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DPFC
Table of Contents Introduction Technologies Yield Higher Performance at Lower Cost Product Benefits Performance Standards Control Testing & Qualification Testing Method of Manufacturing Product Scope - Technical Data Pipe Classification Selection Pipe Dimensions Couplings Dimensions Fittings Shipping, Handling and Storage General Installation Factors Affecting Installation Pipe Joining Field Hydrotest - G.R.P. Piping Surge Water Hammers Thrust Blocks, Concrete Encasement, Rigid Connections Field Adjustments Small Diameter Pipes Environmental Guide for DPFC Pipe
Page No. 1 2 3 4 5-6 7 8-11 12 13 14 15 16-18 19-21 22 23-25 26-28 29 30-32 33-34 35-36 37-38
WHITE
Introduction
DPFC
Dubai Pipes Factory Co. is a Pipes and Fittings manufacturing firm located in Jebel Ali Industrial Area in Dubai-United Arab Emirates. The first commissioned production line is made for the manufacturing of Glass Reinforced Plastic Pipes and Fittings upto and including 2400mm diameter. Continuous winding is the process utilized for the GRP pipe production as per the Know How and Technology supplied from Flowtite Technology. All manufacturing and testing equipment are of the latest version in the pipe technology supplied by Flowtite Technology. The GRP manufacturing, installation procedures, design, testing and qualifications are in accordance to the Know How and Technology supply agreement between Dubai Pipes Factory Co. and Flowtite Technology. DPFC holds kitemark licenses that confirm the compliance of DPFC GRP pipes with requirement set by international organizations such as ISO, BSI, EN and ASTM. The second commissioned production line is made for the production of GRP pipes but using the Helical Winding Process. DPFC is quality committed and ISO 9001:2008 approved. DPFC is also committed to the Environment, and our company is certified for complying with ISO 14001:2004 standard. DPFC GRP pipe has been tested and approved for the conveyance of portable water. Testing and approval are conducted by Water Regulations Advisory Scheme.
Water transmission and distribution (potable and raw water) Sanitary sewerage collection systems (gravity flow and force main) Storm water Effluent water Sea water intake and outfalls Circulating cooling water, make-up and blowdown lines for power plants Industrial applications Irrigation Odor control piping Oil field injection piping Fire fighting lines Ducting Slip lining for piping rehabilitation Insulated pipes for district cooling lines: core pipes as well as jacket pipes.
DPFC-GRP pipe delivers long, effective service life with low operating and maintenance costs. And DPFC-GRP pipe is the lowest cost option upfront too !
*Diameter availability is dependent on manufacturing equipment.
Product Benefits
DPFC
DPFC-GRP pipe is bringing a product to the market that can provide low cost, long-term piping solution to the customers around the world. The long list of features and benefits add up to provide the optimum installed and life cycle cost system. Features Corrosion resistant materials. Benefits Long, effective service life. No need for expensive cathodic protection. No need for costly pipe coating, wrapping, lining, painting, or use of polyethylene bags. Low maintenance costs. Hydraulic characteristics essentially remain unchanged over time. Ease of joining helps reduce installation time. Tight, efficient joints designed to eliminate infiltration and exfiltration. Costly joint diapers are not required. Allows for flexible alignment, accommodating changes in line direction with fewer fittings. Easy to install. No need for expensive handling equipment. Low delivery cost. Fewer joints reduce installation time. Low friction loss means less pumping energy needed. Minimum slime build up can help lower cleaning costs. Assures high quality product specification.
Double bell coupling joints manufactured of corrosion resistant glass fiber, and sealed with elastomeric gaskets.
th
Performance Standards
DPFC
Standards developed by BSI, EN, ISO, ASTM and AWWA are applied to a variety of fiber glass pipe applications including conveyance of sanitary sewage, water and industrial waste. A thread common to all of the product performance based documents. This means that all the required performance and testing of the pipe is specified. designed to comply with these standards: ISO 10467 Plastic Piping Systems for Pressure and Non-pressure Drainage and Sewerage. ISO 10639 Plastic Piping Systems for Pressure and Non-pressure Water Supply. AWWA AWWA C950 is one of the most comprehensive product standards in existence for fiberglass pipe. This standard for pressure water applications has extensive requirements for pipe and joints, concentrating on quality control and prototype qualification testing. Like ASTM standards, this is a product performance standard. DPFC-GRP pipe is designed to meet the performance requirements of this standard. AWWA issued a standard manual, M-45, which includes several chapters on the design of GRP pipe for buried and above ground installations. AWWA ASTM Currently, there are several ASTM Product Standards in use which apply to a variety of fiberglass pipe applications. All product standards require the flexible joints to withstand hydrostatic testing in configurations (per ASTM D4161) that simulate exaggerated in-use conditions. These standards include many tough qualification and quality control tests. DPFC-GRP pipe is designed to meet all of these ASTM standards. ASTM ASTM ASTM D3262 D3517 D3754 Gravity Sewer Pressure Pipe (Water) Pressure Sewer AWWA C950 M45 Fiberglass Pressure Pipe Fiberglass Pipe Design Manual
ISO The International Standards Organisation (ISO) established product standards that specify the properties of piping system components made from glass-reinforced thermosetting plastics (GRP). The standards are applicable to GRP piping systems, with flexible or rigid joints with or without thrust blocks for water, drainage, or sewerage applications with or without pressure. DPFC-GRP pipes are
requirements. The most important of these, and generally specified at the same level of performance in all the previously defined standards is joint, initial ring deflection, long-term ring bending, long-term pressure and strain corrosion capability. DPFC-GRP pipe is rigorously tested to verify conformance to the ASTM D3262, ASTM D3517, AWWA C950, BS EN 1796 and 14364 requirements. Strain Corrosion Testing A unique and important performance requirement for GRP gravity pipe used in sewer applications is the chemical testing of the pipe in a deflected or strained condition. This strain corrosion testing is carried out in accordance with ASTM D3681, and requires a minimum of 18 ring samples of the pipe to be deflected to various levels and held constant. These strained rings are then exposed at the invert of the interior surface to 1.0N (5% by weight) Sulphuric acid (see Figure 1). This is intended to simulate a buried septic sewer condition. This has been shown to be representative of the worst sewer conditions including those found in the Middle East, where many FLOWTITE pipes (our know how supplier) have been successfully installed. The time to failure (leakage) for each test sample is measured. The minimum extrapolated failure strain at 50 or 60 years, using a least squares regression analysis of the failure data, must equal the values shown for each stiffness class in Table 1. The value achieved is then relatable to the pipe design to enable prediction of safe installation limitations for GRP pipe used for this type of service.
