ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER: DGS-PU-010 Rev: 0 Date: March 2006 REQUIREMENTS FOR GLASS-FIBER REINFORCED EPOXY AND POLYESTER PIPES AND FITTINGS CONNECTIONS Page 1 of 25 TAKREER DESIGN GENERAL SPECIFICATION (DGS) REQUIREMENTS FOR GLASS-FIBER REINFORCED EPOXY AND POLYESTER PIPES AND FITTINGS CONNECTIONS REVIEWED REV DATE DESCRIPTION BY ENDORSED APPROVED 0 MAR 2006 Base Reference – Project 5601 DGS-PU-010
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ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER: DGS-PU-010
Rev: 0 Date: March 2006
REQUIREMENTS FOR GLASS-FIBER REINFORCED
EPOXY AND POLYESTER PIPES AND
FITTINGS CONNECTIONS
Page 1 of 25
TAKREER DESIGN GENERAL SPECIFICATION (DGS)
REQUIREMENTS FOR GLASS-FIBER REINFORCED
EPOXY AND POLYESTER PIPES AND
FITTINGS CONNECTIONS
REVIEWED REV DATE DESCRIPTION BY
ENDORSED APPROVED
0 MAR 2006 Base Reference – Project 5601
DGS-PU-010
ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER: DGS-PU-010
13.0 QUALIFICATION TESTING PROGRAM FOR MANUFACTURER PRIOR TO FIRST DELIVERY
OF GRP PIPING ....................................................................................................................................17 13.1 FINISHED PRODUCTS .............................................................................................................17 13.2 PIPING SYSTEMS .....................................................................................................................20
14.0 PRODUCTION TESTS FOR SUBSEQUENT GRP PIPING DELIVERIES AFTER MANUFACTURER SATISFIES QUALIFICATION TESTING PROGRAM .....................................22 14.1 INSPECTION/TESTING - GENERAL ......................................................................................22 14.2 ACCEPTANCE TESTS...............................................................................................................22
APPENDIX 1 STANDARD DIAMETERS OF GRP PIPES.........................................................................25
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1.0 GENERAL
1.1 INTRODUCTION
This specification covers the general quality requirements for pipes, fittings and flanges made from
Glass-Fiber Reinforced Epoxy, or GRE (see Paragraph 11.3), and from Glass-Fiber Reinforced
Unsaturated Polyester, or GRUP (see Paragraph 11.4): Both belong to the family of Glass-Fiber
Reinforced Thermosetting Plastics (GRP, or RTRP).
1.1.2 Unless otherwise stated, these general requirements apply for both types of Glass-Fiber Reinforced
Thermosetting Resin materials. Requirements applicable to only one specific material will be
clearly indicated.
1.1.3 Described are pipes, fittings and flanges made by the filament-winding, centrifugal casting or
pressed-sheet molding process.
1.1.4 A number of requirements in this specification are comparable to those of API Specification 15LR.
1.2 PURPOSE
1.2.1 The purpose of this specification is to provide minimum requirements for the purchase, inspection
and transportation of Glass-Fiber Reinforced Epoxy (GRE) and Glass-Fiber Reinforced Unsaturated Polyester (GRUP) Piping, in order to standardize materials and piping components,
improve reliability, and attain consistency in piping fabrication and maintenance.
1.2.2 This specification is intended for use in oil refineries, chemical plants, gas plants, and in exploration, production and new ventures.
1.3 DEFINITIONS
For the purposes of this specification, the following definitions shall apply:
General Definitions:
CONCESSION REQUEST − A deviation requested by the SUBCONTRACTOR or VENDOR, usually after receiving the Contract Package or Purchase Order. Often, it refers to an authorization
to use, repair, recondition, reclaim, or release materials, components or equipment already in
progress or completely manufactured but which does not meet or comply with COMPANY requirements. A CONCESSION REQUEST is subject to COMPANY approval.
SHALL − Denotes mandatory action or requirement
SHOULD − Denotes an action or requirement which is not mandatory but which is strongly recommended.
Specific Definitions:
DESIGN CONDITIONS − Unless otherwise specified in this specification, pressures and
temperatures refer to DESIGN CONDITIONS (i.e., Paragraph 13.1.6).
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ITEM DESCRIPTIONS − The ITEM DESCRIPTIONS shown in the individual LINE CLASSES
are abbreviated and shall not be used for purchase.
LINE CLASS/PIPING CLASS − An assembly of piping components, suitable for a defined service
and design limits, in a piping system. The Piping Classes for the PROJECT are contained in
Project Specification DGS-PU-003.
MESC − Materials and Equipment Standards and Code. The MESC system provides ITEM
DESCRIPTIONS, references to international codes and standards, technical specifications and
minimum levels of certification. Using the MESC system standardizes the piping materials ordered
for construction and maintenance (see Paragraph 9.1.1).
PURCHASE DESCRIPTIONS − For (MESC) PURCHASE DESCRIPTIONS, refer to the Piping
Project Materials Catalogue (to be developed during detailed design).
1.4 GRP PIPING APPLICATIONS
1.4.1 When excellent corrosion resistance over a wide temperature range is a necessity, GRP material
should be considered as a viable alternate to the traditional use of exotic alloys (i.e., Monel, Alloy
20, etc.): Aside from cost, the advantages of GRP piping over these alloys is its low weight,
chemical inertness over a broad range of services, as well as its ability to be buried underground
without any need for a corrosion-resisting coating (or cathodic protection). In general, GRP material is recommended for use in utility services only.
