Professional Documents
Culture Documents
Petroleum Development Oman L.L.C.
Document title: GRP Specification Part 1
Document ID SP‐2092‐1
Document Type Specification
Security Restricted
Discipline Materials & Corrosion
Owner UEOC (CFDH Materials, Corrosion and Integrity)
Issue Date July 2013
Version 1
i Document Authorisation
ii Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details
of all revisions prior to these are held on file by the issuing department.
TABLE OF CONTENTS
Clause no. Description Page no.
1. INTRODUCTION 7
1.1 SCOPE 7
1.3 DEFINITIONS 7
1.10 EXCEPTIONS 13
2. MATERIALS 14
2.1 GENERAL 14
2.2 RESINS 14
2.6 UV PROTECTION 17
3. MANUFACTURING 17
3.1 GENERAL 17
3.3 PIPE 18
3.4 FITTINGS 19
3.5 FLANGES 19
4. QUALIFICATION 21
4.7 REQUALIFICATION 28
5.1 GENERAL 35
5.7 RETEST 42
6. COMPONENET MARKING 43
6.1 GENERAL 43
6.2 REQUIREMENTS 43
1. Introduction
1.1 Scope
This document specifies requirements and recommendations for the GRP piping and
pipeline systems and shall be used as the base specification for Design, Qualification,
Manufacturing, Installation and commissioning of all new GRP piping and pipeline
systems.
Part 3 – Specifies Handling, Storage and Installation of GRP piping and pipeline
systems.
The objective of this specification is to enable to have easy interpretation and to get
consistent quality of materials from the GRP vendors.
1.3 Definitions
1.3.1 General Definitions:
The contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning of a project, or operation or maintenance
of a facility.
1.3.2.3 Degradation: Loss of property due to aging, sustained stress and other service
conditions.
1.3.2.4 ECR or C-glass – Glass fibre having better chemical resistance against acids than E
glass used primarily as a reinforcement for the resin rich internal liner.
1.3.2.5 Lot (pipes) - A Lot of GRE pipes consists of 100units or less in a continuous
production of each size and pressure class produced for company orders.
1.3.2.6 Lot (fittings) - When used in connection with manufacture of fittings or spools the
following shall apply.
Fittings lot shall be defined as the 100 units of fittings produced for company orders
using the same method of construction (Example – filament winding, handlayup,
moulded fittings, mitered fittings etc,) for each type (Example - Elbow, Tee, Reducer,
Flange, Coupler, Stub end and saddle with pick) and pressure class.
1.3.2.7 Pipeline systems – Pipe with components subject to the same design conditions and
typically used to transport fluids between wells, field facilities, processing plants and
storage facilities. It is recommended that, all GRE pipeline systems in the PDO
exploration and production areas shall be installed underground.
1.3.2.8 Piping system – Pipe with components subject to the same design conditions and
typically used in above ground application within a processing facility. The piping
system also includes pipe supports, but doesn’t include support structures.
1.3.2.10 Sour Service: Sour service is defined as greater or equal to region 2 of ISO-15156-
2.
1.3.2.12 Shall: Used to indicate that a provision is mandatory within this specification.
1.3.2.13 should: Used to indicate that a provision is not mandatory but recommended as
good industry practice within this specification.
All other technical terms and definitions shall be referenced as per ISO14692-1. Symbols and
Abbreviations.
T – Tee (fitting)
1.4.2 Abbreviations
GRP – Glass Reinforced Plastic. It is the general terminology used for the reinforced
plastic pipes and fittings. It includes GRE, GRV and Glass Reinforced Polyester pipes
and fittings.
CV – Component Variant.
1. Material and corrosion Engineer shall obtain all essential data to propose the
material option. All quantified process or functional requirements to be reviewed
and confirm the suitability of the GRE materials based on the applications as
specified in the section 1.7.
3. Material and corrosion engineer shall ensure clear understanding of GRP risks
and risks may be associated with project engineering community.
5. GRE pipe system shall not be installed above ground for hydrocarbon services.
a. Above ground GRE piping or pipelines shall not be installed in areas
classified as zone 0, zone1 and zone 2 in accordance with IEC60079-10-1
(area zone 0, 1, 2).
b. Any exposed GRE piping/pipeline system part (2mtrs max) shall be protected
from fire/heat exposure and external mechanical impacts/damages, to a risk
level equivalent to buried GRE if considered ALARP in QRA study.
Wrapping of GRE pipe for protection can be considered for low pressure
(<70bar) non hydrocarbon and closed drain service. Protection should be of
physical (passive) nature.
a. GRE pipe can have no elbow with angles sharper than 45 degrees.
b. Stresses on GRE pipeline are calculated and in compliance with standards
ISO 14692/DEP 31.40.10.19.
c. GRE/Metallic interface connections shall be protected from external impact
and fire/heat exposure to a risk level equivalent to buried GRE.
d. GRE pipe should be continually supported to prevent local stresses; stilts and
other intermittent supports will not be allowed.
e. Final design shall be reviewed and approved by pipeline design function.
Well heads.
Drains,
Lamination joints are not permitted to use for sour oil and gas applications. Only
qualified adhesive bonded joints and threaded connections with qualified sealants are
permitted to use for sour service applications.
225
200
175
150
125
100
75
50
25
0
0 500 1000 1500 2000 2500 3000
Internal diameter (mm)
Threaded
NA NA Up to 150mm 120 bar
Connections
Note: The maximum application temperatures based on the resin system used and
shall be as per the table 2 of this specification.
