°

Taper)o Straight Male Spigot


Bondstrand®

Taper Joint• Features

o Taper Bell and Spigot (1-3/4 ° or 2-1/2 °depending on size)

o Thin Adhesive LineThin Adhesive Line


Bondstrand®

Key-Lock Joint• Features

o Reliable and Reusableo Simple and Speedo O-Ring Seal and Nylon Key Lock


Bondstrand®

Key-Lock Expansion Joint• Features

o As in Key-Lock Jointo Allow for Expansiono For Easy Valve Removal when Used in Valve

PitExpansion Key-Groove


Bondstrand®

Double O-Ring Joint• Features

o Reliable and Reusableo Simple and Speedo O-Ring Seal, Expansion and Extraction


Bondstrand®

Double O-Ring CPLG Joint• Features

o As Double O-Ring Jointo Ease of Assembly and Dismantleo Nylon Key Lock @ One Side


Bondstrand®

Coil-Lock Joint• Features

o Reliable and Simpleo High Pressure Performanceo Spiral Nylon Key Forming Lock for Joint


Flange Joint• Features

o Valve, Equipment, Vessel, and Other Pipe Interface

o Various Drilling Pattern (CL150, DIN, JIS, etc)


Metallic Coupling Joint• Features

o Simple and ReusableBut, Special end configuration and specified pipe

OD, special design/machine fiberglass pipe might be required

Straub Coupling Victaulic CouplingNOV Fiber Glass System - <Bondstand® Pipe Bonder Training Program> 21 February 2014

Bondstrand®

Butt & Wrap Joint• Features

o Preparation of Joint from outsideo Low Pressure (25bar) Performanceo Versatileo Flexibility to accommodate minor misalignmento Skill Required


Joint Type Abbreviations• QLF – Quick-Lock Female• QLM – Quick-Lock Male• TF – Taper Female• TM – Taper Male• KLF – Key Lock Female• KLM – Key Lock Male• DOF – Double O-ring Female• DOM – Double O-ring Male• DOM/K – Double O-Ring Male with Key Groove• PE – Plain End• ME – Machined End


NOV FGS Bondstrand® ProductsSeries 2000 2000M 2000M-FP 2020 2020C 2410

Resin Type Epoxy Epoxy Epoxy Epoxy Epoxy Epoxy

Curing Agent Aromatic amine

Aromatic amine

Aromatic amine

Aromatic amine

Aromatic amine

Aromatic amine

Rating 12 bar 16 bar 16 bar 20 bar 20 bar 10 barAllowable Velocity

4.6 m/s 4.6 m/s 4.6 m/s 4.6 m/s 4.6 m/s 4.6 m/s

Liner Thickness

0.5 mm 0.5 mm 0.5 mm 0.5 mm NIL 0.5 mm

Fire Protection / Conductive

No / No No / No Yes / No No / No No / Yes No / No

=<1-1/2" QL (RP34) QL (RP34) QL (RP34) QL (RP34) QL (RP60) NA2"-4" QL (RP34) QL (RP34) QL (RP34) QL (RP34) QL (RP60) Taper (RP48)

6"-16" QL (RP34) QL (RP34) QL (RP34) Taper (Rp48) Taper (RP60) Taper (RP48)

18"-40" Pipe and Fitting

NA Taper (RP48) Taper (RP48) Taper (Rp48) Taper (RP60) Taper (RP48)

18"-40" Flange Only

NA QL (RP34) QL (RP34) Taper (Rp48) Taper (RP60) Taper (RP48)


NOV FGS Bondstrand® ProductsSeries 2412 2414 2416 2416FM 2420 2420FM



Aromatic amine

Aromatic amine

Aromatic amine

Aromatic amine

Aromatic amine


4.6 m/s 4.6 m/s 4.6 m/s 4.6 m/s 4.6 m/s 4.6 m/s

Liner Thickness

0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm


No / No No / No No / No No / No No / No No / No

=<1-1/2" NA NA NA NA NA NA

2"-4" Taper (RP48) Taper (RP48) Taper (RP48) Taper (RP48) Taper (RP48) Taper (RP48)



Taper (RP48) Taper (RP48) Taper (RP48) NA Taper (RP48) NA

18"-40" Flange Only

Taper (RP48) Taper (RP48) Taper (RP48) NA Taper (RP48) NA


NOV FGS Bondstrand® ProductsSeries 2425 2432 2440 2450 2410C 2412C



Aromatic amine

Aromatic amine

Aromatic amine

Aromatic amine

Aromatic amine


4.6 m/s 4.6 m/s 4.6 m/s 4.6 m/s 4.6 m/s 4.6 m/s

Liner Thickness

0.5 mm 0.5 mm 0.5 mm 0.5 mm NIL NIL


No / No No / No No / No No / No No / Yes No / Yes

=<1-1/2" NA NA NA NA NA NA




Taper (RP48) Taper (RP48) Taper (RP48) NA Taper (RP60) Taper (RP60)

18"-40" Flange Only

Taper (RP48) Taper (RP48) Taper (RP48) NA Taper (RP60) Taper (RP60)


NOV FGS Bondstrand® ProductsSeries 2416C 2420C 2425C 4000 5000 5000C

Resin Type Epoxy Epoxy Epoxy Epoxy Vinylester Vinylester


Aromatic amine

Aromatic amine

Aromatic amine

BPO/DMA BPO/DMA


4.6 m/s 4.6 m/s 4.6 m/s 4.6 m/s 4.6 m/s 4.6 m/s

Liner Thickness

NIL NIL NIL 1.3 mm 1.3 mm 1.3 mm


No / Yes No / Yes No / Yes No / No No / No No / Yes

=<1-1/2" NA NA NA QL (RP34) QL(RP105) QL(RP106)

2"-4" Taper (RP60) Taper (RP60) Taper (RP60) QL (RP34) QL(RP105) QL(RP106)

6"-16" Taper (RP60) Taper (RP60) Taper (RP60) QL (RP34) QL(RP105) QL(RP106)


Taper (RP60) Taper (RP60) Taper (RP60) NA NA NA

18"-40" Flange Only

Taper (RP60) Taper (RP60) Taper (RP60) NA NA NA


NOV FGS Bondstrand® ProductsSeries 6000 (FM) 7000 7000M 7000M-FP PSX-L3-

16BarPSX-JF-16Bar

Resin Type Epoxy Epoxy Epoxy Epoxy Phenolic Phenolic


Aromatic amine

Aromatic amine

Aromatic amine

Acid base Acid base


4.6 m/s 4.6 m/s 4.6 m/s 4.6 m/s 4.6 m/s 4.6 m/s

Liner Thickness

0.5 mm NIL NIL NIL 0.5 mm 0.5 mm


No / No No / Yes No / Yes Yes / Yes No / No Yes / No

=<1-1/2" QL (RP34) QL (RP60) QL (RP60) QL (RP60) QL (PSX34) QL (PSX34)2"-4" QL (RP34) QL (RP60) QL (RP60) QL (RP60) QL (PSX34) QL (PSX34)

6"-16" QL (RP34) QL (RP60) QL (RP60) QL (RP60) Taper (PSX34)

Taper (PSX34)


NA NA Taper (RP60) Taper (RP60) NA NA

18"-40" Flange Only

NA NA QL (RP60) QL (RP60) NA NA


NOV FGS Bondstrand® ProductsSeries PSX-L3C-

16BarPSX-JFC-

16BarXXX-FP XXX-WD

Resin Type Phenolic Phenolic See XXX See XXX

Curing Agent Acid base Acid base See XXX See XXX

Rating 16 bar 16 bar See XXX See XXXAllowable Velocity

4.6 m/s 4.6 m/s See XXX See XXX

Liner Thickness

NIL NIL See XXX See XXX


No / Yes Yes / YesYes / See-

XXXYes / See-

XXX

=<1-1/2" QL (PSX60) QL (PSX60) See XXX See XXX2"-4" QL (PSX60) QL (PSX60) See XXX See XXX

6"-16" Taper (PSX60)

