Employer Doc. No.

NSRP Contractor Doc. No.

Complex Project Nghi Son Refinery and Petrochemical S-000-1360-0012V
Limited Liability Company Rev. 0 Page 1 of 42
Nghi Son, Vietnam
Employer Contract No.: XXXXX, Contractor JOB Code: 0-6495-20 Date: 29/OCT/13

Technical Specification for GRP Pipes and Piping

Components (Incl. CIVIL)

Unit No.: Not Applicable

Unit Abbreviation.: Not Applicable

Document Class: X

Rev Date Page Description Prep'd Chk'd App'd

For Construction (Incorporated

0 29/OCT/13 All H.M T.S T.Y
Employer’s comments)
A 31/MAY/13 All First issue H.M. T.S. T.Y.

Operation Centre JOB Code: Operation Centre Doc. No.:

Responsible Company Prepared by Checked by Approved by
JVD H. Mihira T. Shoji T. Yamamoto
 Employer Doc. No.

NSRP Contractor Doc. No.

Complex Project Nghi Son Refinery and Petrochemical S-000-1360-0012V
Limited Liability Company Rev. 0 Page 2 of 42
Nghi Son, Vietnam
Employer Contract No.: XXXXX, Contractor JOB Code: 0-6495-20 Date: 29/OCT/13

Issue Purpose For Construction

Rev Date Page Description Prep'd Chk'd App'd

For Construction (Incorporated

0 29/OCT/13 All H.M T.S T.Y
Employer’s comments)
A 31/MAY/13 All First issue H.M. T.S. T.Y.

Operation Centre JOB Code: Operation Centre Doc. No.:

Responsible Company Prepared by Checked by Approved by
JVD H. Mihira T. Shoji T. Yamamoto
 Employer Doc. No.
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FOREWORD

This specification is sourced from ITB document 3550-8310-SP-0003 “GRP Pipe, Fittings and Installation
Requirements for Underground Services” for purchasing GRP pipes and piping components.

For pressurized piping requirements, refer to project specification 3550-8440-SP-0002 “Materials

Requirements for Pressurized Equipment and Piping”.
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CONTENTS

1 PURPOSE AND SCOPE..................................................................................................................... 5

1.1 Scope of Material Supply.................................................................................................................. 5

1.2 Service Fluid [HOLD]......................................................................................................................... 5

1.3 Service Conditions............................................................................................................................ 6

1.4 Stress and Surge Analysis................................................................................................................ 6

1.5 Pipe Supports for Aboveground GRP Piping..................................................................................7

2 DEFINITIONS...................................................................................................................................... 7

3 REFERENCE DOCUMENTS............................................................................................................... 8

3.1 Project Specifications & Standards.................................................................................................8

3.2 International Standards..................................................................................................................... 8

4 REQUIREMENTS.............................................................................................................................. 10

4.1 General............................................................................................................................................. 10

4.2 Base Materials.................................................................................................................................. 11

4.3 Resin................................................................................................................................................. 11

4.4 Design............................................................................................................................................... 12

4.5 Dimensions....................................................................................................................................... 13

4.6 Technical Requirements.................................................................................................................. 14

5 MANUFACTURE............................................................................................................................... 14

5.1 Filament-wound pipe....................................................................................................................... 14

5.2 Fittings and Flanges........................................................................................................................ 14

6 QUALIFICATIONS TESTING............................................................................................................ 14

6.1 Finished Products............................................................................................................................ 15

6.2 General Qualifications Requirements............................................................................................ 15

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6.3 Special Qualification Requirements............................................................................................... 17

7 INSPECTION AND TESTING............................................................................................................ 19

7.1 General............................................................................................................................................. 19

7.2 Acceptance Tests............................................................................................................................ 19

8 QUALITY REQUIREMENT................................................................................................................ 20

8.1 Quality Assurance........................................................................................................................... 20

8.2 Quality Control................................................................................................................................. 20

8.3 Certification...................................................................................................................................... 21

9 DOCUMENTATION........................................................................................................................... 21

9.1 Vendor’s Drawings.......................................................................................................................... 21

10 PRESERVATION AND PACKING.................................................................................................... 21

10.1 Marking............................................................................................................................................. 21

10.2 Packaging......................................................................................................................................... 22

11 INSTALLATION OF GRP PIPING SYSTEM.....................................................................................22

11.1 Piping Materials............................................................................................................................... 22

11.2 Installation........................................................................................................................................ 22

11.3 Design of Pipes, Joints and Fittings.............................................................................................. 24

11.4 Receiving, Handling and Storage................................................................................................... 25

11.5 Assembly of Pipe and Fittings........................................................................................................ 25

11.6 Placing of Pipe in Trench................................................................................................................ 25

11.7 Hydro-testing of Pipe....................................................................................................................... 25

11.8 Flanged Connections...................................................................................................................... 25

12 TECHNICAL INFORMATION REQUIRED FROM VENDOR............................................................26

12.1 Technical Details.............................................................................................................................. 26

ATTACHMENT-1: SERVICE CONDITIONS OF GRP FLUID SYSTEMS......................................................28

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1 PURPOSE AND SCOPE

This specification covers the technicalrequirements for GRP (Glass-fiber Reinforced Plastic)
pipes and piping components in NSRP(Nghi Son Refinery and Petrochemical) Complex Project.

1.1 Scope of Material Supply

The following are the items to be supplied by Vendor:

 Pipes

 Fittings

 Flanges

 Bolts and Nuts

 Gaskets

 Pipe Supports for A/G (Note 1)

 Adhesive Kits (Note 1)

 Special Tools

 Materials for Trainings

Note 1: Vendor shall propose the required quantities.

The prices shall be indicated separately in the proposal, and included in the total price.

1.2 Service Fluid [HOLD]

The following service fluids are applicable to GRP piping systems:

1.2.1 Pressurized Piping Systems

(1) Sea Water (A/G, U/G)

(2) Fire Water (U/G)

(3) Potable Water (U/G)

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(4) Cooling Water (U/G)

(5) Treated Water

(6) Continually Oil Contaminated (COC) Water for Pressurized Piping

(7) Service (Process) Water

1.2.2 Non-pressurized Piping Systems

(1) Accidentally Oil Contaminated (AOC) Water

(2) COC Water for Non-pressurized Piping

1.3 Service Conditions

The design and operating conditions (pressures and temperatures)for each service fluid are
summarized in Attachment-1.

