Installation Manual - GRE PIPE - For Marine - Rev.2

HYUNDAI LIFEBOATS CO.
,LTD
Installation Manual of HGP
PIPE
For Marine

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HGP
GRE PIPE

INSTALLATION MANUAL OF

HGP

GRE PIPE

FOR MARINE
Complete Pipe System Solutions
Marine Offshore Industry Oil & Gas
Underground

HYUNDAI LIFEBOATS CO.,LTD
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For Marine

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HGP
GRE PIPE
Content

1. Introduction

2. Jointing Pipes
2.1 Butt and Wrap (Overlay, Laminate) Joint
2.2 Bell & Spigot joint (Adhesive Bonding Joint)
2.3 Flanged Joint
2.4 Flexible Steel Coupling
2.5 GRE Expansion Coupling Joint

3. U.V. Resistance

4. Supports, Anchors, And Guides
4.1 Six basic rules
4.2 Guides Support
4.3 Fixed Support
4.4 Flange Frame
4.5 Support
4.6 Maximum Support Span
4.7 Maximum Alignment Allowance

5. Installation in Hull Block

6. Squareness Tolerance

7. Repair

8. Cutting Edge

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1. Introduction
This manual is written as a guide for supervisors and field engineers and explains the correct
methods of handling and installing HGP
(Hyundai GRE PIPE) GRE PIPE systems. In addition

this manual provides guidance on how to avoid and solve problems during installation. Glass
Reinforced Plastic (GRE) pipe systems offer, by their specific nature, many applications and
advantages compared with other materials, to carefully observe these guidelines. Please note
that these instructions are for guidance only. Specifications written for a particular project will
have precedence.
Although the procedures written in this manual are as complete as possible, it is not possible to
describe all the different circumstances you may meet. For this reason our experienced
supervisors may vary the described procedures in order to achieve an optimum installation.

2. Jointing Pipes

2.1 Butt and Wrap (Overlay, Lamination) Joint

HGP
pipe sections are typically jointed to overlay method. Other jointing systems such as
flanges, Spigot joints (bonding joint), Coupling (Mechanical, Sliding Expansion) may also be
used for jointing HGP
pipe. HGP
jointing system on pipe and overlay is all butt joint unless

otherwise requirement

The Butt & Wrap joint consists of plain-ended pipes and fittings, prepared, aligned and
laminated with reinforcing fibers and adhesives. The pipe ends are abutted end to end, aligned
on the same centerline, and the joint over wrapped with layers of resin impregnated glass-fiber
materials. Before work on laminated joint is started, all necessary equipment for completing the
procedure must be available. A jig or other holding device should be used to ensure that the

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pipes are maintained with joint faces held tightly together without offset. The restraints should be
left in place until the joints has fully cured.

All butt welds are to be made in accordance with ASTM C582 or NBS Specification PS 15-69.

The actual procedure will be performed as follows:
Procedure for Butt & Warp (Overlay, Laminate)
1. Cutting , Puttying on the pipe and Grinding
- Measure off length of pipe (or duct) required and using a
marker and straight edge, draw a line completely around
surface to be cut
Wipe the sanded area with a clean, dry, lint-free cloth, and
avoid touching the surfaces with bare hands or dirty gloves.
Do not use solvents.
- For 24" and larger piping, use a die grinder to sand the
interior surface of the pipe 3" from the joint ends. This will
provide a proper bonding surface for applying the veil, mat,
and resin to the pipe's interior surface.

2. Preparing fiberglass

- Lay out fiberglass mat strips on work table. Length of each
strip(fiberglass) should be 50mm longer than circumference of
the pipe. The width of strip (fiber-glass) in accordance with
HGPmanual (See table for length of Laminate). The width of
the first layer shall be 50mm minimum. The woven roving shall
not be greater in width than the layer of chopped strand mat.

