ABS-137-2005.pdf
GUIDE FOR CERTIFICATION OF FRP HYDROCARBON PRODUCTION PIPING SYSTEMS MAY 2005 American Bureau of Shipping Incorporated by Act of Legislature of the State of New York 1862 Copyright 2005 American Bureau of Shipping ABS Plaza 16855 Northchase Drive Houston, TX 77060 USA Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:43:02 MDTNo reproduction or networking permitted without license from IHS -,-,- This Page Intentionally Left Blank Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:43:02 MDTNo reproduction or networking permitted without license from IHS -,-,- ABS GUIDE FOR CERTIFICATOIN OF FRP HYDROCARBON PRODUCTION PIPING SYSTEMS . 2005 iii Foreword This Guide specifies the ABS requirements for the certification of offshore pipes and piping components that are made of fiber reinforced plastics (FRP). Included are the requirements for design, manufacturing, construction, testing and survey during and after construction for the FRP pipes and piping components used in offshore topside modules. The requirements for piping components made of thermoplastic materials, such as polyvinyl chloride (PVC), commonly designed for minor applications, such as drainage, are intentionally excluded due to its limited usage. The significant enhancements in this Guide are made to the design considerations and the survey requirements for FRP pipes and piping components. More specific testing requirements are also provided for clarification purposes. The requirements presented in this Guide are based on existing methodologies and common practices that are deemed to provide an adequate level of safety. Other technological approaches that can be proven to produce an equivalent level of safety will also be considered as an alternative to those given herein. This Guide is applicable to the certification of topside FRP pipes and piping components for which applications or contracts for certification are received on or after 1 May 2005. This Guide supersedes the requirements on FRP piping installations specified in Appendix 1, “Plastic Pipe Installations,” of the ABS Guide for Building and Classing Facilities on Offshore Installations (ABS Facilities Guide) and is to be used in conjunction with other parts of the ABS Facilities Guide. Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:43:02 MDTNo reproduction or networking permitted without license from IHS -,-,- This Page Intentionally Left Blank Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:43:02 MDTNo reproduction or networking permitted without license from IHS -,-,- ABS GUIDE FOR CERTIFICATOIN OF FRP HYDROCARBON PRODUCTION PIPING SYSTEMS . 2005 v GUIDE FOR CERTIFCATION OF FRP HYDROCARBON PRODUCTION PIPING SYSTEMS CONTENTS SECTION 1 Scope and Conditions of Certification.1 1 Applicability1 1.1 Process.1 1.3 Certificates and Reports2 1.5 Representations as to Certification .2 1.7 Scope of Certification2 3 Documents to be Submitted 2 3.1 General .2 3.3 System Plans3 3.5 Contents of System Plans.3 3.7 Booklet of Standard Details.4 3.9 Material Specifications 4 3.11 Design Data and Calculations.4 3.13 Test Reports .4 3.15 Installation Manual4 3.17 Operations Manual4 3.19 Maintenance Manual.5 3.21 Additional Documentation .5 5 Survey, Inspection and Testing .5 5.1 General .5 5.3 Inspection and Testing in Manufacturing Phase6 5.5 Inspection and Testing during Installation.7 5.7 Conditions for Surveys after Construction.8 SECTION 2 Design.9 1 Internal Pressure9 1.1 Using Testing Methods .10 1.3 Using Design Strain Method .11 3 External Pressure 11 5 Axial Strength.12 7 Bending Strength.13 9 Axial Compressive Strength (Buckling) .14 11 Biaxial Stress Ratio of Pipes, Fittings and Joints 14 Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:43:02 MDTNo reproduction or networking permitted without license from IHS -,-,- vi ABS GUIDE FOR CERTIFICATOIN OF FRP HYDROCARBON PRODUCTION PIPING SYSTEMS . 