Table 1 – Size and pressure limitations to apply GRE materials in PDO facilities.
Use of higher pressures or larger diameters outside the range specified in the above
table 1 is subject to specific approvals from the CFDH materials and Corrosion and
upon satisfactory qualification before finalizing concept material selection.
- System design
- Product qualification and supply;
- Construction & testing activities
- Pre commissioning and commissioning activities.
All pipe, fittings and flanges for an installation shall be manufactured by the same
vendor to avoid incompatibility due to intermixing of product from different
manufacturers.
1.10 Exceptions
The user (Manufacturers, Contractors and project Engineers) shall conduct a GAP
analysis against this specification and shall obtain written approval for deviations prior
to contract award from CFDH materials and corrosion.
Any unauthorised deviations shall be rejected by the Company and the user shall be
accountable for any subsequent re-work to comply with this specification.
2. Materials
2.1 General
The material selection process shall ensure that the material is compatible with the
service fluids to which it is exposed over the full design temperature range so that the
mechanical, physical and chemical properties of the GRP satisfy the design
requirements throughout the intended lifetime. Manufacturer shall provide the details
of the raw materials and resin systems intended to be used for the project during the
technical bid stage for the company Review and acceptance.
Aliphatic amine;
Cyclo aliphatic amine (IPD);
Aromatic Amine (MDA);
Anhydride.
2.2.2 Polyester resins
For water services, e.g. sea-water cooling, Isophthalic polyester resin is typically
used. Isophthalic polyester is a relatively low cost resin, with limited chemical
resistance.
The actual temperatures shall be confirmed by qualification testing but it shall not be
greater than the maximum design temperature in table 2.
The maximum design temperature for GRP pipeline system shall not be greater than
Tg minus 30deg C and the maximum design temperature specified in table 2.
The minimum design temperature for GRP regardless of the resin system is minus
40 C.
The chemical resistance information shall state whether the material has been
laboratory tested according to ASTM C 581 (or other equivalent standard). Guidance
on the selection of GRP is given in Table 3:
Acids *, *** X X X √ X
Alkalis ** √ √ X √ X
(caustic)
Solvents √ √ X X X
(BTX)
Water √ √ √ √ √
sea/brackish
√ - Resin and curing agents can be used for the production of GRP
(*) Hydrochloric acid, up to 28% concentration, e.g. used in demin units. GRE
(epoxy) has limited resistance against hydrochloric acid (< 10 %) and therefore
GRVE (vinyl ester) shall be used, lined with a resin rich layer (liner), reinforced with
double ECR/C-glass or other qualified synthetic veils such as Nexus liners;
(**) Sodium hydroxide (caustic), up to 50 % concentration, e.g. used in chemical
plants. Glass-fibre is not resistant against sodium hydroxide, and therefore only
“lined” GRE or GRVE shall be used. The resin rich liner shall be reinforced with
double synthetic veil (e.g. Nexus), and thickness of the liner shall be minimum
1.5 mm;
(***) Sodium hypochlorite solution, e.g. used in chlorination units. Sodium
hypochlorite, typically produced on-site using electrolytic cells, i.e. concentrations
typically up to 1 %, and pH in the range 9 to 10, will attack all thermo-set resins.
However, UPVC lined GRVE is a proven option for the transport of sodium
hypochlorite.
Further information about chemical resistance of resins typically used for GRP, in a
variety of chemical environments, is given in DEP 30.10.02.13-Gen.
GRP manufacturer shall select the suitable resin system from the above table 3 &
supply a chemical resistance list for the selected material (Reinforcement, liner, resin
& curing system) showing highest known service pressure & temperature that the
pipe and its component variants are subjected to and the service life that have been
achieved under those conditions. Alternatively, the supplied resin system chemical
resistance list (data sheet) shall state whether the material has been laboratory tested
according to ASTM C581and life expectancy in intended actual service. If required,
manufacturer shall demonstrate the chemical resistance of the selected resin system
by carrying out the laboratory testing as per ASTM C581 for specific applications.
2.3.1 Pipes
Continuous E-glass/ECR-glass fiber roving shall be used for constructing the
reinforced wall thickness of GRP pipes. Additional woven roving reinforcements may
be used to achieve the required strength of the pipes at the ends.
Other reinforcement materials like carbon fibers for conductive pipes can be used in
accordance with the specific agreement in the purchase requisition/purchase
specification.
2.3.2 Fittings (Tees, Elbow, Reducer coupler etc,)
Fittings shall be manufactured using E-glass/ECR glass reinforcement materials.
Fittings shall be manufactured with the same fiber glass reinforcement materials used
for the qualification (ref Clause 4.4).
Fittings manufactured by direct roving, the top minimum 4 layers shall be constructed
using the woven roving/knitted fabric /bidirectional tape glass reinforcement materials
even if the original qualification was conducted without these additional layers.
The gasket material, e.g. used for flanges, shall match the pressure, temperature and
chemical resistance capabilities of the piping system. Further information about the
chemical resistance of non-metallic materials in a variety of chemical environments is
given in DEP 30.10.02.13-Gen. Selected gasket material shall be tested for the
sealing properties as per ASTM D4024. This test can be done on product sector
representative flange joints.
Where the fire resistance additional requirement specified, and then ISO14692 part 3
sections 9.4 shall be applied.
3.0 MANUFACTURING
3.1 General
For manufacturing GRP pipe components, filament winding, and/or hand lay-up shall
be used. Any fillers such as sand-filled GRP pipe and fittings shall not be used for
pipeline and piping systems.
