1. SCOPE ……………………………………………2. REFERENCES
3. TERMS AND DEFINITIONS
4. OWNER’S QUALITY ASSURANCE (QAPROGRAM & FITNESS FOR SERVICEREQUIREMENTS ……………………………..4.1
Goal
4.2 Examinations and Inspections
4.3 Responsibilities
……………………………
4.4 QA and Inspection Objectives
4.5 Owner’s QA Plan Preparation
4.6
Fabricator / Contractor Audit
4.7 Owner’s Inspector …………………………4.8
Intended Service Description Review
4.9 Materials System Review
4.10 Specification Review …………………….4.11 Fabricator Qualification
4.12 Fabricator Physical Property
Production Testing
4.13 Contractor Qualification …………………4.14 Contractor’s Methods Statement
4.15 Contractor Delivery Examinations
4.17
System Hydrostatic Testing ……………
4.18 Acoustic Emission (AE) Testing
4.19
Repairs
4.20 Owner Warranty Inspections ………….5. X-RAY
6. ULTRASONIC TESTING
7. ACOUSTIC EMISSION (AE) TESTING ..8. VIBRATION MONITORING
9.
INFRARED THERMOGRAPHY
10. FABRICATOR QC PROGRAM
REQUIREMENTS ……………………………..10.1 Application
10.2 QC Plan
10.3 Examination
…………………………………
10.4
Testing
Procedures
10.5 Witness Points
10.6 Hold Points …………………………………..10.7
Non-Conformances
10.8 Management of Change
11. QUALITY CONTROL MANUAL …………..12. PURCHASE ORDERS
13. CHANGE
ORDERS 1
14. CONTRACTS ……………………………………15. SPECIFICATIONS 116. DRAWINGS
17. CALCULATIONS ……………………………….18.
INSPECTION DOCUMENTATION
19. TESTING DOCUMENTATION
20. MATERIALS CERTIFICATION …………….21. MANUFACTURING PROCEDURES
22. CORRESPONDENCE 23. MINIMUM QUALITY REQUIREMENTS 23.1
Baselines
23.2 Defect Evaluation and Acceptance
Criteria 123.3 Field Installation ……………………………23.4 Field
Joining
23.5 System Testing
24. SYSTEM COMMISSIONING ………………24.1 Post-Installation System Testing
24.2 Pipe Condition
24.3 Examinations ……………………………….24.4 Hydrostatic Pressure Testing
24.5 Post-Installation Repairs
APPENDIX
A Terms & Definitions ……………………………
B
Joiner Certification
C Fabricator Qualification
D Contractor Qualification ………………………E Preventive Maintenance (PM) Program
1. Scope
This standard establishes the requirements for quality assurance in fiberglass reinforced plastic (FRP)
piping systems and components for use in SABIC facilities, and to assure life-cycle fitness for service.
The requirements described in this standard apply to both custom and commodity pipe and for joints and
fittings applicable to FRP pipe. These requirements also apply to intended service, description, materials,
design, manufacture, installation and preventive maintenance of FRP pipe and components. Intended
services, materials, designs, manufacturing and installation of pipe materials not described herein are
considered outside the scope of this standard.
2. References
Reference is made in this standard to the documents listed below. The latest issue, amendments and
supplements to these documents shall apply unless otherwise indicated.
SABIC Engineering Standards (SES)
SES P01-E28 Design Requirements for FRP Piping Systems
American Society for Testing and Materials (ASTM)
D 638 Test Method for Tensile Properties of Plastics
D 790 Test Method for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical
Insulating Materials
D 883 Standard Terminology Related to Plastics
D 2584 Standard Test Method for Ignition Loss of Cured Reinforced Plastics
D 3517 Standard Specification for “Fiberglass” Pressure Pipe
British Standards Institution
BS 7159, Appendix E Non-Destructive Testing
3. Terms and Definitions
The terminology of this specification is consistent with ASTM D 883-80C, “Definitions of Terms Relating to
Plastics.” For the purposes of this standard, the definitions applied are found in Appendix A, “Terms &
Definitions.”
4. Owner’s Quality Assurance (QA) Program & Fitness for Service Requirements
4.1 Goal
The owner’s QA program is intended to assure the mechanical integrity of the FRP piping system so that it
will be fit for service and perform successfully over its intended life.
4.2 Examinations and Inspections
This standard distinguishes between the terms “examinations” and “inspections.”
4.2.1 “Inspections” are the functions performed for the owner by the owner’s inspector or the inspector’s
delegate. References in this standard to “inspector” are references to the owner’s inspector or to the
inspector’s delegate.
a. The owner’s inspector shall have access to any place where work on any owner piping system is
being performed. This includes, but is not limited to, gaining access to facilities or sites where project
fabrication, post-curing, installation or testing is being performed.
b. The owner’s inspector shall have the right to inspect the piping using any inspection method
available to assure the engineering design requirements are met.
4.2.2 “Examinations” are the quality control (QC) functions performed by the contractor or fabricator.
References in this standard to “examiner” are references to the fabricator’s/contractor’s examiner or
examiner’s delegate.
4.3 Responsibilities
4.3.1 Responsibilities of the Owner
a. The owner shall develop a QA strategy specific to his own project needs and applications. This
strategy shall be documented and communicated to the qualified engineer, inspector and other
personnel on the owner’s QA team. The owner’s QA program is intended to assure fitness for service
through enforcement of the contract documents to protect the owner’s best interests, and is in no way
meant to replace or diminish the responsibilities under this standard of the contractor, the fabricator,
materials suppliers or any other participants in the project.
b. It is the owner’s responsibility, through the owner’s engineers and inspectors, to verify that all
fabricator and contractor system designs, manufactured products and installations are in conformance
with the contract documents, related standards and fitness for the intended service.
c. It is the owner’s responsibility to verify that all required examinations and testing performed by
the fabricator and contractor are appropriate for the project requirements. The owner shall also
independently evaluate the piping system to be satisfied that it is in conformance with all applicable
contract documents.
d. It is the owner’s responsibility to provide appropriate preventive maintenance evaluations of the
FRP pipe system during service to assure its ongoing mechanical integrity.
4.3.2 Responsibilities of the Fabricator
a. It is the fabricator’s responsibility to assure that all program procedures, techniques, products,
examinations and tests are in conformance with the contract documents.
b. It is the fabricator’s responsibility to provide the assistance of his QC personnel while the owner’s
inspector performs his inspection duties under this standard. The fabricator shall make available to the
inspector all necessary tools and test equipment so the inspector may properly conduct all inspections
required by this standard and the project specification.
c. It is the fabricator’s responsibility to satisfy the requirements of the contract documents.
d. The fabricator is not relieved of any other of his contract responsibilities or warranties for goods
and services as a result of the owner’s QA program.
4.3.3 Responsibilities of the Contractor
a. It is the contractor’s responsibility to assure that all program plans, engineering designs,
products, examinations and tests are in conformance with the contract documents.
b. It is the contractor’s responsibility to satisfy the requirements of the contract documents.
c. The contractor is not relieved of any other of his contract responsibilities or warranties for goods
and services as a result of the owner’s QA program.
4.4 QA and Inspection Objectives
4.4.1 The purpose of QA inspection activities prior to commissioning is to identify design inadequacies and
fabricator and contractor non-conformances as early as possible and generate a plan for prompt, effective
corrective action.
4.4.2 Once the piping is in service, the role of QA, engineering and inspection includes, but is not limited to:
a. Assure technical integrity,
b. Form a basis for maintenance evaluation and planning, and
c. Contribute to the improvement of current and future designs and examination strategies.
4.4.3 QA issues shall be taken into account as part of the original equipment design during the design
phase of an FRP piping system.
4.5 Owner’s QA Plan Preparation
This section specifies the fundamental components required for an owner’s QA plan covering pipe design,
fabrication and installation.
4.5.1 At a minimum, the owner’s QA plan shall include the following:
a. A description of the design reviews, inspections, and testing or certifications function, to be
performed.
b. A controlling specification as a reference.
c. The expected frequency of the inspection or examination function.
d. Specific criteria to which the function is to be performed; e.g., audit, test, witness point or hold
point.
4.5.2 A materials section shall assure that all materials used for the FRP piping project meet specification
requirements.
4.5.3 A pipe fabrication or installation section shall provide the necessary information to assure that all
pipe manufactured and/or installed meets all specification requirements.
4.5.4 A fittings fabrication section shall provide the necessary information to assure that all fittings
manufactured meet all specification requirements.
4.5.5 A spooling fabrication or installation section shall provide the necessary information to assure that all
spooling that is manufactured or installed meet all specification requirements.
4.5.6 A testing section shall describe the procedures and techniques required to assure that all relevant
testing is conducted in conformation with this standard.
4.6 Fabricator / Contractor Audit
4.6.1 A quality audit of the fabricator’s facility or contractor’s site shall be performed by the owner’s
inspector to assure that all work is being performed in accordance with this standard and with the project
specification.
