INSPECTION  

AND  SUPERVISION  REQUIREMENTS:    

STEEL  VERSUS  GRP  PIPES  
 
MJ  Shand  
Aurecon,  Cape  Town  
 
ABSTRACT  
 
Independent   inspection   of   the   manufacture   and   laying   of   steel   and   Glass   Reinforced   Plastic  
(GRP)   pipelines   by   competent   independent   inspectorates   and   Resident   Engineering   staff   is  
essential   for   ensuring   that   the   pipelines   will   perform   satisfactorily   throughout   their   design  
lifetimes.    This  paper  examines  some  of  the  inspection  and  site  supervision  requirements  for  steel  
and  GRP  pipes  and  pipelines.  
 
1.   INTRODUCTION  
 
The  50  to  100  year  design  lifetime  of  a  pipeline  depends  on  the  correct  design,  and  also  on  the  
manufacture   of   the   pipe,   the   correct   handling   of   the   pipe   before   installation   and   the   correct  
installation.   These   principles   apply   to   all   types   of   pipes,   with   quality   control   of   the   manufacture  
and  installation  being  provided  by  appropriate  supervision,  inspection  and  testing  procedures.    
 
This  paper  examines  some  of  the  features  of  steel  pipelines  and  of  glass  reinforced  plastic  (GRP)  
pipelines   that   require   particular   engineering   skills,   or   inspection   and   supervision   of   their  
manufacture  and  installation.      
 
The  original  paper  was  published  in  Civil  Engineering  in  June  2010.  
   
2.   PIPE    MANUFACTURE  
 
2.1   Steel  Pipelines  and  Specials  
 
An   independent   inspectorate   is   frequently   appointed   to   check   the   manufacture   of   steel   pipes,  
including   the   type   of   steel,   the   plate   thickness,   the   factory   welds   and   the   finished   diameter,   for  
compliance   with   tolerances   and   testing   requirements.     Hydrostatic   pressure   tests   may   also   be  
specified  and  witnessed.  
 
The   coatings   and   linings   of   steel   pipes   are   necessary   to   protect   the   pipes   against   corrosion,   to  
ensure   their   longevity.   Therefore   the   steel   surface   preparation,   the   use   of   the   correct  lining   and  
coating   materials,   and   their   application   to   the   correct   thicknesses,   is   very   important.     It   is   also  
very   important   to   appoint   an   independent   inspectorate   to   witness   the   lining   and   coating   of   steel  
pipes  in  the  factory,  and  to  undertake  testing  for  compliance  with  the  specifications.  
 
Steel   specials   are   usually   manufactured   in   a   separate   factory,   with   the   welding   undertaken   by  
suitably  coded  welders  and  subject  to  liquid  penetrant,  ultrasonic  and/or  radiographic  testing.  The  
coatings  and  linings  of  specials  are  often  the  same  material.  As  the  manufacture  of  the  specials  is  
generally  a  manual  process,  witnessing  or  checking  by  an  independent  inspectorate  is  particularly  
important.        
 
2.2   GRP  Pipes,  Couplings  and  Specials  
 
Flowtite  and  Vectus  GRP  pipes  are  manufactured  in  South  Africa.    The  Flowtite  pipes  discussed  
in  this  document  are  manufactured  by  the  continuous  process  shown  in  Figure  1.    The  materials  
used  for  manufacture  are  subjected  to  quality  control  testing  before  use  and  the  flow  of  materials  
during   manufacture   is   continuously   monitored   and   recorded.     The   dimensions   of   each   pipe   are  
checked  (particularly  the  ends)  before  rapid  hydrostatic  leak  testing  to  twice  the  working  pressure.    
Each  Flowtite  pipe  is  identified  by  a  unique  number  identifying  the  details  of  the  materials  and  the  
manufacturing   process.     Samples   are   taken   from   each   pipe   run   for   further   non-­destructive   and  
destructive   testing   in   the   factory.     Additional   assurance   of   the   quality   of   the   manufacturing  
process  can  be  provided  by  appointing  an  independent  inspectorate  to  witness  the  manufacturing  
process  and  review  the  quality  assurance  results.  
 

 
Figure  1:  Continuous  Process  for  Manufacture  of  Flowtite  Pipes  
 
It   is   important   to   be   aware   that   the   stiffness   of   Flowtite   pipes   can   be   increased   during   the  
manufacturing  process  at  minimal  additional  cost  by  increasing  the  thickness  of  the  “Core”  shown  
in  Figure  1.    Stiffnesses  of  SN2500,  SN5000  or  SN10000  can  be  specified.  
 

