Quick Guide To Iso-14692 1m71v
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QUICK GUIDE INTO ISO 14692 1. Introduction ISO (the International Organization for Standardization) is a worldwide network of national standard institutes. The ISO 14692 standard is an international standard dealing with the qualification, manufacturing, design and installation of GRE piping systems. This document gives a brief summary of the ISO 14692 standard only and is not intended to replace the ISO 14692 standard. To ensure a trouble free GRE pipe system, three major important conditions must be met: 1. Use qualified products. 2. Perform system design. 3. Install according to manufacturers standards and guidelines.
Qualification
The above mentioned three points are addressed in the ISO 14692 Standard in Part 2, Part 3 and Part 4 respectively.
Troublefree pipe system
System design
Installation Figure 1. The key to success
Content 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Introduction What is ISO 14692? Part 1: Vocabulary, symbols, applications and materials Part 2: Qualification of components Part 3: System design Part 4: Fabrication, installation and operation Conclusion ISO in brief References Deviations list to the ISO quality program
1 2 3 3 5 7 9 9 9 10
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2. What is ISO 14692? ISO 14692, is an international standard dealing with the qualification of fittings, ts and pipes for certain applications. It describes how to qualify and manufacture GRP/GRE (Glass Reinforced Epoxy) pipe and fittings, how to conduct system design and finally it gives guidelines for fabrication, installation and operation. The ISO 14692 consists of 4 parts: Part 1: Vocabulary, symbols, applications and materials. Part 2: Qualification and manufacture. Part 3: System design. Part 4: Fabrication, installation and operation. ISO 14692-2, ISO 14692-3, ISO 14692-4, follow each individual phase in the life cycle of a GRP/GRE piping system, i.e. from design through manufacture to operation. Each part is therefore aimed at the relevant parties involved in that particular case. It is primarily intended for offshore applications on both fixed and floating topsides facilities, but may also be used as guidance for the specification, manufacture, testing and installation of GRP/GRE piping systems in other similar applications found onshore.
Ameron has obtained a Design Examination Statement from DNV. This examination statement consists out of a combination of two specifications namely: ISO 14692 and AWWA M45. ISO 14692 covers the design of suspended pipe systems and the qualification of GRP/GRE products, AWWA M45 covers the design and installation of buried pipe systems. Together these specifications cover all design and installation aspects. In cases the specifications conflict the ISO 14692 supersedes the AWWA. Therefore, on basis of this design examination statement the scope can include also application of GRP/GRE piping systems onshore (buried and suspended). Main s of the ISO 14692 document are: governments, end s, engineering companies, inspection companies, manufacturers, installers. The advantages of the ISO 14692 standard are: - Standardizing principles, norms, working methods. - Allows everybody to have the same understanding. - Main engineering and installation of GRP/GRE issues are handled. - Accepted by all engineering companies, third party inspection companies and governments. - Accepted in Europe by convention of Vienna and equal to CEN-standards. - Everybody speaks the same language. The disadvantages of the ISO 14692 standard are: - Needs thorough studying, the standard is certainly difficult. - For qualification, expensive tests are required. - Expensive quality control requirements.
Photo 1. Platform under construction
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3. Part 1: Vocabulary, symbols, applications and materials First part of the ISO 14692 gives the , definitions and symbols used. Main objective of this chapter is to achieve that every body speaks the same language. A few examples of common used abbreviations are given: • Composite pipe = pipe manufactured using fibre reinforced thermo set plastics • GRP = Glass Reinforced Plastics • GRE = Glass Reinforced Epoxy • Lower confidence limit, LCL = 97,5% confidence limit of the long-term hydrostatic pressure or stress based on a 20-year lifetime. • Jet fire = turbulent diffusion flame resulting from the combustion of a fuel continuously released with significant momentum in a particular range of directions.
• Impregnate = saturate the reinforcement with a resin. • Part factor f1 = ratio of the 97,5% confidence limit of the LTHP to the mean value of LTHP • LTHP = extrapolated long-term mean static failure pressure of a component with free ends based on a 20-year lifetime. • Part factor f2 = derating factor related to confidence in the pipe work system, the nature of the application and the consequence of failure. • Part factor f3 = part factor that takes of non-pressure-related axial loads, e.g. bending Furthermore, some general applications for GRP/GRE piping are given.
4. Part 2: Qualification of components Part 2 of the standard gives requirements for the qualification and manufacture of GRP/GRE piping and fittings.
4.1 Materials of construction and wall thickness limitations The GRP/GRE components shall be manufactured using a thermosetting resin such as epoxy, polyester, vinylester and phenolic. The reinforcement shall be glassfiber, e.g. continuous and/or woven rovings.
according ASTM D-2992 must be determined (witnessed by third party for example: DNV, Bureau Veritas). The test consists out of at least 18 samples. The test pieces are plain end pipes. The test setup is a closed end pressure vessel. Pipe samples are subject to different pressures. The test medium is water at 65 degrees C. The required failure mode is weeping. The failures shall be in different decades. Figure 2 gives an example of a regression line.
The minimum wall thickness shall be 3 mm for sizes 4 inch and above. The minimum wall thickness for sizes below 4 inch is defined as: WT / ID 0,025.
4.2 Qualification program An extensive qualification program is required to determine the performance of the GRP/GRE components with respect to pressure, temperature, chemical resistance, fire performance, electrostatic performance, impact etc. What has to be done to qualify a GRP/GRE piping system? For each product family (component type), a full regression line Figure 2. Regression curve
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Each product family (pipe, elbow, reducer, tee, flange) is divided into product sectors. Two representative samples, usually the biggest diameter and highest pressure class, from each product sector are taken and fully tested according ASTM 1598 (1000 hrs at 65 C). The test medium is water. The representative samples are called the product sector representatives.
A product sector contains all the items within its diameter and pressure range, the so called component variants. Component variants are qualified by either two 1000 hr tests or through the scaling method.
