Material Characterization of Buried GFRP Pipeline Failed during Hydrostatic T...
Ges01202
1. GES-012-02
GENERAL ENGINEERING SPECIFICATION
FOR
NON-METALLIC PIPING AND COMPONENTS
4 ISSUE FOR RECORD
3A 09/10/98 ISSUE FOR CLIENT APPROVAL AB ST
3 11/11/97 ISSUE FOR CLIENT SIGNATURE
2 10/22/97 ISSUE FOR CLIENT SIGNATURE UVP
1 09/17/97 FINAL UVP
0 08/14/97 ISSUE FOR APPROVAL UVP
REV DATE DESCRIPTION PREPARED REVIEWED APPROVED
ARABIAN PETROCHEMICAL COMPANY
PETROKEMYA
This document is the property of Arabian Petrochemical Company (PETROKEMYA). The
technical information herein may not be used nor reproduced without the written permission
of PETROKEMYA
GES NO. TITLE REV. NO. PAGE NO.
GES-012-02 NON-METALLIC PIPING AND COMPONENTS 4 1 of 14
3. Petrokemya GES-012-02
Non-Metallic Piping and Components
Rev. 4
October, 1999 Page 3 of 14
1. SCOPE
This specification covers the general requirements for design, materials, fabrication, erection,
test and inspection of non-metallic piping systems including fiberglass reinforced pipe and
piping components, polyvinyl chloride pipe and piping components and prestressed concrete
pipe and piping components.
2. REFERENCE
The requirements contained in the latest edition of the following codes and standards shall form
a part of the requirements of this specification in the manner and to the extent indicated herein:
• ASME B1.20.1
• ASME B31.3
Pipe Threads, General Purpose (Inch)
Petroleum Refinery Piping (Latest Edition)
• ASME B16.1 Cast Iron Pipe Flanges and Flanged Fittings
• ASME B16.5 Steel Pipe Flanges
• AWWA C301 Prestressed Concrete Pressure Pipe., Steel-Cylinder type,
for water and other liquids
• AWWA C900 Standard for Polyvinyl Chloride (PVC) Pressure Pipe 4 in.
through 12 in. for water
• AWWA C950 AWWA Standard for Fiberglass Pressure Pipe
• AWWA Manual M9 Concrete Pressure Pipe
• ASTM D 1598 Test Method for Time-to-Failure of Plastic Pipe under
Constant Internal Pressure
• ASTM D 1599 Test Method for Short-time Rupture Strength of Plastic
Pipe, Tubing, and Fittings
• ASTM D 1784 Specification for Rigid Polyvinyl Chloride (PVC)
Compounds and Chlorinated Polyvinyl Chloride
Compounds
• ASTM D 1785 Specification for Polyvinyl Chloride (PVC) Plastic Pipe,
Schedules 40, 80, and 120
4. Petrokemya GES-012-02
Non-Metallic Piping and Components
Rev. 4
October, 1999 Page 4 of 14
• ASTM D 1898 Recommended Practice for Sampling Plastics.
• ASTM D2105 Standard Test Method for Longitudinal Tensile Properties
of ‘Fiberglass’ (Glass-Fiber-Reinforced Thermosetting-
Resin) Pipe and Tube
• ASTM D 2122 Method of Determining Dimensions of Thermoplastic Pipe
and Fittings
• ASTM D 2241 Specification for Polyvinyl Chloride Plastic Pipe
• ASTM D 2290 Test Method for Apparent Tensile Strength of Ring or
Tubular Plastics
• ASTM D2310 Standard Classification for Machine-Made ‘Fiberglass’
(Glass-Fiber-Reinforced Thermosetting-Resin) Pipe.
• ASTM D 2412 Test Method for External Loading Properties of Plastic
Pipe by Parallel Plate Loading
• ASTM D 2467 Specification for Socket-Type Polyvinyl Chloride (PVC)
Plastic Pipe Fittings
• ASTM D2513 Thermoplastic Gas Pressure Pipe, Tubing and Fittings
• ASTM D2517 Reinforced Epoxy Resin Gas Pressure Pipe and Fittings
• ASTM D 2563 Classifying Visual Defects in Glass Reinforced Laminate
Parts
• ASTM D 2564 Specification for Solvent Cements for Polyvinyl Chloride
(PVC) Plastic Pipe and Fittings
• ASTM D 2583 Test for Indentation Hardness of Rigid Plastic by Means of
a Barcol Impressor
• ASTM D 2584 Ignition Loss of Cured, Reinforced Resins
• ASTM D 2672 Specification for Bell-End Polyvinyl Chloride (PVC) Pipe
• ASTM D 2837 Method for Obtaining Hydrostatic Design Basis for
Thermoplastic Pipe Materials
5. Petrokemya GES-012-02
Non-Metallic Piping and Components
Rev. 4
October, 1999 Page 5 of 14
• ASTM D 2992 Standard Method of Obtaining Hydrostatic Design Basis
for “Fiberglass” (Glass Fiber-Reinforced Thermosetting
Resin) Pipe and Fittings
• ASTM D 2995 Filament wound “Fiberglass (Glass-Fiber-Thermosetting
Resin)
• ASTM D 2996 Filament Wound Fiberglass RTR Pipe
• ASTM D 2997 Standard Specification for Centrifugally Cast ‘Fiberglass’
(Glass-Fiber-Reinforced Thermosetting-Resin) Pipe.
