PETRONAS TECHNICAL STANDARDS DESIGN AND ENGINEERING PRACTICE
TECHNICAL SPECIFICATION
SPOOLABLE FIBRE-REINFORCED PLASTIC PIPES
PTS 31.40.10.20 December 2009
© 2010 PETROLIAM NASIONAL BERHAD (PETRONAS) All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
PREFACE PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication,of PETRONAS OPUs/Divisions. They are based on the experience acquired during the involvement with the design, construction, operation and maintenance of processing units and facilities. Where appropriate they are based on, or reference is made to, national and international standards and codes of practice. The objective is to set the recommended standard for good technical practice to be applied by PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical plants, marketing facilities or any other such facility, and thereby to achieve maximum technical and economic benefit from standardisation. The information set forth in these publications is provided to users for their consideration and decision to implement. This is of particular importance where PTS may not cover every requirement or diversity of condition at each locality. The system of PTS is expected to be sufficiently flexible to allow individual operating units to adapt the information set forth in PTS to their own environment and requirements. When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, it is expected of them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the owner. The right to use PTS rests with three categories of users: 1) 2) 3)
PETRONAS and its affiliates. Other parties who are authorised to use PTS subject to appropriate contractual arrangements. Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) and 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, PETRONAS disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any PTS, combination of PTS or any part thereof. The benefit of this disclaimer shall inure in all respects to PETRONAS and/or any company affiliated to PETRONAS that may issue PTS or require the use of PTS. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by users to any company or person whomsoever and the PTS shall be used exclusively for the purpose they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of PETRONAS. The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe custody and PETRONAS may at any time require information satisfactory to PETRONAS in order to ascertain how users implement this requirement.
TABLE OF CONTENTS 1. 1.1 1.2 1.3 1.4 1.5
INTRODUCTION ........................................................................................................ 2 SCOPE........................................................................................................................ 2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 2 DEFINITIONS ............................................................................................................. 2 ABBREVIATIONS ....................................................................................................... 3 CROSS-REFERENCES ............................................................................................. 4
2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7
MATERIALS ................................................................................................................ 5 GENERAL ................................................................................................................... 5 THERMOSET MATERIALS ........................................................................................ 5 THERMOPLASTIC MATERIALS ................................................................................ 6 REINFORCEMENT MATERIALS ............................................................................... 7 EXTERNAL LAYER .................................................................................................... 7 CHEMICAL RESISTANCE ......................................................................................... 7 PERMEATION ............................................................................................................ 7
3. 3.1 3.3 3.4 3.7 3.8
DESIGN ASPECTS .................................................................................................... 9 GENERAL ................................................................................................................... 9 CYCLIC / STATIC SERVICE ...................................................................................... 9 TENSILE LOAD RATING ............................................................................................ 9 LINER THICKNESS .................................................................................................. 10 JOINTS ..................................................................................................................... 10
4. 4.1 4.2 4.4 4.5 4.6 4.7 4.8
QUALIFICATION ...................................................................................................... 11 GENERAL ................................................................................................................. 11 PRODUCT FAMILY .................................................................................................. 11 SHORT-TERM BURST TESTS ................................................................................ 11 1000 HOURS QUALIFICATION TESTS ................................................................... 11 TENSILE STRENGTH TESTS.................................................................................. 12 VACUUM TESTS ...................................................................................................... 12 REQUALIFICATION ................................................................................................. 12
5. 5.1 5.2 5.3 5.4 5.5 5.6 5.7
QUALITY ASSURANCE AND CONTROL ................................................................ 14 GENERAL ................................................................................................................. 14 QUALITY CONTROL EQUIPMENT ......................................................................... 14 MILL HYDROSTATIC TEST ..................................................................................... 14 ONGOING PRESSURE TESTS ............................................................................... 14 FIBRE CONTENT ..................................................................................................... 15 DIMENSIONS ........................................................................................................... 15 QUALITY CONTROL RECORDS ............................................................................. 15
6. 6.1 6.2
COMPONENT MARKING ......................................................................................... 17 GENERAL ................................................................................................................. 17 REQUIREMENTS ..................................................................................................... 17
7. 7.1 7.2 7.3
HANDLING, STORAGE AND TRANSPORTATION ................................................. 18 HANDLING................................................................................................................ 18 STORAGE................................................................................................................. 18 TRANSPORTATION ................................................................................................. 18
8 8.1 8.2 8.3
INSTALLATION AND TESTING ............................................................................... 19 GENERAL ................................................................................................................. 19 FLUSHING ................................................................................................................ 19 HYDROTEST ............................................................................................................ 19
9.
REFERENCES ......................................................................................................... 20
PTS 31.40.10.20 December 2009 Page 2 1.
