SP-2092 - 2018 Revisions Highlighted PDF

Petroleum Development Oman L.L.C.
Document title: GRP Specification Part 1
Document ID SP-2092-1
Document Type Specification
Security Restricted
Discipline Materials & Corrosion
Owner UEC (CFDH Materials, Corrosion and Integrity)
Issue Date 10.06.2018
Version 2
Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the
whole nor any part of this document may be disclosed to others or reproduced, stored in a
retrieval system, or transmitted in any form by any means (electronic, mechanical, reprographic
recording or otherwise) without prior written consent of the owner.
Revision: 2
Petroleum Development Oman LLC Effective: June-18
This page was intentionally left blank
Page 2 Specification SP2092-1 rev.2 Printed 19/06/18

The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
Revision: 2
i Document Authorisation
Authorised For Issue
Document Authorisation
Document Author Document Custodian Document Owner

UEC13; Uec1 UEC
(Rama Ramanahalli) Talal Nabhani Nasser Al Behlani
Behlani, Nasser UEC NABHANI,TALAL UEC1 Ramanahalli, Rama UEC13
Date : 19-06-2018 12:00 Date : 19-06-2018 10:23 AM Date : 11-06-2018 7:37 AM
AM

Revision: 2
ii Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details
of all revisions prior to these are held on file by the issuing department.
Revision Date Author Reviewed by Approved Revision note

# by
Rev. 0 Jan 2010 UEC125/ UEOC1 UEC1 Initial issue
UEC122
Rev. 1 July 2013 UEOC13 UEOC1 UEOC Revision incorporates the
Yibal fire incident
investigation team
recommendations in
section 1.3.2.11, 1.6 & 1.7
Rev. 2 June 2018 UEC13 UEC1 UEC Revision incorporates the
lesson learnt, revised
ISO14692-1,2,3,4 version
2017 std. and
DEP31.40.10.19 edition
2018 and API 15HR and
LR where applicable.
iii Related Business Processes

Code Business Process (EPBM 4.0)
CP-208 Corrosion management code of practice
iv Related Corporate Management Frame Work (CMF)

Documents
The related CMF Documents can be retrieved from the Corporate Business Control
Documentation Register CMF.

Revision: 2
TABLE OF CONTENTS
Clause no. Description Page

no.
1. INTRODUCTION 7
1.1 SCOPE 7
1.2 CHANGES TO THE SPECIFICATION. 7
1.3 DEFINITIONS 7
1.4 SYMBOLS & ABBREVITIONS 8
1.5 CROSS REFERENCES 9
1.6 GRP MATERIAL SELECTION PRICIPLE 9
1.7 GRP APPLICATIONS 10
1.8 PROJECT EXECUTION 12
1.9 CONFLICTING REQUIREMENTS 12
1.10 EXCEPTIONS 13
2. MATERIALS 14
2.1 GENERAL 14
2.2 RESINS 14
2.3 REINFORCEING MATERIALS 16
2.4 GASKET MATERIALS 17
2.5 INTERNAL SURFACE 17
2.6 UV & WEATHERING PROTECTION 17
2.7 FIRE RESISTANCE 17
3. MANUFACTURING 17
3.1 GENERAL 17
3.2 FILAMENT WINDING 17
3.3 PIPE 18
3.4 FITTINGS 19
3.5 FLANGES 19
3.6 MANUFACTURING PROCESS REQUIREMENTS 20
3.7 PROCESS VALIDATION 21
4.0 QUALIFICATION 21

Revision: 2
4.1 MANUFACTURER QUALIFICATION 22
4.2 PLANT QUALIFICATION 23
4.3 WALL THICKNESS LIMITATIONS 23
4.4 FULL QUALIFICATION PROCEDURE 24
4.5 SUPPLEMENTARY QUALIFICATION REQUIREMENTS 29
4.6 ADDITIONAL COMPONENT PROPERTIES 29
4.7 REQUALIFICATION 31
4.8 COMPONENT DEFINITIONS 31
4.9 BASELINE DATA 34
4.10 LEAK TESTING FOR GAS AND MULTIPHASE SERVICE 35
4.11 QUALIFICATION RECORDS 35
5. QUALITY ASSURANCE AND CONTROL 37
5.1 GENERAL 37
5.2 QUALITY CONTROL EQUIPMENT 38
5.3 QUALITY CONTROL TESTS 39
5.4 VISUAL INSPECTION 42
5.5 ACCEPTANCE CRITERIA AND REMEDIAL ACTION 43
5.6 OPTIONAL QUALITY CONTROL TESTS 44
5.7 RETEST 44
5.8 QUALITY CONTROL RECORDS 44
6. COMPONENET MARKING 45
6.1 GENERAL 45
6.2 REQUIREMENTS 45
7. HANDLING, STORAGE AND TRANSPORATION 45
8. FINAL MANUFACTURING DOCUMENTAION 46

(MANUFACTURER RECORD BOOK)
APPENDIX A LIST OF REFERENCE STANDARDS AND CODES 47
USER COMMENT FORM 49

Revision: 2
1. Introduction
1.1 Scope
This document specifies requirements for Qualification & Manufacturing of GRP
components used in the construction of GRP piping and pipeline systems.
The objective of this specification is to enable to have easy interpretation and to
get consistent quality of materials from the GRP vendors.
For design and installation ISO14692-3; 2002(E), ISO14692-4; 2002(E) and
SP1208 shall be followed.
1.2 Changes to the Specification

This specification shall not be changed without approval from the Custodian
(UEC1, CFDH materials and corrosion), who owns this specification. If you think
any part of this specification is not correct, write your comments on a copy of the
User Comments Form. The form is included as the last page of this specification.
Send the copy with your comments and personal details to Document Control
Section (DCS).
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 of a project, or operation or
maintenance of a facility.
The Supplier/Manufacturer/Vendor is the party that performs Design,

Qualification, Manufacturing, testing and supply of GRP pipes and fittings,
installation tools and services as specified in the purchase specification and
contract.
The Company/Owner/Principal is Petroleum Development Oman.
1.3.2 Specific Definitions

1.3.2.1 Acceptance criteria: Defined limits placed on characteristics of materials,
products, or services.
1.3.2.2 Date of manufacture: Date of cure.
1.3.2.3 Degradation: Loss of property due to aging, sustained stress and other service
conditions.
1.3.2.4 ECR or C-glass – Glass fibre having better chemical resistance against acids
than E glass used primarily as a reinforcement for the resin rich internal liner.
1.3.2.5 Lot (pipes) - A Lot of GRE pipes consists of 100units or less in a continuous
production of each size and pressure class produced for company orders.
1.3.2.6 Lot (fittings) - When used in connection with manufacture of fittings or spools
the following shall apply.

Revision: 2
Fittings lot shall be defined as the 100 units of fittings produced for company
orders using the same method of construction (Example – filament winding,
handlayup,
moulded fittings, mitered fittings etc,) for each type (Example - Elbow, Tee,
Reducer, Flange, Coupler, Stub end and saddle with pick) and pressure class.
1.3.2.7 Pipeline systems – Pipe with components subject to the same design conditions
and typically used to transport fluids between wells, field facilities, processing
plants and storage facilities. It is recommended that, all GRE pipeline systems in
the PDO exploration and production areas shall be installed underground.
1.3.2.8 Piping system – Pipe with components subject to the same design conditions
and typically used in above ground application within a processing facility. The
piping system also includes pipe supports, but doesn’t include support structures.
1.3.2.9 Pi tape : A tape unit to measure circumference and convert to diameter
1.3.2.10 Sour Service: Sour service is defined as greater or equal to region 2 of ISO-
15156-2.
1.3.2.11 Zones definitions for use of GRE pipes
Zone 0 Area in which an explosive gas atmosphere is present continuously

or for long periods or frequently.
Zone 1 Area in which an explosive gas atmosphere is likely to occur in
normal operation occasionally.
Zone 2 Area in which an explosive gas atmosphere is not likely to occur in
normal operation but, if it does occur, will persist for a short period
only.
Non hazardous A non hazardous area is an area in which an explosive atmosphere

area(safe area) is not expected to be present.
Note: Zones are defined as per IEC60079-10-1.
1.3.2.12
The word shall indicate a requirement.
The capitalized term SHALL [PS] indicate a process safety requirement.
The word should indicate a recommendation.
The word may indicate a permitted option.
All other technical terms and definitions shall be referenced as per ISO14692-1; 2002(E)
section 3.
1.4 symbols and abbreviations
1.4.1 Symbols: All the symbols as stated in ISO14692-1 section 3 shall apply for this
specification except the following changes.
tn – Nominal wall thickness. (tn = tl + tr + ts)
tr – Average Reinforced wall thickness.
Revision: 2
ts – Thickness of the outer sheath or protective layer.

tl – Internal layer liner thickness.
T – Tee (fitting)
1.4.2 Abbreviations: The Abbreviations as stated in ISO14692-1 section 3 shall

apply for this specification except the following changes.
GRP – Glass Reinforced Plastic. It is the general terminology used for the
reinforced plastic pipes and fittings. It includes GRE, GRV and Glass Reinforced
Polyester pipes and fittings.
GRE – Glass Reinforced Epoxy
GRV – Glass Reinfoced Vinylester
GRUP – Glass reinforced unsaturated Polyester
PSR – Product sector representatives.
CV – Component Variant.
BTEX –Benzene, Toluene, Ethyl Benzene and o-xylene.
IPD – ISO Phorone Di-Amine (Cyclo Aliphatic Amine)
M & C - Material and corrosion.
LCL – Lower Confidence Limit.
HDB – Hydro Static Design Basis
TPI – Third party Inspection
1.5 Cross References:

Where cross-references are made, the number of the section or sub-section referred to is
shown in brackets. All publications referred to in this Specification are listed in Appendix
A.
1.6 GRE Material Selection Principle:

The following shall be followed in selection of GRE material.
1. Material and corrosion Engineer shall obtain all essential data to propose the
material option. All quantified process or functional requirements to be
reviewed and confirm the suitability of the GRE materials based on SP-2156
& the applications as specified in the section 1.7.
2. Qualification of Materials for technical acceptability – Material and corrosion

engineer is responsible to ensure if the GRP material proposed is within the
experience envelop and have successfully been used. Above ground/
Underground applications and process parameters such as Diameters,
pressure, temperature and process parameters within the qualified / proven
range.
3. Material and corrosion engineer shall ensure clear understanding of GRP

risks and risks may be associated with project engineering community.
4. Quantitative risk assessment when required to be carried out by the project.