Table 1
Continued
joints to withstand hydrostatic testing in configurations that simulate very severe in-use conditions. Pressures used are twice those rated and 100KPa (1 bar) is used for gravity flow pipe. Joint configurations include straight alignment, maximum angular rotation and differential shear loading. A partial vacuum test and some cyclical pressure tests are also included. Initial Ring Deflection All pipes must meet the initial ring deflection levels of no visual evidence of cracking or crazing (Level A) and no structural damage to the pipe wall (Level B) when vertically deflected between two parallel flat plates or rods as shown in Table 2.
Table 2 Deflection Level* 2500 Stiffness Class SN 5000 10000
A B
15% 25%
12% 20%
9% 15%
*Laboratory Test *Different deflection values apply for higher stiffness classes
100
101
102
104
105
50 Years
Joint Testing This important qualification test is conducted on joint prototypes for elastomeric gasket sealed couplings. This is a severe test carried out in accordance with ASTM D4161. It incorporates some of the most stringent joint performance requirements in the piping industry for pipe of any material within the pressure and size ranges of DPFC pipe. ASTM D4161 requires these flexible
Long-Term Ring Bending A GRP pipes long-term (50 or 60 years) ring deflection or ring bending (strain) capability, when exposed to an aqueous environment and under a constant load, must meet the Level A deflection level specified in the initial ring deflection test. This expression of the requirement only exists in ISO and EN standards. AWWA C950 requires the test to be carried out, with the resulting 50-year predicted value used in the pipes design. Pipes produced as per Flowtite technologies are tested using the guidelines of ASTM D5365 Long-Term Ring Bending Strain of Fiberglass Pipe and meet the requirements.
Method of Manufacturing
DPFC
Most of the DPFC-GRP pipes are mainly manufactured using the continuous advancing process (Continuous Filament Winding) which represents the state of the art in GRP pipe production. This process allows the use of continuous glass fiber reinforcements in the circumferential direction. For a pressure pipe or buried conduit the principle stress is in the circumferential direction, thus incorporating continuous reinforcements in this direction and not just chopped discontinuous roving such as in a centrifugal casting process, yields a higher performing product at lower cost.
Exterior Surface Outer Structural Layer Core Inner Structural Layer Barrier Liner Interior Liner
Using technology developed by material specialists, a very dense laminate is created that maximizes the contribution from three basic raw materials. Both continuous glass fiber rovings and choppable rovings are incorporated for high hoop strength and axial reinforcement. A sand fortifier is used to provide increased stiffness with placement near the neutral axis, in the core. The process has the capability of applying a special inner resin liner for severe corrosive applications while utilizing a less costly resin for the structural and outer portion of the laminate. (See section on Environments for special resin applications).
Method of Manufacturing DPFC filament winding machine represents the most advanced state of the art technology in use, and is the foremost method of manufacturing glass fiber pipe. Simply, this manufacturing machine consists of a continuous steelband mandrel supported in a cylindrical shape by beams. As the beams turn, friction pulls the steel band around and roller bearings allow the band to move longitudinally so that the entire mandrel moves continuously in a spiral path towards the exit assembly. As the mandrel rotates, all composite materials are metered onto it in precise amounts. First, mould-release film, followed by various forms and patterns of glass fibers, embedded in a polyester resin matrix. Inert filler can be interspersed within the structural laminate for some products. It is the continuous application of these materials onto the mandrel which forms the pipe. After the pipe has been formed on the mandrel it is cured and later cut to required length.
Diameters DPFC-GRP pipe can be supplied upto 2400 mm diameter. Lengths The standard length of DPFC pipe is 12 meters for diameters over 300mm. Lengths of 6 and 18 meters are also available. Load Capacity Values For design purposes the following values can be used for hoop tensile and axial tensile load capacity. Hoop Tensile Load Capacity Minimum initial hoop (circumferential) load, N per mm of lengths are shown in Table 4. Axial Tensile Load Capacity Minimum initial axial (longitudinal) load, N per mm of circumference are shown in Table 5. Fittings and Accessories All commonly used fittings or accessories can be supplied such as bends, tees, wyes and reducers. Stiffness Class DPFC-GRP pipe can be supplied to the following specific initial stiffness (EI/D3) are shown in Table 3.
Table 3
PN1
(N/mm)
PN6
(N/mm)
PN10
(N/mm)
PN12
(N/mm)
PN16
(N/mm)
PN20
(N/mm)
PN25 1522 1776 2030 2284 2537 3045 3427 3806 4567 4949 5328 6089 6472 6851 NA NA NA NA NA NA NA NA NA NA
PN32 1948 2273 2598 2923 3247 3897 4387 4871 5845 6335 6820 7794 8283 8768 NA NA NA NA NA NA NA NA NA NA
(N/mm) (N/mm)
300 350 400 450 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400
60 70 80 90 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480
366 427 488 549 609 731 823 914 1097 1189 1280 1463 1554 1646 1828 1920 2011 2194 2285 2377 2468 2560 2743 2925
609 711 812 914 1016 1219 1371 1523 1828 1981 2133 2437 2590 2742 3047 3199 3351 3656 3808 3960 4113 4265 4570 4874
731 853 975 1097 1218 1462 1645 1828 2193 2376 2559 2924 3107 3290 3655 3838 4021 4386 4569 4752 4935 5117 5483 5848
975 1137 1299 1462 1624 1949 2193 2436 2924 3168 3411 3898 4142 4385 4873 5116 5360 5847 6091 6334 6578 6822 7309 7796
1218 1421 1624 1827 2030 2436 2741 3045 3654 3959 4263 4872 5177 5481 NA NA NA NA NA NA NA NA NA NA
Table 5
PN1
(N/mm)
PN6
(N/mm)
PN10
(N/mm)
PN12
(N/mm)
PN16
(N/mm)
PN20
(N/mm)
PN25 190 215 240 265 290 345 395 450 505 555 610 660 710 760 NA NA NA NA NA NA NA NA NA NA
PN32 220 253 285 315 345 415 475 545 620 685 723 760 875 990 NA NA NA NA NA NA NA NA NA NA
(N/mm) (N/mm)
300 350 400 450 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300
95 100 105 110 115 125 135 150 165 185 195 205 215 225 238 250 263 275 288 300 313 325 338 350
115 125 130 140 150 165 180 200 215 230 245 260 275 290 305 320 335 350 365 380 395 410 425 440
140 150 160 175 190 220 250 280 310 340 360 380 400 420 440 460 480 500 520 540 560 580 600 620
143 155 168 185 200 232 263 295 325 357 382 407 432 457 482 507 532 557 582 607 373 387 400 707
150 165 185 205 220 255 290 325 355 390 425 460 495 530 565 600 635 670 705 740 775 810 845 880
170 190 210 235 250 295 340 380 420 465 513 560 595 630 NA NA NA NA NA NA NA NA NA NA
Note: Data for DN below 300 are available in page 36 of this document.
