HDPE SPECIFICATION SOCAR AURORA FUJAIRAH TERMINAL FZE, UAE

Spec. 100101-MEC-TS-015R00; rev. dated 22-05-2010

Specification: Owner:

HDPE Specification SOCAR AURORA Fujairah Terminal FZE, P.O. Box 5385, Fujairah, United Arab Emirates

Engineer:

MUC Oil & Gas Engineering Consultancy FZC, Fujairah Free Zone, Main Office Building, No. 12D P.O. Box 4986, Fujairah, United Arab Emirates 22-05-2010 100101-MEC-TS-015R00; rev.0; 22-05-2010

Date: Specification:

Revision 00

Date 22-05-2010

Prepared By O.A

Checked By M.S

Approved By M.S

TABLE OF CONTENT

Introduction ........................................................................................................................................................ 3 1.1 Purpose..................................................................................................................................................... 3 1.2 Scope ........................................................................................................................................................ 3 1.3 Order of Precedence ................................................................................................................................. 3 References .......................................................................................................................................................... 3 2.1 Industry Codes and Standards .................................................................................................................. 3 Design ................................................................................................................................................................ 4 3.1 General Purpose Piping ............................................................................................................................ 4 3.2 Factory Mutual (FM) Approved Piping.................................................................................................... 4 Materials ............................................................................................................................................................. 4 Fabrication.......................................................................................................................................................... 4 5.1 Heat Fusion Joining .................................................................................................................................. 4 5.2 Heat Fusion Training ................................................................................................................................ 4 5.3 Heat Fusion Training Services ................................................................................................................. 5 5.4 Butt Fusion of Unlike Wall Thicknesses (General Purpose piping) ......................................................... 5 5.5 Butt Fusion of Unlike Wall Thicknesses (FM Approved piping) ............................................................. 5 5.6 Mechanical Joining (General Purpose piping) .......................................................................................... 5 5.7 Mechanical Joining (FM Approved piping) ............................................................................................. 6 5.8 Branch Connections ................................................................................................................................. 6 Installation .......................................................................................................................................................... 6 6.1 General ..................................................................................................................................................... 6 6.2 Large Diameter Fabricated Fittings .......................................................................................................... 6 6.3 Mechanical Joint and Flange Installation (General Purpose piping)......................................................... 6 6.4 Flange Installation (FM Approved piping) ............................................................................................... 7 6.5 Pipe Handling ........................................................................................................................................... 7 Visual Examination ............................................................................................................................................ 7 Testing ................................................................................................................................................................ 8 8.1 Butt Fusion Testing .................................................................................................................................. 8 8.2 Pressure Testing ....................................................................................................................................... 9

2 3

4 5

7 8

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Fujairah Free Zone Main Office Building, No. 12D P.O. Box 4986 - Fujairah, UAE Phone: (..)971 50 3915107 (..)971 50 4627798 E-mail: udink@muc.ae / shahin@muc.ae

Page: 3 of: 10 pages Report no.: 100101-MEC-TS-015R00; rev.; Date: 22-05-2010 Subject: HDPE Specification

1 1.1

Introduction Purpose The purpose of the Specification is to provide installation requirements for use by persons involved with the installation, examination, and testing of high density polyethylene piping (HDPE) systems.

1.2

Scope This Specification applies to installation of HDPE piping for use in refinery and petrochemical processing plants. This Practice applies to both General Purpose HDPE piping in accordance with ASME B31.3 and Factory Mutual (FM) Approved piping in accordance with NFPA 24.

1.3

Order of Precedence For General Purpose piping, in case of conflict between this Specification and the drawings, the drawings take precedence. For FM Approved piping, in case of conflict between this Practice and NFPA 24, NFPA 24 takes precedence.

References Applicable requirements in the following industry standards shall be considered an integral part of this Practice. The latest edition and addenda in effect at time of purchase shall be the governing document unless otherwise noted. Short titles will be used herein where appropriate.

2.1

Industry Codes and Standards American Society of Mechanical Engineers (ASME) A S M E B31.3 - Process Piping National Fire Protection Association (NFPA) N F P A 24 - Standard for the Installation of Private Fire Service Mains and Their Appurtenances

M.U.C. Oil & Gas

Fujairah Free Zone Main Office Building, No. 12D P.O. Box 4986 - Fujairah, UAE Phone: (..)971 50 3915107 (..)971 50 4627798 E-mail: udink@muc.ae / shahin@muc.ae

Page: 4 of: 10 pages Report no.: 100101-MEC-TS-015R00; rev.; Date: 22-05-2010 Subject: HDPE Specification

3 3.1

Design General Purpose Piping Unless specified otherwise, General Purpose piping shall comply with ASME B31.3.

