Specfication GRP

UPPER ZAKUM 750 ISLANDS SURFACE FACILITIES PROJECT – EPC2 PROJECT No. P7512 SPECIFICATION FOR GLASS REINFORCED PLASTIC (GRP) PIPING Doc. No. P7512-TS-2000-P-0005

Rev. B4

Page: 2 of 36

TABULATION OF REVISED SECTIONS / PAGES

Revision

Page/Section

Description

B4

5 / Clause 1

Scope of this document is updated with service fluids as per Fluid List document no. P7512-GD-2000-F-0017

B4

8 / Clause 3.2

Document number for Piping Material Specification is updated.

B4

9 / Clause 5.1

System design conditions are updated for GRP Pipe classes as per Fluid List document no. P7512-GD-2000-F0017

B4

12 / Clause 6.10

Gasket material requirement for GRP pipe classes are updated to include GRP manufacturer’s recommendation.

B4

14 / Clause 7.4

Flange types for GRP pipe classes are updated to include GRP manufacturer’s recommendation.

B4

24 / Clause 11.9

Hydrostatic test frequencies for GRP components are newly added as per VDCA No. PE-103-PPFP008-DCA001 dated 30-Nov-2014

B4

25 / Clause 12

B4

B4

Additional requirement for 50 bar GRP piping (Pipe class 35 / Annexure - 1 B51V) are newly added as per COMPANY letter no. UZ750/P7512/ZAD /PED/LET/3562 dated 08-Jul-2015

36 / Annexure - 2

TABUL ATION OF HOLDS

Page/Section

Marking with labelling is newly added as per VDCA No. PE-103-PPFP008-DCA-002 dated 30-Sep-2014

Description

Stress analysis philosophy is newly added for 50 bar GRP piping as per COMPANY letter no. UZ750/P7512/ZAD/ PED/LET/3562 dated 08-Jul-2015 and Attachement-3 of MOM no. UZ750/P7512/PED/FPI/MOM/0002 dated 06May-2015


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Table Table of Contents 1.

SCOPE OF DOCUMENT .............................................................. ................................................................................................................ .................................................. 5

2.

TERMINOLOGY TERMINOL OGY AND A ND A B BREVI ATIONS .......................................................... ...................................................................................... ............................ 5

3.

CODES, STANDA ST ANDA RDS AND SPECIFICATIONS SPECIFICAT IONS .......................................................... ........................................................................... ................. 6 3.1 3.2

................................................................. ........................ 6 INTERNATIONAL CODES AND CODES AND STANDARDS ......................................... ............................................................................................. ...... 8 PROJECT SPECIFICATION: .......................................................................................

4.

ORDER OF PRECEDENCE ........................................................................................................... ........................................................................................................... 8

5.

SYSTEM DESIGN ............................................................. .......................................................................................................................... ............................................................... 9

6.

VENDOR’S / MA NUFACTURER’ S RESPONSIB ILITIES ILIT IES ...................................................... ............................................................ ...... 10

7.

DESIGN, FABRIC FA BRICATION ATION A ND SUPPLY ..................................................................................... ..................................................................................... 13 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8

8.

MATERIAL MAT ERIAL .................................................... ................................................................................................................. ................................................................................ ................... 16 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8

9.

................................................................................................ ................................... 13 ENVIRONMENTAL DATA ............................................................. .................................................................................................................................. ...................................... 14 PIPE ............................................................................................ ......................................................................................................................... 14 FITTINGS .......................................................................................................................... ......................................................................................................................... ........................... 14 FLANGES .............................................................................................. .......................................................................................................... ............... 15 WALL THICKNESS ........................................................................................... ............................................................................................................. ....................................................... 15 PIPE SUPPORTS ...................................................... ............................................................................................................... ....................................................... 16 BURIED PIPING ........................................................ ...................................................................... .. 16 SMALL BORE BRANCH CONNECTIONS .....................................................................

............................................................................................................................. ......................................................... 17 RESINS .................................................................... ............................................................................................... ............. 17 CHEMICAL RESISTANCE .................................................................................. ............................................................................................................... 17 GLASS FIBERS ................................................................................................................ ................................................................................................... ......................... 17 LINER AND LINER AND TOP COAT ........................................................................... ....................................................................................................................... 18 ADHESIVE ADHESIV E ........................................................................................................................ ............................................................................................... .................................. 18 FILLERS AND FILLERS AND PIGMENTS ............................................................. ............................................................................................................... ................ 18 CONDUCTIVITY ............................................................................................... ..................................................................................... ... 19 EXTERNAL FIRE RESISTANCE ...................................................................................

JOINT SYSTEM ........................................................................................................ ............................................................................................................................ .................... 19

10. PERFORMANCE REQUIREMENTS ........................................................................... ............................................................................................ ................. 20

..................................................................................... ............................................ 20 10.1 QUALIFICATION PROGRAMME ......................................... ........................................................................................................... ................................... 21 10.2 JOINT STRENGTH ........................................................................ .................................................................................................................. .................................................................. ..... 21 10.3 STIFFNESS ..................................................... ........................................................................................................... ................................... 21 10.4 BEAM STRENGTH ........................................................................ ............................................................................................. ... 21 10.5 ULTIMATE HOOP STRESS .......................................................................................... .......................................................................................... .... 21 10.6 AXI AL TENSILE STRENGTH ....................................................................................... ........................................................................................... ............................................ 21 10.7 HOOP TENSILE STRENGTH ............................................... ......................................................................................................... ......................... 22 10.8 BOIL RESISTANCE ................................................................................. 10.9 IMPACT RESISTANCE .................................................................................................... 22 ...................................................................................................................... ................................... 22 10.10 HARDNESS ................................................................................... .......................................................................... .. 22 10.11 HYDROSTATIC DESIGN BASIS (HDB) .........................................................................


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10.12 GLASS CONTENT ............................................................................................................ 22 10.13 SAFETY FACTOR ............................................................................................................ 22 10.14 FLANGES ......................................................................................................................... 22 10.15 DEGREE OF CURE .......................................................................................................... 23 11. INSPECTION AND TESTING ....................................................................................................... 23 11.1 CHECKS OF RESIN QUALITY ......................................................................................... 23 11.2 SHORT TERM WEEPING TESTS .................................................................................... 23 12. IDENTIFICATION, MARKING AND PACKING ........................................................................... 25 13. DOCUMENTATION ...................................................................................................................... 25 13.1 13.2 13.3 13.4 13.5 13.6 13.7

VENDOR’ S / MANUFACTURER’ S DRAWINGS AND DATA SHEETS ............................ 25 PRE-QUALIFICATION AND QUALIFICATION ................................................................ 26 INSTALLATION MANUAL ............................................................................................... 27 SAFETY PRECAUTIONS ................................................................................................. 27 QUALITY ASSURA NCE / QUALITY CONTROL REQUIREMENTS................................ 27 QA / QC PLAN .................................................................................................................. 28 QA / QC RECORDS .......................................................................................................... 29

14. FIELD FABRICATION, INSTALLATION AND TESTING ............................................................ 29 14.1 14.2 14.3 14.4

GENERAL ......................................................................................................................... 29 PREFABRICATION .......................................................................................................... 29 ASSEMBLY AND ERECTION .......................................................................................... 30 INSPECTION AND TESTING REQUIREMENTS ............................................................. 31

15. GUARANTEE ............................................................................................................................... 34 16. SINGLE POINT RESPONSIB ILITY DURING PROJECT EXECUTION ...................................... 34 ANNEXURE - 1: ADDITIONA L REQUIREMENTS FOR 50 B AR GRP PIPING (PIPE CLASS: B51V)……………………………………………………………………..35 ANNEXURE - 2: STRESS AN ALYSIS PHILOSOPHY FOR VERIFICATION OF EFFECT DUE TO TRANSIENT FORCES……………………………..………………………..36


1.

Rev. B4

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SCOPE OF DOCUMENT This specification defines the minimum requirements for the design, engineering, qualification, material, manufacturing, supply, fabrication, shipment, protection, installation, inspection and testing including documents, handling and storage of glass-fibre Reinforced Plastic (GRP) piping system for the sea water (cooling water and fire water system), produced water, potable water, hypochlorite, filter aid for vent and drain, closed drain, open drain, demineralized water, service water, drilling water, vent and neutralized waste water piping associated with Upper Zakum 750 Islands Surface Facilities, to be built by CONTRACTOR during EPC-2 Phase. This specification shall be reviewed/ endorsed by GRP Specialist to be appointed by PED on behalf of ZADCO.

2.