2005 13 Temperature 15 15 Material Compatibility.15 17 Environmental Conditions16 19 Impact Resistance .16 21 Hydraulic Design16 23 Ship Motions 16 25 Stress Analysis 16 25.1 Design Conditions .17 25.3 Material Properties 18 25.5 SIFs and Flexibility Factors .19 25.7 Allowable Stresses and Deflections 19 25.9 Stress Analysis Calculations .19 27 Fire Endurance 22 27.1 Level 1.22 27.3 Level 2.22 27.5 Level 3.23 27.7 Level 3 Modified Test 23 27.9 Fire Endurance Coating.23 29 Flame Spread 23 31 Electrical Conductivity24 31.1 Rating24 31.3 Non-homogeneous Conductivity .24 31.5 Design Requirements24 33 Marking 25 TABLE 1 Biaxial Stress Ratios15 TABLE 2 Electrical Conductivity Risk Assessment Guidelines25 TABLE 3 Fire Endurance Requirements Matrix26 FIGURE 1 Flowchart of FRP Pipe Mechanical Design .9 FIGURE 2 Stress Analysis Flowchart17 SECTION 3 Installation29 1 Supports.29 1.1 Spacing .29 1.3 Bearing30 1.5 Heavy Components.30 1.7 Working of the Hull on a Floating Installation 30 1.9 Thermal Expansion .30 3 External Loads.30 5 Pipe Connections.30 5.1 General Requirements 30 5.3 Procedure and Personnel Qualifications .31 Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:43:02 MDTNo reproduction or networking permitted without license from IHS -,-,- ABS GUIDE FOR CERTIFICATOIN OF FRP HYDROCARBON PRODUCTION PIPING SYSTEMS . 2005 vii 7 Electrical Conductivity31 7.1 Resistance Measurement .31 7.3 Grounding (Earthing) Wire 31 9 Shell Connections on Floating Installations.31 11 Bulkhead and Deck Penetrations 32 13 Application of Fire Protection Coatings32 TABLE 1 Typical Support Spacing Values (fluid SG = 1.0) 29 SECTION 4 Manufacturing 33 SECTION 5 Pipe Bonding Procedure Qualification 35 1 Procedure Qualification Requirements35 1.1 Joint Bonding Parameters.35 1.3 Re-qualification .35 3 Procedure Qualification Testing.35 3.1 Test Assembly.35 3.3 Pipe Size.35 3.5 Bonding Operator Qualification.36 SECTION 6 Tests by Manufacturer Fire Endurance Testing of FRP Piping in Dry Condition (For Level 1 and Level 2)37 1 Test Method.37 1.1 Furnace Test Temperature .37 1.3 Furnace Temperature Control.37 1.5 Furnace Temperature Measurement.37 3 Test Specimen.38 3.1 Pipe Joints and Fittings.38 3.3 Number of Specimens.38 3.5 End Closure 38 3.7 Orientation 38 3.9 Insulation.38 3.11 Moisture Condition of Insulation38 5 Test Condition38 7 Acceptance Criteria39 7.1 During the Test39 7.3 After the Test.39 7.5 Alternative Tests .39 SECTION 7 Tests by Manufacturer Fire Endurance Testing of Water-filled FRP Piping (For Level 3).41 1 Test Method.41 1.1 Burner .41 1.3 Pipe up to 152 mm (6 in.) OD .41 1.5 Pipes more than 152 mm (6 in.) OD41 Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:43:02 MDTNo reproduction or networking permitted without license from IHS -,-,- viii ABS GUIDE FOR CERTIFICATOIN OF FRP HYDROCARBON PRODUCTION PIPING SYSTEMS . 2005 1.7 Burner Type and Arrangement41 1.9 Burner Position41 3 Test Specimen.42 3.1 Pipe Length.42 3.3 Pipe Joints and Fittings .42 3.5 Number of Specimens.42 3.7 End Closure.42 3.9 Moisture of Insulation 42 3.11 Orientation.43 3.13 Relief Valve.43 5 Test Conditions43 5.1 Sheltered Test Site43 5.3 Water-filled43 5.5 Water Temperature .43 7 Acceptance Criteria43 7.1 During the Test43 7.3 After the Test.43 TABLE 1 Qualification of Piping installations of Different Sizes 42 FIGURE 1 Fire Endurance Test Burner Assembly44 FIGURE 2 Fire Endurance Test Stand with Mounted Sample44 SECTION 8 Tests by Manufacturer Wet/Dry Fire Endurance Testing of FRP Piping Used in Deluge System (For Level 3 Modified Test Level 3 WD) (Adopted from USCG PFM 1-98).45 SECTION 9 Tests by Manufacturer Flame Spread.47 SECTION 10 Testing Onboard49 1 Documentation and Receiving Inspection .49 3 Handling and Storage49 5 Visual Inspection49 7 Resin/Adhesive Degree of Cure52 9 Documentation of Site Bonding.52 11 Repair Methods52 13 System Hydrostatic Test52 15 Maintenance 53 15.1 Impact Damage.53 15.3 Erosion53 15.5 Earthing Cables.53 15.7 Chalking/“Fiber Bloom“53 Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:43:02 MDTNo reproduction or networking permitted without license from IHS -,-,- ABS GUIDE FOR CERTIFICATOIN OF FRP HYDROCARBON PRODUCTION PIPING SYSTEMS . 2005 ix 15.9 Scale Deposits53 15.11 System Failures 53 15.13 Flange Damage/Cracks 54 TABLE 1 Defects Acceptance Criteria and Corrective Action.50 APPENDIX 1 References55 Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:43:02 MDTNo reproduction or networking permitted without license from IHS -,-,- This Page Intentionally Left Blank Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:43:02 MDTNo reproduction or networking permitted without license from IHS -,-,- ABS GUIDE FOR CERTIFICATOIN OF FRP HYDROCARBON PRODUCTION PIPING SYSTEMS . 