Taper (PSX60)

See XXX See XXX


NA NA See XXX See XXX

18"-40" Flange Only

NA NA See XXX See XXX


Approvals - Marine and Offshore (1)• Det Norske Veritas (DNV)• Lloyds Register of Shipping (LRS)• American Bureau of Shipping (ABS)• Germanischer Lloyds (GL)• Bureau Veritas (BV)• Registro Italiano Navale (RINA)• United States Coast Guard (USCG)


Approvals - Marine and Offshore (2)• Nippon Kaiji Kyokai (NKK)• Korean Register of Shipping (KRS)• Marine Department, Singapore• Register of Shipping of the People’s Republic of

China (ZC)


Approvals and Listings–Industrial/Oilfield

• Factory Mutual (FM)• Underwriters Laboratory (UL)• API 15LR• API 15HR• PUB approval for potable water• KIWA (The Netherlands)• London Fire and Civil Defense Authority• Fire Safety Bureau (FSB) of Malaysia• US Military Specification (MIL-P-29206)


Quiz Game1) Name out common joint method use by Bondstand?

2) Advantage of fiber glass pipe compare steel pipe?


2) Health, Safety and Environment!!!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• HSE Rules in NOV FGS Plants• HSE Requirement - Others


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


Chemical and Dust HazardsResin, 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;


Chemical and Dust Hazards• 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.


HSE Rules in NOV FGS Plants

All employees and visitors shall accept safety responsibilities, put safety, health and environmental training into practice in the work place, eliminate unsafe environments, and practice the guidelines provided.

•Proper PPE•Chemical and Dust Hazards Recommendations•Eating and Smoking at designated zone


HSE Requirement - OthersHSE is very important worldwide.• Safety requirements and rules vary with

industries and organizations;• Safety induction prior to work commencing;• Fire retardant overall in oil/petrochemical

plant, FPSO, FSO, production platform, etc;


HSE Requirement - Others• BOSIET (Basic Offshore Safety Induction &

Emergency Training) for offshore visit;o Offshore Orientationo First Aid / CPR / EARo Basic Fire Fightingo Sea Survivalo Helicopter Underwater Escape Training (HUET)


3) Responsibilities and Documentation

• Bondstrand Bonder/Fitter Responsibilities• Documentation


ResponsibilitiesPerforming satisfactory and independent pipe

fabrication and installation of Bondstrand Fiberglass pipe.

• Shall work on qualified scope only (Size range, parent product material, type of joint, pressure rating);

• Following procedure and instruction;• Following design drawings and document;• Preparation of work record/document;• Feedback information to Supervisor if any

issue;


DocumentationPrepare all necessary work process record for

quality assurance and work trace-ability.• Relevant and latest construction drawings,

procedures, and so on;• Joint Log Sheet (Refer to “Fiberglass Pipe

Jointing);• Any other document whichever is required;


Sample Adhesive Bonding Joint Log Sheet

Project Title Product Series:Drawing No.

REMARKS

JOINT DATE BONDER SIZETM - Nose Thickness/ SANDING JOINT ALIGNMENT BATCH NO OF HUM TEMP

No I.D. (in) QLM - OD (40~60grit) Clean & Dry ADHESIVE TYPE SPREAD SPEC ACTUAL START FINISH (%) (degC)

R-H-

R-H-

R-H-

R-H-

R-H-

R-H-

R-H-

R-H-

R-H-

R-H-

QC Inspector

Sign.NameDate

JOINT PREPARATION ENVJOINT CURING

TEMP

ADHESIVE BONDING LOG SHEET

ADHESIVE BONDED JOINT

TIMEADHESIVE INSERTION DEPTH


4) 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


Goods 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


Handling and Transportation• Handling and Transportation

o Proper support and protection with protection pado Securely fastenedo Forklifts should have at least a 6-foot carriage, spacer of at

least 2-inch thickness are located.o Fittings shall be loaded onto pallets, crates or baskets with

sufficient protection.


Handling and Transportationo 3m or less pipe and spool could be lifted by

single 4” wide canvas or suitable plastico Pipe and spool greater than 3m (in length) shall

be lifted in using two or more canvas or suitable plastic

o Prohibitions• Being thrown or dropped from any height.• Using chains, wire ropes or clamps for

lifting


StorageCarrying out inspection for good storage preparation

and carrying out periodical inspection• Fiberglass Pipe

o 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

o Side supports; not exceed 5-ft height; proper tie down

o Protective end cover must be in place


Storageo 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 storeo Fiberglass Fabricated Spools

• Shall be kept in shipping pallet or skid• End cover / protection shall not be removed

until installationo 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


5) Fiberglass Pipe Jointing and Repair• Adhesive Bonding (Quick-Lock & Taper) Joint• Adhesive Bonding (Saddle & Saddle Reducing)• Lamination Joint (Butt & Wrap)• Mechanical O-Ring Joint (Double O-Ring and Key-

Lock Joint)• Flange Joint• Other Mechanical Joint• Threaded Joint / Coil-Lock Joint• Modification & Repair


Adhesive Bonding (QL & Taper) Joint

• Assembly Procedure• QA/QC Measurement• Typical Defects• Sample Bonding Joint Log Sheet


Adhesive Bonding Joint – Assembly Procedure

1. Measurement, Marking & Cutting2. Shaving3. Surface Preparation4. Spigot Insertion Depth5. Dry fit & Alignment of fitting6. Applying Adhesive7. Joint Assembly8. Curing9. Marking Identification


Bonding Joint–QA & QC MeasurementProcess Measures Measurement Remarks

Cutting & Marking

Pipe End Square DN4” and below – 1.5mm;DN6”-16” – 3.0mm;DN18” and above – 5.0mm

Shaving Length Marking

DS(Insertion Depth)+30mm Marking line is in place and clear

Taper Joint Only

Shaving Nose Thickness Within tolerance range Taper Only

Shaving Angle Right angle and within tolerance Taper Only

Spigot Diameter Within tolerance range Quick-Lock

Shaving Length Within tolerance range

Surface Preparation

Surface condition Clean, Dry, and dull and fresh finish not a polished look

Insertion Scribe line DS+50mm, clear

Dry Fit & Alignment

Match Marking Match Marking line(s) in place


Process Measures Measurement Remarks

Applying Adhesive

Type of Adhesive Correct adhesive per product series

Adhesive Condition Not expired; no leaking; no damage on packing

Mixing Ratio All hardener is poured into resin

Mixing Quality Stir thoroughly for at least 1 min and no streak is visible

Adhesive coverage Full coverage of bonding surface including pipe stop and pipe cut end

Quantity of Adhesive Not to apply excessive adhesive onto bell surface, the thickness shall be around 1mm

Temperature of bonding surface

Between 15oC(23oC-ISO14692) ~ 40oC

Otherwise, heating or cooling

Bonding Joint–QA & QC Measurement



Joint Assembly

Adhesive Condition Mate the joint immediately; adhesive shall not be hardened

Alignment and Tolerance

Alignment of match marking line; Within “Maximum Dimensional Tolerance”

Insertion Depth 50 ±3mm from scribe line to fitting edge

Quick-Lock Only

50mm +6/-12 from scribe line to fitting edge

Taper Joint Only

Excessive Adhesive Inside pipe, adhesive bead shall not be greater than 2.5% of pipe ID or 10mm whichever is smaller




Curing Heating Blanket Right size; Right voltage; good condition

Contact Holding apparatus shall be in placed

Curing Duration Refer to FP170 for Quick-Lock; and Refer to FP564 for Taper Joint

Except Fire Protection Product

Curing Temperature 100 ~ 150oC

Marking Project specification Trace-ability

General Environment temperature and Humidity

Environment temperature shall be greater than 15oC, otherwise, bonding surface shall be preheated; Humidity shall be below 75%, otherwise visual inspection and apply heat to disperse water content if necessary



Bonding Joint – Typical DefectsProcess Root Cause Possible Failure Mode Action

Cutting Square-ness out of tolerance

Misalignment Repair on cutting end

Crack / Fracture Leakage Cut off crack section and Re-work

Shaving Spigot Diameter Undersize (QL)

Misalignment; Leakage; Wrong Dimension

Replace

Nose Thickness Undersize (Taper Joint)

Wrong Dimension Trim shaved end, re-shave if necessary, ensure pipe length is sufficient, otherwise, replacement.



