Harouge Oil Operations

CONTRACT 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

23/08/2010

ITT

MON

VS

HA

Rev

Date

Issued for

Originator

Checked

Approved

Issued

HAROUGE OIL OPERATIONS

LIBYA

Contract No. Bid Document

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

..

CONTENT

PAGE

1.

SCOPE OF SPECIFICATION

2.

GENERAL

3.

PRODUCT DESIGN

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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Ras Lanuf Tank Farm Replacement Of 500,000 Us Bbl Tank Number 7
Specification for GRP Piping Systems
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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 and
packing of glass fibre reinforced thermosetting resin pipe (RTRP) systems.
This specification is related to ANSI-ASME B 31.3 for nominal diameters of
25 to 1200 mm, adequate to convey water or chemical products. The
components of the glass fibre reinforced plastic pipe system are to be
suitable for a maximum operating pressure, as specified, for a service life of
50 years.

1.2

This specification shall be read in conjunction with the relevant documents

referenced herein.

1.3

CONTRACTOR Responsibility

1.3.1

It shall be CONTRACTORs responsibility to be, or become, knowledgeable

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

1.3.2

Compliance by CONTRACTOR with the provision of this specification, or any

omission herein, does not relieve him of his responsibility to furnish materials,
equipment and accessories of a suitable and safe design to meet the
specified 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 the
performance on the package.

1.3.4

Quality Assurance/Quality Control

CONTRACTORs proposed quality assurance and quality control system
shall be in accordance with the project procedures and specific requirements
attached to purchase requisition.
CONTRACTOR shall 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 to
purchase requisition.

1.4.2

Where no exceptions/qualifications are stated, it shall be understood that the

supply is in full compliance with the specified requirements and any
subsequent claims arising out of non-conformance with the specifications
will not be considered.

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Specification for GRP Piping Systems
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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 CONTRACTORs documents.

2. General
2.1.

Project Definitions
For the purposes of this specification, the following Project definitions shall
apply:

CODE

CODE is defined as the applicable Design Code

CLIENT

CLIENT is defined as HAROUGE OIL OPERATIONS LIBYA.

CLIENT is the company to whom all materials and equipment will be
delivered and is the end user of such materials and equipment.

PURCHASER

PURCHASER is the company appointed by HAROUGE OIL

OPERATIONS LIBYA to place the purchase order for the material or
equipment 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 CONTRACTOR shall
be referred to as BIDDER.

SUBCONTRACTOR

SUB-CONTRACTOR is 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 to
CLIENT approval.

CONTRACTOR

CONTRACTOR is the company appointed by HAROUGE OIL

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

INSPECTION
AUTHORITY

INSPECTION AUTHORITY is defined as the organisation that

verifies that the material or equipment supplied by the
CONTRACTOR has been designed, constructed, inspected, and
tested in strict accordance with the requirements of the applicable
design code.

INSPECTOR

INSPECTOR is defined as a qualified individual representing the

CLIENT or PURCHASER who verifies that the material or equipment
supplied by the CONTRACTOR has been designed, constructed,
inspected, tested, and packed and delivered in strict accordance
with the requirements of this specification and all other Purchase
Order 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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Specification for GRP Piping Systems
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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

Local Authority or Statutory Regulations

Equipment Data Sheets

This Specification

Purchase Requisition

Referenced Industry Design Codes and Standards

CONTRACTORs Instructions

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

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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Glass fibre reinforced thermosetting resin pressure

pipe (Rev. 01)

American Society for Testing and Materials:

Test Method for Water Absorption of Plastics
Test Method for Time to Failure of Plastic Pipe Under
Constant Internal Pressure
Test Method for Resistance to Short-term Hydraulic
Failure Pressure of Plastic Pipe, Tubing and Fittings
Test Method for Longitudinal Tensile Properties of
Fibreglass (Glass-Fibre-Reinforced ThermosettingResin) Pipe and Tube
Test Method forApparent Hoop tensile strength of
plastic or reinforced plastic Pipe by Split Disk Method
Classification for Machine-Made Fibreglass (GlassFibre- Reinforced Thermosetting Resin) Pipe
Test Method for Determination of External Loading
characteristics of Plastic Pipe by Parallel-Plate
Loading.

