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PETRONAS TECHNICAL STANDARDS

DESIGN AND ENGINEERING PRACTICE

TECHNICAL SPECIFICATION

SPOOLABLE FIBRE-REINFORCED PLASTIC PIPES

PTS 31.40.10.20

December 2009

2010 PETROLIAM NASIONAL BERHAD (PETRONAS)All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic,

mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.

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PREFACE

PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication,ofPETRONAS OPUs/Divisions.

They are based on the experience acquired during the involvement with the design, construction,operation and maintenance of processing units and facilities. Where appropriate they are based on,or reference is made to, national and international standards and codes of practice.

The objective is to set the recommended standard for good technical practice to be applied byPETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemicalplants, marketing facilities or any other such facility, and thereby to achieve maximum technical andeconomic benefit from standardisation.

The information set forth in these publications is provided to users for their consideration anddecision to implement. This is of particular importance where PTS may not cover every requirementor diversity of condition at each locality. The system of PTS is expected to be sufficiently flexible toallow individual operating units to adapt the information set forth in PTS to their own environment and

requirements.

When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for thequality of work and the attainment of the required design and engineering standards. In particular, forthose requirements not specifically covered, it is expected of them to follow those design andengineering practices which will achieve the same level of integrity as reflected in the PTS. If indoubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility,consult the owner.

The right to use PTS rests with three categories of users:

1) PETRONAS and its affiliates.2) Other parties who are authorised to use PTS subject to appropriate contractual

arrangements.3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users

referred to under 1) and 2) which requires that tenders for projects, materialssupplied or - generally - work performed on behalf of the said users comply with therelevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with users,PETRONAS disclaims any liability of whatsoever nature for any damage (including injury or death)suffered by any company or person whomsoever as a result of or in connection with the use,application or implementation of any PTS, combination of PTS or any part thereof. The benefit of thisdisclaimer shall inure in all respects to PETRONAS and/or any company affiliated to PETRONASthat may issue PTS or require the use of PTS.

Without prejudice to any specific terms in respect of confidentiality under relevant contractualarrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by usersto any company or person whomsoever and the PTS shall be used exclusively for the purpose theyhave been provided to the user. They shall be returned after use, including any copies which shallonly be made by users with the express prior written consent of PETRONAS.

The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe custodyand PETRONAS may at any time require information satisfactory to PETRONAS in order to ascertainhow users implement this requirement.

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TABLE OF CONTENTS

1. INTRODUCTION ........................................................................................................ 21.1 SCOPE ........................................................................................................................ 21.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 21.3 DEFINITIONS ............................................................................................................. 21.4 ABBREVIATIONS ....................................................................................................... 31.5 CROSS-REFERENCES ............................................................................................. 42. MATERIALS ................................................................................................................ 52.1 GENERAL ................................................................................................................... 52.2 THERMOSET MATERIALS ........................................................................................ 52.3 THERMOPLASTIC MATERIALS ................................................................................ 62.4 REINFORCEMENT MATERIALS ............................................................................... 72.5 EXTERNAL LAYER .................................................................................................... 72.6 CHEMICAL RESISTANCE ......................................................................................... 72.7 PERMEATION ............................................................................................................ 73. DESIGN ASPECTS .................................................................................................... 93.1 GENERAL ................................................................................................................... 9

3.3 CYCLIC / STATIC SERVICE ...................................................................................... 93.4 TENSILE LOAD RATING ............................................................................................ 93.7 LINER THICKNESS .................................................................................................. 103.8 JOINTS ..................................................................................................................... 104. QUALIFICATION ...................................................................................................... 114.1 GENERAL ................................................................................................................. 114.2 PRODUCT FAMILY .................................................................................................. 114.4 SHORT-TERM BURST TESTS ................................................................................ 114.5 1000 HOURS QUALIFICATION TESTS ................................................................... 114.6 TENSILE STRENGTH TESTS .................................................................................. 124.7 VACUUM TESTS ...................................................................................................... 124.8 REQUALIFICATION ................................................................................................. 125. QUALITY ASSURANCE AND CONTROL ................................................................ 145.1 GENERAL ................................................................................................................. 145.2 QUALITY CONTROL EQUIPMENT ......................................................................... 145.3 MILL HYDROSTATIC TEST ..................................................................................... 145.4 ONGOING PRESSURE TESTS ............................................................................... 145.5 FIBRE CONTENT ..................................................................................................... 155.6 DIMENSIONS ........................................................................................................... 155.7 QUALITY CONTROL RECORDS ............................................................................. 156. COMPONENT MARKING ......................................................................................... 176.1 GENERAL ................................................................................................................. 176.2 REQUIREMENTS ..................................................................................................... 177. HANDLING, STORAGE AND TRANSPORTATION ................................................. 187.1 HANDLING................................................................................................................ 187.2 STORAGE................................................................................................................. 187.3 TRANSPORTATION ................................................................................................. 188 INSTALLATION AND TESTING ............................................................................... 198.1 GENERAL ................................................................................................................. 198.2 FLUSHING ................................................................................................................ 198.3 HYDROTEST ............................................................................................................ 199. REFERENCES ......................................................................................................... 20