Revision: 2
5. The following conditions shall apply when GRE piping/pipeline installed in

above ground application.
a. Above ground GRE piping or pipelines shall not be installed in areas

classified as zone 0, zone1 and zone 2 in accordance with IEC60079-
10-1 (area zone 0, 1, 2).
b. GRE pipelines for hydro carbon applications shall be buried. If any part
of GRE piping/pipeline is exposed it shall be limited to maximum 2mtrs.
The exposed GRE portion shall be protected from fire/heat and external
mechanical impacts/damages, to a risk level equivalent to buried GRE.
ALARP study SHALL [PS] be used to confirm the adequacy of the
protection against the predicted risks.
6. GRE - Metallic interface connections (Buried GRE to above ground

transition).
Buried GRE pipe and metallic interface connections shall be done in a
covered flange pit. If flange pit is not feasible, QRA shall be done with risks
level considered ALARP & the following requirements shall be applied for
engineering GRE-metallic connections:
a. GRE pipe can have no elbow with angles sharper than 45 degrees (Not
applicable for low pressure ≤10bar drains).
b. Stresses on GRE pipeline are calculated and in compliance with
standards ISO 14692/DEP 31.40.10.19.
c. GRE/Metallic interface connections shall be protected from external
impact and fire/heat exposure to a risk level equivalent to buried GRE.
d. GRE pipe should be continually supported to prevent local stresses; stilts
and other intermittent supports will not be allowed.
e. Final design shall be reviewed and approved by pipeline design function.
7. GRE piping/pipeline SHALL [PS] not be connected directly to rotating

equipments or any other equipments or pipes where vibration is expected
such as pumps, compressors, etc.
8. GRE piping shall not be connected to static equipments where frequent
service/ maintenance are required.
1.7 GRP Applications

This specification is generally applicable to:
 Pipeline and piping systems for non –hydrocarbon applications.
 Pipelines for hydrocarbon applications.
 Straight headers with simple configurations for on plot hydrocarbon

applications.
 Piping and Pipeline systems for chemicals – CFDH shall be consulted.
This specification is not applicable to:

 Well Casing and Tubing.
 Well heads.
 GRP tanks and GRP tank liners.

Revision: 2
 Pipe systems that incorporate internal thermo plastic or elastomeric

liners.
Typical applications of for the use of GRP pipe include:

Boiler feed water, Condensate (water & gas), Sea Water
Cooling water, brackish water, Produced water
Potable water, process water, Sour water
Demin water, Sewer, Hydrocarbon drains,
Water/oil mixtures, Flow lines, Water injections,
Glycol, Fresh water, Fire water
Drains,
This specification is applicable in the pressure-diameter range indicated in table 1, which

represents a compromise between the current shell Group experience envelope of GRP
pipelines and piping systems & PDO past experience. The range of diameters and
pressures identified in the table 1 should be applied in conjunction with the figure 1.
Qualified lamination joints are permitted to use only for repairs, tie in joints and large
diameter/low pressure (as per table 1) applications. Only qualified adhesive bonded joints
and threaded connections with qualified sealants are permitted to use for sour service
applications.
Internal pressure (bar)

250
225
200
175
150
125
100
75
50
25
0
0 500 1000 1500 2000 2500 3000
Internal diameter (mm)
Figure 1 - Current Group experience envelope of pressure/diameter range of GRP

pipeline and piping systems

Revision: 2
Above ground application (on Under ground application (off

plot piping) plot)
Type of
joint Design
Pressure
Size (mm) Pressure Size (mm)
(bar)
(bar)
Threaded
Up to 150mm Max 70 bar Up to 150mm 120 bar
Connections
25 to 150mm Max 70 bar Up to 150 70 bar
200 to 300mm Max 45 bar. 250 to 300mm 70 bar
Adhesive
bonded 350 to 450mm Max 35 bar. 350 to 450mm 60 bar
Connections 500 to
Max. 30 bar 500 to 600mm 50bar
600mm.
650 to
Max 15bar. 650 to 800mm 15 bar
Lamination 800mm.
joints 850 to Max 10bar. 850 to 10 bar
1200mm 1200mm
Note: The maximum application temperatures based on the resin system used
and shall be as per the table 2 of this specification.
Table 1 – Size and pressure limitations to apply GRE materials in PDO facilities.
Use of higher pressures or larger diameters outside the range specified in the
above table 1 is subject to specific approvals from the CFDH materials and
Corrosion and upon satisfactory qualification before finalizing concept material
selection.
1.8 Project Execution

Project Manager shall appoint “single point” responsibility for each GRP project to
oversee the overall project execution. The individual shall have a minimum TA2 in
project engineering with specialized GRE competencies. He shall be responsible
for the following.
- System design
- Product qualification and supply;
- Construction & testing activities
- Pre commissioning and commissioning activities.
All pipe, fittings and flanges for an installation shall be manufactured by the same
vendor to avoid incompatibility due to intermixing of product from different
manufacturers.
1.9 Conflicting Requirements

In case of conflicting requirements between documents relating to an inquiry or
order, the following priority of documents shall apply:
- Contractual Scope of Work, Purchase Orders and Variations thereto.
- Project Specification and Requisition Sheets.

Revision: 2
- This document and PDO/Group standards referred to in this document.
- International Standards and Specifications referred to in this document.
1.10 Exceptions
The user (Manufacturers, Contractors and project Engineers) shall conduct a
GAP analysis against this specification and shall obtain written approval for
deviations prior to contract award from CFDH materials and corrosion.
Any unauthorised deviations shall be rejected by the Company and the user shall
be accountable for any subsequent re-work to comply with this specification.

Revision: 2
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 GRP satisfy the
design requirements throughout the intended lifetime. Manufacturer shall provide
the details of the raw materials and resin systems intended to be used for the
project during the technical bid stage for the company Review and acceptance.
2.2 Resins & Thread sealants

The resins selected shall be of a suitable commercial grade that complies with the
technical requirements of the application as per the table 2 and 3.
If the manufacturer intends to use the additives to enhance the UV resistance
properties of the material, it shall be agreed by the principal. The additives, used
shall not contribute in any way masking to identify any visual imperfections in the
material and shall be compatible to the resin system. UV resistance test data as
per ASTM G90 should be provided to the company for review.
2.2.1 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;
 Cyclo aliphatic amine (IPD);
 Aromatic Amine (MDA);
 Anhydride.
2.2.2 Polyester resins

For water services, e.g. sea-water cooling, Isophthalic polyester resin is typically
used. Isophthalic polyester is a relatively low cost resin, with limited chemical
resistance.
2.2.3 Vinyl ester resins

Compared to polyester, vinyl ester resin has very good chemical resistance,
especially against acids. High temperature and chemical resistant vinyl ester
based resins, e.g. Novolac vinyl ester, are also available.
2.2.4 Temperature limitations

The maximum allowable temperature is determined by the resin type and state of
cure. Experience of typical GRP systems suggests the following maximum
allowable design temperatures depending on resin type (Table 2).

Revision: 2
Table 2 Temperature limitations for GRP

Type GRP Maximum Design
temperature
Glass-fibre/epoxy (GRE)
- Aromatic-amine cured (MDA) 100 °C
- Cyclo-aliphatic cured (IPD) 100 °C
- Aliphatic-amine cured 85 °C
- Anhydride cured 65 °C
Glass-fibre/vinyl ester (GRVE)
- Bisphenol A 90 °C
- Novolac 100 °C
Glass-fibre/polyester (GRUP)
- Isophthalic 60 °C
The actual temperatures shall be confirmed by qualification testing but it shall not be
greater than the maximum design temperature in table 2.
The maximum design temperature for GRP pipeline system shall not be greater than
Tg minus 30deg C and the maximum design temperature specified in table 2.
The minimum design temperature for GRP regardless of the resin system is minus
40 C.
2.2.5 Chemical resistance

Resin, Adhesives & Thread sealants manufacturer shall supply chemical resistance data
for the relevant service fluids and the specific resin/sealant material, quoting the highest
known service temperature that the material has been subjected to and, if available, the
service life that has been achieved under the service conditions.
The chemical resistance information shall state whether the material has been
laboratory tested according to ASTM C 581 (or other equivalent standard). Guidance on
the selection of GRP is given in Table 3:
Table 3 Chemical resistance of GRP material

Fluid GRE GRE GRE GRVE GRUP
type Aliphatic Aromatic Anhydride Vinyl ester Polyester
Acids *, X X X √ X
***
Alkalis ** √ √ X √ X
(caustic)
Solvents √ √ X X X
(BTX)
Water √ √ √ √ √
sea/brack
ish
Note: The following aggressive chemicals may be transported in GRP piping or
pipeline systems, with the following restrictions:

Revision: 2
√ - Resin and curing agents can be used for the production of GRP
X – Material shall not be used for these services.
(*) Hydrochloric acid, up to 28% concentration, e.g. used in demin units. GRE (epoxy)
has limited resistance against hydrochloric acid (< 10 %) and therefore GRVE (vinyl
ester) shall be used, lined with a resin rich layer (liner), reinforced with double ECR/C-
glass or other qualified synthetic veils such as Nexus liners;
(**) Sodium hydroxide (caustic), up to 50 % concentration, e.g. used in chemical
plants. Glass-fibre is not resistant against sodium hydroxide, and therefore only
“lined” GRE or GRVE shall be used. The resin rich liner shall be reinforced with
double synthetic veil (e.g. Nexus), and thickness of the liner shall be minimum
1.5 mm;
(***) Sodium hypochlorite solution, e.g. used in chlorination units. Sodium
hypochlorite, typically produced on-site using electrolytic cells, i.e. concentrations
typically up to 1 %, and pH in the range 9 to 10, will attack all thermo-set resins.
However, UPVC lined GRVE is a proven option for the transport of sodium
hypochlorite.
Further information about chemical resistance of resins typically used for GRP, in a
variety of chemical environments, is given in DEP 30.10.02.13-Gen.
GRP manufacturer shall select the suitable resin system from the above table 3 &
supply a chemical resistance list for the selected material (Reinforcement, liner, resin
& curing system) showing highest known service pressure & temperature that the
pipe and its component variants are subjected to and the service life that have been
achieved under those conditions. Alternatively, the supplied resin system chemical
resistance list (data sheet) shall state whether the material has been laboratory tested
according to ASTM C581and life expectancy in intended actual service. If required,
manufacturer shall demonstrate the chemical resistance of the selected resin system
by carrying out the laboratory testing as per ASTM C581 for specific applications.
2.3 Reinforcing materials

The principal reinforcing material for the structural wall of GRP piping shall be a
suitable grade of glass fiber having a glass finish compatible with the resin system
used. Other types of reinforcement fibers may be used, to be agreed by the Principal.
2.3.1 Pipes
Continuous E-glass/ECR-glass fiber roving shall be used for constructing the
reinforced wall thickness of GRP pipes. Additional woven roving reinforcements may
be used to achieve the required strength of the pipes at the ends.
Other reinforcement materials like carbon fibers for conductive pipes can be used in
accordance with the specific agreement in the purchase requisition/purchase
specification.
2.3.2 Fittings (Tees, Elbow, Reducer coupler etc,)
Fittings shall be manufactured using E-glass/ECR glass reinforcement materials.
Fittings shall be manufactured with the same fiber glass reinforcement materials used
for the qualification (ref Clause 4.4).
Fittings manufactured by direct roving, the top minimum 4 layers shall be constructed
using the woven roving/knitted fabric /bidirectional tape glass reinforcement materials
even if the original qualification was conducted without these additional layers.