Shaving Spigot Diameter Oversize (Quick-Lock)

Wrong Dimension; Insufficient bond thus joint separation

Re-work to achieve appropriate spigot diameter

Nose Thickness Oversize (Taper)

Wrong Dimension; Insufficient bond thus joint failure

Re-work to achieve required nose thickness

Incorrect Shaving Angle (Taper)

Wrong dimension; Joint failure; Misalignment

Check shaver, re-shave or rework

Over-shave in Length

Shaved area might expose after bonding. No impact on overall strength

Coat expose shaved area using adhesive after bonding

Under-shave in Length

Joint separation; Wrong Dimension

Re-work to right shaving length



Surface Preparation

Contaminated Surface (Oil or Dust)

Leakage; Joint Separation Remove dust using dry and clean cloth; Remove oil with soap water and apply heat, otherwise cut off and re-shave

Surface not Dry Leakage; Joint Separation Apply hot air or heating blanket

Polished Surface Leakage; Joint Separation Re-work - Sanding

Insertion Scribe line not marked

Loss of reference point for insertion depth verification

Re-work unless other reference point is available

Dry Fit & Alignment

Match Marking line not marked

Misalignment; Wrong Orientation

Re-work with match marking line


Bonding Joint – Typical Defects

Process Root Cause Possible Failure Mode Action

Applying Adhesive

Wrong Adhesive Weak Joint; Chemical Contact, Loss of Conductivity

Rework

Expired, Leaking or Damaged Adhesive;

Leakage; Joint Separation; Re-work with good condition adhesive

Adhesive is too cold Difficulty to mix; poor adhesion thus leakage

Preheat prior to mix

Incorrect Mixing Ratio

Weak joint; Separation Use new adhesive

Poor Mixing Quality Weak Joint; Leakage; Joint Separation

Mix well prior to application

Insufficient Adhesive coverage

Leakage; Joint Separation Re-work to achieve full coverage



Applying Adhesive continued

Excessive Adhesive on Bell Surface

Adhesive beading out of tolerance

Remove excessive adhesive immediately; remove excessive bead immediately after bonding

Bonding surface is too cold / too hot

Weak Joint, Joint Separation Heat up / cool down bonding surface

Joint Assembly

Adhesive Gelled prior to assembly

Joint Separation Remove adhesive and Re-work

Out of Alignment and Tolerance

Wrong dimension, wrong orientation

Seek for compensation, otherwise re-work

Insufficient Insertion Depth

Wrong dimension; Leakage; Joint Separation

Reject and Re-work

Rotation Joint after Insertion

Leakage; Joint Separation Reject and Re-work



Curing Undersize Heating Blanket; Poor contact

Weak Joint; Leakage; Joint Separation

Change of heating blanket; apply two or more heating blanket; tie down heating blanket

Insufficient Curing Duration

Weak Joint; Leakage; Joint Separation

Proper record to ensure curing duration

Movement during curing

Misalignment; Leakage; Joint Separation

Sign board, warning message, and so on.

Marking No joint identification

Lack of trace-ability Re-train bonder about the requirement

General Cold Bonding Surface / High Humidity

Leakage; Joint Separation Preheat with dry hot air or heating blanket


Sample Adhesive Bonding Joint Log Sheet

Project Title Product Series:Drawing No.

REMARKS

JOINT DATE BONDER SIZETM - Nose Thickness/ SANDING JOINT ALIGNMENT BATCH NO OF HUM TEMP

No I.D. (in) QLM - OD (40~60grit) Clean & Dry ADHESIVE TYPE SPREAD SPEC ACTUAL START FINISH (%) (degC)

R-H-

R-H-

R-H-

R-H-

R-H-

R-H-

R-H-

R-H-

R-H-

R-H-

QC Inspector

Sign.NameDate

JOINT PREPARATION ENVJOINT CURING

TEMP

ADHESIVE BONDING LOG SHEET

ADHESIVE BONDED JOINT

TIMEADHESIVE INSERTION DEPTH


Adhesive Bonding [(Reducing) Saddle]

o Assembly Procedureo QA/QC Measuremento Typical Defectso Sample (Reducing) Saddle Bonding Log Sheet


(Reducing) Saddle– Assembly Procedure

1. Measurement, Marking2. Branch Outlet Preparation

(For Reducing Saddle Only)3. Surface Preparation4. Applying Adhesive5. Saddle Assembly6. Curing7. Marking Identification


(Reducing) Saddle–QA & QC Measurement


Marking Bonding Area Marking

Location and Orientation (Tolerance: Refer to Fabrication)

Alignment Marking Marked on both pipe body and saddle in both axial and circumferential directions

Branch Hole Marking Location and Orientation (Tolerance: Refer to Fabrication)

Reducing Saddle Only

Hole Cutting

Hole Diameter Within tolerance range Reducing Saddle OnlyCutting Edge Smooth, and no sharp edge

Pipe Body after Cut Good condition, no fracture

Surface Preparation

Surface condition Clean, Dry, and dull and fresh finish not a polished look


Process Measures Measurement RemarksApplying Adhesive

Type of Adhesive Correct adhesive (Adhesive used for saddle might be different from parent product series)

Adhesive Condition Not expired; no leaking; no damage on packing

Mixing Ratio All hardener is poured into resin

Mixing Quality Stir thoroughly for at least 1 min and no streak is visible

Adhesive coverage Full coverage of bonding surface including cut edge of branch hole

Quantity of Adhesive The thickness shall be around 1mm

Temperature of bonding surface

Between 15oC(23oC-ISO14692) ~ 40oC

Otherwise, heating or cooling




Saddle Assembly

Adhesive Condition Mate the joint immediately; adhesive shall not be hardened

Alignment and Tolerance

Alignment of match marking line; Within “Maximum Dimensional Tolerance”

Excessive Adhesive Inside pipe (Either header or branch outlet), adhesive bead shall not be greater than 2.5% of pipe ID or 10mm whichever is smaller

For Saddle Reducing Only

Fitness (Between Saddle and Pipe OD)

No visual gap, and adhesive is squeezed out from bonding surface when saddle is being tightened using band clamp



Process Measures Measurement RemarksCuring Heating Blanket Right size; Right voltage; good condition

Contact Holding apparatus shall be in placed

Curing Duration 3 Hours (Heating on External); Duration could be reduced if heating can be applied to both external and internal, duration depending on pipe thickness)

Curing Temperature 100 ~ 150oC

Marking Project specification Trace-ability

General Environment temperature and Humidity

Environment temperature shall be greater than 15oC, otherwise, bonding surface shall be preheated; Humidity shall be below 75%, otherwise visual inspection and apply heat to disperse water content if necessary