1.4.2 For detailed information comparing the characteristics of GRE and GRUP piping, the use of GRP
material in general, or the recommended joining systems for various applications, refer to Project
Specification DGS-PU-011.
1.4.3 The use of GRE and GRUP piping in different applications shall be in accordance with Project
Specification DGS-PU-003.
1.5 EXCLUSIONS
The following are excluded from the requirements of this specification:
1.5.1 High-Pressure Piping, as defined by API Specification 15LR (approximately 71.3 kg/cm2, or 70
bar), Casing and Tubing.
1.5.2 Reinforced Plastic Mortar Piping.
1.5.3 Piping applications that exceed the maximum temperature limit for GRE (Glass-fiber Reinforced
Epoxy) piping (i.e., 110°C). In these situations, alternative materials should be considered.
2.0 CODES AND STANDARDS
The following codes and standards, to the extent specified herein, form a part of this specification. The latest edition in place shall apply.
American National Standards Institute (ANSI):
ANSI/ASME B16.5 Pipe Flanges and Flanged Fittings
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American Society of Mechanical Engineers (ASME):
ASME B31.3 Chemical Plant and Petroleum Refinery Piping
American Society for Testing and Materials (ASTM):
ASTM D 570 Water Absorption of Plastics
ASTM D 696 Coefficient of Linear Thermal Expansion
ASTM D 1599 Resistance to Short-Time Hydraulic Failure Pressure of Plastic Pipe,
Tubing, and Fittings
ASTM D 2412 External Loading Characteristics 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 “Fiberglass” (Glass-Fiber Reinforced Thermosetting Resin) Pipe Under Full Bore Flow
ASTM D 2992 Obtaining Hydrostatic or Pressure Design Basis for “Fiberglass” (Glass-
Fiber Reinforced Thermosetting Resin) Pipe and Fittings
ASTM D 3418 Transition Temperatures of Polymers by Differential scanning Calorimetry
ASTM D 3567 Dimensions of “Fiberglass” (Glass-FiberReinforced Thermosetting Resin)
Pipe and Fittings
ASTM D 4024 “Fiberglass” (Glass-Fiber Reinforced Thermosetting Resin) Flanges
American Petroleum Institute (API):
API Standard 5B Threading, Gauging, and Thread Inspection of Casing, Tubing and Line
Pipe Threads
API Standard 15LR Low Pressure Fiberglass Line Pipe.
American Water Works Association (AWWA)
AWWA AWWA M45 for Burried RTR Design and Analysis
British Standards Institution (BS):
BS 3396 Woven Glass Fiber Fabrics for Plastics Reinforcement
BS 3691 E Glass Fiber Rovings for Reinforcement of Polyester and Epoxy Resin
Systems
BS 5750 Quality Systems
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Deutsches Institut Fur Normung E.V. (DIN):
DIN 16945 Testing of Resins, Hardeners and Accelerators, and Catalyzed Resins
International Organization for Standardization (ISO):
ISO 62 Plastics - Determination of Water Absorption
ISO 14692 All Parts fro Above Ground
ISO 9001 - 2000 Quality Management System Requirements
ISO 9004 - 2000 Quality Management Guidelines for Performance Improvement System
ISO 9011 Guidelines for Quality and/or Environmental System Auditing
Nederlands Normalisatie-Instituut (NEN):
NEN 7037 Glass-Fiber Reinforced Thermosetting Plastic Pipe for Drains and Sewers - Requirements for Test Methods
3.0 REFERENCE DOCUMENTS
Project Specifications:
DGS-MU-002 Preservation and Export Packing
DGS-MU-013 Criticality Rating Calculation Method
DGS-MU-014 Minimum Shop Inspection and Certification Requirements
DGS-PU-003 Technical Specification for Piping Systems
DGS-PU-011 Design and Installation of Glass-Fiber Reinforced Epoxy and Polyester
Piping
DGS-PU-016 Piping Material Purchase Specification (SPE Specs)
Project Summaries:
XXXX-PP-500 Piping Line List (for Unit XXXX) (XXXX denotes Unit #)
4.0 DOCUMENT PRECEDENCE
4.1 COMPLIANCE WITH SPECIFICATIONS
It shall be the VENDOR’S responsibility to be, or to become, knowledgeable of the requirements of
the referenced Codes and Standards (including Project Specifications).
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4.2 CONFLICT RESOLUTION
The VENDOR shall notify the CONTRACTOR of any apparent conflict between this specification, national and/or local regulations, MANUFACTURER’S Instructions, the Codes and Standards, and
any other specifications noted herein. Resolution and/or interpretation of precedence shall be
obtained from the CONTRACTOR in writing before proceeding with the design/manufacture.
In case of conflict, the order of precedence shall be stated in the AGREEMENT or other PROJECT
documents as applicable.
5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL
Any technical deviations to the Purchase Order and its attachments including, but not limited to, the Piping Drawings and Project Specifications shall be sought by the VENDOR only through
CONCESSION REQUEST format. CONCESSION REQUESTS require CONTRACTOR’S and
COMPANY’S review/approval, prior to the proposed technical changes being implemented.
Technical changes implemented prior to COMPANY approval are subject to rejection.
