NDE2019, 027, v1: ’CP-310: GRE Pipe Manufacturing Defects, Installation and NDE . . .

CP-310: GRE Pipe Manufacturing Defects, Installation and NDE

Requirements

Engr.Sangili Gunasekaran,
More info about this article: http://www.ndt.net/?id=25748

QA-QC Department, Heavy Engineering Industries & Shipbuilding Co. K.S.C (Public)
Kuwait
sangili.gunasekaran@heisco.com

ABSTRACT

Glass Reinforced Vinyl or Epoxy (GRV/E) is resistant, both internally and externally to corrosive effects
of Water, oil and many chemicals. Cathodic Protection System (CPS) Or Coating is not required. This
paper will focus the application of GRE/V Pipes in refinery construction, fabrication and erection errors
and Non-destructive Examination (NDE).

If the machine setup is according to the specifications in setup sheet and raw materials are tested and
approved, there are normally no problems with defects on pipes and Fittings. But sometimes process
variables changes during the production and may cause defects on pipes on fittings. Defects can occur
in either the GRP material or in the Lamination & adhesive bonded joints that make up a piping system.
Manufacturer instructions were not followed by constructor leads to defects and delay of project
completion. Leak testing failures also affect completion of project and rework required to bring to
acceptable limit.

In this section will discuss the possible defects associated with the manufacturing & Installation of
GRE/GRV pipes, from the point of view of human error, and or lower manufacturing skinless due to new
technology introduction in the area. Also in this part will be concerning the defect types, causes, and the
prevention or corrective action of such defects and NDE applications.

Keywords: Glass Reinforced Vinyl or Epoxy (GRV/GRE), Cathodic Protection System (CPS), Non-
destructive Examination (NDE), Lamination & adhesive bonded joints, Defects, Leak testing failures etc.
2 NDE2019, 027, v1: ’CP-310: GRE Pipe Manufacturing Defects, Installation and NDE . . .

CP-310: GRE Pipe Manufacturing Defects, Installation and NDE

Requirements
Engr.Sangili Gunasekaran,
Unit Head-Quality Operations, ASNT NDT Level-3 (RT/UT/MT/LT/VT), ASNT Section Officer, QA-QC
Department, Heavy Engineering Industries & Shipbuilding Co. K.S.C (Public)
Kuwait
sangili.gunasekaran@heisco.com

1.0 Introduction
Glass Reinforced Vinyl or Epoxy (GRV/E) is resistant, both internally and externally to corrosive effects
of Water, oil and many chemicals. Cathodic Protection System (CPS) Or Coating is not required.

If the machine setup is according to the specifications in setup sheet and raw materials are tested and
approved, there are normally no problems with defects on pipes and Fittings. But sometimes process
variables changes during the production and may cause defects on pipes on fittings. Defects can occur
in either the GRP material or in the Lamination & adhesive bonded joints that make up a piping system.
Manufacturer instructions were not followed by constructor leads to defects and delay of project
completion. Leak testing failures also affect completion of project and rework required to bring to
acceptable limit.

2.0 Body of Knowledge

2.1 Table -1 Glass Reinforced Plastic Pipes – Manufacturing defects and installation defects

Definition Causes Consequences Corrective action

Surface Void: Small air pockets
or voids beneath the surface
mat. Air pockets can be broken
with ball pen.
Curing speed is too high Weep age failure Single void: If >1.5mm
(styrene is entrapped in deep or >15mm diam.,
surface). then repair. Group of
voids: Only repair if
there are more than 4
voids per 0.1m2 and dia
<15mm and depth <1.5
mm:

Cracks/ Delamination: Bright Poor quality Weep age failure Reject

solid” area in laminate due to manufacture
lack of bond between resin and
fibers. Separation of layers
(plies) within laminate.

