02625 GRP Pipe for Seawater

SECTION 02625 GLASS FIBER REINFORCED PLASTIC PIPE (GRP) (FOR SEAWATER PIPE)

PART 1 – GENERAL 1.1

DESCRIPTION OF WORK

A.

The work of this Section includes requirements for glass fiber reinforced plastic pipe (GRP), couplings, fittings, and accessories for seawater supply and return systems. This Section applies to underground seawater piping required for site work. For specifications applicable to process piping work refer to Division 15 and Section-D4.

B.

Pipe and fittings shall be a corrosion resistant flexible composite piping fabricated to transport aggressive industrial water under a pressurized system.

C.

Related Work: 1.

Section 02200:

Earthwork

2.

Section 02610:

Pipe and Pipe Fittings

3.

Section 02623:

Glass Fiber Reinforced Plastic Pipe for Service Other Than Seawater System

4.

Section 02713:

Water Distribution Systems.

5.

Section 15103:

Valves and Expansion Joints for Seawater Service

6.

Section 15643:

Condenser and Accessories

7.

Section 15913:

Flow Meters (Seawater System)

1.2

PIPE MATERIAL REQUIREMENTS

A.

The material, design and fabrication for the large diameter pipe seawater cooling system shall be: 1.

Filament wound reinforced thermosetting resin (glassfiber) pipe in accordance with AWWA Standard C-950.

2.

The term "large diameter pipe" used in this document shall apply to conditions common to pipe sizes 600 mm diameter and larger to be used in seawater cooling system.

P.O. Number : 7200018725

1.3

EQUIPMENT AND CONTRACTOR

SERVICES

TO

BE

FURNISHED

BY

A.

The materials and services shall be supplied in accordance with this document and the details and notes on the approved construction drawings.

B.

Contractor shall include the services of pipe manufacturer's representative for advice and consultation at the jobsite during installation of the large diameter pipe. Contractor shall provide MARAFIQ with written site storage instructions and plans.

C.

Contractor shall provide manufacturers' recommended procedures for installing the large diameter pipe including the preparation of trenches, bedding, and backfill.

D.

The quantity of pipe furnished by Contractor shall include one (1) excess standard length, plus four (4) gaskets and couplings for each pipe size.

E.

Other services to be furnished by Contractor shall include the following: 1.

Detailed drafting and design for layout and alignment of all pipes and accessories.

2.

Inspection and Testing according to the manufacturer’s recommendation procedures and the Contract Specifications.

3.

Documentation as specified herein.

4.

Procurement, expediting, scheduling and other services which shall ensure prompt delivery or availability at jobsite of all fabricated materials specified, including fittings and accessories.

F.

Contractor shall submit a design analysis report to substantiate the application of pipe material and construction to be used in the seawater cooling system site based on a 30-year life.

G.

Contractor shall supply the equipment and services for: 1.

Unloading, storing, installing and testing the pipe after installation.

2.

Excavation, bedding, trenching and backfilling.

3.

Site storage.

P.O. Number : 7200018725

1.4

SITE CONDITIONS

A.

Equipment furnished in accordance with this document shall be suitable for installation and operation under the conditions shown in Table 1. 1.

Freeze protection is not required.

B.

Seismic Risk Assessment: The Madinat Yanbu Al-Sinaiyah area, is equivalent to Zone 1 as proposed in Madinat Yanbu Al-Sinaiyah Building Code.

C.

Climate: The coastal site at the Red Sea is subject to occasional sandstorms.

D. in

Installation Location: The furnished large diameter pipe will be installed Madinat Yanbu Al-Sinaiyah.

E.

Operating and Performance Requirements: 1.

The large diameter pipe furnished and installed under this specification shall operate at the below listed requirements: Location

Underground (buried)

Water Quality

Seawater from the Red Sea (See Section 15643)

Water Temperature

42°C Max.

Max. Working Pressure

51.1 Meters (Water), Contractor to verify.

Expected life span at design 30 years pressure with the same flow characteristics

Ground water quality

Brackish and comparable to seawater above (see Section 15643)

P.O. Number : 7200018725

1.5

QUALITY ASSURANCE

A.

Source Quality Control: The following tests shall be carried out at least once a day during the manufacturing period:

B.

1.

Determination of glass/resin composition as per ASTM D2584.

2.

Determination of the Barcol hardness of the laminate as per ASTM D2583.

3.