All piping systems shall withstand the full vacuum condition at ambient temperature.

Non-pressurized Piping System shall have an atmospheric design and operating pressures.
Minimum and maximum temperatures the system shall be subjected are between 0 to 50° C.

1.4 Stress and Surge Analysis

Vendorshall conduct stress and surge analyses. It is his responsibility to completely evaluate the
effects of temperature changes, internal pressure surges and pipeline geometry as per 3550-
8230-SP-0004 – Pipe Stress Analysis Guide (to be replaced with S-000-1360-0005V
“Specification for Stress Analysis”) and 3550-8230-SP-0005-Stress Critical Line Index Guide (to
be replaced with S-000-1360-0006V “Guideline for Stress Critical Line List Preparation”). It is also
his responsibility to determine the need and locations of thrust blocks and anchorages.

The analyses shall be completed prior to fabrication.

Vendorshall submit the structural design of pipe for the various criteria as listed below:

 Buoyancy for varying water table

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- to be considered. Water table to be considered as same level with finished grade

level.Not to be considered.

 Burial depth (H)

- Pressurized Piping System: 300mm to 3,000mm

- Non-pressurized Piping System: 300mm to 3,000mm

 Backfill type/density

- Embedment Material: Sand with Fine

- Compaction Degree: High (95% standard density at optimum moisture content as

determined by the Modified Proctor test on BS 1377)

- Soil Stiffness Category: SC3

- Soil Density: 20kN/m3

- Soil Modulus: 30MPa for H≤1000

20 MPa for H>1000

 Maximum/minimum installation temperatures

- Min. Temperature: 10 deg.C

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- Max. Temperature: 36 deg.C

 Live loading

The following two load cases shall be considered:

- LC-1: 75 kN

- LC-2: 100 kN

In addition, special impact load during start-up, test, or emergency shut-down shall be
considered, if any.

1.5 Pipe Supports for Aboveground GRP Piping

Vendor shall inform Contractor of pipe support locations and types for aboveground piping
systems based on the result of stress analysis.

Vendor shall submit the following pipe support information with his quotation:

 Engineering Guide for Pipe Supports

 Support Type

 Standard Support Drawings

 Unit Price for Pipe Supports, if Vendor can supply them

2 DEFINITIONS

The following definitions shall apply:

Employer- Nghi Son Refinery and Petrochemical Limited Liability Company (NSRP)

Contractor- A Joint Venture formed by JGC Corporation, Chiyoda Corporation, GS Engineering &
Construction Corporation, SK Engineering & Construction Co., Ltd., Technip France and Technip
Geoproduction (M) Sdn. Bhd., as Contractor for the execution of the NSRP Complex Project

Vendor- nominated by the Contractor and approved by Employer

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Installation Team(s) - Vendor’strained and qualified GRP Pipe System installers provided by
Contractor

3 REFERENCE DOCUMENTS

3.1 Project Specifications & Standards

3.1.1 Project Specifications

3550-8110-PH-0005 Drainage Philosophy

3550-8310-SP-0004 Pipe Stress Analysis Guide

3550-8230-SP-0005 Stress Critical Line Index Guide

3550-8310-SP-0009 Earthwork Specification

3550-8310-SP-0011 Drainage Materials and Workmanship

3550-8440-SP-0002 Materials Requirements for Pressurized Equipment and

Piping

3550-8840-SP-0008 Protective Painting Systems

3550-8552-SP-0009 Instrument Piping Specification

3.1.2 Project Drawings

To be informed later.

3.2 International Standards

Where no specific revision numbers or issue dates of the international standards are specified,
the latest versions of them as of 27, January 2013 shall govern.

3.2.1 British Standards

BS 5750 Quality Systems

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BS 3396 Specification for E Glass Fibre Rovings for Reinforcement of

Polyester and Epoxy Resin Systems

BS 3691 Specification for Loom-State Fabrics, Woven Glass

FibreFabrics for Plastics Reinforcement.

3.2.2 American Society of Mechanical Engineers (ASME)

ASME B16.47 Large Diameter Steel Flanges NPS 26 through NPS 48

ASME B16.5 Pipe Flanges and Flanged Fittings

ASME B31.3 Process Piping

3.2.3 American Society for Testing Materials (ASTM)

Standard Test Methods for:

ASTM D 570 Water Absorption of Plastics

ASTM D 696 Coefficient of Linear Thermal Expansion

ASTM D 1599 Short-Time Hydraulic Failure Pressure of Plastic pipe,

Tubing and Fittings

ASTM D 2412 External Loading Properties of Plastic pipe by Parallel-plate

Loading

ASTM D 2563 Visual Defects in Glass Reinforced plastic laminated Parts

ASTM D 2583 Indentation Hardness of Rigid Plastics by Means of a Barcol

Impressor

ASTM D 2584 Ignition Loss of Cured Reinforced Resins

ASTM D 2925 Beam Deflection of Reinforced Thermosetting Plastic Pipe

under Full Bore Flow

ASTM D 2992 B Obtaining Hydrostatic Design Basis for Reinforced

Thermosetting Resin Pipe and Fittings

ASTM D 3418 Transition Temperature of Polymers by thermal Analysis

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ASTM D 3567 Dimensions of Reinforced Thermosetting Resin Pipe and

Fittings

ASTM D 4024 Reinforced Thermosetting Resin Flanges

ASTM D 638 Tensile properties of Plastic

ASTM D 695 M Compressive properties of Rigid Plastic

ASTM D 2105 Longitudinal Tensile Properties

ASTM D 2290 Apparent Hoop Tensile Strength

3.2.4 Dutch Standard

NEN 7037 Glass-fibre Reinforced Thermosetting Plastic Pipes for Drain

and Sewers. Requirements for Test Methods

3.2.5 European Standards

EN 59 Glass Reinforced Plastic – Measurement of Hardness by

Means of a Barcol Impressor (Glass Reinforced Plastics-
Determination of Loss on Ignition)