4.6.2 All records pertaining to joining and installing FRP pipe shall be made available promptly for the
inspector’s review. These records include, but are not limited to, documentation regarding:
a. Assembly
b. Joining
c. Erection
d. Installation, including trenching, bedding and backfill
e. Quality control
f. Scheduling
4.6.3 All documentation regarding examinations performed by the contractor and/or fabricator shall be
available for the owner’s inspector.
4.6.4 It is the contractor’s and fabricator’s individual responsibility to maintain records in accordance with
the project specifications. These records shall be updated daily.
4.7 Owner’s Inspector
4.7.1 The owner’s inspector shall be an employee of the owner, an employee of an engineering firm, or an
employee of a recognized inspection company acting as the owner’s representative. The owner’s
inspector shall not represent or be an employee of the piping contractor or fabricator unless the owner is
also the piping contractor or fabricator.
4.7.2 The owner’s engineer and/or inspector shall have demonstrated experience in the fabrication and
inspection of industrial FRP pressure piping.
4.7.3 The owner’s inspector shall be qualified to perform inspection functions that satisfy this standard and
the project specification.
4.7.4 The owner’s inspector shall refer to the project specification, the governing standards and the
approved design and contract documents as the basis for all inspection activities.
4.7.5 The owner’s inspector shall document in a written QA report all non-conformances found during
inspection.
4.7.6 The owner’s inspector shall bring all non-conformances to the immediate attention of the responsible
QA engineering representatives and associated project managers for appropriate action.
4.8 Intended Service Description Review
4.8.1 The accuracy and completeness of the intended service description shall be reviewed and confirmed
by the owner’s qualified process engineer prior to the award of any work.
4.8.2 If, during the life of the piping system, any process change is made that could affect the intended
service description, a further review of the description by the owner’s qualified process engineer shall be
made.
4.8.3 The owner’s qualified process engineer shall be notified prior to the start-up of the system if there is a
change in the services operation so that any potential incompatibilities can be resolved before the system
is put into operation under the new conditions.
4.9 Materials System Review
4.9.1 The manufacturing specifications for related to the pipe laminate shall be reviewed for adequacy for
the intended service by the owner’s qualified process engineer. This review of laminate sequence, resin,
reinforcement, additives and post-cure shall include, as a minimum:
a. A review of the resin and glass properties.
b. Confirmation, using acceptable testing procedures, of the pipe’s physical properties and strength
for the proposed materials at design temperature.
c. A review of the adequacy and completeness of the proposed manufacturing specification details
for pipe, fittings and joints based on the project specification.
d. A review of the resin and glass QC testing for conformance to the owner’s project requirements.
e. A review of the actual laminate construction for conformance to manufacturing specifications and
design physical property assumptions.
4.10 Specification Review
The owner shall perform a design review to ensure conformance to the “Design Report Requirements” of
Section 7.0 of SABIC Standard P01-E28.
4.11 Fabricator Qualification
The fabricator shall be qualified in accordance with the requirements listed in Appendix C, “Fabricator
Qualification.”
4.12 Fabricator Physical Property Production Testing
4.12.1 The fabricator is responsible for producing laminates that will meet or exceed mechanical property
values established in the project design. These requirements are addressed in the “Design Report
Requirement” of Section 7.0 of SABIC Standard P01-E28.
4.12.2 The fabricator shall ensure during the course of fabrication that laminate reinforcing and mechanical
properties meet or exceed the requirements of the project design.
4.12.3 The fabricator’s QC program shall include procedures and forms to control the ongoing process of
checking laminate reinforcing and mechanical properties. All such ongoing checks and/or tests shall be
performed either by the fabricator or by an approved independent testing laboratory.
4.12.4 All testing procedures and results shall be documented by the fabricator’s examiner and shall be
audited by the owner’s inspector.
4.12.5 Laminate physical property testing is mandatory for all pipe built to this standard.
4.12.6 Frequency of laminate and physical property testing shall be established in accordance with the QA
plan between the owner and the fabricator.
4.12.7 For pipe, at least one set of mechanical property tests is required in accordance with ASTM D 638
and one set of ignition loss tests in accordance with ASTM D 2584. Data obtained from these tests shall be
the tensile strength and the tensile modulus of elasticity, the reinforcing content weight percent, and the
reinforcing sequence.
4.12.8 The following requirements shall apply to all physical property tests:
a. Test specimens prepared from pipe laminates shall be cut in the axial direction to minimize
surface curvature.
b. Test specimens shall not be machined on either the inner or outer surface.
c. When the design requires that all or a portion of the corrosion barrier be excluded as a
contributor to the structural strength of a laminate, that portion must be removed from test specimens
or the test results shall be adjusted to reflect the structural reinforcement of the sample.
4.13 Contractor Qualification
The contractor shall be qualified in accordance with the requirements listed in Appendix D, “Contractor
Qualification.”
4.14 Contractor’s Methods Statement
4.14.1 The contractor shall prepare a written methods statement that outlines the requirements for
handling, storage, joining and installation of the piping system.
4.14.2 The contractor’s methods statement shall provide, as a minimum, detailed procedures for:
a. Pipe
joining
b. Storage and handling
c. Trenching, de-watering, shoring, bedding and backfill for buried pipe
d. Pipe supports and pipe erection for above-ground pipe
4.14.3 The contractor’s methods statement shall conform with all contract documents and shall be
reviewed for adequacy and completeness by the owner’s QA team.
4.14.4 The contractor’s methods statement shall provide detailed instructions for all qualified joiners and
examiners.
4.14.5 The owner shall evaluate the fabricator’s methods statement for conformance to contract
documents.
4.15 Contractor Delivery Examinations
4.15.1 The quantity, pressure rating, nominal dimensions and relevant special requirements of all piping
system components shall be verified by the contractor’s QC manager for compliance with the purchase
order documents. Any piping components received that are not in compliance with the purchase order
documents shall be reported to all responsible personnel for corrective action.
4.15.2 It is the responsibility of the contractor’s QC manager to document and properly record all delivery
examinations.
4.15.3 The contractor’s QC manager or his examiner shall visually examine all piping components for
manufacturing faults and/or shipping damage.
a. All (100%) of exterior surfaces shall be visually examined.
b. Internal surfaces shall be visually examined where accessible.
c. All end-protective or face-protective devices shall be removed to allow examination of flange
faces and of machined or ground male spigots and female bells. End-protective and face-protective
devices shall be replaced after examination unless immediate installation is planned.
4.15.4 Acceptance or rejection of any piping components shall be in accordance with the project
specification.
4.15.5 Any piping component that fails to meet the acceptance criteria of the project specifications shall be
rejected.
4.15.6 The contractor’s QC manager or examiner must clearly mark rejected piping components to prevent
inadvertent installation.
4.15.7 See Section 4.19 below for repair requirements.
4.16 Field Installation Examinations and Inspections
4.16.1 Field installation inspections shall be part of the owner’s total QA program
4.16.2 Field installation inspections shall include all shop examination and inspection procedures.
4.16.3 Emphasis during field installation examinations and inspections shall be given to:
a. Environmental conditions,
b. Proper handling and support pipe during joining,
c. Surface preparation,
d. Details of joint application,
e. Curing,
f. Bedding and backfill,
g. Pipe shape distortion during burial, and
h. Condition and/or damage to the pipe as a result of shipping, storage and handling.
4.16.4 All pipe and fittings shall be examined and inspected to assure that, as installed, there is no damage
as a result of handling during assembly and installation.
a. Defect acceptance criteria, and defect repair, shall be determined by the project specification.
b. All previous repairs shall be examined and inspected.
4.16.5 When pipe and fittings are ready for joining, the rigidity and adequacy of the pipe supports for
assembly shall be verified.
4.16.6 Prior to surface preparation and joining, environmental conditions shall be verified to assure
humidity and temperature limits are in conformance with the project specification.
4.16.7 Prior to beginning lamination or of adhesive application, the surface preparation shall be verified for
conformance to the project specification.
4.16.8 Upon completion of the cure cycle, the following shall be evaluated for conformance to the project
specification:
a. Adequacy of cure,
b. Presence of visual defects,
c. Surface cleanliness, and
d. Dimensional accuracy of finished spools.
4.16.9 For above-ground piping systems, all details of pipe support type, position and installation shall be
reviewed for conformance to the approved installation drawings.
4.16.10 For buried piping systems, all installation requirements for the following shall be in compliance
with the contract documents:
a. Trench depth,
b. Grade,
c. Water conditions,
d. Foundation,
e. Bedding,
f. Backfill materials,
g. Joints, and
h. Pipe deflection levels. Deflection acceptance criteria shall comply with the project specification.
