Bondstrand Bonder Training

Bondstrand Bonder Training
Fiberglass Pipe
Contents
Part-1: General
Part-2: AMERONs Bondstrand Products
Part-3: HSE & Product handling
Part-4: Fabrication & Installation
Part-5: Hydro-testing
Bondstrand Bonder Training for PTSC M&C - 2009
Part-1 : General
Training Purpose
To provide knowledge of AMERONs

Bondstrand Products
To qualify bonder for bonding certification
required for fabrication and installation of
AMERONs Bondstrand Products
Part-1 : General
Achievements : Trainee must complete
below points to get certificate
Understanding AMERONs Bondstrand

Products
Understanding product data and QC form
Pass hydrotest on practice
Part-1 : General
Bonding certificate
Issued by AMERON to trainee who pass

hydrotest on spool practice
2-year validity
Part-2 : AMERONs Bondstrand Products

Abbreviations
RTRP - Reinforced Thermosetting Resin Pipe

FRP - Fiberglass Reinforced Pipe
GRE - Glass Reinforced Epoxy
GRV - Glass Reinforced Vinylester
GRP - Glass Reinforced Polyester (in some
specifications it means Glass Reinforced Pipe)

Abbreviations
QLF - Quick Lock Female
QLM - Quick Lock Male
TF - Taper Female
TM - Taper Male
B&W - Butt & Wrap
Spigot - Bondstrand Male Pipe End
Bell - Bondstrand Female Pipe End

Filament-wound pipe & fittings with
advanced resins
Epoxy (GRE)
Vinylester (GRV)
Bondstrand Product Lines

Bondstrand 2000/2000M
Bondstrand 2400/3400 series
Bondstrand 2000
A lined epoxy system
for applications where
corrosion resistance
and light weight are of
paramount
importance.
Bondstrand 2000M
A lined epoxy system
for applications where
corrosion resistance
and external pressure
are of paramount
importance.
10
Unique patented pipe saddle drains
off static charge build-up
Design equal to Bondstrand

2000/2000M
An epoxy system with

conductive elements
incorporated in the wall
of the pipe to prevent
accumulation of static
electricity produced by
the flow of liquids inside,
and external effects
outside the pipe.
11
Bondstrand Series 2400/3400

An
* Also conductive
epoxy system where corrosion

resistance and light weight are of
paramount importance.
Pressure class determined by
internal pressure requirements.
No external pressure requirements.
Internal pressure class : 10, 12, 14,
16, 20 and 25 bar.
12
13
Joining System
Quick-Lock Joint
An
adhesive-bonded joint with

straight spigot and tapered bell.
The integral pipe stop in the
Quick-Lock bell ensures
accurate laying lengths in close
tolerance piping.
Sizes : 25-400 mm (1-16)
Sizes : 450-600 mm (18-24)
14
Joining System
Taper/Taper Joint
An
adhesive-bonded joint with

matching tapered male and
female ends offering superior
strength by controlled adhesive
thickness. Available in sizes :
50-1000 mm (2- 40).
Internal pressure class : 10, 12,
14, 16, 20, 25 bar.
15
Joining System
Flanged Joint
A
mechanical joint. Available

in sizes: 25-1000 mm (140).
Various drilling patterns
available (e.g. CL150, JIS
10K, DIN 10, etc.) Compatible to Steel flanges.
16
Joining System
Butt & Wrap Joint
A
lamination joint. Available

in sizes: 25-1000 mm (140).
Time costly.
Versatile. Most use on repair.
17
Adhesive System
RP-34C
A
two-part amine cured

epoxy resin system
Non-conductive
Use on Quick-Lock joint
Available in 3 oz. kit and 6
oz. kit
18
Adhesive System
RP-60B
A
two-part thermosetting,
electrically conductive epoxy
resin system
Conductive
Use on Quick-Lock joint and
Taper/Taper joint
oz. kit
19
Adhesive System
RP-48
A
two-part amine cured

epoxy resin system
Non-conductive
Use on Taper/Taper joint
oz. kit
20
Tools & Equipment
Special Tools
Other Accessories
Pipe Shaver & Power Drive

Heating Blanket
Band Clamp
Lever Hoist
Bore Polisher (Flapper Wheel)
Common Pipe Tools
21
Special Tools Pipe Shaver & Power Drive

!!! Pipe 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: , , 1, 1 , 2, 3, 4, 5 & 6
To individual size only;

Straight Spigot (For QuickLock Joint) only.
Driven by common electrical
tools or air tools, such as hand
drill.
Cutting Insert
For detail guide, See FP376F, Ameron B-1F Pipe End Preparation Tool
22
M-74 Shaver
For 2 16 pipes
Use with arbor set
Straight Spigot (For
Quick-Lock Joint) only.
Driven by hand or
electrical tools (RIDGID700).
For detail guide, See FP696A, M-74 Pipe Shaver