Applicable for 1 in. through 14 in. (25 mm through 350
mm) pipe of polyester or epoxy resins.
• ASTM D 3139 Specification for Joints for Plastic Pressure Pipes Using
Flexible Elastometric Seals
• ASTM D 3262 Specification for “Fiberglass” (Glass-Fiber-Reinforced
Thermosetting Resin) Sewer Pipe
• ASTM D 3517 Standard Specification for ‘Fiberglass’ (Glass-Fiber-
Reinforced Thermosetting-Resin) Pressure Pipe.
Applicable for pipes 8 in. through 144 in. (200 mm through
3,600 mm) diameter, with or without siliceous sand, and
polyester or epoxy resin
• ASTM D 3567 Standard Method for Determining Dimension of
“Fiberglass” (Glass Fiber-Reinforced Thermosetting Resin)
Pipe and Fittings
• ASTM D 3681 Standard Test Method for Chemical Resistance of
“Fiberglass” (Glass Fiber-Reinforced Thermosetting Resin)
Pipe in a Deflected Condition
• ASTM D 3754 Standard Specification for Fiberglass (Glass- Fiber-
Reinforced Thermosetting-Resin) Sewer and Industrial
Pressure Pipe
• ASTM D 3839 Standard Practice for Underground Installation of
‘Fiberglass’ (Glass-Fiber-Reinforced Thermosetting-Resin)
Pipe
6. Petrokemya GES-012-02
Non-Metallic Piping and Components
Rev. 4
October, 1999 Page 6 of 14
• ASTM D 4161 Specification for ‘Fiberglass’ Glass-Fiber-Reinforced
Thermosetting-Resin Pipe Joints using Flexible
Elastometric Seals
• ASTM F 437 Rev. A Standard Specification for Threaded Chlorinated Poly
(Vinyl Chloride) (CPVC) Plastic Pipe Fitttings, Schedule
80
• ASTM F 438 Rev. A Standard Specification for Socket-Type Chlorinated Poly
(Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 40
• ASTM F 439 Rev. B Standard Specification for Socket-Type Chlorinated Poly
(Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 80
• ASTM F 441/F441M
Rev. 2
Standard Specification for Chlorinated Poly (Vinyl
Chloride) (CPVC) Plastic Pipe, Schedules 40 and 80
• ASTM F 477 Standard Specification for Elastomeric Seals (Gaskets) for
Joining Plastic Pipe
• ASTM F 493 Standard Specification for Solvent Cements for
Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe
and Fittings
• ASCE WPCF Manual of Practice, No. 9 Design and Construction
of Sanitary and Storm Sewers
General Engineering Specification
• GES-001 Design Requirements
• GES-012-01 Piping
• GES-013-02 Sewer System
• GES-016 Plumbing
• GES-024 Threads, and Bolts and Nuts
• GES-025-01 Inspection
• GES-025-02 Alloy Verification
7. Petrokemya GES-012-02
Non-Metallic Piping and Components
Rev. 4
October, 1999 Page 7 of 14
3. GENERAL
1) When there is a conflict among the requirements of the Project Specification and this
specification, the requirements of Project Specification shall govern.
2) When there is a conflict among the requirements of the applicable standards and this
specification, the requirements herein shall govern.
3) All drawings and documents shall be based on combination of modified metric and US
customary units as specified in GES-001, paragraph 3.3.
4. DESIGN
4.1 GENERAL
1) All piping shall be designed, fabricated and installed by a qualified contractor in
accordance with this specification, individual job specifications and procedures
approved by OWNER.
2) Non-metallic piping shall generally be used for underground applications as it precludes
the necessity of outside coating/wrapping and cathodic protection.
3) In case, specific project requirements dictate the need or feasibility for above ground
installation of non-metallic piping, special attention is to be paid to design and layout for
its protection from mechanical damage and ultraviolet rays. Care is also to be exercised
in the design of supporting system to avoid over stress of piping.