3.3 Pipe
Pipes shall be produced with the reciprocal filament winding process.
Standard length for line pipes manufactured by filament winding process shall be
supplied as specified in the below table.
2 50 to 80mm 3 meters
Any additional reinforcements (woven rovings) required in the socket and spigot
areas (TB/TS joints) shall be as per the base line sample used in the qualification
process. Application of the woven roving shall be by using the helical winding
machine. The woven roving winding lengths start and finish shall be controlled by
CNC programming or mechanically driven machines. No manual application is
permitted. Knotting of the glass bobbins shall be done using the splicing gun or
suitable method to restrict the resin pockets accumulated across the manual knots.
End scrap cutting should be established during qualification, based on the method of
winding to achieve the required winding angle at the ends. The same shall be
followed during regular production.
During the process of winding, if there is any resin mix started gelling, winding shall
be stopped and the pipe shall be rejected. Should there be a machine stop for any
reason the resin mix shall be inspected for gelling by QC inspector and give
clearance to proceed.
Winding angle of the pipes produced should be in the range of 53 to 57. The
tolerance of the produced pipes shall be +/- 2 of that of the qualified product. Method
and location used to measure the winding angle shall be same as one used for
qualification sample. The winding angle shall be measured in two locations (internal
and external surface) for the pipes with thickness greater than 10mm.
Fully automated resin mixing & dispensing equipments shall be used. The
measurement of quantity of resin and hardener shall be through the automatic
dispensing unit. The resin mixing and dispensing units shall be calibrated in
accordance with the equipment manufacturer recommendations. The frequency of
calibrations shall be defined in the manufacturer’s quality management System.
3.4 Fittings
Mitered method of construction shall be limited to max 30 bar design pressure subject
satisfactory qualification.
All the GRE fittings should be pre cured between 90 to 100deg C before de-moulding.
In addition to the adhesive bonded joint, woven roving reinforcement shall be applied
on branch and saddle of the reducing tee.
The fittings shall be constructed using the qualified process. Manufacturer shall
establish, document and qualify the process description and Recipe to be used for
the construction of each type, size and pressure class of fittings.
The manufacturer shall demonstrate that the following variables remain constant
throughout the manufacturing of each type, size and pressure class of the fittings.
Resin type & curing agent (hardener) with brand name and mixing ratios.
Dimensions of cut roving if any to be used (Tees) and the locations, layers
and sequence of the cut roving to be applied.
If the winding of the fittings not completed during the shift or if the resin mix
is gelled, surface preparation needs to be done before restarting the winding
process. The method of surface preparation shall be the same as that of the
qualified specimen.
Liner and top coat material and number of layers, sequence and over lap
details.
Only certified operators shall be used for manufacturing of fittings. Refer: QA section
for the qualification of winding operators.
3.5 Flanges
3.5.1 General
The outside diameter and hole spacing of GRP flanges shall meet the requirements
of ASME B16.5 for flanges diameter below 600mm & ASME B16.47 for flanges
diameter more than 600mm. The flanges shall be flat face.
For flange diameters larger than 1000 mm, an O-ring based seal design may be
selected, to be agreed by the Principal.
Flanges with an O-ring seal require special moulding and tooling (O-ring groove) and
are typically fabricated by the filament winding process.
Two types of flanges are typically used:
Filament wound flanges are strong in the hoop direction but weak in axial bending. To
prevent cracking in the flange during loading, e.g. during assembly, it is
recommended to reinforce the flange in the neck area woven roving/knitted fabric to a
minimum thickness of 3mm.
The glass roving used in the construction of the flange should be tapered with a
waving pattern towards the flange face to increase the strength. The tension on the
glass roving shall be optimised preferably using tension controller such that
consistent glass content is achieved in the flange construction.
Reinforcement type (E glass, C Glass, ECR glass, Armaid fiber, carbon fiber,
woven roving or direct roving, CSM etc.,) composition, sizing and tow tex
details for each layer of construction in the form of Recipe or winding
sequence.
Bandwidth, number of roving strands, type of comb and the end cutting
dimension details.
The above information shall be made available to the access of company authorized
representatives upon request for verification or inspection.
Component design.
Resin mixing.
Threading process.
4.0 QUALIFICATION
This section of the specification gives requirements for the qualification of GRP
pipeline or piping components in order to enable to build up the confidence to
purchase the GRP materials with known and consistent properties from any
manufacturer.
The vendor shall demonstrate that their product is qualified in accordance with this
section prior considering any project. This effectively means that the GRP
Manufacturer shall demonstrate, through testing, that its products will satisfy the
design specifications
The qualification programme consists of standard methods for quantifying GRP pipe
component performance with respect to internal pressure and elevated temperature
for different applications.
The qualification programme results shall be used as baseline acceptance criteria for
quality control where it is not specifically defined in the specification.
4. 1 Manufacturer qualification:
The manufacturers shall be qualified based on the long term regression as per ASTM
D2992 with free ends using the pipe and joint with diameter minimum 50mm.
Gradient (G), LCL and the HDB values shall be established. The regression test shall
be performed at temperature 65 deg C or at design temperature if it is higher for each
individual resin system. A manufacturer having only plain pipe regression data shall
demonstrate the HDB of pipe plus joint is equal to or superior to the plain pipe
regression data. The reconfirmation test and evaluation shall be done in accordance
with clause 12 of ASTM D2992 – 06.
