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( Special Modification for SEP Project in Accordance with Sabic Specs.

SES-P13-C05 )
Important: Store all fiberglass component i n a d r y but not too
Materials
cool area in order to avoid surface condensation when used in warmer
(Cont..)
conditions outside. Perform moisture content checks by weighing samples prior
to and after one hour of heating at 115C. A moisture content higher than
0.2% makes the fiberglass fabric unacceptable for lamination use. SES P13-
C05 sect.6.4.3.a shall be followed.

Since the curing agent IPD is hygroscopic, keep it stored in closed containers
when not in use. Prepare IPD batches shortly before mixing with the resin
component.

Equipment Check 0 Hacksaw


List 0 Abrasive Cutting Disc (Diamond Grit or Carborundum)
0 Pipe Supports
0 White Marker
0 Wrap-Around
0 Flapper-Wheel Sanders (Grit-16 to 24 )
0 Drilling Machine
0 Balance (Weighing Scale)
0 Air-Relieve Rollers (1.5" through 0.375" Diameter)
0 Infra-Red Burners or Hot-Air Guns
0 Heating Blankets
0 Resin Mixer
0 Paint Brush, 4-Wide
0 Rubber Scraper Plate

Pipe End
Preparation Pipe Cutting.
Note: This initial step shall be applicable only i f a factory-prepared pipe
end needs to be cut and replaced, or a pipe length requires field adjustment.
Mark the pipe section to be cut using a wrap-around and a white marker.

Cut the pipe using a hacksaw or a cutting disc.: make sure that a proper
square cut has been made see Figure 1 Step 1.

Preparation of Lamination Area.


Refer to Table 2 for the required lamination length to be prepared for sanding and
grinding.

For Pipes 10 and Larger.


The area to be prepared for lamination should be equal to one-half of the
nominal size -see Lamination Length or L in Table 2.

For 8"NO Pipes or Smaller.


The lamination length shall always be120 mm. Mark the required lamination
lengths and proceed to the end-preparation step.

For straight-joint butt-and-wrap, SES P13-C05 sect. 6.4.2 requires that s urfaces
that will receive a laminated joint overlay shall be abraded prior to application of
the overlay, extending a minimum of 25mm beyond the inten ded edge of t he
overlay. Sandblast or sand, or grind with disks that are new and not
contaminated and a grit size of 16 to 24 t he lamination area until the resin-rich
topcoat is removed and clear fiberglass is visible; clean the total external surface of the
pipe sections to be laminated. If abraded area shows any indication of contamination, it shall be
cleaned with solvent, the solvent shall be allowed to evaporate, and abrasion of the area repeated.
If application of the lamination joint overlay does not begin within four hours of surface abrasion, the
abrasion shall be repeated. Dust shall be removed from the abraded area immediately prior to
beginning application of the overlay by vacuuming or brushing with clean nonmetallic brushes or by
wiping with clean dry rags. Dust shall be removed with solvent or with compressed air. See Figure
1, Step 2. Sand or grind the cross section of the pipes (the cut ends) before
cleaning or re-clean the pipe as described above as well.

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Adhesive Fit Layer.
Position the pipe s ections for joining. As per SES P13-C05, s ection 6.4.5.c &
6.4.5.d, tolerances on gap between cut ends and misalignment of inside
surfaces shall not exceed one third of the thickness of the thinner
component. Angular de flection in laminated butt joints shall not exceed
5, except a s detailed otherwise for a specific joint in the design report.
Pipe ends shall be trimmed to accommodate the angle without gaps or
misalignment of the interior surfaces. Also, se ct. 6.4.3.b through 6.4.3.f
of SES P1 3-C05 requires for the environmental control as follows:
Except as ot herwise allowed by the manuf acturer, temperature of materials a nd
laminate surface during field joining operations shall be maintained within a range
of 60F to 95F and a minimum of 5 F above dew point. If necessary, field
joining contractor shall employ positive methods to assure that environmental
condition are maintained in the field joining work area. This may require temporary
enclosures and localized heating or cooling. Materials and laminate surfaces
shall be protected from dust, fog, rain and other contaminants. If any of the
above requirements are exceeded after surface preparation is completed or
during lamination, any affe cted plies shall be removed. Surface exposed due to
the removal of the plies shall be prepared again before applying new laminate.
Contaminated material shall not be used in field joining. Prepare the adhesive
mixture according to given instructions. Coat the cut ends w i t h a d h e s i v e
i n order to protect them against penetration of the medium. Voids shall be
filled with resin putty, allowed to cure, and then ground to smooth
contour. Ensure that Putty is not extruded into the bore of the pipe to the
extent that a significant blockage is created. Extruded putty shall not
exceed the lesser of 10 mm or 5 percent of the pipe diameter. Coat the
external surfaces of the pipe ends approximately 100 mm. in width, and join
them together (Figure 1 Step 3).

