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In the pursuance to establish the main infrastructure industries with top of the line water system production lines and technology, The Saudi Pipe Systems Company has successfully established its manufacturing plants in Phase 4, Jeddah Industrial Zone, Jeddah, Saudi Arabia. SPS is one of the leading manufacturer of all kinds and sizes of Ductile Iron (D.I.) and Cast Iron (C.I.), Epoxy Powder Coated Valves, Fittings, Fiber Glass (GRP/FRP) Pipes, Pre-Insulated Pipes and Fittings and HDPE Pipes as well. Valves include: Gate, Butterfly, Check, Globe, Air Release, Float, Pressure Reducing Valves and several other types of valves, Fire Hydrants, Strainers, Flanges and other industrial materials related to Water sector. Beside D.I. Valves and Fittings, SPS manufactures wide ranges of Fiber Glass (GRP/FRP) and Pre-insulated Pipes and Fittings. The production ranges from 100mm to 3000mm with pressure rating from 6 Bars to 24 Bars. The annual production capacity is 87,000 L/M.
Moreover, SPS has also established a most advanced plant with fully automated extrusion lines for the manufacture of High Density Polyethylene (HDPE) Pipes with a minimum capacity of 8,500 tons / year approximately, covering the size ranges from 16mm – 630mm with pressure rating from 5 bars to 16 bars. SPS has full technical support from leading Companies namely: DUKER OVENTROP (Germany), and CLA-VAL (Switzerland). All SPS product are being tested at every stage of production by its highly qualified, competent and most experienced Quality Assurance Engineers prior to dispatch within and outside the Kingdom. All SPS products are being tested at every stage of production by its highly qualified, competent and most experienced Quality Assurance Engineers prior to dispatch within and outside the kingdom. SPS products are not only used by all renowned customer of the Kingdom of Saudi Arabia, but its products are being exported throughout the GCC countries and many other countries like: Egypt, Yemen, Sudan, etc.
Company Profile
1 P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
Specializes in producing GRP Pipes and Fittings from small to big ranges with standard specifications, through filament helical winding and continuous filament winding processes.
HDPE (HIGH DENSITY POLYETHELENE) PIPES FACTORY
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FOUNDRY AND VALVES FACTORY
Specializes in the processing and production of all types of Valves, Pipes Fittings, Pipe Clamps, and Flanges, which are essential for Water Sewage, Fire Fighting Systems, and Central Air Condition Systems. The factory also produces engineered castings of variety of metals (Ferrous and Non-Ferrous, e.g. Cast Iron, Ductile Iron, Aluminum, and Copper).
GRP ( FIBER GLASS POLYESTER ) PIPES AND FITTINGS
Specializes in producing HDPE Pipes through small to big sizes. The factory uses most advanced Machinery and Equipment which are operated by well qualified engineers and technicians.
Saudi Pipe Systems Division
P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
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UNI9032 Pipes in glass-reinforced thermosetting resin (GRP)
UNI9033 and/or mortar pipes used in any application.
ASTM D 2996-88 Filament-Wound Reinforced Thermosetting Resin Pipe.
ASTM D3262-88 Reinforced Plastic Mortar Sewer Pipe
ASTM D3754-88 Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin Sewer and Industrial Pressure Pipe
ASTM D3517-88 Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin Pressure Pipe
AWWA C950-95 Standard for Glass-Fiber-Reinforced Thermosetting-Resin Pressure Pipe.
BS 5480-90 Specification for Glass fiber reinforced plastics (GRP) pipes and fitting to use for water supply or sewerage
ASTM D3262 Gravity Sewer
AWWA C950 Fiberglass Pressure Pipe
AWWA M45 Fiberglass Pipe Design Manual
SASO-1577 Gravity Sewer
SASO-1578 Pressure Sewer ASTM D3839 and Appendix AWWA C950-95 in relation to the inspection standards buried pipes.
GRP Pipe Characteristic Unit of Measurement Filament Winding
Traction Resistance Circ. direct
Kg/cm² 2500-3000
Axial Direct 800-1300
Elasticity Young Modules
Circumferential direct. Kg/cm²
240-3000
Axial direct. 105-125
Density Kg/cm³ 1.9
Barcol Hardness 35-45
Thermal Conductivity Kcal/mh˚C 0.22
Coefficient of Linear Thermal Expansion
cm/cm˚C 1.6*10¯⁵
Electrical Resistivity ohm/cm 10^14
Dielectric Constant F/cm 3-4
Three Base Materials Are Used For The Pipes Having Distinct Characteristic. •Polyster thermosetting resin being of three types : Isophtalic, Bisphenolic, and Vinylester •Continuous fiberglass roving. •Silica sand (optional)
Standards The SPS pipes produced in our plant are manufactured in glass reinforced thermosetting resin (GRP) by the Filament and Continuous Winding system. Reference is made to the following international standards.
GRP Pipe Component
P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
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GRP PIPE PRESSURE Vs. DIAMETER CHART
RTRP (REINFORCED THERMOSETTING RESIN PIPE) A fiberglass pipe without aggregate. Manufactured by the filament winding process up to 24 in. nominal size.
RESIN USED IN SPS RTR PIPES
1.ISOPHTHALIC POLYESTER RESIN
Used for moderate corrosion resistance to water, acids, weak bases, and hydrocarbons such as gasoline and oil. 2.VINYL ESTER RESIN
Offers maximum corrosion and temperature resistance to acid, alkalis, hypochlorite, and many solvents. These products have been formulated for maximum performance with methyl ethyl ketone peroxides. It is well documented that these catalysts provide optimal cure and thus maximum corrosion resistance. PRODUCT USAGE OF VINYL ESTER RESIN
1.Flame retardant / Heat resistance
2.Chemical resistance
3.Ultra Violet Rays 4.High strength to weight ratio
5.Electrical and thermal insulation.
Characteristic of Pipes
P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
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HYDROSTATIC LEAK TEST
PRESSURE REQUIREMENTS
PRESSURE CLASS, Kpa
HYDROSTATIC PRESSURE TEST, Kpa
345 689
689 1034
1034 1379
1379 2068
2068 1724
1724 3447
MINIMUM PIPE STIFFNESS REQUIREMENTS
FOR 5% DEFLECTION
DN STIFFNESS CLASS
62 124 248 496
mm MIN. PIPE STIFFNESS REQUIRED, Kpa
25-200 NR NR 36 72
250 NR 18 36 72
300-3600 9 18 36 72
DEFLECTION LEVEL STIFFNESS CLASS (SN)
2500 5000 1000
A 15% 12% 9%
B 25% 20% 15%
HYDRAULIC FAILURE TEST
ASTM D1599
Every pipe must be tested to two times the nominal pressure for two minutes or as long as a specific standard requires. To reduce the risk of making scrap, there should never be more than 4 untested pipes.
HYDROSTATIC DESIGN BASIS – HDB
ASTM D2992
Requires pipe to withstand a constant pressure of 1.8 times the maximum operating condition. Considering internal pressure and external soil loads, Hydrostatic pressure testing to failure (leakage) of pipe sample at variety of very high constant pressure level is applied.
INITIAL RING DEFLECTION
LEVEL A - No visual evidence of cracking. LEVEL B - No structural damage to the pipe wall. GRP pipe’s long term (50 year) Ring deflection/bending (strain) capability when
exposed to an aqueous environment and under a
constant load must meet level A deflection level.
PARALLEL PLATE LOADING TEST ASTM D2412-02 Parallel Plate Stiffness testing machine is designed to determine the load deflection characteristics of GRP pipe under parallel-plate loading. The characteristics determined by this method are pipe stiffness, stiffness factor, and load at specific deflections
Long Term Material Properties Testing
P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
6
UNI9032 Pipes in glass-reinforced thermosetting resin (GRP)
UNI9033 and/or mortar pipes used in any application.
ASTM D 2996-88 Filament-Wound Reinforced Thermosetting Resin Pipe.
ASTM D3262-88 Reinforced Plastic Mortar Sewer Pipe
ASTM D3754-88 Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin Sewer and Industrial Pressure Pipe
ASTM D3517-88 Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin Pressure Pipe
AWWA C950-95 Standard for Glass-Fiber-Reinforced Thermosetting-Resin Pressure Pipe.
