Installation Instructions For High Pressure GRE Line Pipe
Installation Instructions For High Pressure GRE Line Pipe
Installation Instructions For High Pressure GRE Line Pipe
Contents
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Preface
Chapter I Storage and Transportation
Packaging
Inspection
Loading and Unloading
Storage
Transportation
Chapter II Tools and Equipment
Tools and Equipment for Installation of High Pressure GRE Line Pipe
Tools and Equipment Used for Field Thread Bonding and High Pressure Maintenance System
Chapter III Installation
Personnel
Stringing Pipeline Along the Ditch
Joining
Torque
Chapter IV Cutting and Taper Milling
Cutting
Taper Milling
Installation of Field Thread
Curing Time of Adhesive
Heating method for Adhesives
Chapter V Joining with other Systems
Threaded Adaptors
Crossovers for Different Threads
Flanges
Chapter VI Buried Installation
Ditch Preparation
Rocky Areas
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5
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4
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3
Road Crossing
Backfilling
Work in Winter
Chapter VII Installation of Thrust Blocks
Thrust Block
Fixed Support
Chapter VIII Maintenance of High Pressure GRE Pipelines
Flanges
Repair Collar
Moving Joint for Repair
Field Thread with Flange
The Entire Pipeline with Flange
Chapter IX Line Proof Test
Frequency
Filling the System with Water
Pressurization
Safety Precautions
Chapter X Transportation of Gases
Surface Transportation
Buried Transportation
Joining the Pipelines
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Preface
This Instruction provides guidelines for installation of high pressure Glassfiber
Reinforced Epoxy (hereinafter referred to asGRE) line pipe manufactured by Shengli Oil
Field Xinda Guanye Science and Technology Development Co., Ltd. (hereinafter referred to as
Xinda) and relevant precautions to be taken. It is strongly recommended by Xinda that all
installation personnel, prior to installation of the GRE pipes produced by Xinda, should
thoroughly read this Installation Instruction and receive field training and or installation
training. Please contact the installation dept. of Xinda for any specific issues.
The GRE pipes and fittings produced by Xinda are standard series products. Xinda will
be exempted from any liability for any personal injuries, property losses or civil disputes
caused by unauthorized alterations to the products or use of the products to other systems
beyond Xinda pipe systems, in which case all warranties of Xinda will become void.
Safety Warnings
This is a very important safety warning sign. Please take notice when this sign appears at
any processing position or operation procedure, so as to prevent personal injuries.
Attention
GRE pipeline may carry toxic substances while running under high pressure, so it is of
ultimate importance for the operators to observe the regulations herein. Accidents may happen
due to improper installation. In order to prevent personal injuries, all the operators must read
user instruction to adhesive agents, heater band, propane torch, electric saw and other tools,
and work as instructed. If necessary, the operators should wear working suits, gloves, and
safety goggles. In addition, the worksite should be clean and tidy with good ventilation.
Page 3 of 27
5. Transportation
When transporting the pipes to the installation site, use flat bed trailers with wooden floor
or use steel pipe trailers with 4 to 6 pieces of wood boards across. If the trailer is not long
enough, then the length of the pipe hanging off the trailer should not be over 1.2m (see Fig.1.2).
Prior to transportation, use hessian rope, nylon rope or soft belt to fasten the pipes; do not use
metal ropes like steel wires or chains, etc.
1.0
1.1
1.2
Caution: prior to use, select strap wrenches and friction wrenches, which are suitable
for the size of the pipe OD.
Refer to Table 2.0. Select and use the recommended tools for products of different
specifications. If two wrenches are recommended, then use one of them as the joining
wrench, and use the other as supporting wrench. When three wrenches are recommended,
then use two of them as the joining wrench, and the third one as supporting wrench.
For example, 2B+1C listed in the table means that two strap wrenches (2B, strap
wrench with aluminum handle of 0.6m long) are joining wrenches, and one friction
wrench (1C) is supporting wrench.
2) Iron wire brush or scrubbing brush
3) Supports
(1) Pipe rack or adjustable pipe support
(2) Wooden support or fixed pipe support
4) Fine quartz powder (as detergent powder) or chalk for strap wrench
5) Top thread sealing sealant
Xinda suggests that this sealing sealant be used as the main sealant when installing
threaded pipelines. See Table 2.1 for doses of this sealant.
Customers may use other thread sealant at their own discretion, but the sealant should
meet the following requirements as a minimum:
* Content of polytetrafluoroethylene: 25%
* Grains of polytetrafluoroethylene: 60mesh to 120mesh (do not use powder material).
* Lubricants must conform to components of thread lubricant of API Oilfield Standard.
* Lubricants should not be thickened with additives like abrasive powder or clay, etc.