4.2 DESIGN CONDITIONS
Except for the specific line conditions, design conditions for underground piping are as follows:
1) Typical soil conditions at pipe depth:
• Soil Type (Note 1) Coarse-grained soils with little or no
........................... fines
• Compaction (Note 1, 2) Slight; 40% relative density
• Type of installation (Note-2) Coarse-grained, shaped bedding with
slightly compacted backfill
material placed at the sides of the
pipe; 40-70% relative density
• Groundwater Level (Note 1) 1500mm below ground level
• Soil specific weight (Note 2). 1,900 kg/m3
2) Burial Depth to top of pipe (unless dictated by specific project requirements and
designed accordingly)
3000mm (Note 3) Maximum
1500mm (Note 3). Minimum
3) Live loads for road crossing only (Note 3)
8. Petrokemya GES-012-02
Non-Metallic Piping and Components
Rev. 4
October, 1999 Page 8 of 14
Vehicular traffic load/Single-wheel load. . . . 9000kg
NOTES:
Note 1 - To be verified with soil report
Note 2 - To be verified with vendor data and details developed during engineering.
Note 3 - Stringent requirements may apply depending on vendor requirements or specific road
traffic, e.g., for modularization path or for continuous burial of pipe under the road.
4.3 DESIGN STUDIES AND SPECIAL CONSIDERATIONS
1) The following studies shall be performed for each underground system:
• Thrust load study
• External load study
• Thermal expansion study
• Hydraulic study
2) The following pipe properties to be used for design studies and calculations shall be
reported by the manufacturer:
• Hoop tensile module of elasticity : EH
• Hydrostatic design basis :HDB
• Ring flexual modulus of elasticity : :E
• Minimum pipe stiffness :F/y
• Long-term ring-bending strength :Sb
• Poisson’s ratios :Vh, Vl
3) Unbalanced thrust forces at changes in direction and/or at the ends shall be restrained to
prevent joint separation or over-stressing the piping. Relationship of this restraint and
the soil condition surrounding the pipe shall be taken into consideration in the
design of restraints and/or thrust blocks.
4) Uplift forces (buoyancy) and external pressures due to high groundwater level at pipe
depth shall be considered for underground lines especially in their empty condition.
Means to restrain the buoyancy and to withstand the external pressures, may
includes stiffening ribs, increasing pipe wall thickness or other methods as recommended
by the manufacturer.
5) Thermal expansion due to elevated service temperature shall be accommodated by one or
a combination of such means as, flexible system/joints, increased wall thickness, etc.
6) Vendor shall provide hardness and hydrostatic design stress (HDS) values and class
limitations
9. Petrokemya GES-012-02
Non-Metallic Piping and Components
Rev. 4
October, 1999 Page 9 of 14
for FRP/RTR AND PVC piping.
7) Installation parameters, such as type of pipe-zone backfill , degree of compaction, etc., shall
be evaluated by vendor to recommend the most economical pipe installation parameters
based
on his experience.
5. MATERIALS
5.1 GENERAL
1) The manufacturer shall use only approved resin system, reinforcing glass fibers, fillers,
additives, etc., for which a proven history of performance in this particular application
can be provided. The historical data shall have been acquired from material of the same
construction and composition as the proposed product.
2) All fittings shall be manufactured using the same type of materials as the pipe. Alternate
valve materials such as ductile iron however, can be evaluated depending on economics
and service conditions.
3) Piping, fitting and valves shall conform to applicable ASTM and AWWA specifications
for the specific design conditions for each service.
5.2 FIBERGLASS PRESSURE PIPING (FRP)
1) Unless otherwise specified, the piping material shall conform to AWWA C 950.
2) Depending on service conditions, availability and economics, material shall conform to
the following types, grades and liners specified in AWWA C 950:
a) Types. The product type is determined by the method of manufacture, as follows:
• Type I: Filament wound.
• Type II: Centrifugally cast.
b) Grades. The product grade is determined by construction (glass-fiber-reinforced
or glass-fiber-reinforced mortar) and materials (epoxy or polyester) as
follows:
• Grade 1: Glass-fiber-reinforced epoxy (RTRP epoxy).
• Grade 2: Glass-fiber-reinforced polyester (RTRP polyester).
• Grade 3: Glass-fiber-reinforced epoxy mortar (RPMP epoxy).