BS 5480-90 Specification for Glass fiber reinforced plastics (GRP) pipes and fitting to use for water supply or sewerage
ASTM D3262 Gravity Sewer
AWWA C950 Fiberglass Pressure Pipe
AWWA M45 Fiberglass Pipe Design Manual
SASO-1577 Gravity Sewer
SASO-1578 Pressure Sewer ASTM D3839 and Appendix AWWA C950-95 in relation to the inspection standards buried pipes.
GRP Pipe Characteristic
Unit of Measurement Filament Winding
Traction Resistance Circ. direct
Kg/cm² 2500-3000
Axial Direct 800-1300
Elasticity Young Modules
Circumferential direct. Kg/cm²
240-3000
Axial direct. 105-125
Density Kg/cm³ 1.9
Barcol Hardness 35-45
Thermal Conductivity Kcal/mh˚C 0.22
Coefficient of Linear Thermal Expansion
cm/cm˚C 1.6*10¯⁵
Electrical Resistivity ohm/cm 10^14
Dielectric Constant F/cm 3-4
Base Materials Used For The Pipes Having Distinct Characteristic. •Polyster thermosetting resin being of three types : Isophtalic, Bisphenolic, and Vinylester •Continuous fiberglass roving. •Silica sand (optional)
Standards The SPS pipes produced in our plant are manufactured in glass reinforced thermosetting resin (GRP) by the Filament and Continuous Winding system. Reference is made to the following international standards.
GRP Pipe Component
P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
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STRAIN CORROSION TEST Covers the procedure for determining the chemical - resistant properties of fiberglass pipe in a deflected condition.
Quality Control
P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
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APPLICABLE PROCEDURES / DOCUMENTS INSPECTION / TESTING
ASTM D2563 Visual Inspection
ASTM D3567 Dimension Control
ASTM D2583-87 Barcol Hardness
ASTM D2105-90 Longitudinal (Axial) Tensile Strength
ASTM 2290-00 Hoop (Circumferential Tensile Strength
ASTM D1599 Hydrostatic Leak Test (Hydraulic)
ASTM D2412-02 Stiffness Test
ASTM D2584-68 Glass Reinforcement Content (Loss of Ignition)
QUALITY CONTROL ON PRODUCTS The test, which the products undergo during the manufacturing stages and before dispatching ensures that they fully comply with the international specifications and that they suitable for the usage which they have been made for.
SPS STANDARD SPECIFICATION FOR FIBER GLASS PIPE
Quality Control
BASIN WITH CORROSIVE SOLUTION
DEFLECTED PIPE
P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
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LABORATORY SPS has made the effort to have state of the art laboratory of testing department. This department supervise and issue certificate on all test perform or according to project consulting required.
TESTING SPS-GRP PIPES undergo a series of tests to assure quality standards, these tests are performed on each pipe/batch. • Testing starts on raw materials by making sure of choosing the highest quality raw material we can assure top quality final product. • By inspecting-dimensions and visual/weight throughout production line. • Step by step: follow up checking of materials as they advance throughout the production line. All the way to finished products. • All raw materials undergo extensive testing to assure and confirm that it meets technical specifications and standard of products.
RESINS Density at 25˚C ASTM D 792 Viscosity at 25˚C ASTM D2393-86 Gel Time at 25˚C ASTM D2471-94 Exothermic Peak ASTM D2471 Acid Number - ASTM D1639 H.D.T. ( 264 psi) ASTM D648 Color(Gardener Scale) ASTM D1544 Volumetric Shrinkage UNICHEM2–1969 GLASS MASS PER UNIT AREA ISO 3374-2000 PERCENT HUMIDITY ISO 3344-1997 LOSS OF IGNITION ISO 1887-1995
TEST FOR THE APPROVAL OF RAW MATERIALS Besides test based on workability and test based on verification of the chemicals inertness for resins, for the approval of new raw materials the tests listed in the former paragraph shall be completed with the following tests.
RESIN -Tensile Strength ASTM D 638 M 87 b -Flexural Strength ASTM D 790 M 86
GLASS -Split Disk ASTM D 2290 / 76
Quality Assurance and Testing
PROPERTIES OF SPS GRP PIPES •SERVICE LIFE OF 50 YEARS. •ENVIRONMENTALLY FRIENDLY. •CAN BE TRANSPORTED AS NESTED. •CORROSION RESISTANCE. Resistant to corrosion in a wide range of fluid handling applications. •STRENGTH TO WEIGHT Pipe strength per unit weight surpasses iron, carbon, and stainless steels. •LIGHTWEIGHT 1/6 the weight of other steel with similar properties and 1/10 the weight of similar concrete product. •NON-CONDUCTIVE not necessary to dissipate static electricity build-up when transporting certain fluids such as jet fuel. •DIMENSIONAL STABILITY meet the most stringent material stiffness, dimensional tolerance, weight and cost criteria. •LOW MAINTENANCE COST Resistant to rust and require minimal protection from the environment.
P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
RESIN -Polyester resins based on bisphenol or bisphenol A. -Polyester resins based on Isophthalic acid. -Vinyl Ester resins based on urethane modified or epoxy based. In all cases the resins are taken as a solution of 45 to 50% of styrene monomer.
MAT -A fibrous material consisting of random-oriented, chopped, or swirled filaments loosely held together with a binder.
SURFACING MAT -A thin mat of fine fibers used primarily to produce a smooth surface on a reinforced plastic.
HOOP DIRECT ROOVING -A collection of parallel glass strand or filaments, coated with a finished or coupling agent, to improve compatibility with resins, gathered without mechanical twist. (Fig. 1)
WOVEN ROOVING -A glass-fiber fabric reinforcing material made by the weaving of glass-fiber roving.
CATALYST -MEKP (Methyl Ethyl Ketone Peroxide) in phthalate plasticizer with 9% active oxygen and 33% peroxide content used on an average of 1.5% in the resin.
PROMOTERS -Cobalt octoate in phthalate plasticizer with 6% metal used on an average of 0.4% in the resin.
INHIBITORS -Pera-t-butyl-catechol, 10%, in phthalate plasticizer used on an average of 0.1% in the resin.
SILICA SAND -Siliceous sand conforming to ASTM C33, except that the requirements for gradation need not apply.
Material Used In Production Process
10 P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
HELICAL FILAMENT WINDING MACHINE Pipes are manufactured using the Filament Winding process on computer controlled machines (CAM), by adjusting the relative speed of mandrel rotation and glass distribution head movement, helical reinforced layer with different angles can be wound. The inside diameter of the finished pipe is defined by the mandrel outside diameter and the designed wall thickness is achieved by repeated passes. Therefore the outside diameter of pipe (OD) is determined by the wall thickness. In order to increase pipe stiffness, specially on large diameter pipe, silica sand can be added to parallel layers of the mechanical wall.
MAIN CHARACTERISTIC OF FILAMENT WINDING PROCESS •Bell and Spigot ends are monolithic with the pipe wall. •Optimization of axial and hoop characteristic can be obtained by changing the winding angles. •Axial strength normally higher than pipe produced with other processes. •Pipe stiffness is not related to joint stiffness that is in any case higher than pipe stiffness. Pipes are manufactured using the filament winding process are used either for above ground and underground installation, with gravity flow, medium and high internal pressure.
GRP Manufacturing Method
MANDREL
RESIN BATH TRANSLATE
ROTATION
11 P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
PIPE WALL STRUCTURE GRP pipe wall consist of three layers perfectly adherent one to the other and each having different characteristic and properties in relation to their function.
LINER Liner or chemically resistant layer is the internal layer of the pipe, it is in direct contact with the conveyed fluid. This layer has the function to guarantee the resistance to the chemical corrosion and the impermeability of the whole pipe. Liner has the internal surface namely the one in contact with the conveyed fluid, particularly smooth. This characteristic of smoothness reduces to minimum the fluid head losses and pumping heads and opposes to the growth of mineral deposits and algae. Liner is made of two monolithic sub-layers (1) Inner, in direct contact with the fluid, is reinforced with glass veil “C” 30 g/m2, with ratio resin content in a range 80% - 90%by weight (2) Outer, reinforced with plies of glass mat “E” of 450 g/m2, with a resin content in a range of 60% - 70% by weight.