Wet out the boat tape w i t h a d h e s i v e a n d a p p l y a m i n i m u m of 3 layers


circumferentially onto the jointed pipe ends - see Figure 1 Step 3. Use a
heating b l a n k e t t o c u r e t h e i n i t i a l laminate for one hour. Sand the
surface after curing before proceeding to the following step.

Lamination
Procedure
Prepare all e q u i p m e n t and construction materials required for the joint
lamination -see Table 1 for estimated material requirements per joint size. Do
not use humid or damp fiberglass materials.

Start the lamination of the fitted sections within two hours after sanding or
tapering; re-sanding of the lamination area shall be required if the waiting period
exceeds two hours. (Refer to SES P13-C05 sect. 6.4.3.b through 6.4.3.f for
environmental control). Remove any possible dew by slightly heating the pipe
ends from the Inside by a heating blanket.
Prepare the resin mix using the correct mixing ratio - Resin = 100 parts by
weight; Hardener = 24 Part by Weight. Take note of the pot life after mixing.
The amount or the mixture depends on the diameter. Several batches could be
used depending on the weather, temperature and gelling time.

Be sure that the curing agent is carefully mixed with the resin. The temperature
or the resin and curing agent mixture should not exceed 25C.

For Pipes 3"ND or Smaller.


For the hand lay-up of the laminate structure, use boat tape as in T a b l e 2
with 50% overlap. Be sure to obtain the m i n i m u m required lamination
thickness as indicated in Table 2.

For Pipes Bigger than 3"ND.


For the hand lay-up of the laminate structure, use boat tape and woven roving in
the sequence as shown in Table 2 and with 50% overlap until the minimum
required laminate thickness is achieved.

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3
.

Make sure that each applied layer of boat tape or woven roving is
t h o r o u g h l y impregnated with the resin mixture.

Apply the layers in a circumferential direction onto the pipe-joint ends - see
Figure 1 - Steps 4 and 5.

During the wrapping process, tension must be appl ied so that the resin under
the layer being laid could be pressed out.

Avoid air getting into the laminate by using the air-relieve rollers continuously.

To give the finishing touch, apply one f i n a l layer or boat tape spirally
wrapped onto the whole surface of the laminate. Use air-relieve rollers to
avoid air enclosures.

After the final boat tape layer, smooth out the resin from the exterior of the
laminate, using a rubber scraper, to leave the resin-rich surface.

Before curing, use a hea t source (hot-air blower, flood light etc.) to allow the
laminate to gel.

Curing and Finishing

Use heating blankets, to cure the butt-and-wrap joint laminate.

Check heating blankets if they are working properly. Temperatures in excess of


120C should be easily achieved if the heating blanket works property. The
surface contact between the heating blanket and the laminate should be as large
as possible; fit the blanket as snugly as possible to the joint.

Cure the laminate for 4 hours minimum. Wherever possible, apply a heating
blanket on the Inside as well and close the pipe ends to avoid drafts.

In cold weather, insulate the heating blanket to trap the heat, but do not cover
the blankets thermostat housing.

After curing, use sandpaper to remove the rough edges or the laminate and to
generally smooth out the external surface.

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4. The Lamination Thickness excludes1.00 mm inner liner.
The liner consists of several layers of C-Veil, or combination of C-veil & Chopped mat.
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