Pioneer in GRP Pipe Installations

1. Pioneer in GRP Pipe Installations Email:info@cesl.in Web:www.cesl.in

2. Agenda • About Organization • GRP Pipes • Transportation and handling of GRP Pipes • Storage of GRP Pipes • GRP Pipe Joining Systems • Joint Methods • Testing • General Safety Recommendations • Personal Hygiene • Field Hydro Testing of Above Ground Pipes • Causes for pressure drop – Hydro Testing • Statutory Documents • Client Details Email:info@cesl.in Web:www.cesl.in

3. AMIBITION • Goal / Vision • About partners • Experience • Achievements – in few lines • Market Share Email:info@cesl.in Web:www.cesl.in

4. About Organization Email:info@cesl.in Web:www.cesl.in

5. Aravindan Sivakumar.C. P Hari Natarajan Site Managers & Site Engineers Safety Engineer Stores & Maintenance Team Supervisors Supervisors Quality Team & Additional Technicians Technicians Technicians About Organization Email:info@cesl.in Web:www.cesl.in

6. GRP Pipes • GRP piping systems are time tested and it’s proven their durability and value in stony environments and brutal applications for decades • Long life:It has a minimum life of 50 years. The smooth inner surface is maintained throughout the entire life of the pipe. • Cost effective:10 % -15 % cheaper than steel pipes & 20% - 30% percent cheaper than pre-stressed cement concrete pipes. • Light weight: GRP pipes weights only 25 % as much as similar steel pipe and 10 % as much as similar concrete product. GRP pipes are light weighted, hence easier handling, faster installation and low transportation costs. The use of heavy equipment is practically eliminated. Email:info@cesl.in Web:www.cesl.in

7. GRP Pipes • Dimension stability: GRP piping system can maintain the required critical tolerances of the most demanding structural and piping application. The materials need the most stringent material stiffness and dimensional tolerance. • Strength to weight ratio:The GRP pipe has excellent strength to weight properties. When the ratio of strength per unit of weight is considered, GRP composites surpass iron, mild steel, HDPE (High-density polyethylene) and PVC (Poly Vinyl Chloride). • Very low friction factor:Value of 'C' in Hazen Williams equation for calculation head loss due to friction in pipes is 150-160 for GRP pipes against 120-130 for steel pipes. Thus, the low friction coefficient and the hydraulic characteristics of GRP pipes lead to significant saving in pumping costs. • Low maintenance cost: No maintenance cost due to absence of corrosion, zero replacement. Email:info@cesl.in Web:www.cesl.in

8. GRP Pipes • Corrosion resistance: GRP piping is having anti-corrosion system in both inside & outside. These pipes has been used for handling dilute acids, saturated brine, organic solvents and other corrosive chemical but there is a zero corrosion as result additional lining and exterior coating are not required. • Low thermal conductivity: Low thermal conductivity of GRP pipe not only causes low temperature losses but also in many cases eliminates condensation or the need for additional thermal insulation. • Installation benefits: GRP pipes are light weight, hence it is easy for installation. These can be manufactured up to 12m long to speed up the installation and eliminates up to 75% of the joints compare to any other materials, hence handling & installation is easier than any other products. GRP pipes are meager heaviness hence it’s reduce the expensive installation, labor and machinery expenditures.. Email:info@cesl.in Web:www.cesl.in

9. Transportation and handling • Prior to unloading of pipes from trailers, all items shall be inspected for any visual/transportation damages. • From the lay-down area to the trench site, the pipes shall be transported through trailers or by using of Hydra. • Single pipe must be unloaded and handled separately (one at a time) by using pliable straps, wide fabric straps, slings or ropes to lift single pipe. (Not using Steel Cables or Chains). • Individual pipe can usually be lifted with a single sling. • At any time during handling or installation of the pipe, any damage such as cracks, de-lamination or fracture occurs, the pipe should be repaired before the section is installed. Email:info@cesl.in Web:www.cesl.in