The regression gradient G, obtained from the 10,000hour testing shall be in the range
of 0.065 to 0.075 for 65deg C and 0.085 to 0.100 for >65 deg C. LCLs value obtained
from the regression curve shall be in the range of 110MPa to 160Mpa for 65deg C
and 85Mpa to 125Mpa.for 90deg C. In case where the manufacturer regression data
falls outside the above specified range, the data shall be verified and CFDH approval
shall be obtained.
Manufacturer shall be required to perform the additional testing as per cl. 4.2.4 as
part of their qualification program.
The NPR quoted by the manufacturer shall satisfy the following equation related to
PLCL
Where PLCL - Is the Lower confidence Limit (PLCL = f1. LTHP). This pressure is the
qualified pressure based on the qualified stress determined through the regression
test.
f1 – Means of the degree of scatter in the long term pressure tests and the evaluation
of the 97.5% confidence limit from the regression test data as defined in ASTM
D2992.
The manufacturer shall provide the values of f2 and f3 used to develop a purchase
quotation. Values of f2=0.67 and f3=0.85 (for above ground) and f3=1.0 (for buried or
under ground pipeline) are recommended as default values. However the value of f3
shall be verified during the system stress analysis.
The pressure ratings of the GRP components shall be verified in accordance with the
requirements described in the section 4.2
Note: Manufacturer may select the more conservative value (0.5 to 0.85) f3 factor. In
all cases, the sum of all hoop stresses and axial stresses in any component in a
pipeline or piping system due to pressure, mass, other sustained loadings, and of the
stresses produced by occasional loads such as wind, blast or earth quake shall not
exceed values defined by the factored long term design envelop.
Minimum reinforced wall thickness of the pipes and fittings supplied shall be more
than or equal to that used in the qualification and it shall meet the minimum system
design requirements for sustained loads & occasional loads specified in ISO14692-3
for above ground piping and AWWA M45 for buried pipeline. Minimum reinforced wall
thickness of pipes shall be verified to meet the requirements with part factor f2=0.89
for hydro testing at 1.5 times the design pressure.
Table 3 – Full qualification procedure for pipe, pipe plus joints and fittings.
Pipe plus Product sector Survival test on two samples for To Verify the
joint, representatives 1000hour or more at 65C, or design value of PLCL
Fittings temperature if it is higher. (As per
+joints and ASTM D1598).
Fabrication
process
Table 3 continued…….
Pipe plus Component Design by scaling method and Carrying Baseline for
joint, Variants out STHP test on two samples or Quality control.
Fittings carrying out 1000hour test.
+joints and
Fabrication Low pressure (Design pressure up to
process 70bar) - The STHP value for pipes,
fittings and joints shall not be less than
3.5 times the design pressure.
Note: 1. For piping, the test spool shall include all the following fittings
Tee, Elbow, Flange, reducer. The spool dimensions shall comply with the ASTM D1598.
For line pipe applications the spool shall include all the above fittings as applicable for the
project.
Two replicate spools with sample product sector representative (PSR) shall be subjected to
1000 hour pressure testing in accordance with ASTM D1598 at 65C or at design temperature
if higher. The PSR is qualified if both spools survive the test duration without any leak. The
minimum length of pipe between adjacent joints or fittings, or end closures, needed to remove
the influence of end-fittings shall not be less than that specified in ASTM D1598.
Test spool shall contain all fittings (Elbow, Flange, Tee, and Reducer), Wherever it is not
possible, at least one fitting shall be a part of the test spool.
Prior to the commencement of 1000-h test, spools filled with water shall be preconditioned by
in oven at the test temperature for minimum 100hours.
After conditioning the specimens Test shall commence only when the pressure and
temperature have stabilised and when no further additions of water are required. Refill may
be allowed providing the component hasn’t failed and pressure was reduced due to other
reasons e.g gasket failure. Minimum 24hour stabilization after reaching the test conditions
shall be required prior to continuing the test. Test spools shall be under continuous observation
at least once in an hour to ensure that there is no change in temperature and pressure i.e. the
system is fully stabilized. The temperature, time and pressure recording system shall be
started after pressurizing the spool. The time count shall start only after complete
stabilization.
The following default test pressure requirements shall apply to all Manufacturers and for all
pipe or fittings (PSRs). 1000hour test shall be conducted in accordance with section 4.4.2
The 1000-h test pressure for a 20 years design life shall be the following:
Design temperature up to 65 C
-Static pressure application: TP1000hr = 2.4Pdesign-static
Design temperature >65 C and < 100 C
-Static pressure application: TP1000hr = 2.6Pdesign-static
Design Pressure greater than 70bar the vendor may conduct a 3500hours test in lieu of
1000hour test and the parameters shall be as follows. The test pressure shall be 2.1times the
design pressure (TP3500r = 2.1Pdesign-static).
Where:
TP1000hr = test pressure to be used in the 1000-h qualification test
Where the design life required is in excess of 20 years, the above 1000-h and 3500h test
pressures shall be increased by 3 % per 10 years.
The wall thickness of component variant shall meet the following requirement. The relation
between Lower confidence limit (PLCL) of CV and PLCL of Product sector shall meet the
following criteria.
Two spools of component variants shall be subjected to STHP test in accordance with ASTM
D1599 to prove the integrity of the pipe plus joint and the burst test pressure of each spool
shall not be less than the values specified in the table 3. The lower of the two test value shall
be taken as baseline STHP value to be used to asses the pipes production lot.