6.0 QUALITY ASSURANCE/QUALITY CONTROL
6.1 QA/QC PROGRAM
To ensure that all detailed design/engineering is performed consistently and accurately, the
VENDOR shall have in effect at all times, a QA/QC program which clearly establishes the
authority and the responsibility of those responsible for the quality system. Persons performing quality functions shall have sufficient and well defined authority to enforce quality requirements
that initiate, identify, recommend and provide solutions to quality problems and verify the
effectiveness of the corrective action.
A copy of the VENDOR’s QA/QC program shall be submitted to the CONTRACTOR with its
quotation for CONTRACTOR’S review and concurrence prior to award. If VENDOR’S QA/QC
program and facility, where the work is to be performed, is ISO 9000 (9001-2000, 9004-2000, 9011) certified, then only a copy of the VENDOR’S ISO 9000 certificate is required. In addition, if
VENDOR’S facility is ISO certified, CONTRACTOR’S QA audit requirements will be waived in
favor of ISO 9000 registrar audits, unless the CONTRACTOR’S trend analysis program indicates areas of concern.
The VENDORS shall identify in purchase documents to its SUBVENDORS all applicable QA/QC
requirements imposed by the CONTRACTOR, and shall ensure compliance thereto. On request,
VENDOR shall provide objective evidence of its QA/QC surveillance of its SUBVENDORS
activities.
6.2 COMPLIANCE WITH SPECIFICATION GUIDELINES
6.2.1 The VENDOR shall furnish CONTRACTOR with copies of VENDOR’S Quality Control Plan,
Inspection and Test Plan.
6.2.2 The MANUFACTURER will be evaluated for ability to perform adequate and sufficient Quality Control (including inspections and tests performed at sufficient intervals before and during
production) to ensure that proper and correct base materials are being used, that the finished
material meets physical and chemical specifications and that the finished product meets all
dimensional and performance requirements.
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BS 5750 will be used as a guideline in this respect.
6.2.3 MANUFACTURER shall comply with a Qualification Testing Program and Production Tests as
specified in Paragraphs 13.0 through 15.0 of this specification.
6.3 MATERIAL AND PRODUCT TRACEABILITY
In order to assure traceability of materials and products, the MANUFACTURER shall 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.
6.4 CRITICALITY RATINGS
6.4.1 A Criticality Rating (CR) shall be assigned to each piping section (between pieces of equipment),
and shall be listed on the Material Selection Diagram and Piping Line Lists, (see 3.0).
6.4.2 The calculation method and checking level requirements (based on Criticality Ratings) are given in
Project Specification DGS-MU-013.
6.4.3 The minimum requirements for factory inspection (based on Criticality Ratings) are given in Project Specification DGS-MU-014.
7.0 DOCUMENTATION
7.1 MANUFACTURERS DRAWINGS - PIPES
The following Pipe dimensions and tolerances, when applicable, shall be stated by the
MANUFACTURER and shall be in accordance with the Certified MANUFACTURERS Drawings:
• Pipe inside/outside diameter.
• Minimum total wall thickness.
• Maximum allowable design conditions (i.e., Pressure and Temperature).
• 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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7.2 MANUFACTURERS DRAWINGS - FITTINGS
The following Fitting dimensions and tolerances, where applicable, shall be stated by the
MANUFACTURER and shall be in accordance with the Certified MANUFACTURERS Drawings:
• Fitting inside/outside diameter.
• Minimum total wall thickness.
• Maximum allowable design conditions (i.e., Pressure and Temperature).
• Overall fitting length.
• Effective fitting length.
• Conical form of spigot/socket taper.
• Length of joint.
• Spigot or socket chamber for rubber sealing ring and for fixation rod.
• Shear length, i.e. distance between chamber for rubber sealing ring and fixation rod.
7.3 MANUFACTURERS DRAWINGS - FLANGES
The following Flange dimensions, where applicable shall be stated by the MANUFACTURER and
shall be in accordance with the Certified MANUFACTURERS Drawings:
• Thickness of the flange.
• Rating.
• Maximum allowable design conditions (i.e., Pressure and Temperature).
• Bolt hole circle and diameter.
7.4 MANUFACTURERS DRAWINGS - PREFABRICATED PIPING SYSTEMS
The following flange dimensions, where applicable, shall be stated by the MANUFACTURER and
shall be in accordance with the Certified MANUFACTURERS Drawings:
• Items as indicated in Paragraphs 7.1 through 7.3 of this specification.
• Face-to-face, centerline-to-face and centerline-to-centerline.
• Lateral off-set of flanges.
• Flange face alignment.
7.5 CERTIFICATION DOCUMENTS
7.5.1 The MANUFACTURER 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. These shall also include the Certificates of the Steel Parts, if any.
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7.5.2 Refer to Paragraphs 10.0 through 15.0 for additional data, information and documentation to be provided by MANUFACTURER.
7.6 TECHNICAL DEVIATION DOCUMENTS
If appropriate, the MANUFACTURER shall issue a Concession Request, showing each deviation
from the Purchase Order.
8.0 SUBCONTRACTORS/SUBVENDORS
8.1 ROLES AND RESPONSIBILITIES - GENERAL
8.1.1 The MANUFACTURER/VENDOR (conducting detailed design and/or fabrication of piping) shall
assume responsibility and overall guarantee compliance to this specification.
8.1.2 The VENDOR shall transmit all relevant Purchase Order documents including specifications to its SUBVENDORS and SUBCONTRACTORS.
8.1.3 It is the VENDOR’S responsibility to enforce all Purchase Order and specification requirements on
its SUBVENDORS and SUBCONTRACTORS.
