INSTALLATION GUIDELINE

ABOVEGROUND PIPE SYSTEM

Document Number: FPI-KSA-FSV-IG-AG

Revision: 0

Field Services Department

Revision & Approval Control

DOCUMENT CONTROL

INSTALLATION GUIDELINE Document Number FPI-KSA-FSV-IG-AG

Title
ABOVEGROUND PIPE SYSTEM Issue Date 24-11-2019

REVISION CONTROL

Revision Date Description Comments

0 24-11-2019 Issued for Review N/A

APPROVALS

Name Position Signature Date

PREPARED BY

Name Position Signature Date

Luqman Ali Field Service Supervisor 24-11-2019

REVIEWED BY

Name Position Signature Date

Saeed Mustafah Field Service Engineer 24-11-2019

INSTALLATION GUIDELINE ABOVEGROUND PIPE SYSTEM | FPI-KSA-FSV-IG-AG Page 1 of 16

Terms of use
The use of the contents and the data published in this brochure have been licensed to
Future Pipe Industries L.L.C. This document contains confidential and proprietary information.
Reproduction or disclosure of any part of this document is only allowed with written
authorisation by Future Pipe Industries L.L.C.
Future Pipe Industries L.L.C. reserve the right to change the data published in this brochure
without any prior notification. All information was correct at the time of going to press.
However, we reserve the right to alter, amend and update any products, systems and
services described in this document. We accept no responsibility for the interpretation of
statements made.
For any technical query please consult Future Pipe Industries L.L.C.

INSTALLATION GUIDELINE ABOVEGROUND PIPE SYSTEM | FPI-KSA-FSV-IG-AG Page 2 of 16

TABLE OF CONTENTS

1. GENERAL
2. REFERENCES
3. HANDLING
4. SYSTEM DESIGN
5. BELLOWS
6. PIPE CONNECTIONS THROUGH WALLS
7. UV-RESISTANCE
8. FIELD HYDROSTATIC TESTING
9. AIR IN PIPELINES, AIR VALVES, etc.
10. HSE REQUIREMENT

INSTALLATION GUIDELINE ABOVEGROUND PIPE SYSTEM | FPI-KSA-FSV-IG-AG Page 3 of 16

1. GENERAL
This manual deals with installation of GRP pipes and fittings manufactured by Future Pipe
Industries (FPI) intended for Aboveground application. It is to be used in conjunction with
the FIBERSTRONG/WAVISTRONG Product Data, Method statements, etc. and is intended
to assist the installer in understanding the requirements and procedures for the successful
handling, jointing and testing of GRP pipes and fittings for aboveground installation.
This manual should be carefully read by the Contractor responsible for installing the pipe as
well as the pipeline Design Engineer. This information should be considered only as a guide.
The Engineers or others involved in pipeline design or laying should establish for themselves
the procedures best suited to the actual site conditions. Sound engineering practices should
always be followed. This document mainly addresses the usual circumstances that may be
encountered in the field. Unique situations requiring special considerations are not
addressed and should be resolved in coordination with the manufacturer.

Aboveground pipe systems may be subjected to various loadings resulting from operation of
the system. The installation shall be performed in accordance with the requirements and/or
conditions which are used in the system design.
The instructions in this document are as complete as possible. However, it is not possible to
describe all circumstances that might be encountered in the field. Therefore, our
experienced supervisors can opt for an alternative method to achieve an optimum solution
using the latest installation techniques and processing methods.
Besides, our supervisors may be consulted for clarification of statements made in this
document and for advice about specific problems encountered in the field.
Definition of words used in these instructions:
- The word “shall” indicates a requirement.
- The word “should” indicates a recommendation.

2. REFERENCES
• AWWA C950 - Standard Specification for Fiberglass pipes
• FPI Standard - Standard know how for GRP products.