4.17 System Hydrostatic Testing
4.17.1 System hydrostatic testing shall be part of the owner’s total QA program.
4.17.2 Any section of new, repaired or replaced piping shall be certified with a hydrostatic pressure test.
See Section 7.1, “System Commissioning,” for further information on hydrostatic pressure testing.
4.17.3 System hydrostatic tests shall be performed in conformance with the project specification.
4.17.4 A formal risk assessment shall be conducted prior to hydrostatic pressure testing.
4.17.5 All supports, guides and anchors shall be in place prior to testing. Temporary supports and
restraints shall be added for safety reasons if necessary.
4.17.6 All adhesive-bonded and laminated joints shall be fully cured prior to pressure testing.
4.17.7 All pressure and vacuum tests shall be conducted in the presence of the owner’s inspector.
4.17.8 All hydrostatic tests shall be conducted with water at ambient temperature. Safety precautions shall
be taken to assure that the system is not over-pressurized during testing.
4.17.9 All pressure and vacuum gauges used for the test, as well as all related testing apparatus, shall
meet the project specification. Certification documenting proper calibration of all testing apparatus shall be
in place prior to testing.
4.17.10 Where practicable, 100% of spool pieces shall be hydrostatic pressure tested.
4.17.11 At completion of the hydrostatic test, all FRP components shall be examined externally and, where
practicable, internally. Any evidence of damage, cracking or crazing of the inner resin surface shall be
grounds for rejecting the components affected.
4.17.12 Evidence of leaking or weeping during the test shall constitute a failure, at which time the test shall
be terminated and repairs effected. The test shall then be repeated.
4.17.13 Gaskets used in the hydrostatic pressure test shall be those specified for the piping system when
installed.
4.17.14 The fabricator’s QC manager shall perform certification and documentation at the successful
completion of the hydrostatic pressure test. A test certificate shall be endorsed by the examiner and by the
owner’s inspector indicating the limits of the test.
4.18 Acoustic Emission (AE) Testing
4.18.1 AE testing shall be part of the owner’s total QA program.
4.18.2 AE testing and data evaluation shall be performed by personnel thoroughly experienced in testing
similar material and products. Qualified personnel shall have, at a minimum, five years experience in:
a. The monitoring of acoustic signals generated within an FRP component by micro-failure
mechanisms during pressure testing.
b. Demonstrated useful interpretation of signals emitted during the test based on demonstrated
knowledge of the behavior of FRP structures under stress, an understanding of the sources of
acoustic signals that such materials generate, and of the equipment used to record and analyze these
signals.
c. Demonstrated knowledge of fracture development in FRP.
4.19 Repairs
4.19.1 All repairs shall be performed in conformance with the project specification.
4.19.2 All defect repairs in non-critical areas of the piping system shall be permitted without owner
authorization.
4.19.3 No defect repairs in critical areas of the piping system shall be permitted without owner
authorization. The contractor shall submit a written repair procedure to the owner and obtain the owner’s
authorization to proceed before affecting any repairs in critical areas of the piping system.
4.19.4 All piping system repairs shall be inspected and accepted by the owner’s inspector prior to the
affected pipe being shipped or installed.
4.20 Owner Warranty Inspections
4.20.1 Owner warranty inspections shall be part of the owner’s total QA program.
4.20.2 Warranty inspections shall be conducted in conformance with the project specification.
4.20.3 The owner’s QA team shall inspect the performance of the entire candidate FRP piping system to
evaluate its performance prior to the expiration of the manufacturer’s warranty period.
4.20.4 Acceptance of the performance of the candidate FRP piping system by the owner’s QA team shall
constitute the hand-off of the system from the owner’s QA team to the plant maintenance and operations
teams.
4.20.5 Owner warranty inspections shall include, as a minimum, the following:
a. External visual inspection.
b. Interior visual inspection where possible.
c. Non-destructive testing (NDT) techniques where internal visual inspection is not possible. NDT
techniques include, but are not limited to:
5. X-ray
6. Ultrasonic Testing
7. Acoustic Emission (AE) Testing
8. Vibration Monitoring
9. Infrared Thermography
a. NDT testing, using such techniques as those listed in 4.20.5.c., shall be conducted in accordance
with the British Standards Institution, BS 7159, Appendix E, “Non-Destructive Testing.”
b. Particular attention shall be paid to the inspection of mechanical, laminated butt and strap and
adhesive-bonded joints, including prefabricated pipe spools.
9.1.1 Wherever damage is revealed during a warranty inspection, appropriate methods of repair shall be
selected based on the extent of the damage, the criticality of the piping system and the availability of spare
parts and/or repair facilities.
a. Where practicable, damage impairing the safe and reliable function of a piping system shall be
corrected with the permanent replacement of the entire pipe spool.
b. Non-conformances with pipe design and specification shall be corrected by the contractor and/or
fabricator. All corrections shall be performed in accordance with the project specification.
9.1.2 The owner’s inspector shall record any damage, external or internal, that can influence system
operation.
9.1.3 All repairs shall be permanently marked and recorded by the inspector.
9.2 Owner’s Preventive Maintenance (PM) and Mechanical Integrity Program
9.2.1 After the piping system has been commissioned and started up, the owner shall implement a PM
program to monitor the system over its life cycle. See Appendix E, “Preventive Maintenance Program.”
10. Fabricator QC Program Requirements
10.1 Application
These requirements apply to all FRP pipe, pipe components and spooling, both custom and commodity.
10.2 QC Plan
10.2.1 See Appendix C, “Fabricator Qualification,” Section 1.2, for specific QC program requirements.
10.2.2 Materials control and tracking shall comply with the project specification.
a. All raw materials shall be tracked and tested from receiving and continue through the
manufacturing process.
b. At any given time during the manufacturing process, the fabricator shall be able to document the
origin and acceptance of all materials.
10.3 Examination
10.3.1 The fabricator shall perform the following examinations during critical phases of the manufacturing
process:
a. Tooling examinations shall be performed prior to fabrication to assure compliance with drawing
and specification requirements.
b. Receiving examinations shall be performed on all raw materials, and shall be performed in
accordance with the project specification.
c.
In-process examinations shall be performed on all materials, components, spooling and
loading/packaging.
d. Final examinations shall be performed on all pipe assemblies (spools).
10.3.2 The fabricator shall be responsible for examining any subcontracted sub-assembly components
that will become a part of the fabricator’s piping system. To be accepted, these components shall meet or
exceed all project specification requirements.
10.3.3 The fabricator’s QC manager shall be responsible for keeping complete, updated QC records. This
responsibility may be delegated to the fabricator’s QC examiner. Record keeping procedures shall satisfy
all project specification requirements.
10.3.4 QC reports shall include, as a minimum:
a. Identification of components,
b. In-process component examinations for pipe and fittings,
c. Assembly examination for spools,
d. Engineering and/or shop production change orders,
e. Non-conformance reports,
f.
In-process materials and component testing reports, and g. All testing documentation.
10.3.5 The fabricator shall maintain all QC records relating to the owner’s project for a minimum of five (5)
years, or as specified by the contract documents. The five-year period shall begin the day the project is
completed.
10.4 Testing Procedures
10.4.1 The fabricator’s QC program shall include provisions directing the performance of testing as
necessary to assure that the FRP equipment is in compliance with project specifications.
10.4.2 All FRP equipment and materials shall be tested during receiving, while in manufacturing process
and during final acceptance.
10.4.3 The fabricator’s QC manager or his delegate shall be responsible for conducting all pipe
qualification testing to assure the fabrication of the FRP equipment is in compliance with the project
specification.
10.4.4 The fabricator’s QC manager shall be responsible for observing all tests performed.
10.4.5 The fabricator’s QC manager shall document and record all testing in accordance with this standard.
10.4.6 All testing procedures shall be in compliance with the project specifications.
10.5 Witness Points
10.5.1 Witness points are pre-determined, scheduled observations, by both the fabricator’s examiner and
the owner’s inspector, of key manufacturing processes to assure that they are performed in accordance
with the project specification. Witness points shall not put a hold on the progress of any work.
10.5.2 Witness points shall be determined using project specifications and the fabricator’s in-house QC and
manufacturing plans.
10.5.3 All witness points shall be established jointly between the owner and the fabricator.
10.5.4 All witness points shall be documented by the fabricator’s QC manager or his examiner.
10.6 Hold Points
10.6.1 Hold points are pre-determined, scheduled observations, by both the fabricator’s examiner and the
owner’s inspector, of key manufacturing processes to assure that these processes are performed in
accordance with project requirements. Hold points shall place a hold on the progress of work at
pre-determined phases of the project.
10.6.2 Hold points shall be determined using project specifications and the fabricator’s in-house QC and
manufacturing plans.
10.6.3 All hold points shall be established jointly between the owner and the fabricator.
10.6.4 All hold points shall be documented by the fabricator’s QC manager or his examiner.
10.7 Non-Conformances
10.7.1 An FRP component is in non-conformance when it exhibits at least one departure of a quality
characteristic from its intended level or state that occurs with a severity sufficient to cause an associated
product or service not to satisfy intended normal usage requirements.