8.1.4 The VENDOR shall submit all relevant drawings and engineering data from its SUBVENDORS
and SUBCONTRACTORS to the CONTRACTOR.
8.1.5 The VENDOR shall obtain and submit all SUBVENDOR warranties to the CONTRACTOR/COMPANY, in addition to the system warranty.
9.0 HANDLING
9.1 MARKING
9.1.1 All pipes and fittings shall be permanently marked with the MANUFACTURER'S name or trade
name, the pressure class, the Nominal Pipe Size (in inches), the MANUFACTURER’S
Identification Code, and the appropriate MESC Number.
9.1.2 The marking shall remain legible under normal handling and installation practices.
9.1.3 Markings for identification purposes shall be made in such a manner as not to impair the integrity
of the pipe/fittings material.
9.2 PACKAGING
9.2.1 The pipes and fittings shall be packed in a manner which will ensure arrival at destination in a
satisfactory condition and which will be acceptable to COMPANY. Pipe ends shall be protected
with suitable protective covers. The covers shall be securely attached.
9.2.2 Fastening is necessary where container transportation is used, to ensure immobilization of pipe
joints.
9.2.3 The bottom of crates shall be provided with skids to facilitate handling by forklift truck.
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9.2.4 Additional packaging requirements shall be in accordance with Project Specification DGS-MU-
002.
9.3 PIPING BULK SHIPMENTS
Assembly, preservation, and preparation for piping bulk shipments shall be in accordance with
Project Specifications DGS-MU-002, DGS-PU-011 and DGS-PU-016 (if applicable).
10.0 DESIGN
10.1 GENERAL REQUIREMENTS
10.1.1 The MANUFACTURER shall submit a piping stress analysis based on data for his specific brand
and in accordance with ASME B 31.3.
10.1.2 If the influence of chemicals is to be taken into account, the MANUFACTURER should state the
maximum allowable operating conditions for continuous chemical service.
10.1.3 Unless otherwise specified, piping for water supply and distribution, including potable water, fire-fighting water, sea water, sewers and other chemical services shall have a smooth uniform resin-
rich lining (per Paragraph 11.6 of this specification).
• The CONTRACTOR shall specify those applications where the presence of an internal lining is
not mandatory, as in cases where less severe chemical resistance is required, or for electrically
conductive piping.
10.1.4 The raw materials shall be checked by the CONTRACTOR against the sales specification as given
by the MANUFACTURER of these materials.
10.1.5 The MANUFACTURER shall check for each production batch per shift of eight hours, the mixing ratio of resin and curing agent: He shall also permanently record the mixing ratios.
10.2 INSTALLATION INSTRUCTIONS
The MANUFACTURER shall provide proper Installation Instructions and, if requested by COMPANY, adequate supervision at all stages of installation.
10.3 POTABLE WATER SERVICE
Piping to be used for the transportation of potable (i.e., drinking) water shall carry an official approval by the local health authorities.
10.4 DIMENSIONS – PIPE
10.4.1 Diameter
a. The pipe standard for filament-wound pipe may be based on either the inside diameter (type
A) or the outside diameter (type B). Standard diameters for both types of pipes are given in
Appendix 1 of this specification.
b. Centrifugally cast pipe is based on the outside diameter (Type B).
c. The inside diameter (Di) of type A1 pipes is equal to the nominal diameter.
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d. The A2 and B1 series are based on a commercial need for pipes with the outside diameters equal to those of pipes made from other materials, e.g. cast iron and steel so as to enable
joints to be made to existing pipes without special jointing adapters.
e. The dimensions of the B1 series are equal to those of API Specification 15LR.
f. The B2 series have their outside diameter (Do) related to the nominal diameter (NPS) by the
equation Do = 1.02NPS + 4mm.
10.4.2 Wall Thickness
The reinforced wall thickness of the pipe shall be sufficient to withstand the temperatures,
pressures, and service conditions of the particular application. It shall, however, be at least 1.8 mm.
10.4.3 Liner/Top Coat
a. If piping has an internal lining (see Paragraph 10.1.3), its thickness for filament-wound pipe
shall be at least 0.5 mm. For centrifugally cast pipe the thickness of this lining shall be at
least 1 mm. Pressed-sheet molding compound (SMC) fittings have no liner but a press skin which shall be at least 0.2 mm thick.
b. All piping shall have a smooth resin rich top coat having minimum thickness of 0.5 mm.
10.4.4 Ovality
The difference between the largest and smallest diameter (ovality) in each cross section, shall be
not more than 0.007 Di (Type A) or 0.007 Do (Type B).
10.4.5 Ends
a. The pipe shall be supplied with plain ends, with shaved ends, with spigot ends, or with one
spigot end and one (integral) socket end or with flanged ends as stated by COMPANY.
10.5 DIMENSIONS - FITTINGS
10.5.1 Wall Thickness
The reinforced wall thickness of the fittings shall be sufficient to withstand the temperatures,
pressures, and service conditions of the particular application. It shall, however, be at least 2.2 mm.
10.5.2 Ovality
The difference between the largest and smallest measured inside diameter (ovality) shall not be
more than 0.007 Di (Type A) or 0.007 Do (Type B).
10.5.3 Ends
Fittings shall be supplied with plain ends, spigot ends, integral socket ends or flanges as stated by
COMPANY.
