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1. Introduction
ISO (the International Organization for Standardization) is a worldwide network of national standard institutes. The ISO 14692 standard is an international standard dealing with the qualification, manufacturing, design and installation of GRE piping systems. This document gives a brief summary of the ISO 14692 standard only and is not intended to replace the ISO 14692 standard.
To ensure a trouble free GRE pipe system, three major important conditions must be met: 1. Use qualified products. 2. Perform system design. 3. Install according to manufacturers standards and guidelines. The above mentioned three points are addressed in the ISO 14692 Standard in Part 2, Part 3 and Part 4 respectively.
Qualification
System design
Content
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Introduction What is ISO 14692? Part 1: Vocabulary, symbols, applications and materials Part 2: Qualification of components Part 3: System design Part 4: Fabrication, installation and operation Conclusion ISO in brief References Deviations list to the ISO quality program 1 2 3 3 5 7 9 9 9 10
Each product family (pipe, elbow, reducer, tee, flange) is divided into product sectors. Two representative samples, usually the biggest diameter and highest pressure class, from each product sector are taken and fully tested according ASTM 1598 (1000 hrs at 65 C). The test medium is water. The representative samples are called the product sector representatives.
For calculation of the test pressure, the regression line of the pipe or the fitting is used. In absence of a regression line, a default value can be obtained from a table given in the ISO. For details on the calculation see the ISO document. In general the 1000 hr test is performed at about 2.5 to 3 times the design pressure. So a 20 bar system is tested around 50 to 60 bar. A product sector contains all the items within its diameter and pressure range, the so called component variants. Component variants are qualified by either two 1000 hr tests or through the scaling method.
Table 1. Overview of product sectors Diameter (mm) Pressure range (bar) 0 - 50 50 - 100 100 -150 25 - 250 A H N 250 - 400 B I O 400 - 600 C J P 600 - 800 D K Q 800 - 1200 E L R
> 150 _ S T
For quality control, short term tests could be performed, if required and agreed with the principal. These are done to establish a baseline value for quality control. Other aspects to be considered are: the glass transition temperature, the glass resin ratio and component dimensions. These have to be determined from the replicate samples and used by quality control during production as base line values.
The piping manufacturer shall have a suitable and accredited quality assurance and quality control system. Pipe and fittings furnished to ISO 14692 shall be tested according to the ISO standard. See chapter 10 for the list of deviations to the quality program.
Table 2. Overview of qualification tests needed Product sector A Component variant 2 inch Component variant 3 inch Component variant 4 inch Component variant 6 inch Product sector representative 8 inch Family representative QC baseline Test standard ASTM D-1598 ASTM D-1598 ASTM D-1598 ASTM D-1598 ASTM D-2992 ASTM D-2992 ASTM D-1598 Pipes or scaling or scaling or scaling or scaling 2 18 5 Elbows or scaling or scaling or scaling or scaling 2 18 5 Tees or scaling or scaling or scaling or scaling 2 18 5 Flanges or scaling or scaling or scaling or scaling 2 18 5
2 2 2 2
2 2 2 2
2 2 2 2
2 2 2 2
5.5.1 Determination of the failure envelope and the long-term design envelope
In the ISO14692 document an algorithm is given how to determine the failure envelope and how the long term design envelope is developed. Determine the short term failure envelope (1 or 2). The idealized long term failure envelope (3) is geometrically similar to the short term envelope with all data points being scaled. This scaling factor (fscale) is derived using the long term regression line. The non factored long term design envelope (4) is based on the idealized long term envelope multiplied by the part factor f2. The factored long term design envelope (5) is derived by multiplication with A1, A2 and A3, where A1 is the de-rating factor for temperature, A2 is the de-rating factor for chemical resistance and A3 is the de-rating factor for cyclic service.
Figure 3. Allowable stress curve
Definitions:
Pipe fitter Person working for a contractor who is responsible for the construction of the GRE pipe system. He must be able to make the relevant joint types according Ameron procedures. This certificate can be compared to a welders certificate. Supervisor Person who is responsible for the quality of the installation and is able to check the quality of the work done by the pipe fitters. This person is normally employed by the responsible contractor for example as a foreman. This certificate is a personal certificate. QA/QC Inspector Person who is able: to check and judge the work of contractor and is able to globally verify the soundness of the installation. This includes lay-out related matters such as support construction and location, flange connections etc. Can be employed by client, contractor, third party (BV, DNV, Lloyds). This certificate is a personal certificate.