2400
Continued
service life of GRP pipe. The outermost surface will be affected with discoloring of the surface observed. If so desired, the installing contractor may paint the exterior surface of pipe with a twopart urethane paint compatible with GRP. However, this will then become an item requiring future maintenance. Poisson's Ratio Poissons ratio is influenced by the pipe construction. For DPFC pipe, the ratio for hoop (circumferential) loads and axial response ranges from 0.22 to 0.29. For axial loading and circumferential response Poissons ratio will be slightly less. Thermal Coefficient The thermal coefficient of axial expansion and contraction for GRP pipe is 24 to 30 x 10-6 cm/cm/0C.
Pressure Rating Upper diameter Bar Limit, mm 1 6 9 10 12 16 20 25 32 2400 2400 2400 2400 2400 2400 1400 1400 1400
The pipes pressure ratings have been established in accordance with the design approach outlined in AWWA M-45, Fiberglass Pipe Design Manual. Pipes are pressure rated at full operating pressure even when buried to the maximum depth recommended. To insure the long service life for which DPFC pipe is designed, the following capabilities should be noted and observed in service. Hydrotesting Standard Factory Test Pressure Maximum Field Test Pressure Surge Maximum Pressure 1.4 x PN (Pressure Class) 2 x PN (for 30 sec. or 1.5 x PN for 5 min.) 1.5 x PN (Pressure Class)
Flow Velocity Maximum recommended flow velocity is 3.0m/sec. Velocities of up to 4m/sec. can be used if the water is clean and contains no abrasive material. UV Resistance There is no evidence to suggest that ultraviolet degradation is a factor that affects the long-term
Continued
57 86 172 344
688 1376
10
Continued
Figure 3
Figure 4
11
diameters, the maximum allowable cover depths, with consideration for traffic loads, for the three different stiffness classes in the six native soil groups are given in Table 19. The correlation between the backfill soil modulus and different backfill soil types at four different levels of relative compaction may be found in Table 20. The second parameter for pipe stiffness class selection is negative pressure, if it exists. Table 18 on page 21 of this brochure shows which stiffness to select for various amounts of negative pressure and burial depths for average native and backfill soil conditions. The stiffness selected should be the higher of that determined to suit negative pressure and burial conditions. Installation Types The illustrations on page 21 show four standard installation types commonly used with DPFCGRP Pipe. DPFC-GRP pipe can be installed in a number of different situations including above ground, subaqueous, trenchless and sloped applications. These applications often require more initial planning and more design considerations than the standard buried pipe installation. Specific instructions have been developed and could be provided when needed.
Stiffness is selected according to two parameters. These are : (1) burial conditions, which include native soil, type of backfill, cover depth, loads on the top of pipes and (2) negative pressure, if it exists. The native soil characteristics are rated according to ASTM D1586 Standard Penetration Test. Some typical soil blow count values relative to soil types and density are given in Table 10. A wide range of backfill soil types are offered in Table 17 to allow each installation to be customized providing the most economical cost. In many instances, the native trench soils can be used as pipe zone backfill. Assuming standard trench construction, and an allowable long-term deflection of 5% for pipe diameters 300mm and larger, and 4% for smaller
Table 10
Blow Counts
1 2 3 4 5 6
compact slightly compact loose very loose very loose very, very loose
33 30 29 28 27 26
very stiff stiff medium soft very soft very, very soft
12
DPFC
DN
DOS Max
DOS Min
PN1PN6
300
324.5
323.5
4.3
350
376.4
375.4
4.9
400
427.3
426.3
5.5
450
478.2
477.2
6.2
500
530.1
529.1
6.8
600
617.0
616.0
8.0
700
719.0
718.0
9.1
800
821.0
820.0
10.3
900
923.0
922.0
11.5
10.3
1000
1025.0
1024.0
12.7
11.3
1100
1127.0
1126.0
13.9
12.4
1200
1229.0
1228.0
15.0
13.4
Pipe Dimensions
1300
1331.0
1330.0
16.2
14.4
13
1400
1433.0
1432.0
17.3
15.4
1500
1535.0
1534.0
18.4
16.4
1600
1637.0
1636.0
19.6
17.5
1700
1739.0
1738.0
21.0
18.5
1800
1841.0
1840.0
22.1
19.5
1900
1943.0
1942.0
23.2
20.5
2000
2045.0
2044.0
24.4
21.6
2100
2147.0
2146.0
25.6
22.6
2200
2249.0
2248.0
26.7
23.6
2300
2351.0
2350.0
27.9
24.6
2400
2453.0
2452.0
29.1
25.6
Measurements in mm unless otherwise noted. *Pipe weights are based primarily on Class PN6, which is the heaviest product. Pipe dimensions may vary from these values in some countries, dependent on local standards and practices. For Smaller Diameter pipes, details are available in page 36.
