Standard GRP Cables Trays, STD-107
Short Description
std for grp trays...
Description
Standard Form Form QAD/04/121 Rev. QAD/04/121 Rev. A A Sheet I of I of I I
STD-107 Rev. 0. doc
Table of Contents Page
1.
2.
GENERAL
3
1.1 1.2 1.3 1.4 1.5
3 3 3 4 4
Scope Quality Assurance Applicable Codes & Standards Environmental Design Criteria Definitions and Abbreviations
TECHNICAL REQUIREMENTS
4
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12
4 5 5 5 5 5 6 6 6 7 7 8
Construction Fire Retardant and Non-toxic Properties UV Resistance Properties Anti-Static Properties Allowable Load Capacity Chemical and Water Resistance Tray Dimensions Tray Cover Ladder Rack Dimensions Ladder Rungs Accessories Surface Quality
3.
INSPECTION & TESTING
8
4.
SHIPMENT
9
5.
DOCUMENTATION
9
APPENDICES
Appendix-A Appendix-B.1 Appendix-B.2 Appendix-C Appendix-D
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: : : : :
List of Referenced Standards Cable Tray Detail Sheet Cable Ladder Detail Sheet Information Required from the Cable Tray/Ladder Manufacturer List of Definitions & Abbreviations
10 11 12 13 14
Issued for Implementation
Description / Text Affected
AD M A-OPCO Standard Form QAD/04/124 Rev. 0
Sheet 1 of 1
STD - 107
SHEET 2
1.
TO CONTENTS
GENERAL 1.1
Scope
This Standard specifies the general requirements of ADMA-OPCO for the procurement of GRP Trays & Ladders for control, electrical and instrument cables installed at both Offshore and Onshore facilities. In addition to the general requirements for the GRP cable Trays and ladders specified in this Standard, the specific requirements to be followed are summarised in Appendix-B1 and B2. 1.2
1.3
Quality Assurance 1.2.1
The Cable Tray/Ladder manufacturer shall operate a Quality Assurance System (QAS) within his organisation which ensures that the requirements of this Standard are achieved.
1.2.2
The manufacturer’s Quality Assurance System shall be based on ISO 9000 or an equivalent which shall provide details for the preparation of a Quality Plan, if required.
1.2.3
The manufacturer shall completely include all technical/manufacturing details, specifications of the GRP Cable trays/ladders along with his offer for ADMAOPCO’s review/approval in accordance with Appendix-C.
1.2.4
The successful bidder shall submit the specific Quality Plan to ADMA-OPCO within two weeks after the award of Purchase Order. This specific Quality Plan shall include provisions for QA/QC of all raw materials and final products to trace the batch, mix, components and fabrication of the cable tray/ladder, details of all tests that would be carried out on the materials during the receipt, production and on the final product. A sample of the test certificate shall be attached along with the Quality Plan.
1.2.5
The effectiveness of this Quality Assurance System may be subject to monitoring by ADMA-OPCO and may be audited following an agreed period of notice.
Applicable Codes & Standards
The list of applicable Standard Engineering Documents e.g. Codes and Standards are provided in Appendix-A.
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Sheet 1 of 1
STD - 107
SHEET 3
1.4
TO CONTENTS
Environmental Design Criteria 1.4.1
The GRP Cable trays/ladders shall be suitable for installation in the Oil & Gas Production facilities in UAE/Abu Dhabi where the environment is abnormally dusty, hot, humid and corrosive. The atmosphere is salt laden and contains traces of H2S, SO2, CO2 and hydrocarbon gases. High winds and dust storms prevail in this area. Hence the technical details to be considered in designing the GRP trays/ ladders are as follows: a. Minimum ambient temperature b. Maximum ambient temperature (under Sunshade) c. Maximum Metal Surface Temp. in direct sunlight d. Maximum Relative Humidity
1.5
: :
5°C 50°C
: :
85°C 100%
Definitions and Abbreviations
Definitions and abbreviation used in this Standard are listed in Appendix - D. 2.
TECHNICAL REQUIREMENTS 2.1
Construction 2.1.1
The cable trays/ladders shall be manufactured from flame retardant Glass Reinforced Polyester (GRP). The complete equipment shall be designed and constructed for a minimum service life of 30 years. Low smoke materials shall be specified for cable trays or ladders used in manned/accommodation areas.
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2.1.2
The cable trays/ladders shall be manufactured by the pultrusion process using a premium grade polyester resin and shall have a resin rich surface veil a minimum of 200 microns thick. The minimum weight percentage of glass in these items shall be 50%.