23

Maintenance
and Store
Shall be kept in original tool box after use;

Keep it in dry location, away from rain and
moisture;
Do not use oil and/or grease as dust will
accumulate on oil and grease;
Remove of dust/dirt using brush.
24
Special Tools Heating Blanket

!!! Heating 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
25
Description of Heating Blanket
26
Using Heating Blanket
Wrap the pipe using the

end with thermostat;
Tie down accessory
shall be used;
Do NOT pull the cable;
27

Packing,
Storage and Transporting
Always roll up the heating blanket when not in used;

Do NOT pack and transport heating blanket in folded
form;
Any heavy object fall on it may damage the heating
blanket;
28
Other Accessories
Band
Clamp with D-Rings
Shall be used when making joints, Quick-Lock,

Taper, Mechanical O-Ring,
Available in 2 width x 6 length, and
Available in 2 width x 13 length, and
Available in 3 width x 13 length
29
Other Accessories
Lever
Shall be used when making joints,

Quick-Lock, Taper, Mechanical ORing,
Available in Ton and 1 Ton,
Alternatively, ratchet puller (chain

block) can be used
Bore
Hoist
Polisher (Flapper Wheel)
Sanding bonding surface

Grid 40~60
Driven by electrical drill or air tool
30
Common Piping Tools

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

31
Part-3 : HSE & Product handling

!!! 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
32
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
33

!!! Resin, 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;
34
Maintain personal hygiene at all time;

Do not rub or scratch irritated area if occurred;
Shower in lukewarm water with soap and a
washcloth at days 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.
35
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
36
Good 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.
37
Proper support and protection with protection pad.

Securely fastened.
Forklifts should have at least a 6-foot carriage,
spacer of at least 2-inch thickness are located.
Fittings shall be loaded onto pallets, crates or
baskets with sufficient protection.
3m or less pipe and spool could be lifted by single
4 wide canvas or suitable plastic.
Pipe and spool greater than 3m (in length) shall be
lifted in using two or more canvas or suitable
plastic.
38
Prohibitions
Being thrown or dropped from any height.

Using chains, wire ropes or clamps for lifting
39
Storage
!!! Carrying out inspection for good storage preparation and
carrying out periodical inspection.
Fiberglass Pipe
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.
Side supports; not exceed 5-ft height; proper tie down.
Protective end cover must be in place.
40
Storage
Fiberglass Fitting and Accessories
Fiberglass Fabricated Spools
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 store.
Shall be kept in shipping pallet or skid.

End cover / protection shall not be removed until
installation.
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.
41
Part-4 : Fabrication and Installation
Drawings
Product data & Pipe length calculation
QC form : Log sheet
Fabrication and Installation Tolerances
Hook-up to Equipment / Other Material
42
Drawings
Spool Drawing
Isometric Drawing
Contain all details of design (Pressure, fluid, system,

temperature,..), fabrication and erection (Materials),
installation (Coordinates, connections) and testing.
Layout Drawing
Contain detail dimensions, fabrication materials, and

erection materials.
Background, surrounding, piping routing, supporting,

interface, equipment, etc.
Piping and Instrument Diagram
Principle such as size, flow direction, design

information, materials specification.
43
Sample Drawing Spool 1
44
45
46
Sample Drawing ISO
47
Sample Drawing Layout
48
Product data & Pipe length Calculation
Product data
Assembling dimension of fittings
Pipe length calculation
To produce pipe cutting table

To calculate pipe length for spool adjustment
To verify installation
Exercise : calculate pipe length.
49
QC Form : Log sheet
To record bonding history for fabrication and site

installation
Part of QC documentation
50
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
Refer to tolerance of different type of joints such as

flange joint, mechanical o-ring joint.
Project specification
51

1.
2.
3.
4.
5.
6.
7.
Face/center to face/center
dimension, or location of
attachment
Lateral translation of branch or
connection
Rotation of flange
End preparation
Alignment of flange face
Angular deflection
Reference: ISO14692-4:2002
52

DN
(Inch)
Tolerances / Dimension Number

1 (mm)
2 (mm)
3 (Degree)
4 (mm)
5 (mm)
6 (Degree)
-8
0.5
0.5
10-12
0.3
0.5
14-16
0.3
1.6
0.5
18-24
0.3
2.0
0.5
26-36
0.2
2.4
0.5
40-48
0.15
2.4
0.5
Reference: ISO 14692-4:2002 and Ameron PF-01.