DPFC
Nominal Diameter CD PN 10 368 420 471 522 574 667 770 873 977 1080 1181 1284 1387 1490 1593 1696 1798 1902 2003 2107 2209 2312 2414 2517 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 330 330 330 330 2112.0 NA NA NA NA 330 2009.0 NA NA NA NA 330 330 330 330 330 330 330 1905.0 NA NA NA NA 330 330 330 330 330 330 330 330 330 1802.0 NA NA NA NA 330 330 330 1699.0 1706 NA NA NA 330 330 330 330 NA NA NA NA NA NA NA NA 1596.0 1602 NA NA NA 330 330 330 330 1493.0 1499 1510 1525* 1542* 330 330 330 330 330 NA NA NA NA NA NA NA NA NA NA 1390.0 1393 1404 1422* 1437* 330 330 330 330 330 1287.0 1291 1301 1313* 1330* 330 330 330 330 330 330 330 330 NA NA NA NA NA NA NA NA NA NA 1184.0 1188 1190 1188* 1225* 330 330 330 330 330 330 1081.0 1087 1097 1109 1128* 330 330 330 330 330 330 330 330 330 330 330 NA NA NA NA NA NA NA NA NA NA 977.0 983 993 1000 1020* 330 330 330 330 330 330 330 874.0 879 889 889 909 330 330 330 330 330 330 330 47 55 63 71 74 86 91 108 119 105*** 107*** 120*** 127*** 136*** 145*** 154*** 163*** 770.0 774 784 784 792 330 330 330 330 330 330 330 40 667.0 669 679 679 679 330 330 330 330 330 330 330 32 574.0 576 586 586 586 270 270 270 270 270 270 270 20 523.0 524 534 534 534 270 270 270 270 270 270 270 18 472.0 473 483 483 484 270 270 270 270 270 270 270 16 421.0 422 432* 432* 437* 270 270 270 270 270 270 270 14 369.0 367* 385* 385* 390* 270 270 270 270 270 270 270 12 PN 12 PN 16 PN 20 PN 25 PN 32 PN1PN6 PN 10 PN 12 PN 16 PN 20 PN 25 PN 32 Weight** (kgs/unit) KL
Outer Diameter
DN
DOS Max
PN1PN6
300
324.5
367
350
376.4
419
400
427.3
469
450
478.2
520
500
530.1
572
600
617.0
665
700
719.0
768
800
821.0
870
900
923.0
972
1000
1025.0
1075
1100
1127.0
1176
1200
1229.0
1280
1300
1331.0
1381
Couplings Dimensions
14
1400
1433.0
1485
1500
1535.0
1586
1600
1637.0
1689
1700
1739.0
1791
1800
1841.0
1894
1900
1943.0
1996
2000
2045.0
2099
2100
2147.0
2200
2200
2249.0
2303
2300
2351.0
2405
2400
2453.0
2508
Measurements in mm unless otherwise noted. *Dimensions are only approximate. Couplings are overwrapped to achieve the rated pressure. **PN16 ***PN10
Fittings
DPFC
Fittings
DPFC-GRP has created a standardized line of GRP fittings that are molded or fabricated using the same materials that are used to produce GRP pipe. One of the benefits of DPFC-GRP pipe is the ability to fabricate a wide assortment of fittings, standard as well as non-standard.
Elbows
Wyes
Tees
Eccentric Reducers
Concentric Reducers
Flanges
Saddles
15
xL
1/ 2
xL
1/ 4
xL
Figure 5
Single Pipes: Single pipes must be unloaded and handled separately (one at a time). Use pliable straps, slings or ropes to lift single pipes. Do not use steel cables or chains to lift or transport the pipe. Pipe sections can be lifted with only one support point (Figure 6) although two support points placed as in Figure 7 make the pipe easier to control. Do not lift pipes by passing a rope through the section end to end. See page 13 & 14 for appropriate weights of standard pipes and couplings. If at any time during handling or installation of the pipe, any damage such as gouge, crack, or fracture occurs, the pipe should be repaired before the section is installed. Contact DPFC for inspection of damage and for recommendation for repair method or disposal. See previous section on Repairing Pipe.
16
Continued
abrupt changes of curvature are not permitted. Storing of pipes outside these limitations may result in damage to the pipes.
Figure 6
Figure 8
Table 16
1/ 4
xL
1/ 2
xL
1/ 4
xL
Maximum Storage Deflections Maximum Deflection Stiffness Class SN (% of Diameter) 2500 2.5 5000 2.0 10000 1.5 Storing Gaskets and Lubricant Rubber ring gaskets, when shipped separate from the couplings, must be protected from exposures to grease or oils, which are petroleum derivatives, and from solvents and other deleterious substances.
Figure 7
Lifting Pipe at Two Support Points Storing Pipe It is generally advantageous to store pipes on flat timber to facilitate placing and removal of lifting slings around the pipe. When storing pipe directly on the ground, be sure that the area is relatively flat and free of rock and other potentially damaging debris. All pipes should be chocked to prevent rolling in high winds. If it is necessary to stack pipes, it is best to stack on flat timber supports at maximum 6 meter spacing (3 meter for small diameter) with chocks (See Figure 8). Insure the stack will be stable for conditions such as high winds, un-level storage area or other horizontal loads. Maximum stack height is approximately 3 meters. Stacking of pipes larger than 1400mm diameter is not recommended. Maximum diametrical deflection must not exceed the values in Table 16. Bulges, flat areas or other
17
Continued
Figure 9
Handling Nested Pipes Pipes to be shipped long distances may be nested (smaller diameter pipes inside of larger sizes) to reduce the transportation cost. These pipes generally have special packaging and may require non-standard procedures for un-loading, handling, storing and transporting. Non-standard practices, if required, will be supplied prior to shipment. Regardless, the following general procedures should always be followed: 1. Always lift the nested bundle using at least two pliable straps (Figure 10). Limitations, if any, for spacing between straps and lifting locations will be specified for each project. Insure that the lifting slings have sufficient capacity for the bundle weight. This may be calculated from the approximate pipe weights given in page 13. 2. Nested pipes are usually best stored in the transport packaging. Stacking of these packages is not advisable unless otherwise specified. 3. Nested pipe bundles can only be safely transported in the original transport packaging. Special requirements, if any, for support, configuration and/or strapping to the vehicle
will be specified for each project. 4. Package removal and de-nesting of the inside pipe(s) is best accomplished at a de-nesting station. Typically, this consists of three or four fixed cradles to fit the outside diameter of the largest pipe of the bundle. Inside pipes, starting with the smallest size may be removed by lifting slightly with an inserted paddle boom to suspend the section and carefully move it out the bundle without touching the other pipes (Figure 11). When weight, length and/or other equipment limitations preclude the use of this method, procedures for sliding the inside pipe(s) out of the bundle will be recommended for each project.