All the components of thread sealant should have the same bearing capacity as the pipes
under specific application conditions.
2.0
Table 2.0
Pipe size (in)
2.1
Tools for Installation of High Pressure GRE Surface Pipes
1-1/2
2-1/2
10
3.5-8
2A
2A
2A
2A
2B
2B+1C
2B+1C
2B+1C
10
2A
2A
2A
2B
3B
3C
2C
3C
14
2A
2A
2B
2B
2B+1C
3C
3C
3C
16
2A
2B
1B+1C
2B+1C
2B+1C
3C
PRMPa
Page 6 of 27
18
2A
2B
2C
2C
3C
20
2A
2C
2C
2C
3C
22
2A
2C
2C
2C
3C
24
2B
2C
2C
2C
3C
Note: A: Xinda strap wrench of 0.6m; B: Xinda strap wrench of 1.0m; C: friction wrench.
For instance, when installing DN100/PN16 pipes, use one friction wrench as backup, and use
two strap wrenches as power wrench; when installing DN150/PN10-16 pipes, use one friction
wrench as backup, and use two friction wrenches as power wrench with additional
augmentation bar of 2m.
The above pipes are suitable for liquid (salt water or crude oil) transportation. Refer to
Chapter X for gas transportation.
N/A= Not available.
Table 2.1 Approximate Dosages of Top Thread Sealant
Sizes of Pipe
(in)
m/gal
1 1/ 2
1016
2
915
2 1/ 2
813
3
711
4
508
6
305
8
230
10
145
* Take 9m for the length of each pipe.
2. Tools and Equipment Used for Field Thread Bonding and High Pressure Maintenance
System
1) Taper milling machine and relevant expanding plug. The OD of the plug should fit
tightly to the ID of the pipeline.
2) Field Thread.
3) Bench friction wrenches or portable friction wrenches. Size of the jaw should be
suitable for the pipe sizes, and rubber, cut-off GRE pipe or sealing materials may be placed on
the jaw to avoid damage to the pipes.
4) Adjustable pipe support or wheeled pipe racks.
5) Cutting equipment
(1) Toothless saw with carborundum or other abrasion-proof materials.
If this kind of circular saw is not available which is recommended by Xinda , then
the following saws may also be used.
(2) Steel handsaw with 32 teeth every inch.
(3) Metal wire saw with carborundum or fine teeth.
Page 7 of 27
optimized joints of male thread is flush with the end surface of female thread, then it is
installed correctly (see Fig.3.0).
(2) Warning: The steel pipe wrenches exert point load, which will cause local stress
and lead to deformation of the pipe walls or an false indication that the pipes are fastened. In
this case, Xinda s warranties for the quality of the pipes will become void. Friction wrenches
with surface jaws or 360o clamp may be used.
(3) Attention: Two or more friction wrenches will be needed for fittings or adaptors of
large size or high pressure ratings; chain wrench may also be used in this regard; see Table 2.0.
But be careful not to cause point load. The chain on the chain wrench should be adjusted to
proper tightness and be perpendicular to the pipe.
2) Preparation prior to joining
(1) Remove the thread protectors. When necessary, brush the external and internal
threads clean with steelwire brush or scrubbing brush. Check and see if there are any damages
to the threads; if any, replace the pipe with a new one.
(2) It is of utmost importance to keep the thread clean. Sand or foreign matter may
damage the threads, cause sealing failure of the threads, and may also cause false indication
that the pipes are fastened tightly.
(3) It is easy to align the pipes and threads with pipe rack and wood blocks. If pipes are
not straight, they may seem to be ok to be tightened but are actually not. So align the pipes
properly before making up.
Wood blocks should be placed under the end of the pipe that is to be fixed when
making up threads, usually under the internal (female) thread end. Then clamp the pipe tightly
from under the end with support wrench, and the handles of the support wrench will be on the
ground bearing the force. Put another pipe to be joined on the pipe rack. The location of the
rack should be about 2/3 of the pipe length to the pipe end to be joined, and then move the rack
and line up the pipe (See Fig. 3.1).
If rotary wrench is used, then place the pipe rack near the end of the pipe to be joined;
align the pipes and threads.
3) Apply Top Thread Sealant
TOP thread sealant (Fig.3.2) is specially used for threaded GRE pipelines manufactured
by Xinda.
Attention: Brand new threads with protectors do not need to be cleaned with solvent
before applying Top sealant. However, any oil on the threads should be removed. The
operators hands, gloves and the tools that come contact with the threads should all be kept
clean. Almost all the threads are coated with a layer of rust-proof oil membrane, which should
be removed first when connected to steel threads.
If there is any doubt that there is oil on the threads, then clean same with solvent.
(1) Use TCA, acetone or butanone to remove the oil or dirt on the threads.