10.7.2 All non-conformances shall be documented and brought to the attention of the parties responsible
for determining corrective action.
10.7.3 Procedures for correcting non-conformances shall be performed in accordance with the project
specification.
10.7.4 The fabricator shall be responsible for correcting or replacing any components in non-conformance.
10.7.5 Correction of non-conformances include, but are not limited to, minor repairs, major repairs or
replacement of the affected component. See Section 4.19, “Repairs,” for specific information regarding the
correction of non-conformances.
10.7.6 Any major repairs recommended by the fabricator or the fabricator’s examiner shall be submitted to
the owner for approval prior to implementation.
10.8 Management of Change
10.8.1 Management of change is a process that assures all FRP components are fabricated in compliance
with the most up-to-date versions of project requirements.
a. Key documents or procedures that, once revised or changed, must be updated and effectively
communicated to both manufacturing and QC team members which include, but are not limited to:
11. Quality Control Manual
12. Purchase Orders
13. Change Orders
14. Contracts
15. Specifications
16. Drawings
17. Calculations
18. Inspection Documentation
19. Testing Documentation
20. Materials Certification
21. Manufacturing Procedures
22. Correspondence
a. All changes to documents shall be reviewed and approved by whomever performed the original
review or approval.
b. Whomever initiates document changes shall notify all responsible parties in writing of the change
and of the purpose of the change, and shall supply all supporting documentation to those affected.
22.1.1 The fabricator’s project manager is responsible for document control. This responsibility may be
delegated to either the fabricator’s QC manager or other QC personnel.
22.1.2 The QC manager shall assure that the latest applicable specifications, drawings, and purchase
orders are utilized for the manufacturing process.
22.1.3 The QC manager shall also establish and maintain a procedure whereby changes are made and all
obsolete documents are discarded.
22.1.4 The fabricator shall maintain all records relating to the owner’s project for a minimum of five (5)
years, or as specified by the contract documents. The five-year period shall begin the day the project is
completed.
22.1.5 Reporting
a. All testing shall be documented and recorded in accordance with the project specification and
this standard.
b. The fabricator’s QC manager is responsible for reporting and documenting all changes.
22.2 Quality Control Implementation
22.2.1 As a minimum, the fabricator shall submit to the owner for approval prior to the start of production
the fabricator’s:
a. Quality control program,
b. Quality control manual,
c. Project manufacturing plan,
d. Project testing plan,
e. Certification program, and
f. Organizational chart.
22.2.2 The fabricator’s documents must meet or exceed the project specifications and the requirements of
this standard.
22.2.3 Approval of the fabricator for manufacturing purposes shall be contingent upon the owner’s review
and approval of the submitted QC program as described in Section 5.9.1.
23. Minimum Quality Requirements
23.1 Baselines
Baselines for the design report shall be confirmed by the fabricator’s QC manager or his delegate.
23.1.1 Thicknesses are construction minimums. It is the fabricator’s responsibility to assure that the
minimum thickness is achieved using the specified sequences, or by adding layers of reinforcement as
necessary.
23.1.2 Laminate sequences shall conform to the design specification, except as allowed due to exotherm
delays or other pre-approved requirements.
23.1.3 Glass content shall conform to the requirements of the project specification. In the absence of
specific guidelines, acceptable industry standards and project engineering requirements shall be used.
23.1.4 Laminate cure shall be in accordance with the resin supplier’s recommendations and the project
specification.
23.1.5 Dimensions and tolerances shall be verified in accordance with the project specification
requirements.
23.1.6 The marking of any and all components shall conform to the project specification requirements.
23.2 Defect Evaluation and Acceptance Criteria
Criteria for the acceptance or rejection of defects shall conform with the visual defects criteria of the project
specification.
23.3 Field Installation
23.3.1 The contractor shall be qualified in accordance with the requirements listed in Appendix D,
“Contractor Qualification.”
23.3.2 The contractor shall designate one individual, experienced in all aspects of FRP piping field
installation, to be responsible for QC throughout the installation of the FRP piping system.
23.3.3 Contractor’s installation QC program shall be based on the implementation of the:
a. Bonding procedure qualification records,
b. Owner’s requirements for FRP piping joint examination,
c. Examination register for FRP piping joints, and
d. Examination of finished fabricated pipe work for compliance with project specifications and
drawings.
23.3.4 The joiner(s) shall be qualified in accordance with the requirements listed in Appendix B, “Joiner
Certification.”
23.3.5 FRP components shall be handled and protected by qualified personnel in accordance with the
project specification and industry standards and manufacturing requirements for FRP piping systems to
avoid mechanical damage from impact, sharp edges and scratching.
23.3.6 Personnel handling FRP components shall be trained in the lifting, loading, shipping and unloading
of all pipe, in accordance with the fabricator’s recommendations.
a. Under no circumstances shall FRP piping components be thrown or dropped from any height.
b. No chains, wire ropes or clamps shall be directly attached to the FRP piping components for the
purpose of lifting or moving.
c. Fittings shall be transported either packed in a container or strapped onto pallets. Fittings shall
be loaded by hand into crates or baskets or onto pallets, with inter-component packing material to
avoid transportation damage. Fittings shall be strapped down during lifting.
d. Temporary restraining supports shall be attached to complex prefabricated spools prior to lifting,
to minimize bending strain.
23.3.7 Piping components shall be stored, when necessary, on a level surface that has no sharp objects
on it, out of high winds and extreme temperatures, and not exposed to ultraviolet radiation.
a. Pipe spools shall not be stacked unless the project specification allows stacking.
b. The fabricator shall pack the pipe spools to prevent damage during transportation.
c. Pipe spools may be stored in their original shipping crates or boxes, provided the packaging is
undamaged and suitable for long-term storage. End protection of pipe spools shall remain in place
during storage.
d. Pipe with bell ends may be stored with the bell ends in alternate directions to avoid contact and
possible damage to the ends. Spacer stripping shall be located clear of the bell ends. End protection
shall protect both inside and outside of the pipe ends, and shall remain in place during storage.
e. Fittings may be stored in their original shipping crates or boxes, provided the packaging is
undamaged and suitable for long-term storage. End protection of fittings and flanges shall remain in
place during storage.
f. Ancillary materials such as rubber “O” rings, flange gaskets, locking strips, reinforcements and
lubricants shall be stored in accordance with the manufacturer’s recommendations.
23.3.8 The requirements for erecting above-ground FRP pipe and installation of buried FRP pipe are
specified in the design section of this standard.
23.3.9 All reporting requirements shall be in accordance with this standard.
23.4 Field Joining
23.4.1 The contractor is responsible for quality control examinations in the field to assure the successful
installation of FRP pipe.
23.4.2 The owner is responsible for quality assurance inspections in the field to assure the successful
installation of FRP pipe.
23.4.3 For adhesive bond field joints, the manufacturer’s recommendations shall be followed regarding
preparation of adhesive, environmental conditions, fit-up and cure.
a. An environmentally controlled preparation area shall be used under adverse weather conditions.
b. Global tolerances shall be within the manufacturer’s guidelines and the project specification.
c. Dimensional tolerances for fit-up and finished assembly work shall conform to project
specification tables.
d. The angular deflection between the bell and spigot components of an adhesive bond field joint
shall be in strict compliance with the fabricator’s angular deflection tolerances. Any out-of-tolerance
components shall be rejected.
e. Heat-assisted curing may be used for adhesive bond field joints. All heat assisted curing shall be
performed in accordance with the manufacturer’s recommended practices. For large assemblies, the
use of ovens is preferable to the use of individual heating collars. Adhesive bond field joint
connections shall not be disturbed during the heat curing cycle. Additional bracing may be used to
prevent accidental movement.
23.4.4 Laminated (butt and strap) field joints shall be applied in accordance with the design standard and
project specification.
a. Surface preparation prior to the application of laminated field joints shall be performed in
accordance with the project specification to assure successful joining.
b. An environmentally controlled preparation area shall be used under adverse weather conditions.
c. Bonding surfaces and joining materials both shall be of a temperature recommended by the
manufacturer prior to and during application.
d. All resin mixing and applications shall be performed in accordance with the resin supplier’s
recommendations for field joining and service conditions. The resin used shall be mixed prior to the
expiration of its normal shelf life. Additives for extreme temperature conditions shall be used only if
pre-approved by the owner.
e. All spool assembly shall be performed in accordance with the manufacturer’s requirements for
acceptable fit-up. The individual components from which the spool piece is fabricated shall have been
previously inspected and accepted prior to use in assembly.
f. Global tolerances shall be within the manufacturer’s guidelines and the project specification.
g. Dimensional tolerances for fit-up and finished assembly work shall conform to project
specification tables. Dimensions shall conform to the baselines quoted by the manufacturer and as
agreed to by the owner. Any out-of-tolerance components shall be rejected.
h. The angular deflection between the piping fittings of a laminated field joint shall be in strict
compliance with the fabricator’s angular deflection tolerances. Any out-of-tolerance components shall
be rejected.
i. The resin cure shall be in conformance with the project specification. Degree of cure, catalysts,
promoters and additives shall all be in conformance with the manufacturer’s recommendations.