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Ras Lanuf Tank Farm Replacement Of 500,000 Us Bbl Tank Number 7
Specification for GRP Piping Systems
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ASTM D 2444

Test Method for Determination of the Impact

Resistance for Thermoplastic Pipe and Fittings by
Means of a Tup (Falling Weight)
Practice for Classifying Visual Defects in Glass
Reinforced Laminate Parts
Test Method for Indentation Hardness of Rigid Plastics
by Means of a Barcol Impresser
Test Method for Ignition Loss of Cured Reinforced
Resins
Test Method for Beam Deflection of Fibreglass
(Glass-Fibre-Reinforced Thermosetting Resin) Pipe
Under Full Bore Flow
Practise for Obtaining Hydrostatic or Pressure Design
Basis
for
Fibreglass
(Glass-Fibre-Reinforced
Thermosetting-Resin) Pipe and Fittings.
Specification for Filament-Wound Fibreglass (GlassFibre-Reinforced Thermosetting-Resin) Pipe
Practise for Determining Dimensions of Fibreglass
(Glass-Fibre-Reinforced Thermosetting Resin) Pipe
and Fittings
Specification for Machine Made Fibreglass (GlassFibre- Reinforced Thermosetting Resin) Flanges

ASTM D 2563
ASTM D 2583
ASTM D 2584
ASTM D 2925

ASTM D 2992

ASTM D 2996
ASTM D 3567

ASTM D 4024

British Standards Institute (BSI)

BS 8010

ISO

Code of Practice for Pipelines Section 2.5 Glass

reinforced Thermosetting Plastics

International Standards Organisation

ISO 9001
ISO 14692

Quality systems Model for Quality Assurance in Design,

Development, Production, Installation and Servicing
Petroleum and natural gas industries Glass-reinforced
plastics (GRP) piping

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

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Specification for GRP Piping Systems
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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.

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Specification for GRP Piping Systems
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3.3.1

Taper Adhesive bonded joint

This system consists of pipe with integral
bell and shaved spigot ends, fittings with
integral bell ends and bell/bell or
spigot/spigot
adapters.
Flanges
are
available with either bell or spigot end.
The components of the system are bonded together with an adhesive. The
figuration of the joint consists of a cylindrical or conical spigot and a conical
socket.
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 in
order to obtain the required strength.

3.3.2

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

The key lock joint is an integral joint. The
spigot end has one or two grooves in which
o-ring seals are mounted and a shoulder that
functions as a stop for the locking strip. The
locking strip takes care of the mechanical junction between the spigot and
the socket and will be hammered through a hole in the socket end once the
actual 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 is
foolproof and quick to install. In general, this type of joint shall be used for
the pipeline installation.

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.

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Specification for GRP Piping Systems
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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

Hydrostatic performance verification shall be done by means of medium term

testing in accordance with ISO 14692. For this test, two representative
samples have to be tested for 1000 hrs at a test pressure exceeding the
pressure level at 1000 hrs resulting from the regression analysis. In practice
this will be 2.5 times the nominal pressure rating. For the qualification
procedure, reference is made to ISO 14692.
For system design purposes, the following additional performance data is
required:
Hoop tensile strength acc. ASTM D 2290
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Specification for GRP Piping Systems
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Longitudinal tensile strength acc. ASTM D 2105

