Method Statement UG GRE R 3 PDF

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METHOD STATEMENT FOR

INSTALLATION OF GRE PIPING
Document No.
E09335-43-00-4S-014
Project Name
BTIP- Onshore Facilities I Offshore Pipelines
Contract No.
E-09335
Client
Shell Petroleum Development Company of Nigeria Limited
/--1
[r. ..~~
-- --=-------- -- --- -
EPIC CONTRACTOR
Rev
Date
09. Mar. 2004
06.Jun.2004
07 July 2004
<
Description
Revised
Reflected hydrostatic test

procedure recommended
by Ameron
Change the order of
Hydro-Test & Water
Flushing
Prepared
Reviewed
Approved
by
by
by
Akerele. J
J.Y.Lee
Dl P ali<
I.T.Koh
J.K.Lee
I.T.Koh
/)
Ai~ ~~oh
AHYUNDAI HEAVY INDUSTRIES CO., LTD.

1, Cheonha-Dong, Dong-Ku, Ulsan, Korea, 682-792, http//:www.hhi.co.kr
Tel: 82-52-230-3370, Fax: 82-52-230-3447, E-mail: hjlee@hhi.co.kr
J. K. Letl'
.HYUNDBI
IEMY .DIISTRES CD. LTD.
CONTRACT NO E-09335
BTIP- ONSHORE FACILITIES I OFFSHORE PIPELINES
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REVISION HISTORY
SPDC
EPIC CONTRACTOR
Rev
0
Date
19. Feb,
2004
09. Mar.
2004
06. Jun.
2004
07. July
2004
Prepared
Reviewed
Approved Validity
Period
by
by
by
S.Y.Kim
J.Y.Lee
Dl Park
6 Years
Akerele. J
J.Y.Lee
01 Park
6
Years
I.T.Koh
I.T.Koh
J.Klee
6
Years
AkereleA.
I.T.Koh
J.Klee
6
Years
Date
Reviewed
Approved
by
by
.HYlJMJBI
CONTRACT NO E~9335
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IMY IIIUSIRIES CD., LTD.
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 DEFINITIONS
4.0 REFERENCE DOCUMENT
5.0 SAFETY
6.0 RESPONSIBILITIES
7.0
HANDLING, STORAGE AND TRANSPORTATION
8.0 WORK SEQUENCE FOR GRP PIPE INSTALLATION

9.0 DOCUMENTATION
10.0 ATTACHMENTS
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_.HYUNDBI
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CONTRACT NO E-09335
BTIP -ONSHORE FACILITIES I OFFSHORE PIPELINES
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1.0 PURPOSE
The purpose of this method is to assign responsibility for the installation of the
underground piping systems. It serves to define the methods and processes to be
adopted to ensure all GRE pipe of underground piping systems are installed in
accordance with the appropriate project specifications
2.0 SCOPE
This method covers the installation, jointing and backfilling of GRE pipe systems
for fire water pipe spool on under ground. Erection of GRE pipe spool is
described in procedure SCS-16. Pressure testing of all piping systems will be
conducted in accordance with the pressure test procedure ..
3.0 DEFINITIONS
1) PDC
2) HHI
3)SCS
4)GRE
5) U/G
Shell Petroleum Development Company.

Hyundai Heavy Industries Co., Ltd.
Standard Construction Specification
Glass-Fiber Fiber Reinforced Epoxy
Underground
4.0 REFERENCE DOCUMENT

1) SCS-S-35:
Contractor Safety
2) DEP 31.38.70.2
Design and Installation Of Glass-Fiber Fiber Reinforced

Epoxy and Polyester Piping.
Requirement for Glass-Fiber Fiber Reinforced Epoxy and
Polyester Pipes and Fittings
Glass-Fiber Fiber Reinforced Epoxy and Polyester Pipes
and Fittings
3) DEP 31.38. 70.37

4) DEP 31.40.10.31
5) GRE Vendor Specification & Installation Manual and hydrostatic test

procedure supplied by AMERON)
6) DEP 31.40.1 0.19-Gen.
GRE PIPELINES AND PIPING SYSTEMS
5.0 SAFETY
5.1 SITE SAFETY
All safety procedures as covered by Standard Construction Specification
SCS-S-35 (Contractor Safety) shall be strictly adhered to.
1) All workers shall wear appropriate personnel protective equipment while
executing the project.
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2) Electrical cables shall be properly arranged to avoid damage and possible

current leakage.
5.2 LIFTING I RIGGING WORKS
1) Mechanical I manual lifting shall be applied in the lifting operation using
quality and experience riggers.
2) All lifting operations including movement of GRE pipes and fittings, -valve
boxes etc shall be carried out by experienced riggers.
3) All lifting equipments including slings, shackles, lifting beam etc, shall be
prepared I inspected and color coded prior to being used.
5.3 SAFETY PRECAUTIONS
The following safety precautions shall be observed when using GRE products.
When cutting or grinding GRE materials the following personal protection is
necessary to prevent dust irritating the skin:
1) A dust mask covering nose and mouth
2) A pair of safety glasses
3) Gloves and coveralls
Using resin and hardener of adhesives or lamination sets. In case of irritation of
the respiratory system care shall be taken that satisfactory ventilation is
provided.
If a system is pressure tested, adequate safety precautions shall be taken as a
" safe test pressure "does not exist. Any pressure in itself is dangerous.
The test equipment shall be operated by experienced personnel. Personnel not
involved in the test or inspection, shall be excluded from the immediate area.
A testing supervisor shall be in charge, and hislherinstructions shall be final.
No on line work shall be carried out during a pressure test.
Leaking joints shall only be repaired after the pressure has been fully released.
The test equipment shall be installed at a sufficient distance (determined by
the safety dept.) from the connection to the pipe system.
All Safety Precaution shall be kept in accordance with the job hazard analysis
for the UIG GRE piping as attached documents.
6.0 RESPONSIBILITIES
6. 1 The piping manager shall be responsible for the following:
1) Preparation and implementation of this method statement
2) Control of Material ,Handling, Storage
3) Establishment and execution of Installation schedule and sequence
4) Control of construction documents and drawing
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5) Overall site safety management

6) Ensures that all installation tasks are carried out as per specification
6.2 The QA/QC manager shall be responsible for the following:
1) Reviewing of this method statement
2) Performance of all inspection works as required
3) Check and monitor the use of latest version/revision of applicable design
documents and drawing in GRE pipe installation.
4) Review and approval of Inspection and Test Plan.
5) Performing inspection on Mechanical/Civil Work relative in method
statement
6.3 The HSE Manager has the overall responsibility regarding development,
implementation and monitoring of HSE program capable of achieving
lowest exposure to hazards and accidents on the site.
6.4 Design department of Project Control Team
The design department of the project control team shall be responsible for
the composition and distribution of Isometric piping drawings, As-Built
drawings and the compilation of piping test packages.
6.5 Manager
Site manager is ultimately responsible for the execution of method
statement.
6.6 Clivil Construction Manager
Civil construction manager is responsible for the excavation and back filling
of piping trenches all associated survey work.
7.0 HANDLING, STORAGE AND TRANSPORTATION
7. 1 Materials control
End protection of piping components shall remain in place during handling
and transportation.
Pipes and fittings shall be handled with care and protected from impact.
Throwing, dropping, bumping or hitting the pipes and the fittings are prohibited.
Pipes shall not be dragged or pushed over sharp objects.
Forklift trucks may only be used for transporting pipes, provided that the forks
are padded with carpeting or some other suitable soft material.
Do not let the pipe rest on the floor of the container where nails, studs or other
.HYUND41
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CONTRACT NO E-09335
BTIP -ONSHORE FACILITIES I OFFSHORE PIPELINES
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sharp objects might damage it. Pipes shall be laid on wooden sleepers.
The pipe should be securely fastened directly over the timbers with tie downs
such as nylon straps or ropes. Do not use steel wire ropes or others sharp
material which might cause damage.
No other materials should be loaded on the top of the pipes.
Do not drop the pipe or walk or stand on it.
When loading 12m lengths of pipes, a minimum of 4 wooden supports must
be used to separate each length.
7.2 Loading
Pipes, fittings and prefabricated spools shall be transported by suitable trucks.
These trucks shall have flat floors. The materials manager or his staff shall
check for and remove any projection or nails etc. before each load. Materials
shall be secured by using wooden supports. These supports shall have a
minimum width of 10 em, GRE pipe shall be tied in place using soft straps.
Chains or steel cables shall not be used. The support distances shall not
exceed 2.5 m. The width of the supports shall be a minimum of 10 em. When
pipes are inserted (one inside the other), the support distance shall not
exceed 3m. Flanges shall be secured against sliding. Flanges shall only be
loaded on their sealing face if they are sufficiently protected against damage.
Pipe ends, machine part, fittings shall be protected without damage.
Pipe ends and machined parts shall be protected, for example, by means of
straw mats, covered by polyethylene sheet or polyethylene netting. pipes and
spools shall be lifted by using cloth belts with a minimum 2 times of lifting
weight and shall be lifted at two points, using the largest diameter of the
prefabricated spool, in such a way that the weight is well balanced.
The truck bottom shall be covered with wood or thick matting to protect the
GRE pipe from damage. Side loading trucks shall be the preferred type of
vehicle for transportation. If pipes are handled by a forklift truck, the forks
shall be padded or covered with suitable materials (plastic ).
7.3 Unloading
The unloading of material is the responsibility of the materials control team
unless agreed otherwise
The following handling points are mandatory:
1) Do not use chains, steel cables or clamps during lifting.
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2) Nylon or cloth hoisting belts with a minimum 2 times of safety load shall be
used.
3) Standard pipe lengths shall be picked up at two supporting points.
4) Ensure that nylon or cloth hoisting belts are always put round the widest part.
5) Pipes shall be unloaded one at a time when sling belts are used.
6) Each part is carefully loaded and shall be inspected on site in order to
ensure that no damage has occurred during transportation.
7.4 Handling
For pipe and components supplied with machined parts, the Manufacturer
shall apply external and internal closed end machined parts protectors to
protect the ends and all exposed machined parts of the pipe, coupling and
fittings from damage under normal handling and transportation. For machined
parts connections, the end protectors shall also protect the end face and the
outer surface of the bell-end to prevent chipping and impact damage.
Machined parts protectors shall exclude foreign matter such as dirt from the
ends. Protector material shall be plastic and contain no compounds capable
of damaging the machined parts or making the protectors adhere to the
machined parts.
7.5 Storage
7.5.1 Pipe
Pipes with bell-ends shall be stored with the bell-ends in alternate directions
to avoid contact with and damage to the ends, mating surfaces or machined
parts.
Wooden or plastic spacers shall be used and shall be of sufficient size and
strength to prevent contact between pipes. Spacers shall be located clear of
the bell-ends.
It is recommended that all pipes and fittings be supplied complete with end
protection (both inside and outside) of the pipe wall and shall be transported
either packed in a container or strapped onto pallets, suitable for site storage
for up to two years.
7.5.2 Storage of materials
In order to avoid damage to the stacked pipes, the following rules are
mandatory:
a) Do not lay the pipes directly on the ground, onto rails or concrete floors.
Provide a flat surface.
b) Suitable supports shall be used with wooden support. To avoid damage to
machined pipe ends, stacking shall be undertaken with care. The
machined ends shall be protected by polyethylene covered straw mats or
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polyethylene netting. The bell/socket and spigot ends shall not come in
contact with each other.
c) The pipes can be stacked economically by alternating the spigot and the
socket/bell ends.
d) To avoid bending of the pipes supports shall be spaced at a maximum of
3 meters intervals and 1 meter from each end.
e) The width of the supports shall be at least 10 em. The maximum allowable
stack height is 1.5 meters. However, for diameters of 800 mm and above,
a maximum of 2 pipes shall be stacked one on top the other.
f) If the product is stacked too high for long storage periods (6-12 months)
and subjected to high temperatures, the supports shall cause flattening.

