600 grp spec rev 1 sept 2010.pdf

8/10/2019 600 GRP spec Rev 1 Sept 2010.pdf

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Harouge Oil OperationsCONTRACT No Bid Document

PROJECT TITLE:

RAS LANUF TANK FARM REPLACEMENT OF 500,000 US BBL

TANK NUMBER 7

DOCUMENT No: V40 / P / A4 / 0600

DOCUMENT TITLE:

GRP PIPING SYSTEMS SPECIFICATION

0 23/08/2010 ITT MON VS HA

Rev Date Issued for Originator Checked Approved Issued

HAROUGE OIL OPERATIONSLIBYA


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Contract No. Bid Document

Ras Lanuf Tank Farm Replacement Of 500,000 Us Bbl Tank Number 7Specification for GRP Piping Systems Page 2 of 14

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Doc No. V4O/P/A4/0600 Rev 00 30/011/2005

CONTENT PAGE

1. SCOPE OF SPECIFICATION 3

2. GENERAL 4

3. PRODUCT DESIGN 6

4. QUALITY ASSURANCE/QUALITY CONTROL 10

5. DOCUMENTATION 10

6. GRP CONTRACTORS SCOPE OF WORK 11

7.0 SYSTEM DESIGN 11

8.0 INSTALLATION 13

9.0 INSPECTION 13

10.0 TESTING 14

11.0 PREVIOUS SUPPLIER 14


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1. Scope of Specification

1.1 This specification covers the design conditions, material requirements,

methods of manufacturing, joining systems, test methods, identification andpacking of glass fibre reinforced thermosetting resin pipe (RTRP) systems.This specification is related to ANSI-ASME B 31.3 for nominal diameters of25 to 1200 mm, adequate to convey water or chemical products. Thecomponents of the glass fibre reinforced plastic pipe system are to besuitable for a maximum operating pressure, as specified, for a service life of50 years.

1.2 This specification shall be read in conjunction with the relevant documentsreferenced herein.

1.3 CONTRACTORResponsibility

1.3.1 It shall be CONTRACTORsresponsibility to be, or become, knowledgeableof the requirements of the referenced Codes and Standards.

The Codes and Standards referenced and specified herein, form part of thisspecification. When an edition date is not indicated, the latest edition in forceat the time of placement of contract / purchase order shall apply.

1.3.2 Compliance by CONTRACTORwith the provision of this specification, or anyomission herein, does not relieve him of his responsibility to furnish materials,equipment and accessories of a suitable and safe design to meet thespecified service conditions, and /or local codes and standards.

1.3.3 Review/approval of CONTRACTOR documents shall not relieve the

CONTRACTOR of his responsibility to supply and guarantee theperformance on the package.

1.3.4 Quality Assurance/Quality Control

CONTRACTORs proposed quality assurance and quality control systemshall be in accordance with the project procedures and specific requirementsattached to purchase requisition.

CONTRACTORshall submit his quality plan with his bid for Client approval.

1.4 Deviations and Concession Control

1.4.1 The technical deviations and concession requests shall be submitted in

accordance with the CONTRACTOR data requirements attachments topurchase requisition.

1.4.2 Where no exceptions/qualifications are stated, it shall be understood that thesupply is in full compliance with the specified requirements and anysubsequent claims arising out of non-conformance with the specificationswill not be considered.


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1.4.3 It will not be the responsibility of the Client/Purchaser to identify exceptions or

deviations from within the CONTRACTORsdocuments.

2. General

2.1. Project Definitions

For the purposes of this specification, the following Project definitions shallapply:

CODE CODEis defined as the applicable Design Code

CLIENT CLIENT is defined as HAROUGE OIL OPERATIONS LIBYA.

CLIENTis the company to whom all materials and equipment will bedelivered and is the end user of such materials and equipment.

PURCHASER PURCHASER is the company appointed by HAROUGE OIL

OPERATIONS LIBYAto place the purchase order for the material orequipment on its behalf.