Short time hydrostatic strength acc. ASTM D 1599
External loading properties acc ASTM D 2412
Beam deflection acc. ASTM D 2925
Thermal expansion acc. ASTM D 696
Joint testing proving the integrity of the joint under internal pressure in
combination with a bending moment, shear forces, misalignment and/or
internal vacuum
Qualification testing shall be carried out by the CONTRACTOR and
witnessed and certified by an independent authority recognised by the
company. Alternatively, testing and certification may be carried out by an
independent testing organisation. This shall be confirmed by submitting a
certificate stating the test results.
4. Quality Assurance/Quality Control
To ensure that all detailed design/engineering is being performed
consistently and accurately, the CONTRACTOR shall have in effect at all
times a QA/QC program, which clearly establishes the authority and
responsibility of those responsible for the quality system. Persons performing
quality functions shall have sufficient and well-defined authority to enforce
quality requirements, initiate, identify, recommend and provide solutions to
quality problems and verify the effectiveness of the corrective action.
A copy of the CONTRACTORs QA/QC program shall be submitted to the
company 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. In
addition, if CONTRACTORs facility is ISO certified, companys QA audit
requirements will be waived in favour of ISO 9001 registrar audits, unless the
CONTRACTORs trend analysis program indicates areas of concern.
The CONTRACTOR shall identify in documents to its sub-CONTRACTORs
all 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-CONTRACTOR
activities.
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), the
Installation 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. He
shall submit a certified record of inspection and testing, together with a
statement of compliance with the requirements.

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Specification for GRP Piping Systems
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If appropriate, the CONTRACTOR shall issue a concession request, showing

each deviation from the purchase order.

6. GRP CONTRACTORs Scope of Work

The GRP pipe system CONTRACTOR shall 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 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.

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 and
degree of glass content, the level of allowable stresses may differ
considerably. For example, for internal pressure piping in which the ration
between tangential and axial stress is 2:1 the optimum winding angle is 55
and this will result in the stress ratio as given for pressure piping.
To achieve a safe allowable design stress, it is necessary to consider the
behaviour of GRP material in the pressurised condition. The bursting
strength is not to be considered as a good basis for allowable stress,
because before the bursting pressure has been reached, an inelastic
deformation occurs. Often, reference is made to the Ultimate Elastic Wall
Stress (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 is
weeping. The weeping phenomenon is caused by inelastic deformation in the
material. Weeping starts at pressure levels exceeding those governed by the
UEWS.
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Specification for GRP Piping Systems
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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

An alternative for the determination of the design stress is described in

ASTM D 2992. This method describes a procedure for obtaining a
hydrostatic design basis for reinforced thermosetting resin pipe and fitting.
From the results of the test, regression lines can be calculated. From these
lines 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 Hydrostatic
Design Basis (HDB). This basis has to be reduced by means of a service
design factor to obtain the hydrostatic design stress (HDS). The service
design factor has to be max. 0.67 for a service life of 50 years.
The reinforced wall thickness of pipes is calculated for different pressure
classes by means of the Barlow formula. The allowable maximum internal
and external working pressure for straight pipe at ambient temperature is
quoted in the CONTRACTOR catalogues.
It should be considered that in most cases the stated values are not
acceptable as design pressures, since most calculations are made in relation
to a specific support distance (span).
7.2 Expansion and flexibility
The pipeline system should be designed so that flexural stresses resulting
from displacement due to expansion, contraction and other movements are
minimised. This concept requires special attention to supports, terminals and
other restraints, as well as to techniques to provide for adequate inherent
flexibility. Often the directional changes in a pipeline system do not provide
sufficient flexibility to compensate for expansion and contraction due to
temperature changes. Therefore expansion joints or loops should be
installed. Key lock joints can accommodate expansion to a certain extent. A
careful pipe stress analysis shall be carried out, giving due consideration to
the specific characteristics of the GRP material.
The concept of strain imposed by restraint of thermal expansion or
contraction and by external movement applies in principle to both metallic
and non-metallic piping.

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Specification for GRP Piping Systems
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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

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 exact
values to be used in calculations shall be as specified by the
manufacturer.
Fittings such as tees, reducers and elbows are very rigid compared
with straight pipe. Expansion loops are assembled from pipe and
elbows in which the elbows are considered as non-flexible parts.
Thermal expansion therefore has to be absorbed by the deflection of
the loop legs.

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.

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Specification for GRP Piping Systems
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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.

Pressure setting testing

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

+39 050 691701

+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 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.
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