(2) Attention: On the package of TOP thread sealant is printed its effective date; any
sealant beyond that date should not be used.
(3) If the male and female threads are washed with solvent, do not apply sealant till the
solvent completely dries out.
(4) Use the brush accompanying the sealant to apply a thin layer of sealant on the male
Page 9 of 27
and female threads, and remove the extra sealant; the extra sealant built up at the joint may
impede flowing of the liquid.
4) Joining
(1) Align the external and internal threads manually, make up a few threads first and, if
its alright, then make up to hand tight, and finally tighten same with proper tool. The best way
is to screw the male thread into the female threads.
(2) Select proper tool as per Table 2.0, and tighten the joints in the following steps:
l The threads with optimized joint locating ring should be screwed to behind the
locating ring and flush with female thread end.
l When pipes with locating ring and pipes without locating rings are joined together,
the way to tighten the joints are:
Attention: When turning the pipelines applied with TOP sealant, keep the torque
consistent, which is the approximate value given in Table 3.0. When the pipe continues
turning to hand tight point, the torque may increase abruptly. At this time, stop turning
and make a mark on the outside of the two ends of the pipe joints along the axis; then
tighten the joints according to the requirements below:
* For threaded pipelines of 11/2 and 10rd, make up two more rounds when beyond hand
tight point or hand tight surface.
* For threaded pipelines of 2 to 4, 8rd, make up two more rounds.
* For threaded pipelines of 6 and 8rd 1 , make up three rounds.
*For threaded pipelines of 8 and 10, 8rd, when pressure rating is 3.5MPa to 8.5MPa,
the male thread should be made up to female thread with 1 to 4 threads left. When pressure
rating is 10MPa to 14MPa, the male thread should be made up to female thread with 1 to 2
threads left.
During installation, check and see of the connection length of the thread is consistent with
the engagement length. If not, or if the engagement allowance is more than 1 round, then
remove the joint and clean same, apply new TOP sealant and make up again. Solvent may not
be necessarily used when cleaning the joints. If the pipes do not meet the requirement after
being rejoined, then replace the pipes.
(3) The ways to use the support wrenches (strap wrench may be used as support wrench):
When using collars, set the support wrench on the pipes.
In case of entire pipeline with threaded connection, the support wrench should be
placed about 300mm to 400mm to the female thread, but not placed about 200mm to 250mm
to the female thread.
(4) Conduct hydrotest promptly after the last piece of pipe is joined. Refer to Chapter IX
for the method, requirement and considerations for hydrotest.
Refer to the instructions inside the package of thread sealant for the method of using
TOP thread sealant and safety precautions.
When TOP sealant is used for joining or after the joint is made, make sure that the fittings
or joints are not displaced. There are two ways to address this problem: use support wrench to
fix the fittings or the joints; and after connection is made, backfill to the fittings or the pipe
body on both sides of the joint, or put sand bags on the pipelines.
When ambient temperature is below 21 , put the thread sealant inside vehicles or in other
Page 10 of 27
Fig..0
Fig..1
Fig.3.2
Table 3.0
Pipe Sizes (in)
1 1/ 2
2
2 1/ 2
3
4
6
9.0
10
8
10
15
10
15
20
* The above are approximate values. Refer to the note (1) below Table 3.1 for the method to
determine the torque.
4. Torque
In Table 3.0 and Table 3.1 are listed the torque values required for joining of Xinda GRE
line pipes with strap wrenches or friction wrench.
Identification of optimized joint pipe
Page 11 of 27
Xinda GRE line pipes with optimized joints have a prominent ring of 6.35mm wide at the
rear of the male threaded pipe end, i.e. the big end of the thread. Before joining the pipes with
optimized joint locating ring, make sure to identify the male and female threads of the pipes by
the above method.
Table 3.1
Pipe
Sizes
Pressure RatingMpa
3.5
10
14
18
22
25
Min.
Max.
12.4
17.3
12.4
17.3
12.4
17.3
12.4
17.3
12.4
17.3
12.4
17.3
Min.
Max.
Min.
Max.
Min.
Max.
Min.
Max.
Min.
11.1
13.8
17.3
20.7
27.7
34.69
51.8
13.8
20.7
22.1
31.1
34.6
47.0
55.3
13.8
20.7
19.4
26.3
24.2
34.6
41.5
55.3
62.2
13.8
20.7
19.4
26.3
31.1
41.5
41.5
55.3
69.1
13.8
24.2
20.7
31.1
31.1
41.5
44.9
58.8
69.1
19.4
27.2
20.7
31.1
31.1
41.5
44.9
58.8
-
19.4
27.2
20.7
31.1
31.1
41.5
44.9
58.8
-
Max.
65.7
69.1
89.9
96.8
96.8
Min.