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3. Laminating

- The precut fiberglass kit is then saturated with catalyzed
resin along side of joint area
4. Overlaying
- Pipe will be placed in the position in which they are to be
welded. Epoxy will be applied to the joint seam. This will
eliminate resin flow through the crack as the actual weld is
applied. Make certain work area and surfaces are as clean
as possible and dry.
- The precut fiberglass kit is then saturated with catalyzed
resin along side of joint area
- The saturated weld is then picked up like a bandage and
wrapped around the joint
5. Remove bubble

- A serrated roller is then used to smooth the weld and remove
any air bubbles that may have been trapped beneath the weld
when applied

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5. Curing

- For complete curing, it needs heating pad.
Wrap up installation point with a heating pad and increase the
heat up to 80~90c and keep maintain temperature during 2
hours or more.
6. U.V(ultraviolet) Coating

- A final U.V(gel coat) is applied after the weld has taken its
initial cure.(Option), In case of underground and inside of
structure, it is not necessary.

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Pipe
Size
5 bar 7 bar 10 bar 12 bar 15 bar
(DN)
mm
t
(mm)
L
(mm)
t
(mm)
L
(mm)
t
(mm)
L
(mm)
t
(mm)
L
(mm)
t
(mm)
L
(mm)
50 5 100 5 100 5 100 5 100 6 120
100 5 120 5 120 5 120 5 130 6 170
150 5 150 5 150 5 150 6 160 6 200
200 5 200 5 200 5 200 7 210 8 230
250 6 220 6 220 6 220 8 250 10 290
300 6 250 7 250 8 250 9 280 11 350
350 7 300 7 300 9 300 11 330 13 410
400 7 330 7 330 10 330 12 380 15 470
450 7 350 8 350 11 350 14 420 17 520
500 8 400 9 400 13 400 15 466 19 580
600 9 500 11 500 15 500 18 560 23 700
650 10 400 12 400 17 550 20 610 25 760
700 11 450 12 450 18 600 21 650 27 810
750 11 480 13 480 19 650 23 700 29 870
800 12 500 14 500 20 680 24 750 30 930
850 12 550 15 550 22 700 26 800 32 990
900 13 600 16 600 23 750 27 840 34 1,050
950 13 650 180 650 25 800 29 890 38 1,160
1,000 13 650 18 650 25 800 30 940 38 1,160

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Pipe
Size
5 bar 7 bar 10 bar 12 bar 15 bar
(DN)
mm
t
(mm)
L
(mm)
t
(mm)
L
(mm)
t
(mm)
L
(mm)
t
(mm)
L
(mm)
t
(mm)
L
(mm)
1,300 17 850 23 850 33 1,050 40 1,220 50 1,510
1,400 18 900 24 900 34 1,100 41 1,310 51 1,570
1,500 19 950 27 950 38 1,200 46 1,400 57 1,740
1,600 21 1,000 29 1,000 42 1,300 50 1,500 63 1,920
1,700 21 1,000 29 1,000 42 1,300 52 1,600 63 1,920
1,800 23 1,050 32 1,050 46 1,400 55 1,680 69 2,090
1,900 25 1,100 35 1,100 50 1,550 68 1,800 74 2,270
2,000 25 1,100 35 1,100 50 1,550 61 1,870 74 2,270
2,200 29 1,300 40 1,300 57 1,750 65 2,050 86 2,620
2,400 30 1,400 43 1,400 61 1,900 73 2,240 91 2,790
2,600 33 1,450 46 1,450 66 2,050 79 2,420 99 3,020
2,800 34 1,500 48 1,500 69 2,100 86 2,610 103 3,140
3,000 38 1,650 53 1,650 76 2,400 91 2,790 114 3,490
Note 1: The recommended maximum tolerance of butt joint gap will not be over than below
dimensions;

Nominal Pipe Size gap (mm)
For 15mm through 500mm 2.0
For Lager than 1000mm 4.5

Note 2: If necessary, over 600mm pipe may be structural laminate in pipe internal. (2mm)
Note 3: putty and beveling works are used in severe chemical (ex: acid, severe corrosion fluid)
fluid piping and piping that is not accessible inside. It is not necessary for putty and beveling for
piping in water supply (Sea water, Demi. water, Potable water, etc)
Note 4: In case of 500mm or under, please, only fill V-notch between pipes with putty. Dont fill
gap with putty.

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2.1.1 Tools for Butt Joint

For butt and wrap joints the following is needed:

- Measuring tape - Gloves, brushes
- Marker pen - hardener and glass reinforcement
- Cleaning-rags Steel rollers , Paint rollers - A pair of scissors +knife
- Grinder - Dust masks
- Sanding - Heating Pad(Important Item)

2.1.2 Gel time

Since many variables affect the cure of the resins. In case of HGP GRE PIPE for marine, Gel
Time is as in the following.