Table 1. Overview of product sectors Diameter (mm) Pressure range (bar) 0 - 50 50 - 100 100 -150 25 - 250 A H N 250 - 400 B I O 400 - 600 C J P 600 - 800 D K Q 800 - 1200 E L R
For calculation of the test pressure, the regression line of the pipe or the fitting is used. In absence of a regression line, a default value can be obtained from a table given in the ISO. For details on the calculation see the ISO document. In general the 1000 hr test is performed at about 2.5 to 3 times the design pressure. So a 20 bar system is tested around 50 to 60 bar.
> _ 150 S T
For quality control, short term tests could be performed, if required and agreed with the principal. These are done to establish a baseline value for quality control. Other aspects to be considered are: the glass transition temperature, the glass resin ratio and component dimensions. These have to be determined from the replicate samples and used by quality control during production as base line values.
4.3 Fire performance If required, fire testing shall be conducted on each piping material system. The performance of the piping system shall be qualified in accordance with the ISO procedure and a classification code shall be assigned.
4.4 Electrical conductivity If required, testing shall be carried out on each piping material system. The performance of the piping system shall be qualified in accordance with the ISO procedure and a classification code shall be assigned.
4.5 Quality program for manufacture Photo 2. Spool for 1000 hrs testing
The piping manufacturer shall have a suitable and accredited quality assurance and quality control system. Pipe and fittings furnished to ISO 14692 shall be tested according to the ISO standard. See chapter 10 for the list of deviations to the quality program.
Photo 3. Overview of elbows needed for qualification up to 8 inch
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Table 2. Overview of qualification tests needed Product sector A Component variant 2 inch Component variant 3 inch Component variant 4 inch Component variant 6 inch Product sector representative 8 inch Family representative QC baseline
Test standard ASTM D-1598 ASTM D-1598 ASTM D-1598 ASTM D-1598
2 2 2 2
ASTM D-2992 ASTM D-2992 ASTM D-1598
Pipes or scaling or scaling or scaling or scaling 2 18 5
2 2 2 2
Elbows or scaling or scaling or scaling or scaling 2 18 5
2 2 2 2
Tees or scaling or scaling or scaling or scaling
2 2 2 2
Flanges or scaling or scaling or scaling or scaling
2 18 5
2 18 5
5. Part 3: System design 5.1 Introduction/abstract
5.4 Hydraulic design
The design guidelines are handled in part 3 of the ISO 14692. The designer shall evaluate system layout requirements such as: • Space requirement (fitting dimensions). • Piping system . • Vulnerability. • The effect of fire (incl. blast) on the layout requirements should be considered. • Control of electrostatic discharge (depending on service and location).
The aim of hydraulic design is to ensure that GRP/GRE piping systems are capable of transporting the specified fluid at the specified rate, pressure and temperature throughout their intended service life.
5.2 Layout requirements In general the same types of fittings available in steel are also available in GRP. Note that the building dimensions of some GRP/GRE fittings can be larger compared to steel fittings.
5.3 distance Recommendations for system : • s spaced to limit sag (< 12.5 mm). • Valves and heavy equipment to be ed independently. • In general, connections to metallic piping systems shall be anchored. • Do not use GRP/GRE piping to other piping. • Use the flexibility of the material to accommodate axial expansion, provided the system is well anchored and guided.
Factors that limit the velocity are: • Unacceptable pressure losses. • Prevention of water hammer. • Prevent cavitation. • Reduction of erosion. • Reduction of noise. • Pipe diameter and geometry (inertia loading). Fluid velocity, fluid density, interior surface roughness of pipes and fittings, pipe length, inside diameter as well as resistance from valves and fittings shall be taken into when estimating pressure losses. The smooth surface of the GRP/GRE pipe may result in lower pressure losses compared to metal pipe. A full hydraulic surge analysis shall be carried out, if pressure transients are expected. The analysis shall cover all anticipated operating conditions including priming, actuated valves, pump testing, wash-down hoses, etc.
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5.5 Structural design
5.6 Stress analysis
Aim of structural design is to ensure that GRP/GRE piping systems shall sustain all stresses and deformations during construction/installation and throughout the service life.
Manual or computer methods can be used for structural analysis of piping systems.
Piping system design shall represent the most severe conditions experienced during installation and service life. Designers shall consider loads given in table 1 in the ISO document. Sustained loads: • Pressure (internal, external, vacuum, hydro-test). • Mass (self-mass, medium, insulation, etc). • Thermal induced loads. • Soil loads and soil subsidence. Occasional loads: • Earthquake. • Wind. • Water hammer.
Caesar II (by Coade) is commonly used to perform stress and flexibility analysis. The piping system can be evaluated for several load-cases. Load-cases can be setup from combinations of pressure, temperature, weight, wind load, displacement, earthquake etc. With the calculation output, the stresses in the piping system, the displacement, the loads on the , the load on equipment nozzles etc., can be checked.
The sum of all hoop stresses and the sum of all axial stresses in any component in the piping system shall lie within the longterm design envelope.
5.5.1 Determination of the failure envelope and the long-term design envelope In the ISO14692 document an algorithm is given how to determine the failure envelope and how the long term design envelope is developed. • Determine the short term failure envelope (1 or 2). • The idealized long term failure envelope (3) is geometrically similar to the short term envelope with all data points being scaled. This scaling factor (fscale) is derived using the long term regression line. • The non factored long term design envelope (4) is based on the idealized long term envelope multiplied by the part factor f2. • The factored long term design envelope (5) is derived by multiplication with A1, A2 and A3, where A1 is the de-rating factor for temperature, A2 is the de-rating factor for chemical resistance and A3 is the de-rating factor for cyclic service. Figure 3. Allowable stress curve
Photo 4. Installation of 54 km 18 inch pipe, pressure rating 20 bar
5.7 Fire performance The fire performance requirements of the piping system shall be determined. Fire performance is characterized in two properties: • Fire endurance (ability to continue to perform during fire). • Fire reaction (ignition time, flame spread, smoke and heat release, toxicity). If piping cannot satisfy the required fire properties, the following shall be considered: • Rerouting of piping. • Use alternative materials. • Apply suitable fire-protective coating.
5.8 Static electricity The use of a conductive piping system might be considered in case the GRP/GRE piping system is running in a hazardous area or if the pipe is carrying fluids capable of generating electrostatic charges.