Revision: 2
2.4 Gasket materials

In order to achieve reliable flange sealing, even with relatively low bolt tensioning, steel
reinforced (G-ST) soft elastomer gasket with shore hardness within the range of A55 to
A75 should be used. Spiral wound gaskets may be used with satisfactory qualification
(Ref 4.4.4C & E). The gasket material properties shall be compatible with
DEP30.10.02.13 Gen requirements. Elastomeric and metallic gaskets shall be selected
as per SP2161.
The gasket material, e.g. used for flanges, shall match the pressure, temperature and
chemical resistance capabilities of the piping system. Further information about the
chemical resistance of non-metallic materials in a variety of chemical environments is
given in DEP 30.10.02.13-Gen. Selected gasket material shall be tested for the sealing
properties as per ASTM D4024. This test can be done on product sector representative
flange joints.
2.5 Internal surface

For GRP pipe systems transporting non-aggressive fluids, e.g. water, crude oil,
hydrocarbons, etc., an internal resin-rich liner with minimum thickness of 0.5 mm shall be
applied, which shall be reinforced with C glass or ECR glass veil.
For GRP pipe systems transporting chemicals, e.g. hydrochloric acid or caustic, an
internal resin-rich liner, reinforced with veil of C glass, ECR glass, synthetic fibre, or other
suitable material shall be used. Thickness of the liner shall be minimum 1.5 mm, and the
fiber reinforcement content should be in the range 20 % to 30 % by weight.
2.6 UV & Weathering Protection

External surface of the above ground Pipes and fittings shall be protected against
weathering, sunlight, UV, etc. A resin-rich poly veil external layer shall be applied, with a
thickness of 0.3 to 0.5 mm. Use of UV resistance pigments in lieu of poly veil external
layer may be considered by the company if sufficient qualification data in accordance with
ASTM G90 is submitted for approval.
External surfaces of the buried pipeline or piping system materials should be
manufactured with a resin rich top coat layer.
2.7 Fire resistance

Where the fire resistance additional requirement specified, and then ISO14692 part 3
sections 9.4 shall be applied.
3.0 MANUFACTURING
3.1 General
For manufacturing GRP pipe components, filament winding, and/or hand lay-up shall be
used. Any fillers such as sand-filled GRP pipe and fittings shall not be used for pipeline
and piping systems.
3.2 Filament winding

Filament winding is the process of impregnating glass fibre reinforcement with resin, then
applying the wetted fibres onto a mandrel in a prescribed pattern, and thickness.
Chopped glass roving may be used as additional reinforcement. Filament winding
includes reciprocal and continuous filament winding.
Revision: 2
3.2.1 Reciprocal filament winding

Reciprocal filament winding is the most widely used manufacturing method for
GRP pipe components. The winding angle of the component is controlled by the
synchronised translation speed of the fibre/resin bath and the rotational speed of
the mandrel.
3.2.2 Continuous filament winding

This specification is not applicable for the continuous filament winding process.
3.3 Pipe
Pipes shall be produced with the reciprocal filament winding process.
Standard length for line pipes manufactured by filament winding process shall be
supplied as specified in the below table.
Srl No. Diameter Minimum length
1 12.5 to 40mm 1 meters
2 50 to 80mm 3 meters
3 100 and above 8 to 12meters
Any additional reinforcements (woven rovings) required in the socket and spigot
areas (TB/TS joints) shall be as per the base line sample used in the qualification
process. Application of the woven roving shall be by using the helical winding
machine. The woven roving winding lengths start and finish shall be controlled by
CNC programming or mechanically driven machines. No manual application is
permitted. Knotting of the glass bobbins shall be done using the splicing gun or
suitable method to restrict the resin pockets accumulated across the manual
knots.
End scrap cutting should be established during qualification, based on the method
of winding to achieve the required winding angle at the ends. The same shall be
followed during regular production.
During the process of winding, if there is any resin mix started gelling, winding
shall be stopped and the pipe shall be rejected. Should there be a machine stop
for any reason the resin mix shall be inspected for gelling by QC inspector and
give clearance to proceed.
Winding angle of the pipes produced should be in the range of 53 to 57. The
tolerance of the produced pipes shall be +/- 2 of that of the qualified product.
Method and location used to measure the winding angle shall be same as one
used for qualification sample. The winding angle shall be measured in two
locations (internal and external surface) for the pipes with thickness greater than
10mm.
3.3.1 Resin mixing
Fully automated resin mixing & dispensing equipments shall be used. The
measurement of quantity of resin and hardener shall be through the automatic
dispensing unit. The resin mixing and dispensing units shall be calibrated in
accordance with the equipment manufacturer recommendations. The frequency

Revision: 2
of calibrations shall be defined in the manufacturer’s quality management

System.
3.4 Fittings
Fittings (Tee, Elbow, Reducer and Coupler) shall be manufactured by filament winding
or hand lay-up or by joining standard GRP pipe sections using laminated joints, to
form mitered bends as detailed below.
Fittings diameter less than or equal to 600mm shall be moulded fittings.
Mitered method of construction shall be limited to max 30 bar design pressure subject
satisfactory qualification.
All the GRE fittings should be pre cured between 90 to 100deg C before de-moulding.
In addition to the adhesive bonded joint, woven roving reinforcement shall be applied
on branch and saddle of the reducing tee.
The fittings shall be constructed using the qualified process. Manufacturer shall
establish, document and qualify the process description and Recipe to be used for the
construction of each type, size and pressure class of fittings.
The manufacturer shall demonstrate that the following variables remain constant
throughout the manufacturing of each type, size and pressure class of the fittings.
 Resin type & curing agent (hardener) with brand name and mixing
ratios.
 Type of reinforcement to be applied including mass, width, tows tex.
 Number and sequence of layers for each type of roving.
 Dimensions of cut roving if any to be used (Tees) and the locations,

layers and sequence of the cut roving to be applied.
 If the winding of the fittings not completed during the shift or if the resin
mix is gelled, surface preparation needs to be done before restarting the
winding process. The method of surface preparation shall be the same
as that of the qualified specimen.
 Liner and top coat material and number of layers, sequence and over
lap details.
Only certified operators shall be used for manufacturing of fittings. Refer: QA section for
the qualification of winding operators.
3.5 Flanges
3.5.1 General
Flanges shall be manufactured by filament winding and/or hand lay-up. Filament winding
is typically used for flanges smaller than 600 mm, and hand-lay up for larger diameter
flanges. Filament wound flanges up to dia 600mm shall be constructed on a mould.
Diameter greater than 600mm flanges can be constructed directly on the pipe.
The outside diameter and hole spacing of GRP flanges shall meet the requirements of
ASME B16.5 for flanges diameter below 600mm & ASME B16.47 for flanges diameter
more than 600mm. The flanges shall be flat face.

Revision: 2
For flange diameters larger than 1000 mm, an O-ring based seal design may be
selected, to be agreed by the Principal.
Flanges with an O-ring seal require special moulding and tooling (O-ring groove)
and are typically fabricated by the filament winding process.
Two types of flanges are typically used:
 Integral-type flange, adhesive-bonded or laminated to the GRP pipe ends;
 Loose ring type flanges, with GRP collars adhesive-bonded or laminated to the
pipe ends (stub-end) with loose backing flanges in GRP or steel.
The flanges shall be flat and perpendicular to the axis of the fitting. GRP Flanges
SHALL [PS] be post-cured. The neck area of the filament wound flange SHALL
[PS] be reinforced with continuous fibres eg mat or woven rovings. The flange
faces shall be clean free from resin drops and sharp edges. Flange machining shall
not be permitted by using hand tools. The machined surfaces shall be coated with
resin layer.
3.5.2 Hand lay-up

Hand lay-up is the simplest manufacturing technique for flanges and involves
applying layers of resin-impregnated mat or woven roving to a mould by hand.
Manufacturing of hand lay-up flanges shall be in accordance with ASTM D 5421.
For maximum mechanical properties and chemical resistance, flanges shall be
post-cured.
3.5.3 Filament winding

Filament winding of flanges involves wrapping continuous roving wetted with resin
over a mould. Manufacturing of filament wound flanges shall be in accordance with
ASTM D 4024.
Filament wound flanges are strong in the hoop direction but weak in axial bending.
To prevent cracking in the flange during loading, e.g. during assembly, it is
recommended to reinforce the flange in the neck area woven roving/knitted fabric
to a minimum thickness of 3mm.
The glass roving used in the construction of the flange should be tapered with a
waving pattern towards the flange face to increase the strength. The tension on the
glass roving shall be optimised preferably using tension controller such that
consistent glass content is achieved in the flange construction.
3.6 Manufacturing Process requirements
Manufacturer shall establish and document the process of manufacturing for each
product (each diameter and pressure class) of the pipes and fittings. The process
of manufacturing shall include the following minimum information. Change in the
process parameters shall be authorised by the principal or needs re-qualification as
defined in section 4.
 Reinforcement & the sequence of application (Recipe/winding
sequence)
 Method of construction (moulded or mitred construction)
 Reinforcement type (E glass, C Glass, ECR glass, Aramid fibre, carbon

fibre, woven roving or direct roving, CSM etc.,) composition, sizing and
tow tex details for each layer of construction in the form of Recipe or
winding sequence.
Revision: 2
 Resin and curing system.
 Curing time, temperature and method of curing.
 The details of winding angle, geometry, dimensions and joint

configurations.
 Bandwidth, number of roving strands, type of comb and the end cutting
dimension details.
The above information shall be made available to the access of company authorized
representatives upon request for verification or inspection.
3.7 Process validation
The following processes shall be considered as critical processes and shall be
documented, implemented, controlled and monitored as per ISO 9001.
 Selection of raw material suppliers.
 Incoming inspection of raw material.
 Storage & Handling of the raw materials and including ancillaries.
 Component design.
 Resin mixing.
 Control of temperature and relative humidity.
 Component fabrication and jointing process.
 Curing (monitoring of time and temperature)
 Threading process.
 Inspection and testing.
 Marking, packing and handling.
4.0 QUALIFICATION
This section of the specification gives requirements for the qualification of GRP pipeline
or piping components in order to enable to build up the confidence to purchase the GRP
materials with known and consistent properties from any manufacturer.
The vendor shall demonstrate that their product is qualified in accordance with this
section prior considering any project. This effectively means that the GRP Manufacturer
shall demonstrate, through testing, that its products will satisfy the design specifications
The qualification programme consists of standard methods for quantifying GRP pipe
component performance with respect to internal pressure and elevated temperature for
different applications.
All the qualification tests specified in this specification (sections 4.0 to 4.11) are type tests
& doesn’t require to repeat for each project/orders from the company unless there is no
change in the variables as stated in the table 4.