The product (in particular machined parts) shall be stored under tarpaulins
or white polyethylene sheeting.
g) Pipe stacks shall have side supports or blocks to prevent rolling or slipping
of the stack during stormy weather.
h) Store rubber a-rings, gaskets, plastic locking strips, adhesive kits, resins,
hardeners, woven roving and lubricants in their original packages, below
35 C. Keep dry, avoid direct sunlight and ozone.
i) Observe the shelf life of the adhesives and resins. Order these as required.
j) Unprotected flange faces shall never be placed directly on the ground or
on concrete floors.
'\.., ..
k) If any damage during transportation or installation is observed such as

scratches, cracks or pits, repair or replace. Do not install any damaged
material even if the intent is to repair it later.
8.0 WORK SEQUENCE FOR GRP PIPE INSTALLATION
8. 1 All GRE pipe installation sequence shall be performed in accordance with
the GRP bondstrand installation manual supplied by Ameron.
Inspection for civil work, excavation, compaction , GRE pipe installation
shall be executed in accordance with the relevant ITP. (Doc.no. ITP-C-002,
ITP-C-01 0, ITP-P-003)
8.2 Hydrostatic pressure test
Hydrostatic Pressure test shall be conducted in accordance with HydroTesting Procedure for GRE I GRV Pipe (Doc. No.: AME/INS-004) by
Ameron. But, Test pressure shall be held for a minimum period of 60
minutes and leak test shall be maintained at design pressure for at least
60 minutes , Operating pressure shall be use for integrity test for 24hrs
and all joints, connections shall be examined for leak
Tighten the come-a-longs (provided by

user) on both sides so that the 0-ring
enters smoothly without being pushed
out of its groove
Insert the male end until the scnbe One is

about ~ inch (6mm) from the leading
edge of the female end or coupHng.
Lubricate the locking key (supplied by

Ameron) before insertion. Depending on
the project requirements, metallic or
plastic locking keys may be used.
Place lubricated locking key into the

keyhole and slowly close the joint until the
key will slip easily into the keyway
Check the pipe alignment.
Drive the locking key only until you can

see its leading end through the keyhole. If
the key is driven in too far, it may bind,
making later removal difficult or
impossible
Thanks to the reusability of the Key-Lock

mechanical joint, this slurry water pipeline
can be readt7y extended or relocated as
required at some future time.
.HYUNDill
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Inspection for hydrostatic Pressure test shall be executed in accordance

with the relevant ITP. (Doc. no. ITP-P-007)
8.3 Water flushing
Flushing shall be in accordance with Flushing Procedure for Bondstrand
Pipe by Ameron (Doc. no.: AMEIINS-005).
8.4 Back filling, Compacting and Final back fillirig shall be performed in
accordance with the GRP bondstrand installation manual supplied by
Ameron.
Inspection for back filling, compacting and final back filling shall be
executed in accordance with the relevant ITP. (Doc. no. ITP-C-002)
8.5 Final inspection
Inspection and Test Plan (Doc. no. ITP-P-003) shall apply and be
monitored by the responsible QA/QC Personnel. Also all reports and
other documents resulting from the Inspections and other checks as
may apply during the process of this work shall be dully prepared,
controlled maintained and afterwards submitted to SPDC at sign-off of
this work
9.0 DOCUMENTATION
All relevant documents shall be applied the latest version
All relevant documents such as AFC drawing, method statement, ITP,
JHA and HSE presentation shall be maintained at the work site office.
The inspection and test record or check list verified by QA/QC inspector shall
be maintained in QA/QC office.
10.0 ATTACHED DOCUMENTS

1) Job Hazard Analysis for the U/G GRE Piping
2) Hydro-Testing Procedure for Bondstrand GRE I GRV Pipe (Doc. No.:
AME/INS-004).
3) Flushing Procedure for Bondstrand Pipe (Doc. No.: AME/INS-005).
JOB HAZARD ANALYSIS FOR THE U/G GRE PIPING

RISK ASSESSMENT
NO TASK
HAZARD
STEP
DESCRIPTION
Task Name: Site Preparation
1 Preparation of work
- Sharp objects
site including
- Debris, scraps
contractor temporary
& waste.
facilities
- Community disburtance.
EXPOSED
coNSEQUENCES
SUBJI;:CT
-Personnel
- unpremmobed
vehicle, eqpts
Inexperienced
personnel
-Personnel
-Property
- Environment
Third parties
activities
Personnel
Injury to personnel
Potential fatality or
multiple fatality
- Damage to existing surface &

underground utilities
Seve Likely Riskl

rity
hood
M
'
2 Site measuremenU
surveying
Harmful insects
-Workers
- High noise near
involved
running plants.
Sharp objects
Third party activities
Open ditches
Trip or fall
Injury to personnel
Potential fatality
I'
'---~-~-----~-~--
---
L_~
CONTROL
MEASURE
RECOVERY
MEASURES
- First aid kit

- Watch out for sharp
materials.
- Medevac
- Use proper PPE's always procedure
- Use specified uitility
detector
Waste magt system
- First aid kit
Premob of equipment is
- Medevac
mandatory
procedure
Equipment maintanance
schedule
Use PTW
- First aid kit
Hold tool box meetings
- Medevac
- Follow guidelines on
community/client relations procedure
Seek guidance from SPDC
on community issues
provide day/ night security
Post warningg signs in the
area
- First aid kit
- Watch out for open
drains
- Medevac pro
Barricade work sites
- Use ear muff
near running plants.
- Wear correct PPE
Use PTW
I
- Guide assistant(s)
iproperl~
ACTION
PARTY
-Workers
- Supervisor &
safety officer
- Supervisor &
safety officer
- Supervisors &
workers.
- Supervisor & safety
-Foreman
-Foreman
-Foreman
r,.,

RISK ASSESSMENT
HAZARD
EXPOSED
CONSEQUENCES
CONTROL
NO TASK
Seve Likely Risk!
STEP
DESCRIPTION
MEASURE
SUBJECT
rity
hood
Task Name:Transportation of Materials by Road
3 Transportation of
-Personnel
Injury to personnel
Unpremmobed
M
L
L - Check a pre-journey
personnel and
vehicles
- Pedestrian
-Damage to property
vehicle.
materials to site
-Ensure load is properly
damage
Weak pipe support other personnel Pipe falling out of truck
secured.
improper stacking in the area
Injury to personnel
H
L
M - Check vehicle is not
overload.
Damage to other fac.
Vehicle overspeed -Vehicle
Collision with other
- Obey all road safety
-Driver
vehicles
rules.
L
L - Check fire extinM
guishers before
each journey to see
that they are serviceable.
I
Task
N
M ---- I Handli
------.:__v__
4 Move load materials - Personnel obM
L
L - Supervise closely
- Loading crew - Injury to personnel
follow approved routes
from one point to
structing moveanother by hand
- Wear correct PPE
- Materials &
-Damage to
ment of load/
personnel
equipment
equipment, materials
(e.g. hand gloves,
coverall etc.)
- Load slipping
from hand.
-Riggers
- Fall/ tripping
--------
---
------
- -
RECOVERY
MEASURES
ACTION
PARTY
- First Aid & Ki -Driver

-Emergency
-Rigger
procedure
MEDIVAC
-Foreman
- Safety Officer
-Driver
~~
Bad lifting position
Personnel
Injury to the back of

personnel
back strain, pains
- Follow safe lifting

procedure/position
Maintain good housekeeping
HSE induction for all
personnel to include
ergonomics
- Keep access to load
destination clear from
all obstructions
First Aid office

on site
MEDIVAC
- Rigger Foreman,
Safety officer
- Rigger Foreman,
Safety officer
-Foreman

RISK ASSESSMENT
NO TASK
STEP
Task Name: Mechanical
5 Lift load (materials)
from one point to
another by use of
crane and low bed
HAZARD
DESCRIPTION
Lifting
Unpremmobed
equipment
Inexperienced
operator
Uncertified lifting
slings and gears
uncertified riggers
SUBJECT
operators
other personnel
personnel
operators
- Riggers,helpers
Other personnel
-----
- -
Crane operator
other personnel
third parties
Personnel
Body irritation from
contact with GRE
material Burn sustained from Ill health
-----
hood
-Damage to
equipment,
cargo, and
workers
Riggers
Heavy object falling
Impact on immediate
environment
- High noise level
Body contact with

GRE materials
Exposure to
adhesive jointing
materials
Seve Likely Risk

rity
-Riggers,
helpers
I
I
6 Pre- fabricate GRE

piping spools
coNSEQUENCES
-Personnel under
suspended load
EXPOSED
----
-----
-----
CONTROL
MEASURE
RECOVERY
MEASURES
site First Aid

- Check and conform
integrity of lifting
office
MEDIVAC
equipment.
Select experienced persons
Wear correct PPES
M Check to confirm integrity
of lifting rope/shackle
and sling correctly.
- Use tag rope when
necessary.
- Dedicate a signal man
- All lifting equipment
to be colour coded
Use PTW
Maintain SWL of eqpt.
L - Ensure "no rider"
sign is written on
equipment due to
model, all load to be
lifted must be identified by its weight.
L - Operator to use ear muff
--
First Aid kit

Use complete PPEs to
include Coverall, hand
gloves nose muff
Select experienced persons
I
USE MSDS
ACTION
PARTY
- Rigger foreman and
safety officer.
Safety Officer
Safety Officer
- Safety officer
- Operator foreman
Supervisor
Sfety officer
~-