INTRODUCTION
1.1
SCOPE This new PTS specifies requirements and gives recommendations for the use of spoolable fibre-reinforced plastic (FRP) pipe systems, both onshore and offshore. This PTS is limited to spoolable pipe made from thermoplastic lined fibre-reinforced thermosetting resins, socalled S-FRP and pipe made from fibre-reinforced thermoplastic resins, so-called S-RTP. Operating pressures are typically up to 300 bar, temperatures between –30 ºC and 90 ºC, diameters between 25 mm and 150 mm, and continuous length up to 10 km, depending on reel capacity.
1.2
DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorized by PETRONAS, the distribution of this PTS is confined to companies forming part of the PETRONAS Group or managed by a Group company and, where necessary, to Contractors and Manufacturers nominated by them. This PTS is intended for use in oil refineries, chemical plants, gas plants, exploration and production facilities and, where applicable supply/marketing installations. When PTSs are applied, a Management of Change (MOC) process should be implemented; this is of particular importance when existing facilities are to be modified. If national and/or local regulations exist in which some of the requirements may be more stringent than in this PTS, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable as regards safety, economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements of this document which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned with the object of obtaining agreement to follow this document as closely as possible.
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 or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party that manufactures or supplies equipment and services to perform the duties specified by the Contractor. The Principal is the party that initiates, and ultimately pays for, the project. The Principal will generally specify the technical requirements. The Principal may also include an agent or consultant, authorised to act for the Principal. The word shall indicate a requirement. The word should indicate a recommendation.
1.3.2
Specific definitions Design pressure Maximum internal pressure intended to be experienced by a component during its service life. Design temperature for each design condition, maximum fluid temperature that can be reached during service. Mill hydrostatic test short-term hydrotest at the mill, or factory, use as a quality control check, which is carried out at a pressure above the rated pressure.
PTS 31.40.10.20 December 2009 Page 3 Occasional load maximum short-term duration load intended to be experienced during the component’s service life. Operating pressure normal or anticipated standard internal pressure to be experienced by a component which should not exceed the rated pressure, determined in accordance with this PTS. Pressure rating rated pressure maximum allowable continuous pressure, relating to its long-term resistance to failure when subjected to either static or cyclic internal pressure loading, determined in accordance with this PTS. Product family component type all of whose variants have the same function. Product family representative component that is taken to be representative of a particular product family. Product sector subdivision of a product family that groups variants into specific diameter and pressure ranges. Product sector representative component that has the highest nominal diameter and highest pressure rating in a particular sector. Qualification process of demonstrating that a component is in accordance with the requirements of this PTS. Rated temperature maximum allowable continuous temperature at the rated pressure determined in accordance with this PTS. Short term hydraulic burst strength Short term hydrostatic pressure strength burst pressure measured during a short-term test. Tensile load rating maximum allowable continuous tensile load, determined in accordance with this PTS. 1000 hour test medium survival test to demonstrate long-term strength performance. 1.4
ABBREVIATIONS GRE
Glass-fibre-reinforced epoxy
GRP
Glass reinforced plastic
NPRs
Nominal pressure rating, static pressure service
NPRc
Nominal pressure rating, cyclic pressure service
PA
Polyamide
PE
Polyethylene
PEX
Cross-linked polyethylene
PP
Polypropylene
PVC
Polyvinylchloride
PVDF
Polyvinylidenefluoride
Pmin
Minimum pressure during pressure cycle
PTS 31.40.10.20 December 2009 Page 4
1.5
Pmax
Maximum pressure during pressure cycle
R
Minimum / maximum pressure ratio during cyclic service
SLT
Standard laboratory temperature
S-FRP
Spoolable fibre-reinforced plastic
S-GRP
Spoolable glass-fibre-reinforced plastic
S-RTP
Spoolable reinforced thermoplastic
STHP
Short-term hydrostatic pressure strength
TLR
Tensile load rating
TP1000hrs
Test pressure to be used in 1000-hour qualification test
TS
Tensile strength pipe
Tg
Glass transition temperature
UV
Ultraviolet
CROSS-REFERENCES Where cross-references to other parts of this PTS are made, the referenced section number is shown in brackets. Other documentations referenced in this PTS are listed in (9).
PTS 31.40.10.20 December 2009 Page 5 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 structural wall satisfy the design requirements throughout the intended lifetime. The materials selected shall be of a suitable commercial grade that complies with the technical requirements of the application. The recommendations of the resin Suppliers for the use of hardeners, catalysts and accelerators shall be followed. If specified by the Principal, the external pipe layer may be pigmented to provide suitable resistance to UV degradation effects and/or earthing requirements.