3. HANDLING
3.1 Receiving
Generally, pipes will be handed over to the Contractor or his representative at the factory or
at the job site or as agreed upon in the Contractor’s purchase order. In case of Ex-works
delivery, the pipes and fittings shall be loaded on the Contractor’s trucks, by the factory
loading staff. If the loading staff considers the transport unsuitable they will advise the
contractor or his representative accordingly. Inspection is thoroughly made by the factory

INSTALLATION GUIDELINE ABOVEGROUND PIPE SYSTEM | FPI-KSA-FSV-IG-AG Page 4 of 16

loading staff of the goods being loaded. Nevertheless, the contractor or his representative
should make their own inspection of the goods during dispatch.
The Contractor should make the following inspection at the time of reception of the goods:
a. All pipes and fittings should be inspected upon receipt at the job site to ensure that,
no damage has occurred during transport.
b. Total quantity of pipes, couplings, rubber rings, fittings, lubricant, etc. should be
carefully checked against the delivery notes.
c. Any damaged or missing item must be pointed out to the dispatcher or driver and
noted on the delivery note.
d. Materials that have been damaged during transportation should be isolated and
stored separately on site, until the material is checked by our site representative and
repaired or replaced.
Note: Damaged or defective material must not be used before it is repaired or replaced.
3.1.1 Repair
Pipes with minor damage can be repaired at the job site by a qualified technician. If in
doubt about the condition of the pipe, do not use it.
The site services representative can help to determine whether repair is required, possible
and practical. Repair method can vary due to pipe thickness, wall composition,
application, and the type and extent of the damage. Therefore, do not attempt to repair
a damaged pipe without consulting the manufacturer first. Repairs must be made by a
trained repair technician. Improperly repaired pipes may not perform as intended.
3.2 Unloading Pipe
Unloading the pipe at the job site must be carried out carefully under the control and
responsibility of the Contractor. Do not drop the items and extreme care should be taken to
avoid impact the pipe with any solid object (i.e. other pipes, ground stones, truck side etc.).
FPI’s handling and storage procedure shall be referred for further details.
3.2.1 Unloading by hand
Unloading by hand with two men is only allowed for small diameter pipes, not exceeding 40
kg.
3.2.2 Mechanical unloading
Mechanical unloading is required for pipes heavier than 40 kg. Flexible slings or straps should
be used combined with a mobile crane. When unloading is done with a mobile crane, care
must be taken that the pipes not to slide off the slings. Therefore, it is recommended to use
two slings or nylon lifting straps to hold and lift the pipes. Steel cables must not be used for
lifting or handling GRP pipes. GRP pipe can also be lifted with one sling or strap balanced in
the middle with the aid of a guide rope.

INSTALLATION GUIDELINE ABOVEGROUND PIPE SYSTEM | FPI-KSA-FSV-IG-AG Page 5 of 16

 Figure-1 Figure-2
Lifting Single Pipe.

Figure-3
Lifting Unitized Package.

Caution: Hooks must not be used at the pipe ends to lift the pipes, nor should the pipe be
lifted by passing a rope or sling through the pipe.
3.4 Storing rubber gaskets, and raw materials on site
Project specific handling and storage procedure shall be referred for the complete
information on the storage conditions of various raw materials and components.
3.5 Storing pipe on site
Avoid placing the pipes where they can be damaged by traffic or blasting operations. If
possible, Store pipes on soft level ground (e.g. sand), timber bearers or sand bags. It is

INSTALLATION GUIDELINE ABOVEGROUND PIPE SYSTEM | FPI-KSA-FSV-IG-AG Page 6 of 16

generally advantageous to store pipe on flat timber to facilitate placement and removal
of lifting slings around the pipe.
3.5.2 Storing in stock piles
Care must be taken that the storage surface is levelled, firm and clear of rocks or solid
objects that might damage the pipes. Store the pipes in separate stock piles as per their
class and nominal diameter. If it is necessary to stack pipes, it is best to stack on flat timber
supports at maximum 6 meters spacing (3 meters for small diameters). The maximum stack
height is 1.5m without supports and approximately 3 meters with side supports those are
placed at a distance maximum 4.0m. Stacking of pipes larger than 1400 mm diameter is not
recommended. This height is limited for safety purpose and to avoid excessive loads on the
pipe during storage.
Wooden wedges, which are used to prevent the pipe stack from sliding should be placed
on both sides of the stack on the timber bearer, as shown in figure 4.

Figure-4

4. SYSTEM DESIGN
System design is important to ensure stress in the pipe remain within allowable limits under all
loading conditions. Wall thickness calculations only consider internal (and external) pressure.
System design will consider all possible loadings including temperature, wind, seismic, blast,
structural displacements etc.
System design will consider the actual routing of the system together with the support
locations and functions and determines the response of the system under various loading
conditions. Based on the results, modifications to supports, routing or thickness of
components could be recommended.
4.1 Stress analysis
Analysis to determine the stresses in the pipe, displacements and loads on supports due to
applied loadings.
4.2 Surge analysis
Analysis to determine the pressure in the pipe and unbalanced hydraulic forces resulting
from certain upset conditions of the system such as pump start and stop, valve opening and
closure etc.