MECHANICAL RESISTANT LAYER Glass reinforced layers guarantee the mechanical resistance of the whole pipe against stresses due to internal and/or external pressure, external load due to handling and installation, and thermal loads. The layer is obtained by applying on the previous partly curved liner, continuous roving of glass wetted with resin, under controlled tensioning. This layer can contain aggregates (inert granular material such as silica) in order to increase the stiffness of the whole pipe. Thickness of mechanical resistant layer depends on the design condition.
TOP COAT Top coat or Gel coat is the outer layer of the pipe which consist of pure resin added with UV protectors to protect the pipe from sun exposure. In case of severe exposure conditions, i.e. aggressive soils or very corrosive environment, the gel coat can be reinforcement with a surfacing veil or added with fillers or pigments.
MECHANICAL RESISTANT
LAYER
TOP COAT
LINER
GRP Pipe Helical Filament Winding
12 P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
NOMINAL DIAMETER INSIDE DIAMETER
mm in mm in
100 4 100 4
150 6 150 6
200 8 200 8
250 10 250 10
300 12 300 12
350 14 350 14
400 16 400 16
450 18 450 18
500 20 500 20
600 24 600 24
700 27 700 27
800 30 800 30
900 36 900 36
1000 39 1000 39
1100 42 1100 42
1200 48 1200 48
1300 51 1300 51
1400 54 1400 54
1500 60 1500 60
1700 66 1700 66
1800 72 1800 72
2000 78 2000 78
2200 84 2200 84
2300 90 2300 90
2400 96 2400 96
2600 102 2600 102
NOMINAL DIAMETER ASTM D3567
INSIDE DIAMETER SERIES
SPS pipes manufactured in Helical Filament Winding are ranging from diameters 100mm to 2600mm. Nominal diameter coincides with the internal diameter. Any nominal diameter can be manufactured. Larger diameters can be manufactured at site by means of special equipment.
DIMENSION OF PIPE
DN
Dimension Control
13 P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
GRP Pipe Continuous Filament Winding Machine
The Continuous Filament Winding Machine is designed for the continuous production of GRP pipes. Similar to Helical Filament Winding, but continuous, this process allows to produce only cylindrical parts like pipes, based on a special continuous mandrel design. In this process, both single-end roving and chop (multi-end) roving are necessary. It is designed for very high production capacity. It is ideal choice when the GRP pipes are used for water transmission and distribution, desalination plants, cooling systems in power plants, irrigation projects and sewage systems.
Using this technology and developed by material specialist, a very dense laminate is created that maximizes the contribution from the three basic raw materials. Both the continuous glass fiber roving and chop able roving are incorporated for high hoop strength and axial reinforcement. A sand as fortifier is used to increased the stiffness with placement near the neutral axis in the pipe wall core.
The basic machine for manufacturing (winder) is composed of a continuous steel band supported by beans which form a cylindrically shaped mandrel. The beans rotate, friction pulls the band around and roller bearings allow the band to move longitudinally so that the entire mandrel continuously moves in a spiral path toward the end of the machine. As the mandrel moves fine graded filler, glass fibers and resins and surface materials are metered on in precise amount under the direction of a programmable logic controller (PLC) and computer (PC). The PLC-PC modules provide integrated process control based on the recipes encoded. Only basic pipe such as diameter pressure and stiffness class need to be entered and the computer calculates the settings.
14 P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
GRP Pipe Wall Structure
The wall of the pipe manufactured on continuous filament winding machine is made of several layers.
OIOU OUTER LINER
OUTER SKIN
MORTAR CORE
INTERNAL SKIN HOOP ROVING AND CHOP REINFORCEMENT
ANTI-DIFFUSION BARRIER CHOP MATERIAL REINFORCEMENT
INTERNAL LINER – RESIN RICH SURFACING VEIL REINFORCEMENT
TOTA
L TH
ICK
NES
S
INTERNAL LAYER Layer directly contact with the internal fluid, and is resin rich (approx.90% by weight), reinforced with a surfacing veil made of C glass (chemical resistant very light fiberglass mat), or polyester veil. Thickness ≈ 0.2mm for 1 only surfacing veil, but can be doubled.
ANTI DIFFUSION BARRIER Part of the internal layer, is resin rich (approx.70% by weight) and is reinforced with chopped roving of E glass. The function is to stop the propagation of micro-cracks from the mechanical layer (inner skin) to the internal layer. Thickness ≈ 0.8 mm to 2 mm or more according to project-specification. The standard is 0.8 mm.
INNER HIGH STRENGTH SKIN Forms the mechanical resistant layer together with the core and the outer skin. Reinforced with high strength hoop wound fiberglass roving (50-60% by weight), and chopped roving (10-20% by weight). The resin content is 25-30% by weight.
MORTAR CORE To increase the thickness and the stiffness of the pipe without using a lot of valuable raw materials. the main constituent of the mortar core is silica sand, with a few hoop and chop roving and as low as possible resin.
OUTER HIGH STRENGTH SKIN As the inner skin. Generally it has the same thickness of the inner skin, but can be different.
OUTER LINER The outer liner can be simply pure resin, but can be also reinforced with a surfacing veil, in order to increase the finishing and the chemical resistance to the environment.
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P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
Outside Diameter Series
SPS pipes manufactured in Continuous Filament Winding are standardized on the basis of the outside diameter in order to use standard coupling. Nominal Diameter (DN) and outside Diameter (OD) are taken from the International Standards, basically the AWWA C-950.
DIMENSION OF PIPE FOR CONTINUOUS FILAMENT WINDING
z DN
OUTSIDE DIAMETER SERIES OUTSIDE DIAMETER SERIES
NOMINAL DIAMETER OUTSIDE DIAMETER NOMINAL DIAMETER OUTSIDE DIAMETER
mm mm mm mm
300 310 1300 1332
350 361 1400 1434
400 412 1500 1536
450 463 1600 1638
500 514 1700 1740
600 616 1800 1842
700 718 1900 1944
800 820 2000 2046
900 924 2100 2148
1000 1026 2200 2250
1100 1128 2300 2351
1200 1229 2400 2453
2500 2556
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DN PN1 PN6 PN10 PN16 PN20 PN25 PN32
80 N/A 89 178 238 269 N/A N/A
100 N/A 119 238 318 358 N/A N/A
150 N/A 178 357 477 538 N/A N/A
200 N/A 238 476 636 717 N/A N/A
250 N/A 297 595 795 896 N/A N/A
300 N/A 357 714 95 1076 N/A N/A
350 70 420 400 1120 1400 1750 2240
400 80 480 800 1280 1600 2000 2560
450 90 540 900 1440 1800 2250 2880
500 100 600 1000 1600 2000 2500 3200
600 120 720 1200 1920 2400 3000 3840
700 140 840 1400 2240 2800 3500 4480
800 160 960 1600 2560 3200 4000 5120
900 180 1080 1800 2880 3600 4500 5760
1000 200 1200 2000 3200 4000 5000 6400
1200 240 1440 2400 3840 4800 6000 7680
1400 280 1680 2800 4480 5600 7600 8960
1600 320 1920 3200 5120 N/A N/A N/A
1800 360 2160 3600 5760 N/A N/A N/A
2000 400 2400 4000 6400 N/A N/A N/A
2400 480 2880 4800 7680 N/A N/A N/A
2500 500 3000 5000 8000 N/A N/A N/A
LENGTH
The standard length of SPS Pipe is normally 12 meters for DN150 and above. DN100 are only available in 9 meter standard lengths.
LOAD CAPACITY VALUES
The following values can be applied for axial tensile and hoop tensile for design objectives.