65.6
65.6
65.6
65.6
113.9
83.1
185.7
113.9
83.1
185.7
113.9
83.1
185.7
113.9
10
Max.
Min.
Max.
in
SDC(1)
1 1/ 2
2
2 1/ 2
3
4
6
Note: (1) Values in the table are 75% of the torque at which the female thread failed
(stuck, broken, etc) in approval tests at factory. The test pieces are 8rd or 10rd pipes; the
conditions of the test are as below:
a. Apply thread sealant on male and female threads.
b. Connect the pipe and collar with proper torque.
c. The torque value is just what is needed to join the pipes or the collars, not including
pipe weight, misalignment or resistance of pipe racks.
d. Torque value is measured when rotating the pipes, so torque should be measured when
pipes are rotated at worksite. When threads are 100% tightened or engaged, torque value =
length of handle perpendicular to the pipe (m)weight or applied stress(Kg).
Cutting
Page 12 of 27
GRE pipes can be cut using toothless circular saw with carborundum jaw, electric circular
saw with fine teeth or handsaw. Xinda suggests that lines be drawn on the outside circle of the
pipe first and the cut surface should be perpendicular to the axis of the pipe as much as
possible.
2. Taper Milling
Tight fitness of conical surface by Xinda is the key to excellent performance of field
threads. Xinda can provide a number of taper milling machines (Fig. 4.0, 4.1).
All the tools can grind tapers of 143156 on pipe ends, which is suitable for
installation of field threads and maintenance of high pressure system, also suitable for
installation of low-pressure fittings.
If protractor or angular ruler are not available on site (which are used for setting angles of
blades on taper milling machines), then place the miller machine on the male threads of the
pipe, adjust the position f the blades so that the blades are tightly against thread crest, and lock
the blade when the angle is set. When taper is milled at the pipe ends, put the field thread on to
the tapered end, check the matching of the taper and the length of tapered surface. If the
clearance is too large, then cut off the taper head, reset the blade and mill the taper again.
5) Mix the adhesives evenly as per the instructions. (See paras. 1 and 5 of the instruction
for curing time and working life).
6) Apply adhesive with hairbrush on the tapered pipe end and the inner surface of field
thread and remove the air bubbles. Apply a thin and even layer of adhesive on both bonding
surfaces.
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7) Put field thread onto the taper surface coated with adhesive, screw up while pushing till
it is tight; remove extra adhesive. Be careful that underneath the protective belt and exposed
threads should be clear of any adhesive. When field thread is installed, remove the protective
belt carefully. If there is any adhesive on the thread, clean same carefully.
8) In cold weather, electric heat belt or chemical heat bag may need to be used to cure
adhesive completely. A better practice is to wrap a layer of aluminum foil on the thread, then
warm the thread with electric heat belt or heat bag as per instructions. When working in cold
weather, Xinda recommends that electric heat belt or chemical heat bags be used to shorten the
curing time of adhesives.
9) The dusts or chips produced when cutting GRE line pipes are not hazardous, but they
may irritate the eyes, upper respiratory tract or skin. So the worksite should be well ventilated
and operators should try not to be exposed to these dusts.
Xinda suggests that operators should wear masks and goggles when working with dusts
around; wear comfortable cotton working suits to prevent skins from contacting directly with
dusts.
4. Curing time of Adhesive
Curing time is the period for adhesive to harden. The length of curing time depends on
types of adhesives and ambient temperatures (see Table 4.0); heating will shorten curing time.
When ambient temperatures fall below 23oC, it is suggested that external heating be used to
cure.
Table 4.0 Ambient Temperatures and Curing Time
DS-8000 Series of Set Adhesives
Temperatures (oC)
13
24
16
16
18
11
21
24
4.5
27
29
3.5
32
38
2.5
Table 4.1
1 1/ 2
75
90
155
Page 15 of 27
200
285
315
10
400
steps:
Attention: On each package of the heat bag is printed expiry date; no heat bag should
be used beyond that date. Wear gloves and safety goggles when mixing the chemical heat
bags. Strictly follow the regulations in safety instructions accompanying the heat bags.
(1) When field thread is installed, wipe out extra adhesives.
Attention: Thread
should be clear of any adhesive; may be wrapped up with aluminum foil or protective belt. In
this way, the surface of heat bags can be kept flat, so to prevent the heat bag from falling down
into the threads due to the plastic bag being heated.
(2) Remove the separating clamp and make a small hole on both sides of the package to
eliminate the vacuum. Then use adhesive tape to seal the holes; shake and turn around the
package to both sides for at least 25 times till completely mixed.
(3) Line up the heat bag with the bonding area of the joint and wrap around the joint. The
chemicals inside the bag should be evenly scattered along the length direction.