2.1.3
The cable trays shall be perforated or slotted base type
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Description / Text Affected
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2.2
2.3
TO CONTENTS
Fire Retardant and Non-toxic Properties 2.2.1
The material of construction for cable trays/ladders must possess self extinguishing properties to meet the requirements of ASTM D635.
2.2.2
The GRP cable tray/ladder material characteristics must comply with the Class 1 flame rating when it is fire tested against BS 476 Part 7.
2.2.3
The cable tray/ladder must possess a flame spread index of 25 or less when it is tested in accordance with ASTM E84 Standard.
2.2.4
Only when recommended for accommodation modules or air-conditioned area, the complete cable tray/ladder and its constituents must exhibit a combustion toxicity index of 2.5 or less when subjected to a test in accordance with NES 713.
UV Resistance Properties
The cable tray/ladder and accessories shall be UV resistant. An UV inhibitor shall be included in the resin systems to minimise UV degradation. 2.4
Anti-Static Properties
The resin system used shall contain a graphite filler or carbon fiber interwoven matting to prevent the accumulation of static electricity. The surface resistivity of the cable trays/ladders shall not exceed 3 x 10 9 ohms at 23 oC and 50% relative humidity. 2.5
Allowable Load Capacity
The cable tray/ladder design shall meet or exceed the allowable loading capacity requirements in accordance with NEMA FG1. The manufacturer shall provide certified test data to verify compliance with loading and deflection data. A minimum safety factor of 1.5 shall be considered. 2.6
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Chemical and Water Resistance 2.6.1
The cable tray/ladder shall be resistant to a wide range of organic, inorganic substances, saliferous and Hydrogen Sulphide atmosphere.
2.6.2
All the selected materials of construction for these equipment shall provide enhanced chemical resistance under the minimum, normal and maximum conditions of temperature and corrosive environment.
2.6.3
The Cable tray/ladder and its constituent materials shall not exceed 0.7% of weight increase when subjected to water absorption test for twenty four hours
Issued for Implementation
Description / Text Affected
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2.7
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Tray Dimensions
The following are the preferred nominal dimensions for cable trays. For specific dimension requirements, refer to detail sheet attached in Appendix-B1.
2.8
a. Length of Straight Sections should be :
3 or 6 metres
b. Widths should be
:
50 mm, 73 mm, 100 mm, 150 mm, 200 mm, 300 mm or 400 mm
c. Outside Depths should be
:
25 mm, 40 mm, 50 mm, 60 mm, 80 mm, or 100 mm
d. Radius of Bends should be
:
Manufacturer’s standard dimensions which shall be reviewed/approved by ADMA-OPCO
e. Angle of Arc for Elbows should be
:
30, 45, 60 or 90 degrees.
Tray Cover
The tray covers shall be designed to ‘snap-fit’ into place without the need for additional clips. Where this is not practicable, GRP clips shall be supplied for fixing the covers. 2.9
Ladder Rack Dimensions
The following are the preferred nominal dimensions for ca ble ladders. For specific dimension requirements, refer to the attached Appendix-B2. a. Lengths of Straight Sections should be
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: 3 or 6 metres
b. Widths should be
:
150 mm, 200 mm, 300 mm, 400 mm, 500 mm, 600 mm, 750 mm or 900 mm
c. Outside Depths should be
:
75 mm, 100 mm, 150 mm, 175 mm, 200 mm
d. Rung spacing (on Straight Sections) should be e. Radius of Bends should be
:
200 mm, 400 mm or 500 mm
:
Manufacturer’s standard dimensions which shall be reviewed/ approved by ADMA-OPCO.
Issued for Implementation
Description / Text Affected
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STD - 107
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2.10 Ladder Rungs
2.10.1 The cross rungs of ladder sections shall allow convenient use of cable clamps and reduce tendency for sections to fail by torsional instability. 2.10.2 Rungs shall be fixed firmly in place by non-metallic UV resistant nylon/glass filled nylon or GRP bolts and fixings, to prevent any roll over during cable pulling. 2.10.3 Rungs shall be installed in such a way to ensure no fluid build-up in the ladder rack. 2.11 Accessories 2.11.1 All the fittings such as couplers, bends, risers, tees, crosses, reducers etc. shall be fabricated from the same material of cable trays/ladders as a single piece construction. 2.11.2 The nuts, bolts and fasteners should be fabricated from non-metallic UV resistant nylon/glass filled nylon or GRP material. Rivets for couplers plates are not acceptable.