Determination of the laminate strength of tensile bars extended in the longitudinal direction of the pipe as per ASTM D638.

4.

Determination of pipe stiffness using a 300 mm long pipe sample, carried out in accordance with ASTM D2412.

Codes and Standards: The design, material, fabrication, inspection, and testing of all materials furnished shall be, unless otherwise specified, in accordance with the latest revisions of the applicable codes and standards of the following United States regulatory agencies and standards organizations in force on date of Award of Contract. In the event of conflict between this Document and any codes or standards, the Contractor shall refer this matter to MARAFIQ for resolution. American Society for Testing and Materials (ASTM) American Society of Mechanical Engineers (ASME) American Welding Society (AWS) American Water Works Association (AWWA) International Standard Organization (ISO) National Fire Protection Association (NFPA) Steel Structures Painting Council (SSPC) American Iron and Steel Institute (AISI) Hydronics Institute (HI) Underwriters' Laboratories, Inc. (UL) Pipe Fabricators Institute (PPI) American National Standards Institute (ANSI)

P.O. Number : 7200018725

C.

Material meeting other standards, which ensure quality and safety equal to or higher than United States standards, regulations, and codes, will also be acceptable, subject to the approval of MARAFIQ. In these instances, the Contractor shall be required to demonstrate the equivalency of the standard(s), and shall furnish MARAFIQ with one copy of the standard(s), used for the design and fabrication of the equipment.

D.

Contractor shall be responsible for the quality of pipe in accordance with the material, fabrication, qualification testing, and acceptance requirements of the ASTM Standards and, specifically, the ASME Boiler and Pressure Vessel Code, Section III, Division I, Code Case N-155-2 (1792-2) except as amended herein. Piping supplied shall only be from material manufacturers and material suppliers as defined by the code case.

E.

GRP Pipe Applicable Documents: In addition to documents listed in 1.5 B, the following documents and references shall be used when applicable as a source for GRP pipe data to fulfill the requirements of this document. 1.

Raw Materials: ASTM D 2393 and D 445 Viscosity of Resin ASTM D 2343 Tensile Properties of Glass Fibers

2.

General GRP Pipe Specifications: AWWA C-950 Glass-Fiber-Reinforced Thermosetting-Resin Pressure Pipe ASTM D 2996 RTR Filament Wound Pipe ASME Code Case 1792-2 (N-155-2) Nuclear RTRP Standards PS 15-69 GRP Products ASTM D 3139 Elastomeric Joints

3.

Pipe Design Standards: ASME Code Case 1792-2 (N-155-2) Nuclear Pipe Standards

P.O. Number : 7200018725

ASTM D 2353 Method for Calculating Internal Pressure Stress ASCE Proceeding 37 M & R No. 37 Chapter 9 NSI B16.1 and B16.5 Standard Dimensions for Cast Iron and Steel Flanges ASTM D 2992 Hydrostatic Design Basis ASTM D 3567 Dimensioning of RTR Pipe and Fittings 4.

Tests for Material Properties of Finished Product: ASTM D 2583 Barcol Hardness of Product ASTM D 638 Tensile Properties ASTM D 790 Flexural Properties ASTM D 695 Compressive Properties of Rigid Plastic ASTM D 1599 Short-Time Rupture Strength of Pipe ASTM D 2105 Longitudinal Tensile Properties of RTRP ASTM D 2412 External Loading Properties by Parallel-Plate Loading ASTM D 2563 Level III Classifying Visual Defects in GRP Laminate Parts AWWA C 207 Steel Pipe Flanges for Waterworks Service (4 in. to 144 in.)

P.O. Number : 7200018725

F.

Factory Tests (GRP Pipe): 1.

General:

(a)

The manufacturer shall test the material for random sections of pipe or fittings at a rate that ensures at least one test lot for every 250 meters of pipe which is produced. The manufacturer shall obtain coupon test samples from nozzle cut-outs, miter cuts or from a section of pipe which has not had its thickness increase by the dwell turn at the ends of the pipe section.

(b)

Factory tests for GRP pipe shall include but not be limited to tests designated in this section.

2.

Destructive Tests: The following random destructive tests shall be performed:

(a)

Tensile Strength and Tensile Modulus: These properties may be verified by following test methods utilizing strain gages as specified by ASTM D 638. The shape of the sample coupon must be adjusted to accommodate the orientation of the continuous glass filaments.