EPOXY Resin: SE-510B
EPOXY Hardener: SH-420B

Typical Gel Time for Resin ()
Temperature
()
Gel Time
(hour)
Mixing (%)
SE-510B SH-420B Remark
80~90 2 hours 100 40 100 : 40

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2.2 Bell & Spigot joint (Adhesive Bonding joint)

Procedure for Bell & Spigot joint (Adhesive Bonding joint)
1. Determine the desired length and Cut the pipe
- Scribe the pipe using a pipe fitters wrap-around.
- When holding the pipe in a vice, use rubber padding or
similar to protect the pipe from damage.
- Contaminated pipe surfaces should be cleaned prior to
machining the pipe ends.
- Use a hacksaw or an abrasive wheel.
- Ensure that cut ends remain within the tolerances
- These tolerances can be checked by using e.g. the arbor of
the shaver flush with the cut end of the pipe.

2. Support and fix the pipe firmly
- Prevent the pipe from being damaged
3. Adjust the shaver to the required pipe size.
- Be sure to use the correct taper angle and Length
-Take care when shaving the first layer, because the pipe-
wall may be not be equally thick on all sides.
4. Shave the taper spigot.
- Maximum shaving depth / feed is 2 mm.
- Repeat the shaving action until the required spigot diameter /
spigot nose thickness is achieved.
- Due to possible tolerance spreading it is recommended to
use a nominal sized dummy bell end. This may avoid too long
or too short assembly lengths. If the insertion depth in the
dummy is too small, the spigot end to be shaved has to be
adjusted.
- Shaving the diameter of a taper spigot 1 mm smaller, with a
taper angle of 0.5 will result in 23 mm additional insertion in

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the socket. For a taper angle of 1.75 this is 33 mm.
5. Sand all bonding surfaces.
- Thoroughly sand within 2 hours from assembly.
- Use flapper wheel sanders with a small drilling machine
(1700 - 2000 rpm) or emery cloth with a grid of 60.
- Bonding surfaces must be dry and clean before sanding.
Refer to step 10.
- Sanded surfaces must have a dull, fresh finish, not a
polished look.
- Check the assembly length and mark pipe and fitting for
alignment of elbows, flanges, etc.
- Use a clean dry cloth or brush to remove sanding dust etc.
- Do not touch the sanded surfaces after sanding and
cleaning.
6. Prepare the adhesive.
- Add the curing agent to the resin.
- Stir thoroughly until no streaks are visible and the mixture
has an even colour (after 2 to 3 minutes).

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7. Apply a thin layer of adhesive
- Use a spatula or an adhesive scraper for applying the
adhesive.
- All surfaces to be bonded (sanded areas) must be
completely covered with adhesive, approximately 0.5 mm in
the bell and 1 mm on the spigot.
- A too thick layer of adhesive may result in flow restrictions
8. Insert the spigot in the bell.
- When inserting the spigot pay attention to the marks and
position and keep the joint together. Letting the spigot slip
back or turning the spigot after complete insertion may result
in a bad joint.
- For removing excessive adhesive, also from the inside if
possible, a spatula may be used.
- Wrap the required size HGP heating blanket around the joint
keeping the power supply cable free from the blanket.
- Make sure the voltage is correct.
- Good blanket to pipe surface contact is essential for proper
curing of the adhesive
- Open pipe ends should be closed during curing preventing
cooling down by draught

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Maximum tolerance on squareness of cut spigot end
Pipe Size Range Tolerance
mm inch mm
25 100 1 4 1.5
150 - 400 6 -16 3.0
400 1000 16- 40 5.0

Adhesive per joint
PIPE Size Spigot Length Taper Angle Adhesive
mm mm degrees g
50 30 0.5 80
100 52 0.5 80
150 57 0.5 125
200 64 0.5 125
250 70 0.5 300
300 76 0.5 300
350 89 1.75 450
400 102 1.75 500
450 111 1.75 500
500 127 1.75 600
600 178 1.75 600
650 178 1.75 900
700 178 1.75 1200
750 178 1.75 1500
800 178 1.75 2000
850 178 1.75 2500
900 203 1.75 3000
950 203 1.75 4000
1,000 410 1.75 5000
Note1 : Adhesive Packing Kit Resin : 450g, Hardness : 600g
Note2 : Adhesive Cure time - 2hr(Heating Pad), 24hr(Natural Curing)

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2.3 Flanged Joints

Flanged joints are used in piping systems for easy of installation and connection to equipment
or other material. All flanges are designed for the requirement pressures specified by the client.