RISK ASSESSMENT
HAZARD
NO TASK
EXPOSED
STEP
DESCRIPTION
SUBJE;CT
Task Name: Workshop Pre-fabrication of GRE spools
Exposure to hot
Personnel
surface
-CONSEQUENCES
Seve Likely Risk

rity
Burn sustained from
hood
ACTION
PARTY
RECOVERY
MEASURES
CONTROL
MEASURE
First Aid kit
Use PTW
Hod toolbox meetings
epoure to hot surfaces
Wear complete PPEs

GRE particles
personnel
Poor housekeeping
~---
Maintain good house-
- - - -
---------
Train workers on GRE

handling
keeping
provide SHOC for all matls

---~-----
Task Name:Excavatlon and road crossings

7 Excavation and road
crossings
Underground
- Third party
Damage to under-
facilities
personnel
ground facilities
Sharp objects
Environment
Injury to personnel
First Aid
- Keep off human traffic
- Supervisor &
MEDIVAC
at work.
safety officer
- Dedicate flagmen/
open ditch
signal men to control
limited work space
human traffic.
Road closed for a
- Probe work area so
long period
as to safeguard existing
Other road users
utilities I third part property MEDIVAC
stone and splinters
Wear complete PPEs
from road breakage
First Aid
Use PTW
Unstable excavated personnel

wall
water logged ditch
Use well point where

excavation is> 3.0m
personnel
provide shoring for excavated
Environment
wall> 3.0m
Cordon off open excavation
Post warning signs at

-
L__
excavated areas
---
----
--~-----
/''

RISK ASSESSMENT
NO TASK
STEP
'
HAZARD
EXPOSED
DESCRIPTION
SUBJECT
CONSEQUENCES
Seve Likel~~ Risk!

rity
hood
CONTROL
MEASURE
RECOVERY
MEASURES
ACTION
PARTY
Task Name: Demobilisatlon

8 Remove equipment
Inexperienced
-All personnel
- Body injury,
- Use correct PPE
- Safety officer
materials & per-
personnel
- Client site rep
sonnel from site
Use of faulty or
- Site Supervisor
unpremobbed eqpt
Clean up of work
Sharp objects
site, reinstate site
excess, left over
to original condition
materials
- All personnel
- Environmental
pollution
Damage to materials
third party property
- Use journey mana hemen! slip

- Liaise with HSE
.a
Bondstrand Installation
1\~FRO:-.;
..................
,.
Series 2400 and Series 3400

-piping systems
using the Key-Lock mechanical joint
Introduction
This guide provides recommendations for the installation of Bondstrand piping

systems using the Key-Lock mechanical joint. Many of the skills, techniques and
principles of steel pipe installation also apply to fiberglass piping. As you work with
Bondstrand fiberglass piping, you will find that it weighs much loss than steel and
that it is more flexible, but it must be handled more carefully than uncoated and
unlined carbon steel pipe. In addition, fiberglass pipe often needs protection against
abrasion at points of support.
To accommodate these characteristics of Bondstrand fiberglass piping, the following
installation recommendations should be followed. You are encouraged to contact
Ameron or your Bondstrand distributor for more help on specific problems or
questions.
Receiving piping
materials
Unloading and handling
Inventory and inspect all incoming shipments of Bondstrand pipe and fittings.
If the inventory does not exactly match the delivery receipt, recount the materials in
the presence of the truck driver Any discrepancy in the inventory and any obvious
shipping damage must be noted on the receipt. Insist that the receipt be signed by
the truck driver. If it is evident that materials have been lost or abused, damage
claims must be initiated before accepting the shipment. Under customary shipping
procedures, title and risk of loss pass to buyer upon delivery of material to carrier
Ameron's Standard Terms and Conditions of Sale require that the buyer promptly
notify both seller and carrier of any damages or shortages.
Examine pipe and fittings carefully for shipping damage. In particular examine (a)
key and 0-ring grooves on pipe ends with damaged or missing end protection, and
(b) fittings received in damaged containers. Pads which are damaged or suspected
of being damaged should beset aside and reported as stated above
Pipe, except when crated, is normally unloaded as single lengths or bundles. To
prevent damage to grooved pipe ends, do not drag or slide pipe in any way that
abrades or dislodges the end protection. Do not bump pipe or grooved pipe ends.
Pipe maybe moved either by hand or by lifting equipment using nonmetallic ropes or
straps. Single-point pickup is permissible for pipe 8 inches (200 mm) and larger in
diameter in 20-foot (6 m) lengths. Two-point pickup using a spreader bar is
recommended for all other sizes and lengths.
Caution: Do not throw or drop pipe or fittings. Bondstrand product packaging is not
designed to withstand dropping from a truck onto the ground. Do not use a f0f1<1ift to
handle pipe unless forks are padded with carpeting or some other suitable material.
liners can be damaged to the point of allowing leakage even though
the outside surface shows no signs of mishandling. Handle all material
carefully at all times.
'C Anwron 1916 FP111 0 DS/93 Printed in Holland
Storage
Pipe or pipe bundles may be stored for extended periods in stacks up to four feet
(1.25 m) high. Pipe stacks must have side supports or blocks to prevent! them from
rolling or slipping. Pipe stored in stacks should be supported using bearing boards
and spacer boards as shown in Table 1 on a level surface'. free of rocks and other
hard or sharp objects. Bearing boards under the stack and spacer boards between
the pipe layers must ensure that bell and spigot ends remain round. not distorted by
stack loads. Bearing and spacer boards should be at least three inches (75 mm)
wide and cushioned with a suitable foamed plastic or other material. More supports
may be required for telescoped (nested) pipe. Contact Ameron or your Bondstrand
distributor for advice regarding this special case.
Table 1
Sueeort SQacing for PiQe Storage
Support Distance
Pipe
Pipe
from End of Stack
Diameter
Length
(mm)
(ft)
(in)
(mm)
(ft)
(m)
4
1.2
all sizes
6.1
20
1.8
6
9.1 all sizes
30
12.2.
1.5
50-100
5
40*
2-4
2.4
150+
8
6+
12.2
40
*Add third support in center of stack or 40-foot pipe in 2-4 inch sizes.
Fittings should be removed from cartons, closely inspected and stored on shelves,
preferably inside a warehouse Extended outdoor storage may impair the exterior
appearance of fittings but will not affect their physical strength. Outdoor storage of
cartons is not recommended since they are not weatherproof.
Caution: 0-ring grooves on ends of stored pipe and fittings must be
protected from direct sun.
Locking keys and 0-rings are often shipped to the jobsite in cartons with the
0-rings separately packaged. Locking keys and 0-rings are to be stored indoors.
Adhesives must be stored indoors at temperatures below 100 F (38 "C). Extended
storage at higher temperatures will degrade the catalyst and the resin and reduce
adhesive strength.
Each adhesive kit is stamped with an expiration date. In order to monitor the storage
life remaining and to rotate the stock so that older kits are used first, all kits should
be removed from shipping cartons and stacked upright so that the expiration dates
are visible.
Preparing for
installation
Pipe in trenches: Trench construction,. bedding preparation and backfill must

conform to the project plans and specifications. If no requirements are given. refer to
ASTM D3839 and the Ameron publication, "Guide for Installing Buried Pipe, for
basic guidelines.
This guide gives permissible bending radii which may be used for either horizontal
vertical curvature of the trench bottom (that is, the pipeline). A small deflection at
Key-Lock joints is also permissible provided that pipe-to-trench support is
maintained. The angle between adjacent pipe at keyed joints must not exceed the
values in Table 2.
or
Once the trench has been prepared and the sand bedding brought to grade and
compacted. the pipe sections may be lowered into place. Remove enough sand from
the graded bottom at joint locations to maintain a working clearance while
assembling the joint Additional clearance can be obtained by placing a temporary
wooden block support under the joint during assembly. Dig block out after assembly
without lifting pipe.
Table2
Permissible Angular Deflection
at Key-Lock Joints
Nominal Pipe Size
Maximum Joint Deflection
(in)
(mm)
Male x Female
CouQiing
2-16
50-400
}4
1
18-24
450-600
y.
y,
Suspended pipe: Refer to ltle project plans and specifications for details and
locations of supports and anchors. The Ameron publication, "Bondstrand
Engineering Guide for Suspended Pipe," BEG-13. outlines general design principles
for' suspended fiberglass piping systems including hanger detailing. The guide also
contains information on rates of expansion and contraction and on the design of
systems restrained against movement.
If span lengths are not shown on the plans, consult Ameron or your Bond-strand
representative for span recommendations at the operating temperature of the
system.
Bondstrand pipe should not be point supported. Place supports under pipe rather
than fittings. All shields and hangers in contact with the pipe should be free of burrs.
Provide abrasion protection for the pipe where it slides through fixed supports or
guides. Firm attachment of abrasion protection is necessary where movement is
possible between pipe and support.
Use a material compatible with service environment such as those listed below:
Bondstrand support saddles provide a clean, corrosion-free surface and act as
a stiffening saddle for the pipe. Support saddles are adhesive bonded to the pipe.
A half section of the same size pipe may be bonded to the line pipe to provide
light-duty abrasion protection for pipe eight inches (200 mm) and larger in diameter.
Elastomeric materials such as rubber, neoprene or even cut-up tire casings may
be held in place by pipe clamps or pipe insulation straps.