Missing Fiber: Broken or cut Scraping, scuffing or Reduced Accept

outer Roving's. manufacturing pressure to cause
process Weep age.
 NDE2019, 027, v1: ’CP-310: GRE Pipe Manufacturing Defects, Installation and NDE . . . 3

Surface Pits : Small crater in the Poor quality Weep age failure Reject/Major Repair as
inner surface of the laminate, manufacture for large pits per project specification
with width (max. diameter)
similar to or smaller
than depth
Resin drops in pipes through Resin flow is too high Minor effect on Minor Repair above 3
out /Improper removing of Performance. mm height as per
excess resin project specification

Resin Pin holes during winding Resin flow is too low Weep age failure Reject/Major Repair as
and lack of top coat. for large pits per Project
Non Uniform Socket build up Poor Quality Reduce the Joint Specification
Manufacture Strength and Reject and instruct
feasibility for Machine operator to
Leakage or keep the socket build up
Weep age thickness uniformity as
per project
specification.

Foreign objects: Black spots Foreign Objects on Weep age failure Before winding clean
inside the pipes mandrel mandrel properly.

Resin Rich : Excess resin out Excess resin is not Minor effect on Minor Repair as per
side removing properly / performance project specification.
Remove excess resin
properly by wiping.

Air pockets: Voidage within Poor quality Minor effect on Minor repair if within
laminate or outer gel coat manufacture performance outer gel coat.
caused by entrapped air

Cutting damage Lack of Good Weep age failure Bonder should Confirm
workmanship pipe completely cut by
the cutter before
removing the cutter
form the pipe

End Damage Due to improper Weep age failure Damaged area to be cut
handling and removed.

Dry Joint: Area of incomplete Poor quality Bonding Major effect on Reject/Major repair as
surface film where the performance per project specification
reinforcement has not been
wetted by resin, leaving bare
exposed fibers.

Air pockets : Voidage within Poor quality Bonding Minor effect on Apply serrated layup
laminate or outer gel coat performance roller on intervals of
caused by entrapped air lamination

Burned Laminate : Thermal Interaction with Reduced Minor Repair as per

decomposition evidenced by external heat source. pressure to cause projects specification.
distortion or discoloration of Weep age.
the laminate surface
4 NDE2019, 027, v1: ’CP-310: GRE Pipe Manufacturing Defects, Installation and NDE . . .

Lack of adhesive: Unbonded Too little adhesive or Weakened joint Reject

area of joint face. not applied uniformly or Leakage.
Movement during
Curing.

Rupture of laminate with Strength of joint Weep age failure Reject

complete penetration. reduced
Majority of fibers broken.
Visible as lighter coloured area
of inter laminar separation.

2.2 GRV /GRE Application steps:

It will vary manufacturer to manufacturer. The manufacturer instructions shall be followed at site works.

 Check Surface Temperature, Relative Humidity, avoid direct sun light/dust during the jointing.
 Marking and cutting
 Machining- Minimum .Grinding -0.5 MM and chambering (1: 6 slope)
 Wedging-Pipes/Fittings – 3 MM (max. Gap)
 Building up the joints
 Fit layers & curing (0.5 Hours : 130 to 160 Deg.C)
 Main reinforcement , Top layer & curing
 Final curing (1.5 to 3 Hours : 130 to 160 Deg.C)
 Visual inspection and hardness test
 NDE2019, 027, v1: ’CP-310: GRE Pipe Manufacturing Defects, Installation and NDE . . . 5

2.3 Application Precautions

6 NDE2019, 027, v1: ’CP-310: GRE Pipe Manufacturing Defects, Installation and NDE . . .

Fig. 1 Improper preparation of chemicals & Fig.2 Shortage of thermometer Probe

shortage of belts for latching/Blanket Fig.3 Chemical storage in proper way
 NDE2019, 027, v1: ’CP-310: GRE Pipe Manufacturing Defects, Installation and NDE . . .
Figure .4 Curing not done more than 24 Hours –
Crack on lamination joints
Fig.6 Direct sun light & no dust proof shelter during
jointing
Table-2 Non Destructive Testing Methods requirements:
a) Visual Testing
• Deformation and dimensional deviations.
• Surface cracks & micro cracks.
• Near surface delamination's, inclusions & air
entrapments.
7
Fig.5 Improper end cap provided –sand
cleaning is required
Fig. 7 handling of woven materials at site
b) Pressure Testing (Leak Testing)
• Adhesive bonded joints lacking adhesive or
improperly prepared and assembled.
• Inadequate cured adhesive in the bonded
joints.
8 NDE2019, 027, v1: ’CP-310: GRE Pipe Manufacturing Defects, Installation and NDE . . .