Connecting to FF Flange
Full Face Gasket
Full Face Flange

Full Face Gasket
Full Face Flange

All flanges manufactured by HGP
are continuous glass fiber reinforcing from the hub into the
flange face.
Manufacturing method for flanges are filament winding method and hand lay-up & contact
molded with smooth radius.

The Neck flange type was used for the pipes below 12, and Lap joint flange was used for the
pipes over 12
HGP
standard is a bolting pattern which flanges are manufactured in accordance with

international codes. Bolting dimension system such as ANSI, AWWA, DIN, J IS can be supplied.
Flat face GRE flanges must be bolted to flat face companion flanges, with full gaskets or O-ring.
HGP
flanges thickness design in accordance with ASME, ANSI standards. (If you want to
detail information see the our Manufacturing guide)

GRE flanges should be jointed according to the following procedure;

1. Thoroughly clean the flange face and O-ring groove.
2. Ensure the O-ring gasket is cleaned and undamaged. Do not use defective gaskets.

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3. Position O-ring in groove and secure in position with small strips of adhesive tape.
4. Align flanges to be jointed.
5. Insert bolts, washers and nuts. All hardware must be cleaned and lubricated to avoid
incorrect tihtening. Washer must be used on the all GRE flanges.
6. Using the torque wrench, tighten all bolts to 40 N.m(4 kg.m) torque 20 N.m(2 kg.m) for
small diameter in accordance with standard flanges bolt tightening sequences.

7. Repeat this procedure, increasing torque untile the recommend value for bolt torque. Do not
exceed this torque. To do may cause permanent damage to GRE flanges.
8. Check bolt torques one hour later and adjust to recommend bolt torque for each size of
flanges

GASKET

1. NBR Gasket (Standard)
- Maximum service temperature : 100C
- Thickness : 3t
- Color : Black
Used by itself or in combination with other outstanding polymers, NBR is ideally
suited for the manufacture of all Connecting to RF Flange

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2. HNBR Gasket (Option)
- Maximum service temperature : 151 C
- Thickness : 3t
- Color : Black
Similar to NBR, HNBR provides broader thermal and chemical resistance.

3. EPDM Gasket (Option)
- Maximum service temperature : 150 C
- Thickness : 3t
- Color : Black
Incompatible with mineral oils, EPDM is resistant to many fluids that are
incompatible with other elastomers, including steam and brake fluid.

Connecting to RF Flange

If raised face flanged equipment is connected to GRE flanges, a hard plastic or metal filler ring
must be added to provide a flat connection surface, in figure. The best material for filler ring may
be the same as the full face gasket material or the hardness shall be more than full face gasket
(EX: PE, PVC).

2.3.1 Bolt, Nut & Washer
All nuts, bolts and washers will be in accordance with piping material specifications.
Dimensional requirement for bolts and nut will comply with ANSI standard (inch or metric
Thread) and the length of bolts will be in accordance with ANSI B16.5. When jointing HGP

fiberglass products flanges to flanges of other material or manufactures, bolt length will be
calculated.

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2.3.2 Recommended Bolt Torque
Based on Full Face Flat Gaskets 15mm through 1000 mm and O-ring Gaskets 300mm through
2500mm diameter experience has shown these values to work. However, these values may be
increased 50% safely. Call HGP
before exceeding 100% of these values. Bolt torque must be

uniform within a 10% range of recommended values.
Note: Uniformity of bolt torque is critical.
<Flat Face Flange>
Bolt Torque Depend on Pressure Unit : kgm
Diameter 5 bar 7 bar 10 bar 12 bar 15 bar 20 bar
50 4 4 4 4 4 4
80 4 4 4 4 4 4
100 6 6 6 6 6 6
150 8 8 8 8 8 8
200 10 10 10 10 10 10
250 15 15 15 15 15 15
300 17 17 17 20 20 25
350 23 23 23 25 25 30
400 26 26 26 30 30 30
500 35 35 35 40 40 50
600 50 50 50 60 60 80
700 50 50 50 60 70 -
800 60 60 60 70 70 -
900 60 60 60 80 100 -
1000 65 65 65 100 100 -

