PROJECT TITLE:
RAS LANUF TANK FARM REPLACEMENT OF 500,000 US BBL
TANK NUMBER 7
DOCUMENT TITLE:
23/08/2010
ITT
MON
VS
HA
Rev
Date
Issued for
Originator
Checked
Approved
Issued
..
CONTENT
PAGE
1.
SCOPE OF SPECIFICATION
2.
GENERAL
3.
PRODUCT DESIGN
4.
10
5.
DOCUMENTATION
10
6.
11
7.0
SYSTEM DESIGN
11
8.0
INSTALLATION
13
9.0
INSPECTION
13
10.0
TESTING
14
11.0
PREVIOUS SUPPLIER
14
Rev 00
30/011/2005
Contract No.
Ras Lanuf Tank Farm Replacement Of 500,000 Us Bbl Tank Number 7
Specification for GRP Piping Systems
Page 3 of 15
1. Scope of Specification
1.1
1.2
1.3
CONTRACTOR Responsibility
1.3.1
1.3.2
1.3.3
1.3.4
1.4
1.4.1
1.4.2
Rev 00
23/08/2010
Contract No.
Ras Lanuf Tank Farm Replacement Of 500,000 Us Bbl Tank Number 7
Specification for GRP Piping Systems
Page 4 of 15
1.4.3
2. General
2.1.
Project Definitions
For the purposes of this specification, the following Project definitions shall
apply:
CODE
CLIENT
PURCHASER
CONTRACTOR
SUBCONTRACTOR
CONTRACTOR
INSPECTION
AUTHORITY
INSPECTOR
SHALL
SHOULD
Rev 00
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Contract No.
Ras Lanuf Tank Farm Replacement Of 500,000 Us Bbl Tank Number 7
Specification for GRP Piping Systems
Page 5 of 15
2.2
Conflicting requirements
CONTRACTOR shall advise the Client of any conflicting requirements.
In case of conflicting requirements, the following order of precedence shall
govern:
2.3
This Specification
Purchase Requisition
CONTRACTORs Instructions
Referenced Publications
American National Standards Institute (ANSI)
ANSI/ASME B 16.5
ASTM
ASTM D 570
ASTM D 1598
ASTM D 1599
ASTM D 2105
ASTM D 2290
ASTM D 2310
ASTM D 2412
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Contract No.
Ras Lanuf Tank Farm Replacement Of 500,000 Us Bbl Tank Number 7
Specification for GRP Piping Systems
Page 6 of 15
ASTM D 2444
ASTM D 2563
ASTM D 2583
ASTM D 2584
ASTM D 2925
ASTM D 2992
ASTM D 2996
ASTM D 3567
ASTM D 4024
ISO
ISO 9001
ISO 14692
3. PRODUCT DESIGN
Pipes furnished under this specification are classified in accordance with
ASTM 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, also
identifying the cell classification designations of the short-time rupture
strength, 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 filament
winding process. In this process the continuous fibrous glass strand roving
are wound onto the outside of a mandrel in a predetermined pattern under
Rev 00
23/08/2010
Contract No.
Ras Lanuf Tank Farm Replacement Of 500,000 Us Bbl Tank Number 7
Specification for GRP Piping Systems
Page 7 of 15
controlled tension. The roving are saturated with the resin/curing agent
mixture and helical wound under a calculated winding angle. The inside
diameter (ID) of the finished pipe is fixed by the mandrel outside diameter.
The number of helical wound layers determines the outside diameter (OD) of
the finished pipe.
3.1.1
Wall structure
The pipe wall
components:
consists
of
the
following
Liner
The liner of pipes and fittings consists of
thermosetting plastic resin, reinforced with
C-glass with a low alkali content. The resin
content 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 with
continuous 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 in
order to assure an optimal adhesion between those two layers. The thickness
of the reinforced wall depends on the pressure rating and will be according to
the CONTRACTORs standard, meeting the requirements specified herein.
Topcoat
The resin used for the topcoat will be a pure thermosetting plastic resin and
will be the same as used for the structural wall underneath to assure a good
adhesion between these two layers. The resin will be exempted of fillers. The
thickness 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-impregnated
woven 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 that
the joints are capable to take up full end load due to internal pressure.
Therefore for the intended system no anchor blocks are required.
Rev 00
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Contract No.
Ras Lanuf Tank Farm Replacement Of 500,000 Us Bbl Tank Number 7
Specification for GRP Piping Systems
Page 8 of 15
3.3.1
3.3.2
3.3.3
Flanged joint
The flange face is flat with two concentric
ribs, which gives an extra local compression
of the gasket. Flanges shall be drilled to
standard 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 or
assemblies into alignment by exceeding the maximum specified bolt torque is
not allowed.
Depending on the conditions, the CONTRACTOR shall advise on a suitable
gasket for the intended service and prescribe the maximum bolt torque that
can be applied.
Rev 00
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Contract No.
Ras Lanuf Tank Farm Replacement Of 500,000 Us Bbl Tank Number 7
Specification for GRP Piping Systems
Page 9 of 15
3.3.4
Laminated joint
The Laminated joint utilises an external
laminate consisting of a number of layers of
mat, followed by alternating layers of
fibreglass
mat
and
woven
roving
impregnated with hot-curing epoxy resin.
The minimum strength of the laminated joint
shall be equal to the minimum pipe wall
strength. The minimum length and thickness of the laminate shall be
according to the CONTRACTORs standard.
