4== “n= sr vFr= BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV. A PAGE 1 OF 19 SPECIFICATION FOR RTP LINE PIPE a | tssuenror serrova, | uuzazmi |uucjonenis.| wancnx | ranxn | DONGL REV. DESCRIPTION DATE PREP’D ‘CHK'D: REVD APP’DBASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV. A PAGE 2 OF 19 CONTENT 1.0 GENERAL. 4 1.1 Scope. 4 1.2 Definiti 4 2.0 CODES, STANDARDS AND SPECIFICATIONS... 4 3.0 ABBREVIATIONS 6 4.0 MATERIAL. 6 44 Liner Material 6 4.2 Reinforcement Layer.. 7 4.3 External Layer.. 8 5.0 _ END-FITTINGS AND PIPE-TO-PIPE COUPLINGS (FIELD-FITTINGS). 9 6.0 QUALIFICATION PROGRAM 9 61 9 62 6.3 Short-term Burst Tests. 6.4 — 1000 Hours Qualification Tests. 65 Vacuum Tests. 6.6 — Hydrocarbon Permeation Tests. 6.7 _ Elevated Temperature Test for End Fitting. 6.8 Minimum Bend Radius/Re-spooling Tests .. 69 — Tensi Strength Tests... 6.10 External Load Performance. 6.11 Minimum Allowable Operating Temperature Tests 6.12 Requalification.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV. A PAGE 3 OF 19 7.0 OTHER REQUIRED TESTING... 14 7.1 Chemical Resistance 14 7.2 Solar Radiation Resistance Tests 15 7.3. Impact Resistance Test 15 7.4 — Thermal Expansion Coofficient . 15 7.5 Growth and Shrinkage on Application of Pressure. 16 8.0 QUALITY ASSURANCE AND CONTROL REQUIREMENTS: 16 8.1 Short-term Burst Test. 16 8.2 Hydrostatic Test. 16 8.3 Dimensions 16 9.0 MARKING .. 17 10.0 HANDLING, STORAGE AND TRANSPORTATION . AAT 10.1 Handling, AAT 10.2 Storage... AT 10.3. Transportation. AT 11.0 DOCUMENTATION .. 18 11.1. Certification of Conformance. 18 11.2 Quality Assurance Test Reports. 18 11.3. Record Retention 18 11.4 Qualification Test Report 18 APPENDIX-1 Project Information Checklist 19BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV. A PAGE 4 OF 19 1.0 14 12 20 GENERAL Scope This specification gives the requirements and recommendations for the use of flexible composite pipe systems Reinforced Thermoplastic Pipe (RTP) for crude oll flowline. This specification addresses thermoplastic pipe reinforced using thermoplastic composites or thermoset composites. Design pressure is typically 4MPa, service temperature is no more than 85 °C. diameter is 150 mm, and continuous length is no less than 200m, depending on reel capacity. RTP pipe shall be supplied in reel delivery condition. The technical requirements in this specification are supplement to API SPEC 15S, and shall be used with API SPEC 15S. All RTP products shall be qualified according to API ‘SPEC 15S. The test report certificated by an independent third party authority or API ‘SPEC 168 certification shall be supplied by the SUPPLIER. Any deviation from this specification must be provided by SUPPLIER in writing and approved by COMPANY. Such written approval must be obtained prior to the ‘commencement of any work which would constitute such a deviation. The design life for RTP pipe is 20 years minimum. Definition WORD MEANING COMPANY PetroChina Intemational Iraq FZE Iraq Branch ‘The organization selected and entrusted by COMPANY to perform the CONTRACTOR Engineering, Precurement, Construction, Start-up, pre-Commissioning and Commissioring of the Project. ‘The party who is in charge of awarding agreement on behalf of PURCHASER COMPANY / CONTRACTOR for the supply of goods and services in connection with the work. The party to the contract andlor purchase order which has undertaken SOBCONTRACTOR ” | the obligation to supply the goods andlor services which are ordered and specified herein ‘Shall Indicates a mandatory requirement ‘Should Indicates a strong recommendation to comply with the requirements of this document CODES, STANDARDS AND SPECIFICATIONS ‘SUPPLIER shall meet or exceed the requirements of the latest edition of the following codes, regulations and standards, except as superseded herein. In cases where more than one code, regulation or standard apply to the same condition, the most stringent shall be followed. In the event of a conflict between this specification and other ‘specifications or correspondence, the COMPANY shall be consulted and a ruling, in writing, shall be obtained before any work is started.