2.2
THERMOSET MATERIALS Thermoset resins, typically used for the manufacture of fibre-reinforced pipe components, are epoxy, polyester, and vinyl ester. The resin shall have a glass transition temperature T g of at least 30 °C above the rated temperature of the pipe component.
2.1.1
Polyester resins Types of polyester resins, typically used for GRP pipe components, are: Isophthalic polyester. This is a relatively low cost resin, which is rarely used for chemical services. It is typically used in thermoplastic lined GRP pipe systems. The minimum glass transition temperature, Tg, is 90 °C; Bisphenol A polyester. This is a high temperature, chemically resistant resin that is extensively used in chemical service. It is a general-purpose resin and is easy to manufacture. The minimum glass transition temperature, T g, is 120 °C; Chlorinated polyester. This resin has many of the properties of bisphenol A resins, but has an inherent fire retardant characteristic. This fire resistant property can be enhanced by addition of antimony oxide particles to the resin mix. The minimum glass transition temperature, Tg, is 110 °C.
2.1.2
Vinyl ester resins Compared to polyester, vinyl ester resins have improved chemical resistance. High temperature resistant vinyl ester versions, e.g. Epoxy-Novolac, are also available. The minimum glass transition temperature, T g, is 115 °C.
2.1.3
Epoxy resins Epoxy resins are resistant to a wide range of moderately strong acids and alkalis, and most hydrocarbons. There are several types of base epoxy resins and associated curing agents. Curing agents typically used for epoxy resin are: Aliphatic amine - Good resistance against caustics and solvents. Resistance against acids is fair. Minimum glass transition temperature, T g, is 115 °C; Cyclo Aliphatic Amine – Excellent resistance against caustics and solvents. Resistance against acids is fair. Minimum glass transition temperature, T g, is 140 °C; Aromatic Amine - Excellent resistance against caustics and solvents. Resistance against acids is fair. Minimum glass transition temperature, T g, is 140 °C; Anhydride – Excellent resistance against acids. Resistance against caustics and solvents is poor. Minimum glass transition temperature, Tg, is 115 °C.
PTS 31.40.10.20 December 2009 Page 6 2.1.4
Temperature limitations of resins The maximum allowable temperature is determined by the resin type and state of cure. Experience of typical GRP systems suggests the following maximum allowable temperatures, depending on resin type: Table 2.1.4.1: Temperature limitations Resin Type
Temperature limit
Epoxy
110 °C
Vinyl ester
100 °C
Polyester
70 °C
The temperatures listed in Table 2.1.4.1 are for initial guidance only. The maximum operating temperature for GRP may, however, be considerably lower, depending on the aggressiveness of the specific fluid and its concentration and the specific curing agent of the resin system. Information about chemical resistance of GRP materials is given in PTS 30.10.02.13. 2.3
THERMOPLASTIC MATERIALS
2.3.1
Lining Thermoplastic materials, typically used for liners, are: Polyethylene (PE), as specified in ISO 1872; cross-linked PE (PEX), specifications to be agreed by the Principal; Polyamide (PA), as specified in ISO 1874, and API 17TR2; Polyvinylidene fluoride (PVDF), as specified in ISO 15014; Polypropylene (PP), as specified in ISO 15013; Polyvinyl chloride (PVC), as specified in ISO 1163.
2.3.2
Matrix Polyethylene is the thermoplastic matrix material typically used for spoolable fibre-reinforced thermoplastic (RTP) pipe. Other materials may also be used, e.g. polypropylene, polyamide, etc.
2.3.4
Temperature limitations of thermoplastics Experience of typical thermoplastic materials suggests the following maximum allowable temperatures: Table 2.3.2.1 - Temperature limitations Thermoplastic Type
Temperature limit
Polyethylene (PE)
65 °C
Polyamide (PA-11)
80 °C
Polyvinylidene fluoride (PVDF)
130 °C
Polypropylene (PP)
85 °C
Polyvinyl chloride (PVC)
65 °C
The temperatures listed in Table 2.3.2.1 are for initial guidance only. The maximum operating temperature for thermoplastic may, however, be considerably lower, depending on the aggressiveness of the specific fluid and its concentration. Rsistance of thermoplastic materials is given in PTS 30.10.02.13.