23.4.5 Joints with two or more elastomer sealing “O” rings or lip-sealing rings may be used.
a. Preparation of “O” ring joints shall be in accordance with the manufacturer’s recommendation
and the project specification. The bell and spigot ends should both be examined prior to installation to
assure they are not damaged. Damaged parts shall be evaluated by qualified personnel.
b. Surfaces to be connected, including the gasket grooves, shall be thoroughly cleaned immediately
prior to assembly.
c. An environmentally controlled preparation area shall be used under adverse weather conditions.
d. Air contaminants that may interfere with proper fit-up and insertion of gaskets and “O” rings shall
be eliminated from the environment. Airborne contaminants shall be eliminated.
e. Only clean, uncontaminated lubricant shall be used on both seals and spigot ends prior to
insertion. The lubricant used shall be as recommended by the manufacturer and the project
specification.
f. All assembly work with “O” rings shall be in accordance with the manufacturer’s
recommendations and the project specification. The individual components from which the “O” ring
joints are fabricated shall be previously inspected and accepted.
g. The correct equipment shall be used to enter the spigot into the bell to avoid jamming or damage
to the seals. This is particularly important for larger dimension pipe.
h. Global tolerances shall conform with the project specification.
i. Dimensional tolerances for fit-up and finished “O” ring work shall conform to the project
specification. The seal ring and groove, and the ring cross-section and diameter in particular, shall be
inspected to assure conformance with specified dimensions and to assure they conform with the
manufacturer’s baseline.
j. The maximum angular deflection shall not exceed the manufacturer’s installation specifications.
k. Any out-of-tolerance components shall be rejected.
23.4.6 Joining procedures and techniques for flanged joints shall conform with the project specification.
a. All flange surfaces shall be examined for damage prior to installation. Damaged parts shall be
set aside for evaluation in accordance with project specifications.
b. All surfaces to be connected shall be thoroughly and properly cleaned prior to connection.
c. Global tolerances shall conform with the standards relating to assembly work and the project
specification.
d. All dimensions shall conform with the manufacturer’s baseline.
e. Any out-of-tolerance components shall be rejected.
f. FRP flanges shall be connected to flat face flanges wherever specified. Depending on gasket
type, spacer rings may be used when flanges are connected to raised face flanges to minimize
excessive bending stresses when the bolts are torqued.
g. Flange assembly and bolting shall conform with the manufacturer’s requirements and with
accepted industry standards. Bolt tightening sequences, torque increments, maximum torque and
gasket selection shall also conform with the manufacturer’s recommendations.
h. The maximum angular deflection shall not exceed the manufacturer’s installation specifications.
23.5 System Testing
23.5.1 System testing shall conform with the SABIC Standard P01-E28 and with the project specification.
23.5.2 Partial burial requirements for hydrostatic testing purposes shall conform with the SABIC Standard
P01-E28 and with the project specification.
23.5.3 See Section 4.17 for specific requirements regarding hydrostatic pressure testing.
23.5.4 See Section 4.18 for specific requirements regarding acoustic emission (AE) testing.
24. System Commissioning
24.1 Post-Installation System Testing
All closed FRP piping systems shall be hydrostatically pressure tested after installation. Systems that are
open to atmosphere (e.g., drains) shall, as a minimum, be subjected to a hydrostatic leak test. If open FRP
piping systems may be subject to system pressure, they shall also be hydrostatically pressure tested after
installation.
24.2 Pipe Condition
The FRP piping system shall be installed as necessary for proper structural support so that testing is
representative of actual operation but the system will not be damaged during the test.
24.3 Examinations
24.3.1 All required examinations by the contractor’s QC manager, and all examination reports, shall be
completed prior to applying load during the test.
24.3.2 Additional visual examinations shall be performed during the test, and any leaking or weeping shall
constitute a failure. A repair shall be effected before the test is repeated.
24.4 Hydrostatic Pressure Testing
See Section 4.17 for specific requirements regarding hydrostatic pressure testing.
24.5 Post-Installation Repairs
24.5.1 Rejected components shall be replaced or repaired by the manufacturer.
24.5.2 Pipe sections with major damage shall be replaced in compliance with the project specification.
24.5.3 Major repairs to pipe sections shall be allowed only with the owner’s permission.
24.5.4 Minor repairs to pipe and fittings may be made on site in conformance with the project specification.
24.6 Certification and Documentation
Upon completion of successful testing, a pressure test certificate showing the limits of the test shall be
endorsed by the owner and shall be incorporated into the relevant test and QA documents.
APPENDIX A
Terms & Definitions
Adhesive joint – A rigid type of joint which consists of a bell end and a machined (cylindrical or tapered)
spigot end.
Commodity pipe – Fiberglass reinforced plastic pipe that is manufactured in standard sizes and classes for
general use.
Composite pipes – Pipes manufactured using fiber reinforced plastics.
Contractor-The designated party responsible for installation and/or field joining of the equipment. The
contractor may be the same party as the manufacturer.
Contract documents – Includes the purchase order and all other documents, such as fabrication and
installation specifications and drawings, invoked by the contract to control the end product.
Cure cycle – The time/temperature/pressure cycle used to cure a thermosetting resin system.
Custom pipe – Fiberglass reinforced plastic pipe manufactured for project-specific requirements.
Design pressure – Maximum positive internal pressure differential intended to be experienced by a
component during its service life.
Design temperature – Maximum fluid temperature for each design condition that can be reached during
that operating condition.
Designer – The party that carries out all or part of the design for a project or facility.
Elastomeric bell and spigot sealed joints – Joint connection made up of a spigot end and a socket end with
“O” or lip-sealing rings.
Environmental stress cracking (ESC) – Formation of cracks in a polymer or composite caused by exposure
to a chemical or an environment.
Examiner – Personnel designated by the manufacturer or contractor to examine the equipment during
fabrication and after completion to verify compliance with all aspects of the governing contract documents.
Failure – Transmission of a fluid through the wall of a component or via a joint, resulting in rupture or
weeping.
Filament winding – Process for fabricating a composite structure in which continuous reinforcements
(filament, wire, yarn, tape or other reinforcements) are either previously impregnated with a matrix material
or impregnated during the winding.
Fitter / joiner – A tradesman able to perform satisfactory and independent work in the installation and
joining of composite pipes.
Fitting – Generic name for a component of any type other than pipe.
Flange joint – Mechanical joint with face flanges where the bolt circle and face dimensions conform to a
recognized standard.
FRP – Fiber reinforced plastic; a general term covering any type of plastic reinforced with glass cloth, mat,
strands or any other type of fiber. A thermosetting plastic-based composite that is reinforced with glass
fibers.
Function – Ability of the piping system to perform its primary purpose, i.e. to deliver a minimum quantity of
fluid above a minimum pressure.
GRP – Glass reinforced plastic pipe.
Intended service description – An accurate description by the owner of the intended service conditions and
expected product performance. Used primarily by the designer, the description shall include normal and
upset operating conditions, which include, as a minimum, pressures, temperatures, chemical compositions and velocities. The description shall also include performance expectations, physical
appearance, system details (e.g., size, accessibility and components) and support requirements.
Joint – Means of connecting two or more components, e.g. plain pipe to a fitting or plain pipe to plain pipe.
Laminated joint – Joint consisting of plain-ended pipe and fittings laminated together with reinforcing fibers
and resin/hardener mixture.
Liner – The continuous, resin-rich coating on the inside surface of a pipe component used to protect the
laminate from chemical attack or to prevent leakage under stress.
Long-term hydrostatic pressure (LTHP) – The estimated long-term failure pressure of a component variant
determined in accordance with a recognized standard, with free ends, at 65°C or higher.
Long-term hydrostatic strength (LTHS) – The estimated long-term failure strength of a pipe determined in
accordance with a recognized standard, with free ends, at 65°C or higher.
Manufacturer or fabricator – Primary party responsible for the fabrication of the equipment.
Matrix – Essentially homogeneous resin or polymer material in which the fiber system is embedded in a
laminar arrangement. Thermoplastic and thermoset resins may be used, as well as metals, ceramics and
glasses.
Mechanical integrity – Minimum structural capability required to enable the pipe to fulfill its function. A
mechanical integrity program ensures that process equipment and piping operate as intended without any
problems. It includes development of maintenance procedures, personnel training, documented testing
and examination procedures, and correction of equipment defects.
Mechanical joint – Joint between FRP piping components not made by bonding.