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6. Part 4: Fabrication, installation and operation 6.1 Introduction Part 4 of the ISO 14692 gives requirements and recommendations for fabrication, installation and operation of GRP/GRE pipe systems. Past experience with GRP/GRE installations is that a great deal of the problems that occur are associated with bad fabrication and installation. One of the tools to detect fabrication and installation mistakes is to hydro test the GRP/GRE pipe system. In other words: to guarantee that a GRP/GRE pipe system is fit for purpose, it is common practice that a GRP/GRE pipe system is hydro tested as part of the commissioning procedure. This means that any possible problems are detected in a late phase in the project. Repairs in this late phase of the project can be costly and difficult due to limited access.
• Pipe spools. Take care that impact damage is prevented by proper packaging and use of protection material. In all cases pipe spools should not be stacked. • Adhesives. Check recommended storage temperatures. • O-rings, gaskets etc. shall be stored in a cool place, free from UV radiation, chemicals etc.
6.2.2 Installer requirements All GRP/GRE components shall be installed by qualified GRP/GRE pipe fitters and thereafter approved by a qualified GRP/GRE piping inspector.
Definitions: Pipe fitter Person working for a contractor who is responsible for the construction of the GRE pipe system. He must be able to make the relevant t types according Ameron procedures. This certificate can be compared to a welder’s certificate. Supervisor Person who is responsible for the quality of the installation and is able to check the quality of the work done by the pipe fitters. This person is normally employed by the responsible contractor for example as a foreman. This certificate is a personal certificate. QA/QC Inspector Person who is able: to check and judge the work of contractor and is able to globally the soundness of the installation. This includes lay-out related matters such as construction and location, flange connections etc. Can be employed by client, contractor, third party (BV, DNV, Lloyds). This certificate is a personal certificate.
Photo 5. Hydro-test of spool
6.2 Fabrication and installation What can be done to prevent/reduce the above problem?
6.2.1 Inspection It starts with checking the incoming goods • Check supplied quantity. • Check nominal dimensions of supplied material • Check supplied pressures class • Perform a visual control of supplied material (transport damage, impact) • Check if storage is correct • Check availability of documentation (packing lists, certification) Handling and storage of the incoming goods • Use the Ameron lifting, loading and unloading procedure. • Storage. Pay attention to the stacking of the pipe; width and stacking height, end protection of pipe and fittings. • Preferably, pipes should be transported in containers or crates.
Photo 6. Typical work of a GRE pipe fitter
Training of pipe fitter • The quality of the ts is mainly dependent on craftsmanship of the pipe fitter. Therefore, the ISO 14692 demands that the qualification organization is independent of the organization that carries out the training. In the case of Ameron the independent organization is DNV. The training consists of a theoretical and a practical part. • The theoretical part will end with a written exam for which a 70% mark is required. The practical part will end with making a t that will be hydro-tested according the requirements of the ISO 14692. These tests are witnessed
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by a third party. When ing both exams the pipe fitter will receive a pipe fitter certificate issued by DNV. • The purpose of the entire training is to teach the pipe fitter those things he or she can have influence on.
E.g.: • Impact > replace (major defect) or repair (minor defect) • Misaligned ts > replace components (major defect) remake t (minor defect)
Training of Supervisor - QA/QC inspector • Ameron and DNV are developing an individual certification for Supervisor - QA/QC inspector based on ISO 14692 requirements. Objective is to train Supervisor - QA/QC inspector on aspects like storage, inspection of pipes and fittings, ing, ting, hydro testing etc. etc. in such a way, that they can act as Supervisor - QA/QC inspector on a GRE pre-fabrication and installation job. An important factor is that they also learn what can go wrong. The educating company will be Ameron as they have in contrast to most institutes a large knowledge, obtained over decades, in this particular area. Examination committee will be DNV. The certificate that can be obtained will be a personal certificate.
6.2.3 Installation methods Installation method shall be according manufacturers approved installation manual. ing • Follow the installation guides from the Manufacturer. • Other guidelines not different from the Ameron procedures are given in the ISO 14692. Installation General requirements are given in the ISO 14692 for the installation of GRP/GRE components such as bending, bolt-torquing, tolerances, earthing of conductive piping, t selection, quality control, etc. Most important point is that all piping shall be installed so that they are stress-free. Quality program for installation The contractor shall maintain a high level of inspection to ensure compliance with all requirements. The contractor shall designate one individual to be responsible for quality control throughout the installation. Record of following items shall be made: starting and end time of the curing process; pipe fitter nr.; batch number of the adhesive and heating blanket; measured temperature of the heating blanket; ambient temperature, date, t number, relative humidity.
6.2.4 System testing All GRP/GRE piping systems shall be hydrostatically pressure tested after installation. Water shall be used as a test medium.
Photo 7. Spool fabrication shop
6.3 Maintenance and repair GRP/GRE pipes are generally maintenance free, but the following points shall be given attention during inspection and are addressed in the ISO document: - Removal of scale and blockages. - Electrical conductivity. - Surface and mechanical damage. - Chalking, ageing and erosion. - Flange cracks and leaks. Repair shall be in accordance with manufacturers procedures.
6.2.5 Visual inspection Visual inspection shall be carried out of all ts and surfaces. Possible defect along with acceptance criteria and corrective actions are given in the ISO document.
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7. Conclusion ISO 14692 is a worldwide accepted standard for the manufacturing, qualification, design and installation of Glassfiber Reinforced Epoxy piping systems. When the guidelines laid down in the ISO 14692 standard are followed, it will result in a trouble-free GRE pipe system.
8. ISO in brief ISO (International Organization for Standardization) is a global network that identifies what International Standards are required by business, government and society, develops them in partnership with the sectors, that will put them in use, adopts them by transparent procedures based on national input and delivers them to be implemented worldwide.
ISO – a non-governmental organization, is a federation of national standards, bodies of over 149 countries, one per country, from all regions of the world, including developed, developing and transitional economies.
ISO standards distil an international consensus from the broadest possible base of stake holder groups. Expert input comes from those closest to the needs for the standards and also the results of implementing them. In this way, although voluntary, ISO standards are widely respected and accepted by public and private sectors internationally.
