FIP, FUTURE PIPE INDUSTRIES INSPECTION & TEST PROCEDURES (GRE Pipes & Fittings) PROJECT GC 11107100 CLIENT AL BALAGH TRADING &CONTRACTION LOCATION MASAIEED END USER QATAR PETROLEUM DOC. REF ITP/PROCEDURE/GRE/ALBALAGH/01, REV. 0 Revision No. Date Prepared by 0 221-2012 Vivek Naik (QC Manager ) Doe No: FPL/GREZALBALAGH Ins & Test Proc, Rev 0 Page 1 of 6A. Raw Material Testing Values of raw material acceptance it will be as per the Wavistrong specification A. I Resin viscosity (Epoxy). Reference standard: - ASTM D 445 & ISO 2555. Apparatus: - Brookfield Viscometer, Thermocouple & Thermometer. Procedure: - Fill a | litre tin 3/4 full with resin. Condition the resin at a temperature of 25 + 0.2 °C for a minimum of | hour. Choose a spindle according to type of resin and the viscosity range (Spindle No. 63 for epoxy resin) and screw it on to the viscometer. Place the tin under the spindle and lower the apparatus until the resin level just reaches the mark on the spindle. Start the apparatus and adjust to the required speed (Speed 10 rpm for epoxy resin), Allow the viscosity reading to stabilize (~ 10 to 15 seconds) and then record the viscosity value directly from the digital display. Acceptance criteria: - Measured viscosity should be in the range of 11000 + 1000 eps. A. 2 Resin gel time, gel to peak time and peak exothermic temperature (Epoxy). Reference standard: STM D 2471. Apparatus: - Paper cup, weighing balance, thermometer, thermocouple & timing device. Procedure: - Take 100 g of resin in a paper cup (Cup diameter ~ 7 em, Volume ~ 200 ml) and condition it at 25 + 1 °C temperature for | hour. Add recommended quantities of hardener into the resin sample and mix well. Start the timing device immediately after mixing. Temperature of the resin mixture is measured by inserting a thermocouple/thermometer into the resin mixture. As the curing reaction progresses, the resin gel- time, gel-to-peak time and peak exotherm temperature are determined. Gel time is the time taken from the start of the test to the gel point at which the reaction mixture becomes a gel. Gel-to-peak time is the time taken from the gel point to the peak exotherm of the reaction. Peak exotherm temperature is the maximum ‘temperature attained during the exothermic reaction, Acceptance criteria: - Gel-Time (90 + 30 min), Gel-to-peak time (10 + 5 min) and Peak exotherm temperature (200 + 40°C). A. 3 Glass fiber roving’s (Moisture content, binder content and Tex properties). Apparatus: - Mufile furnace, porcelain crucible, desicator, oven, measuring tape & weighi Procedure: - Moisture content of the glass fiber is determined as the percentage wé known amount of glass fiber sample at 105 3 °C for 3 hours. Binder content of the glass fiber is determined as the percentage loss on ignition of aki glass fiber at ~ 600 °C for minimum of 30 minutes. X ‘The Tex (linear density) of the glass fiber is determined by weighing ~10-20 meter of ot is expressed as the weight in grams of 1000 meter of the glass fiber roving. S ‘Acceptance criteria: - Measured values of moisture conten, binder content and Tex should be within the FPL specification forthe particular typelgrade of glass fiber roving. ‘Doe No: FPUGRE/ALBALAGH ins & Test Proc, Rev 0 Pape 2 of 6A. 4 C- Veil, CSM, WR (Moisture content, binder content & Area density). ‘Apparatus: - Muffle furnace, porcelain erucible, desicator, oven, measuring tape & weighing balance. Procedure: - Moisture content of the C-Veil/CSM/WR mat is determined as the percentage weight loss on heating a known amount of glass sample at 105 + 3 °C for 3 hours. Binder content of the glass is determined as the percentage loss on ignition of a known amount of dried glass fiber mat/veil at ~ 600 °C for minimum of 30 minutes. To determine the area density, the fiber matveil is cut in a rectangular shape with a mass not less than 5 grams. The area density (g/m*) is then calculated by dividing the weight of the specimen by the area of the ‘specimen taken. Area density (g/m?) is expressed as the weight in grams of 1 m’ of the glass sample. Acceptance criteria: ~ Measured values of moisture content, binder content and area density should be within the FPI specification for the C-glass veil / CSM / WR mat. B. Product testing and inspection, B. 1 Determination of specific tangential initial stiffness (STIS). Reference standards: - ASTM D 2412, AWWA C 950 and BS 5480, Apparatus: - Stiffness testing machine, inside micrometer, vernier caliper and measuring tape. Procedure: - One ring specimen of 300 & 5 mm is cut from the pipe specimen and conditioned at ambient temperature for a minimum of 2 hours. 1) Measure the thickness of the specimen at 8 places along the circumference of the ring using a vernier caliper. Calculate the average thickness from the 8 readings. 2) Measure the inside diameter of the specimen at 4 places along the circumference using an inside micrometer. Calculate the average inside diameter from the 4 readings. 