TERMINOLOGY AND ABBREVIATIONS For the purpose of this document, the words and expressions listed below shall have the meanings assigned to them as follows: PROJECT

Upper Zakum 750 - Islands Surface Facilities - EPC2 Project No.P7512

COMPANY

ZAKUM DEVELOPMENT COMPANY (ZADCO)

CONTRACTOR

Petrofac Emirates LLC and Daewoo shipbuilding & Marine Engineering Co. Ltd (PED)

THIRD PARTY CONSULTANT

FFP Engineering SAL (FFP)

API

American Petroleum Institute

ASME

American Society of Mechanical Engineers

ASTM

American Society for Testing and Materials

AWWA

American Water Works Association

BTEX

Benzene, Toluene, Ethylbenzene, and Xylene

EPC

Engineering Procurement and Construction

FEED

Front End Engineering and Design

GRE

Glass-fibre reinforced epoxy

GRP

Glass Reinforced Plastic

GRVE

Glass-fibre reinforced vinyl ester

HDB

Hydrostatic Design Basis

IMO

International Maritime Organization

ISO

International Standards Organization for Standardization


3.

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MAY/ CAN

Indicates an acceptable course of action

NPS

Nominal Pipe Size

P & ID

Piping & Instrumentation Diagram

PTFE

Poly Tetra Fluoro Ethylene

SHALL

Indicates a mandatory requirement

SHOULD

Indicates a strong recommendation to comply with the requirements of this document

UV

Ultraviolet

VENDOR / SUPPLIER / MANUFACTURER

Any and all persons, firms, partnerships, companies, bodies, entities or a combination thereof including sub-vendors and vendors, who are providing GOODS (including any of the foregoing whose purchase orders are novated or assigned by COMPANY to CONTRACTOR) and the successors and assigns of such persons, firms, partnerships, companies, bodies, entities or a combination thereof

WBS

Work Breakdown Structure

CODES, STANDARDS AND SPECIFICATIONS The following Specification and International Codes & Standards shall form an integral part of this specification. Reference to any code or standard shall mean the latest edition of that code or standard including addenda or supplements or revisions (effective date as on 4th April 2013) unless otherwise stated.

3.1

INTERNATIONAL CODES AND STANDARDS Reference

Title

ASME B 16.5

Pipe Flanges and Flanged Fittings NPS ½ through NPS 24

ASME B 16.21

Non-metallic flat gaskets for pipe flanges

ASME B 16.47

Large Diameter Steel Flanges, NPS 26 through NPS 60

ASME B 31.3

Process piping

ASTM C 581

Standard practice for determining chemical resistance of thermosetting resins used in glass-fibre reinforced structures intended for liquid service

ASTM D 570

Test for water absorption of plastics


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Reference

Title

ASTM D 638

Standard Test Method for tensile properties of plastics.

ASTM D 1598

Standard test method for the time to failure of plastic pipe under constant internal pressure

ASTM D 1599

Standard test method for short-time rupture strength of plastic pipe, tubing and fittings

ASTM D 2105

Standard test method for longitudinal tensile properties of “fiberglass” (glass-fiber reinforced thermosetting resin) pipe and tube

ASTM D 2122

Standard test method for determining dimensions of thermoplastic pipe and fittings

ASTM D 2290

Standard test method for apparent hoop tensile strength of plastic or reinforced plastic pipe by split disk method

ASTM D 2412

Standard test method for external loading properties of plastic pipe by parallel-plate loading

ASTM D 2444

Standard test method for determination of impact resistance of thermoplastic pipe and fittings by means of a tup (falling weight).

ASTM D 2563

Standard practice for classifying visual defects in glass reinforced plastic laminate parts

ASTM D 2583

Standard test method for indentation hardness of rigid plastics by means of a Barcol impresser

ASTM D 2584

Standard test method for ignition loss of cured reinforced resins

ASTM D 2925

Standard test method for beam deflection of “fiberglass” (glass-fiberreinforced-thermosetting resin) pipe under full bore flow.

ASTM D 2992

Standard practice for obtaining hydrostatic or pressure design basis for “fiberglass” (glass-fiber reinforced thermosetting resin) pipe and fittings

ASTM D 2996

Standard Specification for filament wound “fiberglass” reinforced thermosetting resin) pipe

ASTM D 3567

Standard practice for determining dimensions of “fiberglass” (glassfiber-reinforced thermosetting resin) pipe and fittings.

ASTM D 4024

Standard specification for machine (glass-reinforced-thermosetting resin) flanges

made

“fiberglass”

ASTM D 5421

Standard specification for contact (glass-reinforced-thermosetting resin) flanges

molded

“fiberglass”

AWWA M45

Fiberglass Pipe Design

AWWA C950

Fiberglass Pressure Pipe

(glass-fiber


3.2

4.

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Reference

Title

ISO 11357-2

Plastics – Differential Scanning Calorimetry determination of glass transition temperature.

ISO 14692-1

Petroleum and Natural Gas Industries – Glass-reinforced Plastics (GRP) Piping —Part 1: Vocabulary, symbols, applications and materials

ISO 14692-2

Petroleum and natural gas industries — Glass-reinforced plastics (GRP) piping —Part 2: Qualification and manufacture

ISO 14692-3

Petroleum and natural gas industries — Glass-reinforced plastics (GRP) piping —Part 3: System design

ISO 14692-4

Petroleum and natural gas industries — Glass-reinforced plastics (GRP) piping —Part 4: Fabrication, installation and operation

ISO 9001:2008

Quality management Systems - Requirements

ISO 29001

Petroleum, petrochemical and natural gas industries — Sector-specific quality management systems — Requirements for product and service supply organizations

(DSC)

–

Part

2:

PROJECT SPECIFICATION: P7512-TS-2000-P-0004

:

Piping Material Specification

P7512-GD-2000-G-0060

:

Specification for General Environmental Data and Units of Measurement

P7512-TS-2000-Y-0003

:

Coating and Lining Specification

P7512-TS-2000-P-0001

:

Specification for Pipe Stress Analysis

EXHIBIT Z10

:

Quality Management Requirements

ORDER OF PRECEDENCE The following is the order of precedence in case of conflict: •

National or Local Regulations

•

Job Specifications

•

Material Requisitions

•

COMPANY Standards and Specifications

•

International Codes and Standards

In the event of any conflict between this specification, the codes and standards and other specifications mentioned herein, the most stringent shall apply


5.

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SYSTEM DESIGN

5.1

The GRP piping system is meant for the following systems with service condition as indicated below, the fluid composition shall be as per fluid list attached in Material Requisition. Design Pressure psig (barg)

Design Temperature Deg. F (Deg C)

A21V

Hydrocarbon Liquid Drain (Closed Drain), Open drain

125 (8.62)

212 (100)

Sour service (Adhesive bonded Socket / Spigot ) joints(A/G & U/G), Full Vacuum (With BTEX)

2

A11V

Open Drain (AOC), Open drain (COC), Open drain (OD3), Closed drain

125 (8.62)

131 (55)

(Adhesive bonded Socket /Spigot) joints up to 24”, Laminated (butt & strap) Joints above 24” (A/G & U/G) (With BTEX)

3

A31V

Potable Water , Demineralized water

180 (12.4)

160 (71.1)

(Adhesive bonded Socket / Spigot joints) (AG), (NSF 61 or equivalent approval)

4

A11V

Sea Water (Fire Water)

232 (16)

160 (71.1)

Flow may contain sand particles (Adhesive bonded Socket / Spigot joints) (A/G & U/G), Full Vacuum

5

A11V

Sea Water (Cooling Water), Service Water, Drilling Water

232 (16)

131 (55)


6

A11V

Potable water, Vent

232 (16)

160 (71.1)

Adhesive bonded Socket / Spigot joints (A/G & U/G)

A1S

Hypochlorite (Electro Chlorination), Filter Aid, Neutralized waste water

232 (16)

160 (71.1)

Adhesive bonded (Socket / Spigot) ‘or’ Laminated (butt & strap) joints (A/G)

A41V

Sea Water (Cooling Water)

280 (19.31)

131 (55)


B51V

Sea Water (Cooling Water)

620 (42.75)

131 (55)


Sl. No

1

7

8

9

Pipe class

Fluid

REMARKS


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CONTRACTOR / MANUFACTURER shall design the entire GRP piping system taking in to consideration of the following requirements, so that the piping system is fit-for-purpose for a design life cycle of 30 years. •

Design conditions.

•

Stress analysis and support design to ensure adequate flexibility in the piping system against thermal & surge conditions. CONTRACTOR shall carry out preliminary stress analysis to establish the preliminary pipe routing. MANUFACTURER shall further carryout the stress analysis as defined under para 6.5 of this specification.

•

Hydraulic analysis to ensure the piping system is suitable against the pressure surge and water hammer, cavitation, velocity limitation, erosion etc.

•

Other design consideration as required by ISO 14692.

•

The design of buried GRP piping shall also be according to AWWA M45, or equivalent internationally accepted standard, to be agreed by the COMPANY/CONTRACTOR.