(4) In order to make sure that the chemicals are evenly scattered, flatten the bag with hand
when wrapping the bag. Fasten the bag with iron wire. Some joints need two heat bags to cure,
such as molded flanges, bonded tapered joints, 4 and 6 field thread. However, two heat bags
cannot be used simultaneously; when one bag is used up, then continue with another one.
(5) Use the peg on the separating clamp to punch the aluminum boil 3 to 4 times.
(6) Inject 10ml water into the bag with the accompanying injector. Inject the water along
an oblique angle into the plastic bag through the aluminum foil. Exothermal reaction occurs
immediately inside the bag and the heat will come out of the hole made as indicated in above
(2). The people at the site should stay 2m away, till the heat reduces (for at least 2 minutes). If
package is broken and chemicals spills out but it needs to be cured immediately, then replace
the heat bag and repeat the curing process.
(7) In cold weather, the heat bags should be kept warm. Wrap the heat bags with insulating
layers and make sure that the bags are fully packed.
Attention: When ambient temperatures or cold wind temperatures are at 0oC or below,
Xinda suggests that insulating layers be used to the outside of the heat bags. The insulating
layers are optional, available from Xinda.
(8) Usually, the heat from the heat bag can cure the adhesive in an hour, but the length of
time depends on the temperature of the products to be cured.
(9) Attention: All the field threads and joints should not be applied any stress before
cooled down to hand touch, and should not be overbent or tensioned during being heated.
(10) The expired or broken heat bags should be seriously dealt with as per the following
steps:
Wear protective goggles and gloves;
In well ventilated area, mix evenly the two chemicals in the package or in other vessels.
Mix one bag only every time.
Use a metal bucket to deal with the chemicals; do not use plastic bucket, because the
heat produced from the treatment may melt plastic bucket.
After the chemical powders are fully mixed, pour them into a metal bucket and then add
a cup of cold water.
Wait till the chemicals reacts completely and the heat fully disperses. The residual
Page 17 of 27
material after the reaction should be pasty. Make sure that chemicals and water are mixed
evenly without lumps. If there are lumps, then agitate the remaining material and disperse them,
then treat the next bag.
The method to treat the next bag is the same as above. Attention: The remaining material
after reaction is non-hazardous matter, which can be disposed of like garbage.
Remember: Mix only one bag at a time.
(11) Refer to the instructions inside the package for safety precautions.
Note: If temperature fluctuation is over 10oC or the pressure is equal to or over 16MPa,
Xinda suggests that the crossover for GRE pipe end is male thread, and the steel pipe end is
female; this is because the linear expansion factor of GRE is larger than that of steel.
3. Flanges
When working pressure is below 3.5MPa, GRE flange should use flat sealing washers of
3.2mm thick and 60-70 Shore hardness (see Fig.5.2).
If the washer is squeezed out when tightening connecting bolts on flanges, it indicates that
the materials of the washer have low hardness; so washers with high hardness should be used
instead. When GRE flange is used together with male flange or marginal valve, spacer washers
should be used to prevent GRE flange from being damaged by bending stress.
If flange is used under pressures of over 3.5MPa, it is suggested harder washers be used,
or special Flexitallic winding metallic gasket or equivalent sealing gaskets.
When fixing threaded bolt into flange screw, both ends of the bolt should be added with a
flat washer to prevent flange surface from being damaged when tightening the bolts.
Attention: Do not use flange bolt to forcefully join two pipes with ends not closely
tightened, otherwise GRE flange thread will be damaged.
See Fig.5.3 for tightening sequence of bolts after flange is connected.
Fig.5.3 Tightening
sequence of flange bolt
2. Rocky Areas
If pipelines are to cross rocky areas, the pipe ditch should be dug deeper, and the ditch
bottom should be placed with a layer of sand or pure soil, and the pipelines should also be
covered with sand or soil, which will protect the pipelines against rocks (see Fig.6.1). The
backfilled sand and soil around the pipes should be at least 150mm thick
3. Road Crossing
When crossing roads or streams, it is suggested that GRE pipelines be put into steel
conduit. If it is not practical to use steel conduit, place contact Xinda and determine the burial
depth to prevent ground load from damaging the pipelines. When steel conduit is used to
protect the pipelines, the two ends of the conduit should be padded to avoid local stress or
abrasion to GRE pipelines. Usually the pipe is protected at the entry and exit with rubber
protective jacket or plastic centralizer (See Fig.6.2). the GRE joints inside the steel conduit
should also be protected with plastic centralizers or other similar materials. The plastic
centralizers should be mounted on pipelines at the coupling or joints every 3 meters.
On some occasions (like circulating pressure and high temperature, etc.), more protection
may be needed. Customers may contact Xinda regarding fluid media, weight, temperature and
other application conditions.