Figure 11
18
General Installation
DPFC
Long life and the good performance characteristics of GRP pipe can only be achieved by proper handling and installation of the pipe. It is important for the owner, engineer and contractor to understand that glassreinforced plastic (GRP) pipe is designed to utilize the bedding and pipe zone backfill support that will result from recommended installation procedures. Engineers have found through considerable experience that properly compacted granular materials are ideal for backfilling GRP pipe. Together, the pipe and embedment material form a high performance pipe-soil system. The following information is a partial review of installation procedures; it is not intended to replace the installation instructions which must be followed for any project. Trenching Details of a standard trench must always be wide enough to permit placement and compaction of the pipe zone backfill materials and provide proper pipe support. The depth of cover charts presented in this brochure are based on an assumed trench width 1.75 times the pipes nominal diameter. Widths down to 1.5 times DN may be achievable, however the burial limits will be affected. Consult us if your conditions will vary from these assumptions. Bedding The trench bed, of suitable material, should provide uniform and continuous support for the pipe. Backfill Materials To ensure a satisfactory pipe-soil system, correct backfill material must be used. Most coarse grained soils (as classified by the Unified Soils Classification system) are
Table 17 Backfill Soil Type Descripion Unified Soil Classification Designation, ASTM D2487
acceptable bedding and pipe zone backfill material. Where the instructions permit the use of native soil as backfill, care should be taken to ensure that the material does not include rocks, soil clumps, debris, frozen or organic material. Table 17 identifies acceptable backfill soils.
Checking the Installed Pipe After installation of each pipe, the maximum diametrical vertical deflection must be checked. With DPFC-GRP pipe this procedure is fast and easy. Installed Diametrical Deflection The maximum allowable initial diametrical deflection (typically vertical) shall be 3% for diameters 300mm and larger, and max 5% is the long-term allowable deflection. These values will apply to all stiffness classes. Bulges, flat areas or other abrupt changes of pipe wall curvature are not permitted. Pipe installed outside of these limitations may not perform as intended.
A B C D E F
Crushed stone and gravel, < 12% fines Gravel with sand, sand, < 12% fines Silty gravel and sand, 12 - 35% fines, LL < 40% Silty, clayey sand, 35 - 50% fines, LL < 40% Sandy, clayey silt, 50 - 70% fines, LL < 40% Low plasticity fine-grained soils, LL < 40%
GW, GP, GW- GP - GM GW - GC, GP - GC, SW, SP, SW-SM, SP-SM, SW-SC, SP-SC GM, GC, GM - GC, SM, SC, SM - SC GM, GC, GM - GC, SM, SC, SM - SC CL, ML, CL - ML CL, ML, CL - ML
19
General Installation
DPFC
INSTALLATION TYPE 1 I Carefully constructed bed I Backfill 70% relative Density Gravel I Backfill compacted to 300mm over pipe crown
Continued
Negative Pressure: Allowable negative pressure is a function of: (1) Pipe stiffness. (2) Burial depth, and (3) Type of installation. Table 18 are given max. burial depth, based on average native soil & backfill soil condition High water table: A minimum of 0.75 diameter of earth cover (minimum dry soil bulk density of 1900Kg/m3) is required to prevent an empty submerged pipe from floating. Alternatively, the installation may proceed by anchoring the pipes. If anchoring is proposed, restraining straps must be a flat material, minimum 25mm wide, placed at maximum 4.0m intervals.
INSTALLATION TYPE 2 Backfill to 60% of pipe diameter with gravel or sand (primary pipe zone) I Backfill from 60% to 300 mm over the pipe crown with compactible native soil compacted to 90% Standard Proctor
I
Traffic: All pipe zone backfill material should be compacted to grade level when traffic loads are to be present. Minimum cover restrictions maybe reduced with special installations such as concrete encasement, concrete cover slabs, casings, etc. (See Table 21)
Table 18 Negative Pressure Native Soil Group 3 (En = 10.3 Mpa) Backfill Type C at 90% SPD (Eb = 14 Mpa) Water Table Below Pipe Standard Trench Installation
20
General Installation
DPFC
Table 19
Continued
Table 21
Table 20
21
A. Depth of Cover:
Traffic Load
Fill-to-Grade
Native Soil
Backfill Material DPFC GRP Operating Pressure Negative Pressure Geologic Conditions
A.
Maximum allowable depth of cover is affected by: Backfill soil modules Trench width Native soil modules Traffic load Pipe stiffness Water table elevation Negative pressure
B. Pipe Diameter (DN)
E. D. B. F.
The area from the bottom of the bedding to 300mm over the crown of the pipe is defined as the pipe zone.
D. Compacted Backfill:
C.
The soil modules, Eb, of the backfill material depends on type and degree of compaction.
E. Trench Width:
Haunching
Minimum trench width is a function of pipe diameter. Standard Width = 1.75 x DN.
F. Side Clearance:
Bedding
G.
Water Table
Sufficient side clearance must be allowed to permit specified compaction of haunching and backfill soil.
G. Depth of Bedding:
The compacted bedding for the pipe is calculated as DN/4 with a maximum depth of 150 mm.
Installation Types Type 1 (full embedment) embedment)
Fill to grade with native soil
Type 2 (split
Compact backfill from 60% of DN to 300mm over pipe crown, compacted, if necessary, to achieve a minimum modulus of 1.4 mPa
Define diameter 2. Select pressure class 3. Define native soil classification 4. Check minimum depth of cover and operating pressure 5. Check minimum depth of cover for traffic load 6. Define native pressure (vacuum) 7. Select trench type 8. Check allowable burial depth and select SN and Eb 9. Select alternate trench construction, if necessary 10. Select backfill soil type and degree of compaction
1.
Effluent: PN: Group: OK? OK? Negative pressure (Vacuum): Type (full or split): SN: Alternative: Type:
DN:
Eb: %:
22
Pipe Joining
DPFC
Joining pipes DPFC-GRP pipe sections are typically joined using GRP double bell couplings. Pipe and coupling will be supplied separately. Other joining systems such as flanges, mechanical couplings and lay-up joints may also be used with DPFC-GRP pipe.