Nominal diameter – Numerical designation of size which is common to all components in a piping system
other than components designated by outside diameters or by thread size. It is a convenient round number
for reference purposes and is only loosly related to manufacturing dimensions.
Non-Conformance Report (NCR) – The owner’s inspector’s documented evidence of poor workmanship,
mistakes in fabrication or lack of compliance with any aspect of the contract documents. Lack of
compliance with any aspect of the contract documents become grounds for rejection of the equipment if not
corrected to the satisfaction of the owner.
Operator – The party which assumes ultimate responsibility for the operation and maintenance of the piping
system. The operator may or may not be the same as the owner or the owner’s agent.
Owner – The party that initiates the project and ultimately pays for its design and construction.
Pipe supports – Fixtures and structural attachments. Fixtures include elements which transfer the load from
the pipe or structural attachment to the supporting structure or equipment. They include hanging-type
fixtures such as hanger rods, spring hangers, sway braces, counterweights, turnbuckles, struts, chains,
guides and anchors; and bearing-type fixtures such as saddles, bases, rollers, brackets and sliding
supports. Structural attachments include elements which are bonded or molded into the pipe, such as clips,
lugs, rings, clamps, clevises, straps and skirts.
Piping – Assemblies of piping components used to convey, distribute, mix, separate, discharge, meter,
control or restrict fluid flows.
Piping components – Elements of the assembled piping system, such as pipe, elbows, reducers, tees, pipe
flanges, joints, piping supports, valves and expansion joints.
Piping system – Interconnected piping subject to the same set or sets of design conditions. The piping
system also includes pipe supports but does not include support structures.
Post-cure – Additional elevated-temperature cure, usually without pressure, to improve final properties
and/or complete the cure or to decrease the percentage of volatiles in the compound. In certain resins,
complete cure and ultimate mechanical properties are attained only by exposure of the cured resins to
higher temperatures than those used during curing.
Pressure rating – Rating for a component, relating to its long-term resistance to failure when subjected to
either static or standardized cyclic internal pressure loading.
Preventive Maintenance (PM) – A program of ongoing examinations that provide an intelligent basis for
determination of appropriate maintenance or timely replacement of individual pieces of equipment.
Purchaser – The buyer of the equipment or his designated representative. The purchaser is normally the
plant owner.
Quality – Fitness for use in the intended service.
Quality Control (QC) – Comprehensive in-house examination procedures implemented by the fabricator to
assure compliance with the fabrication specification and shop fabrication drawings. As a minimum, the
fabricator’s QC program normally includes examination and documentation of visual defects, laminate
thickness and sequence, glass content, barcol hardness, dimensional tolerances, adherence to
construction details, surface preparation and environmental conditions.
Quality Assurance (QA) – Comprehensive evaluation procedures implemented by the owner to verify:
a. Fitness for use for the intended service as described in the specifications and contract
documents
b. Conformance to equipment description minimum requirements of the specifications and contract
documents
c. Assurance that proper corrective action is taken regarding non-conformance issues
RTR – Reinforced thermosetting resin. See FRP.
Saddle – Length of an arc of FRP material adhesively bonded to the outside of the pipe.
Site – The location where an FRP piping system is installed.
Specification – Documents that cover all design and fabrication issues affecting the long-term performance
of FRP equipment. These specifications provide for verification of the important criteria through
examination and testing.
Spool piece – Permanent assembly of FRP pipe and fittings fabricated in the factory using laminated or
adhesive joints.
Winding angle – Angle of main reinforcement to pipe longitudinal axis. Can be either positive or negative.
Appendix B
Joiner Certification
Techniques used for the installation and joining of fiber reinforced plastic (FRP) pipe differ considerably
from those used for the installation of ferrous or non-ferrous metal pipe, but the integrity of both systems
depends upon the training and craftsmanship of the joiner. Training and certification of personnel is an
important element in ensuring the quality and cost-effectiveness of FRP pipe installation. This section
specifies the minimum requirements for training, qualification and certification of personnel for the joining of
FRP pipes. This section is limited to FRP pipes reinforced with glass fibers in a matrix of polyester, vinyl
ester, epoxy and/or phenolic resins. All other types of pipe are considered to be outside the scope of this
specification.
1.1 General Requirements
1.1.1 All personnel considered for joiner certification must be a minimum of 18 years of age.
1.1.2 All personnel considered for joiner certification shall be in good physical condition to satisfactorily
perform the joining tasks.
1.1.3 All personnel considered for joiner certification shall have at least two years of documented
experienced with joining and installation of composite pipes for the specific type of joining system (e.g.,
lamination, adhesive).
1.1.4 All personnel considered for joiner certification shall have a working knowledge of the appropriate
joining specification (e.g., lamination, adhesive).
1.1.5 Although personnel considered for joiner certification may be qualified in only one area of joining,
there are certain basic requirements that all candidates for certification must understand, regardless of
what discipline in which they specialize. Section 1.2 below, “Basic Requirements,” outlines these.
1.1.6 All personnel considered for joiner certification should demonstrate proper procedure and use of
materials, and consistently achieve acceptable joining quality. See requirements for the individual type of
joining listed in Section 1.3, “Specific Joint Type Requirements,” below.
1.2 Basic Requirements
Joiner demonstrates the following proficiencies to obtain acceptable results:
1.2.1 Understanding the requirements for control of environmental conditions as related to the specific joint
procedure.
1.2.2 Proper methods for cleaning, preparing, aligning and supporting pipes to be joined.
1.2.3 Proper use of fixtures, hand tools and joint-specific apparatus.
1.2.4 Ability to react to and compensate for expansion-contraction problems related to the specific joint
application.
1.2.5 Knowledge of tolerances related to the appropriate specification and joining task.
1.2.6 Working knowledge of remedial work related to the appropriate specification and joining task.
1.2.7 Working knowledge related to the handling and storage requirements for pipe, fittings, pipe spools,
materials and related equipment.
1.2.8 Successful completion of a joint through project-specific testing, such as hydrostatic, peel testing or
other tests as directed by the engineering group responsible for the project. See Section 1.4, “Testing,” for
specific information relating to hydrostatic testing.
1.2.9 Proper inspection techniques related to pipe, fittings and pipe spools prior to joining.
1.2.10 Proper cutting and shaving techniques (where applicable) prior to joining pipe, spools and fittings.
1.2.11 Mixing adhesives and catalysts to proper resin ratios for specific joining techniques (where
applicable).
1.2.12 Proper health and safety practices for joining applications.
1.2.13 Proper quality control procedures and documentation.
1.3 Specific Joint Type Requirements
Certification requirements for joint types most commonly used in the industry are described below. For a
type of joining that is not listed, consult the project specification or appropriate supplier for joining
requirements.
1.3.1 Lamination (Butt and Strap)
In addition to the Joiner Certification Basic Requirements, the following lamination-specific qualifications
must be met for a joiner to be certified in this type of joining procedure:
a. Demonstrates proper methods for cleaning, abrading and preparing pipe, fittings and spools
prior to performing lamination/joining procedures.
b. Demonstrates proper application of joint filler; e.g., putty.
c. Demonstrates proper preparation procedures for resin and catalyzation.
d. Demonstrates proper wet-out of laminate sections.
e. Demonstrates ability promptly and constructively to react to rapid exotherms to save affected
laminations.
f. Demonstrates proper centering, tapering and staggering when applying laminate sections to the
joint.
g. Demonstrates correct procedure for preparing incomplete laminates for completion in
accordance with project specification requirements.
h. Demonstrates correct procedure for performing laminate finish work, including exterior coating.
1.3.2 Adhesive
In addition to the Joiner Certification Basic Requirements, the following adhesive joint-specific
qualifications must be met for a joiner to be certified in this joining procedure:
a. Demonstrates proper knowledge of correct handling and storage of adhesives.
b. Demonstrates correct method for detailed alignment of pipe sections prior to applying adhesive.
c. Demonstrates correct shaving/abrading and dry fit-up procedures prior to applying adhesive.
d. Demonstrates proper knowledge of mixing procedures of adhesive components.
e. Demonstrates proper procedure for application of adhesive to bell and spigot components along
with insertion techniques to avoid leaks.
f. Demonstrates correct procedure for curing adhesive joints.
1.3.3 Double Bell Coupling
In addition to the joiner certification basic requirements, the following double bell coupling joint specific
qualifications must be met for a joiner to be certified in this joining procedure:
a. Demonstrates proper methods for handling and storage of gaskets (“O” ring) material.
b. Demonstrates proper methods for cleaning couplings, pipe and gasket materials.
c. Demonstrates proper alignment of pipe for joining purposes.
d. Demonstrates proper surface preparation of coupling and gaskets.
e. Demonstrates proper connection and seating of pipe and coupling components.