CONTRACTOR CONTRACTOR is defined as the company engaged in a purchase

contract with PURCHASER, for the supply of materials or

equipment. During the Bidding or Tender stage CONTRACTORshall

be referred to as BIDDER.

SUB-

CONTRACTOR

SUB-CONTRACTORis defined as a company awarded a sub-order

by CONTRACTOR for part of the work awarded to the

CONTRACTOR. Note that SUB-CONTRACTORs are subject toCLIENTapproval.

CONTRACTOR CONTRACTOR is the company appointed by HAROUGE OIL

OPERATIONS LIBYA to carryout the installation of material orequipment on its behalf.

INSPECTION

AUTHORITY

INSPECTION AUTHORITY is defined as the organisation thatverifies that the material or equipment supplied by the

CONTRACTOR has been designed, constructed, inspected, andtested in strict accordance with the requirements of the applicabledesign code.

INSPECTOR INSPECTOR is defined as a qualified individual representing the

CLIENTor PURCHASERwho verifies that the material or equipment

supplied by the CONTRACTOR has been designed, constructed,inspected, tested, and packed and delivered in strict accordancewith the requirements of this specification and all other PurchaseOrder requirements.

SHALL The word Shall denotes that the requirement is mandatory.

SHOULD The word Should denotes that the requirements is highly

recommended but is not mandatory.


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2.2 Conflicting requirements

CONTRACTORshall advise the Client of any conflicting requirements.

In case of conflicting requirements, the following order of precedence shallgovern:

Local Authority or Statutory Regulations

Equipment Data Sheets

This Specification

Purchase Requisition

Referenced Industry Design Codes and Standards

CONTRACTORs Instructions

2.3 Referenced Publications

American National Standards Institute (ANSI)

ANSI/ASME B 16.5 Pipe flanges and flanged fittings

ASME B 31.3 Chemical plant and petroleum refinery piping

ANSI/AWWA C950 Glass fibre reinforced thermosetting resin pressurepipe (Rev. 01)

ASTM American Society for Testing and Materials:

ASTM D 570 Test Method for Water Absorption of PlasticsASTM D 1598 Test Method for Time to Failure of Plastic Pipe Under

Constant Internal PressureASTM D 1599 Test Method for Resistance to Short-term Hydraulic

Failure Pressure of Plastic Pipe, Tubing and Fittings

ASTM D 2105 Test Method for Longitudinal Tensile Properties ofFibreglass (Glass-Fibre-Reinforced Thermosetting-Resin) Pipe and Tube

ASTM D 2290 Test Method forApparent Hoop tensile strength ofplastic or reinforced plastic Pipe by Split Disk Method

ASTM D 2310 Classification for Machine-Made Fibreglass (Glass-Fibre- Reinforced Thermosetting Resin) Pipe

ASTM D 2412 Test Method for Determination of External Loadingcharacteristics of Plastic Pipe by Parallel-PlateLoading.


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ASTM D 2444 Test Method for Determination of the ImpactResistance for Thermoplastic Pipe and Fittings byMeans of a Tup (Falling Weight)

ASTM D 2563 Practice for Classifying Visual Defects in Glass Reinforced Laminate Parts

ASTM D 2583 Test Method for Indentation Hardness of Rigid Plasticsby Means of a Barcol Impresser

ASTM D 2584 Test Method for Ignition Loss of Cured ReinforcedResins

ASTM D 2925 Test Method for Beam Deflection of Fibreglass(Glass-Fibre-Reinforced Thermosetting Resin) PipeUnder Full Bore Flow

ASTM D 2992 Practise for Obtaining Hydrostatic or Pressure DesignBasis for Fibreglass (Glass-Fibre-ReinforcedThermosetting-Resin) Pipe and Fittings.