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<RF Flange>
Bolt Torque Depend on Pressure Unit : kgm
Diameter 5 bar 7 bar 10 bar 12 bar 15 bar 20 bar
50 5 5 5 5 5 5
80 5 5 5 5 5 5
100 7 7 7 7 7 7
150 10 10 10 10 10 10
200 12 12 12 12 12 12
250 18 18 18 18 18 18
300 20 20 20 24 24 30
350 27 27 27 30 30 36
400 30 30 30 36 36 48
500 41 41 41 48 48 60
600 60 60 60 72 72 96
700 60 60 60 72 84 -
800 72 72 72 84 84 -
900 72 72 72 96 120 -
1000 76 76 84 120 120 -

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2.3.3 Recommend Procedure for Flange Installation
In butt joint (overlay) the flange to the GRE pipe, first ensure that the bolt holes are aligned with
those on the mating flange. Do not joint the pipe to pipe or fitting before flange connection. The
use of flat washers on all nuts and bolts must be required. The maximum allowable torque is
indicated on each flange and is also shown in Table (Bolt Torque Depend on Pressure). Full
face gasket materials, 3.0mm thick, with a Shore A hardness of 60 to 70 hardness are
recommended for HGP
fiberglass products flanges.

Procedure of Flange J oint

Cut pipe vertically & Grind
end of pipe by grinder

Cover adhesive inside of
flange and insert flange to
pipe.

Maintain level horizontally
by horizontal instrument and
curing by heating pad.

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Insert gasket between flange
and other side.
At last, fasten a bolt with a
nut as correct bolt torque.

2.4 Flexible Steel Coupling

When connecting HGP
GRE pipe to pipe, fitting and other pipe materials with different
diameter, flexible steel coupling are one of the preferred jointing methods. These couplings
consist of a steel mantle with an interior rubber sealing sleeve. They may also be used to join
HGP
GRE pipe sections together, for example in a repair or for closure.

Regardless of the corrosion protection applied to the steel mantle, the balance of the coupling
needs to be corrosion protection as well. Control of the bolting torque value of flexible steel
coupling is most important. Do not over torque as this may over stress the bolt or the pipe.
Follow the coupling manufactures recommended assembly instructions, but HGP
will be
recommended for bolt torque limits.

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2.5 GRE Expansion Coupling Joint

Expansion couplings are used to board ships to replace conventional steel mechanical
couplings. It does not require corrosion protection or maintenance.

Procedure of GRE Expansion Coupling joint

Pipes which is located at expansion
coupling is aligned.

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Install adaptor for expansion coupling to
each pipes by using taper/taper joint
method.
Adaptor which has two grooves is for
moving part, Adaptor which has three
grooves is for fixing part by key lock.

Insert two rubber-ring on each adaptor
and Lubricate entire surface of rubber-ring.

Insert key socket into each adaptor.

Key socket should be installed correct
direction, key hole direction should be
located on adaptor which has three
grooves.

Adjust key hole to locate on 3
rd
groove and
insert Key-Lock in to key hole.

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4. Supports, Anchors, And Guides

4.1 Six basic rules
There are six basic rules to follow then designing and positioning supports, anchors, guides.
These are described in the following paragraphs.

Rule 1 : Avoid point loads
Use curved supports fitted to contact the bottom 120 of the pipe and that have a maximum
bearing stress of 586kPa. Do not allow unprotected pipe to press against roller supports, flat
supports, such as angle iron or I-Beams, or U-bolts. Do not allow pipe to bear against ridges
or points on support surfaces. Use metal or fiberglass sleeves to protect pipe if these
conditions exist.

Rule 2 : Meet minimum support dimensions
Standard pipe supports designed for steel pipe can support fiberglass pipe if the minimum
support widths provided in Table are met. Supports failing to meet the minimum must be
augmented with a protective sleeve of split fiberglass pipe or metal. In all cases, the support
must be wide enough that the bearing stress does not exceed 586kPa.
Sleeves augmenting supports must be bonded in place using adhesives stable at the systems
maximum operating temperature.
Prepare all pipe and sleeve bonding surfaces by sanding the contacting surfaces.