1.3.4 Key Lock
In addition to the joiner certification basic requirements, the following key lock joint specific qualifications
must be met for a joiner to be certified in this joining procedure:
a. Demonstrates proper knowledge of handling and storage of gaskets (“O” rings), spigots and
couplings.
b. Demonstrates proper methods of cleaning couplings, spigots and gasket (“O”) ring materials.
c. Demonstrates proper alignment of pipe for joining purposes.
d. Demonstrates proper preparation of couplings, gaskets and locking keys.
e. Demonstrates proper lubrication of gaskets (“O” rings), couplings, spigots and locking keys.
f. Demonstrates proper connection of pipe (spigot) and coupling sections.
g. Demonstrates ability promptly and constructively to react to expansion-contraction problems
relating to testing requirements.
h. Demonstrates working knowledge of procedures to correct failed tests.
1.4 Testing
1.4.1 In order to be certified for a specific type of connection, the joiner shall successfully complete a
connection that passes specific hydrostatic test requirements.
1.4.2 Each test assembly shall consist of one FRP pipe-to-pipe connection, representing the type of joint
that is to be used on the piping project.
1.4.3 If more than one type of connection (e.g., adhesive, butt and strap, key lock) is used on the same
construction project, the joiner must certify separately on each type of joint.
1.4.4 Test joint preparation
a. The length of pipe on each side of the connection shall be at minimum the equivalent of five pipe
diameters.
b. The pipe ends shall be closed and the joint assembly shall have a connection for pressure
(hydraulic) testing purposes.
c. Before conducting any pressure test, the test area shall be roped off and warning signs erected
at all access points. The safety officer shall be informed of the intended test in sufficient time to
perform his own inspection if required.
d. Water shall be admitted at a low point in the system. Provision shall be made for bleeding the air
at high points to prevent damage to piping and personnel in the event of an unexpected failure during
the pressure test.
e. Pressure tests shall duplicate pressure, hold periods and other procedures specified for the
piping project. Unless otherwise specified, the test pressure shall be raised over a period of 30
minutes to 1.5 times the system design pressure. Any sudden increase in pressure shall be avoided.
f. Pressure gauges utilized for testing purposes shall be calibrated and certified in accordance with
the project specification.
g. The pressure test shall be conducted for a minimum of one hour. The lack of any weeping, a drop
in pressure, or leaks during the one-hour duration shall indicate a successful test.
h. Any leaking or weeping of the joint shall constitute a failure, and the test shall be terminated.
1.5 Certification
1.5.1 Upon completion of successful testing, the joiner shall be issued an individual Bonding Qualification
Certificate for each specific type of FRP joint tested.
APPENDIX C
Fabricator Qualification
This section specifies the minimum standards that a fabricator must meet to become certified to perform
the tasks of fabricating FRP pipe and fittings in accordance with the owner’s project requirements.
1.1 Fabrication Capability
The fabricator shall be a firm which is highly experienced in and, as a normal practice, engages in FRP
fabricating. The firm shall have a minimum of five years of related experience.
1.1.1 The fabricator must demonstrate the ability to perform fabricating techniques to ensure full
compliance with the project requirements prior to the initiation of any work.
a. Demonstrated filament winding ability shall be performed in accordance with the specific
requirements for the shop filament winding qualification section of this specification.
b. Demonstrated hand lay-up ability shall be performed in accordance with the specific
requirements for the shop hand lay-up section of this specification.
c. Documentation of demonstrated ability shall be on file at the facility during the course of the
project.
1.1.2 The fabricator shall maintain and make available for review an in-house qualification procedure
which classifies workers by skills and experience. Each worker assigned to the project shall be identified
as to their qualification level and experience.
1.2 Quality Control Program
1.2.1 The fabricator shall maintain a Quality Control program to assure that fabricating and spooling
activities meet the owner’s project requirements.
1.2.2 The fabricator shall provide to the owner or to the owner’s representative an organizational chart
which indicates reporting responsibility and authority.
a. The chart shall identify the fabricator’s various organizational groups with the particular function
for which they are responsible.
b. The chart shall clearly show the relationship between management and engineering,
purchasing, construction, inspection, quality control and safety.
c. The chart shall show that the Quality Control function is independent of the fabricating group.
1.2.3 The program shall include a procedure for the inspection of received goods, including but not limited
to raw materials, purchased items and any equipment that will become part of the finished FRP
equipment.
1.2.4 The program shall include in-process inspections of:
a. Resin mixing,
b. Raw material disbursement,
c. Component fabrication and assembly procedures, including verification of filament winding,
d. Fittings fabrication,
e. Joint preparation,
f. Joint application,
g. Verification of lamination sequences (if applicable) and
h. Post-curing procedures (if applicable).
1.2.5 The program shall include documentation of all critical aspects of fabrication milestones, including
receiving, in-process, final inspections and shipping.
1.2.6 The program shall include a procedure for scheduling and notification for inspector’s hold points, and
for final acceptance inspections.
1.2.7 The program shall include a procedure for correcting non-conformances in accordance with the
owner’s project requirements.
1.2.8 The program shall include a procedure for qualifying quality assurance personnel, which procedure
shall satisfy the owner’s project requirements.
1.2.9 The program shall include a procedure to assure the proper maintenance and calibration of all
inspection instruments and test equipment. This procedure shall include standards for documenting all
maintenance and calibration.
1.2.10 The program shall include a procedure to assure that testing is performed and documented in
accordance with the owner’s project specification requirements.
1.2.11 The program shall include a stipulation allowing complete access by the owner or the owner’s
representative during all phases of construction activities to verify installation practices for compliance to
project requirements.
1.3 Fabrication Facilities
1.3.1 The fabricator shall maintain a facility for the purpose of managing manufacturing activities with full
communication services, including a phone, fax and internet capability.
1.3.2 The fabricator shall provide adequate structures to assure all fabricating and joining activities are
performed in a controlled environment that meets project requirements for optimum manufacturing
considerations.
1.3.3 The fabricator shall provide adequate shelters for the proper storage of resins, catalysts, promoters,
solvents and other chemicals.
1.4 Fabrication Management
1.4.1 The fabricator shall designate a manager responsible for all manufacturing activities. The manager
shall fulfill the fabrication project responsibilities.
1.4.2 The fabricator shall provide a manufacturing schedule that designates all activities and completion
dates within the overall project time frame.
1.4.3 The fabricator shall maintain the manufacturing schedule, report and revise reporting procedures as
required to record progress, project all milestone changes, and maintain all other pertinent project
information.
1.5 Fabrication Safety
1.5.1 The fabricator shall establish and maintain a safety program adequate to meet all requirements of the
local and national safety standards for fabrication safety.
1.5.2 The fabricator shall designate a facility safety officer who shall have full authority and responsibility
for all facility safety.
1.6 Documentation
1.6.1 In addition to the documentation required in the Quality Control program, the fabricator shall have a
program in place to:
a. Ensure that only the most current revision of the latest drawings, specifications, purchase orders
and correspondence are used for construction purposes.
b. Record all special material certifications, resins, catalysts and other raw materials, promotion
and/or mixing formulas, and testing results.
c. Provide a daily log that documents information regarding quality issues.
d. Ensure that a record keeping system that satisfies the requirements of this specification is in use
and available for audit at any time by the owner or the owner’s representative.
1.6.2 The record keeping system shall satisfy this standard and all project specifications. Furthermore, it
shall be in use and available for audit by the owner or the owner’s representative at any time.
1.7 Testing
1.7.1 The fabricator shall be qualified to perform laboratory testing and shall be qualified to provide test
report documentation to substantiate fabrication technique requirements.
1.7.2 In the event that the fabricator uses independent laboratories for testing services, the laboratory shall
be qualified to perform testing that meets the requirements of the project specifications.
APPENDIX D
Contractor Qualification
This section specifies the requirements that a contractor must meet to become qualified to perform the
tasks for installing FRP pipe in accordance with the owner’s project requirements.
1.1 Construction Capability
The contractor shall be a firm which is highly experienced in and, as a normal practice, is engaged in FRP
field piping installation. The firm shall have a minimum of five years of related experience.
1.1.1 The contractor’s firm must demonstrate the ability to perform proper joining and fabrication
techniques to assure full compliance with the project requirements.
a. Demonstrated ability shall be performed in accordance with the specific requirements for the
Joiner Certification section of this specification.
b. Documentation of demonstrated ability shall be on file at the site construction facility during the
course of the project and available for audit by the owner or the owner’s representative at all times.
1.1.2 The contractor shall maintain and make available for review an in-house qualification procedure
which classifies workers by skills and experience. Each worker assigned to the project shall be identified as
to their qualification level and experience.
1.1.3 The contractor shall maintain a crew of certified joiners in accordance with the Joiner Certification
section of this standard.
1.2 Quality Control (QC) Program
The contractor shall maintain a QC program to assure that installation and construction activities meet the
owner’s project requirements. The QC program must, as a minimum, include a Quality Control Manual
which details the quality control and quality assurance activities to be utilized by the contractor.
