Installation Manual Frp Pipe

Sunrise Industries (India) Ltd.

HANDLING, INSTALLATION AND MAINTENANCE MANUAL

FOR FRP PIPES AND DUCTS

SUNRISE INDUSTRIES (INDIA) LTD. (AN ISO 9001:2008 CERTIFIED COMPANY)

860/3, G.I.D.C., MAKARPURA, BARODA –390 010, GUJARAT, INDIA. PH. NO. 0265-2645421 / 2644958 FAX NO: 0265-2638742

E-MAIL: [email protected] / [email protected] WEBSITE: www.sunrisepolymers.com


UNLOADING OF PIPES: The unloading of the material is the responsibility of the client. Because of the relative lightness of glass fiber reinforced plastic (approximately a quarter compared to the steel) handlers may be tempted to handle it roughly, or unload it by letting it drop of its own accord. This may cause serious damage to the material and therefore FRP material should be handled with care.

Other points :

1. Do not use chains, steel cables or clamps during lifting 2. Nylon or canvas hoisting belts with a minimum width of 10 cm must be used. 3. Ensure that hoisting belts are always put round the widest part. 4. We strongly recommend that the pipes are unloaded and must be inspected

on site in order to ensure that no damage has occurred during transportation. This will avoid disputes with regards to responsibilities


STORAGE OF THE MATERIAL: In order to avoid damage to the stacked pipes, the following preventive measures are important:

1. Do not lay the pipes directly on the ground, onto rails or concrete floors. Provide a flat surface.

2. Ensure suitable supports are used for example wooden beams, measuring 10 x 5 cm. To avoid damage to machined pipe ends, stacking should be undertaken with care. The machined ends must be protected for example by polyethylene covered straw mats or polyethylene netting. The socket and spigot ends should not touch each other.


3. The pipes can be stacked economically by altering the spigot and the socket,

as illustrated below. 4. In order to avoid bending of the pipes, the beams should be laid directly

above each other in a vertical line. Supports should be spaced at a maximum of 3 metre intervals and about 1 metre from each end. The width of the supports should be at least 10 cm. The maximum allowable stack height is 1.5 meters. However, for diameters of 800 and above, a maximum of 2 pipes may be stacked one on top of the other.

5. If the product is stacked too high for long storage period (6 -12 months) and subjected to high temperatures, the supports may cause flattening. It is recommended that the product (in particular machined parts) is stored under tarpaulins or white polyethylene sheeting.

6. Pipe stacks should have side supports per blocks to prevent rolling or slipping of the stack during stormy weather.

7. Store rubber o-rings, gaskets, plastic locking strips, adhesive kits, resins, hardeners, woven roving and lubricants in its original pack, below 35 deg. cent. Keep dry away from frost, direct sunlight and ozone.

8. Protected flange-faces should never be placed directly on the ground or on concrete floors.

9. If any damage during transportation or installation is noticed such as scratches, cracks or pits Sunrise Polymers & Industries (India) Ltd should be contacted for any repair or replacement. Never use any damaged material.


RUBBER SEAL JOINTS: Before assembling the rubber seal joints, all safety precaution will need to be checked. Ensure that all necessary tools and materials are available. Tools for runner seal joints: For assembly of rubber seal joints the following is needed. 1. Lubricant for O-ring and locking strip 2. A rod or stick 3. 2 pipe clamps 4. Chain tackles (2) up to ID 500 mm pulling force 750 kg ID > 500 mm pulling force up to 1500 kg 1. Plastic or wooden mallet to drove the locking strip in to the rubber seal lock

joint Rubber ring joint: To assemble a rubber ring joint follow the procedure mentioned below: 1. Rubber ring joint:

a) Clean the spigot and socket end thoroughly with a clean cloth before jointing. Do not use material like dusters in order to avoid fibers from sticking to the surface of the seal.

b) Check both pipe ends for damage. c) Position the rubber ring in to the groove of the spigot end. d) Use a round tool like a screwdriver underneath the runner ring and

work it around a few times in order to distribute the tension. e) Apply lubricant to the rubber ring and the entire inner surface of

the socket end. Avoid any lubricant under the rubber ring in order to prevent it from slipping out of the groove. Do not try to assemble the joint without the use of any lubricant. The standard lubricant can cause fillers to block. Soft soap can be used as an alternative for the lubricant.


f) Fit the rubber lined clamps on both sides of the socket end and

that both sections are fully aligned. g) Ensure that the spigot end is positioned right in front of the

socket end and that both sections are fully aligned. h) Attach the chain tackles to the clamps on both sides of the parts

to be connected and ease the spigot slowly and gradually in to the socket until the mark is in line with the front of the socket end.

i) If in doubt, check with a thin feeler gauge around the circumference, to confirm that the rubber ring is in the right position in the groove.