PTS 31.40.10.20 December 2009 Page 7 2.4
REINFORCEMENT MATERIALS Glass fibre is the reinforcing material typically used for fibre-reinforced plastic (e.g. GRE) pipe components. However, other type of fibre materials may also be used, e.g. carbon and aramide. The reinforcing material shall be a suitable grade of fibre having a finish compatible with the matrix material used. Glass-fibre materials typically used for fibre-reinforced thermoset (e.g. GRE) pipe components are: E-glass fibre, the most commonly used type of glass. It is relatively inexpensive and has good mechanical properties. However, E-glass has limited chemical resistance and shall therefore be protected by the resin from direct exposure to the fluid; C-glass fibre has a high degree of chemical resistance. It is used where the fluid may come into contact with the reinforcement. Other fibres, which may be used, are: Carbon fibre is typically used for low weight, high strength and high stiffness FRP structures. Single carbon fibre rovings may be included within the structural laminate to achieve an electrically conductive wall structure to prevent build up and discharge of static electricity; Aramide fibre is typically used for low weight, high strength and moderate stiffness FRP structures, including reinforced thermoplastic (RTP) pipe components; Steel cords are typically used to reinforce flexible components, e.g. pneumatic tyres, hoses, etc., in accordance with ASTM D 2969. NOTE:
Steel cord reinforced spoolable plastic pipe systems may be designed according to API 17J if agreed by the Principal. However, long-term strength performance shall be demonstrated by 1000 h qualification tests (4.5).
In view of the possible permeation of fluids through polymer materials used for the liner (S-GRP) and matrix material (S-RTP), the Manufacturer shall demonstrate that the fibre material is resistant against the service fluid, at rated temperature. 2.5
EXTERNAL LAYER To protect the external pipe surface against UV degradation, especially when constantly exposed to strong sunlight, e.g. in tropical, and desert areas, a pigmented external surface layer shall be used, such as carbon black, or white pigment, e.g. rutile (TiO2). The Manufacturer shall demonstate that the external pipe surface is UV resistant within the design life, in accordance with ISO 11507. Spoolable fibre-reinforced GRP (e.g. GRE) pipe which may be in contact externally with a fluid, e.g. a sub-sea or buried system, shall be protected by a robust fluid-tight external layer, e.g. polyethylene, at least 2 mm thick.
2.6
CHEMICAL RESISTANCE The Manufacturer shall supply chemical resistance data for the relevant service fluids and the specific material (liner, matrix, and fibre), including the highest known service temperature that the material has been subjected to and, if available, the service life that has been achieved under the service conditions. The chemical resistance information shall state whether the material has been laboratory tested according to ASTM C 581 (or equivalent standard) and shall state the life expectancy for the intended service. Information about chemical resistance of non-metallic materials in a variety of chemical environments is given in PTS 30.10.02.13.
2.7
PERMEATION For hydrocarbon service, toxic and very toxic service, as defined in PTS 01.00.01.30. or for other services at the request of the Principal, the Manufacturer shall provide permeation
PTS 31.40.10.20 December 2009 Page 8 data, i.e. coefficients for permeability, diffusivity and solubility for the composite pipe wall, at the rated temperature.
PTS 31.40.10.20 December 2009 Page 9 3.
DESIGN ASPECTS
3.1
GENERAL The spoolable pipe system shall be designed to withstand the most severe anticipated conditions experienced during installation and within the service life of the system. Designers shall consider the loads that can potentially be experienced by the pipe system during the anticipated service life. Typical loads include internal pressure, hydrostatic test, bending, tensile, and vacuum.
3.2
PRESSURE RATING Because of the catastrophic (burst) failure mode of spoolable fibre-reinforced plastic pipe, design shall be based on short-term burst strength (STHP). The Manufacturer shall determine the Nominal Pressure Rating (NPR), by means of shortterm hydraulic burst strength testing (4.4) with a safety factor of at least 3.75. The nominal pressure rating is defined by the following: NPR = STHP / 3.75 NOTE:
3.3
For steel cord reinforced spoolable plastic pipe designed according to API 17 J, a minimum safety factor of 2.5 (instead of 3.75) may be used if agreed by the Principal.
CYCLIC / STATIC SERVICE This section addresses service conditions that can be considered to be neither static nor fully cyclic. It defines the NPR in terms of either NPR s (static) or NPRc (dynamic) or both of them as a function of the amplitude of the internal pressure cycle, R. R is defined as:
where Pmin and Pmax are the minimum and maximum of the pressure cycle. If the number of cycles is less than 7 000 then the service shall be considered static. NOTE:
R = 0 corresponds to fully cyclic service whereas R = 1 corresponds to static service.
Table 3.3.1 defines the NPR for the full range of service from static to fully cyclic as a function of R: Table 3.3.1
3.4
Determination of the NPR as a function of R
0 < R < 0.4
Fully cyclic regime
NPR = 0.4 x NPRs
0.4 < R < 0.8
Intermediate regime
NPR = (NPRc2(1-R2) + NPRs2R2)1/2
0.8 < R < 1
Static regime
NPR = NPRs
TENSILE LOAD RATING During the installation of spoolable pipe, a powered device is required for pulling the pipe off the spool. The pulling capability of the powered device shall not exceed the tensile load rating (TLR) of the spoolable pipe. The Manufacturer shall determine the tensile load rating, by means of tensile strength (TS) testing (4.6) with a safety factor of at least 3. The tensile load rating is defined by the following; TLR = TS/3.