Support Spacing vs. Specific Gravity
Specific Gravity of Liquid
0.75 0.90 1.00 1.10 1.25 1.50
Adjustment
Factor
1.05 1.02 1.00 0.98 0.95 0.91

Rule 3 : Protect against external abrasion
If vibrations or pulsations are possible, protect contacting surfaces from wear. When frequent
thermal cycles, vibrations, or pulsating loadings affect the pipe, all contact points must be
protected. This is typically accomplished by bonding a wear saddle made of fiberglass, steel,
or one half of a section of the same pipe to the wall.

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Rule 4 : Support heavy equipment independently
Valves and other heavy equipment must be supported independently in both horizontal and
vertical directions.

Rule 5 : Avoid excessive bending
When laying lines directly on the surface, take care to ensure there are no excessive bends
that would impose undue stress on the pipe.
Laminate
Vertical
Support
Wrong
Right

Rule 6 : Avoid excessive loading in vertical runs
Support vertical pipe runs as shown in figure. The preferred method is to design for pipe in
compression. If the pipe in tension method cannot be avoided, take care to limit the tensile
loadings below the recommended maximum tensile rating of the pipe. Install guide collars using
the same spacing intervals used for horizontal lines.

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Support
Member
Steel Cradle
Allows Movement in Axial Direction Only
Typical Guide
4.2 Guides/Sliding Support

The guide mechanism must loose so as to allow free axial movement of the pipe. However, the
guides must be rigidly attached to supporting structure so that the pipe moves only in the axial
direction. All guides also act as supports and must meet the minimum requirements for supports
as set forth in General Rules.

4.2.1 U-Clamp

1) Protection between pipe and clamp
2) Maintain a gap between pip and clamp
3) The sample shown here is not suitable for strong lateral force.

4.2.1 Double half-clamp

2) Maintain a small gap between pip and clamp to allow axial movement between pipe and
clamp.
3) Lining material shall be permanently fixed to clamp or restrained by clamp.

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4.3 Fixed Support

An anchor must restrain the movement of the pipe against all applied forces. GRP PIPE
anchors divide a pipe system into sections. They attach to structural material capable of
withstanding the applied forces. In some cases, pumps, tanks, and other similar equipment
function as anchors. However, most installations require additional anchors where pipe sizes
change and fiberglass pipe joins another material or a product from another manufacturer.
Additional anchors usually occur at valve locations, changes in direction of piping runs, and
major branch connections. Saddles and laterals are particularly sensitive to bending stresses.
To minimize stresses. To minimize stresses on saddles and laterals, anchor the pipe on either
side of the saddle or anchor the side run. Figure shows a typical anchor. Operating experience
with piping systems indicates that it is a good practice to anchor long, straight runs of
aboveground piping at approximately 90m intervals. These anchors prevent pipe movement due
to vibration or water hammer. One anchoring method features a clamp placed between anchor
sleeves or a set of anchor sleeves and a fitting. The sleeves bonded on the pipe prevent
movement in either direction. Sleeve thickness must equal or exceed the clamp thickness. To
achieve this, it often is necessary to bond two sleeves on each side of the clamp. Anchor
sleeves are usually 1 pipe diameter in length and cover 180 of circumference. Anchors act as
supports and guides and must meet minimum requirements for supports.

4.3.1 Light Anchor

2) Double nuts installation, locking and preventing excessive clamping force.
3) Gap between clamp and stopper shall not be greater than 3mm
4) Not suitable for vertical pipe due to support instability.

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4.3.2 Anchor

Rubber
Pad

2) Double nuts installation, locking and preventing excessive clamping force.
3) Gap between clamp and stopper shall not be greater than 3mm
4) Strength of the support structure is important.

4.4 Flange Frame
Flange Frames are used for supporting flanged valves and flanged heavy inline items
independently. Flange frames can also be installed to pipe flange for other supporting purpose.
The flange frame can be fully welded to structure, thus being a fixed type or anchor type support
also the flange frame can sit loose on a support base with guide bars, thus being a guide type
support.

1) Sufficient coverage of number of bolts
2) Flange frame shall be as short as possible
3) Reinforcement wedge plate if necessary
4) Bolted to flange prior to final secure to structure
5) It can be anchor, guide or rest.