Revision: 2
The qualification programme results shall be used as baseline acceptance

criteria for quality control where it is not specifically defined in the specification.
4. 1 Manufacturer qualification:
The manufacturers shall be qualified based on the long term regression as per
ASTM D2992 with free ends using the pipe and joint with diameter minimum
100mm. Gradient (G), LCL and the HDB values shall be established. The
regression test shall be performed at temperature 65 deg C or at design
temperature if it is higher for each individual resin system. A manufacturer having
plain pipe regression data shall demonstrate the HDB of pipe plus joint is equal
to or superior to the plain pipe regression data by carrying out reconfirmation
test. The reconfirmation test and evaluation shall be done in accordance with
clause 12 of ASTM D2992 – 06.
Regression gradient G, obtained from the 10,000hour testing shall be in the
range of 0.065 to 0.075 for 65deg C and 0.085 to 0.100 for >65 deg C. LCLs
value obtained from the regression curve shall be in the range of 110MPa to
160Mpa for 65deg C and 85Mpa to 125Mpa.for 90deg C. In case where the
manufacturer regression data falls outside the above specified range, the data
shall be verified and CFDH approval shall be obtained.
Manufacturer shall be required to perform the additional testing as per cl. 4.4 as
part of their qualification program.
4.1.1 Manufacturer Technical catalogue

Manufacturers shall assign all components a nominal pressure rating (NPR), the
rating shall be given in the Manufacturers' brochures. The manufacturer
published data in the brochures shall be based on either API 15LR/API 15HR or
ISO14692 will only be considered.
NPRs quoted by the manufacturer shall be demonstrated through the
performance based qualification tests. Qualification program consists of
quantifying component performance with respect to static internal pressure,
design temperature, impact with optional methods for quantifying chemical
resistance, electrostatic and fire performance properties, potable water, low
temperature and limited cyclic pressure performance.
The NPR quoted by the manufacturer shall satisfy the following equation related
to PLCL
PNPR < f2. f3.PLCL
Where PLCL - Is the Lower confidence Limit (PLCL = f1. LTHP). This pressure is
the qualified pressure based on the qualified stress determined through the
regression test.
f1 – Means of the degree of scatter in the long term pressure tests and the
evaluation of the 97.5% confidence limit from the regression test data as defined
in ASTM D2992.
f2 – Is a load factor (or safety factor)
f3 – Is a factor to account for the limited axial load capability of GRP.
The manufacturer shall provide the values of f2 and f3 used to develop a
purchase quotation. Values of f2=0.67 and f3=0.85 (for above ground) and
f3=1.0 (for buried or underground pipeline) are recommended as default values.
However the value of f3 shall be verified during the system stress analysis.

Revision: 2
The pressure ratings of the GRP components shall be verified in accordance

with the requirements described in the section 4.2
Notes:
1. Manufacturer may select the more conservative value (0.5 to 0.85) f3 factor. In all
cases, the sum of all hoop stresses and axial stresses in any component in a pipeline or
piping system due to pressure, mass, other sustained loadings, and of the stresses
produced by occasional loads such as wind, blast or earth quake shall not exceed
values defined by the factored long term design envelop.
2. NPR definition from ISO14692-1; 2002 version retained.
4.2 Plant qualification

Individual manufacturing units shall be qualified by carrying out the
reconfirmation test on pipes plus joint in accordance with ASTM D2992-6 cl. 12
and fittings plus joint as per API 15 HR clauses 5.1.2 e & f; provided that the
product, technology and the quality management system of the manufacturing
unit are identical to the mother company which was originally qualified. In
addition the manufacturing unit shall have the technical support and R&D
provided by the mother company. Failing to demonstrate such similarities the
plant will be considered as new manufacturer and the full qualification program
shall be performed as per the clause 4.1
4.3 Wall thickness limitations

In order to provide sufficient robustness during handling and installation,
minimum reinforced wall thickness of any GRP pipe component shall not be less
than 3mm. For the above ground applications & pipe diameters ≥ 100mm, the
minimum reinforced wall thickness shall be 5.0mm.
Minimum reinforced wall thickness of the pipes and fittings supplied shall be ≥
the design thickness or max 5% less than the qualified component whichever is
higher. Reinforced wall thickness shall meet the minimum system design
requirements for sustained loads & occasional loads specified in ISO14692-3 for
above ground piping and AWWA M45 for buried pipeline. Minimum reinforced
wall thickness of pipes shall be verified to meet the requirements with part factor
f2=0.89 for hydro testing at 1.5 times the design pressure.

Revision: 2
4.4 Full qualification procedure

4.4.1 Pipeline or flow line GRE systems.
The table 3 below indicates the full qualification procedure required for the GRE
components for pipe plus joints and fittings.
Table 3 – Full qualification procedure for pipe, pipe plus joints and fittings.
Component Product type Qualification tests Purpose
Pipe plus Family Full regression test at 65C, or To establish

joint and representative 1 design temperature4 if it is higher. PLCL, qualified
fittings (ASTM D2992:2006 – procedure stress &
A or B as applicable). Baseline
gradient (G)
OR
In case manufacturer established
regression data only on plain
pipe, it is permitted to carryout the
reconfirmation test on pipes plus
joint in accordance with ASTM
D2992-6 cl. 12 and fittings plus
joint as per API 15 HR clauses
5.1.2 e & f
Pipe plus Product sector Survival test on two samples To Verify the
joint, Fittings representatives for 1000hour or more at 65C, or value of PLCL
+joints and design temperature if it is higher.
Fabrication (As per ASTM D1598).
process
Carry out the STHP test on two
samples to determine the quality
To establish
control baseline value.
base line
For low pressure (design acceptance for
pressure ≤70bar): The STHP quality control
value for pipes, fittings and joints during
shall not be less than 3.5 times manufacturing.
the design pressure.
For high pressure (design
pressure >70bar) STHP value for
the pipes, fittings and joints
samples shall meet API15HR
requirements

Revision: 2
Table 3 – Continued........
Product
Component Qualification tests Purpose
type
Once Product Sector STHP Baseline

Component Representative selected and value for
Variants tested as per PSR requirements Quality control
covered within stated above, the manufacturer tests shall be
the qualified shall then use scaling rules to taken from
product sectors qualify other component variants STHP test
A, B, C, D, E, N covered within that qualified PSR. done on PSR
& O (ref table 6) Requirements for scaling rules components.
shall be applied as per ISO14692-
2; 2017(E)2 Annex D.
Pipe plus
joint, Fittings The component variants which are Shall be taken
+joints and not within the qualified Product QC base line
Fabrication Sectors A, B, C, D, E, N & O shall value.
process be qualified by carrying out STHP
For items up to
Component tests on two samples. The
70bar, lower of
variants which acceptance criteria is as follows:
the two test
are not within Low pressure (Design pressure value shall be
qualified up to 70bar) - The STHP value for taken as
product sectors pipes, fittings and joints shall not baseline STHP
A, B, C, D, E, N be less than 3.5 times the design value.
& O (ref table 6) pressure.
For items more
High pressure (Design pressure than 70bar,
71 to 120 bar) – STHP value for API 15HR
the pipes, fittings and joints requirements
samples shall meet API15HR shall be
requirements. followed.
Note:
1. Only one size of component diameter not less than 100mm is required to be
tested.
2. In ISO 14692-2 version 2017 Appendix D replace MPR with Qualified Pressure.
3. Each test spool/sample should include all the pipe plus joint, fittings such as tee,
elbow, flange, reducer and saddle as applicable. In case the spool/sample length
is not possible to place in the test bench/chamber, manufacturer can opt for test
spool/sample with pipe plus joint with minimum one fitting. Test spool/sample
dimensions shall comply with the ASTM D1598.
4. Manufacturer having regression test for GRE pipe +joints at or above 90°C, can
use default stress values specified in table 2 of DEP 31.40.10.19 Feb 2018 up to
100°C. However, the design shall be validated through 1000hour testing. Use of
default stress values applicable only for low pressure (Max 20bar) applications.

Revision: 2
4.4.1 Pipe plus joint qualification (Family representative).

Pipe plus joint subjected to regression test (10000 hour test) as stated in section 4.1
provides more accurate and conservative results to use in the piping or pipeline system
design. Manufacturer shall carry out the regression test on spools (pipe plus joint) as per
ASTM D2992 to determine the G and PLCL values. Regression gradient (G), and PLCL
determined on the pipe plus joint can be used for design calculations. Manufacturers
having plain pipe regression shall reconfirm the HDB values as stated in clause 4.1.
4.4.2 Product sector representative.
As a minimum the manufacturer/supplier SHALL [PS] demonstrate by performing
1000/3500 hour survival tests that components are capable of meeting minimum design
requirements. This qualification procedure permits qualification of the PLCL of the product
sector representative based on a design life of 20years or more for pipe plus joint based
on 1000hour test or extended qualification time greater than 1000hours. Qualification
testing shall also include the type of repairs recommended by the Manufacturer. Each
type of jointing system shall be qualified as individual product sector. The preferred test
duration is 1000hours, but manufacturer may carryout testing to a longer duration as
stated in clause 4.4.2.1 of this specification.
Two replicate spools with sample product sector representative (PSR) shall be subjected
to 1000 hour pressure testing in accordance with ASTM D1598 at 65C or at design
temperature if higher. The PSR is qualified if both spools survive the test duration without
any leak. The minimum length of pipe between adjacent joints or fittings, or end closures,
needed to remove the influence of end-fittings shall not be less than that specified in
ASTM D1598.
Test spool shall contain all fittings (Elbow, Flange, Tee, and Reducer), Wherever it is not
possible, at least one fitting shall be a part of the test spool.
Prior to the commencement of 1000-h test, spools filled with water shall be
preconditioned by in oven at the test temperature for minimum 100hours.
After conditioning the specimens Test shall commence only when the pressure and
temperature have stabilised and when no further additions of water are required. Refill
may be allowed providing the component hasn’t failed and pressure was reduced due to
other reasons e.g gasket failure. Minimum 24hour stabilization after reaching the test
conditions shall be required prior to continuing the test. Test spools shall be under
continuous observation at least once in an hour to ensure that there is no change in
temperature and pressure i.e. the system is fully stabilized. The temperature, time and
pressure recording system shall be started after pressurizing the spool. The time count
shall start only after complete stabilization.
Pressure and time shall be recorded in a continuous automatic recording system.

Interruptions to the required pressure and temperature during the 1000-h test may be
permitted however, the time to failure shall not include periods of time during which the
specimen was less than the minimum test pressure and temperature. Interrupted time &
reasons for the interruption shall be clearly recorded and countersigned by witnessing
third party Inspector.
The 1000 hour test pressure shall be in accordance with the clause No 4.4.2.1.
All qualification tests including the regression test shall be carried out by, or witnessed
and certified by an independent third party agent approved by the Principal. The
qualification of each component shall be documented in both qualification report and a
summary as detailed in 4.11. The report shall be prepared and owned by the testing lab
in the lab or manufacturer letterhead format, the TPI role shall be witnessing and
verification of data accuracy.