The GRP piping system shall be designed using tensile resistant pipes, fittings, flanges and joints such that the system does not require the use of thrust blocks. MANUFACTURER shall obtain, from CONTRACTOR, the flow rate with exact design velocity in order to have a proper assessment on erosion of the resin, if any. GRP system shall be designed taking in to consideration the possible sand particles. The maximum velocity data is tabulated as below. Maximum Velocity Sl. No

Fluid

(m/s) (at rated flow)

6.

1

For process Fluids {Hydrocarbon Liquid Drain (Closed Drain), Open Drain(AOC/COC), Potable Water, Sea Water(Cooling Water/ Service Water / Drilling Water),Hypochlorite}

2

For Fire water

3.5 (maximum velocity of 4 m/s during upset or emergency) 4

VENDOR’S / MANUFACTURER’S RESPONSIBILITIES VENDOR / MANUFACTURER shall be responsible for the following –

6.1

Design, qualification, manufacture, testing and supply of the GRP pipes, fittings, flanges, saddles and other fittings required for instrument connection. VENDOR / MANUFACTURER shall provide recommendations on associated equipment such as equipment nozzles, valves, expansion bellows, gaskets, fasteners and other accessories.

6.2

VENDOR / MANUFACTURER shall assume responsibilities and guarantee for the overall performance of the GRP piping system to suit the pressure, temperature and service/environmental conditions for a design life of Thirty (30) years.


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6.3

VENDOR / MANUFACTURER shall offer GRP piping components that have been subjected to the qualification testing strictly as per the requirements indicated under clause 10 of this document with all other mandatory / regulatory tests and inspection with proper QA/QC control carried out.

6.4

VENDOR / MANUFACTURER shall review all the preliminary isometric sketches prepared by the CONTRACTOR and verify the Bill of Materials to ensure that the item type and description suits the product offered. Changes, if any, to suit the design and range of products of the VENDOR / MANUFACTURER shall inform to CONTRACTOR through proper doc umentation.

6.5

The stress analysis shall be carried-out using latest version of CAESAR-II v5.3 and in accordance with project specification for stress analysis P7512-TS-2000-P-0001. This analysis must validate the following: •

Validate the design and routing proposed by CONTRACTOR and / or recommend necessary changes, when applicable.

•

Validate the stability of GRP pipes during transportation. The values for accelerations in three directions shall be furnished during technical evaluation.

•

Location & type of the supports provided.

•

Additional supports provided for stability of GRP pipes during transportation should be identified and marked in the isometric drawings.

•

Confirm the thickness of the pipes, fittings, flanges and joints and Identify areas requiring increased thickness.

•

Identify the locations of integral collars required for supporting the piping.

Analysis shall be done for all pipe sizes as per project specification P7512-TS-2000-P-0001 (Specification for Pipe Stress Analysis). The changes required due to the stress analysis outcome shall be notified to the CONTRACTOR through proper documentation. Such changes shall be discussed with CONTRACTOR, so that the agreed changes will be incorporated in the final “Issued for Construction” isometrics drawings. Developing detailed specification, if any, for special spring supports, expansion bellows, etc. shall be part of VENDOR’s / MANUFACTURER’s responsibility. 6.6

VENDOR / MANUFACTURER shall be responsible to supply all the additional materials required, if any, (i.e. additional local reinforcement, support saddles etc.) to satisfy the requirement of stress analysis and supporting of GRP piping.

6.7

GRP lines under firewater and cooling water network may be subject to surge conditions, which may damage the bonded joints, seals or supports and lead to leakage, permanent deformation and/or pipe rupture. The transient / surge analysis of GRP piping network will be carried out by CONTRACTOR and surge loads shall be furnished to VENDOR / MANUFACTURER. VENDOR / MANUFACTURER shall include this surge load in his stress analysis. Vacuum requirements if any shall be derived from surge analysis.

6.8

VENDOR / MANUFACTURER shall furnish necessary fabrication, installation & hydro test procedures / method statements relevant to the product supplied and other documentation as indicated under clause 13 of this specification.

6.9

VENDOR / MANUFACTURER shall provide details of the tools & tackles required for fabrication, jointing of GRP piping and provide details of consumables like heating blankets, adhesives, O-rings, etc. VENDOR / MANUFACTURER shall indicate the estimated quantities of these materials.


6.10

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Rev. B4

VENDOR / MANUFACTURER has recommended the best type of gasket to be used on flanges, compatible with the nature of the fluid to be conveyed as per below table. Gasket shall be generally Neoprene flame retardant rubber with steel inserts full face 3mm thick with hardness 65 shore A up to 6” and 5mm thick with hardness 60 shore A for 8” and above. For chemical, sour and services with presence of BTEX, expanded PTFE may be used. Asbestoselastomer gaskets shall not be used. However supply of gaskets is excluded from VENDOR’s scope. Pipe Class

Services

Gasket material as per purchase description

GRP manufacturer’s recommendation for Gasket material GORE Gasket (Expanded PTFE)

A11V (Non-sour)

-

NPS ≤ 32 : 3.0 mm thickness, Universal Style – 800 (Flat ring), Or Equivalent.

-

NPS ≥ 34 : 6.0 mm thickness, Joint Sealant DF 17 (Tape type) Or Equivalent.

Open drain (AOC), Open drain (COC), Open drain (OD3), Closed drain

Expanded PTFE

Sea Water (Cooling Water), Fire Water, Service Water Drilling Water, Potable water, Vent

Neoprene rubber

KROLL & ZILLER profile gasket, EPDM with steel insert (G-ST-P/S), Flat Ring Type Or Equivalent.

Expanded PTFE

GORE Gasket (Expanded PTFE) - NPS ≤ 32 : 3.0 mm thickness, Universal Style – 800 (Flat ring), Or Equivalent.

Neoprene rubber


A21V (Sour)


A31V (Non-sour)

Potable Water, Demineralized water

A1S (Non-sour)


Expanded PTFE

GORE Gasket (Expanded PTFE) - NPS ≤ 32 : 3.0 mm thickness, Universal Style – 800 (Flat ring), Or Equivalent.

A41V (Non-sour)

Sea water (Cooling water)

Neoprene rubber


B51V (Non-sour)


Neoprene rubber



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6.11

VENDOR / MANUFACTURER shall review of all proposed field design changes arises due to unforeseen factors, which may affect GRP pipe work and support arrangement throughout the construction phase. Such field design changes must be informed to VENDOR / MANUFACTURER, prior to implementation.

6.12

VENDOR / MANUFACTURER shall provide per diem rates for providing training to CONTRACTOR's personnel in fabrication, erection and testing of GRP piping at the fabrication shop / site.

6.13

VENDOR / MANUFACTURER shall provide per Diem rates for the supervision services to carry out the fabrication, installation and testing of GRP pipe-work at the fabrication shop / site.

6.14

Supply of Equipment and tools required for fabrication and jointing of GRP piping spools e.g. Shavers, pi tapes, Clamps, belt and pullers, Cutting wheels, flapper wheels, heating blankets, etc. shall be in the scope of VENDOR / MANUFACTURER.

6.15

VENDOR / MANUFACTURER, in his quotation, shall inform CONTRACTOR of any exceptions, variations, substitutions or non-compliance with the requirements of this specification.

6.16

In case of technical conflict between any of the Purchase Order documents and any referenced document, the VENDOR / MANUFACTURER shall discuss with CONTRACTOR / COMPANY for resolution.

7.

DESIGN, FABRICATION AND SUPPLY The GRP pipe and piping components shall be designed, manufactured, tested and supplied in compliance to the applicable specifications referred under Section 3 of this document and the additional requirements /amendments/ supplements mentioned in this specification. Materials shall be supplied in accordance with the piping bills of materials after performing all relevant engineering such as review of Isometrics sketches prepared by the CONTRACTOR and ensuring that the product offered suit the item type and description. Substitutions shall not be made unless written authorisation is obtained from COMPANY / COMPANY nominated representative. Such authorisation however, shall in no way diminish the VENDOR’s / MANUFACTURER’s obligation to meet the requirements of the standards and specifications referred in this specification. VENDOR / MANUFACTURER shall furnish the project specific drawings of pipe and piping components, indicating various dimensional details like outside diameter, thickness, length of fittings, dimensions of end connections etc. The dimensions and tolerances shall be determined in accordance with ASTM D 3567. VENDOR / MANUFACTURER shall include details such as laminate construction, layer sequences, overlay widths etc.

7.1

ENVIRONMENTAL DATA GRP piping system shall be designed considering the environmental data indicated in the document P7512-GD-2000-G-0060.