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4.5 Support
To prevent excessive pipe deflection due to the weight of the pipe and the fluid, horizontal pipe
should be supported at intervals recommended in the support spacing Table (support spacing)
with adjustments for temperature and specific gravity.

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4.6 Maximum Support Span
Recommended maximum spans for HGP PIPE at operating temperatures 60C and
below are listed below. These spans are intended for normal horizontal piping
arrangements. The tabular values are for partial span that represent a compromise
between continuous and simple spans.

Pipe
(mm)
5 bar
Span (m)
10 bar
Span (m)
15 bar (m)
Span (m)
20 2 2 2
25 3 3 3
40 3.5 3.5 3.5
50 3.8 3.8 3.8
80 4.3 4.3 4.5
100 4.9 5.0 5.2
125 5.2 5.5 5.6
150 5.5 5.8 6.0
200 6.0 6.0 6.0
250 6.0 6.0 6.0
300 6.0 6.0 6.0
350 6.0 6.0 6.0
400 6.0 6.0 6.0
450 6.0 6.0 6.0
500 6.0 6.0 6.0
600 6.0 6.0 6.0
650 6.0 6.0 6.0
700 6.0 6.0 6.0
750 6.0 6.0 6.0
800 6.0 6.0 6.0
850 6.0 6.0 6.0
900 6.0 6.0 6.0
1000 6.0 6.0 6.0

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4.7 Maximum Alignment Allowance

Force to joint misaligned GRE piping will result in damage on fiber-glass components and/or
leaking at bonding joint. When fiber-glass piping is jointed, the misalignment shall not exceed
maximum allowable misalignment tolerances shown below.

Pipe Size
Maximum Tolerance (Base on 6m)
mm
20 ~ 100 mm 22
125 ~ 300 mm 18
350 ~ 500 mm 12
550 ~ 1000 mm 10

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5. Installation in Hull Block

HGP PIPE fabricated spools shall be placed into hull blocks in block stage. HGP PIPE spools
shall be installed into hull blocks after block painting and blasting. If HGP PIPE spool have to be
installed into bull block prior to blasting and painting, HGP PIPE spools shall be wrapped with
protection canvas or equivalent protection materials.

When HGP PIPE is exposed to the possibility of damage by falling objects, HGP PIPE shall be
protected by wooden plank on top. The protection wooden plank shall be secured.

During installation in hull block, HGP PIPE/SPOOL shall be handled with care, surrounding
hazards shall be observed all the time, thus to prevent;
1) Impact damage due to dropping to hull structure or collision with hull structure
2) Scratch damage when pipe/spool passing through a manhole and/or opening on non-
watertight bulkhead.

During block installation stage, it is recommended to
1) Not fully weld the bulkhead penetration piece so that adjustment at steel can be done at
later stage to accommodate minor piping misalignment.
2) Not fully weld the support structure so that piping alignment can be easily adjusted after
block joint.
3) Install metal expansion coupling or GRE expansion coupling on the pipe end in accordance
with predetermined location shown on lay out.

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6. Squareness Tolerance

Squareness of end cuts. B shall not deviate more than 3.0mm up to and including
600mm diameter and 5.0mm for diameters up to 1200mm.
Summary of Dimension Tolerance
Nominal
Dia.
(mm)
A
(mm)
Nominal
Dia.
(mm)
B
(mm)
Nominal
Dia.
(mm)
C
(mm)
D
(mm)
15 to 25 3.2 15 to 600 3.2
All Size 1.0mm/25cm 2.0
300 to 900 4.8 Over 600 4.8
Q
R

Tolerance of Manufacturing - Fittings
Nominal
Dia.
(mm)
A
(mm)
R
(mm)
L
(mm)
For
Angularlty
Tolerance
Nominal
Dia.
(mm)
Q
(mm)
15 to 200 1.5 1.5 1.5 15 to 100 0.8
250 to 600 2.3 2.3 2.3 125 to 200 1.5
650 to 750 3.1 3.1 4.8 250 to 400 2.3
800 to 1000 4.8 4.8 4.8 450 to 600 3.1
650 to 1000 4.8

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7. Repair

Typically, damaged pipe can be repaired quickly and easily by qualified personnel at a job site.
The repair design depends on the wall thickness, wall composition, application, and the type
and extent of damage. Do not attempt to repair damaged or defective pipe without consulting
the HLB.
Scrapes and gouges on the pipe exterior that are less than 10% the pipe wall thickness
generally require no repair, while deeper scrapes generally require repair. Repair for damage to
the inner layer depends on the damage depth. Scratches, scrapes, and abrasion that do not
penetrate through the entire liner layer generally require no repair.
This HLB Repair manual describes two methods for the eventual repair of HGP
glass fiber
reinforced pipe systems. Procedure 1 is applied when a small damage or large diameter on pipe
and fittings. Procedure 2 is applied for severe damage or small diameter on pipe and fittings.