2005 1 S E C T I O N 1 Scope and Conditions of Certification 1 Applicability This Guide specifies the technical documentation and provides guidelines for design, manufacturing, installation and maintenance of offshore fiber reinforced plastic (FRP) piping installations used in offshore topside modules. The principal objectives are to specify the minimum requirements for certification and continuance of certification by the Bureau. Pipes and piping components made of fiber reinforced plastics (FRP), which are thermosetting plastic materials with reinforcement, may be used in piping installations referred to in Section 2, Table 3, subject to compliance with the requirements specified in this Guide. In this document, the term “certification” indicates that an FRP piping installation has been designed, manufactured, installed and surveyed in compliance with the existing Rules, Guides or other acceptable standards. The continuance of certification is dependent on the fulfillment of requirements for surveys after construction. This Guide supersedes the requirements for FRP piping installation specified in Appendix 1, “Plastic Pipe Installations,” of the ABS Guide for Building and Classing Facilities on Offshore Installations (ABS Facilities Guide), and is to be used in conjunction with other parts of the ABS Facilities Guide. 1.1 Process The Certification process consists of: a) The development of Rules, Guides, standards and other criteria for the design and construction of pipes and piping components b) The review of design and survey during and after construction to verify compliance with such Rules, Guides, standards or other criteria c) The issuance of certificates when such compliance has been verified. The Rules, Guides and standards are developed by Bureau staff and passed upon by committees made up of manufacturers, naval architects, marine engineers, builders, engine builders, steel makers and by other technical, operating and scientific personnel associated with the worldwide maritime and offshore industry. Theoretical research and development, established engineering disciplines, as well as satisfactory service experience are utilized in their development and promulgation. The Bureau and its committees can act only upon such theoretical and practical considerations in developing Rules, Guides and standards. Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:43:02 MDTNo reproduction or networking permitted without license from IHS -,-,- Section 1 Scope and Conditions of Certification 2 ABS GUIDE FOR CERTIFICATOIN OF FRP HYDROCARBON PRODUCTION PIPING SYSTEMS . 2005 1.3 Certificates and Reports Plan review and surveys during and after construction are conducted by the Bureau to verify to itself and its committees that the pipe and piping components are in compliance with the Rules, Guides, standards or other criteria of the Bureau and to the satisfaction of the attending Surveyor. All reports and certificates are issued solely for the use of the Bureau, its committees, its clients and other authorized entities. 1.5 Representations as to Certification Certification is a representation by the Bureau as to the fitness of the pipe or piping component for a particular use or service in accordance with its Rules, Guides and standards. The Rules, Guides and standards of the American Bureau of Shipping are not meant as a substitute for the independent judgment of professional designers, naval architects, marine engineers, owners, operators, masters and crews, nor as a substitute for the quality control procedures of builders, steel makers, suppliers, manufacturers and sellers of marine materials, machinery or equipment. The Bureau represents solely to the Manufacturer, Operator or other client of the Bureau that when certifying it will use due diligence in the development of Rules, Guides and standards and in using normally applied testing standards, procedures and techniques as called for by the Rules, Guides, standards or other criteria of the Bureau for the purpose of issuing and maintaining certification. The Bureau further represents to the Manufacturer, Operator or other client of the Bureau that its certificates and reports evidence compliance only with one or more of the Rules, Guides, standards or other criteria of the Bureau in accordance with the terms of such certificate or report. Under no circumstances whatsoever are these representations to be deemed to relate to any third party. 1.7 Scope of Certification Nothing contained in any certificate or report is to be deemed to relieve any designer, builder, Operator, Manufacturer, seller, supplier, repairer, other entity or person of any warranty express or implied. Any certificate or report evidences compliance only with one or more of the Rules, Guides, standards, or other criteria of the American Bureau of Shipping and is issued solely for the use of the Bureau, i