 
Figure  2:  Flowtite  (Reka)  Couplings  
 
The  Flowtite  (Reka)  couplings  shown  in  Figure  2  are  manufactured  using  the  same  process  as  for  
the   pipes   and   are   then   machined   to   the   correct   dimensions   with   close   tolerances.   Independent  
checking   of   the   coupling   tolerances   is   particularly   important   as   are   the   tolerances   of   the   pipe  
ends.  
 
GRP  specials  for  Flowtite  pipes  are  manufactured  by  hand,  and  the  tolerances  of  the  pipe  ends  
should  also  be  closely  checked.  
 
3.   PIPE  TRANSPORTATION,  UNLOADING  AND  STORAGE  ON  SITE  
 
Steel  and  GRP  pipes  are  generally  carefully  loaded  at  the  factory  to  ensure  that  they  will  not  be  
damaged   during   transportation.     It   is   very   important   that   pipes   are   carefully   unloaded   in  
accordance   with   approved   procedures   and   stored   on   site   so   that   no   damage   is   caused   to   the  
coatings  and  linings  of  steel  pipes  and  to  GRP  pipes.    Careful  visual  inspection  of  both  steel  and  
GRP   pipes   by   the   Contractor   and   the   Resident   Engineer   or   his   staff   is   essential   before  
acceptance  of  delivery  of  each  pipe,  with  particular  attention  being  given  to  the  inspection  of  the  
ends   of   the   GRP   pipes,   as   well   as   the   couplings   and   the   sealing   rubbers.     The   dimensions   of  
each  GRP  pipe  and  coupling  should  also  be  checked  before  acceptance,  particularly  if  this  was  
not  done  by  an  independent  inspectorate  in  the  factory.        
 
3.   CORROSION  PROTECTION  
 
3.1   Steel  Pipelines  
 
The  protection  of  steel  pipes  against  corrosion  is  essential  to  ensure  the  longevity  of  the  pipeline.    
The   planning   and   implementation   of   the   protection   measures   may   include   the   appointment   of   a  
specialist  consultant  to  advise  on  the  various  aspects  described  below:  
 
o   Arranging   and   interpreting   the   results   of   soils   resistivity   surveys   along   the   pipeline   route,  
which   includes   the   potential   corrosivity   of   the   soils,   and   stray   currents   arising   from   power  
lines  and  railways.  
o   The  specification  of  appropriate  linings,  coatings  and  other  protection  measures.  
o   The  planning  of  a  cathodic  protection  system  including  locations  for  impressed  current  (and  
associated   power   supplies),   the   location   of   insulating   flanges,   and   any   particular   insulating  
measures  that  may  be  required  at  scour  valves,  air  valves  and  isolating  valve  chambers  etc.    
Similar  measures  would  be  required  for  a  sacrificial  anode  protection  system.    
o   The  planning  of  temporary  ground  mats  or  other  measures  to  earth  the  pipeline  where  this  is  
parallel   to   a   power   line   and   dangerously   high   currents   could   be   generated   in   the   pipeline  
during  construction.  
o   Planning,   commissioning   of   specialist   contractors   and   interpretation   of   specialist   surveys  
during   construction   to   facilitate   the   identification   of   defects   in   the   pipe   coating,   jointing   and  
specials  to  be  rectified.      The  survey  methods  might  include:  
-­   Pipeline  Current  Mapping  (PCM)  
-­   Direct  Current  Voltage  Gradient  (DCVG)  
-­   Closed  Interval  Potential  Survey  (CIPS)  
 
3.2   GRP    Pipelines  
 
GRP  pipes  are  not  subject  to  corrosion  unless  steel  specials  and  Viking  Johnson  type  couplings  
are  utilised,  in  which  case  these  should  be  appropriately  protected.  
 
 
4.   LAYING  AND  JOINTING  
 
4.1   Steel  Pipelines  
 
The   welding   of   the   joints   of   steel   pipes   must   be   undertaken   by   coded   welders   and   an  
independent  inspectorate  should  be  appointed  for  the  following:  
 
o   Liquid  penetrant  testing  of  welds  
o   Radiographic  testing  of  welds  
o   Ultrasonic  testing  of  welds  
o   Monitoring   and   inspection   of   the   preparation   of   the   steel   for   the   internal   and   external   joint  
protection,  and  testing  of  the  joint  protection  measures.    
o   Inspection   of   coating   and   lining   for   damage   and   holiday   testing   including   monitoring   of  
approved  repair  procedures,  checking  and  testing  of  repairs.  
 
It   is   important   that   the   X-­Ray   test   results   should   be   available   as   soon   as   possible   so   as   to  
minimise  the  length  of  pipe  that  is  exposed  and  potentially  subject  to  flotation.    This  is  discussed  
below.  
 