(Reducing) Saddle Bonding –Typical Defects


Marking Incorrect location and orientation

Misalignment; out of support location; miss-connection

Rework, or consult design engineer

No alignment marking

As Above As Above

Hole Cutting

Hole Diameter undersize

Restraint of flow; Instrument could not be installed

Grind further to required diameter

Hole Diameter Oversize

Leaking Replace, or Consult NOV FGS

Pipe Damaged Leaking Replace pipe and rework

Surface Preparation

Surface not Dry Leakage; Joint Separation Apply hot air or heating blanket

Polished Surface Leakage; Joint Separation Re-work - Sanding


Process Root Cause Possible Failure Mode ActionSurface Preparation

Contaminated Surface (Oil or Dust)

Leakage; Joint Separation Remove dust using dry and clean cloth; Remove oil with soap water and apply heat, otherwise rework

Applying Adhesive

Wrong Adhesive Weak Joint; Chemical Contact, Loss of Conductivity

Rework

Expired, Leaking or Damaged Adhesive;

Leakage; Joint Separation; Re-work with good condition adhesive

Adhesive is too cold

Difficulty to mix; poor adhesion thus leakage

Preheat prior to mix

Incorrect Mixing Ratio

Weak joint; Separation Use new adhesive

(Reducing) Saddle Bonding – Typical Defects


Process Root Cause Possible Failure Mode ActionApplying Adhesive(Continued)

Poor Mixing Quality

Weak Joint; Leakage; Joint Separation; Saddle shear off

Mix well prior to application

Insufficient Adhesive

Leakage; Joint Separation; Saddle Shear Off

Re-work to achieve full coverage

Bonding surface is too cold / too hot

Weak Joint, Joint Separation; Saddle Shear Off

Heat up / cool down bonding surface

Assembly Saddle

Adhesive Gelled prior to assembly

Joint Separation; Saddle Shear Off

Remove adhesive and Re-work

Out of Alignment Dimension and Orientation out of Tolerance

Consult Design engineer, or re-work

Poor Mating Fitness

Leakage (Red Saddle);Shear off (BLK Saddle for Anchor)

Re-work





Curing Undersize Heating Blanket; Poor contact

Weak Joint; Leakage; Joint Separation; BLK Saddle Shear Off

Change of heating blanket; apply two or more heating blanket; tie down heating blanket

Insufficient Curing Duration

As Above Proper record to ensure curing duration

Marking Project Specification Lost of trace-ability Re-train bonder about the requirement

General Cold Bonding Surface / High Humidity

Leakage; Joint Separation Preheat with dry hot air or heating blanket


Sample Log Sheet for (Reducing) Saddle Bonding

Project: Company:

Product Series/Rating: Location:

Report No.: Date:

Reference Procedure:

JOINT No.

PIPE SIZE

SADDLE TYPE

CREWALIGNME

NTPRE-HEAT

SANDING(16-60grit)

CLEAN & DRY

CUT HOLE DIA

CUT HOLE CONDITION

ADHESIVE TYPE

START TIME

END TIME

HUM (%)

TEMP (degC)

R-H-R-H-R-H-R-H-R-H-R-H-R-H-R-H-R-H-

QC Inspector Owner Representative Ameron Representative

Signature: Signature: Signature:Name: Name: Name:Date: Date: Date:

Notes: This "Log-Sheet" is applicable to installation of "Blank Saddle", "Grounding Saddle", "Saddle Reducing Outlet", and "Saddle Reducing Bush".

BONDSTRAND SADDLE ASSEMBLY LOG SHEET

ADHESIVE BONDING CURINGGENERAL JOINT PREPARATION

S/No REMARKSDRAWING No. / LINE No. / LOCATION

ADHESIVE BATCH No.

ENVIRONMENT

7

1

2

3

4

5

6

8

9


Lamination (Butt & Wrap) Joint

o Assembly Procedureo QA/QC Measuremento Typical Defectso Sample Log Sheet for Lamination Joint


Butt & Wrap Joint – Assembly Procedure

1. Measurement, Marking & Cutting2. Surface Preparation3. Adhesive Coating4. Lamination5. Curing


Butt & Wrap Joint–QA & QC Measurement


Measurement; Marking & Cutting

Tight match between two connecting pipes

No obvious gap (Shall not be greater than 5mm)

Surface Preparation

Surface condition Clean; Dry; Free of Oil; Abraded with fiber exposed

Sanding Length Refer to NOV FGS procedures

Surface Temperature 15oC~40oC

Adhesive Coating with boat tape

2 layers; 50-150mm width

Resin Mixing

Resin type and Mixing ratio

Depending type of resin. Follow NOV FGS Procedure

Pot Life Depending type of resin. Follow NOV FGS Procedure


Butt & Wrap Joint–QA & QC Measurement


Lamination Layer Sequence Following NOV FGS Procedure

Numbers of Layers Depending on size, pressure, and resin material. Following NOV FGS Procedure.

Lamination overlap

Material Wet-Up Impregnate mixed resin simultaneously; no sign of original color of boat tape / woven roving.

No Air -

Curing Heating Blanket Coverage

Full coverage

Curing time and Temperature

Depending on type of resin. Following NOV FGS Procedure


Butt & Wrap Joint – Typical Defects

Process Root Cause Possible Failure Mode ActionMeasurement; Marking & Cutting

Excessive gap between two connecting pipes

Resin bead in pipe inner surface

Filled minor gap with adhesive; rework on pipe if necessary

Surface Preparation

Not clean; not dry; not properly sanded; or oil contaminated;

Weak Joint; Leakage Rework on the surface preparation process

Insufficient sanding length

Weak joint; Leakage; Joint Separation

Re-work

Pipe in low temperature

Leakage; Joint separation Preheat the pipe ends

Coating (with boat tape) not cured

Leakage Curing the coating layers with heating blanket.



Process Root Cause Possible Failure Mode ActionResin Mixing

Incorrect Ratio of resin and curing agent

Weak Joint, leakage Make ratio right, or discard resin mix and use new resin and curing agent

Mixed resin is kept for too long before use

Difficult to apply; Weak Joint; Joint Separation

Discard resin mix and use new resin and curing agent

Lamination Short of layers; Insufficient overlap

Weak Joint; Joint Separation Built up more layers to compensate mistakes; or make a new lamination

Poor wet-up Weak Joint; Leakage Apply rich resin for each layer

Air trap Leakage Pull in tension and /or use rubber squeezer




Curing Joint and pipe being moved during curing; Insufficient curing time

Weak Joint; Joint Separation Rework

Insufficient heater blanket coverage

Weak Joint; Leakage Increase curing time; Use more heater blanket

Finishing Finishing coat is not resin rich; heater blanket is applied prior to hand touch gel

Poor appearance, rough surface, sharp corner

Grind surface and coat with working resin / adhesive


Sample Lamination Joint Log Sheet

Project: Company:

Product Series / Rating: Location:

Report No.: Date:


JOINT No.