HOOP TENSILE LOAD CAPACITY Minimum hoop or circumferential load, N per length (mm)
HOOP TENSILE LOAD CAPACITY
SPS Pipe Technical Data
17 P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
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DN PN1 PN6 PN10 PN16 PN20 PN25 PN32
80 N/A 89 178 238 269 N/A N/A
100 N/A 119 238 318 358 N/A N/A
150 N/A 178 357 477 538 N/A N/A
200 N/A 238 476 636 717 N/A N/A
250 N/A 297 595 795 896 N/A N/A
300 N/A 357 714 95 1076 N/A N/A
350 70 420 400 1120 1400 1750 2240
400 80 480 800 1280 1600 2000 2560
450 90 540 900 1440 1800 2250 2880
500 100 600 1000 1600 2000 2500 3200
600 120 720 1200 1920 2400 3000 3840
700 140 840 1400 2240 2800 3500 4480
800 160 960 1600 2560 3200 4000 5120
900 180 1080 1800 2880 3600 4500 5760
1000 200 1200 2000 3200 4000 5000 6400
1200 240 1440 2400 3840 4800 6000 7680
1400 280 1680 2800 4480 5600 7600 8960
1600 320 1920 3200 5120 N/A N/A N/A
1800 360 2160 3600 5760 N/A N/A N/A
2000 400 2400 4000 6400 N/A N/A N/A
2400 480 2880 4800 7680 N/A N/A N/A
2500 500 3000 5000 8000 N/A N/A N/A
Nominal Pressure (PN) Pressure Rating (Bar) Diameter Limit (mm)
1 1 3700
6 6 3700
10 10 2500
16 16 2000
20 20 1400
25 25 1400
32 32 1400
AXIAL TENSILE LOAD CAPACITY Minimum axial or longitudinal load, N per circumference (mm)
PRESSURE Nominal Pressure of SPS pipes are listed below. Some nominal pressures are not available in all diameter and stiffness’s.
SPS Pipe Technical Data
18 P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
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STIFFNESS CLASS N/ m3
SN 2500 2500
SN 5000 5000
SN10000 10000
HYDROTESTING
Standard Factory Test Pressure 1.5 x PN
Maximum Field 1.5 x PN (Nominal Pressure)
Maximum Pressure 1.4 X PN (Nominal Pressure)
SURGE
STIFFNESS CLASS GRP pipe can be supplied to the following stiffness
FLOW VELOCITY The flow velocity for clean water and contains no abrasive material are up to 4m/sec. The recommended maximum flow velocity is 3m/sec.
ULTRA VIOLET DEGRADATION EFFECT Discoloration in the outermost of the SPS pipe may be occurred due to exposure from sunlight or by ultra violet degradation. However, it cannot affect to the long term service of SPS pipe. Proper maintenance is also required to make the service of the pipe longer.
POISON’S RATIO In any pipe constructions the Poison’s ratio is required. The Poison’s ratio of SPS pipe is slightly less by using the following hoop tensile and axial loading ranging 0.22 to 0.29.
THERMAL COEFFICIENT The SPS pipe thermal coefficient of axial expansion and contraction is between 24 to 30 x 104 cm/cm/°C
SPS Pipe Technical Data
19 P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
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Steel, Ductile and Iron pipes 50%
SPS Pipe surge pressure allowance 40% of Nominal Pressure
DN 350-400 450-800 900-2500
SN 2500 meter/sec
PN6 365 350 340
PN10 435 420 405
PN16 500 490 480
DN 350-400 450-800 900-2500
SN 10000 meter/sec
PN6 420 415 410
PN10 435 425 415
PN16 500 465 485
PN25 580 570 560
PN32 620 615 615
DN 80 100 150 200 250
SN 10000 meter/sec
PN6 580 560 540 520 500
PN10 590 570 560 50 520
PN16 640 620 610 600 590
DN 350-400 450-800 900-2500
SN 5000 meter/sec
PN6 405 380 370
PN10 435 420 410
PN16 505 95 480
PN25 575 570560
SURGE AND WATER HAMMER
WATER HAMMER Water hammer or pressure surge is the sudden rise or fall in pressure caused by abrupt change in the fluid velocity within the pipe system.
THE CAUSE OF WATER HAMMER PRESSURE IN THE PIPE: 1. Rapid closing or opening of valves. 2. Sudden starting or stopping of pumps such as during power failure. 3. Change in velocity of the fluid. 4. Rate of change of velocity (valve closing time). 5. Compressibility of the fluid 6. Stiffness of the pipe in the “hoop” direction and physical lay-out of pipe system.
SPS PIPE WATER HAMMER PRESSURE APPROXIMATION AND ALLOWANCE:
An approximate relationship for the maximum pressure variation at a given point in a straight pipeline with negligible friction loss can be calculated from the formula:
ΔH = (w∆v) / g Where: ΔH = change in pressure (m) Δv = change in liquid velocity (m/s) w = surge wave celerity (m/s) g = acceleration due to gravity (m/s) SPS PIPE SURGE WAVE CELERITY
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SPS Pipe Technical Data
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SPS -GRP Pipe Hydraulic Characteristics
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Saudi Pipe Systems Co. (SPS) produces GRP pipes by continuous filament winding machines, by reproducible processes. All these pipes are provided with rich interior layers, providing very smooth inner surfaces. This smooth interior surfaces results in very low fluid resistance.
For hydraulic analysis of the every piping system, pipe roughness is the concern. One of the FAQ by the Hydraulic Engineers / Consultants / Contractors / Clients is what the value of GRP pipe toughness is.
This roughness is being used in various forms in various equations of hydraulic analysis. Find below the summary of the mean value based on the experimental studies.
These values are based on the experimental studies carried out by Owens Corning and SINTEFF from Norway. Complete report is available upon request.
In fact AWWA C-950 also recommends for the usage of similar values. This confirms that above values are in good agreement even with the international standards.
Apart from above, the interior pipe surfaces, typically remains smooth overtime, in most fluid services . Therefore, fluid resistance will not increase with age. This has been demonstrated, when few GRP pipes under operation over the decade were inspected and evaluated. Certificate from respective authorities is available upon request confirming no deterioration.
Roughness Parameters (Means Values)
Flow Rate Cole Brook-White Manning Hazen-Williams
(m3/hr) Є or K (mm) M (m1/3/s) C (10-1.38m0.37/s)
150 N/A 178 357
For any additional hydraulic requirements and clarifications do not hesitate to approach SPS. We are willing to assist you anytime.
ABRASION RESISTANCE Abrasion resistance can be related to the effects that sands or other similar material may have on the interior surface of the pipe. While there is no widely standardized testing procedure or ranking method. SPS-GRP Pipe has been evaluated by using the Darmstadt Rocker method. Results will be highly influenced by the type of abrasive material used in the test. Using gravel which was obtained from the same source as that used at Darmstadt University, the average abrasion loss of SPS Pipe is 0.84mm at 100,000 cycles.
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Head loss chart
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The Engineering department of SPS can assist the costumers in all stages of their projects and is able to issue (but not limited to) the following documentation: STRESS ANALYSIS ON AERIAL / BURIED GRP PIPING SYSTEM BY MEANS OF CEASAR II PROGRAM
Calculation of buried pipes according to AWWA M-45. Calculation of aerial pipes, installed on supports according to AWWA M-45. Hydraulic calculations according to usual formula. Standards and Specifications. Design – Technical and shop drawings in Autocad format. Field assistance.
SPS EXPERTS ARE ABLE TO PROVIDE ASSISTANCE DURING THE FOLLOWING FIELD ACTIVITIES
• Installation
• Laminations
• Hydro-Testing
GRP pipe installation needs special attention if the contractor engaged in laying the pipes has no knowledge or experience with this product. In this case the SPS /GRP by means of its technical team can offer assistance by sending a qualified person to the customer who will train and assist the contractor.
Engineering Services
FIELD OF APPLICATION
•Water transmission and distribution on both civil and industrial (Potable and Raw Water). •Sewer system on both urban and industrial. •Irrigation networks.
•Water intakes for cooling water system. •Waste water outfalls to sea. •Sea lines and river crossings. •Process lines for industrial plants. •Corrosive fluids and verity gas tanks. •Wells casing and wells pump riser. •Penstock. •Flue gas desulphurization. •Gasoline handling and distribution networks. •Flue gas stacks. •Gravity & pressure sewer lines. •Storm sewers. •Circulating water for power plants.
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• Prior to unloading of pipes from trailer, all items shall be inspected for any visual transportation damages. • Single pipe must be unloaded and handled separately (one at a time). Use pliable straps, slings or ropes to lift single pipe. • Do not use steel cables or chains to lift or transport the pipe. • Care shall be taken to prevent pipes from rolling or falling from flat bed trailer and this shall be attained by using proper supports.