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10.6 DIMENSIONS - FLANGES
The outside diameter and drilling template of flanges shall be in accordance with ANSI B 16.5
class 150, class 300 or class 600, depending upon the specified pressure class. The flange face shall
be flat-type.
10.7 PREFABRICATED PIPING SYSTEMS - DESIGN CRITERIA
10.7.1 Prefabricated piping systems may have adhesive-bonded socket/ spigot connections or hand-
laminated butt and strap joints or integral spigots and/or sockets for connections with rubber sealing
rings.
10.7.2 The surfaces without a liner at adhesive-bonded connections exposed to the product shall be covered by the adhesive.
10.7.3 The butt and strap joints shall be laminated over a length of at least the pipe diameter on the
outside, and if the diameter allows, also on the inside.
10.7.4 All machined or cut surfaces, except the spigot ends, shall receive a coat of resin type, formulated
to be resistant to the product to be conveyed and for use at the service temperatures and pressures.
11.0 MATERIALS
11.1 GENERAL REQUIREMENTS
11.1.1 Purchase Specifications
In addition to the component requirements specified in the Purchase Description, pipe, fittings, and flanges shall conform to the individual SPE Specifications (contained in Project Specification
DGS-PU-016), referenced in specific Purchase Descriptions.
11.2 BASE MATERIALS - GENERAL
All Base Materials shall be new and unused, and shall be free from all contaminations and
imperfections. The Base Materials, e.g. Resins, Glass-Fiber 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 MANUFACTURER and certified by the raw materials VENDOR(S) per delivery.
11.3 BASE MATERIALS - EPOXY RESINS
Unless otherwise agreed, the pipes, fittings and flanges shall be made from a Bisphenol A
Epichlorohydrin Epoxy Resin (i.e., EPIKOTE 828), and an Aromatic or Cyclo-Aliphatic Amine-
Type Curing Agent. However, if MANUFACTURER can document the behavior of other resins (for a given service) via laboratory tests and industrial user case histories, MANUFACTURER may
propose alternate resins (i.e., DER 331.3), subject to COMPANY approval. The
MANUFACTURER shall describe the type of resin and curing system chosen.
11.4 BASE MATERIALS - POLYESTER RESINS
11.4.1 Unless otherwise agreed, the pipes, fittings and flanges shall be made from Isophthalic Acid
Polyester, Bisphenol A-Polyester or Vinyl Ester Resin (i.e., DERAKANE 411-45).
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However, if MANUFACTURER can document the behavior of other resins (for a given service) via laboratory tests and industrial user case histories, MANUFACTURER may propose alternate resins
(i.e., DERAKANE 470-45), subject to COMPANY approval. The MANUFACTURER shall state
the type of resin and curing system chosen.
11.4.2 Upon comparing the properties of GRE piping with GRUP, Polyester Resins are not generally
preferred over Epoxy Resin systems (see Paragraph 1.4).
11.5 BASE MATERIALS - GLASS-FIBER REINFORCEMENT, FILLERS AND PIGMENTS
11.5.1 Glass-fiber reinforcement for the reinforced wall shall be made of E-glass (i.e. 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 (Paragraph 11.3) or Polyester Resin (Paragraph 11.4).
11.5.2 Fillers are not acceptable. Thixotropic additives added to the resin/curing agent mixture for
viscosity control shall not exceed 2 percent by weight.
11.5.3 Pigments are only acceptable as long as they do not affect the performance of the components as
defined in Paragraph 13.0 of this specification, or if agreed with COMPANY, in order to fulfill
special application requirements.
11.6 BASE MATERIALS - INTERNAL LINING/TOP COAT
11.6.1 Internal Lining
Unless otherwise agreed (see Paragraph 10.1.3), flange surfaces and all pipes and fittings which are
to be exposed to the fluid, shall have a smooth uniform resin-rich lining consisting of:
• A surfacing mat (tissue) or a veil, commonly comprised of C-glass (i.e., chemical-resistant
glass) for most applications: In situations where improved flexibility and/or impact properties
are required, a Synthetic Fiber (i.e., Linear Polyester Fibers of Polyacrylonitrile Fibers) should
be considered.
• The same resin which is used for the fabrication of the pipe, fitting or flange.
11.6.2 Top Coat
Piping shall have a smooth resin rich exterior surface (i.e., top coat) impregnated with Vinyl Ester
or Epoxy resin (as required by the system type and design conditions). In addition to safeguarding
the piping from abrasion, the top coat shall be able to protect against UV (ultra-violet) exposure for open air installation.
11.7 BASE MATERIALS - ADHESIVES
11.7.1 Adhesive for adhesive-bonded connections shall be of an Epoxy Type, formulated to be resistant to the product to be conveyed, and for the service temperatures and pressures. It shall be of the type
and quality regularly supplied by the pipe MANUFACTURER for the duty intended, and as used
for the Qualification Test (Paragraph 13.2.1) and shall have a proven record of good service.
ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER: DGS-PU-010
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FITTINGS CONNECTIONS
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11.7.2 Adhesive Kits
The Adhesives shall be provided in a kit containing at least epoxy resin and curing agent
(separately in the recommended proportions) and mixing stick, joint cleaner, sandpaper and brush,
together with 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.
11.8 BASE MATERIALS - RUBBER SEALING RINGS
The Sealing Rings for the spigot and socket connections shall be made of a rubber type resistant to
the product to be conveyed and for the service temperatures and pressures. The
MANUFACTURER shall state the type of rubber, providing evidence for its suitability in the proposed application.