PTS 31.40.10.20 December 2009 Page 10 3.5
OCCASIONAL LOAD Occasional load is of short-term duration and the number of occurrences during design life is limited. For fibre-reinforced plastic pipe systems there are no established links between the effects of long-term loading and those of higher loads that are of short-term duration. For steel pipe systems, guidance on the duration of occasional loads permitted is given in ANSI/ASME B31.3 (Section 302.2.4). For the duration of occasional loads permitted for fibre-reinforced plastic pipe systems, the following is recommended: Number of load cycles should not exceed 7000 during life of the pipe system; Duration should not exceed 10 h at any one time and no more than 100 h per year. Occasional loads are typically: - hydro-test, water hammer; - installation loads, e.g. spooling. Unless otherwise specified by the Principal, the maximum allowable occasional load, e.g. hydro-test pressure, surge, spooling load, is 1.5 times the rated value for the pipe component.
3.6
EXTERNAL PRESSURE/VACUUM RESISTANCE The spoolable pipe shall have a collapse (differential) pressure, P c, of at least 1.5 times the short-term and at least 3 times the long-term vacuum or external over-pressure, to be specified by the Principal.
3.7
LINER THICKNESS The thickness of the thermoplastic liner shall not be less than 3 mm, except in pipes of 100 mm diameter or less where the minimum thickness shall be 2 mm.
3.8
JOINTS For services proven to be harmless for the environment, the standard joints should be used. For aromatic hydrocarbon service, very toxic service (as defined in PTS 01.00.01.30.) and for other services if specified by the Principal, joints (e.g. threaded connections including Oring and/or thread compound sealing) should not be used. To prevent emission or reduce it to acceptable levels a thermoplastic welded (S-RTP), or “threaded and glued” or adhesive bonded (S-FRP) joint should be used. The pipe Manufacturer should select a suitable adhesive to seal threaded connections, and demonstrate that it can be simply applied in the field without hampering joining operations, and produce a emission-tight joint at maximum pressure and temperature.
PTS 31.40.10.20 December 2009 Page 11 4.
QUALIFICATION
4.1
GENERAL The qualification programme consists of standard methods for quantifying component performance with respect to static internal pressure, elevated temperature, tensile load, bending, vacuum, cyclic pressure performance, and leak-tightness of joints to be used in hydrocarbon and toxic services (3.8). All tests shall be carried out, or witnessed and certified by an independent third party approved by the Principal. The qualification shall be documented in a qualification report. 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 in this PTS. The definitions product family, product family representative, product sectors, and product sector representative are used in order to rationalize the requirements for qualification testing.
4.2
PRODUCT FAMILY The product family representative is the pipe component that is taken to be representative of that particular product family, i.e. spoolable pipe of the same design, construction, and materials.
4.3
PRODUCT SECTOR A product sector is a sub-division of a product family, e.g. 25 mm to 250 mm diameter spoolable fibre-reinforced polymer pipe/joint less than 100 bar, that groups spoolable pipes into specific diameter and pressure ranges. The size of each product sector shall be limited and should closely match the ranges given in Table 4.3.1. Other size bands of product sectors with similar spacing between product sector representative diameters, e.g. as given in API 15HR, shall be acceptable. The product sector representative is the component (e.g. 250 mm, 150 bar spoolable pipe) that has the largest nominal diameter and highest pressure rating in a specific sector. Table 4.3.1 - Product Sectors
4.4
Diameter - mm
0 to 50 bar
50 to 100 bar
100 to 150 bar
> 150 bar
25 to 250
A
H
N
S
SHORT-TERM BURST TESTS The short-term burst strength (STHP) in bar shall be determined by testing five replicate samples, with minimum test length of 5 times pipe diameter and unrestrained ends, in accordance with ASTM D 1599. The STHP of the product family representative shall be taken as the lower deviated (two standard deviations) value of the five replicate samples. Testing shall be at SLT (Standard Laboratory Temperature).
4.5
1000 HOURS QUALIFICATION TESTS
4.5.1
General To demonstrate long-term strength performance, i.e. minimum design life of 20 years, two replicate samples (pipe+joint) of the product sector representative shall be selected at random and pressure tested with unrestrained ends according to test method ASTM D 1598.