If the allowable loading capacity stated under Subsection 2.5 of this Standard does not permit the use of non-metallic materials, either corrosion resistance material such as AISI 316 or fusion bonded epoxy coated carbon steel may be proposed for ADMA-OPCO review/approval. 2.11.3 The fittings shall be supplied with pre-drilled and resin finished coupling holes to accept manufacturer standard coupler plates. 2.11.4 The coupler plates shall be provided with at least 8 bolts slots. 2.11.5 The cable tray/ladder interior and exterior surfaces shall be free from sharp edges and other projections which could cause damage to cables. 2.11.6 All cut ends and holes completed either at factory or at site must maintain maximum corrosion resistance, UV resistance and anti-static properties of the cable tray/ladder. The manufacturer shall confirm this requirement can be achieved at site without any additional applications of resin coating. It is recommended to use carbide or diamond grit blades for site modifications. Steel tooth blades on circular saw should not be used.
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STD - 107
SHEET 7
TO CONTENTS
2.12 Surface Quality
All profiles shall be free from surface defects, which may reduce the standard mechanical properties or reduce the operational life of the material. Inspection criteria for identifying acceptable surface quality levels shall be submitted by the manufacturer for ADMA-OPCO approval. 3.
INSPECTION & TESTING 3.1
Routine In-Process Inspection & Testing 3.1.1
The manufacturer shall confirm the available testing facilities in their factory.
3.1.2
All the cable trays/ladders and accessories shall be subject to in-process testing and final inspection by the manufacturer. The manufacturer shall carry out all the inspection & testing as per the approved Quality plan and provide all the test reports, test certificates and other relevant quality records to ADMA-OPCO for final approval. Type test certificates/test data shall be provided to show that the trays have been subjected to type tests.
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3.1.3
Dimensions, tolerances and surface finishes shall be measured in accordance with ASTM D3917. Certified product drawings with dimensions and tolerances shall be submitted together for prior approval by ADMA-OPCO.
3.1.4
Random samples shall be checked visually without the aid of magnification for manufacturing defects. Defects shall be classified as to type and level, as shown in Table 1 of ASTM D4385. The inspection shall be concerned with allowable defects and its applicable acceptance level described by the manufacturer’s drawings. Defects in excess of those listed as allowable in the drawings for the tray/ladder shall be cause for rejection.
3.1.5
The trays/ladders (random samples) shall be inspected for conformance with dimensions and tolerances specified on the product drawing. Products with any dimensions exceeding the specified limits shall be rejected.
3.1.6
Upon receipt of the products, ADMA-OPCO will inspect them for their compliance with the specified requirements. If any defects/nonconformances observed, the items are rejected and returned back to the manufacturer for repair or replacement.
Issued for Implementation
Description / Text Affected
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Sheet 1 of 1
STD - 107
SHEET 8
3.2
TO CONTENTS
Certification Requirements
All certification requirements for the tests mentioned in Subsection 3.1 a bove shall be in accordance with EN 10204 Type 3.1B. 4.
5.
SHIPMENT 4.1
The Cable trays/ladders shall be delivered in a seaworthy packing with the specified maximum lengths.
4.2
The cable trays/ladders shall be covered with suitable material to provide physical protection during transit, ordinary storage and handling operations.
DOCUMENTATION 5.1
The manufacturer shall include all technical details, specifications, clause by clause compliance statement in the bid.
5.2
The manufacturer shall submit the final documentation in complete, which shall include but not limited to the following: a. b. c. d. e.
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Technical Data sheets & Specifications Material Test Certificates Dimensional Details Test Certificates Trays / Ladders and Accessories Catalogue Number.
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APPENDIX - A LIST OF REFERENCED STANDARDS
The latest editions of the codes, standards and specifications listed below shall to the extent specified herein represent part of this standard. AMERICAN STANDARD FOR TESTING MATERIALS
ASTM E84
Standard test method for surface burning characteristics of building materials.
ASTM D570
Standard test method for water absorption of plastics.
ASTM D635
Standard test method for rate of burning and/or extent and time of burning of self supporting plastics in a horizontal position.
ASTM D3917
Standard specification for Dimensional Tolerance of Thermosetting Glass Reinforced Plastic Pultered Shapes.
ASTM D4385
Standard Practice for classifying Visual Defects in Thermosetting Reinforced Plastic Pultruded products
BRITISH STANDARD INSTITUTE (BSI)
BS 476
Part 7 Fire Tests on Building Materials & Structures. surface spread of flame test for material.
INTERNATIONAL ORGANISATION FOR STANDARDISATION (ISO)
ISO9000
Quality Management and Quality Assurance Standards
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)
FG1
Fiber Glass Cable Tray Systems
NAVAL ENGINEERING STANDARD UK (NES)
NES 713
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Determination of the Toxicity Index of the products of combustion from small specimens of materials.