INSTALLATION GUIDELINE ABOVEGROUND PIPE SYSTEM | FPI-KSA-FSV-IG-AG Page 7 of 16

4.3 Vibration analysis
A vibration analysis determines the response of the system due to oscillating loadings.
Oscillating loads are characterized by a frequency and amplitude. Applying oscillating
loads could lead to resonance or fatigue.
Vibration analysis is not normally done on a routine basis. It is mostly done when a problem is
experienced. A modal analysis is sometimes requested by the client. A modal analysis is not
the same as a vibration analysis. A modal analysis will determine the natural frequencies of
the system. These frequencies can then be compared to possible excitation frequencies
from equipment (pumps, compressors) to ensure they do not align as that could cause
resonance.
4.4 Support analysis
A pipe support is a designed element that transfer the load from a pipe to the supporting
structures. The four main functions of a pipe support are to anchor, guide, absorb shock, and
support a specified load.
Note: - Support package provided by the detailed engineering team shall be referred for
the details and the installation shall be carried out accordingly.
Supports provide system fixation, transfer of load and stability to the system. Prior to
installation, supports are to be checked for location, type and span as detailed in drawings
and specifications of the project. It is essential that all supports shall be in place prior to
pressure testing.
Pipe supports can be categorized into those that permit movement and those that anchor
the pipe.
The basic types of supports are:
Rest support: This support prevents vertical down movement of the pipe. It allows movement
in all other directions.
Guide support: This support prevents lateral (perpendicular to the pipe axis) movement of
the pipe.
Axial stop: This support prevents axial (along the pipe axis) movement of the pipe.
The above basic support types can be combined such as Rest+Guide, Rest+Guide+Axial
stop.
The following requirements and recommendations apply to the use of system supports.
a) Supports shall be spaced to avoid sag (excessive displacement over time) and/or
excessive vibration for the design life of the piping system.
b) In all cases, support design shall be in accordance with the manufacturer’s
guidelines.
c) Where there are long runs, it is possible to use the low modulus of the material to
accommodate axial expansion and eliminate the need for expansion joints, provided

INSTALLATION GUIDELINE ABOVEGROUND PIPE SYSTEM | FPI-KSA-FSV-IG-AG Page 8 of 16

 the system is well anchored and guided. In this case, the designer shall recognize that
the axial expansion due to internal pressure is now restrained and the corresponding
thrust loads are partly transferred to the anchors.
d) Valves or other heavy attached equipment shall be adequately and, if necessary,
independently supported. When evaluating valve weight, valve actuation torque
shall also be considered.
NOTE :- Some valves are equipped with heavy control mechanisms located far from the
pipe centreline and can cause large bending and torsional loads.
e) GRP piping shall not be used to support other piping, unless agreed with the principal.
f) GRP piping shall be adequately supported to ensure that the attachment of hoses at
locations such as utility or loading stations does not result in the pipework being pulled
in a manner that can overstress the material.
Pipe-support contact surface
The following requirements and recommendations apply to GRP piping support.
a) In all cases supports shall have sufficient length to support the piping without causing
damage and shall be lined with an elastomer or other suitable soft material.
b) Point loads shall be avoided. This can be accomplished by using supports with at least
60° of contact.
c) Clamping forces, where applied shall be such that crushing of the pipe does not
occur. Local crushing can result from a poor fit and all-round crushing can result from
over-tightening. Tighten the clamp’s bolt with sufficient torque to secure the pipe in
the clamp. Consult with FPI’s technical team for specific torque input based on
support design.
d) Supports should be preferably located on plain-pipe sections rather than at fittings or
joints. One exception to this is the use of a "dummy leg" support directly on an elbow
or tee (or piece of pipe).
Anchor supports can transfer the required axial loads to the pipe without causing overstress
of the GRP pipe material. Anchor clamps are recommended to be placed between either
a thrust collar laminated to the outer surface of the pipe or two double 180° saddles,
adhesive-bonded to the outer surface of the pipe. The manufacturer’s standard saddles are
recommended and shall be bonded using standard procedures. (See fig-5)

INSTALLATION GUIDELINE ABOVEGROUND PIPE SYSTEM | FPI-KSA-FSV-IG-AG Page 9 of 16

 Figure-5
If a GRE/GRP flange is connected to a steel flange, the support should preferably be
situated at the side of the steel flange (See fig-06). Pipe sections should not become
overloaded by the weight of the accessories. Supports provided at the steel connections or
valves, to be not only able to carry the full load of the valve but bending and torque forces
caused by opening and closing of valves also.