3.2

Factory Mutual (FM) Approved Piping FM Approved piping shall comply with NFPA 24.

Materials 4.1 All material substitutions must be approved by the owner before purchase and fabrication. HPDE pipe and fittings to be joined by heat fusion shall be produced by the same manufacturer, hereinafter referred to as the Manufacturer. Pipe and fittings from different manufacturers shall not be interchanged.

4.2

5 5.1

Fabrication Heat Fusion Joining 5.1.1 Joints between plain end pipes and fittings shall be made by butt fusion, and joints between the main and saddle branch fittings shall be made by saddle fu sion using only procedures that are recommended by the Manufacturer. The procedures and procedure qualification records must be reviewed by the in spector representing the owner before any heat fusion joining begins. External and internal beads shall not be removed. Saddle branch fittings and saddle fusion joining shall not be used for FM Ap proved piping.

5.1.2

5.1.3 5.1.4

5.2

Heat Fusion Training

5.2.1 5.2.2 The contractor shall ensure that persons making heat fusion joints have received training in the Manufacturers recommended procedure. The contractor shall maintain records of trained personnel, and shall certify that training was received not more than 12 months before commencing construction.

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Fujairah Free Zone Main Office Building, No. 12D P.O. Box 4986 - Fujairah, UAE Phone: (..)971 50 3915107 (..)971 50 4627798 E-mail: udink@muc.ae / shahin@muc.ae

Page: 5 of: 10 pages Report no.: 100101-MEC-TS-015R00; rev.; Date: 22-05-2010 Subject: HDPE Specification

5.3

Heat Fusion Training Services If requested, the Manufacturer shall train the contractors installation personnel, as well as any inspectors representing the owner, in the Manufacturers recommended butt fusion and saddle fusion procedures.

5.4

Butt Fusion of Unlike Wall Thicknesses (General Purpose piping) 5.4.1 Butt fusion shall be performed between pipe ends or between pipe ends and fit ting outlets of like outside diameter and wall thickness. Butt fusion joining between pipe ends with like outside diameters and unlike wall thicknesses or between pipe ends and fitting outlets with like outside di ameters and unlike wall thicknesses is permitted if the difference in standard dimension ratio (SDR) of the two pieces is two SDRs or less (i.e., a component with a SDR of 11 can be joined to a component with a SDR of 15.5). Transitions between like outside diameters and unlike wall thicknesses greater than two standard dimension ratios (SDRs) shall be made with a transition nipple (a short length of the heavier wall pipe with one end machined to the lighter wall) or by mechanical means (i.e., a transition piece is required when joining a component with an SDR of 11 to a component with an SDR of 17).

5.4.2

5.4.3

5.5

Butt Fusion of Unlike Wall Thicknesses (FM Approved piping) 5.5.1 Butt fusion shall be performed between pipe ends or between pipe ends and fitting outlets of like class. Butt fusion jointing between Class 150 and Class 200 shall not be permitted. Transitions between Class 150 and Class 200 shall be made with flange connec tions.

5.5.2 5.5.3

5.6

Mechanical Joining (General Purpose piping) 5.6.1 HDPE pipe and fittings may be joined together or joined to other materials by either flanged connections (flange adapters and back-up rings) or mechanical couplings designed for joining HDPE pipe or for joining HDPE pipe to another material. Mechanical couplings shall be fully pressure-rated and fully thrust- restrained such that when installed in accordance with Manufacturers recommendations, a longitu dinal load applied to the mechanical coupling will cause the pipe to yield before the mechanical coupling disjoins.

5.6.2

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Fujairah Free Zone Main Office Building, No. 12D P.O. Box 4986 - Fujairah, UAE Phone: (..)971 50 3915107 (..)971 50 4627798 E-mail: udink@muc.ae / shahin@muc.ae

Page: 6 of: 10 pages Report no.: 100101-MEC-TS-015R00; rev.; Date: 22-05-2010 Subject: HDPE Specification

5.6.3

External joint restraints shall not be used in lieu of fully restrained mechanical cou plings.