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV. A PAGE 5 OF 19 API SPEC 15S ISO/TS 18226 APISPEC 17 APIRP 17B ASTM C581 ASTM D746 ASTM D885 ASTM D1598 ASTM 01999 ASTM 02105 ASTM 02256 ASTM D2412 ASTM D2444 ASTM D2992 ASTM D3350 ASTM D3567 ASTM D7269 EN 14125 Iso 11507 Iso 17020 Iso 17025 Iso 17065 NACE MRO175/ 18015156 Spoolable Reinforced Plastic Line Pipe Plastics Pipes and Fittings — Reinforced Thermoplastics Pipe ‘Systems for the Supply of Gaseous Fuels for Pressures up to 4 MPa (40 bar) ‘Specification for Unbonded Flexible Pipe Recommended Practice for Flexible Pipe ‘Standard Practice for Determining Chemical Resistance of ‘Thermosetting Resins Used in Glass-Fiber-Reinforced Structures Intended for Liquid Service ‘Standard Test Method for Brittleness Temperature of Plastics and Elastomers by Impact ‘Standard Test Methods for Tire Cords, Tire Cord Fabrics, and Industrial Filament Yaris Made from Manufactured Organic-Base Fibers ‘Test Method for Time-To-Failure of Plastic Pipe Under Constant Internal Pressure ‘Test Method for Resistance to Short-Time Hydraulic Pressure of Plastic Pipe, Tubing, and Fittings ‘Standard Tes! Methods for Tire Cords, Tite Cord Fabrics, and Industrial Filament Yaris Made from Manufactured Organic-Base Fibers Standard Test Method for Tensile Properties of Yams by the Single-Strand Method ‘Standard Test Method for Determination of External Loading Characteristics of Plastic Pipe by Parallel-Plate Loading ‘Standard Practice for Determination of the Impact Resistance of ‘Thermoplastic Pipe and Fittings by Means of a Tup (Falling Weight) ‘Standard Practice for Obtaining Hydrostatic or Pressure Design Basis for Fiberglass (Glass-Fiber-Reinforced Thermosetting- Resin) Pipe and Fittings ‘Standard Specification for Polyethylene Plastics Pipe and Fittings, Materials ‘Standard Pradtice for Determining Dimensions of “Fiberglass” (Glass-Fiber-Reinforced Thermosetting Resin) Pipe and Fittings ‘Standard Test Methods for Tensile Testing of Aramid Yarns ‘Thermoplastic and Flexible Metal Pipework for Underground Installation at Petrol Filling Stations Paints and Varnishes — Exposure of Coatings to Artificial Weathering — Exposure to Fluorescent UV Lamps and Water Conformity Assessment — Requirements for the Operation of Various Types of Bodies Performing Inspection General Requirements for the Competence of Testing and Calibration Laboratories Conformity Assessment — Requirements for Bodies Certifying Products, Processes and Services Petroleum, Petrochemical, and Natural Gas Industries - Materials for Use in H:S-containing Environments in Oil and Gas ProductionBASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV..A | PAGE6OF 49 3.0 ABBREVIATIONS Dsc Differential scanning calorimetry LCL Lower confidence limit MPR Maximum pressure rating NPR Nominal pressure rating oD Outside diameter PE Polyethylene PEX Gross linked polyethylene PFR Product family representative PM Principal mode of faliure RTP Reinforcec thermoplastic pipe SUT ‘Standard laboratory temperature STHP Short-term burst strength Ta Glass transition temperature TLR Tensile load rating P Test pressure 1S Tensile Stength uy Ultraviolet 4.0 MATERIAL 44 444 The material selection process shall ensure that the material is compatible with the service fluids to which itis exposed over the full service temperature range and design pressure so that the mechanical, physical and chemical properties of the structural wall satisfy the design requirements throughout the intended lifetime, The materials selected shall be of a suitable commercial grade that complies with the technical requirements of the application Liner Material General Polymeric compounds shall conform to the materials requirements listed within the standards listed in Table 1 of API SPEC 15S. Fitness for purpose shall be established based upon tests as specified in Table 2 of API SPEC 15S.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV. A PAGE 7 OF 19 44.2 42 424 422 Fusion joints in the liner are permitted provided that they are performed by a qualified operator using a procedure qualified according to a recognized standard of AP] SPEC 158, The liner shall maintain its integrity for the specified fluids under the given service conditions of API SPEC 15S. The final material properties after processing shall be within the acceptable range of properties developed during the qualification program in Section 5 of API SPEC 15S. Special care may be required for liner materials that are strong crystallizers of API SPEC 15S. Processing parameters as documented in Section 6.2 of API SPEC 15S shall be specific and controlled to prevent unwanted changes in microstructure and the consequent unwanted changes in material properties. The thickness of the thermoplastic liner shall not be less than 3 mm and meet the ‘minimum thickness requirement for manufacturing, whichever is stricter. ‘Any changing the liner shall be approved by COMPANY and requalification as per Scetion 5.8 of API EPEC 156 is required Accepted Liner Material ‘Thermoplastic materials shall satisfy the service temperature 85°C at least. Crosslinked Polyethylene (PEX) or other suitable materials with related evidence could be used as liner material after COMPANY'S approval. Cross-linked Polyethylene (PEX) used shall ‘meet the requirement of ASTM F876. Manufacturer shall reconfirm and guarantee that all selected liner