Figure-06

5. BELLOWS
GRE/GRP products can absorb low amplitude vibrations due to the flexible properties of the
composite material.
To eliminate high amplitude vibrations caused by e.g. pumps and to compensate soil
settlement or expansion of tanks joined with pipes, bellows can be applied.
Bellows facilitate dismantling of pipe sections, valves, orifice flanges and gaskets. This
equipment also absorbs pipe movements due to cyclic pressure and/or temperature in pipe
systems that are joined with relatively stiff adhesive bonded joints. (See fig-07)
In many cases, bellows are directly joined to the vibrating item by means of flanges. Note
that the pipe section next to the bellow shall be supported separately to absorb the pipe
loads.

INSTALLATION GUIDELINE ABOVEGROUND PIPE SYSTEM | FPI-KSA-FSV-IG-AG Page 10 of 16

Bolt torque values, as specified by the bellow supplier, might deviate from the torque values
specified by the GRE/GRP manufacturer.

Figure-07

6. PIPE CONNECTIONS THROUGH WALLS

Several alternatives are available for passing pipes through walls. In case of anticipated
settlement of the wall or pipeline, flexible couplings (e.g. bellows) must be installed on both
sides of the wall.
The joints shall be positioned as close as possible outside the wall.
Recommended wall penetration protection is as shown in the figure below. (see fig-08)

INSTALLATION GUIDELINE ABOVEGROUND PIPE SYSTEM | FPI-KSA-FSV-IG-AG Page 11 of 16

 Figure-08

Figure 09 - Rubber Wrapping

INSTALLATION GUIDELINE ABOVEGROUND PIPE SYSTEM | FPI-KSA-FSV-IG-AG Page 12 of 16

7. UV-RESISTANCE
The topcoat of GRE/GRP pipes and fittings consists of a resin rich layer. This layer offers
sufficient protection against UV-radiation.
When exposed to weather conditions the epoxy topcoat may be attacked on the long-
term; this may result in a chalked outer surface. After several years of operation, the chalked
layer may be removed and replaced by a resistant, protective polyurethane paint coating.
Contact the manufacturer for advice.

8. FIELD HYDROSTATIC TESTING

Field hydrostatic testing shall be carried out based on separate specific method statement
for hydrostatic testing. Contractor shall make sure that the relevant approved document is
available at site during this activity.
Refer to the user manual for the details of joint tester. Contact our engineers for more
information about the joint tester.

9. AIR IN PIPELINES, AIR VALVES, etc.

Air in pressure piping system can cause major operational problems. Typical problems
induced by the presence of such air are the reduction in flow capacity because of reduced
cross-sectional areas, and fluctuation in flow caused by expansion and contraction of the
air pockets in the line. High surge pressures can result from the flow fluctuations, which cause
sudden movements of the air from one location to another, followed by slugs of water. Also,
surge (water hammer) can occur in pipelines from opening and closing valves and from the
start-up and shutdown of pumps.
Air can enter a pipeline from many locations:
• Line Drains
• Negative surges (vacuum) causing air to enter at air valves in the pipeline
• Intake Source
• Release of dissolved air from the water by temperature and pressure variation
• Draining parts of the pipeline or the pipe system during normal shut-down. In the first
instance, air shall be prevented from entering the line. This will reduce operational
difficulties.
Suggested solutions for controlling entrapped air in pipelines are as follows:
• The intake point should be provided with low water level pump cut-off
• Release of air: Air dissolved in the water at the intake and released due to
temperature and pressure fluctuations cannot be prevented. However, the quantities
of such air are not large and provisions for releasing the air can be made by means of
air valves. Proper selection of air valves is essential.