Double Bell Coupling The following steps apply to all double bell coupling joining procedures: Step 1: Clean Coupling Thoroughly clean double bell coupling grooves and rubber gasket rings to make sure no dirt or oil is present (Figure 12).
equally above the top of the groove around the whole circumference. Tapping with a rubber mallet will be helpful to accomplish the above. Step 3: Lubricate Gaskets Next,using a clean cloth, apply a thin film of lubricant to the rubber gaskets (Figure 14).
Figure 12
Figure 14
Step 2: Install Gaskets Insert the gasket into the grooves, leaving two or more uniform loops of rubber (depending on diameter) extending out of the groove. Do not put any lubricant in the groove or on the gasket at this stage. There should be a minimum of one loop for each 450mm of gasket ring circumference (Figure 13).
Step 4: Clean and Lubricate Spigots Thoroughly clean pipe spigots to remove any dirt, grit, grease, etc. Using a clean cloth, apply a thin film of lubricant to the spigots from the end of the pipe to the black positioning stripe. After lubricating, take care to keep the coupling and spigot clean (Figure 15).
Figure 13
Figure 15
With uniform pressure, push each loop of the rubber gasket into the gasket groove. When installed, pull carefully on the gasket in the radial direction around the whole circumference to check for well-distributed compression of the gasket. Check also that both sides of the gasket protrude
Caution: It is very important to use only the correct lubricant. Never use a petroleum based lubricant.
23
Pipe Joining
DPFC
Continued
Step 5: Fixing of Clamps Clamp A is fixed anywhere on first pipe or left in position from previous joint. Fix Clamp B on the pipe to be connected in the correct position relative to the alignment stripe on the spigot-end (homeline) so as to act as a stopper (Figure 16).
Figure 16
coupling. While these are held in position the new pipe is entered into the coupling until it rests against the pipe clamp. Come-along jack might need protective blanket under it in order not to touch against the pipe (Figure 17). Note: Approximate joining force 1 kg/mm of diameter.
Figure 18
Note: The mechanical installation clamp is to act both as a stopper to position the coupling and as a device on which to attach the pulling (come-along jacks) equipment. Clamp contact with the pipe shall be padded or otherwise protected to prevent damage to the pipe and to have high friction resistance with the pipe surface. If clamps are not available, nylon slings or rope may be used as in Figure 17, but care must be taken in the alignment of the coupling. A pipe clamp has the advantage of acting as a stopper. However, if not available, insert the pipe spigots until the home-line (alignment stripe) aligns with the coupling edge.
Figure 17
Step 8: Join Pipes Come-along jacks are loosened and timbers removed before re-tightening the jacks for entering the coupling onto the previously connected pipe. Check the correct position of the edge of the coupling to the alignment stripe (Figure 18). Note: When step 8 has been completed, Clamp-B is left in position while Clamp A is moved on to the next pipe to be joined.
Figure 19
Step 6: Pipe Placement The pipe to be connected is placed on the bed with sufficient distance from previously joined pipe to allow lowering the coupling into position. Step 7: Join Coupling Come-along jacks are installed to connect the pipe clamps and two 10cm x 10cm timbers or similar (larger diameters require a bulkhead) are placed between the pipe previously connected and the
24
Pipe Joining
DPFC
Continued
Flanged Joints GRP flanges should be joined according to the following procedure: (Figure 20) 1. Thoroughly clean the flange face. 2. Ensure the gasket is clean and undamaged. Do not use defective gaskets. 3.Place the gasket in position, if necessary, with small strips of adhesive tape. 4. Align flanges to be joined. 5. Insert bolts, washers, and nuts. All hardware must be clean and lubricated to avoid incorrect tightening. Washers must be used on all GRP flanges. 6. Using a torque wrench, tighten all bolts to 35 N.m (25 lb.ft) torque, following standard flange bolt tightening sequences. 7. Repeat this procedure, raising the bolt torque to 70 N.m (50 lb.ft) or until the flanges touch at their inside edges. 8. Check bolt torque one hour later and adjust if necessary. Note: When connecting two GRP flanges, only one flange should have a gasket groove in the face. Other Joining Methods Flexible Steel Couplings: (Straub, Tee Kay, etc.See Figure 21) These couplings can be used for joining as well as for repair. The coupling consists of a steel mantle with an interior rubber sealing sleeve. Three grades are available: A. Epoxy or PVC-coated steel mantle. B. Stainless steel mantle. C. Hot dip galvanized steel mantle.
Control of bolting torque with these couplings is most important. After initial bolt up, the coupling should be rapped with a rubber mallet to help seat and flow the gasket. Bolt torque should then be adjusted up to proper levels. Depending on coupling size, this procedure may need to be repeated several times. Do not over torque as this may over stress the bolts. Follow the manufacturers recommended assembly instructions.
Figure 21
3.3.2 Mechanical Steel Couplings: (Viking Johnson, Dresser etc.See Figure 22) These couplings can be used for joining, typically to other types of pipe or to rigid items. Bolting torque must be controlled to not exceed the manufacturers maximum recommended values. Excess torque could damage the pipe.
Figure 20
Figure 22
Flanges
25
CHECK LIST PRIOR TO PIPE ENDS BLIND : To check each coupling joint is connected correctly and the clearance between the pipe end is uniform all around. (Field joints testing equipment is available upon separate Purchase Order for pipe diameters ranging from 700mm to 2400mm. This test ensures the rubber gasket correct positioning inside the double bell coupling groove. The test shall be conducted prior to start backfill. For details, contact Dubai Pipes Factory Co. - Field Representative). Internal visual inspection shall be carried out for accessible pipe diameters for any possible damage during installation/backfilling. Vertical deflection measurements shall be taken to observe the pipe behaviour after the backfill. Make sure that the pipes are backfilled to the minimum cover depth requirements of hydrotest. For 300mm diameters: Min. 600mm cover over the pipe crown. For 350mm diameters & onwards: Min. 1000mm cover over the pipe crown.
Double bell coupling joints could be exposed in case of the client requirements.
Make sure that the backfilling slope at the joints location is maintained with minimum pipe exposure. PREPARATION PRIOR TO HYDROTEST : Make sure that the test method statement is available with full understanding of implementation to the testing team. Allowance for each branch / manhole to move freely, within limits during the hydrotest. Fixing ventilation at highest points, minimum two pressure gauges and filling points with valves.