4. Backfilling
When backfilling the pipe ditch, make sure that enough backfill or sand bags is put on the
pipe body such that the pipes are fixed; but all the fittings and joints should be exposed for
leakage detection by pressure tests. When pressure test is done, the ditch should be backfilled
immediately.
1) Time
The pipeline system should be backfilled immediately after pressure test is finished,
so to prevent pipe movement, displacement or ditch wall collapse due to water hammer.
2) Backfill Soil
The backfill soil should be clear of any sharp rocks, gravels, large pieces of soil blocks or
frozen soil blocks. Before filling in soil, the backfilled soil under the pipeline must be
compacted. Frozen soil, when melted, cannot support the pipeline and will leave spaces around
the pipe. Brasque or other tamping devices will squeeze small rocks into pipe walls. So when
brasque is used, the pipe must be padded with pure soil. When several pipelines are laid in one
ditch, the pipelines should be separated with pure soil or sand of at least 150mm thick. Be sure
that the backfilled soil fills all around the pipes. Under no circumstances will there be any
clearances below or around the pipes.
Page 20 of 27
Fig.6.0
Fig.6.1
Fig.6.2
5. Work in Winter
If GRE pipelines are to be installed in winter, except observing the regulations
above, the following considerations must be followed:
1) In order to prevent the liquid inside the pipelines from freezing, the GRE pipes must be
buried below the freezing line.
2) The sealing compound for pipe connection may be hard to apply due to high viscosity
in winter; so sealing compound should be better kept at places of high temperatures, and use it
when needed. Or properly warm the pipe ends and then apply sealing compound, but the pipe
ends should not be over heated.
3) When ditch is dug, immediately install the pipes and backfill. If backfill over the night,
then the excavated soil may be frozen on the ground, which should not be used for backfilling,
this is because the frozen soil cannot wholly support the pipe and will leave spaces around the
pipes.
4) When installing GRE pipelines in swampy area, the work can be carried out in winter
after the ground is frozen; at this time, the ditch is relatively stable. Except the abovementioned,
the following measures should also be taken:
(1) Remove accumulated snow, pulverize or grind floating ice on the ground. The broken
ice should be put away from the worksite, so it will not be mixed with the unfrozen soil which
will be used as backfill soil.
(2) The ditch should be dug to stable soil. If soil at ditch bottom is not stable, then use
sand bags or other materials to stabilize the bottom soil, or use metal casing over GRE pipes.
(3) When ditch is dug, immediately install the pipes and backfill, but not with frozen soil
blocks.
Page 21 of 27
Thrust blocks are usually concrete structure. For 4 fittings or smaller, they should be
completely wrapped with concrete of at least 200mm thick. 6 and 8 fittings should be
enveloped with concrete of at least 500mm thick. See Fig.7.0 for these two types of thrust
blocks.
2. Fixed Support
When high pressure GRE pipes need to be joined to steel pipes from injection metering
station or polymer injection stations, it is required that fixed support be constructed near the
joint at the steel pipe side, so as to prevent abrasion due to GRE pipe vibration or leakage of
steel pipe joints.
In addition, when crossover is used between GRE pipe and steel pipe, fixed support
should be constructed at the steel pipe side near the crossover.
The type and standard for steel pipe fixed support will be at customers own discretion.
Elbow
Tee
Vertical view
Side view
vertical view
Fig.7.0 Typical Thrust Blocks
side view
Prior to starting repair, release the pressure inside the system; do not operate under
pressure. In the course of repair, the repaired parts must be kept dry; this is especially
important for repairs with adhesives. When temperatures drop down to below 21oC, it is
suggested that electric heat belts or chemical heat bags be used to heat and cure all the places
with adhesive.
High pressure pipelines can be repaired with the following methods:
1. Flanges
If leaking occurs at the joining area of the threaded collars, then it can be repaired with
flanges. This is the simplest way. Cut the collar into two halves along the middle perpendicular
to the pipe direction, then disconnect the two halves of collar and mount the flanges instead.
2. Repair Collar
The repair collar is a thick-walled collar of 450mm long, with tapered bells at both ends
for adhesion (Fig.8.0). It can be used to repair 11/2 to 6 pipelines with maximum pressures of
up to 16MPa. The repair collars can stand 16MPa pressure used for 11/2 to 21/2 pipes; 14MPa
for 3 to 4 pipes and 7MPa for 6 pipes. Despite that repair collars are designed to repair high
pressure pipes of 16MPa, but, if pipe sizes are matching, they can be used for repair of low
pressure pipes. This repair method can be used for GRE pipes of all specifications. For
pipelines of different sizes and pressure ratings, repair collars of various sizes are available for
selection.