11.9 BASE MATERIALS - FIXATION ROD
The Fixation Rod for thrust-resistant spigot and socket connections with rubber sealing rings shall be made of a flexible thermoplastic material, resistant to the particular service conditions, such as
temperature, surrounding environment, ultra-violet exposure etc. The MANUFACTURER shall
state the type of thermoplastic material, providing evidence for its suitability in the proposed application.
12.0 FABRICATION
Unless otherwise agreed by COMPANY, the following fabrication/construction methods shall be
adhered to:
12.1 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 predetermined pattern
under controlled tension.
12.2 CENTRIFUGAL CAST PIPE
Centrifugal cast pipe shall be manufactured by applying resin and reinforcement to the inside of a
mold that is rotated and heated, subsequently polymerizing the resin system.
12.3 FITTINGS AND FLANGES
Fittings shall be of a filament-wound construction. Flanges shall be of a filament-wound
construction or a pressed-sheet molded compound (SMC) construction. In the latter case the length
of the reinforcing fibers shall be at least 12 mm.
The application of fittings and flanges of another design shall be specifically agreed upon between
COMPANY and the CONTRACTOR(S).
ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER: DGS-PU-010
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13.0 QUALIFICATION TESTING PROGRAM FOR MANUFACTURER PRIOR TO FIRST
DELIVERY OF GRP PIPING
13.1 FINISHED PRODUCTS
The following Qualification Requirements apply to the finished products.
MANUFACTURERS complying to API Specification 15LR shall contact the CONTRACTOR
upon the acceptability of tests carried out and as indicated in this section by means of an
asterisk (*).
All tests to be carried out at ambient temperature, unless otherwise indicated.
13.1.1* Appearance
a. 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 I.
b. The other parts of pipes and fittings shall be classified according to level II of ASTM D 2563, with the following exceptions:
Air bubble : Maximum 2 mm; 3 bubbles/1000 mm2
Pimple : Level III
Pit : Level III, but depth less than 10% of the wall thickness
c. Pipes and fittings shall be uniform in composition and structure, density and other physical
properties.
d. All ends of pipes and fittings shall be cut at right angles to the axis and any sharp edges shall
be removed.
13.1.2 Curing
a. GRE
• The preferred and recommended method for verifying the degree of curing shall be by
determination of the transition temperature through differential scanning calorimetry
(DSC), or differential thermal analysis (DTA), in accordance with ASTM D 3418. The
glass-transition temperature shall be at least 110°C.
• Upon COMPANY approval, the degree of curing of pipe and fittings may also 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 percent
loss of weight.
b. GRUP
• The preferred and recommended method for verifying the degree of curing shall be by
determination of the transition temperature through differential scanning calorimetry
(DSC), or differential thermal analysis (DTA), in accordance with ASTM D 3418. The
glass-transition temperature shall be at least 75°C.
ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER: DGS-PU-010
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• Upon COMPANY approval, the degree of curing of pipe and fittings may also be
determined by testing the rest styrene content in accordance with DIN 16945. The rest
styrene content shall not be more than 2 percent.
13.1.3 Glass Content
a. Filament-Wound Pipe
• The glass/resin ratio shall be tested in accordance with ASTM D 2584. The glass
content of the filament-wound pipe shall be at least 65 percent by weight, whereas for
filament-wound fittings the glass content shall be at least 55 percent by weight.
b. Centrifugally Cast Pipe
• For the structural wall of centrifugally cast pipes and molded fittings, the glass content
shall be at least 45 percent by weight and 30 percent by weight, respectively.
• The maximum glass content shall in all cases be 77 percent by weight.
13.1.4 Consistency of the Pipe Material
Three samples shall be taken from three places situated 120 degrees apart in the same cross section.
The glass content of each sample shall be determined in accordance with ASTM D 2584. The
difference in the glass content between two samples shall be not more than 5 percent by weight.
13.1.5 Water Absorption
Pipes and fittings shall not show evidence of delamination or other impairment when tested in accordance with ISO 62 or ASTM D 570.
13.1.6* Hydrostatic Design Stress, Pressure Ratings and Hydrostatic Pressure Test
a. The long-term hydrostatic strength of pipe, fittings, and joints shall be determined in
accordance with Procedure A or B of ASTM D 2992. The MANUFACTURER shall select the procedure and the size (i.e., diameter) for these tests. Adhesive joints, if any, shall be
included utilizing both the factory and field adhesives and their respective joining and curing
procedures, if different. The samples tested shall carry the full end load due to pressure.
b. Testing shall be conducted at 20°C minimum.
c. The hydrostatic design stress determined in accordance with Procedure A of ASTM D 2992
shall utilize a service (design) factor of 1.0.
d. The hydrostatic design stress determined in accordance with Procedure B of ASTM D 2992
shall utilize a service (design) factor of 0.5.
e. 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 3.2.1 of ASTM D 2992. The
minimum reinforced wall thickness shall be identified.
f. Flanges shall be pressure rated and hydrostatic pressure tested in accordance with ASTM D
4024.
ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER: DGS-PU-010
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g. The pipe, pipe spools or pipe joints shall be subjected to a biaxial loaded hydrostatic pressure test as described in ASTM D 1599.
h. The GRE pipe, pipe spool or pipe joints shall not display a weeping effect below a hoop
stress value of 150 MN/m2.
i. The GRUP pipe, pipe spool or pipe joints shall not display a weeping effect below a hoop
stress value of 95 MN/m2.
j. The test pressure shall subsequently be increased to 3 times the design pressure and be
maintained for at least 5 minutes.
k. During this pressure test the test specimens shall not show any sign of breakage.