9. References • ISO 14692-1 Petroleum and natural gas industries Glass-reinforced plastics (GRP) piping Part 1: Vocabulary, symbols, applications and materials; • ISO 14692-2 Petroleum and natural gas industries Glass-reinforced plastics (GRP) piping Part 2: Qualification and manufacture; • ISO 14692-3 Petroleum and natural gas industries Glass-reinforced plastics (GRP) piping Part 3: System design; • ISO 14692-4 Petroleum and natural gas industries Glass-reinforced plastics (GRP) piping Part 4: Fabrication, installation and operation.
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10. Deviations list to the ISO quality program 8.0 8.2
ISO 14692-2:2002(E) Quality programme for manufacture Calibration Quality Control equipment: Pressure gauges: • Accurate +/- 0,5% • Calibration every two months
Ameron Standard
• Accurate +/- 0.8%
8.3.2.2 Mill hydrostatic test 5% of continuous production (c.p.) =< 600mm 0,89 times qualified pressure > 600mm 0,75 times qualified pressure if pressure class > 32 bar = 100%
5% of total production. 1,5x Design Pressure
8.3.2.3 Spools frequency = 100% (if practicable)
5% (if practicable)
8.3.2.4 Retesting: by failures of one of both retested components, the whole lot to the latest successful hydrotest shall be rejected.
Only the failed components will be rejected. In case of rejected components, 100% will be conducted until the infected range has been determined
8.3.3
According to API 15LR.
Degree of cure: DSC according to ISO 11357-2 Determination of a QC baseline on base-resin or component. Frequency of 1% on c.p.
Min. acc. = 130 / 140 dgr.C Once per shift
8.3.4
Short-term burst test: Agreed with principal
Once per three months
8.3.5
Ongoing pressure tests: yearly 6x 1000hr. test from at least two product sectors
None
8.3.6
Glass content in accordance with ISO 1172 at a frequency of 1% of c.p. Acceptance: 70-82% for filament wound pipe 65-75% filament wound fittings 50-65% hand-lay-up fittings
In accordance with ASTM-D-2584 at a frequency of once a week random two types. Acceptance: 65-77% for filament wound pipe 55-65% for filament wound fittings
8.3.7.2 Visual Inspection: Table 12 and Table A1 of annexure A van ISO 14692-4:2002
ASTM-D-2563 (visual)
8.3.7.3 The principal shall be notified of all repairs
No notification
8.3.8.2 The following dimensions shall be determined in & accordance with ASTM D-3567 for 1% of pipe and 8.3.8.3 each fitting: a) Internal diameter b) Outside diameter c) Mass d) Minimum total wall thickness e) Reinforced wall thickness f) Laying length
Ameron conducts 100% inspection on outside diameter of pipe. Reinforced wall thickness is automatically determined by using fixed inside diameter. All dimensions and tolerances are in accordance with Ameron product drawings.
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8.3.8.4 The following dimensions shall be determined in accordance with ASTM D3567 for 1% of pipe and each fitting: a) Internal diameter b) Maximum outside diameter c) Reinforced wall thickness d) Relevant dimensions as described figure 1 e) Mass
Ameron conducts only 100% inspection on laying lengths and directions/ positions
8.3.9
Thread dimensions
N/A
8.3.10
Conductivity 105 Ω (100V)
Conductivity 106 Ω (500V)
8.3.11
Retest: by failures of one of both retested components, the whole batch to the latest successful test shall be rejected.
Only the failed components will be rejected. To avoid rejecting good products, Ameron will test all products to trace all infected products.
8.4.3
Records to be maintained by manufacturer: • Hydrotest reports • Dim.+Vis.+ cond. Reports • Tg • Glass content • Short term burst test report • Long term test report
Documentation available in QC/Engineering file
9.1
Markings shall be applied on the pipe and fittings within 1 m of the end.
Pipes 3 locations, Fitting one location
9.2
All pipe and fittings shall be permanently marked with details as in Para 9.2: a) Manufacturer’s name b) Product line designation c) Qualified pressure d) Temperature at which qualified pressure is determined (default is 65°C). e) System design pressure f) System design temperature g) Nominal diameter h) Manufacturer’s identification code i) Limitations or referenced to installation requirements: permissible bolt torque, portable water (yes/no), electrical conductivity and fire performance classification.
Pipes and fittings will be marked with: a) Manufacturer’s name b) Not c) Qualified pressure d) Not e) System design pressure f) System design temperature g) Nominal diameter h) Manufacturer’s identification code i) Not
11.4.2
Manufacturing procedure shall be provided if requested by the principal
Not allowed by Ameron
11.4.4
Production quality control reports in acc. 8.4 shall be provided within five working days or other agreed period
Special Manufacturing Record Book
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Group Headquarters Ameron International Corporation - Fiberglass-Composite Pipe Division 9720 Cypresswood Drive, Suite 325 - Houston, Texas 77070 - U.S.A. Phone: +1 832 912 8282 - Fax: +1 832 912 9393 E-mail: [email protected] - Website: http://www.ameron.com
U.S.A. Ameron International Corporation 1004 Ameron Road P.O. Box 878 Burkburnett, Texas 76364 U.S.A. Phone: +1 940 569 1471 Fax: +1 940 569 2764
U.S.A. Centron International, Inc. P.O. Box 490 600 FM 1195 South Mineral Wells - Texas 76068 U.S.A. Phone: +1 940 325 1341 Fax: +1 940 325 9681 E-mail: [email protected] Website: http://www.centrongre.com
Europe Ameron B.V. Fiberglass-Composite Pipe P.O. Box 6 4190 CA Geldermalsen The Netherlands Phone: +31 345 587 587 Fax: +31 345 587 561 E-mail: [email protected] Website: http://www.ameron-fpg.nl
Asia Ameron (Pte) Ltd No. 7A, Tuas Avenue 3 Jurong Singapore 639407 Phone: +65 6861 6118 Fax: +65 6862 1302/6861 7834 E-mail: [email protected] Website: http://www.ameron.com.sg
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QUICK GUIDE INTO ISO 14692 1. Introduction ISO (the International Organization for Standardization) is a worldwide network of national standard institutes. The ISO 14692 standard is an international standard dealing with the qualification, manufacturing, design and installation of GRE piping systems. This document gives a brief summary of the ISO 14692 standard only and is not intended to replace the ISO 14692 standard. To ensure a trouble free GRE pipe system, three major important conditions must be met: 1. Use qualified products. 2. Perform system design. 3. Install according to manufacturers standards and guidelines.