6.2.1 Inspection
It starts with checking the incoming goods Check supplied quantity. Check nominal dimensions of supplied material Check supplied pressures class Perform a visual control of supplied material (transport damage, impact) Check if storage is correct Check availability of documentation (packing lists, certification) Handling and storage of the incoming goods Use the Ameron lifting, loading and unloading procedure. Storage. Pay attention to the stacking of the pipe; support width and stacking height, end protection of pipe and fittings. Preferably, pipes should be transported in containers or crates.
Training of pipe fitter The quality of the joints is mainly dependent on craftsmanship of the pipe fitter. Therefore, the ISO 14692 demands that the qualification organization is independent of the organization that carries out the training. In the case of Ameron the independent organization is DNV. The training consists of a theoretical and a practical part. The theoretical part will end with a written exam for which a 70% pass mark is required. The practical part will end with making a joint that will be hydro-tested according the requirements of the ISO 14692. These tests are witnessed
by a third party. When passing both exams the pipe fitter will receive a pipe fitter certificate issued by DNV. The purpose of the entire training is to teach the pipe fitter those things he or she can have influence on. Training of Supervisor - QA/QC inspector Ameron and DNV are developing an individual certification for Supervisor - QA/QC inspector based on ISO 14692 requirements. Objective is to train Supervisor - QA/QC inspector on aspects like storage, inspection of pipes and fittings, supporting, jointing, hydro testing etc. etc. in such a way, that they can act as Supervisor - QA/QC inspector on a GRE pre-fabrication and installation job. An important factor is that they also learn what can go wrong. The educating company will be Ameron as they have in contrast to most institutes a large knowledge, obtained over decades, in this particular area. Examination committee will be DNV. The certificate that can be obtained will be a personal certificate.
E.g.: Impact > replace (major defect) or repair (minor defect) Misaligned joints > replace components (major defect) remake joint (minor defect)
7. Conclusion
ISO 14692 is a worldwide accepted standard for the manufacturing, qualification, design and installation of Glassfiber Reinforced Epoxy piping systems. When the guidelines laid down in the ISO 14692 standard are followed, it will result in a trouble-free GRE pipe system.
8. ISO in brief
ISO (International Organization for Standardization) is a global network that identifies what International Standards are required by business, government and society, develops them in partnership with the sectors, that will put them in use, adopts them by transparent procedures based on national input and delivers them to be implemented worldwide. ISO standards distil an international consensus from the broadest possible base of stake holder groups. Expert input comes from those closest to the needs for the standards and also the results of implementing them. In this way, although voluntary, ISO standards are widely respected and accepted by public and private sectors internationally. ISO a non-governmental organization, is a federation of national standards, bodies of over 149 countries, one per country, from all regions of the world, including developed, developing and transitional economies.
9. References
ISO 14692-1 Petroleum and natural gas industries Glass-reinforced plastics (GRP) piping Part 1: Vocabulary, symbols, applications and materials; ISO 14692-2 Petroleum and natural gas industries Glass-reinforced plastics (GRP) piping Part 2: Qualification and manufacture; ISO 14692-3 Petroleum and natural gas industries Glass-reinforced plastics (GRP) piping Part 3: System design; ISO 14692-4 Petroleum and natural gas industries Glass-reinforced plastics (GRP) piping Part 4: Fabrication, installation and operation.
8.3.2.2 Mill hydrostatic test 5% of continuous production (c.p.) =< 600mm 0,89 times qualified pressure > 600mm 0,75 times qualified pressure if pressure class > 32 bar = 100% 8.3.2.3 Spools frequency = 100% (if practicable) 8.3.2.4 Retesting: by failures of one of both retested components, the whole lot to the latest successful hydrotest shall be rejected. 8.3.3 Degree of cure: DSC according to ISO 11357-2 Determination of a QC baseline on base-resin or component. Frequency of 1% on c.p.