INSTALLATION GUIDELINE ABOVEGROUND PIPE SYSTEM | FPI-KSA-FSV-IG-AG Page 13 of 16

 • While draining the line, air cannot be prevented from entering the line. Large orifice
air valves should be provided for exhausting the air during refilling. Long filling times
will allow the complete release of air.
• Negative surges (vacuum) - Large volumes of air may be involved here and can
cause serious operational problems. The best way to prevent air from entering under
these conditions is by proper design to eliminate the possibility of water column
separation.
• Studies have shown that suddenly released entrapped air under apparently static
conditions creates a situation like a water hammer. Generated pressures can be of
the order of several times the pipeline test pressure. Any pipeline material can be
seriously affected by the quick increase in the magnitude of pressure loads.
Remedial actions against entrapped air and water hammer are as follows:
• Lay the pipe line essentially to grade wherever possible, avoiding major slopes. It may
be advantageous to create artificial high points by providing a small slope of around
3-4 mm per 1000 m to facilitate air collection at high points. Also, for drainage, it is
recommended to provide a slope of 1-2 m per 1000m.
• Automatic continual acting air release valves should be used at all major high points.
Almost all the air release valve manufacturers limit the maximum distance between
air release valves to around 750 meters
• Air should be sucked out from pipeline slowly.
• Maximum filling velocity of the pipeline is 0.3 m/s.
• Use d/D = 1/10 to 1/15.
d = diameter of air release valve
D = pipe diameter
• Using motorized actuated valves is an effective means of limiting positive surges to an
acceptable level by controlling the rate of opening and closing of the valves.
• Flywheels on pump motors allow the pump to keep on running for a short period after
any power shutdown, before it gradually stops.

10. HSE REQUIREMENTS

10.1 Health and Safety
The HSE Management plan establishes standards to minimize risks to health and
environment, to prevent work accidents and to define the minimum (mandatory) hygienic
and health facilities required at the construction field, including those required for
environmental protection, throughout the execution of Field works.

INSTALLATION GUIDELINE ABOVEGROUND PIPE SYSTEM | FPI-KSA-FSV-IG-AG Page 14 of 16

10.2 Risk Analysis
Entrapments, hits and run over by vehicles
I. Collective systems and organizational measures
• Avoid workers staying inside machinery work zones
• Have a clearly marked loading/unloading area
• Coordinate and supervise vehicles displacements, especially reverse ones
II. PPE: Reflective safety vest, safety shoes and safety helmet
Vehicle overturning
I. Collective systems and organizational measures
• Avoid the circulation and staying of vehicles at a distance smaller than 4m from
excavation borders
• Coordinate and supervise vehicles displacements, especially reverse ones.
II. PPE: Reflective safety vest, safety shoes and safety helmet
Falling from height
I. Collective systems and organizational measures
• Close excavation with fences
• Preparation of wide and moderate slope ramps as trenches access.
• Do not climb trenches walls
II. PPE: Reflective safety vest, safety shoes and safety helmet
Entrapments and burials by detachments

I. Collective systems and organizational measures

• Daily inspection of trenches walls looking for cracks or unstable materials, especially
during and after rainy conditions
• Cleaning and removal of material in excavation borders in case of caves
appearance
• Avoid the circulation and staying of vehicles at a smaller distance than 4m from
excavation borders
• Avoid any material storage at a smaller distance than 4m from excavation borders
• Not allow entrance of not accompanied workers in trenches
• For stable soil, it is allowed a 90° slope between ground and walls. For rest of the types
sloped trench walls should be arranged
II. PPE: Reflective safety vest, safety shoes and safety helmet
Fire, explosions because of existing conductions (gas, etc.)

INSTALLATION GUIDELINE ABOVEGROUND PIPE SYSTEM | FPI-KSA-FSV-IG-AG Page 15 of 16

 I. Collective systems and organizational measures
• Obtain all available information about existing underground conductions
• Stop all works in case of appearance of sand and/or coloured straps during
excavations
• In case of pipe breakage turn off all the machinery, stop all the works and avoid any
source of flames or sparks. Leave the area and inform to supervisors.
II. PPE: Reflective safety vest, safety shoes and safety helmet
Cuts, hits, abrasions

I. Collective systems and organizational measures

• Cover rebar’s ends with plastic protections
II. PPE: Reflective safety vest, safety shoes and safety helmet
Loads falling

I. Collective systems and organizational measures

• Delimited loading/unloading area
• Avoid under load zone
• Respect crane safe loading chart
• Inspect slings to detect damages
• Use two lifting points being symmetrical to the pipe's centre of gravity.
II. PPE: Safety helmet

INSTALLATION GUIDELINE ABOVEGROUND PIPE SYSTEM | FPI-KSA-FSV-IG-AG Page 16 of 16