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Quick Guide into ISO 14692 for GRE pipe and fittings

1. Introduction The ISO (International Standards Organization) 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 piping system, three important conditions must be met: 1. Use qualified products 2. Proper system design 3. Install according to manufacturers standards and guidelines The above mentioned three points are addressed in the ISO 14692 Standard in Part 2, Part 3 and Part 4, respectively.

Qualification

System design Troublefree pipe system Installation

Figure 1. The key to success

Content 1. Introduction 2. What is ISO 14692? 3. Part 1: Vocabulary, Symbols, Applications and Materials 4. Part 2: Qualification of Components 5. Part 3: System Design 6. Part 4: Fabrication, Installation and Operation 7. Conclusion 8. ISO in Brief 9. References 10. Deviations List to the ISO Quality Program

1 2 3 3 5 7 9 9 9 10

2. What is ISO 14692? ISO 14692, is an international standard dealing with the qualification of fittings, joints and pipes for certain applications. It describes how to qualify and manufacture GRP/GRE pipe and fittings, how to conduct system design, and finally it gives guidelines for fabrication, installation and operation. The ISO 14692 consists of four 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 also may be used as guidance for the specification, manufacture, testing and installation of GRP/GRE piping systems in other similar applications found onshore. NOV Fiber Glass Systems has obtained a Design Examination Statement from DNV. This examination statement consists 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 where the specifications conflict, the ISO 14692 supersedes the AWWA. Therefore, on the basis of this design examination statement, the scope can include both applications of GRP/GRE piping systems onshore (buried and suspended). Main users of the ISO 14692 document are: governments, end users, engineering companies, inspection companies, manufacturers, installers.

Photo 1. Platform under construction

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.

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3. Part 1: Vocabulary, symbols, applications and materials • Impregnate = Saturate the reinforcement with a resin • LTHP = Extrapolated long-term mean static failure pressure of a component with free ends based on a 20-year lifetime • Part factor f1 = Ratio of the 97,5% confidence limit of the LTHP to the mean value of LTHP • 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 = Factor that takes account of non-pressure-related axial loads, e.g. bending Furthermore, some general applications for GRP/GRE piping are given.

The first part of the ISO 14692 gives the terms, definitions and symbols used. A few examples of common used abbreviations are given: • Composite pipe = Pipe manufactured using fiber reinforced thermoset 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

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 Wall thickness limitations The structural calculations given in this part of ISO 14692 are only valid for thickness-to-diameter ratios that are in accordance with Equation (1). ( tr / D ) ≤ 0,1 where tr is the average reinforced thickness of the wall, in millimetres, i.e. excluding liner and added thickness for fire protection; D is the mean diameter, in millimetres, of the structural portion of the wall. In order to provide sufficient robustness during handling and installation, the minimum total wall thickness, tmin, of all components shall be defined as: For Di ≥ 100 mm: tmin ≥ 3 mm For Di < 100 mm: ( tmin / Di ) ≥ 0,025 mm

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 according ASTM D-2992 must be determined (witnessed by third party for example: DNV, Bureau Veritas). The test consists of at least 18 samples. The test pieces are plain end. The test setup is a closed end pressure vessel. Samples are subject to different pressures and held at pressure until failure.

where Di is the internal diameter of the reinforced wall of the component, in millimetres. For more onerous applications, for example offshore, consideration should be given to increasing the minimum wall thickness to 5 mm. The minimum wall thickness of the pipe at the joint, i.e. at the location of the O-ring or locking-strip groove, shall be at least the minimum thickness used for the qualified pipe body. Depending on location, the system design pressure and other design factors can significantly increase the required wall thickness.

Figure 2. Regression curve 3

The test medium is water at 65 degrees C. The required failure mode is weeping. The failures shall be in different decades of the log-log plot of time vs. stress. Figure 2 gives an example of a regression line.

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

>_ 150 S T

Each product family (pipe, elbow, reducer, tee, flange) is divided into product sectors. Two representative samples, usually the largest 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. 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. For details on the calculation, see the ISO document. In general, the 1000 hour test is performed at about 2.5 to 3 times the design pressure. A 20 bar system is tested around 50 to 60 bar. 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 hour tests or through the scaling method. For quality control, short-term tests could be performed, if required and agreed with the principle. 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

Photo 2. Spool for 1000 hours testing

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 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 Required Qualification Tests

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

Pipes 2 or scaling 2 or scaling 2 or scaling 2 or scaling

Elbows 2 or scaling 2 or scaling 2 or scaling 2 or scaling

Tees 2 or scaling 2 or scaling 2 or scaling 2 or scaling

Flanges 2 or scaling 2 or scaling 2 or scaling 2 or scaling

ASTM D-2992 ASTM D-2992 ASTM D-1598

2 18 5

2 18 5

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 ISO 14692. The designer shall evaluate system layout requirements such as: • Space requirement (fitting dimensions) • Piping system support • 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. Note that the dimensions of some GRP/GRE fittings can be larger compared to steel fittings.

5.3 Support distance Recommendations for system support: • Supports spaced to limit sag (< 12.5 mm) • Valves and heavy equipment to be supported independently • In general, connections to metallic piping systems shall be anchored • Do not use GRP/GRE piping to support 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 pipe and fittings, pipe length, inside diameter as well as resistance from valves and fittings shall be taken into account 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

The 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, and earthquake, etc. With the calculation output, the stresses in the piping system, the displacement, the loads on the support, 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 ISO 14692 gives requirements and recommen­dations for fabrication, installation and operation of GRP/GRE pipe systems. Past experience with GRP/GRE projects shows that a great deal of the problems that occur are associated with bad fabrication and installation.