• Grade 4: Glass-fiber-reinforced polyester mortar (RPMP
polyester).
c) Liners. The product-liner classification is determined by whether or not a liner is
used and, if used, whether it is a thermoplastic, reinforced, or non-
reinforced thermoset. Classification of liners is as follows:
10. Petrokemya GES-012-02
Non-Metallic Piping and Components
Rev. 4
October, 1999 Page 10 of 14
• Liner A: No liner.
• Liner B: Thermoplastic liner.
• Liner C: Reinforced thermoset liner.
• Liner D: Nonreinforced thermoset liner.
3) The pipe inner surface layer shall be a minimum of 0.50mm (0.02 in.) thick. This
reinforced layer shall contain less than 20 percent by weight of the reinforcement
material.
4) Pipes shall be furnished in lengths that require a minimum of field joints and are
satisfactory for delivery. Where practicable, fasten fittings to the pipe sections. All pipe
fittings shall bear place marks to facilitate accurate field fit-up on each piece of joint
where the line changes direction.
5.3 POLYVINYL CHLORIDE (PVC)
All polyvinyl chloride (PVC) pipe and piping components shall be manufactured from a PVC
compound meeting ASTM D 1784 and ASTM D 1785 Specification for Polyvinyl Chloride
(PVC) Plastic Pipe Schedules 40, 80, and 120 or ASTM D 2241, Specification for Polyvinyl
Chloride (PVC) Plastic Pipe-Pressure Rated.
5.4 PRE-STRESSED CONCRETE PRESSURE PIPE
All pre-stressed concrete pressure pipe and piping components shall be manufactured in
accordance with the requirements of AWWA C 301.
6. DIMENSIONS
1) Pipe outside diameters shall be in accordance with AWWA Standards C 900 and C 950.
For diameters larger than those covered in these documents, outside diameters shall be
selected such that the inside diameter is not less than the nominal size.
2) Except when vendor is responsible for spooling, and unless specified otherwise, pipe
shall be supplied in nominal lengths of 12 meters. Actual laying length shall be the
nominal length ±2 inches. At least 90% of the total footage of each size and class of
pipe, excluding special order lengths, shall be furnished in nominal length sections.
3) The minimum pipe wall thickness at any point shall not be less than 87.5% of nominal
pipe wall thickness when measured in accordance with ASTM D 3567.
4) Flange dimensions, except thickness, of flanges shall be in accordance with the
following:
• 600 ID and smaller : 150lb FF to ASME B16.5
• 700 ID to 1500 ID : 150lb FF to ASME B 16.47 series “B” (API 605
discontinued)
11. Petrokemya GES-012-02
Non-Metallic Piping and Components
Rev. 4
October, 1999 Page 11 of 14
• 1500 ID over : 175lb FF to Taylor Forge
7. PRESSURE CLASS RATING
1. Pressure class rating shall be per ASME B 31.3 and selected for service conditions based
on proven vendor data.
2. The maximum transient (operating plus surge) pressure of the line shall not exceed the
pipe nominal pressure class by more than 40%.
3. Pipe hoop tensile strength shall be verified as specified in the applicable standard ASTM
D 2290. All pipes shall be capable of withstanding a test pressure of 1.5 times the
maximum sustained operating pressure of the line without leaking or cracking. This
performance shall be periodically verified at the factory at least once per lot as defined in
ASTM D 3754, Section 7.1 or per ASTM D 1898.
8. SUPPORTS
The design of supports shall be in accordance with the objective and methods outlined in ASME
B 31.3. Requirement and design of thrust blocks for underground FRP/RTR/RPMP piping shall
be as per manufacturer’s recommendations approved by the OWNER.
9. JOINTS
9.1 Fiberglass Reinforced Piping
9.1.1 Structural Joints
1) Structural joints for shop fabrication and field installation shall be butt and strap type or
as per manufacturer’s standard and proven practice.
2) Butt and strap joints shall be constructed with alternating layers of mat and woven
roving.
3) The first and last layers of butt and strap joints shall be mat.
4) All structural joints 24” diameter and larger shall have an internal sealing laminate.
9.1.2 Installation Joints
Installation joints for pipe connections may either be bell and spigot type, butt and strap type,
flanged or other mechanical type joints depending on:
• System design
• Flexibility analysis
• Economics and availability
• Reliability of offered design and criticality of service
12. Petrokemya GES-012-02
Non-Metallic Piping and Components
Rev. 4
October, 1999 Page 12 of 14
1) Bell and Spigot Joints
The bell and spigot joints shall be double coupling type.
2) Flanged Joints
a) Flanged connections shall be of a face sealing O-ring design or flat gasket seal design.
b) Flanges shall be either full face drilled design or lap-joint type with drilled steel
backing ring. All flanges shall meet ASME B 16.1 or ASME B 16.5.
c) All flange bolting shall be per GES-024.