Fiberglass shields such as manufactured by Glas Mesh Co.
Galvanized sheet metal may be banded to the pipe in environments where it is
expected to have a suitable service life. Recommended minimum metal gauge is
given in Table 3.
Important: Hangers and supports which clamp around saddles, shields or pads
must be sized properly and must be flexible enough to fit and grip without damage.
Check outside diameter of pipe in the appropriate Bondstrand product literature as
th~varies with pressure class.
Table 3
Recommended Thickness
for Galvanized Sheet Metal Protective Wrappers
Pipe Size
Thickness
(in)
(mm)
Gauge
(in)
2-6
50-150
0.0598
46
20().400
8-16
10
0.1345
*A division of Rubco Products, Inc., West Chester, Pennsylvania 19380.
(mm)
1.5
3.4
Lines which are emptied and filled during the cycle of operations may require
anchoring at changes in direction. Bondstrand pipe weighs approximately 1/ 6 as
much as Schedule 40 steel pipe, therefore, thrust generated at turns may move or lift
the line when it is filled rapidly.
- 3
It is sometimes advantageous to use restrained supports, especially in tunnels or

areas where space is restricted- In such cases, guides will be required at spacings
as indicated in the adjoining chart.
8
7
6
5
30
20
01
.,
G>
"0
:;
10
~' ~ \'-.-.
-...........
.......
:a
2
..........
-...........
15
4
c:
;:;
c.CJ)g
I!
r-..
j'-...
r--
~'r-
r:::,.
r...
~I!-............
r--...
..........
f'
f"r---
\'--.,
f"..
Pipe
Size
{in)
12
10
"~
~~
..........
!'
~'r--
!"-
['..
r"
.....
I
20
10
30
40 50 60
20
30
80 100
40 50 60
150 200
80 100
Temperature Change
Figure 1 Guide spacing vs. temperature change for Key-Lock joined fiberglass
pipefines with blocked (restrained) ends. Solution shown assumes an initial
temperature of 60 F and a water-filled line.
Joint assembly
Preparation of Key-Lock joining surfaces: When ready to join the pipe,

remove the end protection from the male pipe end. Loosen and remove dirt and
debris from the grooves using compressed air, a clean, dry rag or a paint brush.
Clean the grooves and sealing surface of the female end or coupling. Sand oft any
projections or rough edges on the entry ramps which compress the 0-ring during
insertion.
Now brush or rub a layer of Ameron lubricant into the 0-ring groove of the male end
and all inside surfaces of the female end or coupling. Apply lubricant only when
you are ready to complete the joint Keep lubricated surfaces clean and free of
sand and dirt as contamination is likely to interfere with joining and sealing. Proper
lubrication of the 0-ring and joint surfaces is important to avoid cutting the 0-ring or
rolling it out of place during assembly.
()o.rtng placement: Lubricate entire surface of the 0-ring and slip it into the first
groove on the male end. Distribute the 0-ring evenly in the groove by slipping a
screwdriver under it and sliding the screwdriver around the joint As an alternative for
distributing the 0-ring in pipe in sizes through 16 inches (400 mm), uses screwdriver
to Jilt the lubricated 0-ring at top center a distance of about 20 percent of the pipe
diameter and let it snap back into the groove.
Do not gouge or abrade the 0-ring. A sound 0-ring is the key to a watertight
joint.
Pipe spigot insertion: Place the band clamps on either side of the joint Rotate the
new pipe so its keyhole(s) are in proper position for driving the key(s) for the next
joint
End protection (supplied by Ameron

should be removed just prior to assembly
to keep joining surfaces and grooves
clean.
Lubricate inside of female end and locking key groove wfth ample amounts
of lubricant (available on order from
Ameron). Note that the pipe already
in place has been properly rotated so
that the key-hole of the next joint
is conveniently positioned.
The male end of the pipe going in

should 8/so be generously lubricated.
Again, make sure that the keyway is
wei/lubricated.
Affer coating the G-ring (supplied by

Ameron) with lubricant, mount it in the
endmost groove in the male pipe end
Insert a screwdriver under the mounted
0-ring and run it around the pipe to
distribute the 0-ring in the groove
Mount the band clamps (available on

order from Ameron) a convenient distance on each side of the joint, making
certain that the pipe going in is properly
positioned to allow access to the keyhOle
of the foiiO'Mng joint.
...
__
Align the pipe for a straight concentric

entry Proper alignment is essential for
joining ease.
Align the male end against the female end or coupling already in place for a straight
concentric entry. Proper alignment is essential for joining. Deflect the joint to conform
to the actual horizontal and vertical alignment of the trench only after the joint is fully
asSembled in the straight position.
An Ameron joint puller is recommended for joint assembly. Connect the ratchet
winches to pulling rings attached to the band damps on either side of the pipe and
ease the joint together It is often convenient to place one band damp just behind the
female end or coupling and the other about 4.5 feet (1.5 m) from the male end.
Tighten the winches evenly on both sides so that the D-ring enters smoothly and
without being pushed or rolled out of its groove Insert the male end until the scribed
line is about %inch (6 mm) from the leading edge of the female end or coupling. To
reduce slippage you may elect to use rubber pads under the band damps.
Straightness of entry adds significantly to the ease of assembly. Sight
along the pipe and carefully observe concentricity and uniformity of entry.
Driving the keys: Place lubricated locking keys into the insertion holes and slowly
dose the joint until the keys will slip into the keyways. Check the straightness of the
entry again by sighting along the pipe and by aligning the scribe mark on the male
end with the edge of the female end or coupling.
Use a hammer or mallet to drive the locking keys through the insertion holes and into
the keyways until the leading end can be seen in the insertion hole and
approximately 3 to 4 inches (75 to 100 mm} remain projecting.
Caution: Drive the key only until you can see its leading end through
the insertion hole. If the key is driven too far. heat may elongate it and cause it to
stick, making later removal impossible.
Protect the projecting keys of piping exposed to sunlight or other ultraviolet radiation
from embrittlement Within several days after installation, spray all exposed key
surfaces with a black acrylic coating or wrap them with duct tape. Also, fill keyholes
with caulking compound to prevent intrusion of sand and dirt which may make later
key removal difficult
Positioning and aligning the joined pipe: After driving the keys, deflect the
joint to fit the hanger supports or trench bottom. With the pipe fully supported in its
final position, release the lifting straps: for buried pipe, extract them carefully from
under the pipe.
Note: When installing buried pipe in sag curves, it may be necessary to leave the
lead lifting strap in position to align the next joint during assembly.
To avoid excessive movement and bending at turns and branches during the
hydrostatic test, pull straight sections of joined pipe forward as assembly progresses,
using a ratchet winch or other means to remove play in the joints.
Anchoring-and blocking
Suspended pipe is anchored against forces tending to move the pipe by supports which grip the pipe barrel or preferably the female end or coupling. The
magnitude and direction of these forces depend on system pressure, temperature, layout geometry and other factors. Refer to the "Bondstrand Engineering
Guide for Suspended Pipe)' BEG-13, for guidance.
It is sometimes necessary to block buried pipe especially for high pressure
or high temperature services. Refer to the Ameron publication, "The Need for
Blocking of Buried Pipe; EB-24.
Blocks on buried lines which experience temperature changes greater than
90"F (SO"C) should encase the fitting so that the block resists the compression
or tension in the line. Alternatively, blocks may be placed on each pipe leg
adjacent to the fitting, thereby leaving the joints and fitting open to inspection.
When blocking in this fashion, bond saddles to the pipe or use special anchor
pipe from Ameron.
Cutting pipe to length
Special pipe lengths are frequently required for fit-up. When pipe is shortened by
cutting off factory-prepared ends, new male ends must be furnished by bonding on
end adaptors. Cutting and bonding often can be avoided by using factory-made short
lengths (pups) with male ends. Special tools, equipment and assembly instructions
are available from your Bondstrand distributor
Connections to other
piping
Bondstrand fiberglass piping maybe connected to either metallic or thermoplastic piping using flanges drilled to ANSI Standard 816.5, Class 150. Other
flange drillings are available on special order Bondstrand filament-wound flanges
may be bolted directly against raised-face steel flanges provided a torque wrench is
used. These flanges also seal well against lined steel configurations. Use a full-faced
1
/.,..inch (3 mm} thick elastomeric gasket with a Shore A hardness of 60 5 for best
results. Consult Ameron literature for complete flange assembly instructions.
For working pressures above 300 psi (20 bar), a special machined steel adaptor is
used to form a matching male end which is then welded to the steel line. Jointhe
Bondstrand Key-Lock .end to the steel adaptor using normal Key-Lock joining
techniques.
Important: Where Bondstrand piping is connected to metallic pipe, anchor the
metallic pipe securely at the point of connection so that expansion and contraction of
the metal line is not transferred to the Bondstrand line.
Field testing
Field testing is best and most safely accomplished using a noncompressible fluid usually water Provide taps for air and vapor removal stall high points in the system.
Trapped gases may creates hazard during test and operation of the system and may
also restrict flow or drainage. Avoid rapid filling of long lines. A rapidly moving
column of fluid has high inertia and can build explosive pressures in trapped sir
1
pockets. Recognize that at 150 psi (10 bar}, air will be compressed to /1o of its
original volume and will stores considerable amount of energy.
Caution: Before testing with compressible fluids such as air or gases,
contact Ameron or your Bondstrand representative for special
recommendations.
Closures for test can be made using blind flanges or valves. A Swei-Piug positivegrip end closure. Model4031*, is a reusable alternative.
For systems intended for noncompressibte fluids. test the piping hydrostatically at the
test pressure cited in the appropriate Bondstrand product data publication for a
period of four hours. Although a drop in the gauge pressure will reveal larger leaks, a
visual surface check of pipe, fittings and joints at the end of the hydrostatic test
period will provide the best evidence of satisfactory installation.
Key-Lock joints Installed with good wol1cmanship will normally be leak-free. However,
small amounts of sand or grit, cut 0-rings or excessive joint deflection may cause
some leakage. For the field test, a leakage allowance of ~ gallon per hour (1.89 liter
per hour} per 100 joints irrespective of pipe diameter is suggested as permitted by
NFPA 24 for private fire service mains.
Temperature has a significant influence on test pressure. Direct sun and the heat of
the day may cause pressures to rise well above the intended test pressure, possibly
overstressing piping, valves and equipment Avoid this by bleeding off excess
pressure. Conversely failing test pressures may indicate cooling of the line; pressure
should be boosted until the cause of the pressure drop has been established.
A product of the Tube Tums Division of Chemetron Corp., Louisville. Kentucky 40201.
10
Leak repair
Leaks in pipe and joints are repaired by replacing the faulty part. The following
procedure describes disassembly of a coupled Key-Lock joint but applies
equally for male x female joints when the pipe can be moved axially in either
direction. If the pipe cannot be moved, the female end must be cut off and replaced
by insertion of an adapter, a length of pipe (pup) and two coupled joints.
When disassembling a Key-Lock joint.. be aware of the effects of temperature on
restrained or buried lines. Disassembly will be far easier if the joint is relatively free of
tension or compression. The warmest time of the day may be best for a joint under
tension, and the coolest time best for one under compression.
Before disassembly, it may not be obvious whether the joint is in tension or
compression. Assume tension in a normally hot system after cooling and compression in a pressurized system after dropping the pressure.
Caution: Pipeline contents may be at unexpected temperatures o,:.
pressures. Pipelines may even contain fluids other than water. Open
the line slowly and carefully to avoid injury to personnel.
Before disassembly, depressurize the line and allow it to cool .. if necessary. The
keys can sometimes be removed more easily when the pipe is relatively cool. Attach
an Ameron key e)(!ractor to the projecting keys and e)(!ract them one at a time. Next,
slide the coupling to the side until the 0-ring can be seen through the keyhole. Using
. a special 0-ring retractor tool, grip the 0-ring firmly and pull a loop out of the hole.
Next. grip the o-rtng firmly using a vise-grip wrench or pliers and remove the retractor
tool, Cut the 0-ring on the short side of the loop. The keyhole is tangental to the
surface of the pipe. Thus, when the 0-ring is pulled straight out of the hole, the short
side is that half of the loop nearest the female end or coupling surface. Push the
short cut end back into the keyhole. Now pull the gripped end to remove the 0-ring.
Now slide the coupling further to the side until the second 0-ring appears and repeat
this process to e)(!ract that 0-ring. In most cases it will be necessary to remove the
coupling using this procedure at the other end of the pipe section as well.
If a locking key or an 0-ring cannot be e)(!racted-. the joint can be disassembled by
making two or more longitudinal sawcuts through the coupling with a portable circular
saw.
Caution: When cutting a coupling, avoid cutting into the pipe surface.
After removing the damaged or faulty pipe section, determine the average distance
between the open ends of the in-line pipe. Note that once the joints of a restrained or
buried line are opened and tension or compression in the line released, the distance
between the open ends may change somewhat because of temperature changes in
the piping. In some buried systems under axial stress. the line will continue to
shorten or lengthen for a time as the pipe slowly moves through its soil envelope.
Therefore, make this measurement just before you are ready to proceed with the
replacement
Using this average distance and allowing for joining dimensions, select an
appropriate pipe length from stock. Insertion of replacement pipe maybe facilitated
by taking advantage of temperature change during the day. One may expect a
correction of 0.025 inches in a 20-toot length for each 10 F of temperature change
(1.1 mm/6 mm/10 "C).
Use new 0-rings and keys for reassembly. Slip the coupling onto one of the pipe
ends at each joint, far enough to expose the 0-ring grooves. Clean and lubricate the
joining surfaces and replace the o-rtngs. Use the Arneron joint puller to ease the first
coupling back over the two spigot ends and insert the keys to complete the joint
Repeat this process at the other end of the pipe to complete the repair.
11
Important notice
This literature and the information and recommendations it contains are based on
data reasonably believed to be reliable. However, such factors as variations in
erwironment, application or installation, changes in operating procedures, or
extrapolation of data may cause different results. Ameron makes no representation
or warranty, express or implied, including warranties of merchantability or fitness for
purpose, as to the accuracy, adequacy or completeness of the recommendations or
information contained herein. Ameron assumes no liability whatsoever in connection
with this literature or the information or recommendations it contains.
Written comments regarding this document are invited. Please write