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Description / Text Affected
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STD - 107
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TO CONTENTS
APPENDIX - B.1 CABLE TRAY DETAIL SHEET
Data sheets for indent and purchase of cable tray to be completed in block capitals by Purchaser or Vendor as applicable B.1a
General Requirements
B.1b
(i) Material of Construction : Glass Reinforced Polyester (Class 1 Type) (ii) Manufacturing Process : Pultrusion (iii) Flame Retardant & Non-Toxic Properties : Required (iv) UV, Chemical & Water Resistance : Required (v) Anti-Static Property : Required (vi) Accommodation/Air Conditioned Areas Installations : Yes/No Dimensional Requirements
Srl. Width Outside Radius of No. (mm) Depth Bends (mm) (mm)
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Nominal Cut Length of Straight Section (m)
Total Length (m)
Weight / Metre Length (Kg/m)
Fittings & Accessories if Required
Catalogue No.
Issued for Implementation
Description / Text Affected
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STD - 107
SHEET 11
TO CONTENTS
APPENDIX - B.2 CABLE LADDER DETAIL SHEET
Data sheets for indent and purchase of cable ladder to be completed in block capitals by Purchaser or Vendor as applicable. B.2a
General Requirements
B.2b
(i) Material of Construction : Glass Reinforced Polyester (Class 1 Type) (ii) Manufacturing Process : Pultrusion (iii) Flame Retardant & Non-Toxic Properties : Required (iv) UV, Chemical & Water Resistance : Required (v) Anti-Static Property : Required (vi) Accommodation/Air Conditioned Areas Installations : Yes/No Dimensional Requirements
Srl. Width Outside Radius No. (mm) Depth of Bends (mm)
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(mm)
Nominal Cut Length of
Rung Spacing
Straight Section (on Straight (m) Section) (mm)
Total Length (m)
Weight / Metre Length (Kg / m)
Fittings & Catalogue Accessories No. if Required
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Description / Text Affected
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APPENDIX - C INFORMATION REQUIRED FROM THE CABLE TRAY/LADDER MANUFACTURER
1.
Material
: ...................................................
2.
Colour
: ...................................................
3.
Density (g/cm3)
: ...................................................
4.
Glass Content (Vol %)
: ...................................................
5.
Hardness
: ...................................................
6.
Oxygen Index
: ...................................................
7.
Continuous Operating Temperature Range (°C)
: ...................................................
8.
Specific Resistance (Ω m)
: ...................................................
9.
Surface Resistance (Ω)
: ...................................................
10. Dielectric Strength (KV/mm)
: ...................................................
11. Toxic Fumes/Halogen Emission (Vol %)
: ..................................................
12. Weather Resistance (% weight increase
: ..................................................
after 500 hrs. of salt spray test ASTM B117-60) 13. Water Absorption (%) (a)
After 24 Hrs
: ..................................................
(b)
After 4 days
: ..................................................
14. Tensile Strength (Mpa)
: ..................................................
15. Tensile Modulus (Gpa)
: ..................................................
16. Compressive Strength (Mpa)
: ..................................................
17. Compressive Modulus (Gpa)
: ..................................................
18. Shear Strength (Mpa)
: ..................................................
19. Shear Modulus (Gpa)
: ..................................................
20. Poisson’s Ratio
: ..................................................
21. Resistance to Acids
: ..................................................
22. Resistance to Alkalis
: ..................................................
23. Toxicity Index
: ..................................................
24. Load/Span Class Designation as per NEMA FG 1
: ..................................................
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Description / Text Affected
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SHEET 13
TO CONTENTS
APPENDIX - D LIST OF DEFINITIONS & ABBREVIATIONS
GRP
:
Glass Reinforced Polyester.
GPa
:
Giga Pascal
MPa
:
Mega Pascal
UV
:
Ultra Violet.
QA
:
Quality Assurance
QC
:
Quality Control
AISI
:
American Iron & Steel Institute
UAE
:
United Arab Emirates
Manufacturer
:
The term, “manufacturer” as used throughout this Standard include manufacturers and suppliers of GRP Cable trays/ladders.
Quality Assurance
:
All those planned ans systematic actions necessary to ensure quality (i.e.) to provide adequate confidence that a product or service will be filt for the intended purpose.
Quality System :
The structure of organisation, responsibilities, activities resources and events that together provide organized procedures and methods of implementation to ensure capabilities of the organisation to meet quality requirements.
Quality Manual :
The document setting out the general Quality Policies, Procedures and Practices of an Organisation.
Quality Plan
A document prepared by the manufacturer setting out the specific Quality practices, resources and activities related to a particular product/order.
:
th
15 Mrch 1999 KAT/MMI/MKM/sr/STD-107
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Mar-99
Rev.
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Issued for Implementation
Description / Text Affected
AD M A-OPCO Standard Form QAD/04/124 Rev. 0
Sheet 1 of 1
STD - 107
SHEET 14
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