7.2

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PIPE Pipes shall be machine made using the continuous filament or dual helical winding process in which continuous fibres impregnated with resin and a curing agent are wound onto the outside of a mandrel under a predetermined winding angle and under controlled tension. The use of chopped glass or uni-axial glass to increase axial properties of the pipe is acceptable. The pipes shall have a solid wall structure. Ribbed pipes shall not be allowed. Use of bulking agent such as sand is not recommended. The dimension of the pipe shall be in accordance with code AWWA C950. The pipes shall be manufactured in standard laying lengths preferable not exceeding 12 meters and not shorter than 6 meters. The tolerance on the MANUFACTURER’S declared length shall not exceed ± 25 mm.

7.3

FITTINGS Fittings such as elbows, tees and reducers shall be equal or superior in performance to the pipe of the same diameter and pressure rating. Fitting in size DN 25 up to and including DN 600 shall be filament wound on precision steel molds. Fittings DN 650 and above, can be built from segmented pipe sections in the form of miters. Elbows & Miters shall have a turning radius of 1.5 times the nominal diameter. However other turning radii are acceptable with prior approval of COMPANY.

7.4

FLANGES Flanges shall be equal or superior in performance to the pipe of the same diameter and pressure rating. Flanges shall be machine made using the filament winding process or contact molded. Flanges shall be flat face / Raised face and drilled in accordance with ASME B16.5 / ASME B16.47 Series A, to the rating specified on the applicable detail drawing and piping material specification. VENDOR / MANUFACTURER shall provide torque sequence, torque increment, maximum torque values and flange qualified pressure for each flange size and pressure rating. Based on the service requirement in GRP Pipe classes, GRP Manufacturer has recommended using following flange types as listed in below table, Pipe Class

A11V (Non-sour)

Services

Flange Type

Flange face

Remarks

Open drain (AOC), Open drain (COC), Open drain (OD3), Closed drain

Stub end flange with steel backing flange

Raised face

BTEX

Sea Water (Cooling Water), Fire Water, Service Water, Drilling Water, Potable water, Vent

Normal Flange

Flat face

--


7.5

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Pipe Class

Services

Flange Type

Flange face

Remarks

A21V (Sour)



Raised face

Sour service, BTEX

A31V (Non-sour)

Potable Water, Demineralized water

Normal Flange

Flat face

--

A1S (Non-sour)



Raised face

BTEX

A41V (Non-sour)


Normal Flange

Flat face

--

B51V (Non-sour)


Normal Flange

Flat face

--

WALL THICKNESS VENDOR / MANUFACTURER shall determine the wall thickness required for each size based on the hydrostatic design basis of the pipe to meet the design requirements as listed in section 5. The wall thickness shall be based on the 97.5 % confidence limit of the hydrostatic design basis, reduced by a suitable service factor. Wall thickness calculation shall be based on ISO 14692 and shall be verified with respect to AWWA M45. In no case shall the total wall thickness of any component be less than listed below: ID < 100 mm ID ≥ 100mm

tmin ≥ 0.025 ID tmin = 3.0 mm

Where, ID is the internal diameter of the structural wall of the piping component, in millimetres.

7.6

PIPE SUPPORTS The piping system shall be supported using support suitable for GRP piping. VENDOR / MANUFACTURER shall supply the design and fabrication drawing for the supports. VENDOR / MANUFACTURER shall review the requirement of any reduction of the span or provide additional wall thickness to ensure the piping can maintain its integrity while subject to self-weight in a fire. Elastomeric pads shall be used to prevent direct contact between the GRP pipe and support.


7.7

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BURIED PIPING VENDOR / MANUFACTURER shall design pipes for buried installation for the design conditions such as minimum and maximum cover depth and wheel loads as specified in the enquiry document. These pipes shall be designed without considering provision of any protective cover like concrete slabs. GRP piping components for buried installation shall be designed by taking in to consideration the following aspects: •

Shallow burial condition

•

Uneven bedding or differential settlement of unstable native soils

•

Installation loads

•

Live truck loads, truck wheel loads (buried pipe should be safe for truck wheel load of 15t at 1.0 m depth (at road crossings)).

•

Reduced effective soil density for high water table

•

Buoyancy due to high water table for empty piping system.

CONTRACTOR / MANUFACTURER shall design the buried GRP piping system by taking into account the soil / pipe interaction, including soil load exerted by the soil cover, live loads, differential soil settlement, buoyancy effect etc. The need for any concrete anchor block or thrust block shall be determined during detailed design, depending upon expected operational pressure surge, temperature change and nature of the soil and geometry of the piping layout. 7.8

SMALL BORE BRANCH CONNECTIONS In small bore branch connection that are manufactured as built-up saddles, the branch pipe shall protrude in to the header pipe for full thickness of the header pipe with reinforcement pad covering full circumference of branch. Stiffener pads shall be added on the branch when connected to valve or instruments that incur loads on the branches.

8.

MATERIAL All basic materials shall be ne w, fresh and free from all deleterious def ects and imperfections. The basic material will be combined into pipe, fittings, and flanges which meet the performance requirements of this specification. VENDOR / MANUFACTURER must have written procedures for acceptance for each raw material used during manufacturing and shall be in compliance with the relevant codes / standard / specifications. The acceptance procedure must identify key raw material property that can affect product manufacturing and final products performance. The qualification of material shall be as per relevant codes and COMPANY approved manufacturer’s standard. The material shall have a corrosion resistant inner liner, structural wall and resin rich external layer.


8.1

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RESINS The pipe, fittings and flanges shall be made from commercial high grade thermosetting epoxy or vinyl-ester type resins. Isophthalic or orthophthalic polyester resin can be used for pipe min. size DN 650 & above upon approval from COMPANY. The actual selection of the resin shall be based on process fluid, flow rate, chemical resistance, fire resistance, UV protection required etc. and cost. VENDOR / MANUFACTURER shall state the type of resin and curing system chosen based on the service conditions given in this specification. The type of resins and curing requirement must be specified based on service conditions and allowable temperature. The same shall be confirmed and agreed with VENDOR / MANUFACTURER. Resin selection shall be supported by a written statement from the resin manufacturer indicating its recommendation for use of the resin in the specified design conditions. The complete liner, structures and protective layer shall be of same resin types.

8.2

CHEMICAL RESISTANCE The resin Manufacturer shall supply chemical resistance data for the relevant service fluids and the specific resin material, quoting 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.

8.3

GLASS FIBERS Two types of glass, having different chemical compositions, shall be used to reinforce thermosetting resins (they are known as "C" glass and "E" glass): •

Inside Layer shall be of ‘C’ Glass or “ECR” Glass with low alkali content.

•

The structural wall shall be reinforced with E-glass with low alkali content.

Glass reinforcements shall be compatible with the resin used. Glass reinforcement materials shall be stored dry and protected against dust or other negative influences. 8.4

LINER AND TOP COAT All parts exposed to the fluid shall have a smooth uniform resin-rich lining / inner layer (with resin content of min. 70% by weight) to provide additional protection against chemical attack. The minimum thickness of this corrosion resistant inner liner shall be 0.5 mm. All piping shall have a smooth resin rich top coat. The minimum thickness of this external layer shall be 0.5 mm or more. For the pipe and fittings installed aboveground, the prolonged exposure to intense sunlight may cause localized degradation of the resin. Hence MANUFACTURER shall consider added pigments or other suitable UV resistant coating on the top coat to protect against UV (ultra-


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violet) radiation, in addition to safeguarding from abrasion. Any surface coating required for UV protection or identification purposes such as process marking shall conform to Specification Number NC 26 of the document Coating and Lining Specification (P7512-TS2000-Y-0003). 8.5

ADHESIVE Adhesive and solvent cleaner for bonded joints shall be of a material suitable for the services and design conditions specified. For all cemented connections, two component epoxy resin shall be used that consists of a pre-measured quantity of curing agent and resin packed in separate containers. Each kit size shall contain a written instruction covering polymerization conditions, surface preparation, mixing, jointing safety, pot life and curing. Shelf life for adhesive and solvent cleaner kits, at 38° C, shall not be less than 9 months from the date of shipment. Adhesive and solvent cleaners shall be suitable for use in 48° C working environment. The adhesive cement shall be an epoxy type formulated to be resistant to the transported media and U.V. deterioration and tested to the service temperature and pressure. The adhesives used shall be conductive to provide an electrically conductive system (See para 8.7 of this specification). VENDOR / MANUFACTURER shall advise the type of joint cleaner to be used if not included in the adhesive cement kit. Adhesive cement shall be suitable for m ixing curing at 35°C at a relative h umidity in excess of 85%. Only adhesive cement material recommended and supplied by the pipes manufacturers shall be used.

8.6

FILLERS AND PIGMENTS Use of fillers within the resin shall be avoided, since they can result in differing properties compared to the base resin, which will affect the long-term performance of the pipe. The acceptability of fillers is subject to COM PANY approval. No pigments or translucent dye shall be used as it is detrimental to visual inspection either during manufacture (QA) or later for maintenance inspection.