Engineering Manager, Ameron Fiberglass Pipe Division
A\
AME RON
..................
FlbeFJius Pipe GI"OIIp
Headq..nen
P.O. Box 801148
HOUIIOn,TXm80
U.S.A.
Phone: {+I) 713 690 7777
Fax: (+1)7136902842
Flberpus Pipe Dlvilfoo

Tile Americas
P.O. Box878
Burkburnett. TX 76364
U.S.A.
Pbonc: (+I) 940 569 1471
Fax:(+I~S692764
lntemec www.ameron-intl.com
Bondslrand pipe is also manufactured in Japan and Saudi Arabia
Fiberglas Pipe Division

Europe
AmeronB.V.
RO.Box6
4 I 90 CA Ocldennalscn
The Nc:therl&Dds
Phone: (+31)34SS87S87
Fax: (31) 345 S87 S61
Flberpua Pipe DMsloa

Alia
Amcroa {Pte) Ltd
No. 7A. TuuAvenuc:3
Jwtlll&
Sinppore 639407
Phoac: (+65)8616118
Fax: ( +65) 862 13021861-7834
II
-=---
FIBERGlASS PIPE GROUP
Installation of Buried
Bondstrand Pipe
Introduction
To ensure long life and trouble-free service from a Bondstrand piping system, the
principles of excavation, joint make-up, bedding, backfilling and field testing must be
property applied. These principles must be reflected in the phrasing of contract
documents and must be enforced through inspection. Be sure that contractor
personnel have been thoroughly trained In Bondstrand assembly procedures by a
cer1lfted Arneron field "'f-W 1tat1ve.
These recommendations for installing buried 8ondstrand pipe are based on two
principles:
Follow Ameron's recommendations for assembling pipe sections and curing the
joints carefully.
Provide evenly distributed support for each section of pipe rather than concentrating
the support at points or short stretches of the pipe bottom. Evenly distributed
support is achieved through proper bedding.
Receiving, storing and

handling fiberglass pipe
Trench design and

excavation
Bondstrand pipe is manufactured from fiberglass reinforced epoxy or vinyl ester resins.
When property handled and installed, fiberglass pipe and fittings will provide a
maintenance-free, hi~performance piping system. Fiberglass rWiforced pipe and
fittings are impact sensitive and must be handled with a reasonable amount of care.
Refer to the Ameron publication SHPPING, HNo.ING, ST'oRAGE 1>HJ INSPECTlON OF
8oNDs'rJwc FtseRc3lASS PIPE, FP167 for pertinent guide6nes and a table of pipe weights.
'
1) The excavation must allow the pipe to be laid to the grades and alignments shown
on the plans.
2) Provide the narrowest practical trench width that will allow proper compaction of the
pipe zone backfil. The trench must have vertical sidewalls from the foundation to at
least the top of the pipe. Maintain a minimum trench width equal to the inside diameter
of the pipe plus 12 inches (300 mm). The maximum trench width from the foundation to
the top of the pipe must not exceed the inside diameter of the pipe plus 24 inches
(600mm}.
IS0-9001
..
II!
--
3} Beneath vehicular traffic, the height of earth cover over the top of the installed
pipe must be no less than 3 feet (.91 m} unless suitable methods are used to
protect the pipe. See ROADWAY CRossiNGS below.
4} Provide firm. but not hard foundations consisting of sound earth 1 or granular
soi!2, and free from stones or lumps exceeding one inch (25 mm) In greatest
dimension that might bear against the pipe. Prepare suitable foundations by
overexcavating the trench for not less than 4 inches {1 00 mm) and backfilling
FP278C (1 0196)
Trench design and

excavation
Rg.2. Pipe ZOIIe backfill should ccnsist of

sound 88lfll or gnn~lllr material free of
stones or lumps exceecing 1 inch (25 mm)
in diameter. The material should not contain
wgetation or debris that could Ieiwe I'Oids
upon decon'rPOSitiof GranuiBr matarial:l
St.JCh as sand, gravel orCIIIshed rock yield

high densities with a ll1inirnlln of
compaction effrxt and have {JfOVflfl iciNJ for
the pipe ZDnfl backfilL GrarXJJar malerials
should PBSS a 'IHnch screen and no more
than 15% should passa No. 200 sieve.
2 inches (50 mm) to subgrade with loose bank run material, graded uniformly in
one plane for the full length of the pipe. Overexcavate at each bell so that the pipe
barrel rests on the bottom of the trench. Foundations must provide uniform
support under the haunches of the pipe along the full length of each pipe section.
5) When the excavation is in soft

or wet. unstable soils that will not
provide sufficient support for the
pipe, overexcavated the trench at
least 6 inches (150 mm} and
backfill to 2 inches (50 mm) below
subgrade with solid granular soil
compacted to at least 85-95%
Proctor (40-70% relative density).
Then complete the subgrade as
described in section 5. The
method described in NFPA No. 24
section 8-4.3 under exception is
not acceptable for fiberglass pipe.
All units in
inclleS(mm)
I
1
Trench Width
~In 10. 12" (300mmll
1Max
10 + 2.a(!CIOmm)t
I
I
Min Bidding
2(50mm)
6) When solid rock, hardpan or

other hard foundation is
encountered during excavation, overexcavate the trench at least 6 inches (150 mm)
and backfill to 2 inches (50 mm) below subgrade with solid granular soil
compacted to at least 85-95% Proctor (40-70% relative density). Then complete
the subgrade as described in section 5.
1) Moat nativ. .oils. with the ucaption of highly Olg8nic, spongy aoilsiW!d fat, tighly plastic _..;.e clays.
2) Send with a maximu'n particle size of 1A inch (6 rnm) or gnMII with a minimum grain siZit of '14 inct1 (6 mm). or
paa gnMII or CNihad rock milced with 8W1CI.
Assembling pipe and

fittings
1) Prepare and assemble Bondstrand Quick-Lock joints in accordance with the rt!COmmendations contained in Ameron publk:ation, FP170. For taper/taper joints to 6 inches
(150 mm), consult Ameron publication FP1 04.
2) Position pipe on 4 x 4 timbers across the trench. Block pipe to hold alignment and
prevent lateral movement during cure. For larger diameters, use of come-afongs for
joint assembly.
Pipe
aoo-2~~
Bending l'lldius
Diameter
Qn)
2
3
4
6
8
10
12
14
16
(mm)
50
80
100
150
200
250
300
350
400
Mid-ordinate to 1QO-ft Chord

2000Series
3000Series
(m)
(ft)
(ft)
(m)
16.5
19.1
5.0
6.0
10.5
13.4
4.7
3.2
8.1
2.5
8.6
2.7
5.3
1.6
6.4
2.0
4.1
12
4.0
1.3
3.2
0.9
3.3
1.0
2.7
0.8
2.8
0.9
2.5
0.8
0.7
2.2
2.2
0.7
1.7
0.5
Bending Radius
2000Series
3000Series
(m)
(ft)
(m)
(ft)
231
75
85
25
125
100
30
38
160
48
150
46
71
235
60
200
305
93
320
98
375 114
380 116
450 138
450 138
560 170
495 150
750 230
565 172
1) Cutvann may be .wtical, horizontal. ora cornbO>alion. ~if~ for

llllgrftWII conlnll. shill -=tl-lllong a! least 4 ~ (100 mm) of pipe surface.
Placing pipe in trench
1) Cure the joints fully before lowering the pipe into the trench. Any vibration or
movement of partialy cured joints wiU increase the risk of joint failure.
2) When the joints have and, raise the pipe slightly to remove the timber supports,
using rope or webbed sling to lift the pipe. Do not use chains. Lower the pipe into the
trench gradually. Do not drop the pipe. When wof1<ing manually, use at least two men
for 6-inch (150 mm) pipe and four men for 8 and 1Q-inch (200 and 250 mm) pipe. Install
larger pipe with lifting equipment. Do not lift pipe C1l/ef' 10 inches (250 mm) in diameter or
30 feet {9 m) in length at a single point use a spreader bar.
3} Should the depth of the trench measured from the top of the supports upon which
the pipe is assembled to the trench bottom exceed 5 feet (1.5 m), do not lower the pipe
by the method outlined in section 4 as it may overstress the pipe. It is the customer's
Placing pipe in trench
responsibility to submit specific laying conditions (trench depth, handling equipment,

pipe diameter, etc.) to Ameron for recommendations for trench depths in excess of
5 feet(1.5 m).
4} Pipe may be installed in curved trenches provided the curvature is uniform and does
not exceed the tabulated values.
1) Grade the trench bottom accurately and bed with sand to provide uniform bearing
and support along the entire length of each pipe section. Provide a shallow depression
for bells and couplings. The grade should not exhibit abrupt changes in di~on or
Bedding and backfill
slope except at fittings.
2) Do not cover pipe joints until all pressure tests have been performed.
3) Compact the backfill uniformly around the pipe giving particular care to the bedding
beneath the haunches of the pipe. Compaction may be done with water if the native soil
is free draining. If the native soil is not free draining, bedding with damp sand will
facilitate compaction. Extend backfill at least 6 inches (150 mm) above the pipe.
Fill the pipeline with water or use