(b)

Flexural Modulus: The flexural modulus of the glassfiber component may be determined by measuring a sample coupon with strain gages in accordance with ASTM D 790. The shape of the coupon must be adjusted to accommodate the orientation of the continuous glass filaments. For components of a diameter of less than 2 meters, parallel plate loading tests shall be performed in accordance with ASTM D 2412.

G.

(c)

Elastomeric Joint Testing: The Contractor shall document joint integrity from tests of previously installed and operating fibreglass piping systems or by means of other testing that the proposed joint is of sufficient strength to survive the anticipated service conditions without leakage or fracture.

(d)

Testing Resin/Glassfiber Overlay Joints: The integrity and strength of a resin/glassfiber overlay joint shall be analytically evaluated to ascertain that the strength of the overlay joint is at least equal to or greater than the axial strength of the GRP pipe. Visual inspection of the overlay joint will be performed to ascertain its reliability.

Proof of Design Test: The basis of design of fiberglass pipe shall be verified by tests conducted on representative specimens prior to manufacture of any of the pipe furnished in accordance with this document.

P.O. Number : 7200018725

Certified reports covering tests made on other pipe of the comparable size, wall thickness, and design as specified herein and manufactured from materials of equivalent type and quality will be accepted as adequate proof of design. H.

Testing for Pipe Integrity: Testing shall be conducted to ensure that the fiberglass piping is able to resist the imposed longitudinal loads of, among others, internal pressure and thermal gradients plus the combined hoop loads of deflection, buckling, and internal pressure. This longitudinal strain is generated by the resistance to the free shortening of the pipe by the cohesion of the surrounding soil, the Poisson Effect, and cooling temperature. The integrity of the fiberglass piping described herein shall be tested on the basis of allowable strain. The pipe manufacturer shall establish the allowable strain for the pipe by means of Hydrostatic Design Basis (HDB) test in accordance with Procedure B of ASTM D 2992, or by means of accelerated aging coupon testing using strain gates to measure the point of strain-to-first-crack (weep point). The test shall be performed so that both the internal and external surfaces of the test sample are fully immersed in water. When the strain-to-first-crack has been established, a 5 to 1 safety factor shall be applied to this figure and be used in all engineering calculations required to determine the appropriate wall structure for normal design conditions. Contractor shall also submit certified documents showing that accelerated aging tests have been conducted by the fiberglass manufacturer. The tests shall demonstrate the suitability of fiberglass pipe materials to withstand the environmental conditions to which it will be exposed during its expected 30-year life. For transient design conditions, a safety factor of 3 on Maximum Working Pressure or as determined during the design verification shall be used. When using Procedure B of ASTM D 2992 as the test basis, a minimum safety factor of 2 shall be applied as normal design maximum allowable strain. In the absence of such test data, the manufacturer shall not exceed the following strain levels in either the internal or external pipe surfaces: Normal design conditions 0.0018 cm/cm max. Transient design conditions 0.0030 cm/cm max.

1.6

SUBMITTALS

A.

Certification: Provide pipe manufacturer's certificate of manufacture. The following data shall be included as a minimum, except where MARAFIQ approval of alternate data is acceptable. 1.

The method of manufacture; construction of Laminate.

P.O. Number : 7200018725

B.

2.

Laminate structure in the circumferential and longitudinal directions of the pipe.

3.

Wall thickness of pipes with tolerances.

4.

Type of resin used.

5.

Type of internal liner.

6.

Type and quality of glass reinforcement.

7.

Glass/resin composition with tolerances.

8.

Type and amount of filler, if any.

9.

Stress regression curves for pressure pipe in the circumferential direction of the laminate at +23°C to at least 10,000 hours. The curves shall be based on the results of tests carried out in principle in accordance with ASTM D 2992 or on the results of a similar method of testing to be approved by the MARAFIQ.

10.

Determination that pipes are capable of being deflected in the longitudinal directions without failure when exposed to 1.0N (5% by weight) H2SO4 in accordance with ASTM D 3681.

Design Calculations: Contractor shall supply detailed design calculations showing calculated strain levels and the safety factors that have been applied. Design loads shall include HS-20 wheel loads plus a minimum of 10% impact, at grade level. The pipes shall be designed in such a way that the strain in the pipe shall be in accordance with AWWA C950.

C.

Contractor shall submit, for approval by MARAFIQ, detailed plan program for all tests and inspections to be performed.

and

MARAFIQ reserves the right to inspect manufacture, review manufacturing procedures, check dimensions against drawings, and review materials, etc. MARAFIQ also reserves the right to monitor Contractor's subcontractors where desired. D.