3.2.6 International Standard Organisation (ISO)

ISO 62 Plastics – Determination of Water Absorption

ISO 9001 Quality Assurance

ISO/TS 10465-1 Underground Installation of Flexible Glass-Reinforced Pipes

Based on Unsaturated Polyester Resin Part 1: Installation
Procedures

ISO/TR 10465-2 Underground Installation of Flexible Glass-Reinforced Pipes

Based on Unsaturated Polyester Resin Part 2: Comparison
of Static Calculation Methods
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ISO/TR 10465-3 Underground Installation of Flexible Glass-Reinforced Pipes

Based on Unsaturated Polyester Resin Part 3: Installation
Parameters and Specification Limits

ISO 14692 Petroleum and Natural Gas Industries- Glass-Reinforced

Plastics Piping (All Parts)

3.2.7 Other Applicable International Standards

API Spec 15LR Reinforced Thermosetting Resin Line Pipe

Class No 1610 Approval Standard –Plastic Pipe and Fittings for

Underground Fire Protection Service, issued by Factory
Mutual Research, 1151 Boston-Province Tumpike, Norwood,
Massachusetts 02061, USA.

AWWA M45 Fiberglass Pipe Design

AWWA C950 Fiberglass Pressure Pipe

4 REQUIREMENTS

4.1 General

Pipe, fittings and flanges shall be made by the filament-winding process and flanges shall be
made by the pressed sheet moulding process.

The entire surface of the GRP pipe and fittings material shall be UV resistant material and shall
have design life of 25 years.

Section 6describes the qualification testing programme and procedure to which a Vendoris
subjected before his first delivery of GRP pipe and fittings.

Section 7 describes the minimum number of production tests to be carried out for each
subsequent delivery of GRP pipe and fittings by a Vendorwhose products have been qualified
successfully.

A number of requirements in this specification are comparable to those of API Specification

15LR”Specification for low pressure fibreglass lines, pipe and fittings”.
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Pressurized piping shall be designed, manufactured and installed in accordance with ISO 14692
Part 1-4.

4.2 Base Materials

All base materials shall be new and unused, and shall be free from contamination and
imperfections. The base, for example, resins, glass-fibre reinforcing materials, pigments and
other materials, when combined as a composite structure, shall produce pipe, fittings and flanges
which meet the requirements of this specification. All base materials shall be specified in writing
by the pipe Vendorand certified by the Vendorof raw materials per delivery.

4.3 Resin

Unless otherwise agreed, the pipe, fittings and flanges shall be made from a bisphenol A
epichlorohydrin epoxy resin and an aromatic or cyclo-alipathic amine-type curing agentVinylester
or Polyester, with a documented history of successful performance on similar service.
Vendorshall provide full details of the type of resin and curing system chosen.

4.3.1 Glass-Fibre reinforcement, Fillers and Pigments

Glass-fibre reinforcement for the reinforced wall shall be made of E-glass (for example, low-alkali
glass) meeting an internationally accepted standard such as BS 3691, BS 3396 and shall have a
finish (coupling agent) which is compatible with the epoxy resin.

Fillers are not acceptable. Thixotropic additives added to the resin/curing agent mixture for
viscosity control shall not exceed 2% by weight.

Pigments are only acceptable as long as they do not affect the performance of the components
as defined in Section 6, or if agreed with Employerin order to fulfil special application
requirements.

4.3.2 Lining Material

Unless otherwise agreed (see Clause 4.3.1), flange surface and all pipe and fittings which are to
be exposed to the fluid, shall have a smooth uniform resin-rich lining consisting of:
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 A surfacing mat (tissue) or veil, which may be either a C-glass (example, chemical-
resistant glass) or a synthetic fibre such as linear polyester fibres or polyacrylontrile
fibres;

 The same resin, which is used for the fabrication of the pipe, fitting and flange.

4.3.3 Adhesive

The adhesive for adhesive-bonded connections shall be of an epoxy type, formulated to be

resistant to the fluid to be conveyed, and for the service temperatures and pressures. It shall be
of the type and quality regularly supplied by the pipe Vendorfor the duty intended, and as used for
the qualification test (Clause 6.2.6) and shall have a proven record of good service.

The adhesive shall be provided in a kit form containing the epoxy resin curing agent (separately
and in the recommended proportions), a mixing stick, joint cleaner, sandpaper and brush,
together with jointing instructions.

The adhesive kit shall have been date stamped at the time of the packaging and shall indicate the
required storage conditions and date of expiration of shelf life.

The adhesive kit shelf life at 40 C shall not be less than six months from the date of shipment or
12 months from the date of production.

4.3.4 Rubber Sealing Rings

The sealing rings for the spigot and socket connections shall be made of a rubber type resistant
to the water to be conveyed and for the service temperatures and pressures. Vendorshall state
the type of rubber, providing evidence for its suitability in the proposed application.

4.3.5 Fixation Rod

The fixation rod for thrust-resistant spigot and socket connections with rubber sealing ring(s) shall
be made of a flexible thermoplastic material, resistant to the particular service condition, such as
temperature, surrounding environment, ultra-violet exposure, etc. Vendorshall state the type of
thermoplastic material, providing evidence for its suitability in the proposed application.
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4.3.6 Lamination

Vendorshall submit the lamination process from preparation to finishing. The lamination surface
shall be warmed up during cold weather application to temperature higher than 18°C.

Pipe diameters larger than 600mm (24”) shall be laminated.

Vendorshall remove the fire protection layer prior to lamination work. After lamination process, fire
protection layer shall be reinstated in accordance with Vendor’s recommendation of protection
layer installation.

4.3.7 Jointing Methods

Jointing method shall be standardized for aboveground and underground systems as follows:

 NPS 24 and below = Adhesive (Taper)

 NPS 26 and above = Laminated

Keylock mechanical joint shall be used for all field joints and for up to 24“pipe diameter. Piping
system shall be fabricated in spooled sections to minimise field joints. Field joints for pipes more
than 24” in diameter shall be laminated joints. Taper/Taper adhesive joint shall be used for all
workshop environment to fabricate more complicated/convoluted spools.

4.4 Design

Vendorshall submit a piping stress analysis report in accordance with ASME B31.3 and full
relevant material data relevant to his specific brand of pipes and fittings to enable the
Contractorto verifythe piping stress analysis of GRP piping in accordance with ASME B31.3.