other appropriate means to prevent
buried pipe from floating during
compaction with water in
cohesionless soils.
4) Place backfill in 6-inch (1 SO mm) maximum lifts to a point at feast 2 feet (.6 m) above
the top of the pipe. Do not use mechanical compactorS directly over the pipe until at
least 12 inches (300 mm)offill have been placed over the pipe, or at least24inches
(600 rrm) if heavy compaction equipment is used. Compact each lift to 85% at
maximum density as determined in accordance with ASTM 01557 for cohesive soils, or
to 70% relative density in accordance with ASTM 02049 for cohesionless soils which
fail to produce a well-defined, moisture-density relationship when tested in accordance
with ASTM 01557. Avoid damage to pipe wall during compaction. Place the remaining
backfill as directed by the engineer. Make in-place tests at soil density in accordance
with ASTM 01556 or ASTM 02167. Contact Ameron Applications Engineemg for
specific information on ASTM specffications.
Mechanical compactors may be used provided harmful shock loads are not
transmitted to the pipe. Maintain at least 121nches (300 mm) between tamping feet
and pipe wall to avoid damage to the pipe.
Roadway crossings
Where Hve loads are less than the conventional H20-S161oading, the burial depth
ITl88SUred from the top of pipe should be at feast 3 feet (.91 m) for all diameters. At road
crossings where the loading exceeds H2D-S16, bury the pipe deeper or use casing
pipe and coBars or sleeves to protect the pipe. Ameron will make recorTVT181'1dations on
increased depth at burial upon request provided complete loading and soil conditions
are submitted tor an engineering analysis.
H-20 load
+f
~.
0 .......
Ext(50 """'
cuing
tMyond
2 II
comPCtlon zone
Roadway surface
Ifoo.._ __
10ft(3 m)
tnDJmum
speang
'
',
Hydrostatic thrust
1) It is the responsibility of the engineer to evaluate the need for thrust blocks. A
complete evaluation must consider singly and in combination the effects of
temperature changes, intennal pressure surges and pipeline geometry.
2) Temperature changes produce stress in buried pipe that is restrained by (1) friction
of the surrounding bedding, (2) passive soil pressure at fittings, or (3) thrust blocks.
Forces developed at fittings in fully restrained pipe are tabulated in Section 8 below.
3) Hydrostatic thrust at fittings is a function of the degree of restraint of the ad;acent
pipe. The magnitude of the hydrostatic thrust experienced by a Bondstrand piping
system is also a function of the method of construction of the pipe: different values
must be used for systems employing reciprocally wound pipe (Series 2000, 2400,
3400, 4000, 5000, 5700 and 7000) and pipe made by the continuous winding process
(Series 3000, 3000A. 3200, 3300 and adhesjve-bonded oilfteld line pipe such<
Bondstrand 200, 300, etc). In a fully restrained reciprocally wound Bondstrand
fiberplass pipe (i.e.; blocked against movement at both ends) wfth all joints bonded, the
Poisson effect produces considerable tension in the pipe wall: as the internal pressure
increases, the pipe expands circumferentia/fy and at the same time tries to contract
longitudinally. The resulting tensile fon:e in the pipe wall acts to reduce the axial
hydrostatic thrust on the fitting byabout 50% compared to the thrust experienced in a
system using continuously wound Bondstrand pipe.
The ttvust forces acting on a bend are defined as follows:
T =
P =
A =
9
2PA sin~
where
Thrust at fitting (I~)

Hydrostatic pressure (ps~
FlowareaofpipeOn2)
Angle of bend (deg)
Use this formula for determining thrust in systems employing Series 3000 and related
continuously-wound products. To determine hydrostatic thrust in pipe using
Series 2000 and related reciprocally-wound piping, use one half the value given by the
above formula. HydrtlStatic thrusts at fitmgs in fully restrained systems at 100 psi
(7 bar} are tabulated in Appendix A. Thrusts at other pressure may be determined
by ratio.
4) Valves should normally be blocked as indicated in section 9.8 (fig. 9.2) to support
their own weight, resist thrust and to prevent excessive torque loads on the pipe
connections.
5} Thrust blocksae required at hydrants and atfH1Ch (150 mm) orlagertfanetertees and
elbows for firewater mai'lsregulated by Fac:tcry MltuaJ Research Caporaticn.
Thrust due to thennal

expansion
Thrus1 forces arising from thermal expansion of the pipe wall in Series 2000 and related
products are tabulated below. The effects of thermal expansion will generally be less in
systems employi"lg Series 3000 and related piping since the pipe wall thickness of
these latter systems is less than for Series 2000 products.
Pipe
Ola
On)(mm)
Thrust at Rttings for a 140" ~Tin 2000 Series Pipi'lg

Tees or
90"
45"
Ends
Elbows
Elbows
Qbrl
(kN)
QbJ
(kN)
ObJ
(kN)
2
3
50
eo
1,880
8.4
2,830
. 12.6
4
6
8
10
12
14
16
100
150
200
250
300
4,550
6,760
9,710
12.200
14,500
17,400
22,000
20.3
30.2
43.3
54.4
64.7
350
400
n.6
98.1
1) Inial '*"perature 60"F (15'C)

Oper.ling ternpenllurw - 200"F(93'C)
2,660
11.9
4,000
17.8
6,430
28.7
9,560
42.6
13,700
61.1
17,300
n.2
20,500
91.4
24,200 1oa.o
27,800 123.6
1,440
2,170
3,480
5,170
7,430
9,340
11, 100
13.200
15,100
6.4
9.7
15.5
23.1
33.1
28.3
49.5
58.9
67.4
Thrust block design

and construction
1) Once the anticipated thrusts have been deterTTiined, thrust block design must
consider soil strength. so stability and location of the water table. Blocks must (a) have
adequate bearing area to resist the soil thrust, (b) bear against undisturbed soil and
(c) be so designed that the resultant thrust vector passes perpendicularly through the
center of the bearing surface (exceptfor valves as in section 9.8). Should the soil be
unstable or th9 installation below the water table, the engineer must make provisions to
ensure stability such as driving piles to anchor to deeper layers of soil. Note that any
connecting metaluc pipe must be anchored at the point of connection to the fiberglass
pipe to prevent transfer of excessive stress.

F~g.
9-7 Thtvst blocks should be cast

wffh the beaiing area against
uncjjsturbecJ native soil.
Cross sectional area of pipe ~n')

Bloclc bearing area (tt')
Widlh of block bearing area (ft)
At,
b
C,
D
f,
F"
H
He
Hb
p
P"
R
T
w
9
Soil cohesion factor

PipeOO(ft)
Safety factor
Sail thrust ~bt)
Height of block bearing area (ft)
Depth ot cc:NfK (It)
Buial depth of pipe (ft)
Depth of block base (ft)
Opetating plus SLI"Q8 pressure (psi)
Passive soil pressure ~b,'ft')
Soil weig.t reduction factor
Thrust force on bend Qbt)
Unit soil weight Oblft')
5011 weig1tlft of pipe (lb,'fl:)
Pipe bend (deg)
Soil friction angle (deg)
Formulas:
2PA
Section A-A
sin! (lb,l
2) Safe bearing pressures for common soil type are tabulated below.
Allowable Soil Bearing Pressure P0

MPa
Soil Description
Qb,~
Rock, hard thick layers
400,000
Rock, good masonry
50,000
Rock,. best brick
30,000
Rock.. poor brick
1 0,000
Clay, always dry
8,000
Clay, fairtydry
4,000
Clay, soft
2.000
Gravel,coarsesand, firm 16,000
Sand, compact. firm
8,000
Sand,clean,dry
4,000
Quicksand, aUuvial soiJ1
-
Reduction
Existing Condition
Factor, A
General construction
backfill soils compacted
to critical void ratio
........'
Well-compacted backfill
and select backfill
to critical void ratio
11)
3)
=-==may
19.2
2.39
1.44
0.48
0.38
0.19
0.1 o
o.n
0.38
0.19
betaqUftd in loose orsolhals, pattic:ua.1y when below
The required bearing area is computed using the fOITTlula:
Ab=
Ao =
=
PP
T
Pp
Bearing area of thrust block (ft2)

llvust (Jbd
Alowable soH bearing pressure O~!ft2)
Thrust block design

and construction
4) Thrust blocks for Bondstrand pipe systems should be poured after hydrostatic
testing to allow for clear visual inspection of all fitting joints during the test. To retain
pipe in proper alignment while testing, placement of sand bedding and backfill per
section 5 may be required. Joints should be left exposed for observation during testing.
5) Thrust blocks should be
shaped with the "designed
bearing area against native

soil of the trench wall. Smaller
blocks using a dry mix may be
shaped by hand but larger
blocks (2 ft2 or greater) require
formwork.
6) Unless otherwise specified
by the engineer, use a
concrete mix consisting of
1 part Portland cement,
2 parts washed sand and

3 parts washed gravel with
Friction Angle.$
(deg)
Soil Description
Well-graded sand
44.5
dry
39.0
saturated
Silt (passing 200 sieve)
dry
40
32
saturated
Cohesive granular soil
13-22
wet to moist
Clay
wet to moist at
max compaction 11.5-16.5
0
0
ll
385-920
460-1175
enough water for a relatively a

dry mix. A dry mix is stronger and is easier to shape.
7) Work the concrete thoroughly around the fittings to maximize surface contact. The
entire area between the fittings and the freshly cut trench wall must be filled with
concrete and be void free. Maintain at least a 2-inch (50 mm) space between concrete
vibrators and pipe or fittings as even indirect contact through the concrete aggregate
may produce excessive impact loads on the fiberglass pipe.
8) Valve blocks should incorporate the steel necessary to support the weight of the
valve and resist any torque loads caused by opening and dosing the valve.
9) Thrust blocks should encapsulate aossovers with at least six inches (150 mm) of
concrete between fittings and native soil.
Rg. 9-2. l4IMts must beb ldepetldenlly

supporledto ,_,rlnlnsfsroftotqueloads
to the fibetglass piping.
Figure 9-3. Provide flfiCIJPSlJ/lft lhlust

blocks for crtiSSOWIIS.
'-~
10 and
Manhole penetrations
connections
1) When making penetrations through concrete walls, run Bondstrand pipe through
metal pipe sleeves at least two sizes larger In diameter than the pipe. Caulk the space
between the sleeve and the pipe with a waterproof compound that dries to a firm but
plable mass.
2) Assemble flanged connections in accordance with the recommendations in
Assaa.Y INs'mUCOONS FOR
St..... p i p e BoNt:lsrRANo AEIERGLASS FLANGES,
FP196.
Rg. 10. 7yPieal wall penetration. The