Qualification
The above mentioned three points are addressed in the ISO 14692 Standard in Part 2, Part 3 and Part 4 respectively.
Troublefree pipe system
System design
Installation Figure 1. The key to success
Content 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Introduction What is ISO 14692? Part 1: Vocabulary, symbols, applications and materials Part 2: Qualification of components Part 3: System design Part 4: Fabrication, installation and operation Conclusion ISO in brief References Deviations list to the ISO quality program
1 2 3 3 5 7 9 9 9 10
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2. What is ISO 14692? ISO 14692, is an international standard dealing with the qualification of fittings, ts and pipes for certain applications. It describes how to qualify and manufacture GRP/GRE (Glass Reinforced Epoxy) pipe and fittings, how to conduct system design and finally it gives guidelines for fabrication, installation and operation. The ISO 14692 consists of 4 parts: Part 1: Vocabulary, symbols, applications and materials. Part 2: Qualification and manufacture. Part 3: System design. Part 4: Fabrication, installation and operation. ISO 14692-2, ISO 14692-3, ISO 14692-4, follow each individual phase in the life cycle of a GRP/GRE piping system, i.e. from design through manufacture to operation. Each part is therefore aimed at the relevant parties involved in that particular case. It is primarily intended for offshore applications on both fixed and floating topsides facilities, but may also be used as guidance for the specification, manufacture, testing and installation of GRP/GRE piping systems in other similar applications found onshore.
Ameron has obtained a Design Examination Statement from DNV. This examination statement consists out of a combination of two specifications namely: ISO 14692 and AWWA M45. ISO 14692 covers the design of suspended pipe systems and the qualification of GRP/GRE products, AWWA M45 covers the design and installation of buried pipe systems. Together these specifications cover all design and installation aspects. In cases the specifications conflict the ISO 14692 supersedes the AWWA. Therefore, on basis of this design examination statement the scope can include also application of GRP/GRE piping systems onshore (buried and suspended). Main s of the ISO 14692 document are: governments, end s, engineering companies, inspection companies, manufacturers, installers. The advantages of the ISO 14692 standard are: - Standardizing principles, norms, working methods. - Allows everybody to have the same understanding. - Main engineering and installation of GRP/GRE issues are handled. - Accepted by all engineering companies, third party inspection companies and governments. - Accepted in Europe by convention of Vienna and equal to CEN-standards. - Everybody speaks the same language. The disadvantages of the ISO 14692 standard are: - Needs thorough studying, the standard is certainly difficult. - For qualification, expensive tests are required. - Expensive quality control requirements.
Photo 1. Platform under construction
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3. Part 1: Vocabulary, symbols, applications and materials First part of the ISO 14692 gives the , definitions and symbols used. Main objective of this chapter is to achieve that every body speaks the same language. A few examples of common used abbreviations are given: • Composite pipe = pipe manufactured using fibre reinforced thermo set plastics • GRP = Glass Reinforced Plastics • GRE = Glass Reinforced Epoxy • Lower confidence limit, LCL = 97,5% confidence limit of the long-term hydrostatic pressure or stress based on a 20-year lifetime. • Jet fire = turbulent diffusion flame resulting from the combustion of a fuel continuously released with significant momentum in a particular range of directions.
• Impregnate = saturate the reinforcement with a resin. • Part factor f1 = ratio of the 97,5% confidence limit of the LTHP to the mean value of LTHP • LTHP = extrapolated long-term mean static failure pressure of a component with free ends based on a 20-year lifetime. • Part factor f2 = derating factor related to confidence in the pipe work system, the nature of the application and the consequence of failure. • Part factor f3 = part factor that takes of non-pressure-related axial loads, e.g. bending Furthermore, some general applications for GRP/GRE piping are given.
4. Part 2: Qualification of components Part 2 of the standard gives requirements for the qualification and manufacture of GRP/GRE piping and fittings.
4.1 Materials of construction and wall thickness limitations The GRP/GRE components shall be manufactured using a thermosetting resin such as epoxy, polyester, vinylester and phenolic. The reinforcement shall be glassfiber, e.g. continuous and/or woven rovings.
according ASTM D-2992 must be determined (witnessed by third party for example: DNV, Bureau Veritas). The test consists out of at least 18 samples. The test pieces are plain end pipes. The test setup is a closed end pressure vessel. Pipe samples are subject to different pressures. The test medium is water at 65 degrees C. The required failure mode is weeping. The failures shall be in different decades. Figure 2 gives an example of a regression line.
The minimum wall thickness shall be 3 mm for sizes 4 inch and above. The minimum wall thickness for sizes below 4 inch is defined as: WT / ID 0,025.
4.2 Qualification program An extensive qualification program is required to determine the performance of the GRP/GRE components with respect to pressure, temperature, chemical resistance, fire performance, electrostatic performance, impact etc. What has to be done to qualify a GRP/GRE piping system? For each product family (component type), a full regression line Figure 2. Regression curve
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Each product family (pipe, elbow, reducer, tee, flange) is divided into product sectors. Two representative samples, usually the biggest diameter and highest pressure class, from each product sector are taken and fully tested according ASTM 1598 (1000 hrs at 65 C). The test medium is water. The representative samples are called the product sector representatives.
A product sector contains all the items within its diameter and pressure range, the so called component variants. Component variants are qualified by either two 1000 hr tests or through the scaling method.