HANDLING OF NESTED PIPES We propose to nest various diameter pipes during transportation. Always lift nested bundles using at least two pliable ropes. Always keep nested pipes on site in the original transportation package only. Stacking of these pipes is not advisable. De-nesting of pipes should be done carefully at pre allocated station. Inside pipe may be removed by lifting slightly with an inserted padded boom to suspend the section and carefully move it out without damaging the outer pipe.
Transportation and Handling
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AVAILABLE METHODS IN PIPE SYSTEM INSTALLATION AND ADJUSTMENT OF JOINT:
•Double O-ring Bell and Spigot Joint •Double O-ring Bell and Spigot with locking key joint. •Mechanical Coupling. •Butt and Strap Joint. •Flanged Joint. •Reka Coupling.
METHODS FOR INSTALLATION OF PIPE AND FITTINGS
1.STANDARD COMPONENTS Adjustment should be made in the field by means of Butt and Strap joining system. 2.PRE-FABRICATED PIPES For quick and easy mounting, narrow tolerances less field joints, and lower installation cost.
CATEGORIES OF ABOVE GROUND INSTALLATION 1. Lines which laid directly on the surface of the ground. 2. Lines which are hung or supported as in typical plant. -Tensile Resistance Couplings should be used. In well-supported pipelines for non-pressure application, a non-tensile resistant system can be used. -- Horizontal pipe should be supported at intervals suggested by support spacing data. - For the supporting of pipes systems, several types of pipe clips can be used. Between pipe and steel collar, a PVC saddle or protective rubber layer should be provided to minimize abrasion.
Installation
GRP OVERLAY
F
F SUPPORT
SUP
PO
RT
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UNDERGROUND INSTALLATION CLASSIFICATION OF NATIVE SOILS
The external loads (soil and traffic) above a GRP buried pipe cause a decrease in the vertical diameter and an increase in the horizontal diameter (deflection), that is indicate of stain(stress) levels in the pipe wall. Native soils according to AWWA 950/95 are classified in 4 soil stiffness category. Native soil groups depend both on soil types (classification) and soil density, which together determine the soil modulus. The symbols GW, GP,SW,SP,GM,SM,SC,ML,CL etc… are in accordance to ASTM-D2488.
SOIL STIFFNESS CATEGORY 1
Crushed Rock and Gravel with <15% Sand and 5% Fines - Provide maximum pipe support for a given density due to low contents of sand and fines. -Can be installed at relatively high soil stiffness over a wide range of moisture contents.
SOIL STIFFNESS CATEGORY 2
Course Grained Soils with Little or no Fines -When compacted, provide a relatively high level of pipe support. However, open-graded groups may allow migration and sizes should be checked for compatibility with adjacent material.
SOIL STIFFNESS CATEGORY 3 Course Grained Soils with Fines -Provide less support for a given density SC1 and SC2 material.
SOIL STIFFNESS CATEGORY 4
Fine Grained Soils with Medium to no Plasticity - The moisture content must be near optimum to minimize compactness effort and achieve the required density. - Can provide reasonable levels of pipe support.
SOIL PIPE SYSTEM
The external loads (soil and traffic) above a GRP buried pipe cause a decrease in the vertical diameter and an increase in the horizontal diameter (deflection), that is indicative of strain (stress) levels in the pipe wall.
The horizontal movement develops a passive soil resistance that enhances pipe support.
The amount of deflection depends on soil load, live load, native soil characteristics, pipe backfill material, trench width, hunching and pipe stiffness.
Buried fiberglass pipes generally accommodate 4-5% long term deformation without structural damage.
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Installation
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INSTALLATION TYPE 1 -Carefully constructed bed. -Backfill 70% relative Density Gravel. -Backfill compacted gravel to 300mm over pipe crown.
INSTALLATION TYPE 2
-Carefully constructed bed. -Backfill 90% standard proctor Sand. -Backfill compacted sand to 300mm over pipe crown.
INSTALLATION TYPE 3 -Backfill to 70% of pipe diameter with gravel or sand (primary pipe zone) -Backfill from 70% to pipe crown with compatible native compacted to 90% standard Proctor.
INSTALLATION TYPE 4 -Prepare pipe bed and haunch with sand or gravel compacted to 90% standard Proctor or 70% Relative Density. -Backfill from 30% of pipe diameter to pipe crown with compactable native compacted to 90% standard Proctor.
INSTALLATION TYPE
GROUND LEVEL
NATIVE SOIL
INIT
IAL
BA
CK
FILL
BEDDING -MIN. 150mm
FIN
AL
BA
CK
FILL
30
0m
m
EXCAVATED TRENCH WIDTH
F F
Where: • F = 200 for pipe DN300 to 500 mm. • F = 300 for pipe DN600 to 900 mm. • F = 450 for pipe DN1000 to 1600 mm. • F = 600 for pipe above DN1600 mm.
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Installation
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FABRICATION METHODS
Fitting are manufactured by the hand lay-up, contact molding and spray-up process. In hand lay-up and contact molding, previous veil and alternate layers of mat and woven roving saturated with resin are applied on the mold. The operation is repeated to reach the required thickness. To fit the special needs of the costumers a study and development can be performed for making non-standards products. Before supplying such products, SPS/GRP needs to be sure that the product is made according the relevant standards and that is tested and proven as a good one.
WALL STRUCTURE
GRP fitting wall such as the pipe wall consist of three layers perfectly adherent one to the other in order to have monolithic structure, each having different characteristics and properties in relation to their function. Liner and top coat are the same as the pipe. The difference consists in the mechanical resistant layer due to the type of reinforcement used.
Fittings
FITTINGS AND ACCESSORIES Supply the following fittings such as Flanges, Elbows, Wyes, Tees, Couplings, and reducers. Large Diameter Fittings are available upon request.
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FLANGE – CALIBRATED END
FLANGE – FLANGE FLANGE –
LAMINATION JOINT END
CALIBRATED END LAMINATION JOINT
L L L
FLANGES
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Fittings
FL/CAL. END FL/FL FL/ LAM. JOINT END
100 105 340 170
150 120 470 235
200 125 540 270
250 135 620 310
300 160 720 360
350 170 800 400
400 195 910 455
450 210 1000 500
500 230 1100 550
600 270 1290 645
700 315 1500 750
800 360 1710 855
900 400 1900 950
1000 430 2060 1030
1100 480 2160 1080
1200 520 2240 1120
1300 550 2300 1150
1400 580 2360 1180
1500 620 2440 1220
DN OVER-ALL LENGTH, L (mm)
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DN
DRILLING
PN10 PN16
T OD PCD HOLE
DIA.
No. OF
HOLES T OD PCD
HOLE
DIA.
