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1、MANUAL GRP PIPELINES AND PIPING SYSTEMS (AMENDMENTS/SUPPLEMENTS TO UKOOA DOCUMENTS) DEP 31.40.10.19-Gen. December 1998 (DEP Circular 60/99 has been incorporated) DESIGN AND ENGINEERING PRACTICE This document is confidential. Neither the whole nor any part of this document may be disclosed to any thi
2、rd party without the prior written consent of Shell International Oil Products B.V. and Shell International Exploration and Production B.V., The Hague, The Netherlands. The copyright of this document is vested in these companies. All rights reserved. Neither the whole nor any part of this document m
3、ay be reproduced, stored in any retrieval system or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owners. PREFACE DEP (Design and Engineering Practice) publications reflect the views, at the t
4、ime of publication, of: Shell International Oil Products B.V. (SIOP) and Shell International Exploration and Production B.V. (SIEP) and Shell International Chemicals B.V. (SIC) The Hague, The Netherlands, and other Service Companies. They are based on the experience acquired during their involvement
5、 with the design, construction, operation and maintenance of processing units and facilities, and they are supplemented with the experience of Group Operating companies. Where appropriate they are based on, or reference is made to, national and international standards and codes of practice. The obje
6、ctive is to set the recommended standard for good design and engineering practice applied by Group companies operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such facility, and thereby to achieve maximum technical and economic benefi
7、t from standardization. The information set forth in these publications is provided to users for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be
8、 sufficiently flexible to allow individual operating companies to adapt the information set forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs they shall be solely responsible for the quality of work and the attainment of the required design
9、 and engineering standards. In particular, for those requirements not specifically covered, the Principal will expect them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier sh
10、all, without detracting from his own responsibility, consult the Principal or its technical advisor. The right to use DEPs is granted by SIOP, SIEP or SIC, in most cases under Service Agreements primarily with companies of the Royal Dutch/Shell Group and other companies receiving technical advice an
11、d services from SIOP, SIEP or SIC. Consequently, three categories of users of DEPs can be distinguished: 1)Operating companies having a Service Agreement with SIOP, SIEP, SIC or other Service Company. The use of DEPs by these Operating companies is subject in all respects to the terms and conditions
12、 of the relevant Service Agreement. 2)Other parties who are authorized to use DEPs subject to appropriate contractual arrangements. 3)Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supp
13、lied or - generally - work performed on behalf of the said users comply with the relevant standards. Subject to any particular terms and conditions as may be set forth in specific agreements with users, SIOP, SIEP and SIC disclaim any liability of whatsoever nature for any damage (including injury o
14、r death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof. The benefit of this disclaimer shall inure in all respects to SIOP, SIEP, SIC and/or any company affiliated to these
15、companies that may issue DEPs or require the use of DEPs. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of SIOP and SIEP, be disclosed by users to any company or person whomsoever and t
16、he DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of SIOP and SIEP. The copyright of DEPs vests in SIOP and SIEP. Users shall
17、 arrange for DEPs to be held in safe custody and SIOP or SIEP may at any time require information satisfactory to them in order to ascertain how users implement this requirement. All administrative queries should be directed to the DEP Administrator in SIOP. NOTE: In addition to DEP publications the
18、re are Standard Specifications and Draft DEPs for Development (DDDs). DDDs generally introduce new procedures or techniques that will probably need updating as further experience develops during their use. The above requirements for distribution and use of DEPs are also applicable to Standard Specif
19、ications and DDDs. Standard Specifications and DDDs will gradually be replaced by DEPs. DEP 31.40.10.19-Gen. December 1998 Page 2 TABLE OF CONTENTS PART AINTRODUCTION.6 1.1SCOPE 6 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS6 1.3DEFINITIONS 6 1.4CROSS-REFERENCES7 PART BAMENDMENTS/SUPP