PIPE SIZE

CREWMATING / ALIGNME

NT

PRE-HEAT

SANDING(16-60grit)

CLEAN & DRY

ADHESIVE COATING

WITH BOAT TAPE

RESIN/ CURE RATIO

NUMBER OF

LAYERS

WET-OUT

LENGTH

START TIME

END TIME

1

2

3

4

5

6

7

8

9



Notes:

BONDSTRAND LAMINATION JOINT ASSEMBLY LOG SHEET

LAMINATION CURINGGENERAL JOINT PREPARATION



Mechanical O-Ring Joint

---Double O-Ring Joint for Marine;---Key-Lock Joint for Industrial

o Assembly Procedureo QA/QC Measuremento Typical Defectso Sample Log Sheet for Mechanical O-Ring Joint


Mechanical O-Ring Joint –Assembly Procedure

1. Placement of connecting pipe/spool2. Surface Preparation3. O-Ring Placement4. Pipe/spool Spigot Insertion5. Driving the Nylon Key6. Positioning and Aligning the Jointed Pipe

(UG)


Mechanical O-Ring Joint–QA & QC Measurement


Placement of Connecting Pipe/spool

Lateral offset 1.0mm Maximum

Angular Deflection 2”-16”, 1/2o; 18”-28”, 1/4o;30”-40”, 3/16o

Distance between two Spigots

Product requirement Only when Coupling in Used

Surface Preparation

Clean and Lubricate Full Coverage

Projection / Rough edge

No projection and rough edge is allowed

O-Ring Placement

Size and Quantity Correct size and quantity as per Product Dimension Table

O-Ring Condition New, No damage, lubricated

O-Ring Groove Correct size according to design


Mechanical O-Ring Joint–QA & QC Measurement


Insertion Lock end Positioning Leading edge of Female is 0~6mm to Scribe line

Free end Positioning Within maximum and minimum scribe lines

Double O-Ring Joint

Driving Nylon-Key

Size and Quantity Correct size and quantity as per Product Dimension Table

Key Condition New, No damage, lubricated

Positioning Aligning

Refer to Buried Installation, FP278C

Underground Installation


Mechanical O-Ring Joint – Typical Defects


Placement of Connecting Pipe/spool

Lateral Offset; Angular Deflection

Pipe damage due to applying force to meet alignment

Release pipe support and realign pipes; or modify piping to achieve alignment

Gap (Between two male ends) is too big/small

Over insertion or insufficient insertion

Check acceptance criteria, otherwise modification work.

Surface Preparation

Surface not clean; not lubricated; Projection on surface; and sharp edge

O-ring Damage and Joint Leakage

Re-work on surface preparation, and replace damaged O-Ring

O-Ring Placement

Wrong size; Poor Condition

Joint Leakage; could not be assembled

Replace O-Ring


Mechanical O-Ring Joint – Typical Defects

Process Root Cause Possible Failure Mode Corrective Action

Insertion Over insertion or insufficient insertion

Unable to install Nylon-Key Adjust insertion depth as per spec.

Insertion beyond of acceptance criteria

Insertion too much, pipe to pipe touch – damage; Insertion insufficient -Leakage

Make adjustment, or modify piping if necessary

Driving Nylon Key

Wrong size/quantity; poor condition

Joint Separation Replace Nylon-Key


Sample Mechanical O-Ring Joint Log Sheet

Project:

Series :

Product Size :

Line Number:

Report No.:

S/NJOINT

No.DATE

INSTALLER I.D.

ALL SURFACES

CLEAN & DRY

*REMOVE SHARP /ROUGH

EDGES

LUBRICATE GROOVE &

ALL SURFACES

O-RING SIZE AND

CONDITION

CLEAN & LUBRICATE O-RING(S)

DISTRIBUTE O-RING(S) EVENLY

ALIGNMENTINSERTION

DEPTHKEY(S) SIZE &

CONDITIONLUBRICATE

INSERTION (ABLE TO SEE

LEADING END)

1

2

3

4

5

6

7

8

9

10

11

12



Notes: ** Centre scribe line on male end is in line with edge of female end (For joint with Locking Key)** The edge of Female End is fall in between maximum and minimum installation scribes (For Double O-Ring without Lock Key)

LOG SHEETINSTALLATION OF KEY-LOCK JOINT / DOUBLE O-RING JOINT

GENERAL

REMARKS

JOINT PREPARATION KEYSINSERTION

Ø D

2

Ø D

1

* Remove any rough/shargp edges


Flange Joint

o Assembly Procedureo QA/QC Measuremento Typical Defects


Flange Joint – Assembly Procedure

1. Checking flange condition2. Alignment3. Preparation of bolts, nuts, washers and gasket4. Bolt Tightening

Reference: FP196“Assembly Instructions forBondstrand fiberglassFlanges”


Flange Joint – QA & QC MeasurementProcess Measures Measurement Remarks

Checking flange condition

Flange Seal Ring condition

No damage

Matching Seal Rings contact

At least two seal rings are fully contacted with counter flange

When joint to other flanges

Alignment Gap between mating face.

Refer to next slide for details.

Preparation of bolts, nuts, washers and Gasket

Size According to relevant drilling standard

Material and Treatment

According to project material specification

Lubrication Bolt threads and washer lubricated

Tightening Torque increment & torque value

Recommendation of FP196

Torque sequence Recommendation of FP196


Flange Joint – Misalignment Tolerances

Size (inch)

A (mm)

B (mm)

½”-12” 1.0 2.0

14”-16” 1.6 3.2

18”-24” 2.0 4.0

26”-40” 2.4 4.8


Flange Joint – Typical DefectsProcess Root Cause Possible Failure Mode Corrective Action

Checking flange condition

Damaged flange seal rings

Leakage Replace the flange

Matching Poor contact between flanges

Leakage Detail study required

Alignment Misalignment Leakage; Damage of bonding joint if force align by tightening bolts.

Re-align pipes; rework problematic flange

Preparation of bolts, nuts, washers and gasket

Incorrect / poor quality materials

Leakage Use correct / good quality material

Poor lubrication Leakage Re-work

Bolt tightening Insufficient / Over torque

Leakage / Damage of flange and flange joint

Re-work

Wrong torque sequence

Leakage Re-work


Sample Log Sheet – Flange JointProject: Company:

Product Series / Rating: Location:

Report No.: Date:


TORQUE

JOINT No.

PIPE SIZE

CREWFLANGE STANDA

RD

TYPE OF GASKET (FF/RF)

GASKET THK (mm)

GASKET MATERIAL

BOLT SIZE (mm)

BOLT MATERIAL

LUBRICATION

PLAIN WASHER

A (mm) B (mm)fb.lb OR

N.M

1

2

3

4

5

6

7

8

9



Notes:

BONDSTRAND FLANGE JOINT ASSEMBLY LOG SHEET

ALIGNMENTGENERAL MATERIALS



Other Mechanical Joint

o Other type mechanical joints• Metallic Couplings (Dresser, Straub……)• Victaulic Couplings

o Installation Guidance• Reference should be made to the

manufacturer’s data with consideration of fiberglass pipe features


Threaded Joint and Coil-Lock Joint

o Assembly Procedureo QA/QC Measuremento Typical Defects

To be added in future as it is not common used for Bondstrand product series.


Modification & Repair

Generally, GRP pipes are maintenance-free for its application function. But modification work and repair are required from time to time due to many causes such as: design change, impact damage, improper design, mishandling, etc.

• Typical Defects and Corrective Actions• Typical Modification Works• Modification and Repair Methods• Inspection of modification and Repair• Recommended Procedure


Typical Defects and Corrective Actions - 1

Defects Description Action(s) RemarksBody Impact

DamageLight area with or without broken fibers on surface and/or layers under resin rich top surface

Over-Wrap; Partial

Replacement

Pipe End Damage

Visual broken, crack, de-colored area, burnt

Partial Replacement

DOM, KLM, TM, QLM,

Threaded Male, ME, etc

Surface Damage

Scratch and shallow mark cause by improper handling, storage or transportation. !!!No leakage is observed at any time.

Surface Repair

Not more than 10% of WT or

1mm whichever is lower


• Consult NOV FGS in case-by-case basis


Defects Description Action(s) Remarks

Bonding Joint Leakage

Weep or Continuous Leak from adhesive bonding joint

Partial Replacement

Remove excessive

adhesive if it is difficult to judge

Fiber Blooming /

Surface Chalking

Fiber blooming on outer surface due to UV radiation.