4.5.2
Test pressure and temperature The test pressure (TP) shall be at 65 C or design temperature if higher. The product sector representative (pipe+joint) is qualified if it survives the test duration, i.e. does not leak, lose
PTS 31.40.10.20 December 2009 Page 12 pressure, or structural integrity during the test duration. The test duration shall be 1 000 h, and the test pressure shall be related to the Manufacturer’s nominal pressure rating (NPR) by the following equation: TP1000h = 2.2 x NPR (up to 65 °C) 4.5.3
Pre-conditioning of 1000-h test specimen Before starting the 1000-h qualification test, the test samples shall be pre-conditioned at Standard Laboratory Temperature (SLT) by a total of at least 10 bending cycles, at minimum bending radius of 2 m or smaller, if so specified by the Principal. Pre-conditioning shall be performed by the following methods (a) bending around a mandrel with a maximum diameter of 4 m, or (b) four point bend test using an outer support span of 2 m and an inner span (loading jig) of 1 m. Bending shall be performed at a minimum mid-span deflection of 65 mm, equivalent to a bending radius of 2 m.
4.6
TENSILE STRENGTH TESTS The tensile strength (TS) in kN shall be determined by testing five replicate samples in accordance with ASTM D 2105. The tensile strength (TS) of the product family representative shall be taken as the lower deviated (two standard deviations) value of the five replicate samples. Testing shall be at SLT (Standard Laboratory Temperature).
4.7
VACUUM TESTS The Manufacturer shall demonstrate the ability of spoolable pipe to withstand vacuum by full-vacuum testing two replicate, 1000-h tested samples of each product family at 65 C or design temperature if higher. The product family representative is qualified if it survives the test duration, i.e. collapse of pipe or liner shall not be permitted. The test duration shall be at least 1 h. Test pipes with a length of at least 5 times the pipe diameter, and not more than 3000 mm, shall be used. For hydrocarbon services, additional full-vacuum testing shall be performed for thermoplastic lined S-GRP pipe systems. Vacuum testing shall be performed after 1000 h internal exposure testing to pentane fluid at 65 C or design temperature if higher. Collapse of pipe or liner, or liner blistering, shall not be permitted.
4.8
REQUALIFICATION
4.8.1
General Changes to a spoolable pipe component to an extent beyond that agreed with the Principal shall invalidate the component's previous qualification. Examples of changes in component design requiring requalification are defined in Table 4.8.1.1
PTS 31.40.10.20 December 2009 Page 13 Table 4.8.1.1 Changes in component design requiring requalification Reinforcement
Thermoset resin Thermoplastic
Minor change - reinforcement manufacturing process - reinforcement composition -
curing system supplier curing temperature curing schedule supplier
-
Major change reinforcement finish (sizing) filament diameter tow tex type of fibre resin grade curing system type
- grade - type Design - geometry, dimensions winding angle (> ± 5%) - reinforcement weight weight fraction (> ± 5%) Manufacture - change of manufacturing plant Note: The qualification reports and summaries of each such revalidated variant shall be amended to include reference to this revalidation and the relevant details.
PTS 31.40.10.20 December 2009 Page 14 5.
QUALITY ASSURANCE AND CONTROL
5.1
GENERAL The Manufacturer shall have a suitable (ISO 9000) and accredited (Lloyds, DNV, or equivalent) quality assurance and quality control system. The Supplier shall identify manufacturing processes and activities that affect component performance and shall ensure that these processes and activities are adequately controlled. Critical processes or activities for which procedures should be developed and maintained include, but are not limited to, the following: raw material acceptance; resin mixing (GRP); extrusion procedures (thermoplastic liner, RTP); pipe manufacturing practices; inspection and test procedures; acceptance / rejection criteria; repair procedures; training and certification of personnel; training and certification of inspectors; marking, packing, handling and transportation. In addition, a quality plan and flow diagram shall be produced, showing all the proposed tests and inspections during component fabrication). All records, documents and procedures shall be made available for inspection upon request by the Principal. It shall be the responsibility of the Manufacturer to maintain copies of the relevant records, documents and procedures for a minimum of five years from the date of commissioning acceptance.
5.2
QUALITY CONTROL EQUIPMENT All inspection, measuring, and testing equipment shall be maintained and calibrated. Test pressure measuring devices shall be either pressure gauges or pressure transducers with a full-scale range of no more than two times the test pressure and shall be accurate to at least ± 0.5 % of full-scale range. A dead weight testing device shall be available at the Manufacturer’s facility to calibrate gauges. All pressure measuring devices shall be calibrated with a dead weight pressure tester or other suitable device every six months.