Flanges shall be subjected to the following qualification tests to demonstrate the integrity of
the flange design and manufacturing process. The samples selected for all the qualification
tests shall be from the same lot as those used for 1000hour test.
B. 1000 hour survival test. (Part of 1000hour test spool as stated in clause No 4.4.2)
C. Sealing test.
D. Cyclic test.
E. Torque test.
Flanged components shall be tested in accordance with the test method ASTM D 1599 with
free end closure. The pressure in the specimen shall be increased until failure of the flange
occurs. Pressure testing in atmospheric environment is permissible. Minimum failure time
shall be 60s: no restriction shall be placed on maximum time to failure. Leaking past the
gasket is permissible during this test. Bolt torque maybe increased as necessary during the
test in order to minimise the gasket leaking and to achieve the pressure necessary to cause
flange failure. Flanges shall withstand a hydrostatic load of at least four times their rated
design pressure.
B. 1000hour pressure test: Two flanges shall be part of 1000hour survival test in
accordance with the clause 4.4.2 to demonstrate the PLCL of the flanges equal to or more than
that of other piping/pipeline system components (Elbow, Tee or pipe). In case of any leakage
past the flange face, the test may be interrupted to seal the flanges by increasing the bolt
torques to an appropriate value. Testing may then be continued to complete the required
period of testing.
C. Flange sealing test: flange sealing test shall be carried out at 1.5 times the design
pressure for the duration of 168 hours without any visible leak through the flange sealing
surface. Service gaskets, spacer ring if applicable, bolts, nuts and washers recommended by
the manufacturer shall be used during the sealing test. Gasket shall be rated for the equal or
greater design temperature and pressure. The flanges shall be assembled and tightened to
full recommended torque. The sequence and torque increments shall be strictly followed
during the torquing in accordance with ASTM D4024. The testing method and the spool
configuration shall be in accordance with the ASTM D4024.
D. Cyclic pressure test: This test shall be done to verify the performance of the flange
system (combination of the gasket, flange geometry and the recommended bolt torque) to
withstand variations in pressure during the operations and testing. The flange spool length
shall be more than the manufacturer’s recommended minimum support distance. The spool
supported at both the ends leaving test flanges hanged at centre. The method followed for
assembling the flanges shall be in accordance with the one used for sealing test. The sample
shall be assembled using qualified (by seal testing) gasket and bolt torque as recommended
by the manufacturer. The test spool shall be subjected to 10 pressure cycles. Each cycle
starts at 0 and rises to 1.5XDesign Pressure and then reduces to 0. Testing can be done at
ambient conditions. Each cycle represents study pressurization (steady pressurization rate of
5bar per minute is recommended) up to 1.5 X Design pressure, hold for 5 minutes and
gradually release the pressure to zero. Repeat the above step until the required number of
cycles completed. If there is a leak through the gasket face, the test shall be stopped and
replace with the new gasket and continue the test.
Upon completion of the above C & D tests the flanges shall be disassembled and visually
inspected for any damages. Any cracks and/or de-lamination to the flange constitute failure.
E. Torque test: Using the gasket and hardware (Nuts, bolts, washers and spacer ring etc.,)
recommended by the manufacturer, bolt the flange against the raised face or flat face flange
to simulate the installation recommendations by the manufacturer. Tighten the nuts by hand
until they are snug. Prior to fit up, the nuts, bolts, and washers should be well lubricated,
using a non-fluid thread lubricant. Establish uniform pressure over the flange face by
tightening bolts in 15N-M increments according to the sequence recommended by the
manufacturer. Increase the torque uniformly until flange failure occurs or until all the bolts
have been torqued to two times the level qualified in B & C above. Any sign of flange
damage, (crumbling, flaking, cracking or other breaking) shall constitute failure.
Criteria for acceptance: the flanges shall withstand, without visible sign of damage a bolt
torque of at least 2.0 times that recommended by the manufacturer for sealing of the flange at
its rated pressure.
The above tests shall be conducted in accordance with ISO14692-2:2002(E) clause 6.4.2,
6.4.3, 6.4.4, 6.4.5, 6.5 and 6.6 respectively.
b. Short term axial strength, determined in accordance with ASTM D 2105 at SLT.
e. Hoop tensile modulus and Poisson’s ratio, determined in accordance with API 15HR
at SLT.
f. Hoop bending strength and modulus, determined in accordance with ASTM D2412 at
SLT.
g. Poisson’s ratio for an axial tensile load and the resulting hoop contraction determined
in accordance with ASTM D2105 at SLT but modified in order to measure hoop
contraction.
The above tests shall be revalidated after every 10 years or any change in the raw materials
(Type of resin and reinforcement materials). Test records shall be maintained and shall be
made available for verification.
4.7 Requalification
Any change of parameters specified in Table 4 shall mandate re-qualification in
accordance with this specification as described in (4.2).
In order to keep the total test burden within acceptable limits but at the same time to
control the use of test data beyond their limits of applicability, the concept of a
product family and its sub-divisions is used.
A product family defines a range of pipes, fittings and joints manufactured by the
same Manufacturer, using the same method and having the same constituent
materials. (Product family consists of plain pipe, joint and fittings such as elbows, tees
and reducers).
A product sector is a sub-division of a product family that groups pipes (plus joints)
and fittings into specific diameter and pressure ranges.
The product sector representative for a product sector is the component that is
representative of that sector and upon which the basic qualification testing (4.4) is
performed.