~pipe,_ thoughsmetalsi!Mwe
n.o pipe simsWgerthan the pipe diamet8r.
7he~be'-'pipeMdalelweia
aalrld Mttl an fllastomer1c caulking

compound.
3) When connecting fiberglass

piping to metallic piping,
anchor the metanic line to avoid
stress transfer to the fiberglass.
4) Support valves independently of fiberglass piping.
Elatorr.ric caulking
2-;n(SOmml m1t1.
~~~~
I!
11
1) Pneumatic testing is not recommended fer reasons of safety.
Field testing
3) Displace all free air in the Bondstrand piping system with the tes: ~uid. Provide taps
tor air and vapor release at all high points in the system.
A Appendix
Hydrostatic Thrust at Reducers at 100 psi 1 in 2000 Series Piping Svstems2

Reducer Size
Thrust
Reducer Size
Thrust
(in x in) (mm x mm)
3 X 11h
3x2
4x2
4x3
6x3
6 x4
8x4
8x6
(ib.)
80X40
SOxSO
100x50
100x80
150x80
150 x 100
200x100
200x150
240
510
270
1,150
880
1,980
1,100
(kNl
(in x in)
(mm x mm)
1.0.
2.3
12
5.1
3.9
8.8
4.9
10 X 6
10x8
12x8
12x10
14x 10
14x 12
16x12
16x14
250 X 150
250x200
300x200
300x250
350x250
350 x 300
400x300
400x350
_;;..;.;..;;___;;;.;~~..;;.____;~;_____;..;..__;__
1) lnaflllly-...ed....,_
___
~1?4
lkNl
2,650
11.8
1,550 _ 6.9
3,.35J
15.i.l
1,800
8.0
6,COO
26.8
2.5LJ
1 ~ .2
7,SOO
31.2
4,~\:0
2" 1
___;;__;,..;..;;._.:..;..;;..:_.___;;~--
-~
- .
2) lnca.dea s.n-2000,2400, 3400, 4000,5000,5100and7000..

2
Hydrostatio:: Thrus~ at RedJr:')rs at 1 (10 os:' in 3000Series ~~?~-~;_":_:":~.:?" __
ReducerSize
Thrust
ReducerSize
Thrust
(in x in) (mm x mm)
(lb.)
(N)
On x in)
(mm x mm) (ib.;
{N)
3x11h
3x2
4x2
4x3
6x3
6x4
8x4
8x6
80x40
80x50
100x50
100x80
150x80
150x100
200x100
200x150
470
1,010
54C
2,300
1,750
3,950
2200
2.1
4.5
2.4
10.3
7.8
17.6
9.8
10x6
10x8
12x8
12x10
14x10
14x12
16x12
16x14
250x150
250x200
300x200
300:-:250
350x250
350x300
400x300
400x350
1) Ina fully IWinlined ~2) ~ Seria3000, 3000A, 3200. 3300, Bondslr3nd 150.200, 300. 450 and
o;-,
Oia
(in)(mm)
2
3
4
50
80
100
6 150
8 200
10 250
12 300
14 350
16 400
."
5,300
3,1CO
6,700
23.6
13.5
29.9
12,CCC
5,000
14,000
9.:::oc
53.5
22.3
62.4
40.1
:3.""::::
113_1
eoo.
Thrust at Frttin~ at 100 ~i' in 2000Series Pioing Svst~

':'"
""":'... -.- ,... .
C::'"':o
45" Laterals
Elbows
Eibows
(ibr)
(k~j)
(kN)
(kN)
(ibr)
(ibJ
170
.8
1.1
130
245
.e
405
1.8
575
310
1.~
2.6
675
3.0
515
950
4.3
2.3
1,550
6.9
9.8
1,200
5.4
2.200
2,650
11.8
3,750
16.7
S.1
2.050
4,200
18.7
5,950
26.5
3,300
37.0
6,000
26.8
37.7
4,600
8,450
20.5
7,300
32.6
10,200
45.5
5,500
24.5
9,500
32.~
42.4
59.3
13,300
7.200
1) In aiiAiy ,_..ined S)'Stem.

2) lncUiea SenM 2000, 2400, 3400, 4000, 5000. 5 I 00 anc17000..
Thrust at Fltti!];!s at 100 ~i 1 in 3000 Series Pieing Svs!ems2

45.
Tees or
90"
45 Laterals
Elbows
Sbows
Pipe
Oia
(ln)(mm)
Qb.)
(kN)
50
80
100
340
810
1,350
3,100
5,300
8,400
12,000
14,600
19,000
1.5
3.6
6.0
13.8
23.6
37.5
53.5
65.1
84.7
2
3
4
6
8
10
12
300
14
350
16
150
200
250
400
1)
In
2)
lndudes
(lb.)
490
1.150
1,900
4,400
7,500
11,900
16,900
20,400
26,600
(kN)
2.2
5.1
8.5
19.6
33.5
53.1
75.4
91.0
118.6
(ib,)
(kN}
260
620
1,030
2,400
4,100
6,600
9200
11,0CO
1.2
<!9. ~
14.400
64.:
2.8
4.6
1C.7
18.3
29.4
41.~
itAly -ined 3)IStern.
s.n. 3000. 3000A. 3200. 3300, ~ 1so. zx. 3CO. ~.5c arxJ ecc.
7
- . . . . ---
Important notice
This rrtararure and the information and recorrvnendations it contains are based on data reasonably beliewd to be
reliable. ~such tac:1ors as varialians in environment, applic:ation or installation, changes in optnt;ng
procedo.ns. or ex1rapolalion of data may c:au. dilfwant results. Ameron makes no reptWa1tation orwana-rty.
e><pniSS8d or implied, induding wananttes of marchantability or fitness lor purpose, as to the aca.racy.
adequacy or~ ot the oiiCOITIII'Iel odations or inlormlltion c:ontared herein. AmMin assumes no
&ability ~in CDrYiedion with this i - or the infcrmation orrecorrrTWidatio it contains.
A\
Doc No. : AME/INS-004

Rev
0
Page
1 of 8
AMERON
INTERNATIONAL
HYDRO-TESTING
PROCEDURE FOR
BOND STRAND
GRE I GRV PIPE
WHLEONG
KSCHONG
YKTAN
26 JUN '00
REV.
PREPARED BY
CHECKED BY
APPROVED BY
DATE
A\
Doc No.
Rev
Page
AMERON
INTERNATIONAL
AME/INS-004
0
2 of 8
HYDRO-TESTING PROCEDURE FOR BONDSTRAND GRE I GRV PIPE
1.0
SCOPE
This procedure covers the m1mmum requirement for the pressure testing of
AMERON piping system at site.
2.0
RESPONSIBILITIES
The execution is under the responsibility of the installer in co-ordination with the
owner representative.
3.0
EXCLUSION
3.1
The following piping accessories and equipment shall be excluded or

isolated from pressure testing of piping.
\.
3.2
Rotating machinery, pumps, compressors, etc .

Filter elements of strainers .
Pressure relieving devices such as rupture discs and pressure relief
valves.
Vessels that would be overstressed at piping test pressures .
All instruments, including level controllers and gauge glasses .
Pressure gauges .
Steel expansion joints I bellows
Orifice plates .
Flow nozzles .
Pressure control valves .
Corrosion probes
Deluge nozzles
Any other piping or equipment designated by owner representative
(packaged units/ Equipment shall be isolated or by-passed as required)
All the elements that are not to be tested along with the piping shall either
be blanked off during testing or spool pieces inserted during testing.
A\
Doc No.
Rev
Page
AMERON
INTERNATIONAL
4.0
5.0
AME/INS-004
0
3 of 8
TEST PRESSURE
4.1
For pressure testing of piping systems, the test pressure indicated in the
construction drawings shall be strictly followed. The recommended test
pressure is 1.5 times the anticipated design operating pressure. When
higher test pressures are desired, the test pressure should not exceed 1 .5
times the maximum rated operating pressure of the lowest rated element in
the system. Therefore it is important to check the pressure rating of all
components of the system, because fittings, tanks, or hoses may carry a
pressure rating lower that that of the pipe.
4.2
Sudden pressure surges or "water hammer" should be avoided during test.

In some instances, surge and hammer can produce pressures of several
times the rating of the pipe and fittings. In order to prevent water hammer
or over pressurization, quick closing valves and booster pumps without
suitable controls must not be used.
4.3
All test gauges used for field-testing shall have a suitable range and shall
be used for test purposes only.
4.4
Pressure gauges shall be selected so that the test pressure of the system
falls between 30% to 75% scale range of the gauge.
4.5
Gauge shall be new, of good quality, and in good working condition.
4.6
The date of calibration shall be certified on the gauges.
TEST MEDIUM
5.1
All AMERON pipe shall be tested hydrostatically with the following

prOVISIOnS:
Water used for testing shall be clean and free from filth or
undissolved solids of any description.
Unless otherwise specified, all piping shall be hydrostatically tested

with fresh industrial water
' '
A\
AMERON
INTERNATIONAL
6.0
Doc No.
Rev
Page
AME/INS-004
0
4 of 8
PRECAUTIONS/ SAFETY
6.1
Qualified and experienced personnel should operate pressunzmg

equipment. Untrained or unauthorized personnel should not be around the
pressurizing equipment.
6.2
Do not make any adjustments on pressurized fittings under pressure. For

example, if an adapter or flange joint is leaking, take the pressure off the
line before attempting to tighten.
6.3
The test operation should be well planned and carried out with all due
precautions. It is always best for one man to be in charge of the operation
so that all other persons on the job take their direction from him.
6.4
Testing with air or gaseous media is particularly dangerous and should be

avoided. Gas or air pipelines shall be hydraulically tested then "dewatered". Never test with flammable fluids or gases.
6.5
The effect of hydrostatic head shall be considered when determining

correct test pressure from gauge reading.
6.6
Caution shall be exercised in system hydrostatic testing to ensure that

simultaneous testing of large sized adjacent equipment and piping does not
overload supporting structures and foundations.
6. 7
Any system under hydrostatic test shall be carefully observed, to prevent

overpressure of lines and any connected equipment.
6.8
The pressure generator shall be disconnected if the operator leaves the

equipment for any reason.
6.9
The testing operations shall be conducted diligently, thoroughly, and in a

safe workman like manner in accordance with accepted piping testing
practices.
6.10
During flushing and testing, safety standards shall be observed at all times.
a)
Barrier distance per pressure test values.
Signs and Notices
b)
c)
Toolbox talks etc.
6.11
The working area shall be roped off and sign positioned.
6.12
This work shall be carried out in open space or shelter with sufficient
ventilation.
6.13
The installer's supervisor shall be responsible for safety provisions.
A\
AMERON
INTERNATIONAL
7.0
Doc No.
Rev
Page
AME/INS-004
0
5 of 8
PREPARATION FOR TESTING

7.1
All vent and other connections, which can serve as pressure test vents shall
be open during filling so that all air can be vented prior to applying test
pressure to the system.
7.2
Lines that are spring or counterweight supported shall be temporary

blocked up during test in order to sustain the hydrostatic load.
7.3
Before pressure testing, all lines or systems shall be inspected to ensure

that all connected parts to be excluded from the test are isolated by blinds.
7.4
Instruments shall be excluded from hydro-test of piping system.
7.5
Adequate temporary supports should be used where volume and weight of

water may cause line deflection.
7.6
Hydrostatic test loops shall have all high points in the piping with a vent
and all low points with a drain, regardless of whether or not they are
specifically shown on the drawings. When filling, the test fluid shall be
introduced at the lowest point of the system to minimize the risk of
entrapped air and all vents shall be opened. Vents and drains shall be
closed once a continuous flow of fluid is obtained through the vent or
drain.
7.7
Calibrated/ certified gauges and recorders should be used for all hydrostatic
tests. The pressure shall be shown in kg/ cm2 or K.Pa. Pressure gauges or
recorders used to indicate and record test pressure shall be dead weight