5.3
MILL HYDROSTATIC TEST After manufacturing, 100% of the spoolable pipe components shall be hydrostatically tested at a pressure of 1.5 times the qualified NPR. Testing of shorter lengths is permitted, however, the minimum test length shall be 5 times pipe diameter. Hydrostatic test pressure shall be maintained for a minimum of two minutes in order to ascertain there is no leakage. If practicable, test components shall have unrestrained ends. Test temperature shall be ambient.
5.4
ONGOING PRESSURE TESTS Pressure testing of spoolable pipe component shall be based on the continuous production schedule rather than specific project orders.
PTS 31.40.10.20 December 2009 Page 15 A minimum of two 1 000 h tests of at least two product sectors shall be performed each year in accordance with Section 4.5, on a continuous basis from the production unit, irrespective of pressure rating, diameter and wall thickness. If any of the 1 000 h tests are failed, then an inspection of the plant production process and quality control procedures shall be required. Also, the previous production batch shall be rejected. Components thathave been subjected to these tests shall not be used as part of a pipe(line) system. 5.5
FIBRE CONTENT The fibre content (mass percentage) of the reinforced wall shall be determined in accordance with ISO 1172, at a frequency of 1% continuous production. Unless otherwise agreed by the Principal, the fibre content (mass fraction) shall be within +/- 5% of the mean value quoted by Manufacturer. If the fibre content is not within the specified range, then the previously produced components, up to the last successful test sample, shall be rejected.
5.6
DIMENSIONS All dimensions shall be compared with the baseline values determined for the qualified product family representative. The following dimensions shall be determined in accordance with ASTM D 3567 for at least 1 % of continuous production: internal diameter; outside diameter; mass; liner thickness; minimum liner thickness; reinforced wall thickness. The measurement location on the component shall be the same as that used to determine the baseline value for the qualified product. Any out-of-tolerance components shall be rejected.
5.7
QUALITY CONTROL RECORDS
5.7.1
General The quality control records are required to substantiate that all components manufactured to this PTS conform to the specified requirements.
5.7.2
Records control Quality control records required by this PTS shall be: legible, identifiable, retrievable and protected from damage, deterioration or loss; retained by the Manufacturer for a minimum of five years following the date of commissioning acceptance; signed and dated.
5.7.3
Records to be maintained by Manufacturer The Manufacturer shall maintain the following records for a minimum of 5 years: test results in accordance with Section 5; any records related to Manufacturer’s process documentation.
PTS 31.40.10.20 December 2009 Page 16 5.7.4
Prefabrication documentation Raw material certificates shall be available for review by the Principal prior to the start of manufacture.
5.7.5
Production quality control reports The Manufacturer shall prepare a set of quality control reports for the supplied components. These reports shall demonstrate that the delivered components have been manufactured in accordance with the requirements listed herein. The quality control report shall: identify the components (including type, nominal diameter, rated pressure and temperature), their date of manufacture, production identification information code and the manufacturing procedure used for their production; reference the prefabrication documentation; report the quality control tests.
PTS 31.40.10.20 December 2009 Page 17 6.
COMPONENT MARKING
6.1
GENERAL Components manufactured in accordance with this PTS shall be marked by the Manufacturer (6.2). Additional project related markings as desired by the Manufacturer or as requested by the Principal should be included. Markings shall be applied by paint or ink stencil, decal, or both as agreed upon between the Principal and Manufacturer. Markings shall be permanent, shall not overlap, and shall be applied in such manner as not to damage the pipe. Markings shall be applied on the pipe components within one metre of the end.
6.2
REQUIREMENTS All pipes and fittings shall be permanently marked with: Manufacturer’s name; rated pressure, tensile load and temperature; nominal diameter; Manufacturer’s identification code; date of manufacture.
PTS 31.40.10.20 December 2009 Page 18 7.
HANDLING, STORAGE AND TRANSPORTATION
7.1
HANDLING All pipes shall be cleaned, dried and packed before handling and transportation. Thermoplastic pipe is susceptible to damage by abrasion and by sharp objects. Spools of pipe tend to be top-heavy loads, and shall be handled with care to avoid overturning the spool and damaging to the pipe and/or spool A spreader bar and non-metallic slings, e.g. nylon, should be used when moving spools with a crane. Moving the spool by “rolling” shall not be permitted.
7.2
STORAGE Pipe end covers shall be used to prevent ingress of moisture or dirt to the inside of the pipe. Pipe spools should be stored on level flat surfaces with no protruding objects that may contact and damage the pipe on the external layer. During long-term storage, the pipe should be protected from freezing water that still may be present in the pipe, e.g. from hydrotesting.
7.3
TRANSPORTATION During field transport, e.g. for deployment, the spool shall be mounted in a suitable spooling frame. Transport should be on a trailer that is as close to the ground as practical. Space constraints and obstacles, especially at a development site, may pose a problem during transportation. Alternative safe methods should be considered.