The components shall also be designed and manufactured to ASME B31.3.

Unless otherwise specified, piping shall have smooth uniform resin-rich lining (Clause 4.3.2).

Vendorshall provide proper installation instructions and, if requested, adequate supervision at all
stages of installation.
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4.5 Dimensions

4.5.1 Pipe

The pipe standard for filament-wound pipe may be based on either the inside diameter (Di) or the
outside diameter (Do).

The reinforced wall thickness of the pipe shall be sufficient to withstand the temperatures,
pressures and service conditions of the particular application. The wall thickness shall be at least
1.8mm.

Lining thickness for filament-wound pipe shall be at least 0.5mm. Pressured-sheet moulding
compound (SMC) flanges have no liner but a pressed skin which shall be at least 0.2mm thick.

All piping shall have a smooth resin rich top outer coat.

The difference between the largest and smallest diameter (ovality) in each cross section shall be
not more than 0.007 Di or 0.007Do.

The pipes shall be supplied with either integral Taper-Taper spigot and socket ends suitable for
adhesive joints or with spigot and socket ends with rubber sealing rings.

4.5.2 Fittings

Fittings shall be supplied with integral socket ends to accept either tapered ends for adhesive
joints or for joints with rubber sealing rings.

The reinforced wall thickness of the fittings shall be sufficient to withstand the temperatures,
pressures and service conditions of the particular application. It shall be at least 2.2mm.

The difference between the largest and smallest measured inside diameter (ovality) shall not be
more than 0.007 Di or 0.007 Do.

4.5.3 Flanges

The outside diameter and drilling template of flanges shall be in accordance with ASME B16.5
class 150 for pipes up to NPS 24,ASME B16.47 series A for pipes larger than NPS 24 up to NPS
60. Vendor shall design the flanges larger than NPS60 based on ASME B31.3 Para.A304.5.1.
Vendor standard drawing for the flanges larger than NPS 60 shall be submitted at the bidding
stage. The flange face shall be flat-type. The flange face finish shall be serrated spiral (stock).
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4.5.4 Gaskets

The gaskets shall be suitable for a full face flange and shall be synthetic rubber with
reinforcement.

Vendorshall provide recommended flange bolt torques for the recommended gaskets.

4.5.5 Bolts

The bolts and nuts materials shall be ASTM A307-B / A563-A. Two washers of ASTM F436 shall
be provided for each bolt. The bolts, nuts and washers shall be galvanized.

4.6 Technical Requirements

Pipe and fittings purchased to this specification shall meet the requirements as stated in Sections
4, 5 and 6.

Pipe and fittings for fire protection service shall have a Factory Manual (FM) approval, which
implies that they meet a number of requirements additional to this specification. This implies that
for pipe, fittings and pipe spools a safety factor of 4 shall be adhered to on the short term weeping
pressure.

The raw materials shall be checked against the sales specification as given by Vendorof these
materials.

Vendorshall check for each production batch per shift of eight hours the mixing ratiosof resin and
curing agent. He shall also record permanently the mixing ratios.

5 MANUFACTURE

Unless otherwise agreed by the Employer, the following manufacturing methods shall be adhered
to:
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5.1 Filament-wound pipe

Filament-wound pipe shall be manufactured by winding resin-impregnated continuous fibrous

glass strand roving or woven glass roving tape on to the outside of a mandrel in a pre-determined
pattern under controlled tension.

Vendorshall provide details of filament winding angle prior to commencement of production.

5.2 Fittings and Flanges

Fittings shall be of a filament-wound construction. Flanges shall be of a filament-wound

construction or a pressed-sheet moulded compound (SMC) construction. In the latter case of
length of the reinforcing fibres shall be at least 12mm.

6 QUALIFICATIONS TESTING

The full program of qualification testing is required before Vendor will be allowed to deliver for the
first time. The Employermay require to repeat, completely or in part, the qualification testing of a
certain make, for example, because of time elapsed or new developments.

Changes in the design and/or method of Vendorof pipes and/or fittings will in any case require
new or additional qualification tests.

The qualification testing shall be carried out on products with representative diameters. The type
of product, its pressure and temperature rating and number, etc shall be mutually agreed with
Employer (to be fixed later).

Representative diameter and products:

Representative Pipe, Elbow 90º, equal Tee and reducer

Products

Representative 50 150 300 600 900 1200

diameter (mm)

Diameter Range 25 80 200 350 750 1050

(mm)
40 100 250 400 900 1200
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50 150 300 450

500

600

Representative Pipe, Elbow 90º, equal Tee and reducer

Products

Representative 2000 3000

diameter (mm)

Diameter Range 1300 2200

(mm)
thru thru

2100 3000

Vendor shall provide materials which werecertified by the qualification testing before as described
herein. The test certificates shall be submitted to Contractor.

Qualification testing as described herein shall be carried out by Vendorand witnessed and
certified by an independent authority recognised by Employer. Alternatively, testing and
certification may be carried out by an independent testing organisation. This shall be confirmed
by submitting a test certificate witnessed by an independent authoritystating the test results.

Employer shall be contacted for those cases where the material will be accepted and released
pending some time consuming qualification tests (e.g. the beam deflection test). Such tests may
be accepted on their satisfactory completion and the material will then receive the final clearance.

6.1 Finished Products

The following qualification requirements shall apply to the finished products. Vendorshall comply
with API Spec 15 LR and carry out the following tests. All tests shall be carried out at room
temperature.
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6.2 General Qualifications Requirements

The general qualifications requirements shall be as per applicable ASTM Standards listed in
Section 3.2.3 of this Specification.

6.2.1 Curing

The degree of curing of pipe and fittings shall be determined by boiling samples in acetone
(dimethyl ethyl ketone) for 3 hours. After boiling and drying to constant weight the samples shall
not show more than 2% loss of weight.

The degree of curing may also be assessed by determination of the transition temperature by
differential scanning calorimetry (DSC) of differential thermal analysis (DTA) in accordance with
ASTM D 3418. The glass-transition temperature shall be at least 110ºC.