No. OF
HOLES
100 23 220 180 16 8 28 220 180 16 8
150 25 285 240 20 8 31 285 240 20 8
200 30 340 295 20 8 36 340 295 20 12
250 35 395 350 20 12 41 405 355 22 12
300 40 445 400 20 12 48 460 410 22 12
350 41 505 460 20 16 50 520 470 22 16
400 41 565 515 22 16 52 580 525 27 16
450 45 615 565 22 20 57 585 640 27 20
500 47 670 620 22 20 60 715 650 30 20
600 53 780 725 27 20 66 840 770 33 20
700 61 895 840 27 24 76 910 840 33 24
800 67 1015 950 30 24 85 1025 950 36 24
900 73 1115 1050 30 28 90 1125 1050 36 28
1000 85 1230 1160 33 28 105 1255 1170 39 28
1100 90 1340 1270 33 32 105 1355 1270 39 32
1200 90 1455 1380 36 32 105 1485 1390 45 32
1300 95 1575 1490 39 32 110 1585 1490 45 32
1400 95 1675 1590 39 36 110 1685 1590 45 36
1500 100 1785 1700 39 36 110 1820 1710 52 36
FLANGES
DXN
OD
PCD
T
30
Fittings
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FLANGE COUPLING
REDUCER
CONCENTRIC REDUCER ECCENTRIC REDUCER
1. Length of A and B = Length of Lamination according to DN and pressure. 2.Length of L = ( D1 - D2 ) x 2.5
FLANGE – CALIBRATED END
FLANGE-BELL END
FLANGE – SPIGOT END
REKA COUPLING
A A L B L B
D1
D1
D2
D2
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Fittings
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ELBOW - MITERED
90 DEGREE 60 DEGREE 45 DEGREE 30 DEGREE
L
L L L
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Fittings
90° 60° 45° 30° 90° 60° 45° 30°
100 223 160 142 113 283 220 202 173
150 345 250 223 180 415 320 293 250
200 446 320 284 227 536 410 374 317
250 548 390 346 273 658 500 456 383
300 640 449 397 310 770 579 527 440
350 736 514 453 352 886 664 603 502
400 798 544 474 359 968 714 644 529
450 884 599 520 390 1084 799 720 590
500 986 669 581 437 1216 899 811 667
600 1144 764 658 567 1404 1024 918 827
700 1302 859 736 534 1607 1164 1014 839
800 1466 958 818 587 1816 1308 1168 937
900 1624 1053 895 636 2014 1443 1285 1026
1000 1782 1148 972 684 2202 1568 1392 1104
1100 1940 1243 1050 732 2290 1593 1400 1082
1200 2103 1343 1132 930 2373 1613 1402 1200
1300 2262 1437 1209 834 2462 1637 1409 1034
1400 2420 1532 1286 883 2550 1662 1416 1013
1500 2578 1627 1364 931 2638 1687 1424 991
DN L (PN10) L (PN16)
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D1 D2 CALIBRATED
JOINT LAMINATION D1 D2
CALIBRATED JOINT
LAMINATION
L H L H L H L H
100 100 240 120 370 185 700
100-300 1400 700 2270 1135
150 100-150 300 145 520 260 350-700 1400 780 2270 1215
200 100 380 210 690 355
800 100-350 1600 800 2590 1295
150-200 400 210 690 355 400-800 1600 900 2590 1395
250 100 470 260 840 440
900 100-400 1840 900 2900 1450
150-250 490 260 840 440 450-900 1840 1020 2900 1570
300 100-150 580 330 1000 530
1000 100-450 2000 1000 3200 1600
200-300 600 330 1000 530 500-1000 2000 1140 3200 1740
350 100-150 680 385 1150 615
1100 100-500 2200 1100 3400 1750
200-350 690 385 1150 615 550-1100 2200 1240 3400 1840
400 100-200 800 400 1320 660
1200 100-500 2400 1200 3600 1900
250-400 800 450 1320 710 600-1200 2400 1340 3600 1940
450 100-200 910 445 1470 735
1300 100-600 2600 1300 3800 1900
250-450 910 505 1470 795 700-1300 2600 1400 3800 2040
500 100-250 1000 500 1640 820
1400 100-600 2800 1400 4000 2100
300-500 1020 570 1640 890 700-1400 2800 1540 4000 2140
600 100-250 1200 600 1950 975
1500 100-700 3000 1500 4200 2200
300-600 1200 660 1950 1035 800-1500 3000 1640 4200 2240
TEE – EQUAL AND UNEQUAL
D2
L
D1
H
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Fittings
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The joint is a double O-ring bell and spigot type with a locking device that is inserted through a bell opening into a hoop groove. Both metallic and shear resistant plastic materials are used for this device. This joint is a non-destructive, separable joint. Higher pressure can be supplied on request. The axial forces have to be sustained by external devices.
SLEEVE COUPLING DOUBLE O-RING BELL AND SPIGOT WITH LOCKING KEY
GRP pipes manufactured by the continuous filament winding machine and cross winding machine are joined with sleeve coupling made of lip-type elastomeric profile (REKA RRA-69) inserted into the grooves of the GRP sleeve and covering the pipe spigot ends. •the pressure of the conveyed fluid against the profile lips •the compression of the elastomeric profile between the pipe external surface.
Maximum Recommended Angular Deflection of Bell and Spigot joint
DN Angular Deflection, Degree
< 500 3
>= 500 to < 900 2
>= 900 to < 1800 1
> 1800 0.5
Application
Diameters Pressure
25 - 500mm up to 30 Bar
600 - 1200mm up to 20 Bar
1300 and above up to 16 bar
BELL END
SPIGOT END
PRESSURE TEST NIPPLE LOCKING KEY
DOUBLE O-RING
REKA GASKET RUBBER
REKA COUPLING
PIPE 1 PIPE 2
Joints
34
PRESSURE TEST NIPPLE
PIPE 1
PIPE 1 ANGLE
BELL SPIGOT JOINT
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BUTT AND STRAP
This permanent joint consist of a hardening of impregnated glass, mats and tissues laminated according to specified with and thickness. The laminated joint provides continuity in both hoop and axial directions.
COUPLING AND EXPANSION JOINT
DN PN10 PN16
T L T L 100 4 100 5 130 150 5 160 7 230 200 6 200 9 290 250 7 240 11 350 300 8.5 270 13 400 350 10 310 14.5 460 400 11 350 16 520 450 12 380 18 580 500 13 420 20 640 600 15 490 23.5 750 700 18 560 27 870 800 20 640 31 990 900 22 710 34.5 1100
1000 24.5 780 38 1220 1100 26 850 41.5 1220 1200 27.5 920 45 1300 1300 29 990 49 1300 1400 32 1060 52 1340 1500 35 1100 56 1340
DN COUPLING EXPANSION JOINT
L NL BL
100 393 1172 672
150 467 1208 708
200 467 1208 708
250 467 1208 708
300 592 1208 756
350 592 1256 756
400 592 1256 756
450 704 1315 815
500 704 1315 815
600 704 1315 815
700 704 1315 815
800 704 1315 815
900 750 1336 836
L
T
DN
NL
NL
NL
L
NL
COUPLING
EXPANSION JOINT
T = P ( ID+2T)/(2H-P) L = P ( ID+2T)/2S
T = THICKNESS OF LAMINATION, Mpa P = DESIGN PRESSURE, Mpa ID = INSIDE DIA., mm T = PIPE THICKNESS, mm H = ALLOWABLE HOOP STRESS, Mpa S = ALLOWABLE SHEAR STRESS, Mpa
The application field of butt and strap joint is related to diameter and pressure classes of pipes to diameter and pressure classes of pipes and fittings to be joint. The dimensions of butt and strap joint are calculated according to the following formulae :
35
Joints
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36
SPS GRP pipe sections are typically joined using GRP double bell couplings or bell and spigot joints. Pipe and couplings may be supplied separately or the pipe may be supplied with a coupling installed on one end.
Other joining systems such as flanges, mechanical couplings and butt and strap lamination joints may also be used with SPS GRP pipe.
JOINING PIPES
DOUBLE BELL COUPLING Cleaning and Gasket Installation the following steps (1 to 4) apply to all double bell coupling-joining procedures.
STEP 1: CLEAN COUPLING Thoroughly clean double bell coupling grooves and rubber gasket rings to make sure no dirt or oil is present.
STEP 2: INSTALL GASKETS Insert the gasket into the grooves, leaving two or more uniform loops of rubber (depending on diameter) extending out of the groove. Do not put any lubricant in the grooves or on the gasket at this stage. There should be a minimum of one loop for each 450mm of gasket ring circumference.
With uniform pressure, push each loop of the rubber gasket into the gasket groove.
When installed, pull carefully on the gasket in the radial direction around the whole circumference to check for well-distributed compression of the gasket.
Check also that both sides of the gasket protrude equally above the top of the groove around the whole circumference.
Tapping with a rubber hammer will be helpful to accomplish the above.
STEP 1
STEP 2
STEP 3
STEP 3: LUBRICATE GASKETS Next, using a clean cloth, apply a thin film of lubricant to the rubber gaskets.
Pipe Joining
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37
STEP 4: CLEAN AND LUBRICATE SPIGOTS Thoroughly clean pipe spigots to remove any dirt, grit, grease, etc. Using a clean cloth, apply a thin film if lubricant to the spigots from the end of the pipe to the black positioning stripe. After lubricating, take care to keep the coupling and spigot clean.
Caution: It is very important to use only the correct lubricant thin film of lubricants to the spigots from the end of the pipe to the black positioning stripe. After lubricating, take care to keep the coupling and spigot clean.