3) Measure the eylinder length of the specimen at 4 places equally spaced along the circumference using ‘measuring tape with an accuracy of 1 mm, Calculate the average length of the specimen from the 4 readings. 4) Place the specimen between the two parallel plates of the testing equipment. Measure and record the weight of the test specimen. 5) Measure the unloaded vertical inside diameter to determine the selfdefleetion of the specimen. 6) Bring the upper plate into contact with the specimen with no more load than necessary to hold it in place. Set the load and deflection indicators to zero. 7) Adjust the traveling speed of the upper plate to 12.5 + 0.5 mm/min, Compress the specimen to the required deflection level of 5% of the inside diameter and record the load applied for the 5% deflection level. 8) If the load required to deflect the specimen to 5 % level is exceeding the machine capacity, restrict the deflection level to 3 % of the inside diameter. 9) GRE Pipes 9 % and 15% Deflection will not be carried out 10) GRE pipes below 80mm will not be tested for Specific Tangential intial Stfiness 11) If due to Stress analysis Recommendation, required reinforcement in the higher thickness than, Stiffhess for that high thickness shall not be conducted 12) Repeat the steps from 5.0 to 8.0 by rotating the specimen by 35° and then by 70" with respect tothe init position. Calculate the STIS value from the average load, length of the specimen and deflection level using the formula Specific Tangential Initial Stiffness, STIS = (1 é an) Fg Ue 2) *tarn* 8 Where, STIS = Specific Tangential Initial Stiffness in Pa F = Load in Newton, AY Deflection (5% of ID) in meters AYL = Deflection (5% of ID + self deflection) in meters. L ‘Average rng length in meters D = Average Inside diameter in meters Acceptance criteria: - Measured STIS values should be > the specified FPI values for the respective piping lass or the customer acceptance stiffness requirement. Doe No: FPUGREJALBALAGH /las & Test Proc, Rev 0 Page 3 oF 6B. 2 Axial tensile strength. Reference standards: - ASTM D 638 and BS 5480. Apparatus: - Universal Testing Machine & Vernier Caliper. Procedure: - Five test specimens, parallel sided strips with a width of 2 to 3 times the thickness of the sample as standard (minimum strip width for pipe ID 50 ~ 150 mm is 20 mm and for pipe 1D = 200 mm is 25 — 39 mm). Dumbbell shaped specimens as per Type III of ASTM D 638 shall be used in case tests with parallel sided strips do not yield proper specimen failures. 1) Measure the minimum width and minimum thickness of the test specimen and record the values. 2) Place the specimen in the grips of the testing machine with correct alignment and having a gauge length of 120+ 10 mm, tighten the grips. Set the speed of testing to 5 mm/min. 3) Subject the test specimen to tension in the axial direction up to failure. Record the maximum load. 4) Axial tensile strength per unit width is determined by dividing the maximum load obtained with the width of the specimen. Axial tensile strength per unit cross sectional arca is determined by dividing the maximum load obtained with the product of the width and thickness of the specimen. 5) Conduct the test on other specimens following steps of I to 4 6) The tensile strength is the average from the values obtained for the five individual specimens. 7) GRE pipes below 80mm will not be tested for Axial tensile strength. 8) If due to Stress analysis Recommendation, required reinforcement in the higher thickness than, Axial test for that high thickness shall not be conducted, Acceptance criteria: - Axial tensile strength for EST pipes, 2 57 N/mm’, B. 3 Hoop tensile strength. Reference standards: - ASTM D 2290 and BS $480, Apparatus: - Split Dise Machine/Universal Testing Machine and Vernier Caliper. Procedure: - Three ring specimens of 5-15 mm width are cut from pipe in the circumferential direction. The. ‘width of the specimen shall not exceed the depth of the split disc groove, 1). Measure the minimum width and thickness of the test specimen at two diametrically opposite positions and record the values, 2) Mount the test pieces on the outside periphery of the split disc test fixture with the points of measurement at the split. Set the speed of testing in the range of 12.5 2.5 mm/mis 3). Subject the test specimen to stress on a split disc machine in the hoop direction up to failure, Record the ‘maximum load. 4) Hoop tensile strength per unit width is determined by dividing the maximum load obtained with twice the ‘width of the specimen. Hoop tensile strength per unit cross sectional area is determined by dividing the ‘maximum load obtained with the product of twice the width and one thickness of the specimen. 5) Conduct the test on other specimens following steps of | to 4, 6) The hoop tensile strength is the average from the values obtained for the three individual specimens. 