3) Butt and Strap Joints
a) Butt and strap installation joints for FRP piping shall be made in field by contractor
under manufacturer’s supervision. Material kits for such joints shall also be supplied
by the manufacturer.
b) For other requirements, see structural joints.
9.2 Polyvinyl Chloride (PVC) Piping
1) Fittings shall conform to the requirements of ASTM D 2467 for socket type.
2) All socket type connections shall be joined with PVC solvent cement complying to
ASTM D 2564.
3) All threaded connections shall conform to ASME B 1.20.1 per GES-024.
4) All flanged connections shall conform to ASME B 16.1 or ASME B 16.5.
5) Installation practices, including support spacing, solvent cement, welding, and curing
duration shall be in compliance with manufacturer’s printed recommendations
9.3 Pre-stressed Concrete Pressure Pipe
1) All steel bell-and-spigot joint rings shall be designed and fabricated in accordance with
AWWA C 301.
2) All gaskets used shall meet the requirements of AWWA C 301.
10. HYDROSTATIC TESTING
1) Manufacturer shall hydrostatically test all pipes for any leaks at works to twice the
working pressure as-a-minimum. For this test, the means of sealing the ends of the pipe
shall be by a test ring incorporating the proposed rubber ring, or a gasket, etc., that will
be used in the installed pipeline.
13. Petrokemya GES-012-02
Non-Metallic Piping and Components
Rev. 4
October, 1999 Page 13 of 14
2) Field hydrotest of all non-metallic piping is mandatory and shall be performed as per
project procedures. Hydrotest pressure, as-a-minimum, shall be as per line designation
table.
3) No hydrostatic testing procedures shall induce loads in the pipe for which it was not
designed.
4) The sealing integrity of each dual O-ring bell and spigot joint shall be predetermined by
use of the test port installed between the O-ring pair prior to filling the pipe with water.
5) The line shall be filled with water in such a way that all air is vented before the line is
pressurized. The line shall be initially pressurized at 50% of the design operating
pressure for 10 minutes to seal all gaskets and O-rings.
6) The line shall then be brought gradually to the test pressure, blanked off and observed for
a period of 2 hours. During this time, the line pressure shall not drop and no leakage
shall occur.
7) After the pressure test, the line shall be emptied and inspected for surface cracks or
structural damages.
11. EXAMINATION AND INSPECTION
1) The seller shall have, as part of his usual business practice, an established, routine, and
documented quality control program. This program shall provide evidence that the
materials, design, fabrication, examination, inspection, and testing of the items conform
to the specifications and requirements established in the Purchase Order. This program
shall ensure that all variables affecting the requirements for reliability, safety, operability
and durability of the complete items have been considered, evaluated, tested, and
controlled. When requested, the Seller shall submit his quality control program for
approval.
2) All items shall be new (not previously used) and the interior and exterior surfaces shall
be free of debris.
3) Inspection shall be per GES-025-01 and project execution procedures for shop and field
inspection.
4) Items containing defects or not in complete compliance with the requirements of the
Purchase Order and referenced documents, will be rejected.
5) Discovery of defects, after inspection and acceptance of the items by the Purchaser, does
not relieve the Seller of the responsibility to comply with the requirements of this
specification and the Purchase Order.
14. Petrokemya GES-012-02
Non-Metallic Piping and Components
Rev. 4
October, 1999 Page 14 of 14
12. REPAIRS - METHODS AND PROCEDURES
1) Repair methods for minor blemishes and damage shall be proposed by the Contractor and
must be completely compatible with the construction of the pipe manufacturer.
2) Repairs will not be allowed when a pipe has a crack extending through the entire wall
thickness, if a hole is made in the pipe wall, or equally serious damage has occurred. In
such cases, the pipe shall be removed and not incorporated in the Works.
13. HANDLING AND SHIPPING
1) All pipe and fittings shall be properly handled in a safe manner that will not allow
damage, scuffing, or over-stressing. The pipe and fittings must not be allowed to impact
on any hard objects as non-visible impact damage may occur resulting in future failures
or leakage.
2) All shipments shall be adequately packaged, braced and cradled in order to prevent
damage during transit. Ends shall be adequately protected from damage.
3) All handling shall be by means of non-abrasive slings for the purpose of preventing
damage to the pipe surface. The use of cables or chains is prohibited.
4) Polyvinyl chloride pipe (PVC) and fiberglass (FRP) piping shall not be stored as above
ground piping in areas exposed to direct sunlight since ultra-violet rays are detrimental to
the life of the pipe.