Caution: It is very important to use only the correct lubricant. STEP 4
STEP 5: FIXING OF CLAMP Clamp A is fixed anywhere on first pipe or left in position from previous joint. Fix clamp B on the pipe to be connected in the correct position relative to the alignment stripe on the spigot-end (home line) so as to act as a stopper.
Note: The mechanical installation clamp is to act both as a stop to position the coupling and as a device on which to attach the pulling (come-along jacks) equipment. Clamp contact with the pipe.
Shall be padded or otherwise protected to prevent damage to the pipe and to have high friction resistance with the pipe surface. If clamps are not available, nylon slings or rope may be used as in Figure 3.6, but care must be taken in the alignment of the acting as a stopper. However, if not available, insert the pipe spigots until the home-line (alignment stripe) aligns with the coupling edge.
STEP 6: PIPE PLACEMENT The pipe to be connected is placed on the bed with sufficient distance from previously joined pipe to allow lowering the coupling into position.
SPS GRP provides sufficient lubricant with each delivery of coupling. If for some reason you run out, please contact SPS GRP for additional supply or advice on alternative lubricants. Never use a petroleum based lubricant.
CLAMP B CLAMP A
STEPS 5 & 6
“COME-ALONG JACK” (one on each side)
PLANK ON BOTH SIDES TO PREVENT PIPE DAMAGE
NYLON OR ROPE SWING
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38
STEP 7: JOIN COUPLING Come-along jacks are installed to connect the pipe clamps and two 10 cm x 10 cm timbers or similar (large diameters require a bulkhead) are placed between the pipe previously connected and the coupling. While these are held in position the new pipe is entered into the coupling until it rests against the pipe is entered into the coupling until it rests against the pipe.
Note: Approximate joining force 1 kg/mm of diameter.
Note: For smaller diameter (100mm to 300mm) it might be possible to joint pipe and coupling without the use of come-along jacks. The use of levers is common to join small diameters.
STEP 8: JOIN PIPES Come-along jacks are loosened and timbers removed before re-tightening the jacks for entering the coupling onto the previously connected pipe. Check the correct position of the edge of the coupling to the alignment stripe.
Note: When step 8 has been completed, clamp-B is left in position while Clamp A is moved on to the next pipe to be joined.
WOOD (10cm x 10cm)
STEP 7 A
WOOD (10cm X 10cm)
B
STEP 8
B
A
A
B
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39
Maximum angular deflection (turn at each coupling joint must not exceed the amounts given in table. The pipes should be joined in straight alignment and thereafter deflected angularly as required
Angular Deflection at Double Bell Coupling Joint
The bending radius depends on the section length of the pipe. In the above table it is shown for the standard section length of 6m to 12 m, but it can be easily calculated since it is inverse relation to the section length (for 3m section length will be half of the radius for 6m section length).
PIPE DIAMETER PIPE TO PIPE ANGULAR
DEFLECTION
BENDING RADIUS
L = 6m L = 12m
300 ≤ DN ≤ 600 4.0° 86 172
600 ≤ DN ≤ 750 3.5° 98 196
750 ≤ DN ≤ 900 3.0° 115 229
900 ≤ DN ≤ 1100 2.5° 138 275
1100 ≤ DN ≤ 1400 2.0° 172 344
1400 ≤ DN ≤ 1900 1.5° 229 458
1900 ≤ DN ≤ 2800 1.0° 344 688
2800 ≤ DN ≤ 3800 0.75° 458 917
3800 ≤ DN ≤ 4000 0.5° 688 1375
COUPLING
PIPE
RADIUS OF CURVATURE
DEFLECTION OF ANGLE
OFFSET
Angular Deflection of Double Bell Couplings
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40
FRP Flange Joining Procedure
GRP flanges with diameter 350mm and larger should be jointed according to the following procedure:
1. Thoroughly clean the flange face and the ‘O’ ring groove with any clean rags and avoid any oil contact for both the groove and the ‘O’ ring.
2. Ensure the ‘O’ ring gasket is clean and undamaged. Do not use defective gasket.
3. Position the ‘O’ ring in the groove and secure in position, if necessary, with small strips of adhesive tape at intermittent locations.
4. Make sure that the two flanges or connecting flange with valve or expansion joint is well aligned with GRP flanges. Any misalignment could lead to high stress at flange neck and could cause damage.
5. Insert bolts, washers and nuts. All hardware must be clean and lubricated to avoid incorrect tightening. Washers must be used on all GRP flanges.
1. Using a torque wrench, tighten all bolts to 35 N-m torque, following standard flange bolt tightening sequences shown in Fig. SPS-2.
2. Repeat this procedure, raising the bolt until the flanges almost touch at their inside edges with a gap of 2-3mm or maximum bolt torque of 100 N-m. Do not exceed this torque without consulting SPS for advice. If done so, this may cause permanent damage to the GRP flange.
3. Uniform pressure should be established over the flange face by tightening bolts in 7 N-m (5 lb-ft) increment according to the sequence shown in Fig. SPS-2. For flanges with more than 20 bolts, similar alternating bolt tightening sequences shall be used, ( As per ASTM D4024-00).
4. Check bolt torque one hour later and adjust as seen necessary to 100 N-m.
5. The maximum torque, in any case, should not be more than 110 to 130 N-m. Care should be exercised while increasing the torque uniformly.
6. The above procedure is applicable for all diameters.
FIG. SPS-2
FIG. SPS-1
METAL FLANGE
GRP FLANGE
“O” RING GASKET
P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
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Note: When connecting two GRP flanges, only one flange should have a gasket groove in the face.
OTHER JOINING METHODS
1. Flexible Steel Couplings: (Straub, Tee Kay, etc – See Fig. SPS-3) These couplings can be used for joining as well for repair. The coupling consist of a steel mantle with an interior rubber-sealing sleeve.
Three grades are available: • Epoxy or PVC-coated steel mantle. • Stainless steel mantle. • Hot dip galvanized steel mantle.
Control of bolting torque with these couplings is most important. After initial bolt up, the coupling should be rapped with a rubber mallet to help seat and flow the gasket. Bolt torque should then be adjusted up to proper levels. Depending on coupling size, this procedure may need to be repeated several times. Do not over torque as this may. Over stress the bolts. Follow the manufacturer’s recommended assembly instructions.
2. Mechanical Steel Couplings: (Viking Johnson, Dresser etc. – See Fig. SPS-4) These couplings can be used for joining, typically to other types of pipe or to rigid items. Bolting torque must be controlled not to exceed the manufacturer’s maximum recommended values. Excess torque could damage the pipe.
FLANGE SLEEVE
GASKET
FLANGE
FIG. SPS-4
FIG. SPS-3
P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
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Site Hydrotest – GRP Piping
UNDER GROUND PIPING SYSTEM- COUPLING JOINTS
Field hydrotest could be conducted in segments or as a complete piping system.
SEGMENT HYDROTESTINGS Certain lengths shall be chosen according to site conditions to test the installed piping system in segments. A clearance of 4 meters minimum shall be maintained between the segments which could be later installed as Make-up pipe piece with double spigot calibration to facilitate the jointing on existing piping segment.
FIXING TEST PLUGS: There are more than one methods to close temporarily the pipe ends for hydrotest purposes:
1.USING BLIND END CAPS: Blind end cap is FRP coupling with one end lamination, while the other end is with groove for rubber gasket to work as sealing the end.
Fix the end cap with the last pipe end to be tested after placing the rubber gasket into end cap groove.
Joint with the spigot pipe end through pullers/come-along jacks.
Necessary openings could be provided to the end caps for ventilation/pressure gauge. After segment test, these end caps could be removed through pullers & could be reused for other segments after rubber gasket replacement. Adequate concrete block supports shall be provided to the end cap to prevent the pipe movement during hydrotest.
2.FLANGED BLIND END: Flanged blind end is a spool consist of flange with pipe piece & blind through a blind flange with bolts at one end while the other end is a spigot calibrated pipe shall be joined with the existing end coupling.
* Further details of above options is available upon request.)
CHECK LIST PRIOR TO PIPE ENDS BLIND:
To check each coupling joint is connected correctly and the clearance between the pipe end is uniform all around. (Field joints testing equipment is available for pipe diameters ranging from 700 mm to 2600 mm ). This test ensures the rubber gasket’s correct positioning inside the double bell coupling groove. The test shall be conducted prior to start backfill. For details, contact SPS field representative.