HLB recommend that repair of pipe as following;

Procedure 1. Applied for a small damage on pipe 600mm through larger.
1. damage of pipe 2. Grinding

Before installation of the straight pipe and
fitting section the installer should inspect if any
damage has occurred due to transport or
storage. If damage on pipe and fitting installer
should be repaired in the field.
Damage area caused during transportation
and installation shall be grinded by grinder up
to inner face. The width of grind should be
enough in order to overlay on damage
location.

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3. Fill up with putty 4. Grinding

After grinding, fill up with putty at first. Hollow
space must be filled by high speed acid
resistant resin and Chopped Strand Mat.
After filled in hollow should be grind until
same level of the pipe outside.
5. Preparing and cutting of fiberglass
Lay out fiberglass mat strips on work table. The overlay length and width depends on the extent
and nature of the damage. Our recommend for Length and width of each strip(fiberglass) will be
longer than10 time of wall thickness at damage end(See Figure Damage of pipe ).
6. Apply resin on fiberglass
Mix prescribed amount of catalyst with required amount of resin in a separate clean container.
Resin will harden in about 20-30 minutes. After mixing the catalyst thoroughly, apply resin to
fiberglass mat by the brush or paint roller.
7. Overlay on pipe 8. Remove bubble

Pick up the completed weld fiberglass by one
end and center it carefully on the pipe. Apply
the taper end first with the narrowest fiberglass
on the pipe weld.
Be sure weld is centered, with care taken to
avoid wrinkles on the under or back side of
the weld. Finished joint should be built up in
successive layer uniformly and without air
bubble. Successive layers shall increase
uniformly to provide minimum total width of
overlay which meet the width of the last layer.
Do not move or disturb weld until it is
thoroughly cured

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9. damage of pipe
L

After overlaying finish, surface should be rough grind by sand paper grinder. After surface
grinding, pipe shall be coated by acid resistant or U.V protective gel coat resin. For top coating
reference is made to the HGP
U.V coating instructions. (See welding procedure on overlay

manual). Ensure that the complete laminate length L is observed on both sides of the damage
location. The total length of the laminate is larger than 10 times of the pipe wall thickness.

Procedure 2. Applied for severe damage on pipe 15mm through 500mm
1. Parch 2. Cutout and replace

Should severe or larger damage have occurred to existing pipelines, there is a risk of the
damaged section should be removed from the pipeline network. The length of cutting on pipe
shall be lager than damage area. The length depends on the extent and nature of the damage.
A diagram of the repair is shown below;

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3. Severe damage on the pipe & Cutting
W

The principle behind this method is that the pipe section containing the leak is cut out the
existing pipeline. Cutting piece of a length W shall be over 50mm on both sides of the
damage end line.
5. Assembly 6. Laminating

A new joint is trimmed to length W and installed in the existing pipeline using two laminate joints,
as described in the HGP
Field Laminate Instructions (See welding procedure on overlay

manual).

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8. Cutting Edge

The maximum gap between the pipe sections to be joined as following:

Maximum gap for Repair pieces
Application size (mm) Maximum gap (mm)
For 150 through 350 3.0
For 400 through 700 4.5
For 750 through 1,000 8.0

Installation Manual - GRE PIPE - For Marine - Rev.2

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HYUNDAI LIFEBOATS CO.

(Hyundai GRE PIPE) GRE PIPE systems. In addition

jointing system on pipe and overlay is all butt joint unless

standard is a bolting pattern which flanges are manufactured in accordance with

before exceeding 100% of these values. Bolt torque must be

fiberglass products flanges.

GRE pipe sections together, for example in a repair or for closure.

U.V coating instructions. (See welding procedure on overlay

Field Laminate Instructions (See welding procedure on overlay

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