Table 1. Overview of product sectors Diameter (mm) Pressure range (bar) 0 - 50 50 - 100 100 -150 25 - 250 A H N 250 - 400 B I O 400 - 600 C J P 600 - 800 D K Q 800 - 1200 E L R
For calculation of the test pressure, the regression line of the pipe or the fitting is used. In absence of a regression line, a default value can be obtained from a table given in the ISO. For details on the calculation see the ISO document. In general the 1000 hr test is performed at about 2.5 to 3 times the design pressure. So a 20 bar system is tested around 50 to 60 bar.
> _ 150 S T
For quality control, short term tests could be performed, if required and agreed with the principal. These are done to establish a baseline value for quality control. Other aspects to be considered are: the glass transition temperature, the glass resin ratio and component dimensions. These have to be determined from the replicate samples and used by quality control during production as base line values.
4.3 Fire performance If required, fire testing shall be conducted on each piping material system. The performance of the piping system shall be qualified in accordance with the ISO procedure and a classification code shall be assigned.
4.4 Electrical conductivity If required, testing shall be carried out on each piping material system. The performance of the piping system shall be qualified in accordance with the ISO procedure and a classification code shall be assigned.
4.5 Quality program for manufacture Photo 2. Spool for 1000 hrs testing
The piping manufacturer shall have a suitable and accredited quality assurance and quality control system. Pipe and fittings furnished to ISO 14692 shall be tested according to the ISO standard. See chapter 10 for the list of deviations to the quality program.
Photo 3. Overview of elbows needed for qualification up to 8 inch
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Table 2. Overview of qualification tests needed Product sector A Component variant 2 inch Component variant 3 inch Component variant 4 inch Component variant 6 inch Product sector representative 8 inch Family representative QC baseline
Test standard ASTM D-1598 ASTM D-1598 ASTM D-1598 ASTM D-1598
2 2 2 2
ASTM D-2992 ASTM D-2992 ASTM D-1598
Pipes or scaling or scaling or scaling or scaling 2 18 5
2 2 2 2
Elbows or scaling or scaling or scaling or scaling 2 18 5
2 2 2 2
Tees or scaling or scaling or scaling or scaling
2 2 2 2
Flanges or scaling or scaling or scaling or scaling
2 18 5
2 18 5
5. Part 3: System design 5.1 Introduction/abstract
5.4 Hydraulic design
The design guidelines are handled in part 3 of the ISO 14692. The designer shall evaluate system layout requirements such as: • Space requirement (fitting dimensions). • Piping system . • Vulnerability. • The effect of fire (incl. blast) on the layout requirements should be considered. • Control of electrostatic discharge (depending on service and location).
The aim of hydraulic design is to ensure that GRP/GRE piping systems are capable of transporting the specified fluid at the specified rate, pressure and temperature throughout their intended service life.
5.2 Layout requirements In general the same types of fittings available in steel are also available in GRP. Note that the building dimensions of some GRP/GRE fittings can be larger compared to steel fittings.
5.3 distance Recommendations for system : • s spaced to limit sag (< 12.5 mm). • Valves and heavy equipment to be ed independently. • In general, connections to metallic piping systems shall be anchored. • Do not use GRP/GRE piping to other piping. • Use the flexibility of the material to accommodate axial expansion, provided the system is well anchored and guided.
Factors that limit the velocity are: • Unacceptable pressure losses. • Prevention of water hammer. • Prevent cavitation. • Reduction of erosion. • Reduction of noise. • Pipe diameter and geometry (inertia loading). Fluid velocity, fluid density, interior surface roughness of pipes and fittings, pipe length, inside diameter as well as resistance from valves and fittings shall be taken into when estimating pressure losses. The smooth surface of the GRP/GRE pipe may result in lower pressure losses compared to metal pipe. A full hydraulic surge analysis shall be carried out, if pressure transients are expected. The analysis shall cover all anticipated operating conditions including priming, actuated valves, pump testing, wash-down hoses, etc.
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5.5 Structural design
5.6 Stress analysis
Aim of structural design is to ensure that GRP/GRE piping systems shall sustain all stresses and deformations during construction/installation and throughout the service life.
Manual or computer methods can be used for structural analysis of piping systems.
Piping system design shall represent the most severe conditions experienced during installation and service life. Designers shall consider loads given in table 1 in the ISO document. Sustained loads: • Pressure (internal, external, vacuum, hydro-test). • Mass (self-mass, medium, insulation, etc). • Thermal induced loads. • Soil loads and soil subsidence. Occasional loads: • Earthquake. • Wind. • Water hammer.
Caesar II (by Coade) is commonly used to perform stress and flexibility analysis. The piping system can be evaluated for several load-cases. Load-cases can be setup from combinations of pressure, temperature, weight, wind load, displacement, earthquake etc. With the calculation output, the stresses in the piping system, the displacement, the loads on the , the load on equipment nozzles etc., can be checked.
The sum of all hoop stresses and the sum of all axial stresses in any component in the piping system shall lie within the longterm design envelope.
5.5.1 Determination of the failure envelope and the long-term design envelope In the ISO14692 document an algorithm is given how to determine the failure envelope and how the long term design envelope is developed. • Determine the short term failure envelope (1 or 2). • The idealized long term failure envelope (3) is geometrically similar to the short term envelope with all data points being scaled. This scaling factor (fscale) is derived using the long term regression line. • The non factored long term design envelope (4) is based on the idealized long term envelope multiplied by the part factor f2. • The factored long term design envelope (5) is derived by multiplication with A1, A2 and A3, where A1 is the de-rating factor for temperature, A2 is the de-rating factor for chemical resistance and A3 is the de-rating factor for cyclic service. Figure 3. Allowable stress curve
Photo 4. Installation of 54 km 18 inch pipe, pressure rating 20 bar
5.7 Fire performance The fire performance requirements of the piping system shall be determined. Fire performance is characterized in two properties: • Fire endurance (ability to continue to perform during fire). • Fire reaction (ignition time, flame spread, smoke and heat release, toxicity). If piping cannot satisfy the required fire properties, the following shall be considered: • Rerouting of piping. • Use alternative materials. • Apply suitable fire-protective coating.
5.8 Static electricity The use of a conductive piping system might be considered in case the GRP/GRE piping system is running in a hazardous area or if the pipe is carrying fluids capable of generating electrostatic charges.