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1. INTRODUCTION

1.1 SCOPE

This new PTS specifies requirements and gives recommendations for the use of spoolable

fibre-reinforced plastic (FRP) pipe systems, both onshore and offshore. This PTS is limitedto spoolable pipe made from thermoplastic lined fibre-reinforced thermosetting resins, so-called S-FRP and pipe made from fibre-reinforced thermoplastic resins, so-called S-RTP.Operating pressures are typically up to 300 bar, temperatures between 30 C and 90 C,diameters between 25 mm and 150 mm, and continuous length up to 10 km, depending onreel capacity.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorized by PETRONAS, the distribution of this PTS is confined tocompanies forming part of the PETRONAS Group or managed by a Group company and,where necessary, to Contractors and Manufacturers nominated by them.

This PTS is intended for use in oil refineries, chemical plants, gas plants, exploration and

production facilities and, where applicable supply/marketing installations.When PTSs are applied, a Management of Change (MOC) process should beimplemented; this is of particular importance when existing facilities are to be modified.

If national and/or local regulations exist in which some of the requirements may be morestringent than in this PTS, the Contractor shall determine by careful scrutiny which of therequirements are the more stringent and which combination of requirements will beacceptable as regards safety, economic and legal aspects. In all cases the Contractor shallinform the Principal of any deviation from the requirements of this document which isconsidered to be necessary in order to comply with national and/or local regulations. ThePrincipal may then negotiate with the Authorities concerned with the object of obtainingagreement to follow this document as closely as possible.

1.3 DEFINITIONS

1.3.1 General Definitions

The Contractor is the party that carries out all or part of the design, engineering,

procurement, construction, commissioning or management of a project or operation of afacility. The Principal may undertake all or part of the duties of the Contractor.

The Manufacturer/Supplier is the party that manufactures or supplies equipment andservices to perform the duties specified by the Contractor.

The Principal is the party that initiates, and ultimately pays for, the project. The Principalwill generally specify the technical requirements. The Principal may also include an agentor consultant, authorised to act for the Principal.

The word shallindicate a requirement.The word shouldindicate a recommendation.

1.3.2 Specific definitions

Design pressureMaximum internal pressure intended to be experienced by a component during its servicelife.

Design temperaturefor each design condition, maximum fluid temperature that can be reached during service.

Mill hydrostatic testshort-term hydrotest at the mill, or factory, use as a quality control check, which is carriedout at a pressure above the rated pressure.

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Occasional loadmaximum short-term duration load intended to be experienced during the componentsservice life.

Operating pressurenormal or anticipated standard internal pressure to be experienced by a component whichshould not exceed the rated pressure, determined in accordance with this PTS.

Pressure ratingrated pressuremaximum allowable continuous pressure, relating to its long-term resistance to failure whensubjected to either static or cyclic internal pressure loading, determined in accordance withthis PTS.

Product familycomponent type all of whose variants have the same function.

Product family representativecomponent that is taken to be representative of a particular product family.

Product sectorsubdivision of a product family that groups variants into specific diameter and pressureranges.

Product sector representativecomponent that has the highest nominal diameter and highest pressure rating in aparticular sector.

Qualificationprocess of demonstrating that a component is in accordance with the requirements of thisPTS.

Rated temperaturemaximum allowable continuous temperature at the rated pressure determined inaccordance with this PTS.

Short term hydraulic burst strengthShort term hydrostatic pressure strengthburst pressure measured during a short-term test.

Tensile load ratingmaximum allowable continuous tensile load, determined in accordance with this PTS.

1000 hour testmedium survival test to demonstrate long-term strength performance.

1.4 ABBREVIATIONS

GRE Glass-fibre-reinforced epoxy

GRP Glass reinforced plastic

NPRs Nominal pressure rating, static pressure service

NPRc Nominal pressure rating, cyclic pressure service

PA Polyamide

PE Polyethylene

PEX Cross-linked polyethylene

PP Polypropylene

PVC Polyvinylchloride

PVDF Polyvinylidenefluoride

Pmin Minimum pressure during pressure cycle

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Pmax Maximum pressure during pressure cycle

R Minimum / maximum pressure ratio during cyclic service

SLT Standard laboratory temperature

S-FRP Spoolable fibre-reinforced plasticS-GRP Spoolable glass-fibre-reinforced plastic

S-RTP Spoolable reinforced thermoplastic

STHP Short-term hydrostatic pressure strength

TLR Tensile load rating

TP1000hrs Test pressure to be used in 1000-hour qualification test

TS Tensile strength pipe

Tg Glass transition temperature

UV Ultraviolet

1.5 CROSS-REFERENCES

Where cross-references to other parts of this PTS are made, the referenced sectionnumber is shown in brackets. Other documentations referenced in this PTS are listed in (9).