The way to use the repair collars:
1) Pipe ditch for 11/2 to 4 buried pipes should be dug 15m longer, and 24m longer for 6
pipelines, so that the repair collar cay be inserted into one end of the pipe.
2) Cut off the damaged part and mill taper at one end of the pipe.
3) Mount collar at the tapered end and make sure they fit tightly. When adhesion is applied, the
collar may go in 6mm to 12mm farther.
4) After repair collar is mounted on the tapered pipe end, then put it against the side of the
other pipe, and measure the length of second taper to be milled with a tape. The length of the
second taper to be milled should make sure that the pipeline fits into the collar perfectly.
Prior to applying adhesive, carry out several times, dry fit tests to ensure accuracy of
measurement of taper length and the milled taper. When cutting off the damaged part, leave
the pipe as long as possible, because the adhesive has some kind of lubrication, which will
allow deeper insertion when installing.
5) Apply adhesive on all the bonding surfaces, then lift the tapered pipe or move it aside, insert
it into the bell of collar; the taper surface should be tight.
6) When installing repair collar onto the first milled taper, put wood blocks below the other
end of collar and strike it with hand hammer. When inserting the second taper into the collar,
tight it with sling or pipe tightener.
3. Moving joint for repair
It can be used to repair 2, 2 1/2, 3 and 4 pipes, with maximum pressure of 16MPa.
The moving joint is a long collar with a moving joint in the middle (fig.8.1), and the way to
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repair the pipe is the same as repair collar. There are conical bell at the both ends of moving
joint (2 to 4 pipe), or having 8rd external upset long form thread joint with female thread (2
to 3 pipes). This moving joint is designed to repair high pressure pipes, and can also be used
for low pressure pipes and FRP pipes of other specifications, but the sizes must be matching.
1) The way to repair pipes of 10MPa and below is the same with repair collar, but not
much pipe is to be exposed; its just that the taper milling machine has enough room to rotate
and the moving joint can be mounted.
2) In case of repairing 2 and 3 pipes with pressure ratings of 14MPa and 18MPa, Xinda
suggests that 8rd threaded moving joints be used together with field thread.
(1) Cut off the damaged part, then mill taper at both ends of the remaining pipe, then
install field thread as per instruction in Chapter IV. Make sure that the sizes are measured
correctly and the moving joint will not stand load after installation.
(2) Repair the moving joint as per instructions in Chapter III.
4. Field Thread with Flange
Repair pipes of various lengths and pressure ratings with Xinda s universal field thread.
After the damaged part is cut off, install field thread as per Chapter IV. Then add collar to the
measured pipes or joints, and finally join the pipes with flanges.
5. The Entire Pipeline with Flange
The fastest way to repair threaded GRE pipes is to remove the entire damaged pipe and
then join with flange. Excavate the backfill over the damaged pipe, cut the pipe at the damaged
area, and disconnect the two halves. If the pipe is connected with threaded collar, then the
collar must be removed so as to install flange. The length of the substitute pipe should be
approximately the same as that of the damaged pipe. For pipelines connected with integral
joint, the repair is usually done by adding short joints, but not cut off the integral joint and then
add field thread. The substitute pipe should be a little bit longer than the damaged pipe in order
to install short joint. The short joints used for this kind of repair are of different lengths, like
50mm-300mm and 600mm-3000mm.
Fig.8.0
Fig.8.1
Pressure testing must be carried out before the installed GRE pipelines are put into use to
ensure line integrity. During the testing, try to avoid pressure fluctuation or water hammer,
because pressure fluctuations and water hammer will generate pressures that are several times
or tens of times of the working pressure or pressure ratings of the pipe or fittings.
Do not use air or other gas to do pressure testing, otherwise very dangerous
results will occur. Please contact Xinda for issues with pressure testing.
1. Frequency
In case of a large or complicated installation project, it is suggested that pressure testing
be done when a section of the pipe is installed. Xinda recommends that the first test should
occur when the first 300m pipe is installed, so to make sure that the installation techniques
meet the requirement. This is also very important for installation people who have not installed
the GRE pipelines of the same specs and pressure ratings to know about the installation
regulations and procedures, improve their installation techniques and to build up their
confidence. Please contact Xinda for any problems.
2. Filling the system with water
Use water as pressure media. The pressure for testing should be the working pressure of
the system or the pressure rating of the pipes, but should not exceed 1.25 times of pipe
pressure ratings. For pipes that have been 100% hydrotested in Xinda factory, the maximum
pressure for testing the pipes after being installed will be the pressure rating of the pipes.
When carrying out hydrostatic tests to GRE pipes, the pressure may not stay stable due to
sunlight, wind or changes of ambient temperatures, because these factors will cause expansion
or contraction of the liquid inside the pipes. If pressure fluctuation is too large, it may be
caused by air existing inside the system.