ASTM D 2996 Specification for Filament-Wound Fibreglass (Glass-Fibre-Reinforced Thermosetting-Resin) Pipe

ASTM D 3567 Practise for Determining Dimensions of Fibreglass(Glass-Fibre-Reinforced Thermosetting Resin) Pipeand Fittings

ASTM D 4024 Specification for Machine Made Fibreglass (Glass-Fibre- Reinforced Thermosetting Resin) Flanges

British Standards Institute (BSI)

BS 8010 Code of Practice for Pipelines Section 2.5 Glassreinforced Thermosetting Plastics

ISO International Standards Organisation

ISO 9001 Quality systems Model for Quality Assurance in Design,Development, Production, Installation and Servicing

ISO 14692 Petroleum and natural gas industries Glass-reinforcedplastics (GRP) piping

3. PRODUCT DESIGN

Pipes furnished under this specification are classified in accordance withASTM D 2310, indicating type, grade, class and long-term pressure strength.The classifications of the axial load resistant type of pipe for a nominal

pressure of 20 bar and higher will apply.

The complete pipe designation code in accordance with ASTM D 2996, alsoidentifying the cell classification designations of the short-time rupturestrength, longitudinal strength, tensile modulus and apparent stiffness of the

pipe, is to be stated by the CONTRACTOR.

3.1 Pipes

Pipes furnished under this specification are manufactured by the filamentwinding process. In this process the continuous fibrous glass strand rovingare wound onto the outside of a mandrel in a predetermined pattern under


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controlled tension. The roving are saturated with the resin/curing agentmixture and helical wound under a calculated winding angle. The insidediameter (ID) of the finished pipe is fixed by the mandrel outside diameter.The number of helical wound layers determines the outside diameter (OD) ofthe finished pipe.

3.1.1 Wall structure

The pipe wall consists of the followingcomponents:

Liner

The liner of pipes and fittings consists ofthermosetting plastic resin, reinforced withC-glass with a low alkali content. The resincontent will be at least 70% by weight and the minimum thickness will be 0.5

mm. The matrix of the liner shall be exempted of fillers.

Reinforced Wall

The reinforced wall consists of thermosetting resin, reinforced withcontinuous fibrous glass strand roving of E-glass with a low alkali content.The resin used for the reinforced wall will be the same as used for the liner inorder to assure an optimal adhesion between those two layers. The thicknessof the reinforced wall depends on the pressure rating and will be according tothe CONTRACTORs standard, meeting the requirements specified herein.

Topcoat

The resin used for the topcoat will be a pure thermosetting plastic resin andwill be the same as used for the structural wall underneath to assure a goodadhesion between these two layers. The resin will be exempted of fillers. Thethickness of the topcoat will be 0.3 mm.

3.2 Fittings

Fittings subject of this specification, are elbows, reducers, tees, flanges,adapters and couplers, made by filament winding, using pre-impregnatedwoven glass fabrics which will be applied onto the outside of a mandrel in a

predetermined pattern under controlled tension. For the fitting wall build-up,reference is made to the pipe.

3.3 Joints

Joints used for this specification shall be tensile resistant which means thatthe joints are capable to take up full end load due to internal pressure.Therefore for the intended system no anchor blocks are required.


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3.3.1 Taper Adhesive bonded joint

This system consists of pipe with integral

bell and shaved spigot ends, fittings withintegral bell ends and bell/bell orspigot/spigot adapters. Flanges areavailable with either bell or spigot end.

The components of the system are bonded together with an adhesive. Thefiguration of the joint consists of a cylindrical or conical spigot and a conicalsocket.

As a standard, the pipes shall be furnished with an integral bell end and a

shaved spigot end. It shall not be necessary to field-wrap the connections inorder to obtain the required strength.

3.3.2 Elastomer Key lock joint (R.S.L.J.)

The key lock joint is an integral joint. Thespigot end has one or two grooves in whicho-ring seals are mounted and a shoulder thatfunctions as a stop for the locking strip. Thelocking strip takes care of the mechanical junction between the spigot andthe socket and will be hammered through a hole in the socket end once theactual joint is made.Due to the fact that the joint is restrained by a loose item, the locking strip,

the key lock joint allows for an angular deflection. This type of joint isfoolproof and quick to install. In general, this type of joint shall be used forthe pipeline installation.