Painting / Coating

No impact on performance





Defects Description Action(s) Remarks

Surface Burnt Light burnt: burning area shall be ground to expose unaffected structural wall. The total affected thickness shall not be greater than 10% of WT or 1mm whichever is lower.

Surface Repair

Serious burnt:Burning effect is more than 10% of WT or 1mm whichever is lower.

Partial Replacement


Typical Modification Works

1. Change of pipe/spool end configuration, such as flange standard;

2. Re-routing;3. Insert/remove component into/from existing

pipe;4. Lengthen/shorten pipe/spool to suit site

condition;


Modification and Repair Methods – 1

Partial Replacement;• Use of socket coupling(s) for jointing existing pipe

and new pipe; alternatively, use lamination for jointing existing pipe and new pipe;

• Ensure cut length is sufficient for shaving & bonding;

• Follow joint assembly procedure such as Quick-Lock, Taper-Taper, etc; nothing is special;

Over-wrapping• Wrap over the problematic location / joint;• Only used for minor damage and minor leaking

joint;• Lamination (Butt & Wrap) skill is required;


Modification and Repair Methods – 2Lamination (Butt & Wrap)

• Good use in constraint space, in which, existing pipe is difficult to move;

• Good use when shaving tool is not available;• Good use when there is misalignment in between

mating pipes;• Lamination (Butt & Wrap) skill is required;• Can be used in conjunction with “Partial

Replacement”;Applying Adhesive / Coating

• Only used for cosmetic purpose only;• Light sanding prior to applying adhesive / coating

Many Other Methods depending on nature of modification/repair work and site condition, consult NOV FGS in case by case basis.


Inspection of Modification and Repair

1. Normal in-process inspection for the specific type of joint;

2. Pre-work inspection to identify cause/reason;3. Testing after relevant piping after

modification/repair.4. Typical reports: NCR (Non Conformance

Report), ECN (Engineering Change Notice), …….


Recommended Procedures

1. Site inspection, Collecting necessary information/document (Such as drawing, reports, safety requirement, etc);

2. Study the cause of defect if applicable;3. Propose modification/repair method(s) with

consideration of cause, feasibility, permanent, etc;

4. Submit modification/repair proposal to relevant party for approval;

5. Carry out modification/repair work in accordance with relevant procedures;

6. Report and/or Record modification/repair work.


6) Tools and Equipment• Special Tools

o Pipe Shaver and Power Driveo Pipe Arbor for Shaverso Heating Blanket

• Other Accessorieso Band Clampo Lever Hoisto Bore Polisher (Flapper Wheel)

• Common Pipe Tools


Special Tools – Shaver and Power DrivePipe 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”o To individual size only;o Straight Spigot (For Quick-Lock Joint) Onlyo Driven by common electrical tools or air tools,

such as hand drill

Cutting Insert

For detail guide, See FP376F, ‘NOV FGS B-1F Pipe End Preparation Tool’


Special Tools – Shaver and Power Drive• M74 Pipe Shaver

o 2”~12” Straight Spigot (For Quick-Lock Joint);

o 14”~16” Straight Spigot when extension arms used

o Driven by Power Drive

For detail guide, See FP696A, ‘M74 Pipe Shaver’Shaver Extension Arms



o 2”~6” Taper Spigot (For 2400 and 3400 Taper Joint);

o 1.75° Taper for 2”, 3” and 4”, 2.5 ° Taper for 6”

o Driven by Power Drive

For detail guide, See FP453A, ‘Bondstrand M86 Pipe Shaver’



o 6”~16” Spigot;o Available Angle Setting 0.0 °, 1 3/4°,

2.5° ……o Driven by Power Drive

For detail guide, See FP454A, ‘Bondstrand M87 Pipe Shaver’


Special Tools – Shaver and Power Drive• M87XL Pipe Shaver


2.5°, 3.5° ……o Driven by Power Drive

For detail guide, See FP455A, ‘Bondstrand M87XL Pipe Shaver’


Special Tools – Shaver and Power Drive

• M88 Pipe Shavero 26”~40” Spigot;o Available Angle Setting 0.0 °, 1 3/4°,

2.5°, 3.5° ……• M95 Pipe Shaver


2.5°, 3.5° ……


Special Tools – Shaver and Power Drive• Power Drive

o To drive pipe shavers;o Available in 115V and 230V, to be

specified


Special Tools – Shaver and Power Drive• Maintenance and Store

o Shall be kept in original tool box after use;

o Keep it in dry location, away from rain and moisture;

o Do not use oil and/or grease as dust will accumulate on oil and grease;

o Remove of dust/dirt using brush


Special Tools - Pipe Arbor For ShaversPipe Arbor: Fitted on pipe shavers, to be inserted

into pipe, thus to hold pipe and shaver together.

• Size to suit Bondstrand Pipe ID;• Not applicable for B-1F shaver;• Different designs due to pipe size;

Arbor for M88&M95Arbor for M74, M86 &M87 Arbor for M87XL21 February 2014NOV Fiber Glass System - <Bondstand® Pipe Bonder Training Program>

Special Tools – Heating BlanketHeating 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


Special Tools – Heating Blanket• Description of Heating Blanket


Special Tools – Heating Blanket• Using Heating Blanket

o Wrap the pipe using the end with thermostat;o Tie down accessory shall be used;o Do NOT pull the cable;


Special Tools – Heating Blanket• Packing, Storage and Transporting

o Always roll up the heating blanket when not in used;

o Do NOT pack and transport heating blanket in folded form;

o Any heavy object fall on it may damage the heating blanket;


Other Accessories• Band Clamp with D-Rings

o Shall be used when making joints, Quick-Lock, Taper, Mechanical O-Ring, ……

o Available in 2”width x 6’length, ando Available in 2”width x 13’ length, ando Available in 3”width x 13’ length


Other Accessories• Lever Hoist

o Shall be used when making joints, Quick-Lock, Taper, Mechanical O-Ring, ……

o Available in ½ Ton and 1 Ton, ……

o Alternatively, ratchet puller (chain block) can be used

• Bore Polisher (Flapper Wheel)o Sanding bonding surfaceo Grid 40~60o Driven by electrical drill or air

tool21 February 2014NOV Fiber Glass System - <Bondstand® Pipe Bonder Training Program>

Common Piping Tools

• Hacksaw or abrasive wheel;

• Paint marker;• Pipe wraparound;• Baby grinder;• Electric or Air drill;• Level Gauge;• Paint Brush;• Nylon/Rubber Mallet;

• Cotton Roller;• Adjustable Pipe

Stands;• Sanding Disc;• Screw Driver;• Scissors;• Air Release Roller;• ……

There are many other common piping tools might be required for fiberglass piping fabrication and installation work, such as:


7) Fabrication and Installation• Drawings• Supports• Fabrication and Installation Tolerances• Hook-up to Equipment / Other Material• Key Installation Features


Drawings• Spool Drawing;

o Contain detail dimensions, fabrication materials, and erection materials

• Isometric Drawing;o Contain all details of design (Pressure, fluid,

system, temperature,…..), fabrication and erection (Materials), installation (Coordinates, connections) and testing

• Layout Drawing;o Background, surrounding, piping routing,

supporting, interface, equipment, etc• Piping and Instrument Diagram

o Principle such as size, flow direction, design information, materials specification


Sample Drawing – Spool-1


Sample Drawing – ISO-1


Sample Drawing – Layout-1


Sample Drawing – Layout-2


Supports

Appropriate supports location and appropriate support type, and appropriate steel support element are the key elements of Fiberglass pipe integrity, security of operation for life long!!!o General Rules;o Type of Supports;o Support Location Determinationo Consequence of Poor Steel Designo Inspection Focus


Supports – General Rules• Supports shall be placed to avoid sag

and/or excessive vibration; Supports shall be placed to ensure sufficient flexibility in the piping system for fatigue in service life;

• Supports shall be designed according to Fiberglass pipe special features, such as OD;

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

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


Supports – General Rules• Fiberglass pipe shall be sufficiently supported to

avoid overstress by piping temporary attachment such as removable hose;

• All support elements and overall design of each support shall be strong enough to undertake forces generated by the piping and fluid;

• Protection against direct contact between pipe structural body and steel element


Supports – Type of Supporto Rest

• Simple;• Free of movement• Protection between pipe body and steel

structure by either “GRE blank saddle bonded onto pipe surface” or “Plastic plate bonded onto top of steel”.