Written notice shall be given to MARAFIQ of all factory tests sufficiently in advance so that arrangements can be made to have a representative present. Witnessing or waiving of witnessing of factory tests shall not relieve the vendor of the responsibility for furnishing the equipment in accordance with specifications.

E.

Four sets of certified factory test reports shall be furnished to MARAFIQ upon completion of factory tests.

P.O. Number : 7200018725

F.

Jointing procedure for GRP pipe.

G.

Delivery, handling and storing procedure.

H.

Drawings for approval: In addition to above, the following project specific shop drawings and calculations shall be submitted for MARAFIQ approval. 1.

Detail drawings showing the details of each section of pipe, tees, bends, couplings, expansion joints, branch connections and other fittings. These drawings shall show, at a minimum, the cut lengths, installation lengths, diameter, overlays, reinforcing pipe rib types and spacing, and mark/tag numbers.

2.

Assembly/Erection drawings showing the plan and profile of seawater supply and return systems, identifying mark/tag numbers of all pipes fittings and valves used in the assembly, installation lengths and slopes. Each assembly/erection drawing shall show a key plan identifying the location of work and also a bill of materials required for the work shown on the drawing.

3.

Design calculations and detailed drawings for the concrete structures, including valve chambers, thrust/anchor blocks and concrete encasements, showing details of rubber wraps, extrusions and expansion joints at pipe connections with rigid structures.

4.

Contractor shall also provide project specific calculations to show that when the pipes are empty, the installation is safe against possible floatation due to ground water.

PART 2 - DESIGN CONSIDERATIONS 2.1

GENERAL

A.

Service - Seawater supply for cooling is pumped through the large diameter pipe from the pump house located at Power Plant (PD&SCD). Seawater return is pumped into a common return pipe to the sealwell at the outfall channel.

B.

Flowing Medium - Seawater from the Red Sea with characteristics as indicated in Section 15643.

C.

At interface points resultant forces and moments must be zero.

D.

Soil Conditions: 1.

Soil reaction modulus E = 28.12 kg/cm2 at 1.2 meters below grade.

P.O. Number : 7200018725

E.

Thrust blocks shall be provided at all changes in direction of the pipe. Thrust blocks in the seawater supply and return systems shall be designed for a hydrotest pressure of 5.0 Bars and 3.0 Bars, respectively or 1.5 times the maximum operating pressure, whichever is higher.

F.

Blind flanges shall be provided at the location of end point and/or interface point for future extension of the pipe systems. (End caps shall not be allowed, except where specifically shown on the drawings). Concrete anchor blocks shall be provided to retain the blind flanges. Design pressures for anchor blocks shall be as given in 2.1.E above.

G.

Valves and expansion joints shall be installed in concrete chambers. Valve flanges shall be appropriately anchored to resist the forces caused by valve in a closed position, at the same time allowing for required movement of the expansion joint.

H.

Air release valves and combination air and vacuum valves shall be located as shown on approved design drawings.

2.2

PRESSURE AND LOADING LIMITATIONS

A.

Comply with following minimum requirements for each class of pipe: 1.

Operating Pressure

36.5 M of Water

2.

Max. Operating Pressure

51.1 M of Water

3.

Surge Pressure

140% of Operating

4.

Maximum Vacuum

-5.0 M of Water

5.

Max. Installed Vertical

Per final design but Deflection not more than 5%

6.

Min. Cover for AASHO H-20 Truck Loading plus impact

1.2 M or enough backfill to prevent floatation whichever is more.

7.

Design Temperature

42°C

8.

Total anticipated pressure including water hammer

51.1 M of Water

2.3

GLASSFIBER PIPE

A.

The GRP pipe shall be manufactured by the glass filament winding process using a thermosetting polyester resin to impregnate the strands of closely spaced continuous glass filaments around a straight

P.O. Number : 7200018725

mandrel at a predetermined pattern and under controlled tension as described in ASTM D 2996. B.