Continued
starts coming. The pressure increment shall be maintained approx. as 0.5 Bar /10 minutes at this stage. When the pressure reaches to 2 bar, the pumps shall be stopped. Keep this stoppage for 15-20 minutes. During this time, following checks shall be made : A) Pressure at each test gauge shall be checked & recorded on inspection sheet. B) Watch the pressure at the water feed point for any decrease in pressure. C) Walk through along with the underground lines to observe any traces of wet soil. Check the coupling joints, if exposed. The inspection sheet shall be maintained for the observations & findings. Anything unusual shall be immediately reported to the team leader. Unless there is no findings which prevent the test from continuing, the segment/system shall be further pressurized. Connect the hose with the pressure pump and start pressurizing the line. At this stage, slightly open the vent. Valve should be fixed at a higher elevation to ensure that no entrapped air is present. Upon confirmation of water coming out of the vent, valve shall be closed. The system is now totally closed and under pressure. Continue pressurizing until pressure reaches 5.0 Bar. Stop the pressure pump once it reaches to 5.0 Bar and let is stabilize. There could be a drop in pressure due to the thermal expansion, which could be resolved by restarting the pump or keep it as is & record it on the inspection sheet. Keep this stoppage for about 30 minutes. During
27
Continued
Continue the installation for the other segments & conduct the hydrotest in the similar manner as described earlier. Keep connecting the segments through closure spools. COMPLETE SYSTEM hydrotest /Final hydrotest Purpose of this hydrotest is to test the pipe closure spools joints. Following arrangements shall be made : 1- All branch connections shall be kept free to move. 2- Separate the line from all connecting equipments. 3- Exposure of joints at closure pipe piece shall be done manually in order to prevent the pipe from any damage. The procedure described for the segment testing is applicable to the final hydrotest. For final hydrotest, it is recommended to maintain the test hold pressure for minimum period of time (to inspect the joint/fittings) and the pressure shall be equal to the maximum rated operating pressure.
28
The water hammer pressure expected for GRP pipe is approximately 50% of that for steel and ductile iron pipe, for similar conditions. The pipe has a surge pressure allowance of 40% of the nominal pressure, as shown in Table 22. An approximate relationship for the maximum pressure variation at a given point in a straight pipeline with negligible friction loss can be calculated from the formula : H = (w v)/g Where : H = change in pressure (meters) w = surge wave celerity (meters/sec) v = change in liquid velocity (meters/sec) g = acceleration due to gravity (meters/sec2)
Table 22
Surge Wave Celerity for DPFC- GRP Pipes DN SN2500 PN6 PN10 PN16 SN5000 PN6 PN10 PN16 PN25 SN10000 PN6 PN10 PN16 PN25 PN32 420 435 500 580 620 415 425 495 570 615 410 415 485 560 615 405 435 505 575 380 420 495 570 370 410 480 560 365 435 500 350 420 490 340 405 480 300-400 450-800 900-2500 Meters/Sec.
29
2- Tees: When the branch pipe is concentric to the header pipe centerline. 3- Valves: Valves must be sufficiently anchored to absorb the pressure thrust. 4- Nozzles: Nozzles are tee branches meeting all the following criteria: i- Nozzle diameter 300mm. ii- Header diameter 3 times nozzle diameter. iii- If the nozzle is not concentric and/or not perpendicular to the header pipe axis, the nozzle diameter shall be considered to be the longest chord distance on the header pipe wall at the nozzle/pipe intersection. Note: It is not necessary to encase nozzle connections in concrete.
Tee
A Reducer
30
Max. 4 meters
Clear area
Figure 25
Rigid Connections When a pipe passes through a wall, or encased in concrete, or meets a junction with a manhole, or is flanged to a pump, valve, or other structure, excessive bending stresses may develop in the pipe if differential movement occurs between the pipe and the rigid connection. For all rigid connections action must be taken by the installer to minimize the development of high discontinuity stresses in the pipe. Two options are available. Alternate A (preferred) uses a coupling joint cast into the concrete-pipe interface. Alternate B wraps the pipe in rubber to ease the transition. Where possible, cast a coupling joint in the concrete at the interface (Figure 26) so that the first pipe outside the concrete has complete freedom of movement (within the joint limits).
Figure 24
Pipe Supports The pipe should be supported in such a way that the concrete can easily flow completely around and fully underneath the pipe. Also, the supports should result in an acceptable pipe shape (less than 3% deflection and no bulges or flat area). Supports are normally placed at strap locations (not exceeding 4 meter spacing)(Figure 25). Concrete Pouring The concrete surround must be placed in stages allowing sufficient time between layers for the cement to set (no longer exert buoyant forces). Maximum lift height is variable with nominal pipe stiffness:
Caution 1- When casting a coupling in concrete, be sure to maintain its roundness, so later joint assembly may be accomplished easily. Alternatively, make up the joint outside the encasement prior to pouring the concrete. 2- Since the coupling cast in concrete is rigid, it is important to minimize the vertical deflection and deformation of the adjacent pipe. Where the standard method is not possible, wrap a band (or bands) of rubber around the pipe prior to placement of any concrete, such that the rubber slightly protrudes (25 mm) from the concrete. Layout the pipeline so the first completely exposed coupling joint is located as shown in Figure 27.
STIS 2500 Larger of 300mm or 1/4 pipe DN. STIS 5000 Larger of 450mm or 1/3 pipe DN. STIS 10000 Larger of 600mm or 1/2 pipe DN
31
Figure 26
Concrete encasement rubber Special Pipe Short Pipe Section Max. Larger of 2m or 2 x D Min. Larger of 1m or 1 x D
Figure 27
Construction Guidelines 1. When the design of the concrete structure is considered, it should be noted that any excessive settlement of the structure relative to the pipe can be the cause of a pipe failure. 2. The pipeline layout shall be such that the first pipe section near the rigid connection is a short length (rocker pipe) as follows : (See Figures 26 and 27) Minimum : larger of 1 meter or 1 diameter Maximum : larger of 2 meters or 2 diameters This rocker pipe section is used to account for some differential settlements that may occur. The rocker pipe should have straight alignment with the concrete structure at the time of installation to provide maximum flexibility for subsequent movements. Multiple short lengths or rocker pipes should not be used, as the short spacing between couplings may result in an unstable condition.