8.7

CONDUCTIVITY The GRP piping system shall be conductive to prevent the accumulation of potential dangerous level of static electrical charges. Pipes, fittings & flanges shall have in-built high strength conductive filaments within the construction. The adhesives used shall also be conductive to provide an electrically conductive system.


8.8

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EXTERNAL FIRE RESISTANCE GRP piping, including joints/connections, in fire water system shall be capable to withstand a fire as indicated below: The GRP piping shall fulfil the requirement 30 minutes of fire endurance test in wet stagnant conditions according to IMO Resolution A.753(18), Level 3, as defined in Annex ‘E’ of ISO 14692-2. The fire protection coatings necessary for achieving the fire resistance requirement shall be as follows,

9.

•

The pipe, fittings, flanges shall be delivered from manufacturer with Protective coating.

•

The fire protection properties of the coating are not to be diminished when exposed to salt water, oil or bilge slops.

•

While selecting protective coatings, characteristics like thermal expansion, resistance against vibrations & elasticity shall be taken in to account.

•

The fire protection coatings shall have sufficient resistance to impact to retain the integrity

•

All the GRP piping joints shall be coated with Fire Protective material to PITTCHAR.XP, Chartek 7, Leigh’s M90 or equivalent coating. VENDOR / MANUFACTURER shall develop the project specific specification for application on FRP piping joints.

•

GRP VENDOR / MANUFACTURER shall submit epoxy intumescent PFP application procedure for review and approval by COMPANY before commencement of work.

JOINT SYSTEM Prefabricated piping systems may have one of the following jointing systems: •

Adhesive bonded socket/spigot joint

•

Laminated (butt and strap) joint

•

Integral spigots and/or sockets for connections with rubber sealing rings and locking keys. However use of this type of joints shall be avoided.

•

Flanged joints.

The butt and strap joints shall be laminated over a length of at least the pipe diameter on the outside, and if the diameter allows, also on the inside. Adhesive bonded joints and Key lock joints are generally applicable to the size DN 600 & below, as make-up of the joint tend to become more difficult in larger sizes. For sizes DN 650 & above, lamination joints are preferred. However MANUFACTURER shall evaluate and propose the type of joints based on his design and submit the same for COMPANY review / approval. Flanged joints are applicable when connected to other metallic system or equipment. A few instrument hook-ups may also have flanged connection. The dimensions of the connections ar e determined by the VENDOR / MANUFACTURER.


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VENDOR / MANUFACTURER shall confirm that joints will not degrade and are suitable for 30 years design life under the severe conditions indicated in the specification. Adhesive bonded joints shall not require a field overlap to develop the required strength.

10.

PERFORMANCE REQUIREMENTS VENDOR / MANUFACTURER shall comply with the following performance requirements, as a minimum. VENDOR / MANUFACTURER shall submit the relevant certified test reports to COMPANY for review prior to commencement of production.

10.1 QUALIFICATION PROGRAMME

The manufacturer shall prepare a qualification programme in line with the requirements of ISO-14692 part 2 section 6 (for both underground and aboveground piping). The qualification tests as specified in ISO-14692 shall be witnessed and approved by an independent COMPANY approved third party. The costs for third party approval shall be deemed included in the VENDOR’s / MANUFACTURER’s scope of work. In order to prevent un-proportional high costs and schedule delays due to the qualification programme, the product range for the project shall at least be split into four product sectors: DN25 – DN600 (adhesive bonded products), DN650 – DN900 (laminated products), DN950 – DN1200 (laminated products) and above DN1200 up to DN1500(laminated products). This is considering that products within each of these four product sectors have the same design basis, raw materials, construction, joint configuration and manufacturing location. Additional product sector divisions shall be implemented by the manufacturer to account for any difference in the design basis, raw materials, construction, joint configuration and manufacturing location. Each product sector shall be qualified as per ISO 14692-2 section 6.2.3. The largest diameter and highest pressure class of each product type (pipe, elbow, tee, reducer, wye, flange and joint) available in the project shall be qualified by a 1000 hours survival test at the project design temperature. Smaller product sizes/ lower pressure products may be qualified using the scaling rule based on the successful completion of the 1000 hours test on the same product type. The testing shall be done bi-axially with un-restrained ends. Test reports of previously qualified products may be accepted in lieu of testing. Manufacturers shall submit as part of the bid a detailed qualification plan, along with the available qualification reports, and technical justification of any proposed deviation to this specification for COMPANY/ CONTRACTOR review and approval. For larger size components, where it is impractical to test at the design temperature, testing at ambient temperature may be accepted. VENDOR / MANUFACTURER shall submit a technical note establishing an increased 1000 hour test pressure, to compensate for the reduction in the test temperature. The proposal shall be submitted to CONTRACTOR/ COMPANY for approval.


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10.2 JOINT STRENGTH

Joints shall be equal or superior in performance to a pipe of equal diameter and pressure rating. The pre-qualification test and procedure shall propose adequate tests for the qualification of jointing methods. FE calculation shall be performed on one size of lamination and adhesive joint as an analytical confirmation of the pre-qualification tests. The qualification testing shall include both internal pressure and bending moments. 10.3 STIFFNESS

The Specific Tangential Initial Stiffness (STIS) shall be determined according to ASTM D 2412. VENDOR / MANUFACTURER shall calculate the required stiffness to meet the design requirements, but in no case shall the stiffness be less than 2500 N/m2 for aboveground pipe & 5000 N/m2 for buried pipe. However these stiffness values of pipes and pipe fittings shall be validated for the actual design conditions. 10.4 BEAM STRENGTH

The axial modulus of elasticity shall be tested in accordance with ASTM D 2925 and shall not be less than 11000 N/mm2. 10.5 ULTIMATE HOOP STRESS

The manufacturer shall derive baseline values for Short Term Failure Pressure as per ISO 14692-2 section 6.8.3 from the qualification program, to be used as minimum failure pressure for the subsequent quality control testing. However the baseline values for short term hydraulic failure strength of pipe and fittings when tested in accordance to ASTM D 1599 shall not be less than 2.7 times the rated pressure. The product sector as specified in Clause 10.1 shall be considered for short term burst qualification testing. 10.6 AXIAL TENSILE STRENGTH

The axial tensile strength of pipes and fittings shall be tested in accordance with ASTM D 638 or D 2105 and shall meet the minimum requirements as specified in AWWA C950 with suitable safety factor needed to accommodate stress analysis as well as to provide a margin for other unexpected loads. 10.7 HOOP TENSILE STRENGTH

The hoop tensile strength of pipes shall be tested in accordance with ASTM D 2290, D 638 or D 1599 and shall meet the minimum requirements as specified in AWWA C950 and shall satisfy qualification requirements for internal pressure.


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10.8 BOIL RESISTANCE

Samples made from pipe and fitting laminates shall show no evidence of de-lamination or other impairment when tested in accordance with ASTM D 570. Water absorption shall be ≤ 1%. 10.9 IMPACT RESISTANCE

Impact resistance test shall be carried out in accordance with ISO 14692-2 and ASTM D 2444. 10.10 HARDNESS

The indentation hardness of pipes and fittings when tested in accordance with ASTM D 2583 shall be at least 30 Barcol. 10.11 HYDROSTATIC DESIGN BASIS (HDB)

The hydrostatic design basis shall be extrapolated from long term regression tests in accordance with Procedure B of ASTM D 2992 with a service factor of 0.5 and for a design life of 30 years. All the calculation shall be done based on 97.5% confidence limit of HDB. Adhesive joints, if any, shall be included utilizing both the factor y and field adhesives and their respective joining and curing procedures, if different. In addition to the above, in order to qualify the pressure, the MANUFACTURER shall demonstrate by performing 1000 hrs. survival tests that the components to be used for piping system are capable of meeting the minimum design requirement as per clause 6.2.2 of ISO 14692-2. The test shall be carried out in accordance with ASTM D 1598 at 65˚ C or design temperature, if higher. Any deviation for the above needs COMPANY approval. 10.12 GLASS CONTENT

The glass content (percentage of glass-reinforcement) of the reinforced wall shall be determined in accordance with ASTM D 2584 and shall be no less than 65% for pipes and 60% for fittings. For pipes installed underground and used in conjunction with a non-tensile resistant joint lower glass content is acceptable. 10.13 SAFETY FACTOR

Pipes and fittings shall have sufficient stiffness of resist vacuum and/or external pressure loads with a safety factor of 2.5. 10.14 FLANGES

Flanges shall be pressure rated and hydrostatic pressure tested in accordance with ASTM D 4024 (machine made flanges) and ASTM D 5421 (contact moulded flanges). Flange qualification testing shall include loading with internal pressure and bending moments.


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10.15 DEGREE OF CURE

Pipes & fittings shall be tested for the glass transition temperature as per ISO 11357-2. The glass transition temperature shall exceed the design temperature by at least 30⁰ C.