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6. Part 4: Fabrication, installation and operation 6.1 Introduction Part 4 of the ISO 14692 gives requirements and recommendations for fabrication, installation and operation of GRP/GRE pipe systems. Past experience with GRP/GRE installations is that a great deal of the problems that occur are associated with bad fabrication and installation. One of the tools to detect fabrication and installation mistakes is to hydro test the GRP/GRE pipe system. In other words: to guarantee that a GRP/GRE pipe system is fit for purpose, it is common practice that a GRP/GRE pipe system is hydro tested as part of the commissioning procedure. This means that any possible problems are detected in a late phase in the project. Repairs in this late phase of the project can be costly and difficult due to limited access.
• Pipe spools. Take care that impact damage is prevented by proper packaging and use of protection material. In all cases pipe spools should not be stacked. • Adhesives. Check recommended storage temperatures. • O-rings, gaskets etc. shall be stored in a cool place, free from UV radiation, chemicals etc.
6.2.2 Installer requirements All GRP/GRE components shall be installed by qualified GRP/GRE pipe fitters and thereafter approved by a qualified GRP/GRE piping inspector.
Definitions: Pipe fitter Person working for a contractor who is responsible for the construction of the GRE pipe system. He must be able to make the relevant t types according Ameron procedures. This certificate can be compared to a welder’s certificate. Supervisor Person who is responsible for the quality of the installation and is able to check the quality of the work done by the pipe fitters. This person is normally employed by the responsible contractor for example as a foreman. This certificate is a personal certificate. QA/QC Inspector Person who is able: to check and judge the work of contractor and is able to globally the soundness of the installation. This includes lay-out related matters such as construction and location, flange connections etc. Can be employed by client, contractor, third party (BV, DNV, Lloyds). This certificate is a personal certificate.
Photo 5. Hydro-test of spool
6.2 Fabrication and installation What can be done to prevent/reduce the above problem?
6.2.1 Inspection It starts with checking the incoming goods • Check supplied quantity. • Check nominal dimensions of supplied material • Check supplied pressures class • Perform a visual control of supplied material (transport damage, impact) • Check if storage is correct • Check availability of documentation (packing lists, certification) Handling and storage of the incoming goods • Use the Ameron lifting, loading and unloading procedure. • Storage. Pay attention to the stacking of the pipe; width and stacking height, end protection of pipe and fittings. • Preferably, pipes should be transported in containers or crates.
Photo 6. Typical work of a GRE pipe fitter
Training of pipe fitter • The quality of the ts is mainly dependent on craftsmanship of the pipe fitter. Therefore, the ISO 14692 demands that the qualification organization is independent of the organization that carries out the training. In the case of Ameron the independent organization is DNV. The training consists of a theoretical and a practical part. • The theoretical part will end with a written exam for which a 70% mark is required. The practical part will end with making a t that will be hydro-tested according the requirements of the ISO 14692. These tests are witnessed
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by a third party. When ing both exams the pipe fitter will receive a pipe fitter certificate issued by DNV. • The purpose of the entire training is to teach the pipe fitter those things he or she can have influence on.
E.g.: • Impact > replace (major defect) or repair (minor defect) • Misaligned ts > replace components (major defect) remake t (minor defect)
Training of Supervisor - QA/QC inspector • Ameron and DNV are developing an individual certification for Supervisor - QA/QC inspector based on ISO 14692 requirements. Objective is to train Supervisor - QA/QC inspector on aspects like storage, inspection of pipes and fittings, ing, ting, hydro testing etc. etc. in such a way, that they can act as Supervisor - QA/QC inspector on a GRE pre-fabrication and installation job. An important factor is that they also learn what can go wrong. The educating company will be Ameron as they have in contrast to most institutes a large knowledge, obtained over decades, in this particular area. Examination committee will be DNV. The certificate that can be obtained will be a personal certificate.
6.2.3 Installation methods Installation method shall be according manufacturers approved installation manual. ing • Follow the installation guides from the Manufacturer. • Other guidelines not different from the Ameron procedures are given in the ISO 14692. Installation General requirements are given in the ISO 14692 for the installation of GRP/GRE components such as bending, bolt-torquing, tolerances, earthing of conductive piping, t selection, quality control, etc. Most important point is that all piping shall be installed so that they are stress-free. Quality program for installation The contractor shall maintain a high level of inspection to ensure compliance with all requirements. The contractor shall designate one individual to be responsible for quality control throughout the installation. Record of following items shall be made: starting and end time of the curing process; pipe fitter nr.; batch number of the adhesive and heating blanket; measured temperature of the heating blanket; ambient temperature, date, t number, relative humidity.
6.2.4 System testing All GRP/GRE piping systems shall be hydrostatically pressure tested after installation. Water shall be used as a test medium.
Photo 7. Spool fabrication shop
6.3 Maintenance and repair GRP/GRE pipes are generally maintenance free, but the following points shall be given attention during inspection and are addressed in the ISO document: - Removal of scale and blockages. - Electrical conductivity. - Surface and mechanical damage. - Chalking, ageing and erosion. - Flange cracks and leaks. Repair shall be in accordance with manufacturers procedures.
6.2.5 Visual inspection Visual inspection shall be carried out of all ts and surfaces. Possible defect along with acceptance criteria and corrective actions are given in the ISO document.
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7. Conclusion ISO 14692 is a worldwide accepted standard for the manufacturing, qualification, design and installation of Glassfiber Reinforced Epoxy piping systems. When the guidelines laid down in the ISO 14692 standard are followed, it will result in a trouble-free GRE pipe system.
8. ISO in brief ISO (International Organization for Standardization) is a global network that identifies what International Standards are required by business, government and society, develops them in partnership with the sectors, that will put them in use, adopts them by transparent procedures based on national input and delivers them to be implemented worldwide.
ISO – a non-governmental organization, is a federation of national standards, bodies of over 149 countries, one per country, from all regions of the world, including developed, developing and transitional economies.
ISO standards distil an international consensus from the broadest possible base of stake holder groups. Expert input comes from those closest to the needs for the standards and also the results of implementing them. In this way, although voluntary, ISO standards are widely respected and accepted by public and private sectors internationally.