PTS 31.40.10.20 December 2009 Page 19 8
INSTALLATION AND TESTING
8.1
GENERAL Installation methods shall be agreed between the Principal and Manufacturer. Copies of installation methods, procedures and quality plan shall be available on-site before work commences.
8.2
FLUSHING On completion of installation, the pipe system shall be flushed. The medium used for flushing shall be seawater or freshwater. All lines requiring a pressure test shall be flushed prior to testing. o
Flushing should preferably be carried out at temperatures above 7 C. When flushing with fresh water in sub-zero temperatures, precautions shall be taken to avoid freezing of the water in the pipe(line) system, i.e. the water should be continually circulating, or glycol antifreeze added, or the system should be drained for the duration of sub-zero temperatures. 8.3
HYDROTEST The spoolable pipe systems shall be hydrostatically pressure tested after installation. Preferably, the system should be installed so that smaller parts of a system can be pressure tested separately and at the earliest opportunity during construction. Water shall be admitted at a low point in the system and provision shall be made for bleeding the air at high points (e.g. by loosening couplings or flange connections). Any compressed air in the system may give erroneous results. Removal of air pockets will prevent damage to the pipe and injure personnel in the event of an unexpected failure during the pressure test. The test pressure shall be raised over a period of 30 minutes or longer to 1.5 times the system design pressure, and held for a period of 15 minutes, or longer. The rate of pressurisation shall not exceeed 2 bar per minute. A further leak test at 1.1 times the system design pressure should also be carried out for a minimum of 24 hours. The pressure during the hydrotest and the leak test shall be recorded continuously.
PTS 31.40.10.20 December 2009 Page 20 9.
REFERENCES In this PTS, reference is made to the following publications: NOTES:
1. Unless specifically designated by date, the latest edition of each publication shall be used, together with any amendments/supplements/revisions thereto. 2.
The PTS’s and most referenced external standards are available to Shell users on the SWW (Shell Wide Web) at http://sww05.europe.shell.com/standards/
PETRONAS STANDARDS Defenition of temperature, pressure and toxicity levels
PTS 01.00.01.30
Non-Metallic Materials – Selection and Application
PTS 30.10.02.13
AMERICAN STANDARDS Process piping
ASME B31.3
Issued by: American Society of Mechanical Engineers ASME International Three Park Avenue, M/S 10E New York, NY 10016 USA
Specification for high pressure fiberglass line pipe
API 15 HR
Specification for Unbonded Flexible Pipe
API 17J
The Ageing of PA-11 in Flexible Pipes
API 17TR2
Issued by American Petroleum Institute Publicastions and Distribution Section 1220 L Street Northwest Washington DC 20005 USA
Standard practice for determining chemical resistance of thermosetting resins used in glass-fiber reinforced structures intended for liquid service
ASTM C 581
Test method for time-to-failure of plastic pipe under constant internal pressure
ASTM D 1598
Test method for short-time hydraulic failure pressure of plastic pipe, tubing, and fitings
ASTM D 1599
Standard Test Method for Longitudinal Tensile Properties of "Fiberglass" (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe and Tube
ASTM D 2105
Standard Test Methods for Steel Tire Cords
ASTM D 2969
Standard Practice for Determining Dimensions of Fiberglass (Glass-Fiber-Reinforced Thermosetting Resin) Pipe and Fittings
ASTM D 3567
Issued by: American Society for Testing and Materials 100 Barr Harbor Drive West Conshohocken PA 19428-2959 USA.
INTERNATIONAL STANDARDS Plastics - Unplasticized Poly (Vinyl Chloride) (PVC-U) Moulding and Extrusion Materials - Part 1: Designation System and Basis for Specifications
ISO 1163
Textile Glass Reinforced Plastics - Determination of Loss on Ignition
ISO 1172
PTS 31.40.10.20 December 2009 Page 21 Plastics - Polyethylene (PE) Moulding and Extrusion Materials Part 1: Designation System and Basis for Specifications
ISO 1872
Plastics - Polyamide (PA) Moulding and Extrusion Materials - Part 1: Designation
ISO 1874
Quality management and quality assurance standards
ISO 9000
Paints and varnishes - Exposure of coatings to artificial weathering - Exposure to fluorescent UV and water
ISO 11507
Extruded Sheets of Polypropylene (PP) - Requirements and Test Methods
ISO 15013
Extruded Sheets of Polyvinylidene Fluoride (PVDF) Requirements and Test Methods
ISO 15014
Issued by: International Organisation for Standardisation Case Postale 56 Geneva 20 Switzerland CH-1211. Copies can also be obtained from national standards organisations.