53
Hook-up to Equipment / Other Material

To 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
Equipment (Including fire hydrant, ballast eductor, .)
shall be independently anchored,
Allowable alignment to avoid excessive stress,
Control torque value strictly if equipment connection is
cast iron material,
Dismantle piece is recommended for testing and
equipment maintenance.
54
Part-5 : Hydro-testing
Fabricated Spool Testing

System Hydro-testing
55
Fabricated Spool Testing

Spool Testing is normally used to verify quality of
fabrication joints (if applicable).
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 :
Spool with Taper Male end,

Spool with QL Female and Taper Female and greater than 16
.
56
System 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-Testing
All piping supports must be completed;

For underground piping, sufficient partial backfill and
temporary block must be in place to prevent excessive
movement;
High point vents / low point drains in place;
Removing/isolating components that shall be excluded
from hydro-testing;
57
Test Pressure
1.5 times of design pressure

1 hour holding minimum, or sufficient time to carry out
line check, or project specification whichever is longer
Testing Equipment
Quick closing valve and booster pump without suitable

control shall not be used, to avoid surge;
Pressure gauges and instrument must be calibrated;
Appropriate pressure gauges shall be selected, the test
pressure shall be between 30% to 75% of reading range
If possible, pressure recorder shall be used;
58
Hydro-Testing
Pressure build up process:

The test pressure shall be raised over a period of
30minutes of longer.
Slowly and gradually to allow for equalizing for
strain, and also in stages to allow for inspection.
Inspection
Instrument reading
Visual inspection of joints, pipes and fittings
24 hour holding @ 1.1 design pressure (ISO14692:4)
Acceptance criteria
No sign of leaking or weeping
No significant pressure lost
59
Possible causes of pressure change
Effect of joint expansion and material creep;

Effect of temperature (Morning, afternoon, night, under
sun, and so on), take precaution to prevent over-pressure
Other Concerns
Glycol antifreeze shall be added when test is carry out

in subzero temperature.
Instrument to prevent from buckling in case of sudden
depressurization
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
60

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Bondstrand Bonder Training

Bondstrand Bonder Training for PTSC M&C - 2009

To provide knowledge of AMERONs

Bondstrand Bonder Training for PTSC M&C - 2009

Understanding AMERONs Bondstrand

Bondstrand Bonder Training for PTSC M&C - 2009

Issued by AMERON to trainee who pass

Bondstrand Bonder Training for PTSC M&C - 2009

Part-2 : AMERONs Bondstrand Products

RTRP - Reinforced Thermosetting Resin Pipe

Bondstrand Bonder Training for PTSC M&C - 2009

Part-2 : AMERONs Bondstrand Products

Part-2 : AMERONs Bondstrand Products

Bondstrand Product Lines

Part-2 : AMERONs Bondstrand Products

Bondstrand Bonder Training for PTSC M&C - 2009

Part-2 : AMERONs Bondstrand Products

Bondstrand Bonder Training for PTSC M&C - 2009

Part-2 : AMERONs Bondstrand Products

Design equal to Bondstrand

Bondstrand Bonder Training for PTSC M&C - 2009

An epoxy system with

Part-2 : AMERONs Bondstrand Products

Bondstrand Series 2400/3400

epoxy system where corrosion

Part-2 : AMERONs Bondstrand Products

Bondstrand Bonder Training for PTSC M&C - 2009

Part-2 : AMERONs Bondstrand Products

adhesive-bonded joint with

Part-2 : AMERONs Bondstrand Products

adhesive-bonded joint with

Part-2 : AMERONs Bondstrand Products

mechanical joint. Available

Part-2 : AMERONs Bondstrand Products

lamination joint. Available

Bondstrand Bonder Training for PTSC M&C - 2009

Part-2 : AMERONs Bondstrand Products

two-part amine cured

Bondstrand Bonder Training for PTSC M&C - 2009

Part-2 : AMERONs Bondstrand Products

Part-2 : AMERONs Bondstrand Products

two-part amine cured

Bondstrand Bonder Training for PTSC M&C - 2009

Part-2 : AMERONs Bondstrand Products

Tools & Equipment

Pipe Shaver & Power Drive

Common Pipe Tools

Bondstrand Bonder Training for PTSC M&C - 2009

Special Tools Pipe Shaver & Power Drive

To individual size only;

Special Tools Pipe Shaver & Power Drive

For detail guide, See FP696A, M-74 Pipe Shaver

Special Tools Pipe Shaver & Power Drive

Shall be kept in original tool box after use;

Bondstrand Bonder Training for PTSC M&C - 2009

Special Tools Heating Blanket

Available in 115V and 230V, to be specified;

Bondstrand Bonder Training for PTSC M&C - 2009

Special Tools Heating Blanket

Description of Heating Blanket

Bondstrand Bonder Training for PTSC M&C - 2009

Special Tools Heating Blanket

Using Heating Blanket

Wrap the pipe using the