• Impact damage • Manufacturing defects in GRP materials.

• Blisters. • Leaking Joints
• Internal excessive of adhesive (Internal
inspection). Demerits :
• Corrosion and Erosion (Internal inspection ) • a) Cost of blinding off system
• b) any corrective action can cause
commissioning delays

c) Ultrasonic Testing ( Pulse Echo)-UT d) Radiological Testing (RT)-10 to 50 Kev

• Areas in bonded pipe joints lacking adhesive. • Incorrect WT up to 20% deviation.
• Delamination's, voids. • Some voids, delamination’s and lack of
• Deviations in Wall thickness(WT)- 20 % adhesive up to 5% deviations.
• Effective WT : 8 TO 25 MM • Axial misalignment
• ( Test Frequency : 0.25 TO 2.25 MHz) • Excessive adhesive on inner wall of pipe at
joint.
• Scale build up on inside pipe.
• Incorrect insertion of pipes in adhesive
sockets
Demerit :
a) poor adhesion not detected in RT

e) IRT- Infrared Thermal Testing f) Acoustic emission testing (AET)

• Scale build up • Growing crack/propagation defect detection
• Major deviations in WT • In adequate structural integrity
• Areas in the joint lacking adhesive. • Growth of delamination crack
• Standard calibration blocks: Demerit and is • Crack growth in matrix material
under R&D. • Fiber fracture and pull out
• Inadequate curing, leading to excessive
strains
• Leakage

g) Differential Scanning calorimetry – Glass

transmission temperature measurement
and Barcol hardness test ( Indirect of
measuring the degree of cure in Vinyl
ester and polyester laminates and
laminated joints)
• Improperly mixed or cured adhesive in
bonded joints.
• Improperly mixed or laminated joints.

Figure-8 & 9 Surface Pits and Surface Void:

 NDE2019, 027, v1: ’CP-310: GRE Pipe Manufacturing Defects, Installation and NDE . . . 9

Figure -10 & 11: Scratch mark in liner and Forging objects:

Figure -12 & 13: End Damage and Dry joint:

Figure -14 & 15: Fracture due to impact and Lack of adhesive
10 NDE2019, 027, v1: ’CP-310: GRE Pipe Manufacturing Defects, Installation and NDE . . .

Figure-16 & 17 Sample failure joints at site

2.4 Legends: Glass Reinforced Vinyl or Epoxy (GRV/GRE), Cathodic Protection System (CPS), Non-
destructive Examination (NDE), Radiological Testing (RT), WT-Wall thickness ,
3.0 Conclusion
The possible defects associated with the manufacturing & Installation of GRE/GRV pipes, from
the point of view of human error, and or lower manufacturing skinless due to new technology
introduction in the area. Also in this part will be concerning the defect types, causes, and the
prevention or corrective action of such defects and NDE applications.

Defects can occur in either the GRP material or in the Lamination & adhesive bonded joints that
make up a piping system. Manufacturer instructions were not followed by constructor leads to
defects and delay of project completion. Leak testing failures also affect completion of project and
rework required to bring to acceptable limit.

Effective inspection and follow the manufacturing instruction will lead to good workmanship and
timely completion of the project.

4.0 References
4.1 DEP 31.40.10.19 Glass –Fiber reinforced plastic pipeline and piping systems.
4.2 ISO 14692 Part-4 Petroleum and Natural gas industries-Glass Reinforced Plastics (GRP)
piping: Fabrication, installation & operation.
4.3 Manufacturers recommendation