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2. MATERIALS

2.1 GENERAL

The material selection process shall ensure that the material is compatible with the service

fluids to which it is exposed over the full design temperature range so that the mechanical,physical and chemical properties of the structural wall satisfy the design requirementsthroughout the intended lifetime.

The materials selected shall be of a suitable commercial grade that complies with thetechnical requirements of the application.

The recommendations of the resin Suppliers for the use of hardeners, catalysts andaccelerators shall be followed.

If specified by the Principal, the external pipe layer may be pigmented to provide suitableresistance to UV degradation effects and/or earthing requirements.

2.2 THERMOSET MATERIALS

Thermoset resins, typically used for the manufacture of fibre-reinforced pipe components,are epoxy, polyester, and vinyl ester. The resin shall have a glass transition temperature T gof at least 30 C above the rated temperature of the pipe component.

2.1.1 Polyester resins

Types of polyester resins, typically used for GRP pipe components, are:

Isophthalic polyester. This is a relatively low cost resin, which is rarely used for chemicalservices. It is typically used in thermoplastic lined GRP pipe systems. The minimumglass transition temperature, Tg, is 90 C;

Bisphenol A polyester. This is a high temperature, chemically resistant resin that isextensively used in chemical service. It is a general-purpose resin and is easy tomanufacture. The minimum glass transition temperature, Tg, is 120 C;

Chlorinated polyester. This resin has many of the properties of bisphenol A resins, buthas an inherent fire retardant characteristic. This fire resistant property can be enhancedby addition of antimony oxide particles to the resin mix. The minimum glass transitiontemperature, Tg, is 110 C.

2.1.2 Vinyl ester resins

Compared to polyester, vinyl ester resins have improved chemical resistance. Hightemperature resistant vinyl ester versions, e.g. Epoxy-Novolac, are also available. Theminimum glass transition temperature, Tg, is 115 C.

2.1.3 Epoxy resins

Epoxy resins are resistant to a wide range of moderately strong acids and alkalis, and most

hydrocarbons. There are several types of base epoxy resins and associated curing agents.Curing agents typically used for epoxy resin are:

Aliphatic amine - Good resistance against caustics and solvents. Resistance againstacids is fair. Minimum glass transition temperature, Tg, is 115 C;

Cyclo Aliphatic Amine Excellent resistance against caustics and solvents. Resistanceagainst acids is fair. Minimum glass transition temperature, T g, is 140 C;

Aromatic Amine - Excellent resistance against caustics and solvents. Resistanceagainst acids is fair. Minimum glass transition temperature, T g, is 140 C;

Anhydride Excellent resistance against acids. Resistance against caustics andsolvents is poor. Minimum glass transition temperature, Tg, is 115 C.

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2.1.4 Temperature limitations of resins

The maximum allowable temperature is determined by the resin type and state of cure.Experience of typical GRP systems suggests the following maximum allowabletemperatures, depending on resin type:

Table 2.1.4.1: Temperature limitations

Resin Type Temperature limit

Epoxy 110 C

Vinyl ester 100 C

Polyester 70 C

The temperatures listed in Table 2.1.4.1 are for initial guidance only.

The maximum operating temperature for GRP may, however, be considerably lower,depending on the aggressiveness of the specific fluid and its concentration and the specificcuring agent of the resin system. Information about chemical resistance of GRP materials is

given in PTS 30.10.02.13.

2.3 THERMOPLASTIC MATERIALS

2.3.1 Lining

Thermoplastic materials, typically used for liners, are:

Polyethylene (PE), as specified in ISO 1872;

cross-linked PE (PEX), specifications to be agreed by the Principal;

Polyamide (PA), as specified in ISO 1874, and API 17TR2;

Polyvinylidene fluoride (PVDF), as specified in ISO 15014;

Polypropylene (PP), as specified in ISO 15013;

Polyvinyl chloride (PVC), as specified in ISO 1163.

2.3.2 Matrix

Polyethylene is the thermoplastic matrix material typically used for spoolablefibre-reinforced thermoplastic (RTP) pipe. Other materials may also be used, e.g.polypropylene, polyamide, etc.

2.3.4 Temperature limitations of thermoplastics

Experience of typical thermoplastic materials suggests the following maximum allowabletemperatures:

Table 2.3.2.1 - Temperature limitations

Thermoplastic Type Temperature limit

Polyethylene (PE) 65 C

Polyamide (PA-11) 80 C

Polyvinylidene fluoride (PVDF) 130 C

Polypropylene (PP) 85 C

Polyvinyl chloride (PVC) 65 C

The temperatures listed in Table 2.3.2.1 are for initial guidance only.