• Steel element shall be adjusted to ensure no gap between pipe and structure.


Supports – Type of Supporto Guide

• Free of movement in axial direction (Full Guide)

• Protection between pipe body and steel structure by either “GRE blank saddle bonded onto pipe surface”, or PVC Sleeve, or engraved rubber, or “Rubber sheet bonded onto inner surface of steel clamp”.

• Two-half type clamp is recommended.


Supports – Type of Supporto Anchor (Fix)

• Restriction in axial, lateral directions.• Bonded onto pipe surface, Fiberglass Blank

Saddle(s) act as stopper.• Protection between pipe body and steel

clamp using rubber sheet or other suitable materials.

• Two-half type clamp is recommended.• Can be placed on vertical pipe


Supports – Type of Supporto Flange Frame

• To support valve and heavy in-line items;

• Wafer valve may be supported at one side only; small bore in-line items need not be supported;

• At least one side shall be kept as axial free movement, two sides fix (Full weld) is not allowed;

• Sufficient bolt holes coverage to avoid bolt shear;

• Sufficient plat thickness and web plate to avoid shear; if the flange frame is welded to structure, it can act as a “Light Anchor”.

• Always consult design engineer and stress engineer if any doubt


Supports – Type of Support

• Directional Stoppero Allow axial movement in single

direction.o Bonded onto pipe surface,

Fiberglass Blank Saddle(s) act as stopper.

o Protection between pipe body and steel clamp

o Can be used independently, or together with rest / guide


Supports – Type of Supporto Thrust (Trunnion)

• Good for directional thrust only;• Pipe laminated onto fitting outer surface,

such as elbow and tee;• Steel structure must be strong in the thrust

direction, and no possibility of bending under thrust;

• Could be vertical, could be horizontal

Flange

Lamination on fitting Surface


Supports – Type of Support

• Many others depending combination of restraints in directions and rotations


Support Location Determination• Support span, depending on material property

and wall thickness, type of fluid.• It is recommended to have support not more

than 6m.• It is recommended to have support not more

than 3m for vertical piping.• Supports shall be placed that primary structure

(Concrete or steel) could be used directly rather than additional structure extension.

• Supports shall be placed at both side of mechanical o-ring joint and mechanical coupling joint

• Give consideration to ease of support (Support base, clamp, bolting) installation


Consequence of Poor Steel DesignStrength of steel element has significant impact on

the integrity of Fiberglass piping system. There are many cases that weaken steel support element result in Fiberglass piping damage by excessive movement.


Supporting Inspection Focus• Support Span within recommendation;• Support type and location are in accordance

with design (Drawings, calculation & analysis);

• Comment on the design (Advisory only);• Curvature of steel clamp against pipe OD;• Protection (Between pipe surface and steel

element) method and materials;• The integrity of each individual support

installation, such as bolting, welding, ……• Strength of the steel element, feedback to

design engineering if it is concern about the strength of steel structure.


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

o Refer to tolerance of different type of joints such as flange joint, mechanical o-ring joint.

o Project specification


Recommended Fabrication Tolerances1. Face/center to

face/center dimension, or location of attachment

2. Lateral translation of branch or connection

3. Rotation of flange4. End preparation5. Alignment of flange face6. Angular deflectionReference: ISO14692-4:2002


Recommended Fabrication Tolerances

Reference: ISO 14692-4:2002 and NOV FGS PF-01.

DN (Inch)

Tolerances / Dimension Number

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


Hook-up to Equipment / Other MaterialTo 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

o Equipment (Including fire hydrant, ballast eductor, ….) shall be independently anchored,

o Allowable alignment to avoid excessive stress,o Control torque value strictly if equipment

connection is cast iron material,o Dismantle piece is recommended for testing and

equipment maintenance.


Hook-up to Equipment / Other Material• Hook-up to Other Piping Materials

• Other piping material shall be fully anchored near interface point, to prevent movement transfer to fiberglass piping system.

• Connecting to welding metallic pipingo It is recommended to complete welding work

prior to jointing fiberglass piping;o Otherwise, cooling method must be adopted

to prevent welding heat transferred to fiberglass piping

• Connecting to threaded metallic pipingo Pay attention to threading standard, such as

NPT, BSP, BSPP, and so on,o Fiberglass material must be properly held to

prevent damage due to threading torque.


Key Installation Features

In different working condition and environment, the key features and factors of success are affected by the nature of the project.• Marine (Shipbuilding)• Offshore (Platform, FPSO Topside,

Construction)• Onshore (Above Ground)• Onshore (Underground)


Marine (Shipbuilding)• Piping Alignment• Appropriate and ‘Strong Enough’ Supporting• Attention to support which is designed and

installed to undertake force generated by un-restrained mechanical joint

• Installation sequences (GRE Pipe installation; hull block construction; penetration installation; support installation) depending on yard preference, but attention shall be paid.


Offshore (Platform, FPSO Topside……)• Piping Alignment• Appropriate Supporting in accordance with

stress analysis recommendation


Onshore aboveground Piping• Piping Alignment• Appropriate Supporting in accordance with

stress analysis recommendation


Onshore Underground Piping• Trench condition (Size, shape, water level……)• Filling and back fill material and condition and

execution procedure;• Nature soil / environment condition;• Road Crossing


Onshore Underground Pipingo Trench Excavation

• Minimum trench width Pipe Diameter + 12”/24” for size (not greater than 32”)/(not less than 36”) respectively

• The trench foundation shall be firm, free from stone and lumps

• Over excavation may be required if the soil is unstable or solid rock


Onshore Underground Pipingo Backfilling Recommendations

• Note.1: Bedding with clean sand or gravel<10mm;

• Note.2: Compact the area below the pipe;• Note.3: Primary backfill and compact about

0.7xD with sand or gravel;• Note.4: Secondary backfill and compact

about 300mm on top of pipe;• Note.5: Final backfill with nature soil,

compact in layers


Onshore Underground Piping• Road crossing protection. Sleeve with centraliser and

end-seal is recommended.o Steel sleeve is recommended regardless of

calculation result;o Centralisers are to provide support to pipe in the

sleeveo End-seal to prevent entering of backfill materials


Onshore Underground Piping

• Valve pit / manhole installation


Onshore Underground Piping• Thrust block installation & Fire Hydrant

Installation


8) Testing

• Burst Test• Qualification Holding Test• Fabricated Spool Testing• System Hydro-testing• Conductivity Test• Other Test Methods


Burst TestBurst Test is normally used for product

qualification, procedure qualification and bonder qualification.