4.2   GRP  Pipelines  
 
Each   GRP   pipe   should   be   very   carefully   inspected   for   damage   prior   to   installation,   and  
particularly   damage   to   the   ends.     Any   repairs   should   be   approved   by   the   manufacturer   and  
should  be  witnessed  for  compliance  with  their  requirements.  
 
The  Resident  Engineer  should  check  that  the  Contractor’s  pipe  laying  staff  have  been  trained  by  
the  pipe  supplier,  and  have  received  competence  certificates.    He  should  also  witness  the  jointing  
of  each  pipe,  and  particularly  ensure  that  the  alignment,  angular  deflection  and  offset  (step),  are  
checked   for   compliance   with   the   manufacturer’s   requirements.     He   should   also   check   that   the  
pipes  are  seated  in  the  couplings  in  accordance  with  the  “insert  up  to  here”  lines,  which  should  be  
drawn  on  the  pipes  as  indicated  in  Figure  3.  
 
 

 
Figure  3:   Jointing  of  GRP  Pipes  (note  “insert  up  to  here  lines”  on  pipes)  
  
5.   BEDDING  AND  SELECTED  BACKFILL    
 
The   bedding   and   backfilling   requirements   for   steel   and   GRP   pipes   are   similar   as   both   of   these  
types   of   pipes   are   flexible.     Therefore   it   is   very   important   that   the   correct   bedding   and   selected  
backfill   materials   are   used,   that   the   specified   compaction   is   achieved,   and   that   the   pipe   is  
checked   for   out   of   roundness   tolerances.     Close   inspection   of   these   processes   is   essential   to  
ensure   that   satisfactory   compaction   is   achieved   beneath   the   pipes,   and   that   the   pipes   are   not  
damaged.    
 
It  is  also  important  to  note  that  steel  and  GRP  pipes  are  particularly  vulnerable  to  flotation  when  
only  the  bedding  and  selected  backfill  have  been  placed,  as  a  relatively  small  volume  of  water  is  
needed   to   saturate   this   material   and   cause   the   pipeline   to   float   as   indicated   in   Figure   4.    
Therefore  it  is  very  important  that  the  length  of  exposed  pipe  is  minimised  and  that  the  full  depth  
of  backfill  is  placed  as  soon  as  possible.    The  Resident  Engineer  should  ensure  compliance  with  
this  aspect  of  the  specification.  
 

 
Figure  4:  Steel  Pipeline  Subject  to  Flotation  
 
6.   VALVE  AND  AIR  VALVE  CHAMBERS  
 
The   design   of   valve   chambers   for   GRP   pipes   should   make   provision   for   potential   differential  
deflection,  which  should  nevertheless  be  minimised  by  suitable  compaction.    It  is  also  important  
that   only   GRP   COD   pipes   (marked   with   a   white   line)   should   be   cut   on   site,   unless   cutting   of   a  
non-­COD  pipe  is  approved  by  the  manufacturer.  
 
7.   HYDROSTATIC  PRESSURE  TESTING  
 
The  requirements  for  the  hydrostatic  pressure  testing  of  steel  and  GRP  pipelines  are  similar  and  
in  both  cases  may  require  the  provision  of  special  arrangements  to  confine  testing  to  the  specified  
lengths.    In  the  case  of  GRP  pipes  it  is  also  essential  that  the  first  1000  m  or  lesser  length  of  pipe  
laid  should  be  pressure  tested  immediately  to  ensure  that  the  laying  procedures  are  correct.        
  
8.   CONCLUSIONS  
 
The  long  term  performance  of  a  welded  steel  pipeline  is  dependent  on  defect  free  welding,  on  the  
long   term   integrity   of   the   lining   and   coating,   and   in   many   cases   also   on   the   correct   long   term  
functioning   of   the   cathodic   protection   system.     Therefore   it   is   strongly   recommended   that   a  
specialist  corrosion  consultant  is  appointed,  and  that  independent  inspectorates  are  appointed  to  
check  the  integrity  of  the  welding,  coating  and  lining  both  in  the  factory  and  on  site.      
 
The  performance  of  GRP  pipes  is  also  dependent  on  their  correct  manufacture,  and  therefore  it  is  
recommended  that  an  independent  specialist  inspectorate  is  appointed  to  check  the  manufacture  
of  GRP  pipes.    The  Contractor  should  be  trained  in  the  handling  and  laying  of  GRP  pipes  and  the  
Resident  Engineer  and  his  staff  in  the  site  inspection  procedures  to  ensure  the  long  term  integrity  
of  the  pipeline.    
 
The  lifetime  benefits  for  pipelines  that  are  provided  by  independent  inspection  and  by  supervision  
with  well  trained  and  experienced  Resident  Engineering  staff,  far  outweigh  the  costs.