The product sectors selected for the qualification is the component that has the largest
nominal diameter and the highest pressure rating in that specific sector. Assuming that the
product range consists of pipes, elbows, tees, Coupler, reducers, flanges, saddle and joints in
diameters up to 250mm and pressure up to 50bar, the product sector representative (PSR) in
product sector A would be:
1. Qualify the product sectors representatives of each sector as per the PSR range
specified in the table 6 or
In case 2, the product sector representatives are identified by selecting first on nominal
diameter and then on pressure rating.
250 to 400 B G K
>2400 O
A component in a product sector where the product sector representative (Item No.2 -
example 350mm, 40bar) which falls under product sector ‘B’ has not been qualified
may be considered qualified based on the qualified component (Item No.1 – example
250mm, 40bar) which falls under product sector A if the following criteria stated in
step No.1, 2 and 3 are satisfied. If any of the criteria stated in step 1, 2 and 3 are not
satisfied, the item No.2 shall be qualified by 1000hour testing.
1) Scaling factors – D1 is the diameter, tr1 is the reinforced thickness, α 1 is the angle
of Elbow, P1 is the design pressure and R1 is the radius of bend of the qualified
component.
D2 is the diameter, tr2 is the thickness, α2 is the Angle of Elbow, P2 is the design
pressure and R2 is the radius of bend of the component not qualified by 1000hour
test.
a. t2 ≥ t1P2D2/ P1D1
b. P2 ≤ P1D1/D2
d. α2 ≤ α 1
e. D2A ≤ D2B D1A /D1B (Reducer where D1A, D1B & D2A, D2B are the diameters of
qualified and non-qualified reducer).
2) Pressure limitation - Design pressure of the component is 0.5 to 1.0 times the
qualified component.
3) Diameter limitations.
a. Size of the component is within +/- 100mm than that of the qualified component, if
the diameter of the component qualified is less than or equal to 400mm.
b. Size of the component is within +100/-200mm than that of the qualified component,
if the diameter of the component qualified is between 400mm and 800mm.
c. Size of the component is within +100/-300mm than that of the qualified component,
if the diameter of the component qualified is between 800mm and above.
The degree of cure (Tg) for the qualified components and joints (adhesive) shall be
determined by one of the following methods:
For polyester and vinyl ester based products, the residual styrene monomer content
in the components used in qualification testing shall be determined. The
measurement shall be performed according to ISO4901. The residual styrene content
shall not be more than 2% (mass fraction) of the resin content.
4.9.1.3 Barcol hardness (for Vinyl ester / polyester resin pipes & fittings)
Barcol hardness testing shall be carried out in accordance with ASTM D2583.
Minimum of 10readings shall be taken on each sample. The two highest and lowest
reading to be discarded and average of remaining six readings shall be considered as
barcol reading.
Hand-lay up fittings 50 % to 65 %
Internal diameter;
Outside diameter;
Mass;
Minimum and Average reinforced wall thickness;
Total wall thickness;
Dimensions of joint.(Taper angles, thread dimensions etc.,)
Laying length (pipes and fittings)
Bend radius.
Taper angle & length of taper (for adhesive bonded connections)
Thread dimensions (as per API spec 5B)
If the test is unsuccessful, the Principal and the Manufacturer shall discuss and agree
the future course of the qualification testing and pipe manufacture.
After a successful test, microstructures taken from the wall of the female end of the
pipe or connector shall be prepared and inspected using optical microscopy. A
minimum of 4 locations is required. The total number and actual location of samples
shall be agreed between the Principal and the Manufacturer. For an acceptable
microstructure, the following requirements shall be met:
i. % of glass content.
l. Jointing records (In the form of check list covering all the control parameters in
accordance with the jointing procedure).
m. Visual & dimensional inspection records for pipes, fittings, joints and threads
(diameter, min reinforcement thickness, liner thickness, total average wall
thickness, spigot and socket taper angle, thread dimensions, length of spool
preferably with as built test spool drawing).
n. Records of ancillaries such as gasket or sealing ring, studs and nuts material
details, torque wrench, pressure, temperature and time recorders calibration
details.
The pipe Manufacturer shall identify fabrication processes and activities that affect
component performance and shall ensure that these processes and activities are
adequately controlled in accordance with ISO 9001. Critical processes or activities for
which procedures shall be developed and maintained include, but are not limited to,
the following:
Component qualification.
Resin mixing;
Component fabrication;
Component identification;
Procedure for criteria, selection and training of pipes and fittings winding
operator certification, laminators, jointers, QC inspectors, lab technicians,
Field service Engineers and design engineers.
Component design;
Field support.
In addition, a quality plan and flow diagram shall be produced, drawn in the
context of a factory plan, showing all the proposed tests and inspections
during component fabrication.
Manufacturer shall produce the specific contract quality plan and inspection and test
plan. Manufacturer and EPC contractor shall agree before the documents submitted
to PDO review after the EPC contractor’s review. These documents shall be
approved by the company quality assurance TA2 authority for non-metallic materials
before start of production. Deviations to this specification shall be approved by CFDH
materials and corrosion. A copy of the approved deviations shall be attached to the
documents.
Contract quality plan shall be prepared in accordance with ISO9001 and SP1171.
CQP shall address the following as minimum
a. Scope of work
b. Process flow chart for the activities showing interfaces between the departments
e. Sub vendors if any and, controls on sub vendors. Pipes and fittings
manufacturing shall not be sub contracted without the approval of CFDH
materials and corrosion. The details of sub vendors, if any shall be identified
during the technical bid evaluation.