The maximum operating temperature for thermoplastic may, however, be considerablylower, depending on the aggressiveness of the specific fluid and its concentration.Rsistance of thermoplastic materials is given in PTS 30.10.02.13.

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2.4 REINFORCEMENT MATERIALS

Glass fibre is the reinforcing material typically used for fibre-reinforced plastic (e.g. GRE)pipe components. However, other type of fibre materials may also be used, e.g. carbon andaramide.

The reinforcing material shall be a suitable grade of fibre having a finish compatible with thematrix material used.

Glass-fibre materials typically used for fibre-reinforced thermoset (e.g. GRE) pipecomponents are:

E-glass fibre, the most commonly used type of glass. It is relatively inexpensive andhas good mechanical properties. However, E-glass has limited chemical resistanceand shall therefore be protected by the resin from direct exposure to the fluid;

C-glassfibre has a high degree of chemical resistance. It is used where the fluid maycome into contact with the reinforcement.

Other fibres, which may be used, are:

Carbon fibre is typically used for low weight, high strength and high stiffness FRPstructures. Single carbon fibre rovings may be included within the structural laminate toachieve an electrically conductive wall structure to prevent build up and discharge ofstatic electricity;

Aramide fibre is typically used for low weight, high strength and moderate stiffness

FRP structures, including reinforced thermoplastic (RTP) pipe components;

Steel cords are typically used to reinforce flexible components, e.g. pneumatic tyres,hoses, etc., in accordance with ASTM D 2969.

NOTE: Steel cord reinforced spoolable plastic pipe systems may be designed according to API 17J ifagreed by the Principal. However, long-term strength performance shall be demonstrated by1000 h qualification tests (4.5).

In view of the possible permeation of fluids through polymer materials used for the liner

(S-GRP) and matrix material (S-RTP), the Manufacturer shall demonstrate that the fibrematerial is resistant against the service fluid, at rated temperature.

2.5 EXTERNAL LAYER

To protect the external pipe surface against UV degradation, especially when constantlyexposed to strong sunlight, e.g. in tropical, and desert areas, a pigmented external surfacelayer shall be used, such as carbon black, or white pigment, e.g. rutile (TiO 2). TheManufacturer shall demonstate that the external pipe surface is UV resistant within thedesign life, in accordance with ISO 11507.

Spoolable fibre-reinforced GRP (e.g. GRE) pipe which may be in contact externally with afluid, e.g. a sub-sea or buried system, shall be protected by a robust fluid-tight externallayer, e.g. polyethylene, at least 2 mm thick.

2.6 CHEMICAL RESISTANCE

The Manufacturer shall supply chemical resistance data for the relevant service fluids andthe specific material (liner, matrix, and fibre), including the highest known servicetemperature that the material has been subjected to and, if available, the service life thathas been achieved under the service conditions. The chemical resistance information shallstate whether the material has been laboratory tested according to ASTM C 581 (orequivalent standard) and shall state the life expectancy for the intended service.

Information about chemical resistance of non-metallic materials in a variety of chemicalenvironments is given in PTS 30.10.02.13.

2.7 PERMEATION

For hydrocarbon service, toxic and very toxic service, as defined in PTS 01.00.01.30. or forother services at the request of the Principal, the Manufacturer shall provide permeation

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data, i.e. coefficients for permeability, diffusivity and solubility for the composite pipe wall, atthe rated temperature.

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3. DESIGN ASPECTS

3.1 GENERAL

The spoolable pipe system shall be designed to withstand the most severe anticipated

conditions experienced during installation and within the service life of the system.Designers shall consider the loads that can potentially be experienced by the pipe systemduring the anticipated service life. Typical loads include internal pressure, hydrostatic test,bending, tensile, and vacuum.

3.2 PRESSURE RATING

Because of the catastrophic (burst) failure mode of spoolable fibre-reinforced plastic pipe,design shall be based on short-term burst strength (STHP).

The Manufacturer shall determine the Nominal Pressure Rating (NPR), by means of short-term hydraulic burst strength testing (4.4) with a safety factor of at least 3.75. The nominalpressure rating is defined by the following:

NPR = STHP / 3.75

NOTE: For steel cord reinforced spoolable plastic pipe designed according to API 17 J, a minimum safetyfactor of 2.5 (instead of 3.75) may be used if agreed by the Principal.

3.3 CYCLIC / STATIC SERVICE

This section addresses service conditions that can be considered to be neither static norfully cyclic. It defines the NPR in terms of either NPR s(static) or NPRc(dynamic) or both of

them as a function of the amplitude of the internal pressure cycle, R.

R is defined as:

where Pminand Pmaxare the minimum and maximum of the pressure cycle. If the number

of cycles is less than 7 000 then the service shall be considered static.