32
Field Adjustments
DPFC
Length Adjustment The following procedure shall be followed for proper length adjustment: 1- Determine the length required and mark a square cut location on the selected pipe. 2- Measure the pipe diameter at point of cut with a circumferential PI tape. 3- Compare the measurement with spigot tolerance range given in page 13. (Note: manufacturers may give the pipe a special marking (Adjustment Pipe) at the factory indicating the entire pipe barrel is within spigot tolerance range). Select one of these pipes (if available) for the field adjustment to avoid spigot machining. 4- Cut the pipe at the appropriate location using a circular saw with a masonry blade. 5- If pipe diameter is within the spigot tolerance range, clean the surface in the joining area, sand smooth any rough spots and with a grinder bevel cut pipe end to ease assembly. No further grinding is necessary. 6- If the pipe diameter is not in the spigot tolerance range use a field lathe or grinder and machine the joining (spigot) surface to the tolerances as indicated in Table 23, Bevel pipe end. (Figure 28)
Table 23
Spigot Dimensions and Tolerances
Diam. Series DN (mm) Minimum DOS (mm) Maximum DOS (mm) CL (mm) BL (mm)
End Coating of Field Cut Sewer Pipe If sewer pipe is intended to ever be subjected to high pressure water jet cleaning, a special
Figure 28 Spigot Width CL BL 70
protective end should be applied at the time of manufacture. Customers are advised to so request upon ordering the pipe. It will be necessary for the installing contractor to similarly coat the ends of all field cut pipes. Alternatively, special short lengths can be ordered, thereby avoiding the need to make field cuts. The above is only necessary for gravity sewer pipes which will be subjected to high pressure (over 80 bar, but less than 120 bar) water jet cleaning. It is not necessary for pipes that are used to convey water or for pumped sewer mains, or where pipes are not cleaned by high pressure water jets. Field Closure 1. Carefully measure the space where the closure piece is to be placed. The closure piece must be 50mm shorter than the length of the space. The piece must be centered with an equal clearance of 25mm left between the inserted pipe and the adjacent ones. 2. Use a special pipe with long machined ends ordered or prepared specifically for this purpose. 3. Two double bell couplings. 4. Pull the couplings onto the machined ends of the closure pipe after lubricating abundantly the ends and the rubber ring. It may be necessary to gently help the second ring over the chamfered end of the pipes.
B2
B1
300 350 400 500 600 700 800 900 1000 1200 1400 1600 1800 2000 2400
323.4 375.4 426.3 529.1 616.0 718.0 820.0 922.0 1024.0 1228.0 1432.0 1636.0 1840.0 2044.0 2452.0
324.5 376.4 427.3 530.1 617.0 719.0 821.0 923.0 1025.0 1229.0 1433.0 1637.0 1841.0 2045.0 2453.0
159.0 161.0 162.0 166.0 170.0 172.0 172.0 172.0 172.0 172.0 172.0 172.0 172.0 172.0 172.0
6.6 8.5 10.4 14.3 17.6 20.0 20.0 20.0 20.0 20.0 20.0 20.0 20.0 20.0 20.0
Note: 1. Series B2 matches with Ductile Iron spigot O.D.s. 2. Series B1 is GRP O.D. series. 3. In some countries the Ductile Iron (B2) series may not be used
33
Field Adjustments
DPFC
5. Lubricate well the ends of the two adjacent pipes after they are cleaned thoroughly. 6. Place the closure pipe in its final position and pull the coupling over the adjacent pipes up to the home line (Figure 29. Steps 2 and 3). 7. The compaction of the backfill around a field closure pipe is very important. Very often the closure piece area is over-excavated for ease of access. It is essential to provide proper backfill support. It is recommended that a backfill soil modulus (Eb) of at least 6.9 MPA be attained in the closure area to prevent excessive movement and joint rotations. Note: After the coupling is in final position a feeler gauge maybe used to assure that gasket lips are properly oriented
Figure 29
Continued
Field Closures with Non DPFC-GRP Couplings Follow the general procedures except that the closure pipe will not typically need to have the special long machined spigot ends. The installation procedures for the particular coupling used must be followed.
34
The Dual Helical Winding Process uses continuous Glass-fiber Filaments impregnated in resin. In this process the fiber glass roving wetted with resin is wound on the steel mandrel at pre-calculated winding angles (in reference to the axis of the mandrel vary from 50-90 Deg.). The dual helical winding pattern is responsible for providing the composite product with maximum mechanical durability. The resin used will decide the extent of its chemical and temperature resistance. The entire process is controlled via the software in which we determine the winding angles as well as the number of layers to be wound on to the product. Silica Sand if used is added during the winding process in the structural wall of the pipe to give necessary compressive strength if required. The dual Helical winding process is illustrated in Figure 1 and Figure 2.
Figure 1
35
Figure 2
Product Range - Pipes & Fittings: Pressure Stiffness SN Diameter DN Class PN (N/m2) (mm) (Bars) 80 100 6 2,500 150 10 5,000 200 12 10,000 250 16 300
Table 24
initial
load
as
shown
in
Pipes with different pressure classes and stiffness could be manufactured depending on clients requirement.
Technical Details: Dimensions & Weight:
Nominal Diameter DN Spigot Outer Diameter DOS Max (mm) DOS Min (mm) Helical pipes with no filler PIPE COUPLING Std. Pipe Min. Pipe Std. Weight* Weight* Length Thickness Coupling (Kg/ (Kg/m) (m) (m) Length (m) unit)
initial
load
as
shown
in
88 108
87 107
6 10 10 12 12 12
2.5 3 4.5 7 10 12
3 3.5 4.5 7 9 10
For design purposes the following values can be used for hoop tensile and axial tensile load capacity.
36
NR
NR
37
Continued
NR
X X X X X X X X X X X X X X X X X X
Note : This guide is intended to serve as a basic guide when considering GRP pipe. Final determination of the suitability of a particular resin system for a given environment is the responsibility of the customer. This list is based on information supplied by resin manufacturers who provide Flowtite producers with their material. Thus this guide provides only general information and does not imply approval of any application as DPFC has no control of the conditions of usage nor any means of identifying environments to which the pipe may unintentionally have been exposed.
38