Inspection and test plan (ITP) shall be prepared separately for pipes and fittings
addressing all the inspection and tests required to be carried out in sequence as per
the specification and applicable standards. The acceptance criteria or reference to it,
testing frequency and responsibilities to perform, witness, review shall be addressed.
The inspector representing the company shall have unrestricted access at all time
while work on the contract is being performed to all parts of the manufacturing/ testing
facility and ancillary units if any.
All records, documents and procedures shall be made available for inspection upon
request by the Principal.
Hydrostatic test pressure shall be maintained for a minimum of two minutes in order
to ascertain there is no leakage. Where practicable, test components shall have
unrestrained ends. Test temperature shall be at ambient conditions.
Manufacturer shall use automatic pressure & time recording system in the hydro test
bench. Where there is no such arrangement, minimum 20% of the pipes and 100%
fittings & spools hydro test shall be witnessed by third party or company inspection
engineer.
Any fittings or spool pieces which are not practicable to conduct hydro test (example
– flange, saddle, coupler, nipple etc.,) shall be summarized and list shall be submitted
in the inspection and test plan for company TA2 approval.
5.3.2 Additional quality control tests for gas and sour applications
After full curing and before hydro testing, pipes and fittings shall be air-tested. The air
test pressure and duration is described in (4.10). Approximately 10 % of produced
pipes and fittings should be air-tested. An air test schedule and frequency shall be
agreed between the Principal and the Manufacturer.
100 % of the first production lot should be air-tested. If all pipes and fittings pass this
air test, the test frequency for the second lot may be reduced to 50 %, for the third lot
to 10 % and for subsequent lots 5 %. If any pipe or fitting fails the air test, all other
pipes or fittings produced in the same lot and all pipes or fittings in the subsequent lot
should be 100 % air-tested. If there are no further failures, the testing frequency may
be reduced to 50 % and so on for subsequent lots. If further failures do occur, the
Principal and the Manufacturer shall discuss the future course of testing and pipe and
fitting production, including the requirement for additional testing of earlier lots of pipe
and fitting not subjected to 100 % testing.
Furthermore, if failures have occurred, microstructures should be taken from the cut-
offs of produced pipes or fittings in order to assist the discussion between the
Principal and Manufacturer. The number of microstructures should be agreed
between the Principal and the Manufacturer, but microstructures should be made
from at least 5 % of cut-offs from the first production lot, reducing to 1 % for
subsequent lots assuming no pipes or fittings fail the air test. The microstructures
made from the produced pipes and fittings should be compared with the reference
microstructures as a further control on the quality of the produced pipes and fittings.
For microstructure acceptance criteria, see (4.6.5).
5.3.3 Degree of cure
The degree of cure shall be determined by the same procedure (4.9.1) used to
determine the degree of cure for the qualified component, at a frequency of
a. One per lot, for continuous production, when the curing is done conveyor type of
curing ovens used.
b. One per charge irrespective of size, type or pressure rating when the fixed type of
oven without conveyor is use for curing. It is recommended to take Tg samples on
the higher thick component in the charge.
In both the cases three samples shall be taken from three locations situated 120 °
apart in the same cross-section and same location, as for the qualified component.
If the Tg is less than the minimum value (minus 5 °C tolerance) measured for the
qualified component, then the production lot shall be rejected, subject to the retest
(5.5). However, the Tg of the on-going produced components shall always be 30 ºC
above the design temperature.
Barcol hardness shall be checked on minimum 100% of the Polyester and vinyl ester
resin components. Average barcol hardness shall not be less than the 95% base line
value established by the manufacturer for each type of resin system. The base line
value shall be taken from the sample used in the PSR qualification.
In case of polyester and Vinyl ester resin system, the styrene content shall be
measured in accordance with ISO4901. The styrene content shall be less than or
equal to 2% (mass fraction) of the resin content.
The glass content measured on the pipes and fittings shall be within +/- 5% than the
qualified component. However maximum glass content of any component shall not be
more than 82%.
If the measured glass content doesn’t meet the required range, then the production
lot shall be rejected subject to retest (5.5)
For the pipes and fittings design pressure more than 70bar, the value of STHP shall
be mutually agreed by the vendor and principal.
Hoop tensile strength – Hoop tensile test shall be carried out on minimum one
sample pipes per order as per ASTM D2290 or ASTM D1599.
The size and pressure class of the pipe selected for the test shall be specified in the
inspection and test plan to be agreed by the principal. Axial and hoop stress values
shall not be less than the manufacturer published values used for the system design.
5.3.7 Dimensions
Key dimensions shall be compared with the baseline values (4.9), in accordance with
ASTM D 3567, at a frequency of one per lot. Tolerances on approved design wall
thickness shall be as specified in Table 8. Any out of tolerance components shall be
rejected.
a. Reinforced and liner wall thickness using optical scale comparator with minimum
7 to 10X magnification.
d. Observed Minimum, maximum and average total wall thickness (tmin , tmax, tave)
e. Mass
f. Laying length - Acceptance criteria for fittings shall be as per ISO14692-2 table
14.
g. Winding angle for the pipes to be measured and recorded at minimum three
places.
* NOTES
1. The plus-tolerance on total and reinforced wall thickness for fittings shall refer to the spot having the
minimum wall thickness.
2. The minimum reinforced wall thickness on components shall not be less than the one used in the
qualification test.
3. In fittings, the surface irregularities shall not be more than + 22.5% of the average wall thickness
measured along single axis of the fittings.