11.

INSPECTION AND TESTING VENDOR / MANUFACTURER shall demonstrate the capability to produce pipes and fittings meeting the requirements of this specification and of consistent properties and quality. A quality and control assurance programme shall be implemented at the manufacturer’s facility and all necessary test equipment shall be present and operated by skilled technicians. VENDOR’s / MANUFACTURER’s quality assurance programme shall be approved by COMPANY prior to start of manufacture.

11.1 CHECKS OF RESIN QUALITY

The resin manufacturer shall perform the epoxy content check. VENDOR / MANUFACTURER shall receive / review the certificates for each batch of resin and keep the complete traceability. The water absorption for resin shall be less than or equal to 0.03% in weight for 24 hours. The test shall be done in accordance with ASTM D 570. 11.2 SHORT TERM WEEPING TESTS

The short term failure pressure of pipes, fittings, flanges, joints and spools shall be carried out as per ASTM D 1599, with a frequency of one in 250 components. The testing shall be done bi-axially with un-restrained ends, on one specimen per test. The specimen to be tested shall be selected at random by the COMPANY/CONTRACTOR. Weeping, burst or loss of pressure shall constitute a failure. The failure pressure shall meet the requirements of section 10.5. 11.3

CONTRACTOR / COMPANY reserve the right to witness any or the entire test and must therefore be given sufficient advance notice. The inspection in no way however relieves the VENDOR / MANUFACTURER of his responsibility for the piping meeting all the requirements of this specification.

11.4

Test result shall be fully documented and reported in test reports submitted to the COMPANY/CONTRACTOR.

11.5

The pipe manufacturer shall perform and give evidence of the tests of materials and / or components used in the manufacture of the pipe. Test reports shall be traceable to the lot of pipe furnished and correctly listed and identified in inspection reports.

11.6

The design of the largest sizes of pipe, joint and fittings shall be checked by tests conducted on representative specimens prior to manufacture of any of the pipe.


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11.7

All pipes, fittings, flanges and shop fabricated spools shall be 100% dimensionally checked in accordance with the requirements of ASTM D3567. Pipes, joints and fittings shall be dimensionally checked against quality standard and dimensional drawings furnished by the VENDOR/ MANUFACTURER to the Contractor. Spool dimensions shall be checked against the “approved for construction” issue of the detail drawings.

11.8

All the pipe and piping components shall be subject to visual inspection as per ISO 14692-4, Annexure A. After minor repair, a hydrostatic test shall be performed on the repaired component.

11.9

Pipes, standard fitting and testable spool shall be hydro-tested at 1.5 times pressure rating for 10 minutes at below frequency:a) GRE Helical winding pipes : 20% of all standard length pipes per type per manufacturing machine. b) GRV Helical winding pipes : 20% of all standard length pipes per type per manufacturing machine. c)

GRV Continuous winding pipes : 100% of all standard length pipes.

d) Glass Reinforced Molded standard fittings : 20% of standard fittings per item type per manufacturing machine e) Testable spools: All testable spools shall be hydro-tested at 100% for all spools sizes. No visible leakage or pressure drop shall occur during the test duration. 11.10 Pipes, fittings, flanges & spool joints shall be tested for the glass transition temperature as per ISO 11357-2, with a frequency of 1% of the continuous production. 11.11 All pipes, fittings, flanges & spool joints shall be tested for Barcol Hardness as per ASTM D 2583. 11.12 Pipes, fittings, flanges & spool joints shall be tested for glass content as per ASTM D 2584, with a frequency of 1% of the continuous production. 11.13 Pipes fittings, flanges & spool joints shall be tested for boil resistance and water absorption as per ASTM D 570, with a frequency of 1% of the continuous production. There shall be no delamination or deterioration after boiling in water for 3 hours. The water absorption shall be less than 1% by weight. 11.14 The axial tensile strength of the pipes shall be determined as per ASTM D 2105 or ASTM D 638, with a frequency of 1% of the continuous production . The test result shall be equal or exceed the short term axial tensile strength value used for developing the pipe design envelope. 11.15 The hoop flexural modulus of the pipes shall be calculated based on stiffness testing as per ASTM D 2412, with a frequency of 1% of the continuous production . The test result shall be equal or exceed the hoop flexural modulus value used in the pipe design calculations for the stiffness and the vacuum considerations.


12.

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IDENTIFICATION, MARKING AND PACKING All pipes and fittings shall be permanently marked with the following: •

MANUFACTURER'S name or trade name,

•

The pressure class / pressure rating

•

The Size in DN on Nominal Pipe Size (NPS)

•

Date of manufacture

•

VENDOR’s / MANUFACTURER’s Identification Code or the Lot Number

•

Appropriate Stock Code or Commodity Code.

Markings shall be applied indelibly and clearly by paint or ink stencil or label. Markings shall be permanent, shall not overlap and shall be applied in such a manner as not to damage the item. Markings shall be applied on the item within 1 m of the end Pipe Spool ends to be protected with plastic or equivalent cap/plug. Crates will be constructed in the most economical manner and are provided with skids to facilitate handling by forklift truck. In case of nesting, pipes will be provided with suitable fillers between pipe walls. Spigots shall be protected by polyethylene covered straw mats. Prior to packing, VENDOR / MANUFACTURER shall ensure that all the items shall be marked with identification number for identification at site or yard. Since each module or stick built area has a different Split/Geo WBS, spools assigned to that area shall be marked with the corresponding Split WBS number for ease of tracking. Moreover, loose pipes and fittings from the same Split/Geo WBS shall be bundled and shipped together. This bundle will clearly show the Split WBS it corresponds to on its packing list. Any damage resulting from the poor packing will be to the account of VENDOR / MANUFACTURER and shall be replaced at no extra cost within the construction period.

13.

DOCUMENTATION

13.1 VENDOR’s / MANUFACTURER’s DRAWINGS AND DATA SHEETS

The following documentation shall be submitted by the VENDOR / MANUFACTURER: a) Pipe and pipe component Data Sheets / drawings with dimensional details and acceptable tolerances. b) Detailed Resin Data. c)

Detailed Glass Reinforcement Data.

d) Detailed Pipe Aggregate Data (if applicable). e) Detailed Joint and Gasket Data. f)

Detailed Manufacturing Process for Pipe, Joints and Fittings.


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g) Roughness Value h) Winding Angle i)

Pipe support arrangement and details.

j)

Maximum recommended pipe support span

k)

Pipe Design Calculations for each diameter / pressure.

l)

Maximum recommended bolt torque for flanges.

m) Pipe thickness calculation note indicating minimum total wall thickness, structural wall thickness etc. n) Pipe stress calculation report and other relevant calculation notes, if any, such as FE analysis report. o) Dimensional details of joints. p) Any other information that is required for verification of design, analysis and fabrication requirements. q) Design calculations for the fittings, flanges and joints. r)

Chemical resistance chart

s)

Engineering guide

t)

Potable water certification

u) The design envelops to be used for system design along with supporting calculations and test reports. 13.2 PRE-QUALIFICATION AND QUALIFICATION

a) VENDOR’s / MANUFACTURER’s Pre-Qualification b)

VENDOR’s / Programme.

MANUFACTURER’s

Quality

c)

Manufacturer’s ISO 9001:2008 Certificate.

Manual

and

proposed

Qualification

d) Proposed Inspection & Test Plan (ITP) e) Qualification test results for long term hydrostatic design basis f)

Qualification test reports as per ISO 14692 and Section 10 of this specification for the offered pipes, fittings, flanges and joints.

g) List of approved Sub-Vendors of manufacturer for raw materials h) List of previous projects that were delivered in compliance with ISO 14692, including project name, end user, product series, diameter and pressure combinations, jointing system and the performed 1000 hour tests.


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13.3 INSTALLATION MANUAL

The manufacturer shall supply its installation manual describing the recommended methods for the following which needs to be approved by CONTRACTOR/ CONTRACTOR appointed GRP Specialist/ COMPANY: a) Handling, transport and storage procedures of finished products. b) Jointing and preparation methods for adhesive bonded joint, flanged joint, laminated joint, mechanical coupler, etc. c)

Burial depth, bedding/ filling material quality for underground installation etc.

d) Tools and tackles required for field fabrication. e) Estimated number of field joints with offered pipe length and size. f)

Estimated number of supervisors required at site.

g) Estimated number of man-days of supervisors for supervision of installation, testing and commissioning. h) Availability and supply of the required site supervision facilities (with day / hour rates).

13.4 SAFETY PRECAUTIONS

VENDOR / MANUFACTURER shall supply to the COMPANY its safety manual describing the precautions to be exercised when processing GRP Products.