Internal visual inspection shall be carried out for accessible pipe diameters for any possible damage during installation/backfilling.
In no case, shall a single person be allowed to get inside of the piping for inspection.
Vertical deflection measurements shall be taken to observe the pipe behavior after the backfill. (Refer to underground installation manual for details).
Make sure that the pipes are backfilled to the minimum cover depth requirements of hydrotest.
For 100mm to 300 mm diameters (Min. 600 mm cover over the pipe crown)
For 350mm diameters and above (Min. 1000mm cover over the pipe crown)
Double bell coupling joints could be exposed in case of the client requirements.
Make sure that the backfilling slope at the joints location is maintained with minimum pipe exposure.
PREPARATION PRIOR TO HYDROTEST:
Make sure that the test method statement is available with full understanding of implementation to the testing team.
Allowance for each branch/manhole to move freely, within limits during the hydrotest.
Fixing ventilation at highest points, minimum two pressure gauges and filling points with valves.
P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
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The values and reading at the pressure shall be calculated taking into account the static head between the lowest pipe invert level along the complete line and the level of the pressure gauge.
All flanges are tightened to the specified torque bolt sequence. Make sure that the values are anchored and the above ground piping, if any is supported as specified.
In no case, shall a single person be allowed to get inside of the piping for inspection.
Upon verification of the inspection, when the finding are all judged acceptable & recorded, manhole covers shall be closed. Prior to start water filling, temporarily piping & blinds shall be installed checked & verified by the client/consultant/contractor/representatives.
WATER FILLING & PRESSURIZING THE SYSTEM:
(It shall be confirmed that all vent points are fully opened to atmosphere, prior to start water filling).
Introduce water filling through temporary hosing & pump at lowest point. Pump capacity shall be chosen according to the pipe diameter and segment/system linear length. (Pump having 100m3 capacity/hour are generally used for large diameter pipes).
The sign of complete water filling is when the water starts coming through higher point ventilation opened valves.
Stop water pumps at this stage & check the flanges, valves and connected accessories for any webpage/leakage while keeping the vents open.
PRESSURIZING:
Start pressurizing the segment/system through pump. Once the water starts coming out through vent opening, close the valves at low elevation. Later on the high elevation end the vent valves shall be closed as well after water starts coming.
The pressure increment shall be maintained approximately as 0.5 bar/10minutes at this stage. When the pressure reaches to 2 bar, the pumps shall be stopped.
Keep this stoppage for 15-20 minutes. During this time, following checks shall be made:
• Pressure at each test gauge shall be checked & recorded on inspection sheet. • Watch the pressure at the water feed point for any decrease in pressure. • Walk through along with the underground lines to observe any traces of wet soil. Check the coupling joints if exposed.
The inspection sheet shall be maintained for the observations & findings.
Anything unusual shall be immediately reported to the team leader.
Unless there is no findings which prevent the test from continuing, the segment/system shall be further pressurized.
Connect the hose with the pressure pump and start pressurizing the line. At this stage, slightly open the vent. Valve should be fixed at a higher elevation to ensure that no entrapped air is present.
Upon confirmation of water coming out of the vent, valve shall be closed. The system is now totally closed and under pressure. Continue the pressure pump until it reaches to 5.0 Bar. During this operation, the pump shall be constantly attended for pressure control.
Stop the pressure pump once it reaches to 5.0 Bar and let it stabilize.
There could be a drop in pressure due to the thermal expansion, which could be resolved by restarting the pump or keep it as is & record it on the inspection sheet.
Keep this stoppage for about 30 minutes. During this period, repeat the same sequence of inspection as described earlier. The findings & observations shall be recorded on inspection sheets.
Any unusual findings shall be reported immediately to the team leader.
P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
Unless there are no findings which prevent the test from continuing, the segment/system shall be further pressurized to the requirement.
The test pressure should not exceed 1.5 times the maximum rated operating pressure. The test pressure shall be maintained for a minimum period of time.
(It is recommended to maintain the test hold time to a maximum of 15 minutes after pressure stabilization).
A thorough inspection shall be made as Final Inspection.
Fill up the inspection sheets accordingly. The test shall be considered as “PASS” if no signs of leakage is observed. The inspection sheets shall be signed by the authorities.
POST HYDROTEST: After completion the test, drain or flush out the filled water from the pipe segment/system through drain valves & vents shall be opened. This pressure release shall be made slowly @ 2 bar/5 minutes.
1. Remove the end cap from the segment as per procedure.
2. Prepare the pipe end to be ready for next installation.
3. Exposed joints may be backfilled using the specified backfill material.
4. Connect the adjacent segment ends with closure pipe piece.
5. Continue the installation for the other segments & conduct the hydrotest in the similar manner as described earlier, keep connecting the segments through closure spools.
6. Complete system hydrotest/Final hydrotest.
The purpose of this hydrotest is to test the pipe closure spools joints.
Following arrangements shall be made: • All branch connections shall be kept free to move. • Separate the line from all connections equipments. • Exposure of joints at closure pipe piece shall be done manually in order to prevent the pipe from any damage.
The procedure described for the segment testing is applicable to the final hydrotest.
For final hydrotest, it is recommended to maintain the test hold pressure for minimum period of time (one is enough to inspect the joint / fittings) and the pressure shall be equal to the maximum rated operating pressure.
44 P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
SPS - GRP Manholes are made of a chemical resistant thermosetting isophthalic polyester resin and fiberglass reinforcement with silica sand or calcium carbonate additives. The standard diameter (DN) of manholes are usually 1000 mm or 1200 mm cylinder with a concentric reducer on top of it to form a 600 mm man way. The concentric reducer (cone) is manufactured separately by hand lay - up process will then be factory jointed with the manhole body to form one piece manhole. GRP manholes conform to the ASTM for GRP manhole Specification D 3753.
•Ultimate Compressive strength in the axial direction, when measured •according to ASTM D695 is 985 Kg/ cm. Cylinder Stiffness ( ASTM D2412)
MANHOLE HEIGHT,
H(mm) MINIMUM STIFFNESS,
KN/m²
1000 – 1800 4.96
2000 - 3600 8.69
3800 - 7600 20.82
USE AND APPLICATION
•The product is applicable to use in corrosive environment such as sanitary sewers, storm and sewers including cooling water lines with a temperature from - 40 to 70 deg. C. •The ring and cover must rest on a course of bricks or a concrete ring, not the fiberglass support ledge. All surcharge load must be applied to the ring and cover. •GRP manholes must be installed in accordance with SPS installation instruction. Holes or arches must be cut in the cylindrical portion of the manhole using a circular cutting diamant disc or similar equipment with a masonry type blade. Axes, hammers, chisels or similar tools are not advisable to use to make cuts on the manhole. Maximum single cutout hole diameter is 750 mm for the 1200 mm manhole and 600 mm for the 1000 mm manhole. Sum of all cutouts must not exceed 1900mm for the 1200 mm manhole and 1500 mm for the 1000 mm manhole.
DIMENSION TOLERANCE
DN 1200 1000 ± 7
H 1000 ~ 7600 ± 50
Wall Thickness
10 10 min
PRODUCT REQUIREMENT AND TOLERANCES Visual Standard SPS-GRP Manhole is to be commercially free from the following defects.
DEFECTS DEFINITION
Fuzz Glass fibers loosely
adhering to the pipe which are not wet out with resin
Protruding Fibers Glass fibers sticking out
from pipe surface that are not wet out with resin
Resin Runs Runs of resin and sand on
surface of pipe
DN
H
Manhole
45 P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: [email protected] Website: www.saudivalve.com
Main Office : Jeddah Industrial Zone Phase IV P.O. Box 34572 Jeddah 21478 Kingdom of Saudi Arabia Tel. +966 2 608 1100 / +966 2 637 0999 Fax +966 2 636 5925 / +966 2 637 9439 www.saudivalve.com / [email protected]
Sales Office : Takhasussi Street P.O. Box 52408 Riyadh 11563 Kingdom of Saudi Arabia Tel. +966 1 482 6006 Fax +966 1 482 8742