10. Transportation and handling of GRP Pipes Lifting pipe at two support points Transporting Pipe Lifting pipe at one support point Email:info@cesl.in Web:www.cesl.in

11. Storage of GRP Pipes • Pipe is generally stored on flat timbers to facilitate placement and removal of lifting slings. • The support timbers should have sufficient width to prevent point loads. • The maximum stack height is typically 8 ft. • When stored directly on the ground, the pipe weight should not be supported by the bell, coupling, or any other joint surface. • The pipe should rest on plane ground and should not rest on rocks, boulders, or other hard debris that may cause a point load sufficient to gouge, crack, puncture. • The pipe interior and all joining surfaces should be kept free of dirt and foreign particles. Email:info@cesl.in Web:www.cesl.in

12. Storage of GRP Pipes Storing Pipes Email:info@cesl.in Web:www.cesl.in

13. GRP Pipe Joining Systems • Unrestrained Pipe Joints • Fiberglass Couplings or Bell and Spigot Joints • Mechanical Coupling Joint • Restrained Pipe Joints • Coupling, or bell and spigot with a restraining device • Flange • Butt and wrap • Wrapped bell and spigot • Bonded bell and spigot Email:info@cesl.in Web:www.cesl.in

14. GRP Pipe Joining Systems 1. Cleaning Coupling 2.Installing Gasket 3. Lubricant Gasket 4.Cleaning Spigot Email:info@cesl.in Web:www.cesl.in

15. GRP Pipe Joining Systems Email:info@cesl.in Web:www.cesl.in

16. GRP Pipe Joining Systems Email:info@cesl.in Web:www.cesl.in

17. Tools for Butt & Wrap Lamination Joints • Measuring tape + pipe fitter's wrap-a-round + marker pen • Cleaning-rags • Angle grinder with diagrit or carborundum cutting disc (grain 24), a handsaw 24 teeth/inch, jig saw with a 14 teeth/inch blade • Angle grinder + sanding disc + flexible support disc • Resin, hardener and glass reinforcement + a pair of scissors • Gloves, brushes, rollers, dust masks in quantities as mentioned in the fit and laminating sets, a pair of safety glasses • Shelter (depending on the weather circumstances) • Hot air gun (paint stripper gun), digital temperature gauge, gas burner, field oven, heating blanket, variable energy control (rheostat) • Pipe clamp, bench and rubber strips (under chain clamp). • Generator Email:info@cesl.in Web:www.cesl.in

18. General Safety Recommendations • The practical or possible fabrication area is to be setup to perform as much of the fabrication work. • Local exhaust ventilation should be provided at areas of cutting and tapering to remove airborne dust and fibers. General dilution ventilation should be provided as necessary to keep airborne dust and fibers below the applicable exposure limits and guidelines. • Work area should be kept clean, including floor or other horizontal surfaces. Rinsing with water or sweeping with brushes or brooms (using floor sweep) is recommended. Brushes should be used to remove residue from shaved surfaces. • Always refer to the Material Safety Data Sheet (MSDS) prior to working with unfamiliar materials or if there are questions concerning the contents of the fiberglass pipe. Email:info@cesl.in Web:www.cesl.in

19. General Safety Recommendations • Barrier creme may be applied to the skin in areas, which may be exposed to shavings prior to beginning work. • Clean clothes should be worn each day. Do not wear clothing that has not been laundered to begin a work shift. More frequent changing may be required by conditions. • Long sleeved shirts or work suits should be used. • Gloves with elastic cuffs should be worn at all times. Replace worn or contaminated gloves as necessary. Gloves with flared, stiff cuffs act as a gathering funnel for shavings. • Pant legs should be worn outside work boots. If necessary for safety purposes, the pant legs can be taped to fit closely to the boot. Over-the-calf socks can be used to prevent chafing of the boot on the skin. Email:info@cesl.in Web:www.cesl.in