6.2.2 Glass Content

The glass/resin ratio of filament-wound pipe shall be tested in accordance with EN 60 or ASTM D
2584. The glass content of the filament-wound pipe shall be at least 65% by weight, whereas for
filament wound fittings the glass content shall be at least 55% by weight.

6.2.3 Consistency of Pipe Material

Three samples shall be taken from three places situated 120º apart in the same cross section.
The glass content of each sample shall be determined in accordance with EN 60 or ASTM D
2584. The difference in the glass content between two samples shall be not more than 5% by
weight.

6.2.4 Water Absorption

Pipe and fittings shall not show evidence of delamination or other impairments when tested in
accordance with ISO 62 or ASTM D 570.
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6.2.5 Linear Thermal Expansion

Vendorshall state in his qualification testing report the coefficient of thermal expansion of a pipe
length as determined in accordance with ASTM D 696.

6.2.6 Adhesive Bonded Piping System

The relevant requirements for the specific component shall also apply for the adhesive bonded
piping system.

The application of an additional overlap laminate to the joint to obtain the necessary strength is
not acceptable.

6.2.7 Spigot and Socket with Rubber Sealing Rings Joint Piping Systems

A spigot and socket with rubber sealing rings joint piping assembly shall meet the following
requirements:

 No leakages shall occur during hydrostatic pressure testing at 1.5 times the design
pressure during ten minutes, whilst the test sections are deflected angularly in such a
way that the centre-line of one section of the assembled specimen makes an angle of
1.5° (for diameters up to 600mm) or 1° (for diameters from 700mm) with the centre-line of
the other section.

 The joint assembly shall withstand a combination of a bending force and an internal
hydrostatic pressure of 1.5 times the design pressure.

 The bending force shall be applied in the middle of the joint and shall be calculated
depending on the length of the specimens and the support distance. The applied
bending force shall be such that the sum of the occurring axial stresses due to the
internal hydrostatic pressure of 1.5 times design pressure plus the occurring axial stress
due to the bending force shall be two times the nominal axial stress.

 After having applied the calculated bending force, ten cycles of 0 to 1.5 times design
pressure shall be performed.

 The pressure cycle time shall be ten minutes (five minutes without pressure, five minutes
at design pressure).
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 The joint assembly shall withstand a combination of a shear force (N) of 20 times the
inside diameter (mm) and an internal hydrostatic test pressure of two times the design
pressure. The test pressure shall be cycled from zero to the test pressure, ten times,
while holding the shear force. The time for one pressure cycle shall be ten minutes (five
minutes without pressure, five minutes at design pressure).

 The test sections shall be deflected while the pipe units are in horizontal position, by
applying a load vertically at the spigot end of the joint. The shear force shall be uniformly
applied over an arc of not more than 180° along a longitudinal distance of one pipe
diameter or 300mm, whichever is the smaller, from the sealing of the assembled joint, at
the unsupported spigot end of the pipe. The specimens in the test shall be supported on
blocks, placed immediately behind the bell. Instead of the applied load by external force,
the use of own weight of the filled specimen can be chosen.

 The joint assembly shall withstand an internal vacuum of 0.74 bar absolute during ten
minutes when

(a) deflected angularly in such a way that the centre-line of one section of the
assembled specimen makes an angle of 1.5° (for diameters up to 600mm) or 1° (for
diameters from 700mm) with the centre-line of the other section, and when

(b) deflected in a horizontal position by a shear force vertically applied at the spigot end
of the joint over an arc of not more than 180° along a longitudinal distance of one
pipe diameter or 300mm, whichever is the smaller, from the sealing of the
assembled joint, at the unsupported spigot end of the pipe

NOTE: (Pressure stabilising for 30 minutes is allowed).

6.2.8 Flanged Piping System

Flanges shall withstand, without any visible sign of damage, a bolt torque of at least 1.5 times that
recommended by Vendorat the design pressure.

For this test a flanged section shall be bolted against a flat face steel flange. The bolts shall be
tightened in 7 mm increments according to the recommended practice.

Two flanged section shall be bolted together using the gasket and bolt torque for standard field
installation as recommended by Vendor. This assembly shall meet the following requirements:
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No leakages shall occur during hydrostatic pressure-testing at 1.5 times the design pressure
during 168 hours.

Retorquing to Vendor’sspecified level after initial pressurisation is permitted.

No rupture of the flanged connection shall occur during hydrostatic pressure testing at two times
the design pressure for ten minutes. Leaking past the gasket interface is permissible during this
test. Bolt torque may be increased if necessary during the test in order to minimise gasket
leaking and to achieve the pressure necessary to cause flange failure.

Vendorshall provide certified documents for mutually agreed piping diameters

6.3 Special Qualification Requirements

The following tests shall be subject to Employer’s approval prior to delivery of pipe and fittings.

6.3.1 Appearances

Unless otherwise agreed, the inside of pipe and fittings shall have a smooth and uniform lining
and be in accordance with ASTM D 2563 Level 1.

The other parts of pipe and fittings shall be classified according to Level II of ASTM D 2563, with
the following exceptions:-

 Air bubble : maximum 2mm; 3 bubbles/1000mm2

 Pimple : Level III

 Pit : Level III, but depth less than 10% of the wall thickness

Pipe and fittings shall be uniform in composition and structure, density and other physical
properties.

All ends of pipe and fittings shall be cut at right angles to the axis and any sharp edges shall be
removed.

6.3.2 Hydrostatic Design Stress, Pressure Ratings and Hydrostatic Pressure Test

The long-term hydrostatic strength of pipe, fittings and joints shall be determined in accordance
with Procedure A or B of ASTM D 2992. Vendorshall select the procedure and the size for these
tests. Adhesive joints, if any, shall be included utilising both the factory and field adhesives and
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their respective joining and curing procedures, if different. The samples tested shall carry the full
end load due to pressure.

Testing shall be conducted at a minimum temperature of 20ºC.

The hydrostatic design stress determined in accordance with Procedure A of ASTM D 2992 shall
utilise a service (design) factor of 1.0.

The hydrostatic design stress determined in accordance with Procedure B of ASTM D 2992 shall
utilise a service (design) factor of 0.5.

Pressure ratings for pipe shall be calculated using the hydrostatic design stress for the specific
pipe material and the ISO formula for hoop stress in section 3.1.8 of ASTM D 2992. The
minimum reinforced wall thickness shall be identified. Vendor shall submit the pipe wall thickness
calculation report for Purchaser approval.