2. Rubber seal lock joint:

a) Position the hole so the locking strip can be inserted easily. b) Follow the assembly instructions for the rubber seal joints.


c) Attach the chain tackles to the clamps on both sides of the pipe and ease the spigot end slowly and gradually into the socket end until the rear stop of the spigot end is past the hole of the locking strip.

d) Apply some lubricant on the first section of the locking strip. e) Insert the locking strip in such a way that the beveled end rests

against the inside of the socket. f) Using a plastic hammer or a piece of wood, tap the locking strip

home until it rests against the first part of the strip.


g) The end of the locking strip sticks out by approximate 100mm. This

allows disassemble of the newly assembled joint.

h) Ensure that the stop of both the socket end and the spigot end

are in contact with the locking strip and that the fully extended system is kept in this position.

3. Disassembly of rubber seal joint:

In principal it is possible to take rubber seal joints apart within a short period after installation. In practice the joint will be cut out due to the lack of space to pull the spigot out of the socket, unless it is the last installed joint. A rubber seal joint can be taken apart without any difficulty. The dismantling procedure for a rubber seal lock joint is as follows: 5. Push the pipe back in to position to free up the locking strip if possible. 6. Grip the locking strip with a pair of pliers or a plate clamp.


7. Tap the pliers or use a crane to pull the plate clamp to remove the locking strip. ( if the locking strip jams, turn the pipe a little while pulling the strip)

8. Pull the spigot end out of the socket until the rubber ring is positioned at the insertion hole of the locking strip.

9. Pull the rubber ring through this hole, cut the runner ring and remove the ring completely through the hole.

10. Now the joint can be released completely. Flanged joint: Tools necessary for assembling of flanges: 1. Ring spanner with required bolt head size 2. Torque wrench with required socket size FRP flanges are flat faced. These flanges must always be accurately aligned and not subject to any stress. On the FRP side of the flanged joint the bolts and nuts must have washers to avoid exceeding the permitted surface pressure. As an alternative, a steel backing ring can be installed. Pipes must not be pulled together by tightening the bolts. If a FRP pipeline is connected to a metal pipe, this metal pipe must be anchored to prevent any movement or loads being transmitted to the FRP line. When assembling a wafer type butterfly valve, the bolts should be tightened first by hand. If leakage occurs during pressure tests, the bolts can be tightened up to maximum values. To prevent damage of the flanges when tightening, spacers may be placed between the FRP flanges. Bolts in flanges must be placed on either side of the centre line unless otherwise specified. The flanges must be connected perpendicular to the axis of the pipe. In practice minor deviations might occur. If this happens, a gasket with an O-ring seal or a profiled gasket with vulcanized steel ring should be used.


Flange Bolting Recommendations:

1. Inspect the flange sealing surface. Check the dents, scratches or corrosion. Be sure that the finish is adequate for the style of gasket being used.

2. Inspect the gasket. Verify to be sure the gasket material is compatible with intended service. Check for the defects and shipping or storage damage.

3. Inspect and clean bolts, nuts and washers. 4. Lubricate bolt threads and the nut contact surfaces. Do not install the bolts

and nuts without lubrication. The lubricant should be compatible with the service temperature.

5. For flanges installed vertically, installation is started by the bolts on the lower parts. Install the gasket then the other bolts.

6. Tighten the bolts approximately 30% of the final torque following the sequence shown in the diagrams below. Number the bolts to facilitate following the tightening order. If the correct tightening sequence is not followed, the flanges may be misaligned, making it impossible to have a uniform seating of the gasket.

7. Repeat step 6, elevating the torque from 50% to 65% of the final value. 8. Continue tightening in the recommended sequence until the final value is

reached. The same bolt normally has to be tightened more than once. 9. All gaskets relax after seating. Retightening is recommended 24 hours after

installation to compensate for the relaxation.


ERECTION AND SAFETY INSTRUCTION 1. No hammering on Flanges 2. Do not use MS slings 3. Do not over tighten the fasteners 4. The Pipes should not be rolled or slid on rough ground. 5. The Pipes must never be set upon fitting or other protrusions, which are

attached to the Pipes. 6. Prevent tools, scaffolding or other objects from striking the Pipes or being

dropped on or inside the Pipes. 7. Protect from heat or metal sparks from metal cutting or welding. 8. The Pipes be lifted with canvas or rope slings (over 25 mm diameter)

positioned near each end of the Pipes. 9. Under no condition should chain or cables be allowed to contact Pipes. 10. When the Pipes are stored on the ground prior to installation, it should be

placed on the shipping cradles and tied down so that it cannot roll because of wind or sloping ground.

11. Use Rubber pad for Pipes cushioning between Saddle and Pipes. 12. All Instruments/valves on Pipes and Fittings should be self-supported. 13. Proper shoe supports with cushion should be provided for Pipes and Fittings. 14. Support spacing for Pipes and Fittings should be as per manufacturer’s

recommendations. 15. Vibration/stress on the Pipes and Fittings should be avoided. 16. Pipes should be used for the Design/Service conditions as per the

manufacturer’s recommendations only. 17. Pipes should be on water level particularly when the key lock joints to get

100% performance. CLEANING PROCEDURE 1. Remove the mylar film if it is inside the piping/ducting. 2. Clean the inside of piping using normal hose and pump arrangement with

water at 2 to 4 bar pressure. There should not be any chemical content in the water. Apply this water for few minutes till the time whole area is covered and dust/deposits are removed.

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Installation Manual Frp Pipe