5.7

Mechanical Joining (FM Approved piping) 5.7.1 HDPE pipe and fittings may be joined together or to other materials by means of flanged connections (flange adapters and backup rings). Mechanical couplings and external joint restraints shall not be used.

5.7.2 5.8

Branch Connections 5.8.1 5.8.2 5.8.3 Branch connections to the main shall be made with saddle fittings or tees. HPDE saddle fittings shall be saddle-fused to the main pipe. Saddle branch fittings and saddle fusion joining shall not be used for FM Approved piping.

6 6.1

Installation General 6.1.1 Installation shall be in accordance with the Manufacturers recommendations and this Practice. All necessary precautions shall be taken to ensure a safe working environment in accordance with applicable codes and standards.

6.1.2

6.2

Large Diameter Fabricated Fittings 6.2.1 Fabricated directional fittings 16 inch IPS and larger shall be butt-fused to the end of a pipe. The flanged directional outlet connections shall be made up in the trench.

6.2.2 6.3

Mechanical Joint and Flange Installation (General Purpose piping) 6.3.1 Mechanical joints and flange connections shall be installed in accordance with the Manufacturers recommended procedure. Flange faces shall be centered and aligned to each other before assembling and tightening bolts. In no case shall the flange bolts be used to draw the flanges into

6.3.2

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Fujairah Free Zone Main Office Building, No. 12D P.O. Box 4986 - Fujairah, UAE Phone: (..)971 50 3915107 (..)971 50 4627798 E-mail: udink@muc.ae / shahin@muc.ae

Page: 7 of: 10 pages Report no.: 100101-MEC-TS-015R00; rev.; Date: 22-05-2010 Subject: HDPE Specification

alignment. 6.3.3 Bolt threads shall be lubricated, and flat washers shall be fitted under the flange nuts. Bolts shall be evenly tightened according to the tightening pattern and torque step recommendations of the Manufacturer. At least 1 hour after initial assembly and full tightening, flange connections shall be re-tightened following the tightening pattern and torque step recommendations of the Manufacturer. A third and final tightening about 4 hours after the second is rec ommended.

6.3.4

6.4

Flange Installation (FM Approved piping) 6.4.1 Flange connections shall be installed in accordance with the Manufacturers rec ommended procedure. Flange faces shall be centered and aligned to each other before assembling and tightening bolts. In no case shall the flange bolts be used to draw the flanges into alignment. Bolt threads shall be lubricated, and flat washers shall be fitted under the flange nuts. Bolts shall be evenly tightened according to the tightening pattern and torque step recommendations of the Manufacturer. At least 1 hour after initial assembly and full tightening, flange connections shall be re-tightened following the tightening pattern and torque step recommendations of the Manufacturer. A third and final tightening about 4 hours after the second is rec ommended. The torque values shall be as recommended by the gasket manufacturer.

6.4.2

6.4.3

6.4.4

6.5

Pipe Handling 6.5.1 When lifting with slings, only wide fabric choker slings shall be used to lift, move, or lower pipe and fittings. Wire rope or chain shall not be used. Slings shall be of sufficient capacity for the load, and shall be inspected before use. Worn or defective equipment shall not be used.

6.5.2 6.5.3 6.5.4

Visual Examination 7.1 Butt fusion joints shall be visually examined to ensure joint quality. The size and

M.U.C. Oil & Gas

Fujairah Free Zone Main Office Building, No. 12D P.O. Box 4986 - Fujairah, UAE Phone: (..)971 50 3915107 (..)971 50 4627798 E-mail: udink@muc.ae / shahin@muc.ae

Page: 8 of: 10 pages Report no.: 100101-MEC-TS-015R00; rev.; Date: 22-05-2010 Subject: HDPE Specification

shape of the fusion beads indicate if a proper joint has been made. 7.2 The width of the double bead shall be 2 to 1-1/2 times the height of the bead from the pipe surface. The double bead shall be uniform in size and shape all around the joint. The depth of the V-groove between the beads shall not be more than half the bead height. When butt fusion is between pipe and a molded fitting, the fitting-side bead may ex hibit some shape irregularities that are caused by the molding process. A slightly ir regular fitting-side bead shall not be cause for rejection provided that the pipe-side bead is properly shaped and the V-groove between the beads is correct. This only ap plies to molded fittings and not to fittings that are fabricated from pipe shapes. The above visual inspection criteria apply to both outside fusion beads and inside fu sion beads. Inside fusion beads shall be examined when accessible, such as at flange adapters, the first fission of an elbow, and the first and second fusion of a tee.