Flanges shall be pressure rated and hydrostatic pressure tested in accordance with ASTM D
4024.

The pipe, pipe spools or pipe joints shall be subjected to a bi-axial loaded hydrostatic pressure
test as described in ASTM D 1599.

The GRP pipe, pipe spool or pipe joints shall not display a weeping effect below a hoop stress
value of 150 MPa.

The test pressure shall subsequently be increased tothree times the design pressure and be
maintained for at least five minutes.

During this pressure test the test specimens shall not show any sign of breakage.

NOTE: (This test will cause irreversible deformations in the material; the test specimens shall
therefore be discarded).

6.3.3 Stiffness of Pipe

The minimum specific tangential initial stiffness (STIS) shall, when tested in accordance with NEN
7037, be not less than:

2.5 kPa for 10 bar piping,

10 kPa for 16 bar piping,

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25 kPa for 20 / 25 bar piping.

Alternatively, the pipe stiffness at 5% deflection in accordance with ASTM D 2412 can be
determined. In that case the pipe shall be free from cracks or delaminations at a minimum
stiffness of:

20 lb/in2 for 10 bar piping

78 lb/in2 for 16 bar piping

200 lb/in2 for 20 / 25 bar piping

6.3.4 Beam Deflection

The modulus of elasticity of the GRP pipe shall have a minimum of 7,000 Mpa at 90ºC when
tested in accordance with ASTM D 2925.

6.3.5 Impact Resistance

A steel ball 50mm in diameter and weighing approximately 550g shall be dropped perpendicularly
on to the surface of the test pipe with a free fall (which may be guided) of 300mm.

The ball shall be caught or deflected after the hit so that the rebound does not strike the pipe
again. The pipe shall be filled with water containing, if possible, a soluble fluorescent dye. The
test shall be made at room temperature and the pipe shall be supported on its bottom axis on a
solid flat support. Four drops shall be made on randomly selected areas which are separated by
a minimum length of one pipe diameter from each other. The test shall be repeated on the same
pipe but with the pipe pressurised at the pressure class of the pipe. Four drops shall be made on
different areas from those previously used. The pipe shall then be pressurised to two times the
pressure class rating at 25ºC for five minutes.

Fittings shall be tested in the same manner except that the drops shall be reduced from four to
one in each test.

The pipe or fitting shall not show any porosity or visual delamination when examined, e.g. with
ultraviolet or normal lamp.
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7 INSPECTION AND TESTING

7.1 General

This section describes the minimum number of acceptable tests required for each delivery of
GRP pipe and fittings purchased to this specification from Vendor whose products have been
qualified successfully to Section 5.

Additional tests may be established by mutual agreement between Vendor and Purchaser prior to
any contract award.

If the material fails to pass any of these tests, this may constitute sufficient cause for rejection.

7.2 Acceptance Tests

7.2.1 Visual Inspection

All pipe, fittings and flanges shall be visually inspected as per Vendor’s standard practice.

7.2.2 Dimensions

The dimensions of all pipe and fittings (Section 4.5.1 and 4.5.2) shall be checked in accordance
with ASTM D 3567.

The dimensions of all flanges shall be checked to meet the requirement of Section 4.5.3.

7.2.3 Curing

The degree of curing of each lot (Note 1) of pipe and fittings shall be checked at random by
means of a Barcol Impressor (ASTM D 2583 or EN 59) and shall have a minimum value of 40.

7.2.4 Glass Content (Note 2)

The glass content of each lot (Note 1) of pipe and fittings shall be checked (Clause 6.2.2).
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7.2.5 Hydrostatic Pressure Test

Pipes Vendor shall perform a hydrostatic pressure test on ten per cent of the pipe in
accordance with his standard manufacturing procedure.

Fittings Vendor shall perform a hydrostatic pressure test on fittingswherehe can offer them as
part of his standard manufacturing procedure.

Ten per cent of the pipe furnished under this specification for ASME class 150 shall be subjected
to a hydrostatic pressure test at room temperature. The test pressure shall be equal to 1.5 times
the pressure class rating and be maintained for at least 15 minutes. During the pressure test the
pipe and/or fittings shall not show any sign of leakage. Unless otherwise agreed all fittings, pipe
spools and prefabricated piping shall be hydrostatic pressure tested at 1.5 times the pressure
class rating of the pipe.

7.2.6 Impact Resistance (Note 2)

The impact resistance of each lot (Note 1) of pipe and fittings shall be checked (Clause 6.3.5).

NOTES:

1. Unless otherwise agreed, a lot of pipe shall consist of 900 metres or a fraction thereof
and a lot of fittings of one fitting, both of one size, wall thickness and grade.

2. These tests are destructive tests; if appropriate a deviation of test frequency shall be
established by agreement between Vendorand the Employer.

8 QUALITY REQUIREMENT

8.1 Quality Assurance

Vendorshall have a Quality Management System in accordance with ISO 9001.

8.2 Quality Control

Vendorwill be evaluated for ability to perform adequate and sufficient quality control (including
inspections and tests performed at sufficient intervals and during production) to ensure that
proper and correct base materials are being used, that the finished materials meets physical and
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chemical specifications and that the finished product meets all dimensional and performance
requirements.

In order to assure traceability of materials and products, Vendorshall keep a record of all quality
control tests performed and shall maintain this record for a minimum period of five years from the
date of manufacture.

8.3 Certification

Vendorshall keep complete quality control and test reports. He shall submit a certified record of
inspection and testing together with a statement of compliance with the requirements.

If appropriate, he shall issue a list, showing each deviation from the purchase order.

9 DOCUMENTATION

9.1 Vendor’s Drawings

9.1.1 Pipe

The following pipe dimensions and tolerances, when applicable, shall be stated by Vendorand
shall be in accordance with the certified Vendor’s drawings:

 Pipe inside/outside diameter

 Minimum total wall thickness

 Overall pipe length

 Effective pipe length

 Outside/inside diameter of the end

 Length of joint

 Conical form of spigot/socket

 Spigot or socket chamber for rubber sealing rings and for fixation rod

 Shear length, i.e. distance between chamber for rubber sealing rings and fixation rod.
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9.1.2 Flanges

The following flange dimensions/information, where applicable, shall be stated by Vendorand

shall be in accordance with the certified Vendor’s drawings:

 Thickness of the flange

 Rating

 Bolt hole circle and diameter

10 PRESERVATION AND PACKING

Preservation and Packing shall be as per Project SpecificationS-000-1450-0001V “Project

Shipping and Packing Instructions to Vendor”.