• 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

When site fabrication is needed, all GRP/GRE components shall A highly recommended approach to a successful installation is be installed by qualified GRP/GRE pipe fitters and thereafter to order the piping system as a set of pre-fabricated spools, to approved by a qualified GRP/GRE piping inspector. the maximum extent possible. This will reduce the possibility of poor fabrications or repairs at a very late and potentially costly Definitions: Pipe fitter stage of the project. Person working for a contractor, who is responsible for the construction of the GRP/GRE pipe system, must be able to make the relevant joint types according NOV Fiber Glass Systems 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 verify the soundness of the installation. This includes lay-out related matters such as support 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 further can be done to prevent site problems?

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 NOV Fiber Glass Systems lifting, loading and unloading procedure • Storage. Pay attention to the stacking of the pipe; support width and stacking height, end protection of pipe and fittings • Preferably, pipe should be transported in containers or crates

Photo 6. Typical work of a GRE pipe fitter

Training of pipe fitter • The quality of the joints is mainly dependent on craftsmanship of the pipe fitter. Therefore, ISO 14692 demands that the qualification organization is independent of the organization that carries out the training. In the case of NOV Fiber Glass Systems, 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% pass mark is required. The practical part will end with making a joint that will be hydro-tested according the requirements of the ISO 14692. These tests are witnessed 7

by a third party. When passing 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 Training of Supervisor - QA/QC inspector • NOV Fiber Glass Systems and DNV are developing an individual certification for Supervisor - QA/QC inspector based on ISO 14692 requirements. The objective is to train Supervisor - QA/QC inspectors on aspects like storage, inspection of pipes and fittings, supporting, jointing, and hydro testing 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 NOV Fiber Glass Systems, as they have in contrast to most institutes a large knowledge obtained over decades, in this particular area. The examination committee will be DNV. The certificate that can be obtained will be a personal certificate.

6.2.5 Visual inspection Visual inspection shall be carried out on all joints and surfaces. Possible defects, along with acceptance criteria and corrective actions, are given in the ISO document. E.g.: • Impact > replace (major defect) or repair (minor defect)

6.2.3 Installation methods Installation method shall be according manufacturers approved installation manual. Supporting • Follow the installation guides from the Manufacturer • Other guidelines not different from the NOV Fiber Glass Systems procedures are given in the ISO 14692 Installation General requirements are given in ISO 14692 for the installation of GRP/GRE components such as bending, bolt-torquing, tolerances, earthing of conductive piping, joint selection, quality control, etc. The 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 • Misaligned joints > replace components (major defect) compliance with all requirements. The contractor shall designate remake joint (minor defect) one individual to be responsible for quality control throughout the installation. Photo 7. Spool fabrication shop Record of following items shall be made: Starting and end time of the curing process; pipe fitter name.; batch number of the adhesive and heating blanket; measured temperature of the heating blanket; ambient temperature, date, joint 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.

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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

7. Conclusion ISO 14692 is a worldwide accepted standard for the manufacturing, qualification, design and installation of GRP/ GRE piping systems. When the guidelines laid down in the ISO 14692 standard are followed, it will result in a trouble-free pipe system.

8. ISO in brief ISO 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 standards distill an international consensus from the roadest possible base of stakeholder groups. Expert input comes from those closest to the need for the standards and also those responsible for implementing them. In this way, although voluntary, ISO standards are widely respected and accepted by public and private sectors internationally. ISO is a non-governmental organization. It is a federation of national standards bodies from over 149 countries, one per country, from all regions of the world.

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

ISO 14692-2:2002(E) 8.0 8.2 8.3.2.2 8.3.2.3

NOV Fiber Glass Systems

Quality programme for manufacture Calibration Quality Control equipment: Pressure gauges: • Accurate +/- 0,5% • Calibration every two months

Standard

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

Spools frequency = 100% (if practicable)

5% (if practicable)

• Accurate +/- 0.8%

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 affected range has been determined

8.3.3



According to API 15LR.



Min. acc. = 130 / 140 dgr.C



Once per shift

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.

8.3.4

Short-term burst test: Agreed with principal

Once per three months

8.3.5

Ongoing pressure tests: yearly 6x 1000 hour. 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 each & 8.3.8.3 fitting: a) Internal diameter b) Outside diameter c) Mass d) Minimum total wall thickness e) Reinforced wall thickness f) Laying length

NOV Fiber Glass Systems 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 NOV Fiber Glass Systems product drawings.

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8.3.8.4 8.3.9

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



NOV Fiber Glass Systems conducts only 100% inspection on laying lengths and directions/ positions

Thread dimensions

8.3.10 Conductivity 105 Ω (100V) 8.3.11 Retest: by failures of one of both retested components, the whole batch to the latest successful test shall be rejected.

N/A Conductivity 106 Ω (500V)

Only the failed components will be rejected. To avoid rejecting good products, NOV Fiber Glass Systems will test all products to trace all affected 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.

ipes 3 locations, P 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.

Pipe 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 NOV Fiber Glass Systems

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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National Oilwell Varco has produced this brochure for general information only, and it is not intended for design purposes. Although every effort has been made to maintain the accuracy and reliability of its contents, National Oilwell Varco in no way assumes responsibility for liability for any loss, damage or injury resulting from the use of information and data herein. All applications for the material described are at the user’s risk and are the user’s responsibility. All brands listed are trademarks of National Oilwell Varco.

North America 17115 San Pedro Avenue Suite 200 San Antonio, TX 78232 USA Phone: +1 210 477 7500

South America Estrada de Acesso à Zona Industrial Portuária de Suape, s/no. Recife, PE, Brazil 55.590-000 Phone: +55 81 3501 0023

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www.fgspipe.com • [email protected]

© 2013 National Oilwell Varco. All rights reserved. GEN1030 - February 2013