Note: This test will cause irreversible deformations in the material, so that the test specimens shall be discarded.
13.1.7* Stiffness of Pipe
a. The minimum specific tangential initial stiffness (STIS) shall, when tested in accordance with NEN 7037, not be less than:
• 2,500 N/m2 for 10.2 kg/cm2 (10 bar) piping
• 10,000 N/m2 for 16.4 kg/cm
2 (16 bar) piping
• 25,000 N/m2 for 25.5 kg/cm
2 (25 bar) piping
b. Alternatively, the pipe stiffness at 5 percent 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:
a. The modulus of elasticity of the GRE pipe shall have a minimum of 7,000 MN/m2 at 90°C
when tested in accordance with ASTM D 2925.
b. The modulus of elasticity of the GRUP pipe shall have a minimum of 5,000 MN/m2 at 60°C
(ASTM D 2925).
13.1.9* Impact Resistance
a. A steel ball 50 mm in diameter and weighing approximately 550 g shall be dropped
perpendicularly on to the surface of the test pipe with a free fall (which may be guided) of 300 mm.
ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER: DGS-PU-010
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b. 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 pressurized at the pressure class of the pipe. Four
drops shall be made on different areas from those previously used. The pipe shall then be
pressurized to 2 times the pressure class rating at 25°C for 5 minutes.
c. Fittings shall be tested in the same manner except that the drops shall be reduced from four to one in each test.
d. The pipe or fitting shall not show any porosity or visual delamination when examined, e.g.
with an ultra-violet or normal lamp.
13.1.10 Linear Thermal Expansion
The MANUFACTURER shall state in his Qualification Testing Report the coefficient of thermal
expansion of a pipe length as determined in accordance with ASTM D 696.
13.2 PIPING SYSTEMS
Upon request of COMPANY/CONTRACTOR(S), the pipe MANUFACTURER shall provide the
following certified documentation for mutually agreed piping diameter(s).
13.2.1 Adhesive Bonded Piping Systems
a. The relevant requirements for the specific component shall also apply for the adhesive
bonded piping system.
b. It is not allowed to apply an additional overlap laminate to the joint to obtain the necessary
strength.
13.2.2 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:
a. No leakages shall occur during hydrostatic pressure testing at 1.5 times the design pressure during 10 minutes, while the test sections are deflected angularly in such a way that the
center-line of one section of the assembled specimen makes an angle1 of 1.5 degrees (for
diameters up to 600 mm) or 1 degree (for diameters from 700 mm) with the center-line of the
other section.
b. The joint assembly shall withstand a combination of a bending force and an internal
hydrostatic pressure of 1.5 times the design pressure.
c. 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.
1 Indicated angles not to be used for actual design calculations.
ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER: DGS-PU-010
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d. After having applied the calculated bending force, 10 cycles of 0 to 1.5 times design pressure shall be performed.
e. The pressure cycle time shall be 10 minutes (5 minutes without pressure, 5 minutes at design
pressure).
f. The joint assembly shall withstand a combination of a shear force (in N) of 20 times the
inside diameter (in mm) and an internal hydrostatic test pressure of two times the design
pressure. The test pressure shall be cycled from 0 to the test pressure, 10 times, while
holding the shear force. The time for one pressure cycle shall be 10 minutes (5 minutes
without pressure, 5 minutes at design pressure).
g. 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 degrees along a longitudinal distance of one pipe diameter
or 300 mm, 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.
h. The joint assembly shall withstand an internal vacuum of 0.76 kg/cm2 (abs) during 10
minutes when:
• Deflected angularly in such a way that the center-line of one section of the assembled
specimen makes an angle2 of 1.5 degrees (for diameters up to 600 mm) or 1 degree (for
diameters from 700 mm) with the center-line of the other section, AND WHEN
• 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 degrees along a longitudinal distance of one
pipe diameter or 300 mm, whichever is the smaller, from the sealing of the assembled
joint, at the unsupported spigot end of the pipe.
NOTE: Pressure stabilizing for 30 minutes is allowed.
13.2.3 Flanged Piping Systems
a. Flanges shall withstand, without any visible sign of damage, a bolt torque of at least 1.5 times
that recommended by the MANUFACTURER at 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 N.m
increments according to the recommended practice.
b. Two flanged sections shall be bolted together using the gasket and bolt torque for standard field installation as recommended by the MANUFACTURER. This assembly shall meet the
following requirements:
• No leakages shall occur during hydrostatic pressure- testing at 1.5 times the design
pressure during 168 hours.
2 Indicated angles not to be used for actual design calculations.
ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER: DGS-PU-010
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• Retorquing to the MANUFACTURER’S specified level after initial pressurization is
permitted.
• No rupture of the flanged connection shall occur during hydrostatic pressure testing
at 2 times the design pressure for 10 minutes. Leaking past the gasket interface is
permissible during this test. Bolt torque may be increased if necessary during the test in order to minimize gasket leaking and to achieve the pressure necessary to cause
flange failure.
13.2.4 Threaded Piping Systems
The qualification testing of threaded piping systems shall be in accordance with the requirements
given by the CONTRACTOR.