Contractor shall design all GRP pipe, fittings, and joints to resist loads imposed on the piping system in accordance with the design criteria which is herein described for the pipe arrangement shown on the approved construction drawings. The final design must reflect consideration of the combined longitudinal, circumferential, and lateral loads which will be imposed on the installed piping system and which will sustain a minimum service life for 30 years. Contractor must assume the worst possible loading and support conditions produced by the interaction of the soil with the piping's rigid wall structure. In addition, load effects must be considered as contributed by a possible unsupported length of two pipe diameters, the composition of the existing soil, the recommended backfill, compaction requirements, anchor blocks, trench width, the effects of ground water, live and surcharge loads, and handling procedures. For these combined loads, the maximum deflection must not exceed 5% of the pipe diameter, unless the allowable stress limits this deflection to a smaller percentage.

C.

Contractor shall also perform a mathematical buckling analysis to determine the minimum wall structure by superimposing internal vacuum conditions of an empty pipe to the external loads described in the previous section. A safety factor of 2.5 shall be used in this analysis in accordance with AWWA C-950.

D.

The pipe shall be supplied with a double bell coupling joint (REKA Joint) for all sizes/diameters categorized as larger diameter pipes (600 mm and larger). Joints of pipes larger than 1100 mm diameter shall be hydrostatically tested after connection by an internal joint tester.

E.

All fittings shall be designed to withstand the same stresses as the adjacent pipes with the appropriate intensification factors.

F.

Branch connections for openings such as manholes and air/ vacuum valves shall be flanged and incorporated in straight pipe and shall be suitably reinforced.

G.

All flanges supplied shall be constructed and drilled at 8.79 kg/cm2 (125 psi) rating per ANSI B 16.1 for all flange sizes up to 2400 mm (96 inches) and AWWA C-207 Class D for all larger size flanges up to and including 3700 mm (144 inches) nominal diameter. The flange thickness shall be designed by the Contractor to satisfy the conditions of 75 psi for pipe material specified. Exposed portions of steel cylinders on which flanges will be mounted shall be 50.8 mm longer than designed to allow for field fit-up.

P.O. Number : 7200018725

H.

All flange bolts, nuts, washers, gaskets and attachments shall be furnished by the Contractor for each joint. Bolts, nuts and washers shall be of aluminium bronze, monel or similar non-corrosive metal to be compatible with the pipe material in submerged seawater service. Gasket materials shall be ethylene propylene (EPM and EDPM rubber) or approved equal.

I.

Isolation ferrules shall be used in bolt holes to prevent direct contact of nuts and bolts with dissimilar metallic flanges, where applicable.

J.

Contractor shall provide a manhole near each pipe bend, at 300 meter intervals in straight pipe runs and as indicated on approved construction drawings. The manholes shall be strategically located to cover all low points so that while draining the pipeline, the water accumulated at low points of pipeline can be pumped-out with the help of a portable pump. These portable pumps will be operated thru the maholes.

K.

The pipe shall be constructed with resin materials so as to include internal and external corrosion barriers of a composition suitable to resist the corrosive effects of the contained and surrounding environments.

PART 3 - PRODUCTS 3.1

ACCEPTABLE MANUFACTURER AND LICENSEE

A.

Below manufacturer and licensee of glassfiber reinforced plastic pipe (GRP) is acceptable to MARAFIQ provided it meets this specification. Amiantit Fiberglass Industries, Ltd. P.O. Box 589 Dammam, Saudi Arabia

B.

Other manufacturers and suppliers within the Kingdom shall be considered, provided they meet the requirements of this specification and approved by MARAFIQ.

3.2

PIPE AND COUPLINGS

A.

Pipes and couplings are a corrosion resistant flexible composite underground pressure piping system. It shall be a composite laminate consisting of a corrosion resistant liner, a structural layer and an external layer. 1.

The interior layer shall be approximately 1.25 mm thick consisting of fiberglass surface mat backed by chopped fiberglass roving impregnated with a thermosetting polyester resin.

P.O. Number : 7200018725

2.

The structural layer shall be a combination of closely spaced continuous glassfiber filament windings and glassfiber chopped rovings. The structural layer shall be impregnated with a thermosetting polyester resin. The glassfiber roving are of "E" type.

3.

The exterior layer shall consist of glassfiber rovings impregnated with thermosetting polyester resin. U.V. inhibitor will be added to the external of all fiberglass piping system components.

4.

Reinforcement ribs may be used to structurally reinforce the pipe wall of the 2400 mm diameter and larger. The ribs shall become integral part of the pipe section without allowing any intrusion of water into the rib form. They shall be continuous filament wound type and must be protected in the same manner as specified for the external surfaces. In addition, the effects of strain in the outermost surfaces of the ribs must be calculated in accordance with the combined hoop strain analysis which examines the pipe for conditions of vacuum pressure, minimum pressure, normal design pressure and maximum transient pressure.