NOTE: R = 0 corresponds to fully cyclic service whereas R = 1 corresponds to static service.

Table 3.3.1 defines the NPR for the full range of service from static to fully cyclic as afunction of R:

Table 3.3.1 Determination of the NPR as a function of R

0 < R < 0.4 Fully cyclic regime NPR = 0.4 x NPRs

0.4 < R < 0.8 Intermediate regime NPR = (NPRc2(1-R2) + NPRs2R2)

1/2

0.8 < R < 1 Static regime NPR = NPRs

3.4 TENSILE LOAD RATING

During the installation of spoolable pipe, a powered device is required for pulling the pipeoff the spool. The pulling capability of the powered device shall not exceed the tensile loadrating (TLR) of the spoolable pipe. The Manufacturer shall determine the tensile load rating,by means of tensile strength (TS) testing (4.6) with a safety factor of at least 3. The tensileload rating is defined by the following;

TLR = TS/3.

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3.5 OCCASIONAL LOAD

Occasional load is of short-term duration and the number of occurrences during design lifeis limited. For fibre-reinforced plastic pipe systems there are no established links betweenthe effects of long-term loading and those of higher loads that are of short-term duration.For steel pipe systems, guidance on the duration of occasional loads permitted is given in

ANSI/ASME B31.3 (Section 302.2.4).

For the duration of occasional loads permitted for fibre-reinforced plastic pipe systems, thefollowing is recommended:

Number of load cycles should not exceed 7000 during life of the pipe system;

Duration should not exceed 10 h at any one time and no more than 100 h per year.

Occasional loads are typically:- hydro-test, water hammer;- installation loads, e.g. spooling.

Unless otherwise specified by the Principal, the maximum allowable occasional load, e.g.hydro-test pressure, surge, spooling load, is 1.5 times the rated value for the pipe

component.

3.6 EXTERNAL PRESSURE/VACUUM RESISTANCE

The spoolable pipe shall have a collapse (differential) pressure, Pc, of at least 1.5 times the

short-term and at least 3 times the long-term vacuum or external over-pressure, to bespecified by the Principal.

3.7 LINER THICKNESS

The thickness of the thermoplastic liner shall not be less than 3 mm, except in pipes of 100mm diameter or less where the minimum thickness shall be 2 mm.

3.8 JOINTSFor services proven to be harmless for the environment, the standard joints should beused.

For aromatic hydrocarbon service, very toxic service (as defined in PTS 01.00.01.30.) andfor other services if specified by the Principal, joints (e.g. threaded connections including O-ring and/or thread compound sealing) should not be used.

To prevent emission or reduce it to acceptable levels a thermoplastic welded (S-RTP), orthreaded and glued or adhesive bonded (S-FRP) joint should be used. The pipeManufacturer should select a suitable adhesive to seal threaded connections, anddemonstrate that it can be simply applied in the field without hampering joining operations,and produce a emission-tight joint at maximum pressure and temperature.

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4. QUALIFICATION

4.1 GENERAL

The qualification programme consists of standard methods for quantifying component

performance with respect to static internal pressure, elevated temperature, tensile load,bending, vacuum, cyclic pressure performance, and leak-tightness of joints to be used inhydrocarbon and toxic services (3.8).

All tests shall be carried out, or witnessed and certified by an independent third partyapproved by the Principal. The qualification shall be documented in a qualification report.

In order to keep the total test burden within acceptable limits but at the same time to controlthe use of test data beyond their limits of applicability, the concept of a product family andits sub-divisions is used in this PTS.

The definitions product family, product family representative, product sectors, andproduct sector representative are used in order to rationalize the requirements forqualification testing.

4.2 PRODUCT FAMILY

The product family representative is the pipe component that is taken to berepresentative of that particular product family, i.e. spoolable pipe of the same design,construction, and materials.

4.3 PRODUCT SECTOR

A product sector is a sub-division of a product family, e.g. 25 mm to 250 mm diameterspoolable fibre-reinforced polymer pipe/joint less than 100 bar, that groups spoolable pipesinto specific diameter and pressure ranges.

The size of each product sector shall be limited and should closely match the ranges givenin Table 4.3.1. Other size bands of product sectors with similar spacing between product

sector representative diameters, e.g. as given in API 15HR, shall be acceptable.

The product sector representative is the component (e.g. 250 mm, 150 bar spoolable

pipe) that has the largest nominal diameter and highest pressure rating in a specific sector.

Table 4.3.1 - Product Sectors

Diameter - mm 0 to 50 bar 50 to 100 bar 100 to 150 bar > 150 bar

25 to 250 A H N S

4.4 SHORT-TERM BURST TESTS

The short-term burst strength (STHP) in bar shall be determined by testing five replicatesamples, with minimum test length of 5 times pipe diameter and unrestrained ends, in

accordance with ASTM D 1599. The STHP of the product family representative shall betaken as the lower deviated (two standard deviations) value of the five replicate samples.Testing shall be at SLT (Standard Laboratory Temperature).