13.5 QUALITY ASSURANCE / QUALITY CONTROL REQUIREMENTS

“The quality assurance & control requirement shall be as per VQRF and applicable QA/QC specifications referred in inquiry/purchase requisition. VENDOR shall submit required QA/QC documents as required by VQRF and applicable QA/QC specifications referred in inquiry/purchase requisition for review by CONTRACTOR/COMPANY. VENDOR shall establish, demonstrate and maintain an effective programme for quality assurance necessary to ensure that the materials utilised, inspection, fabrication, testing, handling and storage functions comply in all respect with the requirements of this Specification & satisfy the requirements of VQRF and applicable project specifications. VENDOR’s quality control procedures shall be in accordance with the relevant section of ISO 9001 and as per Purchase Order conditions. VENDOR may be audited based on agreed notice period. VENDOR’s quality plan and inspection & test plan shall include all stages of preparation, fabrication, inspection and testing performed by or for the VENDOR. They shall also define the method and frequency of inspection; testing and calibration, acceptance criteria and documentation as well as identifying all witness hold and monitor points for the VENDOR and CONTRACTOR/ COMPANY VENDOR shall provide facilities and cooperate with the CONTRACTOR for complying with Quality Assurance requirement during manufacturing, assembly and testing. CONTRACTOR/COMPANY shall have the right to undertake additional inspection or testing


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of materials and workmanship during any stage of manufacture to the VENDOR cost. Materials or workmanship not complying with this Specification shall be rejected at the VENDOR cost. VENDOR shall take full responsibility for the design and the selection of component, material and finishes. VENDOR must prove that the equipment is fully qualified for the service intended. Any adherence to the recommended specification herein is only to be regarded as conforming to a preference. Adherence to the details given shall in no way absolve the VENDOR from total responsibility to provide equipment fit for the intended purpose. VENDOR shall document all test results identified in this Specification, and the planned systematic control of all activities affecting quality. All equipment and test facilities to be used for the work shall be in good condition and suitable for the work. Post manufacturing, VENDOR shall submit MRB/MDR as per VDRL and approved MRB/MDR index, for review and approval by CONTRACTOR/COMPANY. 13.6 QA / QC PLAN

a)

The Manufacturer is required to prepare/submit along with his bid document a proposed "Quality Assurance / Quality Control Plan" including the following as a minimum: •

General quality policies, procedures and practices of the Manufacturer and its SubVENDOR’s, if any.

•

Manufacturer shall submit the below mentioned documents as a minimum as part of the bid and post award a) ISO 9001-2008 b) Compliance to ISO TS 29001 c) QMS Manual d) ITP e) Project Specific Quality Plan

•

The organisation structure, responsibilities, activities, resources and events that together provide organised procedures and method of implementation to ensure the capability of the organisation to meet quality requirements.

•

A particular QA/QC plan defining the specific quality procedures and practices, resources and activities for the implementation of the Project Works.

b) This QA/QC plan should cover as a minimum: •

Origin and traceability of VENDOR / MANUFACTURER supplied material including the tests records of the raw materials

•

Non Conformance Procedure

•

Qualification of personnel

•

Quality control of the work (jointing procedures, inspection, tests, acceptance certificates, non-conformity report, etc.).


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13.7 QA / QC RECORDS

Quality Control records shall be prepared and submitted by the VENDOR / MANUFACTURER to the COMPANY at proper time during the execution of the works, and a Record file shall be maintained and issued with final Manufacture Documentation at the Works Completion.

14.

FIELD FABRICATION, INSTALLATION AND TESTING

14.1 GENERAL

a)

The installation of GRP piping network shall be in accordance with the following, which form part of this specification: •

ISO 14692-Part 4

•

ASME B31.3

•

VENDOR’s / MANUFACTURER’s Installation Manual / Method Statement

b) CONTRACTOR shall prepare and submit for approval a detailed method statement prior to commencement of any installation work. c)

The installation method shall be agreed between the COMPANY, CONTRACTOR and VENDOR / MANUFACTURER. Copies of installation methods, procedures and quality plans shall be available at site at all times.

d) CONTRACTOR shall employ on a full-tile basis, the service of one or more field representative of the VENDOR / MANUFACTURER throughout the pipe installation, testing and commissioning period, who shall supervise all installation work and have the technical authority over the CONTRACTOR. e) CONTRACTOR shall ensure that only qualified personnel will be involved in the installation work. Qualification of personnel shall be in accordance with ISO 14692-4, Annex D. All qualification records for personnel shall be made available to the COMPANY, if requested for. f)

Fully dimensioned arrangement drawings or isometric drawings together with relevant pipe class documents and line list shall be read in conjunction with this specification, detailing particular to construction and material requirements and other basic information. The latest issues of these drawings shall be used for the fabrication/erection of all pipe work.

g) Drawing prepared by the VENDOR / MANUFACTURER shall not depart from details shown in the drawings supplied by the CONTRACTOR. Conflicts if any shall be brought to the CONTRACTOR notice. h)

All documents, drawings and calculations generated by the manufacturer shall conform to the COMPANY documentation procedure.

14.2 PREFABRICATION

a)

For NPS 2" and larger, prefabricated pipe work shall be fabricated according to the spool lengths called for on piping isometrics, and shall be set and agreed taking the following into consideration: •

Site transport and handling equipment limitations.


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•

Installation and erection limitations.

•

Limitations caused by necessity to allow fitting tolerance installation (cut to fit requirements).

b) Pipe ends requiring "Field Joint" (FJ) shall be left with plain ends. c)

Unless otherwise noted on the Piping Drawings, flange bolt holes shall straddle the vertical and horizontal centre lines and shall match the orientation of mating flanges.

d) All joint preparations including adhesive bonding shall be sheltered from wind and rain. Furthermore, the GRP VENDOR / MANUFACTURER shall provide the material for worker's/ personnel protection in accordance with manufacturer’s recommendation. e) GRP VENDOR / MANUFACTURER shall be responsible to prepare the shop drawings with indication of spool N° and Field Fit Joint (FFJ). The spool numbering system shall be compatible with the line identification and shall facilitate field erection of piping.

14.3 ASSEMBLY AND ERECTION

14.3.1

General a) Pipe erection shall conform to the requirement of this specification, ISO 14692-4 and ASME B31.3. b) Pipe erection shall conform to the piping specification and approved drawings. Modifications to these drawings by the VENDOR / MANUFACTURER are permitted only if significant cost reduction or improvement is made and then only when approved in writing. c)

It shall be the CONTRACTOR responsibility to check and verify all clearance between equipment and piping and to make field adjustments, as required, to permit a correct assembly of piping. The method of rectification of major discrepancies shall be submitted for approval.

d) VENDOR’s / MANUFACTURER’s supervisor shall comply with COMPANY’s safety regulations while on the site for installation and commissioning.

14.3.2

Handling GRP piping shall always be handled with care as per Vendor/ Manufacturer recommendations and the following practices followed to prevent damage during handling: a) Always keep the end caps or protection wrap in place. b) Load or unload by hand where practicable. Do not drop the pipe at any stage and ensure that impact with other pipes does not occur, by adequate use of supports and separation devices. c)

Pipe shall always be properly supported to avoid undue flexure when being transported.

d) If slings are used for lifting, straps shall be a minimum of 4” wide webbing. Wire rope or chains shall not be used. e) Hooks or other devices which insert into the ends of the pipe shall not be used. f)

Pipes shall not be stacked without suitable fillers between pipe walls.


14.3.3

14.3.4

Rev. B4

Page: 31 of 36

Storage a)

GRP pipes are generally stored on flat timber surfaces to facilitate placement and removal of lifting slings. The support timbers should be of sufficient width to prevent point loads.

b)

GRP Pipes shall be stacked to prevent rolling in high winds.

c)

The maximum stack height shall follow the respective codes or as recommended by the VENDOR / MANUFACTURER for maximum storage.

d)

Bulges, flat areas or other abrupt changes in pipe curvature are not permitted.

e)

When stored directly on the ground, the pipe weight shall not be supported by the bell, coupling or any other joint surface. The pipe shall rest on level ground and shall not rest on rocks, boulders or any other hard debris.

f)

Any UV protection requirements when GRP piping is stored outdoors shall be as recommended by the VENDOR / MANUFACTURER.

g)

Nested pipes should be stored only in the original transport packaging. Nested pipes shall not be stacked without prior approval of the VENDOR / MANUFACTURER.

Cleaning a)

Prior to erection, the CONTRACTOR shall ensure that all pipe sections or fabricated pieces are free from internal obstructions and foreign matter. Following erection, the CONTRACTOR shall flush all piping systems with water or other approved fluid until free of foreign matter.

b)

After erection, the ends of pipes which are left open temporarily shall be suitably protected against the introduction of dirt, debris, tools, rags, etc.

c)

Prior to connecting adjacent pieces of horizontal piping the open end shall be examined to ensure that all water dirt, tools, rages, bottles and other foreign materials have been removed.

d)

Flange faces shall be cleaned of oil, grease, dirt, inhibitors, etc. and shall be checked to ensure freedom from gouges, nicks, etc.

e)

Air blowing and flushing shall be carried out.