10.1 Marking

All pipe, fittings and flanges shall be permanently marked with Vendor’s name or trade name, the
pressure class, the nominal diameter and Vendor’s identification code. The markings shall
remain legible under normal handling and installation practices.

Markings for identifications purposes shall be made in such a manner as not to impair the
integrity of the pipe/fittings material.

The requirements for marking and colour coding of pipe materials shall be in accordance with
Project Specification S-000-1360-0004V “Specification for Identification of Piping Material”

10.2 Packaging

The pipe and fittings shall be packed in a manner which will ensure arrival at destination in a
satisfactory condition. Pipe ends shall be protected with suitable protective covers. The covers
shall be securely attached.

Fastening is necessary where container transportation is used, to ensure immobilisation of pipe

joints.

The bottom of crates shall be provided with skids to facilitate handling by forklift truck.
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Vendorshall submit his proposed method of packaging for review and approval in accordance
with Project SpecificationS-000-1450-0001V “Project Shipping and Packing Instructions to
Vendor”.

11 INSTALLATION OF GRP PIPING SYSTEM

11.1 Piping Materials

Contractor shall nominate Vendorof the GRP Piping system. This nomination shall be approved
by the Employer.

Detailed design, spooling, fabrication, installation, hydro-testing- and all other tests shall be by
Contractor.

11.2 Installation

11.2.1 Qualification of Installers

Vendorshall train and certify Installation Team(s) suitable to maintain programme requirements to
carry-out the installation and testing of the in-place pipe works

Installation Team Leader for the installation of the pipe shall be appropriately experienced in the
jointing, bedding, laying, testing and backfilling of GRP Piping system.

11.2.2 Site Supervision

Contractor shall supervise Installation Team(s) to ensure compliance with Vendor’s installation
procedures, to include, but not limited to, excavation, bedding, handling and backfilling activities.

This site scope shall include:

 Minimum number of Installation Teamon site shall be advised. Each team shall consist of
an overall Team Leader, Jointing Engineers and Crews. The overall Team Leader shall
be a senior Vendor’s representative with extensive experience on GRP pipe and with
English language skills. Contractor will interview and approve the candidate proposed for
this position. The other team members shall also be identified with listing of contracts
they had worked on.
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 During installation, Installation Team shall monitor all GRP installation works and shall
perform all the jointing to ensure they are done in accordance with this specification.
Installation Team shall keep a daily log of their activities. The Jointing Crews names shall
be recorded for every joint to allow traceability.

 Vendorshall provide advice and support toInstallation Team. Installation Team shall
maintain close liaison with Vendor’s manufacturing facility with respect to drawings,
materials deliveries and technical support, and report to Contractor.

 Contractor shall provide all necessary specialists test equipment and Installation Team
performs all specialist tests on the installation. Contractor shall provide Installation Team
with details of in-situ testing methods, with quotation.

 Responsibility Matrix:

INSTALLATION STEPS VENDOR CONTRACTOR INSTALLATON

TEAM

Training and certifying of Contractors’ X

Installation Team of GRP piping systems

Setting out to line and level of the system, X

excavate trench, provide sheet piling where
necessary and dewatering of trench

Compaction of trench bedding in accordance X

with project specification

Supervision of Installation Team to ensure X

compaction meets the required Specification

Pipe laying and alignment X

Method statement for minimum requirements X

for jointing tolerances

Supply of all necessary equipment to enable X

joint to be completed

Lamination of restrained joints X

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Jointing of unrestrained pipeworks X

Supervision of Installation Team to ensure X

unrestrained pipework is installed in
accordance with Specification

Backfill of pipe surround compacted to Project X

Specification

Supervision of compaction of bedding/pipe X

surround

Testing of the system, in sections, to ensure X

testing meets the requirement of the
Specification

Provide test medium and all testing equipment X

Supervision of hydro-testing X

Provide testing spools, caps, flanges, etc as X

part of the contract to supply

Completion of bedding and backfill X

Supervision of bedding and backfill operations X

to ensure the requirements of the Specification
are complied with

Re-excavation for closing spools X

Removal of end caps X

Install closing spool and align X

Lamination of closing spool joints X

Completion of bedding and backfill X

Supervision of bedding and backfill to ensure X

the requirements of the Specification are met

Final system test X

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Supervision of the final hydro-test X

11.2.3 Final Installation

In order to assure the quality and integrity of the final installation, Contractor is held responsible
for all installation activities. This is expected to include all potentially critical operations such as
pipe bedding, jointing, testing and backfill. Any re-work arising from this will be deemed to be the
responsibility ofContractor.

11.3 Design of Pipes, Joints and Fittings

Design of underground piping shall be in accordance with ISO 14692 as indicated in ASME
B31.3.

Vendor shall include the Finite Element Analysis of selected pipe fittings, as directed
byContractor. Typically, this will include large diameter pipes at road crossings and will take into
account all possible combinations of dead and live loading.

Piping shall be analysed to verify that the maximum stress/strains due to combined loadings are
within the allowable limits. The analysis of fittings shall not include any allowance for backfill
being in place.

Coupling type joints shall not be used for gravity or pressurised systems, full details of jointing
and type of joints to be submitted for approval to the Employer.

11.4 Receiving, Handling and Storage

When pipe arrives on site, it shall be thoroughly examined for damage byContractor. Any damage
or blemishes shall be reported to Employer’s Representative. No damaged pipe shall be used
without the approval ofEmployer’s Representative.

Receiving, handling and storage shall be carried out in accordance with the requirements of
relevant Project Specification.
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11.5 Assembly of Pipe and Fittings

Assembly of pipe and fittings shall be carried out in accordance with the relevant Project
Specification.