Revision: 2
4.4.2.1 Default 1000hour test pressure

The following default test pressure requirements shall apply to all Manufacturers and for
all pipe or fittings (PSRs). 1000hour test shall be conducted in accordance with section
4.4.2.
The 1000-h test pressure for a 20 years design life shall be the following:
 Design temperature up to 65C
-Static pressure application: TP1000hr = 2.4Pdesign-static
 Design temperature >65 C and < 100C
-Static pressure application: TP1000hr = 2.6Pdesign-static
Design Pressure greater than 70bar the vendor may conduct a 3500hours test in lieu of
1000hour test and the parameters shall be as follows. The test pressure shall be 2.1times
the design pressure (TP3500r = 2.1Pdesign-static).
Where:
TP1000hr = test pressure to be used in the 1000-h qualification test
TP3500hr = test pressure to be used in the 3500-h qualification test
Pdesign = design pressure (static) for the pipeline or piping system
Where the design life required is in excess of 20 years, the above 1000-h and 3500h
test pressures shall be increased by 3 % per 10 years.
4.4.3 Component variant (CV)

This qualification procedure permits qualification of pipe plus joint and fittings (Tee,
Elbow, reducer, coupler and saddle openings) based on scaling method as defined in
ISO14692-2; 2017 annex D or STHP tests as stated in the table 3.
Any changes in component variant manufacturing process, raw materials, manufacturing
plant and other variables stated in table 4 than that of representing PSR, then it is
considered as invalid to reference PSR qualification and vendor shall repeat 1000 hour
test on PSR or component variant.
4.4.4 Qualification of flanges (product sector representative)

The joints made using flanges must have strength equal to that of the pipes. Flanges
construction methods and the reinforcement structure are different than that of pipes,
Elbows and Tees. Flanges shall withstand the external bending moments during the
service and hydro test conditions.
Flanges shall be subjected to the following qualification tests to demonstrate the integrity
of the flange design and manufacturing process. The samples selected for all the
qualification tests shall be from the same lot as those used for 1000hour test.
A. Short term rupture strength test.
B. 1000 hour survival test. (Part of 1000hour test spool as stated in clause No 4.4.2)
C. Sealing test.
D. Cyclic test.
E. Torque test.

Revision: 2
A. Short term rupture strength test:

Flanged components shall be tested in accordance with the test method ASTM D 1599
with free end closure. The pressure in the specimen shall be increased until failure of the
flange occurs. Pressure testing in atmospheric environment is permissible. Minimum
failure time shall be 60s: no restriction shall be placed on maximum time to failure.
Leaking past the gasket is permissible during this test. Bolt torque maybe increased as
necessary during the test in order to minimise the gasket leaking and to achieve the
pressure necessary to cause flange failure. For flanges design pressure up to 70bar shall
withstand a hydrostatic load of at least four times the design pressure. Flanges design
pressure more than 70bar, API 15HR STHP requirements shall be applied.
B. 1000hour pressure test: Two flanges shall be part of 1000hour survival test in
accordance with the clause 4.4.2 to demonstrate the PLCL of the flanges equal to or more
than that of other piping/pipeline system components (Elbow, Tee or pipe). In case of any
leakage past the flange face, the test may be interrupted to seal the flanges by increasing
the bolt torques to an appropriate value. Testing may then be continued to complete the
required period of testing.
C. Flange sealing test: flange sealing test shall be carried out at 1.5 times the design
pressure for the duration of 168 hours without any visible leak through the flange sealing
surface. Service gaskets, spacer ring if applicable, bolts, nuts and washers
recommended by the manufacturer shall be used during the sealing test. Gasket shall be
rated for the equal or greater design temperature and pressure. The flanges shall be
assembled and tightened to full recommended torque. The sequence and torque
increments shall be strictly followed during the torquing in accordance with ASTM D4024.
The testing method and the spool configuration shall be in accordance with the ASTM
D4024.
D. Cyclic pressure test: This test shall be done to verify the performance of the flange
system (combination of the gasket, flange geometry and the recommended bolt torque)
to withstand variations in pressure during the operations and testing. The flange spool
length shall be more than the manufacturer’s recommended minimum support distance.
The spool supported at both the ends leaving test flanges hanged at centre. The method
followed for assembling the flanges shall be in accordance with the one used for sealing
test. The sample shall be assembled using qualified (by seal testing) gasket and bolt
torque as recommended by the manufacturer. The test spool shall be subjected to 10
pressure cycles. Each cycle starts at 0 and rises to 1.5XDesign Pressure and then
reduces to 0. Testing can be done at ambient conditions. Each cycle represents study
pressurization (steady pressurization rate of 5bar per minute is recommended) up to 1.5
X Design pressure, hold for 5 minutes and gradually release the pressure to zero. Repeat
the above step until the required number of cycles completed. If there is a leak through
the gasket face, the test shall be stopped and replace with the new gasket and continue
the test.
Upon completion of the above C & D tests the flanges shall be disassembled and visually
inspected for any damages. Any cracks and/or de-lamination to the flange constitute
failure.
E. Torque test: Using the gasket and hardware (Nuts, bolts, washers and spacer ring
etc.,) recommended by the manufacturer, bolt the flange against the raised face or flat
face flange to simulate the installation recommendations by the manufacturer. Tighten
the nuts by hand until they are snug. Prior to fit up, the nuts, bolts, and washers should
be well lubricated, using a non-fluid thread lubricant. Establish uniform pressure over the
flange face by tightening bolts in 15N-M increments according to the sequence
recommended by the manufacturer. Increase the torque uniformly until flange failure
occurs or until all the bolts have been torqued to two times the level qualified in B & C
above. Any sign of flange damage, (crumbling, flaking, cracking or other breaking) shall
constitute failure.

Revision: 2
Criteria for acceptance: the flanges shall withstand, without visible sign of damage a bolt
torque of at least 2.0 times that recommended by the manufacturer for sealing of the
flange at its rated pressure.
A single flange spool may be used for sealing test, cyclic test & torque test.
4.4.5 Qualification of flanges (Component variant)
Two spools of component variants shall be subjected to STHP test in accordance with
ASTM D1599 to prove the integrity of the flanges. The acceptance criteria for low
pressure (up to 70bar design pressure) shall not be less than 4 times the design
pressure. For high pressure applications (71 to 120bar), the STHP shall meet API15 HR
requirements.
Any changes in component variant manufacturing process, raw materials, manufacturing
plant and other variables stated in table 4 than that of representing PSR, is considered
as invalidation of the existing or reference PSR qualification and all the flange
qualification tests as described in section 4.4.2 shall be performed on the component
variant.
4.5 Supplementary qualification requirements

In addition to the qualification requirements of 4.2.2, components shall also be qualified
for the following requirements when specified by the principal.
a. Potable water certification when used for potable water application
b. Impact resistance for above ground application.
c. Low temperature performance if the design temperature is less than

minus 30degC.
d. Fire performance test for above ground applications.
e. Electrical conductivity and Electrostatic dissipative properties when

conductive pipes are used.
The above tests shall be conducted in accordance with ISO14692-2:2017(E) clause 5.5.
4.6 Additional component properties

Each manufacturer shall establish the following properties for each plain pipe family
product representative:
a. Long term failure envelop of pipe, determined in accordance with Annex C of
ISO14692-2 at 65deg C or higher.
b. Short term axial strength, determined in accordance with ASTM D 2105 at SLT.
c. Axial tensile modulus, determined in accordance with ASTM D2105 at SLT.
d. Axial bending modulus, determined in accordance with ASTM D2925 at SLT.
e. Hoop tensile modulus and Poisson’s ratio, determined in accordance with API
15HR at SLT.
f. Hoop bending strength and modulus, determined in accordance with ASTM

D2412 at SLT.

Revision: 2
g. Poisson’s ratio for an axial tensile load and the resulting hoop contraction
determined in accordance with ASTM D2105 at SLT but modified in order to
measure hoop contraction.
h. Thermal coefficient of expansion in the axial direction in accordance with ASTM

D696.
i. Thermal conductivity of component and protective coatings, determined for radial

direction in accordance with ASTM C177.
j. Density of the component in accordance with ASTM D D792.
k. Hoop pipe stability – Stiffness factors as per ASTM D2412 for buried
applications.
The above tests shall be revalidated after every 10 years or any change in the raw
materials (Type of resin and reinforcement materials). Test records shall be maintained
and shall be made available for verification.

Revision: 2
4.7 Requalification
Any change of parameters specified in Table 4 shall mandate re-qualification in
accordance with this specification as described in (4.2 & 4.4).
Table 4 - Major changes in component requiring requalification
Reinforcement - Reinforcement manufacturing process {SHALL [PS]}.
- Reinforcement type and composition.
- Reinforcement finish (sizing)
- Tow (roving) tex / yield change of ±25%
- Any change in reinforcement (example woven roving to
direct roving or vice versa, Roving density and Roving
manufacturer).
- Resin/adhesive/curing agent manufacturer

- Curing procedure for pipe, fittings & joints (example: heating
Resin and adhesive
blanket to oven curing or vice versa).
- Curing time and temperature (±20%)
- Change of thread compound (adhesive and sealants)
Design - Change in Geometry, dimensions of the components.

- Joint type & design.
- Winding angle (> +/- 5 )
- Reinforcement mass fraction (> +/- 5 %) {SHALL [PS]}
Manufacture - Component manufacturing process – moulded, mitring
process, filament winding and Hand layup.
- Change in the manufacturing recipe related to the
reinforcement, and sequence & orientation of reinforcements.
- Decrease in number of passes per layer and increase in
average thickness per layer.
Component Changing the manufacturing plant SHALL [PS] require the

manufacturing plant component to be re-qualified.
4.8 Component definitions

In order to keep the total test burden within acceptable limits but at the same time to
control the use of test data beyond their limits of applicability, the concept of a product
family and its sub-divisions is used.
A product family defines a range of pipes, fittings and joints manufactured by the same
Manufacturer, using the same method and having the same constituent materials.
(Product family consists of plain pipe, joint and fittings such as elbows, tees , flanges and
reducers).
The family representative is the component that is taken to be representative of that
particular product family. It is the family representative that is tested under ASTM D 2992
to determine the long-term behaviour and LCL, of the product. Testing shall be carried
out on pipe product/pipe plus joint with a diameter of 50mm or larger.
A product sector is a sub-division of a product family that groups pipes (plus joints) and
fittings into specific diameter and pressure ranges.

Revision: 2
The product sector representative for a product sector is the component that is
representative of that sector and upon which the basic qualification testing (4.4) is
performed.
Qualification of the product sector representative also qualifies similar components with
smaller diameter which are part of that product sector. The following product sectors shall
be used:
Fig: Breakdown of a product family in to family representative, product sectors,

and product sector representatives.
The product sectors selected for the qualification is the component that has the largest
nominal diameter and the highest pressure rating in that specific sector. Assuming that
the product range consists of pipes, elbows, tees, Coupler, reducers, flanges, saddle and
joints in diameters up to 250mm and pressure up to 20bar, the product sector
representative (PSR) in product sector A would be:
a. 250mm, 20bar pipe plus joint.

b. 250mm, 20bar Elbow.
c. 250mm, 20bar flange.
d. 250mm, 20bar reducer or coupler (provided the manufacturing method is
similar)
e. 250mm, 20bar Tee.
f. 250mm, 20bar saddle.