7). GRE pipes below 80mm will not be tested for Hoop tensile strength. 8) If due to Stress analysis Recommendation, required reinforcement in the higher thickness than, Hoop tensile test for that high thickness shall not be conducted. Acceptance criteria: - Hoop tensile strength for EST pipes, > 210 Nimm:, B. 4 Loss on ignition test. Reference standard: - ASTM D 2584. Apparatus: - Mufile furnace, porcelain crucible and weighing balance. rocedure: - Three pieces of 35 + 3 x 35 +3 mm dimensions are taken from the pipe speci and topcoat) in porcelain crucible weighed and burt in the muffle furnace at ~ 600 °C (<\ hours depending on the thickness of the sample). The burnt specimens are weighed after c' ambient temperature. The resin ‘glass °% is determined from the retained glass residue after the ignition of the sample. The structural lass ‘content is calculated as the average from the values of three specimens. Acceptance criteria: - Structural glass content for pipe is minimum 65 % , Molded fittings Min 60 % Doc No: FPUGRE/ALBALAGH /Ins & Test Proc, Rev 0 Page 4 of 6B. 5 Water absorption / Boil resistance. Reference standard: - ASTM D 570. Apparatus: - B Procedure: - Three test specimens of 15 x 50 mm dimension are cut from the pipe. The test specimens are conditioned for one hour in an oven at 105 + 3 °C and cooled down to ambient temperature in a desicator and weighed. Specimens are then immersed in boiling water and kept for 3 hours, after finish the excess water from the surface is removed and weighed immediately. Water absorption / boil resistance is determined as the percentage change in weight of the test specimens. ing apparatus, oven, desicator and weighing balance. Acceptance criteria: - Maximum 1 %. B. 6 Degree of curing - TG Value. Reference standard: - ASTM D 3418. Apparatus: - Differential scanning calorimeter and weighing balance. = A small piece of pipe specimen weighing about 6 - 10 mg is put in an Aluminum crucible and placed in the DSC instrument. The specimen is scanned from 30 to 175 °C temperature ata rate of 10 °C/min, ‘The curve generated is then analyzed to determine the TG value. Acceptance criteria: - Measured value should be > 125 °C, B.7 Barcol hardness. Reference standard: - ASTM D 2583. Apparatus: - Barcol Impressor, Model No. 934-1. Procedure: - Set the point sleeve on the surface to be tested. Hold the impressor firmly between the instrument legs and the point sleeve. Apply quick thrust by hand against the specimen surface until the dial reading reaches a maximum value. The maximum value reached is the Barcol reading. Impressions should not be made within 3 mm of the edge of the specimen or of other impressions. Acceptance eriteria: - Barcol Hardness 35. B. 8 Dimensional Control. Reference standard: - ASTM D 3567. Apparatus: - Vernier Caliper, thickness gauge, ci Procedure: - Dimensions of the FRP pipe, fittings and spools are determined by using suitable calibrated ‘measuring devices and following the procedure and guidelines of ASTM D 3567. The average of dimensional parameters is determined from the measured individual values. Acceptance criteria: - Dimensions shall be in accordance with the values specified in the pipe data sheet and product drawings, ‘umferential (x) tape, measuring tape and Micrometer. B. 9 Visual inspection (Appearance). Procedure: - The interior and exterior of the item is thoroughly checked for any visual defé guidelines of ASTM D 2563 (Pipes: level II & Fittings: level IID). Acceptance criteria: - For pipes, visual appearance should be in accordance with FPL sti ASTM D 2563, Doc No: FPVGRE/ALBALAGH /ns & Test Proc, Rev 0 Page 5 of 6B. 10 Hydrostatic pressure test. ‘Apparatus: - Hydro test apparatus, pressurizing system, pressure gauge, timing device and suitable end closure and support. Procedure: - Attach the end closures to the test specimen. Fill the pipe with water ensuring that no air is ‘entrapped. Pressurize the pipe to the required test pressure and hold for 5 minutes. During the required test period the specimen is examined for leakage and weeping. Acceptance criteria: - There shall be no leakage, weeping or drop in pressure during the test period. Leakage from the end closure shall be considered as an invalid test item, not a failure. B. 11 Marking and identification of pipes, fittings and spools. All the pipes produced for this project shall have the following marking (Stenciling) details: 1) Manufacturer's Name/Logo: FPL 2), Product Line Designation: WAVISTRONG 3) Nominal Diameter: DN-XXXX 4), Nominal Pressure: PN-XX 5) Nominal Stiffness: SN-XXXX 6) Nominal Thickness: XX.X mm 7), Manufacturer's Identification Code: Pipe/Fitting Unique Number 8) Manufacturing Date: DD-MM-YY 9}, Country of Origin: Made in Qatar 10) FM requirements: ‘Doe No: PPUGRE/ALBALAGH /Ins & Test Proc, Rev 0 Page 60f6