4.5 1000 HOURS QUALIFICATION TESTS

4.5.1 General

To demonstrate long-term strength performance, i.e. minimum design life of 20 years, tworeplicate samples (pipe+joint) of the product sector representative shall be selected atrandom and pressure tested with unrestrained ends according to test method

ASTM D 1598.

4.5.2 Test pressure and temperature

The test pressure (TP) shall be at 65 C or design temperature if higher. The product sectorrepresentative (pipe+joint) is qualified if it survives the test duration, i.e. does not leak, lose

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pressure, or structural integrity during the test duration. The test duration shall be 1 000 h,and the test pressure shall be related to the Manufacturers nominal pressure rating (NPR)by the following equation:

TP1000h = 2.2 x NPR (up to 65 C)

4.5.3 Pre-conditioning of 1000-h test specimen

Before starting the 1000-h qualification test, the test samples shall be pre-conditioned atStandard Laboratory Temperature (SLT) by a total of at least 10 bending cycles, atminimum bending radius of 2 m or smaller, if so specified by the Principal. Pre-conditioningshall be performed by the following methods (a) bending around a mandrel with a maximumdiameter of 4 m, or (b) four point bend test using an outer support span of 2 m and an innerspan (loading jig) of 1 m. Bending shall be performed at a minimum mid-span deflection of65 mm, equivalent to a bending radius of 2 m.

4.6 TENSILE STRENGTH TESTS

The tensile strength (TS) in kN shall be determined by testing five replicate samples inaccordance with ASTM D 2105. The tensile strength (TS) of the product family

representative shall be taken as the lower deviated (two standard deviations) value of thefive replicate samples. Testing shall be at SLT (Standard Laboratory Temperature).

4.7 VACUUM TESTS

The Manufacturer shall demonstrate the ability of spoolable pipe to withstand vacuum by

full-vacuum testing two replicate, 1000-h tested samples of each product family at 65 C ordesign temperature if higher. The product family representative is qualified if it survives thetest duration, i.e. collapse of pipe or liner shall not be permitted. The test duration shall beat least 1 h. Test pipes with a length of at least 5 times the pipe diameter, and not morethan 3000 mm, shall be used.

For hydrocarbon services, additional full-vacuum testing shall be performed forthermoplastic lined S-GRP pipe systems. Vacuum testing shall be performed after 1000 h

internal exposure testing to pentane fluid at 65 C or design temperature if higher. Collapseof pipe or liner, or liner blistering, shall not be permitted.

4.8 REQUALIFICATION

4.8.1 General

Changes to a spoolable pipe component to an extent beyond that agreed with the Principalshall invalidate the component's previous qualification. Examples of changes in componentdesign requiring requalification are defined in Table 4.8.1.1

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Table 4.8.1.1 Changes in component design requiring requalification

Minor change Major change

Reinforcement - reinforcement manufacturingprocess

- reinforcement composition

- reinforcement finish (sizing)- filament diameter

- tow tex- type of fibre

Thermoset resin - curing system supplier- curing temperature- curing schedule

- resin grade- curing system type

Thermoplastic - supplier - grade- type

Design - geometry, dimensionswinding angle (> 5%)

- reinforcement weightweight fraction (> 5%)

Manufacture - change of manufacturing plant

Note: The qualification reports and summaries of each such revalidated variant shall be

amended to include reference to this revalidation and the relevant details.

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5. QUALITY ASSURANCE AND CONTROL

5.1 GENERAL

The Manufacturer shall have a suitable (ISO 9000) and accredited (Lloyds, DNV, or

equivalent) quality assurance and quality control system.The Supplier shall identify manufacturing processes and activities that affect componentperformance and shall ensure that these processes and activities are adequatelycontrolled. Critical processes or activities for which procedures should be developed andmaintained include, but are not limited to, the following:

raw material acceptance;

resin mixing (GRP);

extrusion procedures (thermoplastic liner, RTP);

pipe manufacturing practices;

inspection and test procedures;

acceptance / rejection criteria;

repair procedures;

training and certification of personnel;

training and certification of inspectors;

marking, packing, handling and transportation.

In addition, a quality plan and flow diagram shall be produced, showing all the proposedtests and inspections during component fabrication).

All records, documents and procedures shall be made available for inspection upon requestby the Principal.

It shall be the responsibility of the Manufacturer to maintain copies of the relevant records,documents and procedures for a minimum of five years from the date of commissioningacceptance.

5.2 QUALITY CONTROL EQUIPMENT

All inspection, measuring, and testing equipment shall be maintained and calibrated.