Revision: 2
Manufacturer can select either to

1. Qualify the product sectors representatives of each sector as per the PSR range
specified in the table 6 or
2. Qualify based on the project specific requirements.
In case 2, the product sector representatives are identified by selecting first on nominal
diameter and then on pressure rating.
Table 6 Product sector definition
Diameter range Pressure range (bar)
(D) mm
≤ 20 21- 50 51 – 101 – 150 *
151 – 250
100 *
≤ 250 A F J M R
251 to 400 B G K P
>401 to < 600 C H L Q
>601 to < 800 D I J
>801 to < 1200 E
>1201 to < 2400 N
>2400 O
*
Note: High pressure threaded joints shall be qualified for pressure 100bar and 120bar
unless there is any requirements to go for higher pressure range than 120bar.
A component in a product sector where the product sector representative (Item No.2 -
example 350mm, 40bar) which falls under product sector ‘G’ has not been qualified may
be considered qualified based on the qualified component (Item No.1 – example 250mm,
40bar) which falls under product sector ‘F’ if the following criteria stated in step No.1, 2
and 3 are satisfied. If any of the criteria stated in step 1, 2 and 3 are not satisfied, the
item No.2 shall be qualified by 1000hour testing.
1) Scaling factors – D1 is the diameter, tr1 is the reinforced thickness, α 1 is the angle of
Elbow, P1 is the design pressure and R1 is the radius of bend of the qualified component.
D2 is the diameter, tr2 is the thickness, α2 is the Angle of Elbow, P2 is the design pressure
and R2 is the radius of bend of the component not qualified by 1000hour test.
a. t2 ≥ t1P2D2/ P1D1
b. P2 ≤ P1D1/D2
c. R2 ≥ R1 D2/ D1 (for bends)
d. α2 ≤ α 1
e. D2A ≤ D2B D1A /D1B (Reducer where D1A, D1B & D2A, D2B are the diameters of
qualified and non-qualified reducer).

Revision: 2
2) Pressure limitation - Design pressure of the component is 0.5 to 1.0 times the
qualified component. All previously qualified components with product sectors
defined in table 6 of SP2092-1, rev.1 can be accepted without repeating the
qualification test because of the change in the product sector.
3) Diameter limitations.
a. Size of the component is within +/- 100mm than that of the qualified component,
if the diameter of the component qualified is less than or equal to 400mm.
b. Size of the component is within +100/-200mm than that of the qualified
component, if the diameter of the component qualified is between 400mm and
800mm.
c. Size of the component is within +100/-300mm than that of the qualified
component, if the diameter of the component qualified is between 800mm and
above.
4.9 BASELINE DATA

The Manufacturer shall generate, from the qualification programme specified in
section 4.4.2 & 4.4.4 baseline values for the following items and establish
acceptance criteria for the manufacturing quality control programme.
4.9.1 Degree of cure

4.9.1.1 Glass transition temperature
The degree of cure (Tg) for the qualified components and joints (adhesive) shall be
determined by one of the following methods:
 Differential scanning calorimeter (DSC) according to ISO 11357-2;
 Thermal mechanical analyses (TMA) according to ISO 11359-2;
 Heat distortion temperature (HDT) according to ISO 75-1.
Three samples shall be taken from three locations situated 120  apart in the same
cross section of the qualified component.
The lowest Tg or HDT of the qualified component shall be more than 30 C above the
design temperature of the pipeline or piping system.
4.9.1.2 Residual styrene monomer content
For polyester and vinyl ester based products, the residual styrene monomer content
in the components used in qualification testing shall be determined. The
measurement shall be performed according to ISO4901. The residual styrene
content shall not be more than 2% (mass fraction) of the resin content.
4.9.1.3 Barcol hardness (for Vinyl ester / polyester resin pipes & fittings)
Barcol hardness testing shall be carried out in accordance with ASTM D2583.
Minimum of 10readings shall be taken on each sample. The two highest and lowest
reading to be discarded and average of remaining six readings shall be considered
as barcol reading.
4.9.2 Glass content

The glass content (by weight) of the reinforced wall of the qualified component shall
be determined in accordance with ASTM D 2584. Three samples shall be taken from
three locations situated 120  apart in the same cross section of the component. The
glass content of the qualified component should be within the range given in Table 7.

Revision: 2
Table 7 Glass content

Component type Glass content
by mass
Filament wound pipe 70 % to 82%
Filament wound fittings 65 % to 75 %
Hand-lay up fittings 50 % to 65 %
4.9.3 Minimum thickness

The minimum reinforced wall thickness of any GRP pipe component shall not be less
than 3 mm. For the above ground applications with pipe diameters ≥100mm, the
minimum reinforced wall thickness shall be 5.0mm.
4.9.4 Key component dimensions

The Manufacturer shall establish the following baseline dimensions of the qualified
component in accordance with ASTM D 3567 and the qualified data shall be listed in the
product catalogue.
 Internal diameter;
 Outside diameter;
 Mass;
 Minimum and Average reinforced wall thickness;
 Total wall thickness;
 Dimensions of joint.(Taper angles, thread dimensions etc.,)
 Laying length (pipes and fittings)
 Bend radius.
 Taper angle & length of taper (for adhesive bonded connections)
 Thread dimensions (as per API spec 5B)
4.10 Leak testing for gas service.

To demonstrate the gas tightness of the GRP pipe components during qualification, a
single gas test is required. The test configuration shall be 2 connected pipes, with a test
pressure between 5 bar and 10 bar. Compressed air or nitrogen may be used as the test
medium. The test duration shall be a minimum of 15 min. The acceptance criterion is that
no gas shall leak from the joint or pipe wall. Any escaping gas can be detected with the
aid of soapy water or similar foaming mixture.
If the test is unsuccessful, the Principal and the Manufacturer shall discuss and agree the
future course of the qualification testing and pipe manufacture.
4.11 Qualification records

Manufacturer shall maintain cumulative data for all the qualifications performed on PSRs
and Component variants in a controlled excel sheet format. This excel sheet format shall
contain information such as size, pressure, temperature, reinforcements, resin, curing
agent, manufacturing location, test pressure, STHP pressure, report reference etc., as

Revision: 2
Applicable. This qualification data shall be submitted to the company on annual

basis preferably beginning of the year.
The following qualification records shall be maintained by the manufacturer to
substantiate that the qualified components confirms to the requirement of this
specification. All the qualification records shall be endorsed by the manufacturer’s
quality control engineer and the third party inspection engineer. The records shall
be legible, identifiable, and retrievable and protected from damage, deterioration or
loss. The retention period of qualification records shall be maintained for the life
time of the manufacturing plant. Qualification Summary shall be as per the format
in Annex J of ISO14692-2;2002 (E).
a. Manufacturing plant including location.
b. Product series and the test sample number.
c. Raw material technical data sheets, manufacturer certificates shall be part of

qualification records.
d. Resin hardener mixing ratio.
e. Component fabrication method and date of manufacture (recipe – indicating

the number of layers, reinforcement type, number and sequence of layers,
number of passes per layer and average thickness per layer, method of
fabrication such as filament winding or hand lamination etc.,) the fabrication
process shall be witnessed and the records shall be signed off by the third
party representative who involved in the certification of qualified product. The
recipe shall be attached as an enclosure to the qualification report.
f. Curing (monitoring of time and temperature)
g. Identification of the winding operator name and staff number.
h. Glass transition temperature (reinforcement and adhesive used in joint)
i. % of glass content.
j. Barcol Hardness test records.
k. Thread making process records.
l. Jointing records (In the form of check list covering all the control parameters
in accordance with the jointing procedure).
m. Visual & dimensional inspection records for pipes, fittings, joints and threads
(diameter, min reinforcement thickness, liner thickness, total average wall
thickness, spigot and socket taper angle, thread dimensions, length of spool
preferably with as built test spool drawing).
n. Records of ancillaries such as gasket or sealing ring, studs and nuts material
details, torque wrench, pressure, temperature and time recorders calibration
details.

Revision: 2
5. QUALITY ASSURANCE AND CONTROL
5.1 General
The pipe Manufacturer shall have a suitable and accredited quality system in
accordance with ISO 9001.
The pipe Manufacturer shall identify fabrication processes and activities that
affect component performance and shall ensure that these processes and
activities are adequately controlled in accordance with ISO 9001. Critical
processes or activities for which procedures shall be developed and maintained
include, but are not limited to, the following:
 Review of customer requirements and clarify the variances if any before
sending the quotation or the acceptance of the order (Contract review).
 Raw material (including ancillaries) acceptance;
 Raw material (including ancillaries) storage;
 Component qualification.
 Resin mixing;
 Control of temperature and relative humidity;
 Component fabrication;
 Restart after production stops;
 Curing (including time and temperature monitoring);
 Component identification;
 Testing procedures (Tg, glass content, water absorption, raw material

properties determination, All type tests to validate the process or
design, and all destructive and nondestructive tests).
 Procedure for criteria, selection and training of pipes and fittings

winding operator certification, laminators, jointers, QC inspectors, lab
technicians, Field service Engineers and design engineers.
 Dealing with the non-conforming products, corrective and preventive

actions.
 Marking, packing, handling and transportation;
 Component design;
 Pipeline and/or piping design;
 Document & Drawing control register control;
 Field support.

Revision: 2
 In addition, a quality plan and flow diagram shall be produced, drawn in

the context of a factory plan, showing all the proposed tests and
inspections during component fabrication.
Manufacturer shall produce the specific inspection and test plan. Manufacturer
and EPC contractor shall agree before the documents submitted to PDO review
after the EPC contractor’s review. These documents shall be approved by the
company quality assurance TA2 authority for non-metallic materials before start of
production. Deviations to this specification shall be approved by CFDH materials
and corrosion. A copy of the approved deviations shall be attached to the
documents.
Inspection and test plan (ITP) shall be prepared separately for pipes and fittings
addressing all the inspection and tests required to be carried out in sequence as
per the applicable specifications and standards. The acceptance criteria or
reference to it, testing frequency and responsibilities to perform, witness, review
shall be addressed. Use of standard inspection plan by the manufacturer can be
an option to be approved by company quality TA2 for non metallic materials.
The inspector representing the company shall have unrestricted access at all time
while work on the contract is being performed to all parts of the manufacturing/
testing facility and ancillary units if any.
All records, documents and procedures shall be made available for inspection
upon request by 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
commissioning acceptance.
5.2 Quality control equipment

All inspection, measuring, and testing equipment shall be maintained and
calibrated, as described in ISO 9001, with following additional requirements:
 Test pressure measuring devices shall be either pressure gauges or
pressure transducers with a full-scale range of no more than two times
the test pressure and shall be accurate to at least ± 0.5 % of full-scale
range;
 A dead weight testing device shall be available at the Manufacturer’s
facility to calibrate gauges;
 All pressure measuring devices shall be calibrated to certified standard
every two months.
 All pressure, temperature, environment conditions measuring
equipments and time & automatic recorders shall be calibrated to
certified standard every six months.
 Any go or no go type gauges used for dimensional inspection of tapers,
threads etc., shall be calibrated based on the usage frequency or once
in three months.
 Any ultrasonic thickness measuring instruments used to measure the
thickness shall be calibrated using GRP standard thickness sample
prepared from the representative component to ensure the accuracy of
measure thickness.