• Minimum burst pressure shall be reached or exceeded between 60s and 70s;

• Minimum burst pressure is different from base materials and product pressure rating: - In general

o Standard Epoxy Products: 4 Timeso Standard Vinyl ester Products: 3 Timeso Standard Polysiloxane-Phenolic Products:

4 Timeso Consult NOV FGS for non-standard

productsReference: ASTM D1599 – “Standard Test Method for Resistance to

Short-Time Hydraulic Pressure of Plastic Pipe, Tube, and Fittings”


Qualification Holding TestQualification Holding Test is normally used for

bonder qualification program.• Generally, pressure will be lower than required

burst test pressure, and higher than normal hydro-test pressure;

• Holding pressure and holding duration are different from each rules and/or standard;

o ISO 14692: - 1.75*Pq (Product Qualified Pressure) or 3.07*Pd,max for sustained piping (2.61*Pd,max for buried piping); Duration 1 hour

o ABS & BV: - 2.5*Pd,max, Duration 1 hour• Acceptance Criteria:

o No joint separation, no leakingo Pressure drop is accountable and reinstated

immediately


Fabricated Spool TestingSpool Testing is normally used to verify quality of

fabrication joints.• 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 (Refer to ITP for more details):

o Spool with “Taper Male” end,o Spool with QL Female and Taper Female

and greater than 16”NOV Fiber Glass System - <Bondstand® Pipe Bonder Training Program> 21 February 2014

System Hydro-testingSystem 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-Testingo All piping supports must be completed;o For underground piping, sufficient partial

backfill and temporary block must be in place to prevent excessive movement;

o High point vents / low point drains in place;o Removing/isolating components that shall

be excluded from hydro-testing;


System Hydro-testing• Test Pressure

o 1.5 times of design pressureo 1 hour holding minimum, or sufficient time to carry

out line check, or project specification whichever is longer

• Testing Equipmento Quick closing valve and booster pump without

suitable control shall not be used, to avoid surge;o Pressure gauges and instrument must be

calibrated;o Appropriate pressure gauges shall be selected,

the test pressure shall be between 30% to 75% of reading range

o If possible, pressure recorder shall be used;NOV Fiber Glass System - <Bondstand® Pipe Bonder Training Program> 21 February 2014

System Hydro-testing• Hydro-Testing

• Pressure build up process:o The test pressure shall be raised over a

period of 30minutes of longer.o Slowly and gradually to allow for equalizing for

strain, and also in stages to allow for inspection.

• Inspectiono Instrument readingo Visual inspection of joints, pipes and fittings

• 24 hour holding @ 1.1xdesign pressure (ISO14692:4)

• Acceptance criteriao No sign of leaking or weepingo No significant pressure lost


System Hydro-testing• Possible causes of pressure change

o Effect of joint expansion and material creep;

o Effect of temperature (Morning, afternoon, night, under sun, and so on), take precaution to prevent over-pressure

• Other Concernso Glycol antifreeze shall be added when test

is carry out in subzero temperature.o Instrument to prevent from buckling in case

of sudden depressurizationo 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”


Conductivity TestNOV FGS conductive product series incorporate high strength conductive filaments and joint with conductive adhesive, to prevent accumulation of potentially dangerous levels of static electrical charges.•Tools / Instrument

o Ohm Meter (Recommendation: 0~20 M-Ohm)o Wet/Damp Sponge (To extend coverage of

nodes)•Application

o Fabricated Spool Testo Installed Piping System Test

Reference: ‘Procedure for Conductivity and Grounding’.


Conductivity Test• Placement of Probes

o Pipe external wall (Resin rich top surface shall be removed)

o Back of Flangeo Inner surface of fittingso Lug of bonded grounding saddleo Adhesive fillet at bonding jointo Adjacent steel structure or metallic piping or

equipment


Conductivity Test• Fabricated Spool Test

o The test(s) shall cover all joint(s) and all component

• Installed piping testo Selective piping sections with consideration

of field bonding joint, and the effect of mechanical joint(s)


Conductivity Test• Acceptance Criteria: Reading is not exceeding

1.0 Mega Ohm:o Between any points for fabricated spool;o Between fiberglass piping and adjacent

grounding structure, metallic piping or equipment;

o Between piping sections if there is nomechanical joint (Such as Double O-Ring, Key-Lock, Dresser Coupling…)


Other Test Methods‘The hydrotest is considered to provide the best

assurance of a GRP pipe system’s integrity, and is more reliable than other NDE techniques for assessing that the system has been properly fabricated and installed.’ ISO14962-4, Annex-E

• Ultrasonic Testingo Areas in bonded pipe joints lacking

adhesive, however, it is unable to tell poor adhesion;

o Delaminations, voids;o Deviations in wall thickness (20%);


Other Test Methods• Radiographic Testing

o Incorrect wall thickness, up to 20% deviation

o Voids, Lack of Adhesive, however, poor adhesion could not be identified

o Excessive adhesive on inner wall


Other Test Methods• Differential Scanning Calorimetry (DSC) and Barcol

Hardness Testingo ‘Improper mix of adhesive / resin mixo The glass transition temperature (Tg) of our

adhesive systems is difficult to measure because each of the components in the formulation has different phase transition over a temperature range. This different phase obscures the change in heat absorption of the epoxy system at its transition and makes it difficult to determine actual Glass transition.


9) Fire Performance Product

NOV FGS fire performance products provide outstanding resistance to fire and heat, and/or generate low smoke and low toxicity in fire.

• PSX Product• ‘FP’ Product• ‘WD’ Product• ‘FR’ Product• Special Features in Fabrication and Installation


‘PSX’ Product

o Low smoke


‘PSX’ Product

o Low toxicity

MoreToxic

LessToxic


‘PSX’ Product

o IMO A.753(18) Level 3 Testo PSX-L3(C), no fire protection jacketo PSX-JF(C), with integral fire protection jacket


‘-FP’ Product

o ‘FP’ stands for Fire Protectiono Passive Fire Protection layer applied on

standard Bondstrand pipe and fittingo Jet Fire Endurance (for 5 mins dry followed by

25 minutes flowing water)o Available on standard pipe –2000M, 7000M,

2410 ~ 2425, 2410C ~ 2425C ……


‘-WD’ Product

o ‘WD’ stands for Wet/Dryo Passive Fire Protection layer applied on

standard Bondstrand pipe and fittingo Raw Material: Pittchar (Coating form)o Compliance with Guide for ABS Facilities

Offshore Installation, Appendix 1, Section 8 (Modified L3 fire endurance, 5 mins dry followed by 25 minutes flowing water), lower rating than ‘-FP’

o Available on standard pipe – 2000M, 7000M, 2410 ~ 2425, 2410C ~ 2425C ……


‘-FR’ Product

o ‘FR’ stands for Flame Resistanto Flame resistant layer applied on standard

Bondstrand pipe and fittingo Raw Material: Favuseal, Ceramic, …. In Tape

formo Flame Spread - compliance with IMO 653 (16)o Available on standard pipe – 2000M, 7000M,

2410 ~ 2425, 2410C ~ 2425C ……


Special Features in Fabrication and Installation

o Flange Cover Installation (Not for PSX)• Tighten two mating flange covers• Seal of joints between two flange covers,

and between flange cover and pipeo Field Joint

• Seal of all field joints with fire protection coating such as PittChar

• Not necessary for PSX as fire protection adhesive is used for PSX products.


Special Features in Fabrication and Installation

o Installation of Saddle / Saddle Reducing• Fire protection jacket at bonding area shall

be removed• After installation, fire protection layers shall

be installed for saddle reducing.• For blank saddle, the need of patch-back

depends on the purpose of the blank saddle.o Installation of fire protection layers could be

carried out after piping installation.



Thank you

TR-01Bonder Training Program (Main)

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Transcript of TR-01Bonder Training Program (Main)