Test pressure measuring devices shall be either pressure gauges or pressure transducerswith a full-scale range of no more than two times the test pressure and shall be accurate toat least 0.5 % of full-scale range. A dead weight testing device shall be available at theManufacturers facility to calibrate gauges. All pressure measuring devices shall becalibrated with a dead weight pressure tester or other suitable device every six months.

5.3 MILL HYDROSTATIC TEST

After manufacturing, 100% of the spoolable pipe components shall be hydrostatically testedat a pressure of 1.5 times the qualified NPR. Testing of shorter lengths is permitted,however, the minimum test length shall be 5 times pipe diameter.

Hydrostatic test pressure shall be maintained for a minimum of two minutes in order toascertain there is no leakage. If practicable, test components shall have unrestrained ends.Test temperature shall be ambient.

5.4 ONGOING PRESSURE TESTS

Pressure testing of spoolable pipe component shall be based on the continuous productionschedule rather than specific project orders.

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A minimum of two 1 000 h tests of at least two product sectors shall be performed eachyear in accordance with Section 4.5, on a continuous basis from the production unit,irrespective of pressure rating, diameter and wall thickness.

If any of the 1 000 h tests are failed, then an inspection of the plant production process andquality control procedures shall be required. Also, the previous production batch shall berejected.

Components thathave been subjected to these tests shall not be used as part of apipe(line) system.

5.5 FIBRE CONTENT

The fibre content (mass percentage) of the reinforced wall shall be determined inaccordance with ISO 1172, at a frequency of 1% continuous production. Unless otherwiseagreed by the Principal, the fibre content (mass fraction) shall be within +/- 5% of the meanvalue quoted by Manufacturer.

If the fibre content is not within the specified range, then the previously producedcomponents, up to the last successful test sample, shall be rejected.

5.6 DIMENSIONS

All dimensions shall be compared with the baseline values determined for the qualifiedproduct family representative. The following dimensions shall be determined in accordancewith ASTM D 3567 for at least 1 % of continuous production:

internal diameter;

outside diameter;

mass;

liner thickness;

minimum liner thickness;reinforced wall thickness.

The measurement location on the component shall be the same as that used to determinethe baseline value for the qualified product. Any out-of-tolerance components shall berejected.

5.7 QUALITY CONTROL RECORDS

5.7.1 General

The quality control records are required to substantiate that all components manufacturedto this PTS conform to the specified requirements.

5.7.2 Records control

Quality control records required by this PTS shall be:

legible, identifiable, retrievable and protected from damage, deterioration or loss;

retained by the Manufacturer for a minimum of five years following the date ofcommissioning acceptance;

signed and dated.

5.7.3 Records to be maintained by Manufacturer

The Manufacturer shall maintain the following records for a minimum of 5 years:

test results in accordance with Section 5;

any records related to Manufacturers process documentation.

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5.7.4 Prefabrication documentation

Raw material certificates shall be available for review by the Principal prior to the start ofmanufacture.

5.7.5 Production quality control reports

The Manufacturer shall prepare a set of quality control reports for the supplied components.These reports shall demonstrate that the delivered components have been manufactured inaccordance with the requirements listed herein.

The quality control report shall:

identify the components (including type, nominal diameter, rated pressure andtemperature), their date of manufacture, production identification information code andthe manufacturing procedure used for their production;

reference the prefabrication documentation;

report the quality control tests.

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6. COMPONENT MARKING

6.1 GENERAL

Components manufactured in accordance with this PTS shall be marked by the

Manufacturer (6.2). Additional project related markings as desired by the Manufacturer oras requested by the Principal should be included. Markings shall be applied by paint or inkstencil, decal, or both as agreed upon between the Principal and Manufacturer. Markingsshall be permanent, shall not overlap, and shall be applied in such manner as not todamage the pipe. Markings shall be applied on the pipe components within one metre ofthe end.

6.2 REQUIREMENTS

All pipes and fittings shall be permanently marked with:

Manufacturers name;

rated pressure, tensile load and temperature;

nominal diameter;

Manufacturers identification code;

date of manufacture.

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7. HANDLING, STORAGE AND TRANSPORTATION

7.1 HANDLING

All pipes shall be cleaned, dried and packed before handling and transportation.

Thermoplastic pipe is susceptible to damage by abrasion and by sharp objects.Spools of pipe tend to be top-heavy loads, and shall be handled with care to avoidoverturning the spool and damaging to the pipe and/or spool

A spreader bar and non-metallic slings, e.g. nylon, should be used when moving spoolswith a crane. Moving the spool by rolling shall not be permitted.

7.2 STORAGE

Pipe end covers shall be used to prevent ingress of moisture or dirt to the inside of the pipe.

Pipe spools should be stored on level flat surfaces with no protruding objects that maycontact and damage the pipe on the external layer.

During long-term storage, the pipe should be protected from freezing water that still may be

present in the pipe, e.g. from hydrotesting.