20、LEMENTS TO THE UKOOA “GUIDELINES FOR FIBRE REINFORCED PLASTICS USE OFFSHORE“.8 1.SCOPE 9 2.PURPOSE. 10 3.PHILOSOPHY.11 4.COMPONENT/SYSTEM PERFORMANCE FACTORS.12 4.1MECHANICAL LOADS12 4.2DEGRADATION FACTORS12 6.COMPONENT/SYSTEM DESIGN13 6.1DESIGN CONSIDERATIONS.13 9.INSTALLATION AND TESTING.14 11.HEA
21、LTH, SAFETY AND ENVIRONMENT .15 APPENDIX IIGRP PERFORMANCE PARAMETERS (STRUCTURES/ PIPING).16 APPENDIX IVGLOSSARY.18 APPENDIX VCHEMICAL RESISTANCE OF GRP PIPING SYSTEMS19 PART CAMENDMENTS/SUPPLEMENTS TO THE UKOOA “SPECIFICATIONS AND RECOMMENDED PRACTICE FOR THE USE OF GRP PIPING OFFSHORE: PART 1 - P
22、HILOSOPHY -review of the fabrication/installation quality control documentation. DEP 31.40.10.19-Gen. December 1998 Page 14 11.HEALTH, SAFETY AND ENVIRONMENT 11.2Replace this section with the following: All procedures should comply with the relevant national legislation. DEP 31.40.10.19-Gen. Decembe
23、r 1998 Page 15 APPENDIX IIGRP PERFORMANCE PARAMETERS(STRUCTURES/ PIPING) Replace Table headed “GRP Performance Parameters - Piping“ with the following: GRP Performance Parameters - Piping (4.2) PerformanceService Parameter(a)(b)(c)(d)(e)(f)(g)(h)(i)(j)(k)(l)(m) Pressure - internalYYYYYYPPYYYYY Press
24、ure - externalYYNYPYNNYYYYY Impact (1)PPPPPPPPPPPPP Thermal loadsNYNYYYNNPYYYY Blast overpressurePYNYYYNNYPYYY AgeingPYPPYYPPPPYYY Bending loadsYYYYYYYYYYYYY Axial loadsYYYYYYYYYYYYY BucklingPPPYYYPPPYYYY Water hammerYYPYYPNNPYYYY FatigueYYNYNPNNYNYYY ErosionYYNYPYNNNPYYY CavitationYYNYPYNNPYYYY Abr
25、asionPPPPPPPPPPPPP TemperaturePYNPPYPPPNYYY Chemical resistanceYYY(2)PPYYYYPYYY PermeationYYYYNYYYYYYYY EnvironmentYYNYYYYYYYYYY Fire - endurancePYNYYYNNPPYYY Fire - heat releaseYYYPPYYYYPYYY Surface spread of flamePPYPPPPPPPYYY Smoke - visibilityYYYYYYYYYYYYY Smoke - toxicityYYYYYYYYYYYYY Electrica
26、l conductivityYYPYYYPPPYYYY Ground movementYYYYYYYYYYYYY The above Table is only a guide. Performance parameters should be determined for all applications on a case-by-case basis. NOTES: (a)Service water(h)Non-hazardous drains (b)Cooling fluids(i)Chemicals (c)Potable water(j)Ballast water (d)Firewat
27、er - wet systems(k)Emulsions (e)Firewater - dry systems(l)Oil (f)Produced water(m)Gas (g)Grey water (non-hazardous waste) Y=Yes N=No P=Possible (1)Impact to be considered if location/ routing does not preclude impact. (2)May require certification of local health authority (e.g. Water Research Counci
28、l certification) DEP 31.40.10.19-Gen. December 1998 Page 16 Add the following new Table: GRP Performance Parameters - Pipeline System (4.2) PerformanceService Parameter(a)(b)(c)(d)(e)(f)(g)(h)(i)(j)(k)(l)(m) Pressure - internalYYYYYYPPYYYYY Pressure - externalYYNYPYNNYYYYY Impact (1)PPPPPPPPPPPPP Th
29、ermal loadsNYNYYYNNPYYYY Blast overpressureNNNNNNNNNNNNN AgeingPYPPYYPPPPYYY Bending loadsYYYYYYYYYYYYY Axial loadsYYYYYYYYYYYYY BucklingPPPYYYPPPYYYY Water hammerYYPYYPNNPYYYY FatigueYYNYNPNNYNYYY ErosionYYNYPYNNNPYYY CavitationYYNYPYNNPYYYY AbrasionPPPPPPPPPPPPP TemperaturePYNPPYPPPNYYY Chemical r
30、esistanceYYY(2)PPYYYYPYYY PermeationYYYYNYYYYYYYY EnvironmentYYNYYYYYYYYYY Fire - enduranceNNNNNNNNNNNNN Fire - heat releaseNNNNNNNNNNNNN Surface spread of flameNNNNNNNNNNNNN Smoke - visibilityNNNNNNNNNNNNN Smoke - toxicityNNNNNNNNNNNNN Electrical conductivityYYPYYYPPPYYYY Ground movementYYYYYYYYYYY
31、YY The above Table is only a guide. Performance parameters should be determined for all applications on a case-by-case basis. NOTES: (a)Service water(h)Non-hazardous drains (b)Cooling fluids(i)Chemical (c)Potable water(j)Ballast water (d)Firewater - wet systems(k)Emulsions (e)Firewater - dry systems
32、(l)Oil (f)Produced water(m)Gas (g)Grey water (non-hazardous waste) Y=Yes N=No P=Possible (1) Third party damage (2) May require certification of local health authority (e.g. Water Research Council certification). DEP 31.40.10.19-Gen. December 1998 Page 17 APPENDIX IVGLOSSARY Add the following: Hydro
33、carbon fire Flame resulting from the combustion of gas or oil. DEP 31.40.10.19-Gen. December 1998 Page 18 Add new Appendix V: APPENDIX VCHEMICAL RESISTANCE OF GRP PIPING SYSTEMS The following recommended maximum temperatures are given for the sole purpose of a quick check and should only be used for
34、 guidance purposes. The allowable limits for the actual system are a function of both the chosen resin system and the curing agent. The chemical resistance data supplied by the Manufacturer should be based on experience from industry or from testing in the laboratory, in accordance with ASTM C 581.