Revision: 2
5.3 Quality control tests
5.3.1 Hydrostatic mill test

After full curing, 100% of the produced pipe, fittings and spool pieces shall be
hydrostatically tested by the Manufacturer to 1.5 times the specified design pressure
for the piping or pipeline system.
Hydrostatic test pressure shall be maintained for a minimum of two minutes in order to
ascertain there is no leakage. Where practicable, test components shall have
unrestrained ends. Test temperature shall be at ambient conditions.
Any fittings or spool pieces which are not practicable to conduct hydro test (example –
flange, saddle, coupler, nipple etc.,) shall be summarized and list shall be submitted in
the inspection and test plan for company TA2 approval.
5.3.2 Additional quality control tests for gas applications
After full curing and before hydro testing, pipes and fittings shall be air-tested. The air
test pressure and duration is described in (4.10). Approximately 10 % of produced
pipes and fittings should be air-tested. An air test schedule and frequency shall be
agreed between the Principal and the Manufacturer.
100 % of the first production lot should be air-tested. If all pipes and fittings pass this
air test, the test frequency for the second lot may be reduced to 50 %, for the third lot
to 10 % and for subsequent lots 5 %. If any pipe or fitting fails the air test, all other
pipes or fittings produced in the same lot and all pipes or fittings in the subsequent lot
should be 100 % air-tested. If there are no further failures, the testing frequency may
be reduced to 50 % and so on for subsequent lots. If further failures do occur, the
Principal and the Manufacturer shall discuss the future course of testing and pipe and
fitting production, including the requirement for additional testing of earlier lots of pipe
and fitting not subjected to 100 % testing.
5.3.3 Degree of cure

The degree of cure shall be determined by the same procedure (4.9.1) used to
determine the degree of cure for the qualified component, at a frequency of
a. One per lot, for continuous production, when the curing is done conveyor
type of curing ovens used.
b. One per charge irrespective of size, type or pressure rating when the fixed
type of oven without conveyor is use for curing. It is recommended to take T g
samples on the higher thick component in the charge.
In both the cases three samples shall be taken from three locations situated 120 °
apart in the same cross-section and same location, as for the qualified component.
If the Tg is less than the minimum value (minus 5 °C tolerance) measured for the
qualified component, then the production lot shall be rejected, subject to the retest
(5.5). However, the Tg of the on-going produced components SHALL [PS] always be
 30 ºC above the design temperature.
Barcol hardness shall be checked on minimum 100% of the Polyester and vinyl ester
resin components. Average barcol hardness shall not be less than the 95% base line
value established by the manufacturer for each type of resin system. The base line
value shall be taken from the sample used in the PSR qualification.
In case of polyester and Vinyl ester resin system, the styrene content shall be
measured in accordance with ISO4901. The styrene content shall be less than or
equal to 2% (mass fraction) of the resin content.
Revision: 2
5.3.4 Glass content

The glass content (% mass fraction) shall be determined by the same procedure
(4.9.2) used to determine the glass content for the qualified component, at a
frequency of one per lot of pipes. Three samples shall be taken from three
locations situated 120 ° apart in the same cross-section, and same location, as
for the qualified component.
One percent of sample for each type of fittings (Elbow, Tee, Reducer, Coupler,
Saddle, and flange) shall be tested for glass content.
The glass content measured on the pipes and fittings shall be within +/- 5% than
the qualified component. However maximum glass content of any component
shall not be more than 82%.
If the measured glass content doesn’t meet the required range, then the
production lot shall be rejected subject to retest (5.5)
5.3.5 STHP test
Pipes:
STHP test shall be conducted at a frequency of one in 200 pipes for each size
and pressure class for pipelines/flow lines. For piping, GRP pipes test frequency
shall be one sample selected from highest pressure & diameters in each product
sector. Samples shall be randomly selected by TPI/as identified in ITP. The
minimum STHP value shall not be less than 85% of the base line value or 3.5
times the design pressure whichever is higher.
Fittings:
STHP test shall be conducted at a frequency of one in 100fittings for each size,
type and pressure class for pipelines/flow lines. For piping, GRP fittings test
frequency shall be one sample tested in each type per 100components selected
from highest pressure & diameters in each product sector. Samples shall be
randomly selected by TPI/as identified in ITP. The minimum STHP value shall
not be less than 85% of the base line value or 3.5 times the design pressure
whichever is higher.
For the pipes and fittings design pressure more than 70bar, the value of STHP
shall be mutually agreed by the vendor and principal.
5.3.6 Mechanical tests
Axial tensile strength – axial tensile testing shall be carried out on minimum
one sample pipe per order as per ASTM D2105 (for diameter less or equal to
150mm) and ASTM D 638 for the diameter more than 150mm.
Hoop tensile strength – Hoop tensile test shall be carried out on minimum one
sample pipes per order as per ASTM D2290 or ASTM D1599.
The size and pressure class of the pipe selected for the test shall be specified in
the inspection and test plan to be agreed by the principal. Axial and hoop stress
values shall not be less than the manufacturer published values used for the
system design.

Revision: 2
5.3.7 Dimensions
Key dimensions shall be compared with the baseline values (4.9), in accordance with
ASTM D 3567, at a frequency of one per lot. Tolerances on approved design wall
thickness shall be as specified in Table 8. Any out of tolerance components shall be
rejected.
Threads shall be gauged in accordance with API SPEC 5B or to a manufacturer-
produced procedure agreed with the Principal, at a minimum frequency of 10% of
pipes and fittings for machined threads and 1% for moulded threads. For moulded
threads, the first article from new mould and every shift start of production shall be
checked. For machine threads, the components produced at the beginning and end of
the shift shall be included in the 10% samples.
The following dimensions shall be determined in accordance with ASTM D3567 on 1%
of the continuous production.
a. Reinforced and liner wall thickness using optical scale comparator with
minimum 7 to 10X magnification.
b. Average Internal diameter.
c. Average Outside diameter.
d. Observed Minimum, maximum and average total wall thickness (tmin , tmax,
tave)
e. Mass
f. Laying length - Acceptance criteria for fittings shall be as per ISO14692-2

table 14.
g. Winding angle for the pipes to be measured and recorded at minimum three
places.
Table 8 Wall thickness tolerances

Dimensions Tolerance
Total wall thickness +22.5 % *
0%
Reinforced wall thickness +22.5 % *
0%

Revision: 2
* NOTES
1. The plus-tolerance on total and reinforced wall thickness for fittings shall refer to the spot
having the minimum wall thickness.
2. The minimum reinforced wall thickness on components shall not be less than 5% of the
qualified thickness or design thickness whichever is higher.
3. In fittings, the surface irregularities shall not be more than + 22.5% of the average wall
thickness measured along single axis of the fittings.
Total wall thickness & laying length shall be measured and recorded on 100% of
pipes & fittings. Total wall thickness of the fittings shall be determined by using
the calliper, whereas for the pipes either calliper or the pi-tape can be used. For
the pipes more than 350mm the surface roughness correction factor of 0.3mm
shall be deducted from the measured OD of the pipe to calculate the total wall
thickness. For pipe, the measurements shall be made at three locations one in
the middle of the pipe, the other two at approximately1meter distance from both
the spigot and socket neck area.
The following dimensions shall be checked and recorded.
Pipes and fittings socket (minimum 1% for each mould used): Taper
length, socket ID at neck and edge of the socket, taper angle shall be measured
and recorded.
Mould control reports shall be available for all the socket moulds used in the
production line. Traceability shall me maintained and recorded in the inspection
reports.
Pipes and fittings Spigot dimensions (100% of the spigots): Taper length,
OD at the nose, OD at the standard insertion length and taper angle shall be
measured and recorded.
Standard and calibrated jig can be used for checking the spigots and sockets.
The method of controlling the standard jig shall be defined in the manufacturer
quality system.
Flange dimensions (10%): Flange dimensions such as thickness, drill hole
dimensions, Pitch circle diameters and the sealing ring dimensions shall be
checked and recorded. The dimensions shall be within the specified tolerances.
5.4 Visual inspection

All pipes and fittings (100% of the items) shall be subjected to visual inspection
for compliance with acceptance criteria specified herein.
Visual inspection of all pipe and fittings, including corrective actions (correction),
shall be in accordance with ISO 14692-4;2002(E), Annex A. The additional
requirements specified in the table below shall also be applied for the visual
inspection and acceptance criteria for the GRP pipes and fittings manufactured in
accordance with the specification.

Revision: 2
Table: 9 Visual imperfections acceptance criteria

Defect type Description Acceptance criteria
Pit (pin hole) Small crater in the None permitted in the liner. At other
surface of the laminate, locations ISO14692-4 table A1
with its width (diameter) acceptance criteria shall be applied
similar to or smaller except the depth of crater shall be
than the depth less than 10% of the wall thickness
or equal to 0.8mm whichever is
less.
Air bubble Air entrapment within Maximum width 0.8mm and depth
(void) and between the plies less than 10% wall thickness or
of reinforcement, equal to width whichever is less.
usually spherical in
shape
Visible Presence of numerous None permitted in the liner. Other
Porosity on visible pits (pin holes) or areas it shall be maximum 25 pits in
the surface air bubbles porous area of 10in2.
Pimple Small, sharp, or conical Any pimples greater than 3mm dia
elevation on the surface shall be removed by carrying out
of a laminate minor repair.
Resin Pocket An apparent Maximum size 3mm or 10% of wall
accumulation of excess thickness whichever is lower.
resin in a small
None permitted in the liner
localized area within the
laminate
Resin rich In sufficient reinforcing Maximum 0.4mm from the edge.
edge materials at the edge of
moulded laminate
Inadequate Incorrect bonding or Measured Tg shall not be less than
cure of cure procedure minus 5°C than the base line value
lamination or measured for the qualified
adhesive component.
Any imperfections detected shall be classified as allowable, repairable and rejection

imperfections and actions shall be taken accordingly.
5.5 Acceptance criteria and remedial action

The acceptance criteria for the imperfections noticed shall be as defined in the
specification. The recommended corrective actions as per ISO14692-2 table 12
should be followed.
The principal shall be notified for all major repairs. After the repairs, a hydrostatic mill
test in accordance with (5.3.1) shall be performed on the repaired component.
Any repairs other than the removal of imperfections by grinding within the top resin
layer shall be classified as major repair. All minor repairs if any detected during visual
inspection shall be done before the final mill hydro static test.