5.

Resin glassfiber overlay reinforcement shall be added to butt and strap joint for connecting straight pipe to flange ends.

6.

The length and thickness of the overlay at the joint shall have a strength equal to or greater than the strength of the pipe.

7.

Flanged connections shall be used to connect fiberglass pipe and fittings and auxiliary equipment, such as valves, expansion joints, etc. Such flanges shall be constructed by hand lay-up methods with drilling orientation to match ANSI B 16.5 or B 16.1 rating 125 psi for sizes up to 2400 mm and AWWA C-207 Class D for all larger size flanges up to including 3700 mm nominal diameter.

8.

B.

The flanged joint shall be designed with the same hydrostatic test capability as the joint. Also see PART II - DESIGN CONSIDERATIONS.

Mechanical Properties: Nominal design properties for structural layer of pipe wall. 1.

The pipe diameter greater than 2100 mm.

P.O. Number : 7200018725

Ultimate Tensile

Circumferential

Longitudinal

(PSI)

(KPA)

(PSI)

(KPA)

58,681

404,899

13,330

91,977

3,123,861

21.55x106

1,525,684

10.5x106

Strength Ultimate Tensile Modulus

2.

The pipe diameter 2100 mm and smaller.

Ultimate Tensile

Circumferential

Longitudinal

(PSI)

(KPA)

(PSI)

(KPA)

75,393

520,211

8,630

59,547

3,640,839

25.12x106

1243,664

8.58x106

Strength Ultimate Tensile Modulus C.

Couplings: 1.

Couplings shall be double bell type and able to provide at least 1 degree of joint rotation and withstand at least 38 mm (1 1/2 inches) pull-out without jeopardizing joint integrity. Sealing of the double bell coupling is accomplished by the controlled compression of the elastomeric gasket rings.

2.

Rubber ring type gaskets used in association with couplings to form watertight seals at specified condition shall be manufactured to comply with the chemical resistance characteristics for the seawater service (Table 1) and temperature requirements in accordance with Para 2.2.A. Gaskets and lubricants selected shall be compatible with pipe material and shall not support growth of bacteria. Each gasket shall be tested at 100% stretch and examined for any defects while in the stretched condition.

P.O. Number : 7200018725

D.

Raw Materials: 1.

Resins: The resin system selected for the internal corrosion barrier shall be a suitable thermosetting polyester. This resin shall be an isophthalic type. The structural wall portion of the filament would construction shall utilize a isophthalic, thermosetting, polyester and the outer portion of this structural wall shall contain an ultraviolet absorber in order to prevent chalking and assist in weathering capabilities, etc.

2.

Glass: The reinforcing glass fibers used to construct the components necessary for this Fiberglass System shall be a commercial grade of "E" glass filaments meeting the requirements of MIL R60346 B with binder and sizing compatible with the impregnating resin.

3.

Filler: The fillers shall not be added to resins except as required for viscosity control or fire retardance. The limit of filler addition shall be 5% by weight of thixotropic agent which will not interfere with visual inspection. Sand fillers shall not be permitted.

4.

All bolts, nuts and washers, shall be of aluminium bronze, monel or technically equivalent non-corrosive metal and compatible with the pipe material for submerged seawater service.

3.3

RUBBER WRAPS AND EXTRUSIONS

A.

Provide special rubber wraps and rubber extrusions for pipes connected to rigid structures such as valve pits, thrust blocks and manholes to minimize excessive bending stresses that may develop in the pipe if differential movement occurs between the pipe and the rigid structure. Specific usage and dimensions for each type shall be in accordance with the pipe manufacturer's written instructions.

B.

The rubber wrap and rubber extrusion material shall be extruded polyisoprene rubber and shall conform to the requirements of ASTM C361, C443 and C505. Mechanical/ physical properties shall be as follows: Tensile strength (ASTM D412):

2300 psi min.

Percent Elongation (ASTM D412):

425% min.

Shore Durometer Hardness (ASTM D2240):

40 - 60 +5

Compression Set (ASTM D395):

20% max.

Ozone Resistance (ASTM D1171):

Rating 0

P.O. Number : 7200018725

PART 4 – EXECUTION 4.1

FABRICATION AND MANUFACTURE

A.

Geometrical Characteristics:

B.

1.