3.3.3 Flanged joint

The flange face is flat with two concentricribs, which gives an extra local compressionof the gasket. Flanges shall be drilled tostandard DIN/ANSI dimensions.Flanges shall be filament wound epoxy.Press moulded compound flanges are not

allowed.

It is essential that flange alignment is closely held. Pulling pipes orassemblies into alignment by exceeding the maximum specified bolt torque isnot allowed.

Depending on the conditions, the CONTRACTOR shall advise on a suitablegasket for the intended service and prescribe the maximum bolt torque thatcan be applied.


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3.3.4 Laminated joint

The Laminated joint utilises an externallaminate consisting of a number of layers of

mat, followed by alternating layers offibreglass mat and woven rovingimpregnated with hot-curing epoxy resin.The minimum strength of the laminated jointshall be equal to the minimum pipe wallstrength. The minimum length and thickness of the laminate shall be

according to the CONTRACTORsstandard.

As this type of joint costs manpower and is time consuming it is a rathercostly type of joint and only will be used for field adjustments. This techniquemay also be used as a reasonably quick repair method.

3.4 Performance requirementsThe CONTRACTORshall prove the performance of the GRP pipe system bymeans of a qualification program. This qualification test program includes anumber of destructive tests, which have to prove that essentially the productdesign is suitable for the required application. The performance tests includetesting of the material, joining system, pipes and fittings and are executed ona schedule of representative diameters and fittings. Descriptions ofperformance tests have to be issued for the companys approval but shall atleast include the following:

Regression analysis acc ASTM D 2992-B on ID 100 mm pipe, elbow, tee,adhesive bonded joint and/or key lock jointVerification of the applicability of the above mentioned regression analysis forrepresentative diameters according to the table below:

Representativeproducts

Representativediameter

Diameter range

Pipe, 90elbow, equaltee, adhesivebonded joint,rubber seal lock

joint

100 25, 40, 50, 80

250 150, 200

400 300, 350

600 450, 500

Hydrostatic performance verification shall be done by means of medium termtesting in accordance with ISO 14692. For this test, two representativesamples have to be tested for 1000 hrs at a test pressure exceeding thepressure level at 1000 hrs resulting from the regression analysis. In practicethis will be 2.5 times the nominal pressure rating. For the qualificationprocedure, reference is made to ISO 14692.

For system design purposes, the following additional performance data isrequired:Hoop tensile strength acc. ASTM D 2290


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Longitudinal tensile strength acc. ASTM D 2105Short time hydrostatic strength acc. ASTM D 1599External loading properties acc ASTM D 2412Beam deflection acc. ASTM D 2925Thermal expansion acc. ASTM D 696

Joint testing proving the integrity of the joint under internal pressure incombination with a bending moment, shear forces, misalignment and/orinternal vacuum

Qualification testing shall be carried out by the CONTRACTOR andwitnessed and certified by an independent authority recognised by thecompany. Alternatively, testing and certification may be carried out by anindependent testing organisation. This shall be confirmed by submitting acertificate stating the test results.

4. Quality Assurance/Quality Control

To ensure that all detailed design/engineering is being performedconsistently and accurately, the CONTRACTOR shall have in effect at alltimes a QA/QC program, which clearly establishes the authority andresponsibility of those responsible for the quality system. Persons performingquality functions shall have sufficient and well-defined authority to enforcequality requirements, initiate, identify, recommend and provide solutions toquality problems and verify the effectiveness of the corrective action.

A copy of the CONTRACTORs QA/QC program shall be submitted to thecompany with its quotation for the companies review and concurrence prior

to award. If CONTRACTORs QA/QC program is ISO 9001 certified, then

only a copy of the CONTRACTORs ISO 9001 certificate is required. Inaddition, if CONTRACTORs facility is ISO certified, companys QA auditrequirements will be waived in favour of ISO 9001 registrar audits, unless the

CONTRACTORstrend analysis program indicates areas of concern.