Revision: 2
5.6 Optional QC Tests

Conductivity: If specifically requested by the principal for the conductive pipes,
the conductivity tests shall be performed as per ISO14692-2:2002 clause 8.3.10.
Stiffness test: Stiffness measurement test shall be performed in accordance
with ASTM D2412 on 1% of the pipes if specified in the purchase order or
purchase specifications.
5.7 Retest
If any specimen fails the quality control tests (5.0) the lot shall be rejected. The
Manufacturer may elect to make retests, to be agreed by the Principal, on two
additional replicate samples selected at random from the same production lot.
If all the retest samples conform to the requirements then the remainder of the
production lot should be accepted. If any retest specimen fails to conform then
the production lot shall be rejected.
5.8 Quality control records
5.8.1 Purpose
The quality control records are required to substantiate that all components
manufactured to this specification conform to the specified requirements.
5.8.2 Records control

Quality control records required by this specification shall be:
 Legible, identifiable, retrievable and protected from damage,
deterioration or loss;
 Retained by the Manufacturer for a minimum of ten years following the

date of commissioning acceptance;
 Signed and dated.
5.8.3 Records to be maintained by Manufacturer

The Manufacturer shall maintain the following records for a minimum of 10 years.
Qualification records shall be retained by the manufacturer forever.
 Quality control inspection & test results ;
 Any records related to Manufacturer’s process documentation.
5.8.4 Production quality control reports & product certification

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 in accordance with the requirements listed herein.

Revision: 2
The quality control report shall:

Identify the components (including type, nominal diameter and pressure rating), their
date of manufacture, production lot(s) and the manufacturing procedure used for their
production;
 Report the quality control tests of (5.3).
All the products shall be despatched or delivered to the principal locations with ISO 3.2
certification in accordance with EN10204:2004.
6. COMPONENT MARKING
6.1 General
Pipe and fittings manufactured in accordance with this specification shall be marked by
the Manufacturer as specified in (6.2). Additional project related markings as desired by
the Manufacturer or as requested by the Principal should be included.
Markings shall be applied on the pipes, fittings and spools. Method of marking should
be agreed between the Principal and Manufacturer. Markings shall be permanent, shall
not overlap, and shall be applied in such a manner as not to damage the pipe or
fittings. Markings shall be applied on the pipes within one metre from the female end.
Pipes diameter more than 20” shall be marked at three locations at the orientation of
approximately 120deg to each other. For fittings, marking shall be applied minimum
one place. All the markings applied shall be clear and readable.
6.2 Requirements
All pipes and fittings shall be permanently marked with:
 Manufacturer’s name;
 Nominal diameter;
 Design pressure (static or cyclic, as appropriate);
 Qualified pressure (Pq).
 Design temperature
 Date of manufacture;
 Product ID / series;
 Manufacturer’s identification code (Unique identification number for
each pipes and fittings).
 Limitations or reference to installation requirements such as permissible
bolt torques, electrical conductivity, Fire performance classification,
potable water application etc.,
7.0 Handling, storage and transportation:

The handling, storage and transportation of GRP piping and pipeline materials
shall be in accordance with annex ISO14692-4:2002 annexure B.

Revision: 2
All pipes and fittings shall be supplied with rubber or opaque plastic end caps
which can withstand minimum two years desert storage conditions without
affecting the bonding or jointing surfaces. Polyethylene sacks shall not be used
as end caps as they tend to get damage within one or two months in desert
storage conditions.
8.0 Final manufacturing documentation (Manufacturer

Record Book)
Manufacturer shall submit the following documentation and records after
completing the delivery of all the products as per the purchase order in folder
with a title as Manufacturer Record Book either in hard copy or electronic copy.
a. Purchase order and amendments thereafter with related correspondence
with the principal or client.
b. Qualification documents and records in accordance with ISO14692-

2:2002 section 11.3.2 ‘a’ to ‘j’ including those specified in this
specification under clause 4.0 of this specification.
c. Production quality control documentation and records which includes but

not limited the following
 Copy of the approved Inspection and test plan
 Raw material certificates. (From raw material suppliers and internal

test results as per the ITP)
 Production quality control records for each inspection and testing

carried out at all stages as per the approved inspection and test plan.
 Production lot test records
 Visual and dimensional inspection records.
 Lab test records (Tg, % glass, tensile testing records etc., as

applicable in accordance with the approved ITP).
 Spool visual and dimensional records can be in the form of as built

dimensions certified by the QC inspectors and Third party inspector
or company representative as applicable.

Revision: 2
Appendix A
Reference standards
ISO Standards
GRP piping – vocabulary, symbols and application of ISO 14692-1

materials
GRP piping – Qualification and Manufacture ISO 14692-2
GRP piping – System Design ISO 14692-3
GRP piping – Fabrication, Installation and operation. ISO 14692-4
Plastics - determination of temperature of deflection under load – Part 1: ISO 75-1
general test method
Quality management systems - requirements ISO 9001
Plastics – differential scanning calorimetry (DSC) – Part 2: determination ISO 11357-2

of glass transition temperature
Plastics – thermomechanical analysis (TMA) – Part 2: determination of ISO 11359-2

coefficient of linear thermal expansion and glass transition temperature
ASTM Standards
Obtaining Hydrostatic design basis for fibreglass pipes and fittings ASTM D 2992
Resistance to short term hydraulic pressure of plastic pipe tubing and ASTM D 1599
fittings.
Determination of longitudinal tensile properties of fibreglass pipes & ASTM D 2105
Fittings.
Standard specification for machine made Fiberglass flanges ASTM D 4024
Standard practice for classifying visual defects in glass reinforced plastic ASTM D 2563
laminate parts
Standard specification for contact molded fibreglass flanges ASTM D 5421
Standard practice for determining dimensions of fibreglass pipes and ASTM D 3567
fittings.
Standard practice for determining chemical resistance of thermosetting ASTM C 581
resins used in glass-fibre reinforced structures intended for liquid service
Standard test method for ignition loss of cured reinforced resins ASTM D 2584
Pipe flanges and flanged fittings NPS ½ through NPS 24 metric/inch ASME B16.5
standard
Fiberglass pressure pipe AWWA C950
Fibergalss pipe design manual AWWA manual M45

Specification for High pressure Fibergalss line pipe API 15 HR
Specification for Low pressure Fibergalss line pipe & Fittings API 15 LR
SHELL STANDARDS
Definition of temperature, pressure and toxicity levels DEP 01.00.01.30-Gen.

Non-metallic materials – selection and application DEP 30.10.02.13-Gen.

Revision: 2
Piping – general requirements DEP 31.38.01.11-Gen.

Selection of materials for life cycle performance (EP) DEP 39.01.10.11-Gen.
Glass-fibre reinforced plastic pipeline and piping system DEP 31.40.10.19-Gen

Revision: 2
User Comment Form

If you find something that is incorrect, ambiguous or could be better in this document, write your
comments and suggestions on this form. Send the form to the Document Control Section (DCS).
They make a record of your comment and send the form to the correct CFDH. The form has spaces
for your personal details. This lets DCS or the CFDH ask you about your comments and tell you
about the decision.
Procedure Details Title: Issue Date:
Number:
Page Number: Heading Number: Figure Number:
Comments:
Suggestions:
User’s personal details

Name: Ref. Ind.: Signature: Date:
Phone:
Document Control Section Actions
Comment Number: Date: CFDH
Ref. Ind.:
Recd.: To CFDH:
CFDH Actions
Recd. Decision: Inits.: Ref. Date:
Date: Reject:  Ind.:
Accept, revise at next issue: 
Accept, issue temporary amendment 
Comments:
Originator Advised: Date: Inits.: Document Date: Inits.:

Control
Section
Advised:


SP-2092 - 2018 Revisions Highlighted PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SP-2092 - 2018 Revisions Highlighted PDF

Uploaded by

Copyright:

Available Formats

Petroleum Development Oman L.L.C.

Document title: GRP Specification Part 1

Document Type Specification

Discipline Materials & Corrosion

Owner UEC (CFDH Materials, Corrosion and Integrity)

Issue Date 10.06.2018

This page was intentionally left blank

Page 2 Specification SP2092-1 rev.2 Printed 19/06/18

Document Author Document Custodian Document Owner

Page 3 Specification SP2092-1 rev.2 Printed 19/06/18

Revision Date Author Reviewed by Approved Revision note

iii Related Business Processes

iv Related Corporate Management Frame Work (CMF)

Page 4 Specification SP2092-1 rev.2 Printed 19/06/18

Clause no. Description Page

1.2 CHANGES TO THE SPECIFICATION. 7

1.4 SYMBOLS & ABBREVITIONS 8

1.5 CROSS REFERENCES 9

1.6 GRP MATERIAL SELECTION PRICIPLE 9

1.7 GRP APPLICATIONS 10

1.8 PROJECT EXECUTION 12

1.9 CONFLICTING REQUIREMENTS 12

2.3 REINFORCEING MATERIALS 16

2.4 GASKET MATERIALS 17

2.5 INTERNAL SURFACE 17

2.6 UV & WEATHERING PROTECTION 17

2.7 FIRE RESISTANCE 17

3.2 FILAMENT WINDING 17

3.6 MANUFACTURING PROCESS REQUIREMENTS 20

3.7 PROCESS VALIDATION 21

Page 5 Specification SP2092-1 rev.2 Printed 19/06/18

4.1 MANUFACTURER QUALIFICATION 22

4.2 PLANT QUALIFICATION 23

4.3 WALL THICKNESS LIMITATIONS 23

4.4 FULL QUALIFICATION PROCEDURE 24

4.5 SUPPLEMENTARY QUALIFICATION REQUIREMENTS 29

4.6 ADDITIONAL COMPONENT PROPERTIES 29

4.8 COMPONENT DEFINITIONS 31

4.9 BASELINE DATA 34

4.10 LEAK TESTING FOR GAS AND MULTIPHASE SERVICE 35

4.11 QUALIFICATION RECORDS 35

5. QUALITY ASSURANCE AND CONTROL 37

5.2 QUALITY CONTROL EQUIPMENT 38

5.3 QUALITY CONTROL TESTS 39

5.4 VISUAL INSPECTION 42

5.5 ACCEPTANCE CRITERIA AND REMEDIAL ACTION 43

5.6 OPTIONAL QUALITY CONTROL TESTS 44

5.8 QUALITY CONTROL RECORDS 44

7. HANDLING, STORAGE AND TRANSPORATION 45

8. FINAL MANUFACTURING DOCUMENTAION 46

USER COMMENT FORM 49

Page 6 Specification SP2092-1 rev.2 Printed 19/06/18

1.2 Changes to the Specification

The Supplier/Manufacturer/Vendor is the party that performs Design,

The Company/Owner/Principal is Petroleum Development Oman.

1.3.2 Specific Definitions

1.3.2.2 Date of manufacture: Date of cure.

Page 7 Specification SP2092-1 rev.2 Printed 19/06/18

1.3.2.9 Pi tape : A tape unit to measure circumference and convert to diameter

1.3.2.11 Zones definitions for use of GRE pipes

Zone 0 Area in which an explosive gas atmosphere is present continuously

Non hazardous A non hazardous area is an area in which an explosive atmosphere

Note: Zones are defined as per IEC60079-10-1.