7.3 TRANSPORTATION

During field transport, e.g. for deployment, the spool shall be mounted in a suitable spoolingframe. Transport should be on a trailer that is as close to the ground as practical. Spaceconstraints and obstacles, especially at a development site, may pose a problem duringtransportation. Alternative safe methods should be considered.

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8 INSTALLATION AND TESTING

8.1 GENERAL

Installation methods shall be agreed between the Principal and Manufacturer. Copies of

installation methods, procedures and quality plan shall be available on-site before workcommences.

8.2 FLUSHING

On completion of installation, the pipe system shall be flushed. The medium used forflushing shall be seawater or freshwater. All lines requiring a pressure test shall be flushedprior to testing.

Flushing should preferably be carried out at temperatures above 7oC. When flushing with

fresh water in sub-zero temperatures, precautions shall be taken to avoid freezing of thewater in the pipe(line) system, i.e. the water should be continually circulating, or glycolantifreeze added, or the system should be drained for the duration of sub-zerotemperatures.

8.3 HYDROTEST

The spoolable pipe systems shall be hydrostatically pressure tested after installation.Preferably, the system should be installed so that smaller parts of a system can bepressure tested separately and at the earliest opportunity during construction.

Water shall be admitted at a low point in the system and provision shall be made forbleeding the air at high points (e.g. by loosening couplings or flange connections). Anycompressed air in the system may give erroneous results. Removal of air pockets willprevent damage to the pipe and injure personnel in the event of an unexpected failureduring the pressure test.

The test pressure shall be raised over a period of 30 minutes or longer to 1.5 times thesystem design pressure, and held for a period of 15 minutes, or longer. The rate ofpressurisation shall not exceeed 2 bar per minute.

A further leak test at 1.1 times the system design pressure should also be carried out for aminimum of 24 hours.

The pressure during the hydrotest and the leak test shall be recorded continuously.

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9. REFERENCES

In this PTS, reference is made to the following publications:

NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,together with any amendments/supplements/revisions thereto.

2. The PTSs and most referenced external standards are available to Shell users on the SWW(Shell Wide Web) at http://sww05.europe.shell.com/standards/

PETRONAS STANDARDS

Defenition of temperature, pressure and toxicity levels PTS 01.00.01.30

Non-Metallic MaterialsSelection and Application PTS 30.10.02.13

AMERICAN STANDARDS

Process piping ASME B31.3

Issued by:American Society of Mechanical EngineersASME InternationalThree Park Avenue, M/S 10E

New York, NY 10016USA

Specification for high pressure fiberglass line pipe API 15 HR

Specification for Unbonded Flexible Pipe API 17J

The Ageing of PA-11 in Flexible Pipes API 17TR2

Issued byAmerican Petroleum InstitutePublicastions and Distribution Section1220 L Street NorthwestWashington DC 20005USA

Standard practice for determining chemical resistance of

thermosetting resins used in glass-fiber reinforced structuresintended for liquid service

ASTM C 581

Test method for time-to-failure of plastic pipe under constantinternal pressure

ASTM D 1598

Test method for short-time hydraulic failure pressure of plasticpipe, tubing, and fitings

ASTM D 1599

Standard Test Method for Longitudinal Tensile Properties of"Fiberglass" (Glass-Fiber-Reinforced Thermosetting-Resin) Pipeand Tube

ASTM D 2105

Standard Test Methods for Steel Tire Cords ASTM D 2969

Standard Practice for Determining Dimensions of Fiberglass(Glass-Fiber-Reinforced Thermosetting Resin) Pipe and Fittings

ASTM D 3567

Issued by:American Society for Testing and Materials100 Barr Harbor DriveWest ConshohockenPA 19428-2959USA.

INTERNATIONAL STANDARDS

Plastics - Unplasticized Poly (Vinyl Chloride) (PVC-U) Mouldingand Extrusion Materials - Part 1: Designation System and Basisfor Specifications

ISO 1163

Textile Glass Reinforced Plastics - Determination ofLoss on Ignition

ISO 1172

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Plastics - Polyethylene (PE) Moulding and Extrusion Materials -Part 1: Designation System and Basis for Specifications

ISO 1872

Plastics - Polyamide (PA) Moulding and ExtrusionMaterials - Part 1: Designation

ISO 1874

Quality management and quality assurance standards ISO 9000

Paints and varnishes - Exposure of coatings to artificialweathering - Exposure to fluorescent UV and water

ISO 11507

Extruded Sheets of Polypropylene (PP) - Requirements and TestMethods

ISO 15013

Extruded Sheets of Polyvinylidene Fluoride (PVDF) -Requirements and Test Methods

ISO 15014

Issued by:International Organisation for StandardisationCase Postale 56Geneva 20 Switzerland CH-1211.

Copies can also be obtained from national standards organisations.