Total wall thickness & laying length shall be measured and recorded on 100% of
pipes & fittings. Total wall thickness of the fittings shall be determined by using the
calliper, whereas for the pipes either calliper or the pi-tape can be used. For the pipes
more than 350mm the surface roughness correction factor of 0.3mm shall be
deducted from the measured OD of the pipe to calculate the total wall thickness. For
pipe, the measurements shall be made at three locations one in the middle of the
pipe, the other two at approximately1meter distance from both the spigot and socket
neck area.
Pipes and fittings socket (minimum 1% for each mould used): Taper length,
socket ID at neck and edge of the socket, taper angle shall be measured and
recorded.
Mould control reports shall be available for all the socket moulds used in the
production line. Traceability shall me maintained and recorded in the inspection
reports.
Pipes and fittings Spigot dimensions (100% of the spigots): Taper length, OD at
the nose, OD at the standard insertion length and taper angle shall be measured and
recorded.
Standard and calibrated jig can be used for checking the spigots and sockets. The
method of controlling the standard jig shall be defined in the manufacturer quality
system.
Pit (pin hole) Small crater in the None permitted in the liner. At other
surface of the laminate, locations ISO14692-4 table A1
with its width (diameter) acceptance criteria shall be applied
similar to or smaller than except the depth of crater shall be
the depth less than 10% of the wall thickness or
equal to 0.8mm whichever is less.
Air bubble Air entrapment within Maximum width 0.8mm and depth
(void) and between the plies of less than 10% wall thickness or equal
reinforcement, usually to width whichever is less.
spherical in shape
Pimple Small, sharp, or conical Any pimples greater than 3mm dia
elevation on the surface shall be removed by carrying out
of a laminate minor repair.
The principal shall be notified for all major repairs. After the repairs, a hydrostatic mill
test in accordance with (5.3.1) shall be performed on the repaired component.
Any repairs other than the removal of imperfections by grinding within the top resin
layer shall be classified as major repair. All minor repairs if any detected during visual
inspection shall be done before the final mill hydro static test.
5.7 Retest
If any specimen fails the quality control tests (5.0) the lot shall be rejected. The
Manufacturer may elect to make retests, to be agreed by the Principal, on two
additional replicate samples selected at random from the same production lot.
If all the retest samples conform to the requirements then the remainder of the
production lot should be accepted. If any retest specimen fails to conform then the
production lot shall be rejected.
Retained by the Manufacturer for a minimum of ten years following the date
of commissioning acceptance;
All the products shall be despatched or delivered to the principal locations with ISO
3.2 certification in accordance with EN10204:2004.
6. COMPONENT MARKING
6.1 General
Pipe and fittings manufactured in accordance with this specification shall be marked
by the Manufacturer as specified in (6.2). Additional project related markings as
desired by the Manufacturer or as requested by the Principal should be included.
Markings shall be applied on the pipes, fittings and spools. Method of marking should
be agreed between the Principal and Manufacturer. Markings shall be permanent,
shall not overlap, and shall be applied in such a manner as not to damage the pipe or
fittings. Markings shall be applied on the pipes within one metre from the female end.
Pipes diameter more than 20” shall be marked at three locations at the orientation of
approximately 120deg to each other. For fittings, marking shall be applied minimum
one place. All the markings applied shall be clear and readable.
6.2 Requirements
All pipes and fittings shall be permanently marked with:
Manufacturer’s name;
Nominal diameter;
Design temperature
Date of manufacture;
Product ID / series;
All pipes and fittings shall be supplied with rubber or plastic end caps which can
withstand minimum two years desert storage conditions without affecting the bonding
or jointing surfaces. Polyethylene sacks shall not be used as end caps as they tend to
get damage within one or two months in desert storage conditions.
a. Purchase order and amendments there after with related correspondence with
the principal or client.
c. Production quality control documentation and records which includes but not
limited the following
Raw material certificates. (From raw material suppliers and internal test
results as per the ITP)
Production quality control records for each inspection and testing carried
out at all stages as per the approved inspection and test plan.
Lab test records (Tg, % glass, tensile testing records etc., as applicable
in accordance with the approved ITP).
Appendix A
Reference standards
ISO Standards
ASTM Standards
Obtaining Hydrostatic design basis for fibreglass pipes and fittings ASTM D 2992
Resistance to short term hydraulic pressure of plastic pipe tubing and ASTM D 1599
fittings.
Determination of longitudinal tensile properties of fibreglass pipes & ASTM D 2105
Fittings.
Standard specification for machine made Fiberglass flanges ASTM D 4024
Standard practice for classifying visual defects in glass reinforced plastic ASTM D 2563
laminate parts
Standard specification for contact molded fibreglass flanges ASTM D 5421
Standard practice for determining dimensions of fibreglass pipes and ASTM D 3567
fittings.
Standard practice for determining chemical resistance of thermosetting ASTM C 581
resins used in glass-fibre reinforced structures intended for liquid service
Standard test method for ignition loss of cured reinforced resins ASTM D 2584
Pipe flanges and flanged fittings NPS ½ through NPS 24 metric/inch ASME B16.5
standard
Specifications and recommended practices for the use of GRP piping UKOOA April 1994
Specification for Low pressure Fibergalss line pipe & Fittings API 15 LR
SHELL STANDARDS
Quantification of the voids size and through wall distribution of the void OP.01.20636
content of glass-fibre reinforced plastic pipes by microstructural
examination and digital image analysis
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