5% (if practicable) Only the failed components will be rejected. In case of rejected components, 100% will be conducted until the infected range has been determined According to API 15LR. Min. acc. = 130 / 140 dgr.C Once per shift
8.3.4 8.3.5
Short-term burst test: Agreed with principal Ongoing pressure tests: yearly 6x 1000hr. test from at least two product sectors Glass content in accordance with ISO 1172 at a frequency of 1% of c.p. Acceptance: 70-82% for filament wound pipe 65-75% filament wound fittings 50-65% hand-lay-up fittings
8.3.6
In accordance with ASTM-D-2584 at a frequency of once a week random two types. Acceptance: 65-77% for filament wound pipe 55-65% for filament wound fittings
8.3.7.2 Visual Inspection: Table 12 and Table A1 of annexure A van ISO 14692-4:2002 8.3.7.3 The principal shall be notified of all repairs
ASTM-D-2563 (visual)
No notification
8.3.8.2 The following dimensions shall be determined in & accordance with ASTM D-3567 for 1% of pipe and 8.3.8.3 each fitting: a) Internal diameter b) Outside diameter c) Mass d) Minimum total wall thickness e) Reinforced wall thickness f) Laying length
Ameron conducts 100% inspection on outside diameter of pipe. Reinforced wall thickness is automatically determined by using fixed inside diameter. All dimensions and tolerances are in accordance with Ameron product drawings.
8.3.8.4 The following dimensions shall be determined in accordance with ASTM D3567 for 1% of pipe and each fitting: a) Internal diameter b) Maximum outside diameter c) Reinforced wall thickness d) Relevant dimensions as described figure 1 e) Mass 8.3.9 8.3.10 8.3.11 Thread dimensions Conductivity 105 (100V) Retest: by failures of one of both retested components, the whole batch to the latest successful test shall be rejected. Records to be maintained by manufacturer: Hydrotest reports Dim.+Vis.+ cond. Reports Tg Glass content Short term burst test report Long term test report Markings shall be applied on the pipe and fittings within 1 m of the end. All pipe and fittings shall be permanently marked with details as in Para 9.2: a) Manufacturers name b) Product line designation c) Qualified pressure d) Temperature at which qualified pressure is determined (default is 65C). e) System design pressure f) System design temperature g) Nominal diameter h) Manufacturers identification code i) Limitations or referenced to installation requirements: permissible bolt torque, portable water (yes/no), electrical conductivity and fire performance classification. Manufacturing procedure shall be provided if requested by the principal Production quality control reports in acc. 8.4 shall be provided within five working days or other agreed period
Ameron conducts only 100% inspection on laying lengths and directions/ positions
N/A Conductivity 106 (500V) Only the failed components will be rejected. To avoid rejecting good products, Ameron will test all products to trace all infected products. Documentation available in QC/Engineering file
8.4.3
9.1
Pipes 3 locations, Fitting one location Pipes and fittings will be marked with: a) Manufacturers name b) Not c) Qualified pressure d) Not e) System design pressure f) System design temperature g) Nominal diameter h) Manufacturers identification code i) Not
9.2
11.4.2
11.4.4
Group Headquarters Ameron International Corporation - Fiberglass-Composite Pipe Division 9720 Cypresswood Drive, Suite 325 - Houston, Texas 77070 - U.S.A. Phone: +1 832 912 8282 - Fax: +1 832 912 9393 E-mail: marcom@ameronfpd.com - Website: http://www.ameron.com
U.S.A. Ameron International Corporation 1004 Ameron Road P.O. Box 878 Burkburnett, Texas 76364 U.S.A. Phone: +1 940 569 1471 Fax: +1 940 569 2764
U.S.A. Centron International, Inc. P.O. Box 490 600 FM 1195 South Mineral Wells - Texas 76068 U.S.A. Phone: +1 940 325 1341 Fax: +1 940 325 9681 E-mail: info@centrongre.com Website: http://www.centrongre.com
Europe Ameron B.V. Fiberglass-Composite Pipe P.O. Box 6 4190 CA Geldermalsen The Netherlands Phone: +31 345 587 587 Fax: +31 345 587 561 E-mail: info@ameron-fpg.nl Website: http://www.ameron-fpg.nl
Asia Ameron (Pte) Ltd No. 7A, Tuas Avenue 3 Jurong Singapore 639407 Phone: +65 6861 6118 Fax: +65 6862 1302/6861 7834 E-mail: info@ameron.com.sg Website: http://www.ameron.com.sg