20. Personal Hygiene • Wash exposed skin with soap solution (liquid soap preferred) and cool water. • Use washcloth with “brushing” motion to remove dust or fibers. Do not scrub the Skin. This could result in the fibers being imbedded into the skin. • Rinse thoroughly with clean, cold water. • Apply lotion or cream to skin (non-detergent formulas such as baby lotion) to soothe Irritation or prevent further immediate irritation. Email:info@cesl.in Web:www.cesl.in

21. Field Hydro Testing of Above Ground Pipes • Fill with water at the lowest point in the line using a small diameter branch connection and vent the trapped air at the highest points. • Long straight sections may be vented using an inflatable ball or foam pig to expel any air and impurities. • After filling, the line must be pressurized gradually at 0.8 times working pressure dependent. • on the system and must be maintained for 24 hours allowing the pipe system to set. After the system is stabilized, the pressure must be raised gradually to the agreed field test pressure. Email:info@cesl.in Web:www.cesl.in

22. Causes for pressure drop • Temperature change - day as well as night • Leakage of valves, fittings, hydrants, etc… • Leakage of gaskets • Dirt at sealing ring • Wrong installation of O-ring (slip ring) • Pipes or fittings insufficiently blocked in the trench resulting in displacement • Air lock • Leaking test equipment • Leaking joint (adhesive bonded, rubber seal or laminated joint) • Leakage in fittings • Leakage of the pipe as result of damage (cracks) • Settlement of the pipe system Email:info@cesl.in Web:www.cesl.in

23. Statutory Documents Email:info@cesl.in Web:www.cesl.in

24. Statutory Documents Email:info@cesl.in Web:www.cesl.in

25. Statutory Documents Email:info@cesl.in Web:www.cesl.in

26. Client Details – Industrial Pipe Lines • Gujarat Electricity Board/ BSES – Dhuvaran (Various Dia up to 1200 mm). • Reliance Industries Silvassa–(Water intakes system & Fire Hydrant 80 mm to 30 mm) -7800Mtrs. • Shell LNG/Petron (Erection of 13500 Mtrs of Pipes of various dia up to 1450 mm from Sea water intake & reject, Potable water, DM water & Fire Hydrant). • Cairn Energy Pty Ltd. (Sea water bore well header injection line – onshore)- 900 Mtrs. • Hindalco Industries – 600 mm to1800 mm dia (Condenser to Cooling tower System) -1500 Mtrs. • HPCL Project, SALPG Vizag with L&T Chennai (100 mm to 450 mm dia for condenser cooling & Fire Hydrant server)- 1200Mtrs. • IVRCL Infrastructure & Projects Ltd- (100MLD Desalination Plant, Chennai – 80mm to 1600 dia)- 2100 Mtrs. • Reliance Energy Tech Engineers ltd, Dahanu Project-(Fuel Gas Disaffirmation sea water lines, from 50 mm to 1800 mm dia)- 3300 Mtrs. Email:info@cesl.in Web:www.cesl.in

27. Client Details – Cross Country Lines • Bharuch Eco Aqua Industries ltd with Aban Engineering ltd-(Engineering, Logistics & erection of 800 mm dia GRP pipes of 45 Kms). • Hindustan Construction Co Ltd, Pune -(80mm to 400mm dia GRP pipes for 56.94 Kms). • Tata Hydro Power Ltd, Pune- (900mm dia GRP pipes for 1.8 Kms for Rain Water Harvesting System). • Navayuga Engineering Co Ltd Chennai for Chennai Petroleum Corporation ltd for Desalination project-(700 mm to 900 mm dia pipes – 28 kms). • Karnataka Urabn Water Supply & Drainage Board – 350 mm dia pipes for 1.6 Kms. Email:info@cesl.in Web:www.cesl.in

28. Technical Comparison among Different types of pipes for Sewage Application Water Proofing Email:info@cesl.in Web:www.cesl.in

29. Technical Comparison among Different types of pipes for Sewage Application Speed of Installation Email:info@cesl.in Web:www.cesl.in

30. Email:info@cesl.in Web:www.cesl.in

31. Email:info@cesl.in Web:www.cesl.in