In view of safety precautions, hold down the middle of each pipe with sufficient backfill
or sand bags prior to pressure testing, but leave all the joints and fittings exposed, so as to
detect leakage during testing. If the pipes are not backfilled in situ, or not overlain with sand
bags, then do not pressure test. If it is required to install thrust blocks, then the blocks should
be constructed and buried before testing.
It is very important to pressurize slowly. Please remember: fast pressurization may
damage the GRE pipe, because the impact generated by fast pressurization will exert too high
pressure on the pipes.
3. Pressurization
It is recommended to increase the pressure at 0.7MPa per min till test pressure. This rate
should not only be kept at the initial testing, but also for pressuring the pipes later (like when
the pump is repaired) or for re-pressurizing the pipes after they are put into use again.
When pressurized to the test pressure, stop pressurization, and observe for 10min. If
pressure drop does not exceed 1% of the test pressure, and there is no leakage at the joints or
fittings, then decrease the pressure to the working pressure of the system and hold for 4 hrs;
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conduct visual inspection to the appearance of the pipes; pipes with no leakage will be deemed
as up to standard.
In case of leakage, the pipe will be pressure tested after repair.
4. Safety Precautions
Please carefully read the following safety considerations:
Just like any other systems being pressure tested, take proper protective measures
during testing. Pipeline systems should be installed and pressure tested in strict
accordance with regulations and procedures; no negligence is allowed; and do not risk
peoples lives or loss of properties.
Xinda suggests that pipelines, after being installed, should not be pressure tested
with air or other gases. GRE pipes are light in weight and are flexible, so the problems of
GRE pipes are different from those of steel pipes. In case that air other gas is used for
testing, and if it fails, then, due to sudden release of stored energy, the whole system will
shake and vibrate. Enormous energy may cause severe personal injuries to the people on
site and may cause serious loss of pipelines or other properties.
* If customers violate the abovementioned operation regulations and procedures and
safety considerations, or use air or other gas for pressure testing, then Xinda will bear no
responsibility for product quality and warranty provisions contained in the contract or for any
personal injuries, damages to equipment, pipelines or other individual properties or for any
civil disputes caused thereby.
If, under some circumstances, air or other gas has to be used as testing media, Xinda
will recommend testing methods and safety considerations, so as to minimize the risks; but
Xinda will have no responsibly for any losses or injuries so caused, and the risks relating to
such pressure testing will be borne solely by the customer.
Chapter X
Transportation of Gases
Xinda GRE pipeline systems can carry most of the compressed gases(1), sulfur-bearing
or sweetened natural gases, air, SO2, N2, CO2(2) and H2S, etc. but care should be taken for the
following:
1. Surface Transportation
If it is planned to use Xinda GRE pipes for surface transportation of gases, please contact
and consult this Company.
2. Buried Transportation
The burial depth of the pipes should be at least 1m deep for buried
transportation.
1) Buried transportation of toxic or inflammable gases
If GRE pipes are used to transport toxic or inflammable gases like SO2, H2S or methane,
etc. Xinda suggests that safety factors be increased, and the pipelines should be carefully
designed and installed. The safety factor suggested by Xinda is at least 1.5 times of pipe
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pressure rating (i.e. 1.5:1). For instance, in case of 10MPa working pressure, then the pressure
rating of the pipes used should not be less than 15MPa.
GRE pipes can be used under pressure ratings, but when transporting toxic or
inflammable gases without other special design or safety precautions, then the safety
factor proposed by Xinda should be used, and the maximum working pressure should not
be over 10MPa.
2) Buried transportation of non-toxic gases
Xinda suggests that, when transporting non-toxic gases, a safety factor of 1.25:1 should
be used. For instance, if the estimated working pressure is 11MPa, then the pressure rating of
the selected GRE pipe should not be less than 14MPa.
3) Buried transportation of solution gas
Use 1:1 safety factor in this case; but for every 2% of gas dissolution, the safety factor
should be increased by 1%. For instance, in case of 4% of CO2 solution in the pipe, the safety
factor required for the pipe will be 1.02:1.
3. Joining the pipelines
For pipelines carrying high gases, it is suggested that 8rd or 10rd external upset long
threaded joint be used. Some other connection methods for pipe joints and the effectiveness of
sealing compound are favorable; the application of these depends on the objects, safety factors
and industrial specifications. These cases fall beyond the scope of this Installation Instruction.
(1) If GRE pipelines are used to carry O2, please contact Xinda.
(2) The present data shows that anhydrite cured GRE pipes cannot be used for
transportation of CO2 with over supercritical pressure. Supercritical pressure is defined as
7.5Mpa (1,085psi) at 31oC.
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