14.0 PRODUCTION TESTS FOR SUBSEQUENT GRP PIPING DELIVERIES AFTER
MANUFACTURER SATISFIES QUALIFICATION TESTING PROGRAM
14.1 INSPECTION/TESTING - GENERAL
14.1.1 This section describes the minimum number of acceptance tests required for each delivery of GRP
pipes and fittings purchased to this specification from a MANUFACTURER whose products have
been qualified successfully (refer to Paragraph 13.0 of this specification).
14.1.2 Additional tests may be established by mutual agreement between the MANUFACTURER/CONTRACTOR and the COMPANY prior to any contract award.
14.1.3 If the material fails to pass any of these tests, this may constitute sufficient cause for rejection.
14.2 ACCEPTANCE TESTS
14.2.1 Visual Inspection
All pipes and fittings shall be visually inspected in accordance with Paragraph 13.1.1.
14.2.2 Dimensions
The dimensions of all pipes and fittings (Paragraphs 10.4 through 10.6) shall be checked in
accordance with ASTM D 3567.
14.2.3 Curing
The degree of curing of each lot2 of pipe and fittings (Paragraph 13.1.2) shall be checked at random
by means of a Barcol Impressor (ASTM D 2583) and shall have a minimum value of 40.
14.2.4 Glass Content3
The glass content of each lot2 of pipe and fittings shall be checked (refer to Paragraph 13.1.3).
2 Unless otherwise agreed, a lot of pipe shall consist of 900 meters or a fraction thereof and a lot of fittings of one
fitting, both one size, wall thickness and grade. 3 These tests are destructive tests; if appropriate a deviation (i.e., Concession Request) of test frequency shall be
established by agreement between the MANUFACTURER and the CONTRACTOR/COMPANY.
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14.2.5 Hydrostatic Pressure Test
Ten percent of the pipes furnished under this specification for ANSI Class 150 water supply and
distribution and 100 percent of the pipes furnished under this specification for ANSI Class 150
hydrocarbon and chemical services and for ANSI Class 600 service 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 5 minutes.
During the pressure test the pipes and/or fittings shall not show any sign of leakage.
Unless otherwise approved by COMPANY, all fittings, pipe spools and prefabricated piping shall
be hydrostatic-pressure-tested at 1.5 times the pressure class rating of the pipe.
COMPANY shall be contacted for those cases where testing of pipe spools would result in damage of the pipe ends caused by the end caps.
14.2.6 Impact Resistance3
The impact resistance of each lot2 of pipe and fittings shall be checked (refer to Paragraph 13.1.9)
15.0 QUALIFICATION TESTING PROCEDURE
15.1 QUALIFICATION TESTING - GENERAL
15.1.1 The full program of Qualification Testing (as described in Paragraph 13.0) is required before a MANUFACTURER will be allowed to deliver for the first time.
The COMPANY may require to repeat, completely or in part, the qualification testing of a certain
make, for example because of time elapsed or new developments.
15.1.2 Changes in the design and/or method of manufacture of pipes and/or fittings will in any case
require new or additional Qualification Tests.
15.1.3 Unless otherwise approved by COMPANY, Qualification Testing shall be carried out on products
with representative diameters (see Paragraph 15.1.4). The type of product, its pressure and temperature rating, number, etc. shall be mutually agreed with the COMPANY.
15.1.4 Representative diameters and products:
Representative Products Pipe, 90° Elbow, Equal Tee, Equal Lateral, and Reducer
ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER: DGS-PU-010
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15.1.5 Qualification Testing as described in Paragraph 13.0 of this specification shall be carried out by the MANUFACTURER and witnessed and certified by an independent authority recognized by
COMPANY. Alternatively, testing and certification may be carried out by an independent testing
organization. This shall be confirmed by submitting a certificate stating the test results.
15.1.6 The COMPANY 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.
15.1.7 The MANUFACTURER shall state in his Qualification Testing Report, the coefficient of thermal
expansion of a pipe length as determined in accordance with ASTM D 696.
ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER: DGS-PU-010
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APPENDIX 1
STANDARD DIAMETERS OF GRP PIPES1
Nominal Pipe Size
(NPS)
Type A
(based on inside of diameter)
Type B
(based on outside diameter)
in mm
in inch
Type A1
Di in mm
Type A2
Di in mm
Type B12
Do in mm
Type B2
Do in mm
25 1 25 27 33.7 30
40 1.5 40 40 48.3 45
50 2 50 53.1 60.3 55
80 3 80 81.8 88.9 86
100 4 100 105.2 114.3 106
150 6 150 159 168.3 157
200 8 200 208.8 219.1 208
250 10 250 262.9 273 259
300 12 300 313.7 323.9 310
350 14 350 344.4
400 16 400 393.7 429 412
450 18 450 433.8
500 20 500 482.1 532 514
600 24 600 578.6 635 616
700 28 700 738 718
750 30 750 723.1
800 32 800 842 820
900 36 900 867.9 945 922
1000 40 1000 1048 1024
1200 1200 1255 1228
1400 1400 1462 1432
1600 1600 1668 1636
1800 1800 1875 1840
2000 2000 2044
2400 2400 2452
2800 2800 2860
3200 3200 3268
3600 3600 3676
4000 4000 4084
NOTES: 1). These dimensions are not yet accepted and approved by the ISO Council. Some MANUFACTURERS fabricate
pipes with outside diameters which completely differ from those mentioned in the table.
2). These dimensions are equal to the dimensions given in API Specification 15LR.