tested for accuracy according to a procedure, dependent of type of
equipment. The validity of calibration for all gauge and recorder shall be
one (1) year.
7.8
Where required piping and equipment may be insulated or coated before

testing, but all joints shall be left un-insulated or un-coated and exposed
until suitable test acceptance by owner representative. This is applicable to
insulated piping or GRE pipe with fire coating.
7.9
Hydro testing shall be performed via a manifold. The test pump shall be
isolatable from the system with its own pressure gauge. Valves, hoses used
in tests shall be suitably rated (preferably use rating of max. test on line list
throughout to avoid any confusion)
7.10
Lines containing check valves shall have the sources of pressure upstream
of the check valve so that the pressure is applied under the seat. The point
of draining shall be downstream of check valve. If this is not possible, the
check valve disc shall be removed or jacked open.
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AMERON
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7.11
At least 2 gauges and recorders shall be installed in the test system, one
near the pressure generator (at the lowest point) and the other at the highest
point, both of which to be positioned so that they can be easily reached and
observed.
7.12
When testing underground systems, the line should be partially backfilled

and temporarily blocked at directional changes to prevent excessive
movement during the test.
7.13
Care should be taken to prevent above ground systems from buckling or

moving excessively during test or in case of sudden depressurization.
HYDROSTATIC PRESSURE TESTING

8.1
Test pressure shall be in accordance to paragraph 4.0 ofthis procedure.
8.2
Care shall be exercised to a void increase in pressure duet o temperature

variation during the test.
8.3
Hydrostatic testing shall not be done against closed valves.
8.4
Vents shall be open duringfillingofwatersothatairisventedpriorto

applying pressure to the system. Vents will then be closed to permit
pressurization to commence.
8.5
Suitably rated spectacle blinds, spades, skillets, blank inset chokes, blind
flanges or other means of positive closure shall be used for each section of
pipeline tested.
8.6
Hydrostatic pressure tests on each major section of piping shall be carried

out with all pressure relief valves removed and their respective nozzles or
connections blanked off or plugged.
8. 7
Hydrostatic test pressure connections shall be on the upstream side of

check valves.
8.8
The pressure shall be brought up slowly and gradually to allow for

equalizing for strain during the test, and in stages to allow checking for
leaks and inspection of the system. (Pressure shall first be brought up to 10
bar and hold till it stabilizes. After that raise in stages of 2 bars and hold
for 10 minutes before proceed to next stage)
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8.9
Once attained, the test pressure shall be held for a period of two hours or
such time as required for a full visual inspection of the system to be made.
During the first half hour of hydro-test, if pressure drops it is necessary to
bring up to test pressure and test for two hours or such time as required for
a full visual inspection of the system. A 4% pressure change during
hydro-test is acceptable.
8.10
Temperature changes have a definitive effect on the pressure in the line. In

closed systems, where a pipe is directly exposed to the sun, pressure
increases up to 25% may occur. Take necessary precautions to prevent over
pressurization. An overnight decrease in pressure from afternoon to early
morning is normal due to temperature changes and does not necessarily
indicate a leak.
8.11
Any lines changed or modified after they had been tested shall be retested
unless waived by the owner representative in writing.
POST-HYDROSTATIC TEST MEASURES.

9.1
After completion of hydrostatic test, the pressure shall be released

gradually in steps. All the vents and drains shall be kept open until the
lines are fully drained. All temporary facilities installed to facilitate
pressure test shall be removed.
9.2
Where permanent or temporary strainers have remained in place for the

hydrostatic pressure test they shall be removed following the test and
thoroughly cleaned before reinstalling.
9.3
Records are made on each piping system when test is completed. These
records shall be retained in the installer's quality document, as a permanent
record and a copy will be given to owner's representative.
9.4
These records shall be prepared in tabulated forms and shall include:

i)
Date of test
ii)
Identification of piping system and Package number
iii)
Test medium & Pressure
iv)
Test duration
v)
Inspector's name and signature
vi)
Reference P & ID's and Isometrics
vii)
Acceptance of test results by installer and owner representative
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CORRECTIVE ACTIONS
10.1
Ifthe pressure drop is found during the test due to leakage at somejoint(s),
the system shall be depressurized, repaired and re-testing shall be done at
pressure originally specified for the test.
10.2
All joints failing to pass the pressure test ~hall be repaired in accosdance
with the relevant specification and the relevant sections shall be retested to
the applicable test pressure.
..
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AMERON
AME/INS-005
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1 of 3
!NTERNAT!O:'\AL
FLUSHING
PROCEDURE
.)
FOR
BONDSTRAND PIPE
:
I
W H LEONG
K S CHONG
Y K TAN
APPROVED BY
:26 .JUN
oo
REV.
PREPARED BY
CHECKED BY
DATE
.,
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AMERON
INTERN ATIO NA L
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AMEIINS-005
0
2 of 3
FLUSHING PROCEDURE FOR BONDSTRAND GRE PIPE
1.0
SCOPE
This procedure covers the nummum requirement for the tlushing of Ameron
piping system at site.
2.0
RESPONBILITIES
The execution is under the responsibility of the installer in co-ordination with the
owner's representative.
3.0
4.0
PRECAUTIONS
3.1
All equipment and instrument along piping system to be disconnected

during flushing.
..., ')
.)._
Provision shall be made for discharge of water .
FLUSHING MEDIA
All Arneron pipes shall be flushed with the following provisions:
a)
Water used for flushing shall be clean and free from filth or un-dissolved
solids of any description.
b)
Industrial fresh water shall be used for flushing.
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AMERON
INTERNATIONAL
5.0
6.0
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PROCEDURE
5. 1
Flushing to be conducted by .. end to end" method and carried out after

hvdro-test.
5.2
Flushing shall be performed with the maximum combination of ditTerent

test loops to minimize any inconveniences at site. The maximum
combined test loops for each flushing shall be discussed and agreed ~pon.
5.3
Items of equipment that would be sensitive to damage during flushing shall

be removed, blocked off or isolated.
5.4
All in line valves and ball valves (including actuated onioff valves) shall be
flushed in fully open position.
5.5
All instrument leads shall be disconnected prior to t1ushing. Soft-seated

valves should be removed before tlushing.
5.6
At end point of flushing (discharge), the pipe bore area shall be reduced to
25% - 35% of system bore area. This is to increase backpressure to flush
out residual particle in pipe.
5.7
Water shall run through the piping for 15 minutes.
5.8
Discharged water shall be drained to the nearest drainage by flexible hose.

Location shall be discussed and agreed upon.
5.9
After flushing, all lines shall be drained completely. The system shall be
vented while draining" to avoid vacuum.
POST FLUSHING
6. I
All temporary blinds shall be removed and system drained completely.
6.2
All valves. orifice plates. expansion joints. instruments. short pieces of

piping and other excluded components shall be reinstalled
6.3
Temporary pipe supports shall be removed.
6.4
Blir!_d off all pipe ends if for some reasons they are not connt!cted. This is
to prevent ingression of debris or foreign materials.

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.

METHOD STATEMENT FOR

BTIP- Onshore Facilities I Offshore Pipelines

Shell Petroleum Development Company of Nigeria Limited

09. Mar. 2004

Reflected hydrostatic test

AHYUNDAI HEAVY INDUSTRIES CO., LTD.

METHOD STATEMENT FOR

METHOD STATEMENT FOR

IMY IIIUSIRIES CD., LTD.

HANDLING, STORAGE AND TRANSPORTATION

8.0 WORK SEQUENCE FOR GRP PIPE INSTALLATION

METHOD STATEMENT FOR

Shell Petroleum Development Company.

4.0 REFERENCE DOCUMENT

Design and Installation Of Glass-Fiber Fiber Reinforced

3) DEP 31.38. 70.37

5) GRE Vendor Specification & Installation Manual and hydrostatic test

GRE PIPELINES AND PIPING SYSTEMS

METHOD STATEMENT FOR

lEAVY INIIUS1liiES CO., Llll.

2) Electrical cables shall be properly arranged to avoid damage and possible

METHOD STATEMENT FOR

llriY 1111USn1ES CO. LTU.

5) Overall site safety management

METHOD STATEMENT FOR

METHOD STATEMENT FOR

METHOD STATEMENT FOR

and subjected to high temperatures, the supports shall cause flattening.

k) If any damage during transportation or installation is observed such as

Tighten the come-a-longs (provided by

Insert the male end until the scnbe One is

Lubricate the locking key (supplied by

Place lubricated locking key into the

Drive the locking key only until you can

Thanks to the reusability of the Key-Lock

METHOD STATEMENT FOR

lEAVY INIIUITRIEI CO. LTD.

Inspection for hydrostatic Pressure test shall be executed in accordance

10.0 ATTACHED DOCUMENTS

JOB HAZARD ANALYSIS FOR THE U/G GRE PIPING

- Damage to existing surface &

Seve Likely Riskl

- First aid kit

JOB HAZARD ANALYSIS FOR THE U/G GRE PIPING

- First Aid & Ki -Driver

Bad lifting position

Injury to the back of

- Follow safe lifting

First Aid office

JOB HAZARD ANALYSIS FOR THE U/G GRE PIPING

- High noise level

Body contact with

Seve Likely Risk

6 Pre- fabricate GRE

site First Aid

First Aid kit

JOB HAZARD ANALYSIS FOR THE U/G GRE PIPING

Seve Likely Risk

Burn sustained from

First Aid kit

epoure to hot surfaces