35、Maximum recommended temperature, C Fluid / chemicalGREGRVEGRUP (glass/Epoxy)(glass/Vinylester)(glass/Polyester) For Tg (see note)Tg 120 CTg 95 C Water(fresh, sea, cooling, fire mains)1008060 Water, chlorinated 75%NRNRNR Acetone, 5 - 10%6030NR Acetone, 10 - 25%25NRNR Air1109070 Alcohol, methyl, 10%40
36、35NR Alkyl chloride2525NR Benzene50NRNR Butane gas6035NR CO2gas11090NR Citric acid9080NR Condensate9580NR Gas, natural9090NR Gasoline6565NR Glycol, ethylene9090NR Heptane6060NR Hexane6060NR HCL, 0 - 37%9080NR Jet Fuel (kerosine)10070NR Oil, Crude11090NR Petrol; sour, refined -108 octane6060NR Sodium
37、 hydroxide, 2 400G 2.1.1.4Standard service conditions Replace sub-section a) with the following: a) the standard service life for qualification purposes shall be 20 years. Add to sub-section c) the following sentence: In order to minimize the amount of testing a minimum test temperature of 65 C is D
38、EP 31.40.10.19-Gen. December 1998 Page 37 recommended for the regression tests and the 1 000 hour survival tests. 2.1.2Static pressure ratings Replace entire section with the following: Static pressure ratings for pipes (plus joints) and fittings shall be qualified in accordance with (sections 2.1.2
39、.1 to 2.1.2.3). An overview of the qualification test requirements for GRP pipes (plus joints) and fittings is given in (Table D.2.1.2). (Section 2.1.2.3) summarises how the LCLs(the basis for the pressure rating at a specific temperature and for a given design life) is determined from the test resu
40、lts. Table D.2.1.2Summary of qualification requirements for pipes (plus joints) and fittings Section 2.1.2.1Section 2.1.2.2 Family-Full Regression Test at 65 C or Representativedesign temperature if higher (ASTM D 2992 Procedure B) or: -Conservative Gradient ProductSector -2 x 1 000 hr survival test
41、 at 65 C Representativeor design temperature if higher (ASTM D 1598) and: -5x burst tests at SLT (ASTM D 1599) Component-2x burst test at SLT-2x burst test at SLT Variants(ASTM D 1599)(ASTM D 1599) or: -2 x 1 000 hr survival test at 65 C or design temperature if higher (ASTM D 1598) NOTES: 1.SLT is
42、Standard Laboratory Temperature 2.The references to standards in the above table indicate the test procedure and not the number of tests 2.1.2.1Pipe (plus Joints) and fittings: medium term survival tests This qualifying procedure permits qualification of the LCLsof the Product Sector Representative
43、based on a medium term survival test. The test pressure is based on the ASTM D 2992 Procedure B regression line obtained for the Product Family Representative. The objective of this procedure is to demonstrate that the Product Sector Representatives performance is equal, or superior, to the Product
44、Family Representative i.e. that the slope of the regression line for the Product Sector Representative is not steeper than that for the Product Family Representative. The LTHPsof the Product Family Representative shall be determined in accordance with ASTM D 2992 Procedure B, on a product with a dia
45、meter of 50 mm or larger. It is recommended that the test procedure outlined in ASTM D 2992 - Procedure B to generate the regression curve for the family representative is performed by a recognised third party. Two replicate samples of the Product Sector Representative shall be selected at random an
46、d pressure tested according to test method ASTM D 1598 (as amended in section 2.1.2.3) at 65 C or design temperature if higher. The test duration shall be 1 000 hours. The applied pressure shall not be less than the predicted lower confidence limit for the Product Sector Representative at 1 000 hour
47、s. (Figure D.2.1.2.1) presents graphically how to calculate the test pressure for the 1 000 hour test using the regression line for the Product Family Representative. In the absence of data for the Product Family Representative a conservative gradient may DEP 31.40.10.19-Gen. December 1998 Page 38 b
48、e used. The test pressure at 1 000 hours shall be calculated, based on the proposed pressure rating using the following procedure: Determine the proposed LCLsfrom the pressure rating, using equation (2.1) (equation 2.1) It is assumed that the LCLsis based on a 20 year design life. The default gradie
49、nts given in (Table D.2.1.2.1) are applicable based on a regression line defined by equation (2.2); log(pressure) = A - G * log(hours)(equation 2.2) Table D.2.1.2.1Default gradients (for design temperatures up to 65 C) Manufacturing methodDefault gradient, GDefault gradient, G (for Epoxy)(for Vinyl Ester and Polyester) Filament wound components0.0750.1 Hand lay-up components0.10.125 The 1 000 hour test pressure shall be determined from equation (2.3) Test pressure = LCLs* 102.24G(equation 2.3) The following Figure D.2.1.2.1a explains graphically the calculation procedure for the