14.4 INSPECTION AND TESTING REQUIREMENTS

14.4.1

VENDOR’s / MANUFACTURE’s Responsibilities a)

CONTRACTOR shall furnish the VENDOR / MANUFACTURER and his appointees with all reasonable facilities to satisfy them that the piping is erected and tested in accordance with this specification.

b)

VENDOR / MANUFACTURER shall convey in writing to the CONTRACTOR, all defects, discrepancies and alterations prior to rectification.

c)

Any approvals given by the CONTRACTOR does not relieve the VENDOR / MANUFACTURER of any responsibility regarding guarantees, workmanship or compliance with this specification.


14.4.2

Rev. B4

Page: 32 of 36

Visual Examination A visual examination of the erected pipe work will be carried out by the GRE VENDOR / MANUFACTURER and the CONTRACTOR and/or the Inspection Agency to ensure that the pipe system is installed as recommended by specification, codes and standards. All the joints shall be subject to visual inspection as per ISO 14692-4, Table 4. After minor repair, a hydrostatic test shall be performed on the repaired joints. The level of inspection shall be as per ASTM D2563, Level II. Generally following are the most common defects, which needs special attention, both at shop and field joint while conducting the visual inspection: •

Chip

•

Crack

•

Crazing

•

De-lamination at edge and internals

•

Dry Spot

•

Fracture

•

Blister

•

Pin-hole

•

Resin Pocket

•

Resin Rich Edge

•

Scratches

14.4.3

Flushing And Hydrostatic Testing a)

Upon completion of installation, the piping system shall be flushed. The medium used for flushing shall be sea water of fresh water.

b)

For hydrostatic testing, seawater may be used for testing of the installed piping systems.

c)

The temperature of the test water shall in no instance be allowed to fall below 7°C. After filling the piping system, the temperature shall be allowed to stabilize before commencing pressurization.

d)

Once the temperature is stabilized, strength test shall be carried out at a pressure of 1.5 times the system design pressure and held for a minimum of 4 hrs. and not more than 6 hrs. The rate of pressurization shall not exceed 2 bar per minute. Following the pressure test, a leak tightness test shall be carried out at a pressure equal to 1.1 times the system design pressure. The test pressure shall be held for 24 hrs. during which no water shall be added to or removed from the piping system. Any leaking or weeping shall constitute a defect and the test shall be terminated and repair effected. The system shall be retested after repair. CONTRACTOR and/or MANUFACTURER shall develop a detailed method statement defining the detailed procedure for conducting this test.

e)

If prefabricated systems are made in the workshop, it is recommended that these parts be pressure-tested in advance upon CONTRACTOR's approval. 10% of fabricated spools shall be shop tested.

f)

Hydrostatic testing of CONTRACTOR.

GRP piping

after installation

shall be

carried out

by


14.4.4

Rev. B4

Page: 33 of 36

g)

VENDOR / MANUFACTURER will supply all tools, equipment, materials including temporary gaskets and temporary support to perform the testing, at his workshop. The CONTRACTOR shall supply the same for test on site.

h)

When conditions require a test pressure to be maintained for a period of time, during which the system might be subject to thermal expansion, provision shall be made for, to take care of any resultant drop in test pressure.

i)

Where called for by the site circuit testing program, temporary end spades shall be used to isolate equipment from the line continuity test. (The CONTRACTOR shall supply these end spades).

j)

The CONTRACTOR shall prepare a "TEST PACK" for each circuit. This shall include but not limited to: •

Request for piping inspection,

•

Pipe system punch list,

•

Identification of piping tested (system N°),

•

The pressure test record with indication of Test medium, Test pressure and duration, Date of test, Test gauge calibration date and reference.

•

Identification of tested pipe by means of extract of P & ID showing the test limit.

•

"Test Isometric" indicating the location of gauge, vents, drains, test pump and medium.

•

Witnessed by. (VENDOR / MANUFACTURER / CONTRACTOR/ COMPANY).

Acceptance Criteria The system shall be considered to have passed hydro-test if there is no leakage or weeping of the water from the piping and there is no significant pressure loss that cannot be accounted for by usual engineering consideration. Over torqueing of the flanged joints to stop leaking is not permitted. Leaking flanges shall be again made with new gaskets and re-tested. In case of further leaking, flanges shall be replaced with new ones Upon completion of successful testing, pressure test certificate showing the limits of test shall be prepared by CONTRACTOR and endorsed by COMPANY or his representative.

14.4.5

Field Maintenance & Repair GRP piping systems are generally maintenance free, but proper attention shall be during inspection for removal scale and other blockages. VENDOR / MANUFACTURER’s recommendation shall be followed in all cases. Electrically earthed GRP piping system shall be periodically checked to ensure that all the earthing leads are functional and that the electrical resistance to earth from any part of the system is not greater than 106Ω. VENDOR / MANUFACTURER shall develop a method statement describing the procedure and recommendation for any repair required in the GRP piping system. The procedure shall include the repair methods, qualification requirement, type of repairs etc.


15.

Rev. B4

Page: 34 of 36

GUARANTEE CONTRACTOR / VENDOR / MANUFACTURER shall guarantee to meet all requirements of this and other relevant specifications. VENDOR’s / MANUFACTURER’s omission or neglect in interpreting the drawings, specifications and the requirements of this specification, resulting in field changes to the fabricated work shall be back charged to the VENDOR / MANUFACTURER. VENDOR / MANUFACTURER shall recommend alternative materials and procedures, which comply with applicable codes whenever they provide advantages. VENDOR / MANUFACTURER shall advice the CONTRACTOR on any conditions of material procurement that adversely affect delivery and erection schedules, with suggestions for corrective substitutes where feasible. VENDOR / MANUFACTURER shall guarantee the GRE piping system for a period of two years after commissioning against the following (for the reasons attributable to Vendor/Manufacturer):

16.

a)

Obvious deterioration of materials or coatings.

b)

Leakage or defects in factory made joints.

SINGLE POINT RESPONSIBILITY DURING PROJECT EXECUTION During project execution, as a single point responsibility, VENDOR / MANUFACTURER of GRP piping system shall carry out the system design, GRP product qualification, & supply, Supervision during installation and successful hydro testing of the complete system in compliance to all regulatory code and COMPANY / CONTRACTOR specifications. In case of multiple VENDOR’s and considering tie-in of two separate VENDOR systems, the requirements on qualifications shall be detailed out further.


Rev. B4

Page: 35 of 36

ANNEXURE - 1 ADDITIONAL REQUIREMENTS FOR 50 BAR GRP PIPING (PIPE CLASS: B51V)

GRP VENDOR / MANUFACTURER has recommended to use Adhesive bonded joints for 50 bar GRP piping. Following additional requirements to be followed for 50 bar GRP piping along with the requirements specified in this GRP Project Specification: a) All the qualification tests as per this specification shall be carried out for each size of pipes at VENDOR / MANUFACTURER’s location prior to production. This shall be 100% witnessed by COMPANY besides THIRD PARTY CONSULTANT. b) GRP VENDOR / MANUFACTURER shall execute all the joints (100%) including shop and field joints in the module fabrication yard as well as site (if any). This shall be undertaken by experienced GRP VENDOR / MANUFACTURER crew and no personnel from CONTRACTOR or his sub-CONTRACTOR shall be i nvolved. c)

GRP VENDOR / MANUFACTURER shall have their supervisor deputed along with the crew.

d) All the joints shall be closely monitored by THIRD PARTY CONSULTANT. e) GRP VENDOR / MANUFACTURER crew shall perform one full size joint (i.e. for maximum pipe size) at module fabrication yard before undertaking the actual work. This dummy joint shall be subjected to full testing i.e. hydrostatic test and burst test. f)

Hardness testing of pipe and adhesive shall be carried out to document sufficiency of curing.

g) All pipes and fittings shall be 100% hydro-tested at GRP VENDOR / MANUFACTURER works. In case individual fittings could not be hydro-tested then pre-fabricated spools shall be 100% hydro-tested covering all the components. No fittings shall be dispatched without 100% hydro-test. To ensure 100% hydro-test for fittings at shop, flanged spools along with the fittings will be hydro-tested in GRP VENDOR / MANUFACTURER works. In case any spools are not flanged additional flanges needs to be added to pipe and cut after hydro-test. As pipes cannot be fully removed, ends will be prepared to make suitable for connection to TB (Bell for adhesive bonded joints, taper / taper) coupler for further joining. h) Stress analysis shall be carried out in accordance with project specification for Stress Analysis P7512-TS-2000-P-0001 and requirements as per ANNEXURE-2.

Specfication GRP

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