1.2.1 The contractor shall provide to the owner or to the owner’s representative an organizational chart
which indicates reporting responsibility and authority.
a. The chart shall identify the various organizational groups and the particular functions for which
they are responsible.
b. The chart shall clearly show the relationship between management and engineering, purchasing,
construction, inspection, quality control and safety.
c. The chart shall show that the quality control function is independent of the construction group.
1.2.2 The program shall include a procedure for the inspection of received goods, including but not limited
to raw materials, purchased items and with any equipment that will become part of the finished FRP
equipment.
1.2.3 The program shall include in-process inspections of the following:
a. Resin mixing,
b. Raw material disbursement,
c. Component fabrication and assembly procedures, including verification of joint preparation,
d. Joint application,
e. Verification of lamination sequences (if applicable), and
f. Post-curing procedures (if applicable).
1.2.4 The program shall include documentation of all critical aspects of construction/installation milestones,
including receiving, in-process and final inspections.
1.2.5 The program shall include a procedure for scheduling and notifying inspector’s hold points and for
final acceptance inspections.
1.2.6 The program shall include a procedure for correcting non-conformances in accordance with the
owner’s project requirements.
1.2.7 The program shall include a procedure for qualifying quality assurance personnel, which procedure
shall satisfy the owner’s requirements.
1.2.8 The program shall include a procedure to assure the proper maintenance and calibration of all
inspection instruments and test equipment. This procedure shall also include standards for documenting
all maintenance and calibrations.
1.2.9 The program shall include a procedure for ensuring that testing is performed and documented in
accordance with the owner’s project requirements.
1.2.10 The program shall include a stipulation allowing complete access by the owner or by the owner’s
representative during all phases of construction activities to verify installation practices for compliance to
project requirements.
1.3 Construction Facilities
1.3.1 The contractor shall maintain a site facility (construction office) for the purpose of coordinating field
construction activities. This facility shall maintain full communication services including a phone, fax and
internet capability.
1.3.2 The contractor shall provide adequate portable enclosures to assure all fabrication and joining
activities are performed in a controlled environment that meets project requirements for optimum
fabrication considerations.
1.3.3 The contractor shall provide an adequate lay-down area for receiving, protecting and inventory of all
FRP components.
1.3.4 The contractor shall provide adequate portable shelters for the proper storage of resins, catalysts,
promoters, solvents and other chemicals.
1.3.5 The contractor shall take every precaution to assure safe storage and usage of all hazardous
materials.
1.3.6 The contractor shall maintain an on-site storeroom for the purpose of supplying hand tools,
performing maintenance and testing functions, and for providing general FRP-related field supplies for the
project.
1.3.7 Portable laboratory equipment shall be available for the QC testing of received resins, reinforcement
materials, and resin mixes as dispensed to construction laminators.
1.4 Construction Management
1.4.1 The contractor shall designate a manager responsible for all construction activities. The manager
shall fulfill the contractor’s project responsibilities.
1.4.2 The contractor shall provide a construction schedule that designates all construction activities and
completion dates within the overall project time frame.
1.4.3 The contractor shall maintain the construction schedule, report and revise reporting procedures as
required to record progress, project all milestone changes, and maintain all other pertinent project
information.
1.5 Construction Safety
1.5.1 The contractor shall maintain a site safety program to meet all the requirements of local and national
safety standards for construction site safety.
1.5.2 The contractor shall assure that a safety manual is provided to all site personnel.
1.5.3 The contractor shall designate a site safety officer who shall have full authority over and
responsibility for all site safety.
1.6 Documentation
1.6.1 In addition to the documentation required in the QC program, the contractor shall have a program in
place to:
a. Ensure only the most current revision of the latest drawings, specifications, purchase orders and
correspondence are used for construction purposes.
b. Record all special material certifications; resins, catalysts and other raw materials; promotion
and/or mixing formulas; and testing results.
c. Provide and maintain a daily log that documents information regarding quality issues.
d. Ensure that a record keeping system that satisfies the requirements of this specification is in use
and is available for audit at any time by the owner or the owner’s representative.
1.7 Testing
1.7.1 The contractor shall be qualified in hydrostatic testing of all piping systems installed, in accordance
with governing standards and project requirements.
a. The contractor shall ensure that adequate safety measures are in place prior to and during the
testing time frame.
b. The contractor’s safety officer shall draft and submit a test safety plan to the owner for approval
prior to any test being performed.
c. The contractor shall issue documentation for all testing performed.
Appendix E
Preventive Maintenance (PM) Program
1.1 General
By their very nature, FRP piping systems are placed into service for the purpose of conveying corrosive or
erosive liquids or gases. A certain degree of degradation in any piping system is normal, beginning at
start-up and progressing through its designed life expectancy. The degree of degradation is directly
affected by service conditions. To obtain optimum life from a piping system, and to address productivity
and safety issues, a thorough PM program shall be established, implemented and maintained.
This section specifies a methodology for piping system mechanical integrity preventive maintenance on
installed, commissioned piping.
FRP piping systems shall be examined at regular intervals in accordance with the owner’s assessment of
system criticality. FRP piping systems that are not safety-critical, and which may be classified as
ANSI/ASME B 31.3 Category D systems, do not require assessment under this specification.
1.2 Frequency
All piping systems shall be visually examined prior to the expiration of the manufacturer’s warrantee or
within one or two years of commissioning, whichever comes first. After this initial examination, a formal PM
inspection schedule shall be developed that addresses the unique properties of the piping system to be
examined.
1.3 Techniques
1.3.1 Visual
Visual examination shall be used to examine the FRP piping for detection of the following defects:
a. Surface scratches
b. Impact damage, with associated internal delaminations
c. Matrix cracking
d. Damage due to mechanical or environmental overloading
e. Environmental degradation
f. Fire damage
g. Service-related corrosion or erosion
1.3.2 Instrumented, Non-Destructive Testing (NDT)
Instrumented examinations shall be used to detect non-surface-breaking flaws, such as significant
debonding and delamination. Examples of NDT techniques include x-ray and thermal imaging.
1.4 Defects
Defect identification and corrective action shall be at the direction of the owner’s responsible engineer.
1.5 General Repairs
A specific plan shall be drafted and implemented to address those defects identified for repair. Repair
methods described in this section are not intended to replace the manufacturer’s recommendations. The
repair method chosen shall depend on the extent and type of damage, the level of criticality of the piping
system, and the availability of spare parts and/or repair facilities.
1.5.1 Permanent Replacement
Damaged sections shall be permanently replaced if pipes and fittings are available. Replacement of
damaged piping shall be considered new installation and shall be performed according to project
specification requirements.
1.5.2 Emergency Temporary Laminated Joint
Laminated joint repair techniques shall be used as an emergency repair method prior to permanent
replacement only when pipe suffers major failure or leakage and no other replacement or repair techniques
are available. Laminated joint techniques may be used either to patch over a damaged area or to connect
two pipes together after the damaged area has been removed and replaced with a new pipe section.
Damaged areas up to a length equal to one diameter may be repaired according to this method. The pipe
system must be empty and the surface must be dry before this repair work begins.
1.5.3 Temporary Clamps or Saddles
Mechanical clamps or saddles shall be used only if the pipe suffers minor leakage or weeping. Major
damage may be temporarily repaired in this manner only if the pipe service criticality and safety issues are
minor as determined by the owner. In either case, the clamps or saddles shall cover the entire damaged
area.
A mechanical clamp with rubber sealing may be used on a wet pipe, without de-pressurizing the system.
Before a mechanical clamp may be used, the actual outer diameter of the pipe must be verified and the
correctly sized clamp must be chosen. Due to the flexibility of FRP pipe, care must be exercised when
tightening a mechanical clamp to avoid crushing damaged caused by over-torquing.
1.6 Contractor Repairs
The contractor shall designate one individual experienced in all aspects of FRP piping field fabrication to be
responsible for QC throughout any and all repairs made to the FRP piping system. This individual shall be
certified as an installation leader and shall be responsible for maintaining records for all repairs,
examinations and hydrostatic tests.
1.6.1 Each repair shall be permanently marked for purposes of future identification. A log book containing
key values relevant to the repair process shall be maintained, and shall include as a minimum the following:
a. Date(s) of repair
b. Environmental conditions
c. Connections or repair identification numbers
d. Curing results
e. Installers’ signatures
1.6.2 Each field bond between pipes, fittings or flanges shall be examined by a qualified examiner as
required in this specification. A log book sheet shall be filled out for each bond. Examination sheets shall be
retained as long as the piping is in service.
1.6.3 The owner shall have the right to inspect any and all ongoing work, as well as the right to examine the
contractor’s QC program, at any time.
1.7 Emergency Repair Kit
In addition to a practical assortment of spare pipes and fittings, a kit containing necessary equipment to
perform repair of FRP pipes shall be established and maintained. Suitable repair kits may be purchased
from the manufacturer for a specific application.