The CONTRACTOR shall identify in documents to its sub-CONTRACTORsall applicable QA/QC requirements imposed by the company and shall

ensure compliance thereto. On request, CONTRACTOR shall provide

objective evidence of its QA/QC surveillance of its sub-CONTRACTORactivities.

5. Documentation

CONTRACTOR shall submit technical design data, material properties,mechanical- and physical properties necessary to perform system design

calculations (see chapter 3.4: CONTRACTORs scope of work), theInstallation Manual and associated data (i.e. instructions for handling,storage, transportation etc.) for contractor/company review.

The CONTRACTOR shall keep complete quality control and test reports. Heshall submit a certified record of inspection and testing, together with astatement of compliance with the requirements.


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If appropriate, the CONTRACTORshall issue a concession request, showingeach deviation from the purchase order.

6. GRP CONTRACTORs Scope of Work

The GRP pipe system CONTRACTORshall be responsible for the following:

The manufacture and supply of GRP pipe, fittings, flanges, joints, make-up

pieces, support saddles and straps. CONTRACTOR will also supply thegaskets for use in GRP flange connections and provide generalrecommendations on associated equipment such as nuts, bolts etc.

Where required, the CONTRACTOR will perform all relevant engineeringsuch as development of stress isometrics, flexibility analysis, surge analysisand support details (i.e. support locations, type and function).

The fabrication and spooling of the GRP system.

To provide complete on-site supervision during installation, hydro-testing andpre-commissioning of the GRP pipe system. Furthermore, if needed, toprovide additional staff to assist in the installation of the pipeline.

Provide and carry out Quality control/Quality Assurance on site for themanufacturers scope of installation for the GRP pipe system.

Advise the civil contractor on soil compaction requirements.

Provide training to installation contractors personnel.

7.0 System Design

This section contains the basic information necessary for design, so that the

contractor using GRP pipe will have a better understanding of the material.The information given should not be considered as a design handbook.Reference is made to ISO 14692.

7.1 Allowable stress and design limits.

Depending on the fabrication method, winding angle, type of resin anddegree of glass content, the level of allowable stresses may differconsiderably. For example, for internal pressure piping in which the rationbetween tangential and axial stress is 2:1 the optimum winding angle is 55and this will result in the stress ratio as given for pressure piping.

To achieve a safe allowable design stress, it is necessary to consider thebehaviour of GRP material in the pressurised condition. The burstingstrength is not to be considered as a good basis for allowable stress,because before the bursting pressure has been reached, an inelasticdeformation occurs. Often, reference is made to the Ultimate Elastic WallStress (UEWS), i.e. the highest stress at which the strain is reversible(comparable to the yield-point of steel).

Another significant point that can be distinguished when pressurising isweeping. The weeping phenomenon is caused by inelastic deformation in thematerial. Weeping starts at pressure levels exceeding those governed by the

UEWS.


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Bursting pressure and weeping pressure are generally derived from short-term destructive test results. These values still have to be reduced to obtainthe correct design stress. Generally, the following relationships is seen forthis safety factor:

Bursting stress/design stress 10Weeping stress/design stress 3-4UEWS / design stress 2-2.5

An alternative for the determination of the design stress is described inASTM D 2992. This method describes a procedure for obtaining ahydrostatic design basis for reinforced thermosetting resin pipe and fitting.

From the results of the test, regression lines can be calculated. From theselines the expected lifetime at certain stress levels can be read.These tests have to be performed on all critical items in a pipe system, such

as pipes, joints, elbows and tees.

The value determined after extrapolation to 50 years is called the HydrostaticDesign Basis (HDB). This basis has to be reduced by means of a servicedesign factor to obtain the hydrostatic design stress (HDS). The servicedesign factor has to be max. 0.67 for a service life of 50 years.

The reinforced wall thickness of pipes is calculated for different pressureclasses by means of the Barlow formula. The allowable maximum internaland external working pressure for straight pipe at ambient temperature is

quoted in the CONTRACTORcatalogues.