As this type of joint costs manpower and is time consuming it is a rather
costly type of joint and only will be used for field adjustments. This technique
may also be used as a reasonably quick repair method.
3.4
Performance requirements
The CONTRACTOR shall prove the performance of the GRP pipe system by
means of a qualification program. This qualification test program includes a
number of destructive tests, which have to prove that essentially the product
design is suitable for the required application. The performance tests include
testing of the material, joining system, pipes and fittings and are executed on
a schedule of representative diameters and fittings. Descriptions of
performance tests have to be issued for the companys approval but shall at
least include the following:
Regression analysis acc ASTM D 2992-B on ID 100 mm pipe, elbow, tee,
adhesive bonded joint and/or key lock joint
Verification of the applicability of the above mentioned regression analysis for
representative diameters according to the table below:
Representative
products
Pipe,
90
elbow,
equal
tee, adhesive
bonded
joint,
rubber seal lock
joint
Representative
diameter
100
250
400
600
Diameter range
25, 40, 50, 80
150, 200
300, 350
450, 500
Rev 00
23/08/2010
Contract No.
Ras Lanuf Tank Farm Replacement Of 500,000 Us Bbl Tank Number 7
Specification for GRP Piping Systems
Page 10 of 15
Rev 00
23/08/2010
Contract No.
Ras Lanuf Tank Farm Replacement Of 500,000 Us Bbl Tank Number 7
Specification for GRP Piping Systems
Page 11 of 15
The manufacture and supply of GRP pipe, fittings, flanges, joints, make-up
pieces, support saddles and straps. CONTRACTOR will also supply the
gaskets for use in GRP flange connections and provide general
recommendations on associated equipment such as nuts, bolts etc.
Where required, the CONTRACTOR will perform all relevant engineering
such as development of stress isometrics, flexibility analysis, surge analysis
and 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 and
pre-commissioning of the GRP pipe system. Furthermore, if needed, to
provide additional staff to assist in the installation of the pipeline.
Provide and carry out Quality control/Quality Assurance on site for the
manufacturers scope of installation for the GRP pipe system.
Advise the civil contractor on soil compaction requirements.
Provide training to installation contractors personnel.
Rev 00
23/08/2010
Contract No.
Ras Lanuf Tank Farm Replacement Of 500,000 Us Bbl Tank Number 7
Specification for GRP Piping Systems
Page 12 of 15
Bursting pressure and weeping pressure are generally derived from shortterm destructive test results. These values still have to be reduced to obtain
the correct design stress. Generally, the following relationships is seen for
this safety factor:
Bursting stress/design stress
Weeping stress/design stress
UEWS / design stress
10
3-4
2-2.5
Rev 00
23/08/2010
Contract No.
Ras Lanuf Tank Farm Replacement Of 500,000 Us Bbl Tank Number 7
Specification for GRP Piping Systems
Page 13 of 15
The assumption that stresses throughout the piping system can be predicted
from these strains because of fully elastic behaviour of the piping materials is
not generally applicable to non-metallic materials. However:
8.0
Installation
The various installation aspects should be in accordance with the
CONTRACTORs guidelines and the requirements given in the preceding
sections. Installation has to be an item considered from the design phase
onwards.
The CONTRACTOR shall provide proper installation instructions and
adequate 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 cured
before 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 be
gradually heated, approx. 20C per hour to release the stresses. The piping,
especially the pipe ends shall be protected against damage during
installation. For above ground piping, bending of pipe is not permitted to
achieve 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 in
colour, density and other physical properties The pipe shall be round and
straight 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.
Rev 00
23/08/2010
Contract No.
Ras Lanuf Tank Farm Replacement Of 500,000 Us Bbl Tank Number 7
Specification for GRP Piping Systems
Page 14 of 15
10.0
Testing
Before the installed pipe system can be used, the system needs to be tested
to ensure that all the joints function correctly. The pipe system shall be
hydrostatic pressure-tested with water at a pressure of 1.5 times the
maximum working pressure of the system during the following time period to
compensate piping pressure settings:
10.1.
After filling and venting the trapped air at the highest points, the pressure is
gradually increased at 0.8 times the working pressure dependent on the
system and maintained for 24 hours allowing the system to set.
11.0
Previous supplier
The CONTRACTOR that previously supplied all GRP material in line with the
required specification is as detailed below.
Contact
Mr Joseph Albanese
Iniziative Industriali S.p.A. Sarplast
Via Rosignanina, 32
56040 Santa Luce (PI)
ITALY
Phone No
Fax No
Website:- www.sarplast.com
10.2.
The test pressure must be raised gradually to 1.5 times the working pressure
and maintained for 4 hours. After 4 hours the pressure may have dropped by
0.3 bar for diameters <500 mm per 1000-m length.
During the pressure test no weeping is allowed. Care should be taken that
the maximum test pressure will not exceed the lowest rated element in the
system.
It is preferable to test the line in sections, for example the length of one day
of installation, which will be shut off by a temporary flanged joint and a ball
valve. The blind flange should be provided with an air release valve.
If a complete system is tested, it is essential to avoid water hammer.
Generally, the manufacturer allows a water hammer factor of 1.4 times the
maximum design pressure rating of the piping.
For the water testing at site care should be taken that any part of the
installed piping shall not be included in a test loop more than 4 times.
Doc No. V40/P/ A4/0600
Rev 00
23/08/2010