The internal and external surfaces of the pipes shall be clean and free from defects such as blisters, voids, cracks, protruding fibers, marks or foreign matter, etc., that might impair the functional properties of the pipe. The internal surface of the pipes shall be smooth. The pipes must be entirely free from delamination defects. Visual defects will be per the ASTM D 2563 Level 3.

2.

The tolerances for wall thickness, diameter, and out of roundness of the pipes shall be kept to limits within which there are no adverse effects on the fiberglass of the joints and the performance of the pipes in service.

3.

All fittings shall be designed to withstand the same loads as the adjacent pipes.

4.

Manholes and air valves shall be flanged and incorporated in straight pipe and shall be suitably reinforced.

Pipe Wall Construction: 1.

Interior Surface: The interior wall of the pipe (sometimes called the liner or internal corrosion barrier) shall be constructed so as to have a smooth, resin-rich surface. This surface shall not contain dyes or fillers which can hinder visual inspection. The external layer of the interior surface shall be reinforced with a highly corrosion resistant veil of either "C" glass material backed with Fiberglass impregnated with polyester thermosetting resin. The total thickness of the inner liner shall not be less than 90 percent of 1250 micrometers (50 mils) thickness and shall not have a glass content exceeding 35 percent. Contractor shall ensure that any "parting" medium used to prevent bonding between the mandrel and pipe walls, during manufacture, has been completely removed, prior to installation.

2.

Wall Structure: The structural wall of pipe shall consist of closely-spaced continuous glass filaments would per manufacturer's standards which shall, in turn, conform to ASTM standards.

3.

External Surface: A resin-rich post coat containing an ultraviolet screening agent must be applied to the external surfaces of all of the fiberglass piping system components. This protection

P.O. Number : 7200018725

must be provided for both above and below ground components. In addition, all external surfaces must be able to resist the anticipated corrosion imposed by the service conditions. Furthermore, components which will be installed below ground must have an external surface able to resist the anticipated strains imposed by standing surface water. 4.

Reinforcement Ribs: Where stiffener ribs are used to structurally reinforce the pipe wall, they shall be continuous filament wound type and must be protected in the same manner as specified for the external surfaces. In addition, the effects of strain in the outermost surfaces of the ribs must be calculated in accordance with the combined hoop strain analysis which examines the pipe for conditions of vacuum pressure, minimum pressure, normal design pressure, and maximum transient pressure.

5.

Resin glassfiber overlay reinforcements shall be added to butt and strap joints connecting straight pipe to flange ends.

6.

The length and thickness of the overlay at the joint shall have a strength equal to or greater than the strength of the pipe.

C.

Flanged connections shall be used to mate glassfiber pipe and fittings with ancillary equipment, such as, valves, expansion joints, etc. Such flanges shall be constructed by the filament winding and hand lay-up methods with drilling orientation to match ANSI Standard B 16.1 as specified for interface conditions.

D.

Fittings and Pipe Spools: 1.

Pipe, fittings, and specials shall be produced either by the openmolding process (with a perform mold overlayed with alternate layers of chopped mat and woven wire) or by fiberglass welding mitered segments of filament-wound pipe into a single fitting.

2.

Where required, pipe sections adjacent to a pipe spool piece shall be prepared with butt ends compatible in diameter and wall thickness. Material and fabrication for pipe spool shall be the same as the standard pipe sections.

3.

Standard centerline bend radius dimensions will be 1½ times the pipe diameter through 1829 mm and 1 time the pipe diameter for sizes above a 1829 mm diameter.

4.

No silica sand bulk agents shall be incorporated into the production of fittings.

P.O. Number : 7200018725

4.2

DELIVERY, HANDLING AND STORAGE

A.

Pipes shall be suitably cradled, wedged or braced to prevent damage during shipment. A minimum of 2 cradles shall be used and placed in such a way that they support the pipe at the wall. Flange faces shall be protected for shipment. Rubber ring gaskets and lubricants will be shipped in suitable containers. All ribbed pipe shall be stored in a manner that will avoid point loading of the rib area.

B.

Pipe shall not be stacked.

C.

Short pipe section 12 meters or less in length may be lifted using one support point. Any pipe section may be lifted using two support points separated by half of the section length and located equidistant from the pipe section center. Pipe support for lifting must be pliable straps or ropes and shall not be steel cables or chains.

D.

Do not drop or impact the pipe particularly at pipe ends.

E.

Workmen should wear gloves when handling pipe to protect hands from rough exterior surface.

F.