It should be considered that in most cases the stated values are notacceptable as design pressures, since most calculations are made in relationto a specific support distance (span).

7.2 Expansion and flexibility

The pipeline system should be designed so that flexural stresses resultingfrom displacement due to expansion, contraction and other movements areminimised. This concept requires special attention to supports, terminals andother restraints, as well as to techniques to provide for adequate inherentflexibility. Often the directional changes in a pipeline system do not provide

sufficient flexibility to compensate for expansion and contraction due totemperature changes. Therefore expansion joints or loops should beinstalled. Key lock joints can accommodate expansion to a certain extent. Acareful pipe stress analysis shall be carried out, giving due consideration tothe specific characteristics of the GRP material.

The concept of strain imposed by restraint of thermal expansion orcontraction and by external movement applies in principle to both metallicand non-metallic piping.


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The assumption that stresses throughout the piping system can be predictedfrom these strains because of fully elastic behaviour of the piping materials isnot generally applicable to non-metallic materials. However:

In GRP piping systems displacement strains are not likely to produce

immediate failure of the piping but may result in detrimental distortion Overstrain shall be avoided by system layout and if necessary,

excessive displacements shall be accommodated by loops, special(expansion) joints, or other devices permitting movements. The exactvalues to be used in calculations shall be as specified by themanufacturer.

Fittings such as tees, reducers and elbows are very rigid comparedwith straight pipe. Expansion loops are assembled from pipe andelbows in which the elbows are considered as non-flexible parts.Thermal expansion therefore has to be absorbed by the deflection ofthe loop legs.

8.0 Installation

The various installation aspects should be in accordance with the

CONTRACTORs guidelines and the requirements given in the precedingsections. Installation has to be an item considered from the design phaseonwards.

The CONTRACTOR shall provide proper installation instructions andadequate supervision during installation.The GRP piping shall be pre-assembled into subassemblies as much as

practical.Each adhesive bonded joint performed on site shall be performed in full

accordance with the CONTRACTORs instructions and shall be fully curedbefore testing.

The GRP piping shall be installed in such a way that it is free from stresses.If new GRP piping is to be taken into hot service for the first time, it should begradually heated, approx. 20C per hour to release the stresses. The piping,especially the pipe ends shall be protected against damage duringinstallation. For above ground piping, bending of pipe is not permitted toachieve change of direction.

9.0 Inspection

Pipes and fittings furnished under this specification shall be new and unused,free from defects including indentations, de-laminations, bubbles, pinholes,foreign inclusions and resin starved areas.

Pipes as well as fittings shall be as uniform as commercially practicable incolour, density and other physical properties The pipe shall be round andstraight and the bore of pipe and fitting shall be smooth and uniform.

The pipes and fittings will meet the criteria as stated in chapter two.


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10.0 Testing

Before the installed pipe system can be used, the system needs to be testedto ensure that all the joints function correctly. The pipe system shall be

hydrostatic pressure-tested with water at a pressure of 1.5 times themaximum working pressure of the system during the following time period tocompensate piping pressure settings:

10.1. Pressure setting testing

After filling and venting the trapped air at the highest points, the pressure isgradually increased at 0.8 times the working pressure dependent on thesystem and maintained for 24 hours allowing the system to set.

11.0 Previous suppl ier

The CONTRACTORthat previously supplied all GRP material in line with therequired specification is as detailed below.

Contact Mr Joseph Albanese

Iniziative Industr iali S.p.A. Sarplast

Via Rosignanina, 32

56040 Santa Luce (PI)

ITALY

Phone No +39 050 691701

Fax No +39 050 691901

Website:-www.sarplast.com

10.2. Main pressure testing

The test pressure must be raised gradually to 1.5 times the working pressureand maintained for 4 hours. After 4 hours the pressure may have dropped by0.3 bar for diameters

600 grp spec rev 1 sept 2010.pdf

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