7.3 7.4

7.5

7.6

8 8.1

Testing Butt Fusion Testing 8.1.1 8.1.2 For each fusion operator, the first fusion of each day shall be a trial fusion. The trial fusion shall be allowed to cool completely, then fusion test straps shall be cut out. Welds shall be tested by cutting a 12-inch wide ring section of HDPE pipe with the examination and a bend test. The width of the test bend strips is proportional to the pipe wall thickness. If the pipe wall thickness is less than 1.0 inch, a 1.0-inch wide test strip is recommended. If the pipe wall thickness is greater than 1.0 inch, the width of the test strip shall be equal to the wall thickness. 8.1.4 The cross section of the weld will be examined visually, and shall contain no voids or discontinuities.

8.1.3

8.1.5 a. b.

The bend test consists of the followings steps: Each test strip is clamped in a vise 1.0 inch under the weld bead. A steel extension pipe of appropriate diameter and length is then slipped over the free end of the specimen to 1.0 inch above the weld bead.

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Fujairah Free Zone Main Office Building, No. 12D P.O. Box 4986 - Fujairah, UAE Phone: (..)971 50 3915107 (..)971 50 4627798 E-mail: udink@muc.ae / shahin@muc.ae

Page: 9 of: 10 pages Report no.: 100101-MEC-TS-015R00; rev.; Date: 22-05-2010 Subject: HDPE Specification

c.

The bend test is performed by bending the test specimen a minimum of 90 o in the di rection that places the concave interior surface/root of the pipe wall/weld in tension. No failures in the butt fusion area are permitted in all four test strips. If the fusion fails at the joint, a new trial fusion shall be made, cooled completely, and tested. Butt fusion of pipe to be installed shall not commence until a trial fission has passed the bend test.

8.1.6

8.1.7

8.2

Pressure Testing 8.2.1 All joints (mechanical, flanged, and fusion) shall be inspected for leakage during the test. Heat fusion joints must be completely cooled before pressure testing. The temperature of the test medium and the pipe test section should be the same, and if possible, should be less than 100F (38C). Before applying test pressure, ample time shall be allowed for the test medium and the pipe test section to equalize. At temperatures above 100F (38C), test pressure must be reduced. Test pressure may be limited by valves, or other lower pressure rated components. Such components may not withstand the required test pressure. They should be either removed or isolated from the test section to avoid possible damage or failure of these devices. For any test pressure from 1 to 1-1/2 times the system operating design pressure, the total test time (including initial pressurization, initial expansion, and time at test pres sure) must not exceed 8 hours. If the test is not completed due to leakage, equipment failure, etc., depressurize the test section, then allow it to relax for at least 8 hours before bringing the test section up to test pressure again. The preferred testing medium is clean water. The test section should be completely filled with liquid. Trapped air must be purged. While the test section is filling, venting at high points may be necessary to purge air pockets. The test procedure consists of initial expansion and test phases. During the initial ex pansion phase, the test section is pressurized to the test pressure, and enough makeup liquid is added each hour for 3 hours to return to test pressure. The test phase follows immediately for 2 hours. At the end of the test time, the test section is returned to test pressure by adding a measured amount of liquid. If the amount of makeup liquid added does not exceed the following values, leakage is not indicated.

8.2.2

8.2.3

8.2.4

8.2.5

8.2.6

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Fujairah Free Zone Main Office Building, No. 12D P.O. Box 4986 - Fujairah, UAE Phone: (..)971 50 3915107 (..)971 50 4627798 E-mail: udink@muc.ae / shahin@muc.ae

Page: 10 of: 10 pages Report no.: 100101-MEC-TS-015R00; rev.; Date: 22-05-2010 Subject: HDPE Specification

Table 1 Test Phase Makeup Amount

Nominal Pipe Size (in.) 3 4 6 8 10 12 14 16 18 20 24 30 36

Gallons/l00 ft. of Pipe 0.1 2 Hour 5 Test 0.2 5 0.6 0 1.0 1.3 2.3 2.8 3.3 4.3 5.5 8.9 12. 7 18. 0