Shipping cradles, pedding, hold down straps and any other handling or protection device shall be inspected for proper load carrying capability.

G.

Contractor shall inspect for evidence of pipe movement axial and lateral during shipment.

4.3

TAGGING OF EQUIPMENT

A.

All pieces of large diameter pipe fittings and miscellaneous items shall be tagged or securely marked with the following information. 1.

Item and job numbers.

2.

Identifying mark to correspond to the piece mark on the Contractor's layout drawing.

3.

Pipe diameter or size.

4.

Orientation markings in mating up with companion fitting or pipe section in the field.

5.

Shipping weight.

P.O. Number : 7200018725

6.

Normal routing and shipping instructions.

B.

Tags and inscriptions shall be all-weather type. Where items are shipped in a container, each item shall be tagged. A Bill of Materials shall be sent to the field sufficiently ahead of material shipment to allow checking upon receipt of material.

4.4

PRE-INSTALLATION INSPECTION

A.

Examine the areas and trenches where piping is to be laid.

B.

Do not start installation until unsatisfactory conditions have been corrected.

4.5

INSTALLATION

A.

Refer to Section 02200 for trenching and preparation.

B.

Install GRP in accordance with written instructions from pipe manufacturer and pipe jointing procedure.

C.

Hand lay up of joints and repairs to damaged pipe shall not be permitted in the field unless a written execution and repair procedure is submitted to and approved by MARAFIQ.

D.

All coupling joints shall be provided with external joint sealing material to prevent entry of soil and gravel into the gaskets.

4.6

ERECTION, COMMISSIONING AND TESTING PERSONNEL

A.

Erection Supervisor: Contractor shall provide the services of a competent Erection Supervisor to advice personnel in the unloading, site storage, site maintenance, field testing, and complete installation of the larger diameter pipe.

B.

Contractor shall provide the services and expected term for a Commissioning Engineer. This term shall include instruction of installation personnel.

C.

Contractor shall provide the services and expected term for a Testing Engineer.

4.7

FIELD TESTS

A.

Procedure: After completing the installation of a pipe line or a section of the line, each double bell coupling joint shall be tested by an internal joint tester to assure a leak-free joint during the system hydrostatic test. After satisfactory completion of the joint tests, the entire line shall be tested. (The line may be divided in segments for this purpose). For pipes smaller than 1100 mm diameters, individual joint test is not

P.O. Number : 7200018725

required. Lengths of pipe runs (branches) less than 50 meters do not require internal joint tests, but are optional. System hydrotest is required in all cases. For both the joint test and the segmental test, test shall be done in two stages. First, the line or joint shall be tested at 2.0 kg/cm2 and upon satisfactory completion, the second stage shall be performed for a test pressure of 5.0 kg/cm2 for the seawater supply system and 3.0 Kg/cm2 for the seawater return system (or 1.5 times the maximum operating pressures, if higher). The final test pressure shall be maintained for one (1) hour and pressure loss shall not exceed 5% of the test pressure. The line shall be tested by segments; valves will be used to close the ends. Filling the line should be done slowly to prevent possible water hammer and care should be exercised to remove all of the air and pressurization source disconnected after the required test pressure has been attained. The air valve installed in the pipe also serves to vent air from the line while it is filling with water. A small water meter that has been carefully fitted up to give good registration for small flows can be used to measure the aggregate leakage. B.

The following should be noted: 1.

C.

Preparation Prior to Test: Inspect the completed installation to assure that all work has been finished properly. Of critical importance are: (a)

Joints assembled properly and passed pressure test.

(b)

System restraints (i.e. thrust blocks and other anchors) in place and properly cured.

(c)

Flange bolting torqued per instructions.

(d)

Backfilling completed.

(e)

Valves and pumps are anchored. Whenever pipe lines terminate in GRP flanges which cannot be attached to mechanical equipment or other pipe, the mechanical equipment or other pipe must be anchored to resist full hydraulic thrust if the GRP pipe is to be pressure tested.

Joint Testing: Each double bell coupling joint shall be hydrostatically tested by means of an internal joint tester. This joint testers consist of a segmented collapsible aluminium ring, a wide inflatable rubber gasket, water tank, pump, and ancillary hydraulic equipment. The apparatus is

P.O. Number : 7200018725

mounted on a movable wheeled cart for easy handling inside the pipe. Test shall be done in two stages as specified in Para 4.7A of this specification.

P.O. Number : 7200018725