11.6 Placing of Pipe in Trench

Placing pipe in trench shall be carried out in accordance with the requirements of Project
Specifications 3550-8310-SP-0009- Earthwork Specification and 3550-8310-SP-0011- Drainage
Materials and Workmanship. It shall be also in accordance with Technical Report ISO/TS 10465-
1.

11.6.1 Bedding and Backfill

Bedding and backfill shall be carried out in accordance with the requirements of Attachment 1 of
this document and Document No. 3550-8310-SP-0009-Earthwork Specification. Backfill over
drainpipes shall meet the particular requirements of Document No.3550-8310-SP-0011- Drainage
Materials and Workmanship, Section 5.

11.6.2 Protection of Pipe

Pipe bedding, installation, testing and backfilling shall be planned and carried out as a continuous
operation so that pipe is not left open in trenches and exposed to possible damage from
equipment, falling rocks or contamination of bedding or backfill with dislodged rock fragments.

11.7 Hydro-testing of Pipe

Drainpipes shall be tested in conjunction with pits and meet the requirements of Document
No.3550-8310-SP-0011- Drainage Materials and Workmanship, Section 5.
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11.8 Flanged Connections

Supply of Carbon Steel valves, the male flanges and all other loose items shall be by Contractor.
Vendorshall supply the maiden flange. The depth of the maiden flange shall be identified by
Vendorand shall be informed to Contractorfor the determination of bolt length.

12 TECHNICAL INFORMATION REQUIRED FROM VENDOR

12.1 Technical Details

Vendorshall submit the following items with their Quotation:

 Gasket & O-Ring Material Specifications

 Locking Strip Specifications

 Completed Supplier Submittal Form for each service

 GRP Manufacturer and Type

 Resin Manufacturer and Type (including chemical resistance listing for the specific resin,
showing the ultimate service temperature and life)

 Adhesive Manufacturer and Type (including number of bonds per adhesive kit and
working time/pot life)

 Method of manufacture and jointing of pipe, fittings and small bore connections

 Details of Size/Component Restrictions versus Service Design Requirements

 Pipe and Fittings Dimensions and Weight per Diameter

1) Nominal Size

2) Outside Diameter

3) Inside Diameter

4) Wall Thickness

5) Taper Angle

6) Adapter Dimensions

7) Taper Length
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8) Weight

9) Standard Joint Lengths (Pipe only) with Plain Ends, Spigot Ends and Spigot &
Socket Ends

10) Minimum and maximum Prepared Spigot Diameters (Field prepared ends)

11) Spigot Insertion Depths

12) Minimum Bending Radius

13) Maximum Deflection per Pipe Length

14) Minimum Length for 10 Degree Change

 Pipe Performance

1) Static Design Pressure Rating

2) Ultimate Internal Pressure

3) Ultimate Collapse Pressure

4) FV Pressure

5) Maximum Continuous Pressure

6) Maximum Surge Pressure

7) Maximum Installed (Field) Test Pressure

8) Maximum Factory Test Pressure

9) Ultimate Internal (Weep) Pressure

10)Maximum Allowable Vacuum Pressure

11)Specific Tangential Inert Stiffness

12)Transverse Stiffness

 Mechanical Properties

1) Tensile Strength (Longitudinal & Circumferential)

2) Tensile Modulus (Longitudinal & Circumferential)

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3) Hoop Stresses

4) Compressive Strength (Longitudinal)

5) Compressive Modulus (Longitudinal)

6) Long Term Hydrostatic (Design Basis, Static & Cyclic)

7) Poisson’s Ratio (vyx/vxy)

 Physical Properties

1) Thermal Conductivity

2) Coefficient of Expansion (Linear)

3) Flow Coefficient (Hazen-Williams & Manning’s)

4) Specific Gravity

5) Barcol Hardness.
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ATTA CHME NT-1 : S ERVI CE CO NDI TI O NS O F G RP FLUI D SY S TEM S

Serial ServiceCod Fluid System Design Design Operation Pressure Operation Temp. Remarks

No. e Pressur Temp.

Norma Norma
e Min. Max. Min. Max.
l l

(DegC (DegC (DegC (DegC

(kPag) (kPag) (kPag) (kPag)
) ) ) )

Conditions at plate
215 245 355 16 31 34
exchangers
SUPPLY 1000 65
Conditions at power
185 220 350 16 31 34
plant/RFCC B.L
1 SW SEA WATER
Conditions at plate
95 145 330 25 40 40
exchangers
RETURN 1000 65
Conditions at power
105 150 330 25 40 40
plant/RFCC B.L

2 FW FIRE WATER - 1713 60 710 810 1036 15 30 35 Conditions of Refinery Fire

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Serial ServiceCod Fluid System Design Design Operation Pressure Operation Temp. Remarks

No. e Pressur Temp.

Norma Norma
e Min. Max. Min. Max.
l l

(DegC (DegC (DegC (DegC

(kPag) (kPag) (kPag) (kPag)
) ) ) )

Water

1713 65 710 870 1025 16 31 34 Conditions of Salt Fire Water

3 PW POTABLE WATER - 1213 60 615 873 875 15 30 35

SUPPLY 1000 76 515 535 615 20 35 38

4 CW COOLING WATER
RETURN 1000 76 273 335 565 33 48 51

5 TW TREATED WATER - Later

COC WASTE WATERFOR

6 WO - 500 65 - 360 Later - 35 Later
PRESSURIZED PIPING

SERVICE(PROCESS)
7 WP - 813 60 - 476 Later - 35 Later
WATER
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Serial ServiceCod Fluid System Design Design Operation Pressure Operation Temp. Remarks

No. e Pressur Temp.

Norma Norma
e Min. Max. Min. Max.
l l

(DegC (DegC (DegC (DegC

(kPag) (kPag) (kPag) (kPag)
) ) ) )

Note 1: Hydrotest pressure at

AOC WASTE WATER (NON- Atm 100 Atm10
38 AOC - Atm - - - Atm - Vendor shop shall be 1000
PRESSURIZED PIPING) (Note 1) 0
kPag as a minimum.

Note 1: Hydrotest pressure at

COC WASTE WATER FOR Atm100
49 COC - 65 - 100Atm - - 38 - Vendor shop shall be 1000
NON-PRESSURIZED PIPING (Note 1)
kPag as a minimum.