9. References • ISO 14692-1 Petroleum and natural gas industries Glass-reinforced plastics (GRP) piping Part 1: Vocabulary, symbols, applications and materials; • ISO 14692-2 Petroleum and natural gas industries Glass-reinforced plastics (GRP) piping Part 2: Qualification and manufacture; • ISO 14692-3 Petroleum and natural gas industries Glass-reinforced plastics (GRP) piping Part 3: System design; • ISO 14692-4 Petroleum and natural gas industries Glass-reinforced plastics (GRP) piping Part 4: Fabrication, installation and operation.
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10. Deviations list to the ISO quality program 8.0 8.2
ISO 14692-2:2002(E) Quality programme for manufacture Calibration Quality Control equipment: Pressure gauges: • Accurate +/- 0,5% • Calibration every two months
Ameron Standard
• Accurate +/- 0.8%
8.3.2.2 Mill hydrostatic test 5% of continuous production (c.p.) =< 600mm 0,89 times qualified pressure > 600mm 0,75 times qualified pressure if pressure class > 32 bar = 100%
5% of total production. 1,5x Design Pressure
8.3.2.3 Spools frequency = 100% (if practicable)
5% (if practicable)
8.3.2.4 Retesting: by failures of one of both retested components, the whole lot to the latest successful hydrotest shall be rejected.
Only the failed components will be rejected. In case of rejected components, 100% will be conducted until the infected range has been determined
8.3.3
According to API 15LR.
Degree of cure: DSC according to ISO 11357-2 Determination of a QC baseline on base-resin or component. Frequency of 1% on c.p.
Min. acc. = 130 / 140 dgr.C Once per shift
8.3.4
Short-term burst test: Agreed with principal
Once per three months
8.3.5
Ongoing pressure tests: yearly 6x 1000hr. test from at least two product sectors
None
8.3.6
Glass content in accordance with ISO 1172 at a frequency of 1% of c.p. Acceptance: 70-82% for filament wound pipe 65-75% filament wound fittings 50-65% hand-lay-up fittings
In accordance with ASTM-D-2584 at a frequency of once a week random two types. Acceptance: 65-77% for filament wound pipe 55-65% for filament wound fittings
8.3.7.2 Visual Inspection: Table 12 and Table A1 of annexure A van ISO 14692-4:2002
ASTM-D-2563 (visual)
8.3.7.3 The principal shall be notified of all repairs
No notification
8.3.8.2 The following dimensions shall be determined in & accordance with ASTM D-3567 for 1% of pipe and 8.3.8.3 each fitting: a) Internal diameter b) Outside diameter c) Mass d) Minimum total wall thickness e) Reinforced wall thickness f) Laying length
Ameron conducts 100% inspection on outside diameter of pipe. Reinforced wall thickness is automatically determined by using fixed inside diameter. All dimensions and tolerances are in accordance with Ameron product drawings.
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8.3.8.4 The following dimensions shall be determined in accordance with ASTM D3567 for 1% of pipe and each fitting: a) Internal diameter b) Maximum outside diameter c) Reinforced wall thickness d) Relevant dimensions as described figure 1 e) Mass
Ameron conducts only 100% inspection on laying lengths and directions/ positions
8.3.9
Thread dimensions
N/A
8.3.10
Conductivity 105 Ω (100V)
Conductivity 106 Ω (500V)
8.3.11
Retest: by failures of one of both retested components, the whole batch to the latest successful test shall be rejected.
Only the failed components will be rejected. To avoid rejecting good products, Ameron will test all products to trace all infected products.
8.4.3
Records to be maintained by manufacturer: • Hydrotest reports • Dim.+Vis.+ cond. Reports • Tg • Glass content • Short term burst test report • Long term test report
Documentation available in QC/Engineering file
9.1
Markings shall be applied on the pipe and fittings within 1 m of the end.
Pipes 3 locations, Fitting one location
9.2
All pipe and fittings shall be permanently marked with details as in Para 9.2: a) Manufacturer’s name b) Product line designation c) Qualified pressure d) Temperature at which qualified pressure is determined (default is 65°C). e) System design pressure f) System design temperature g) Nominal diameter h) Manufacturer’s identification code i) Limitations or referenced to installation requirements: permissible bolt torque, portable water (yes/no), electrical conductivity and fire performance classification.
Pipes and fittings will be marked with: a) Manufacturer’s name b) Not c) Qualified pressure d) Not e) System design pressure f) System design temperature g) Nominal diameter h) Manufacturer’s identification code i) Not
11.4.2
Manufacturing procedure shall be provided if requested by the principal
Not allowed by Ameron
11.4.4
Production quality control reports in acc. 8.4 shall be provided within five working days or other agreed period
Special Manufacturing Record Book
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Group Headquarters Ameron International Corporation - Fiberglass-Composite Pipe Division 9720 Cypresswood Drive, Suite 325 - Houston, Texas 77070 - U.S.A. Phone: +1 832 912 8282 - Fax: +1 832 912 9393 E-mail: [email protected] - Website: http://www.ameron.com
U.S.A. Ameron International Corporation 1004 Ameron Road P.O. Box 878 Burkburnett, Texas 76364 U.S.A. Phone: +1 940 569 1471 Fax: +1 940 569 2764
U.S.A. Centron International, Inc. P.O. Box 490 600 FM 1195 South Mineral Wells - Texas 76068 U.S.A. Phone: +1 940 325 1341 Fax: +1 940 325 9681 E-mail: [email protected] Website: http://www.centrongre.com
Europe Ameron B.V. Fiberglass-Composite Pipe P.O. Box 6 4190 CA Geldermalsen The Netherlands Phone: +31 345 587 587 Fax: +31 345 587 561 E-mail: [email protected] Website: http://www.ameron-fpg.nl
Asia Ameron (Pte) Ltd No. 7A, Tuas Avenue 3 Jurong Singapore 639407 Phone: +65 6861 6118 Fax: +65 6862 1302/6861 7834 E-mail: [email protected] Website: http://www.ameron.com.sg
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