material shall be suitable for service condition. Reinforcement Layer General The reinforcement layer, including any bonding agents, shall sustain its integrity under the given service conditions. The manufacturer shall document the test data that demonstrates the short-term and long-term load bearing capabilities of the layer, temperature capabilities, required fluid compatibility, and aging characteristics of all materials employed. Joints in the reinforcement shall be made according to a qualified procedure by a qualified operator. Requalification may be required when changing the reinforcement layer. Matrix Material ‘The matrix material shall be purchased in accordance with a written material specification or industry standard and shall be a material suited for the intended purpose. Changes to the matrix material require requalification according to Section 4.2.2.3.5 of API SPEC 15S.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV. A PAGE 8 OF 19 4.2.2.1 Thermoset Resin Material The resin shall have a glass transition temperature Tg of at least 30 °C above the rated temperature of the pipe component. ‘The manufacturer shall define the degree of cure based on the DSC technique, procedure and value obtained after measuring the Tg on each of the pipe samples (minimum 18) used to qualify the product in Section 5.3.3 of API SPEC 15S. 4.2.2.2 Thermoplastic Resin Material 423 43 Thermoplastic resins shall be shown to retain integrity and fitness for purpose at the design conditions based upon tests as specified in Table 2 of API SPEC 15S. Reinforcement Material Within the context of this specification, the reinforcement material is nonmetallic reinforcement materials. Nonmetallic reinforcement material might also suffer from degradation due service conditions and assessments to demonstrate their suitability for the envisaged service. The reinforcing material shall be a suitable grade of fiber having a finish compatible with the matrix material used. Fiber shall be roving or yarn and shall be purchased in accordance with a written material specification or industry standard. The specification shall, as a minimum, include required values and tolerances for physical and mechanical characteristics. The fiber shall meet all the general reinforcement layer requirements of Section 4.2.2.1 of API SPEC 15S and with regard to the fluid compatibility requirements, particular attention shall be paid to hydrolysis and the effects of pH. Fibers may be embedded in a matrix The manufacturer shall prepare a material qualification report that documents the reinforcement conforms to the specified requirements. ‘Only materials with the same materials specification as used in the qualification testing shall be regarded as qualified. Aramid fiber shall be used. Aramid fiber shall be filament yarns or polymer-coated tapes. The specification shall include short-term breaking load for the filament or yarn being specified in accordance with test method ASTM D7269 and shall also include the linear density of the fiber. For yarns, the twistin turns per unit length shall be reported External Layer The cover shall have sufficient low temperature ductility for the intended installation conditions and service temperature ranges. The resistance to installation loads and environmental conditions shall be documented if required by the application or by the PURCHASER To protect the external pipe surface against UV degradation, especially when constantly exposed to strong sunlight, e.g., in tropical and desert areas, a pigmented external surface layer shall be used, such as carbon black, or white pigment, e.g., rutile (TiO2). The manufacturer shall demonstrate that the external pipe surface is UV resistant within the design life, in accordance with ISO 11507.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV. A PAGE 9 OF 19 5.0 6.0 64 The cover material shall sustain its function for the manufacturer specified service conditions. Brittleness temperature shall be at or below the minimum design temperature when tested in accordance with ASTM D746 END-FITTINGS AND PIPE-TO-PIPE COUPLINGS (FIELD-FITTINGS) The field-fitting shall sustain its integrity under the given service conditions. The ‘manufacturer shall document the test data that demonstrates the long-term integrity of the fitting. Fittings shall be fabricated from materials in accordance with either a written specification or an applicable industry standard. The fitting material shall sustain its function for the manufacturer specified service conditions. Only field fittings qualified by the pipe manufacturer shall be used. Considering the service condition crude oil contain HS, joints (eg., threaded connections including O-ring and/or thread compound sealing) should not be used. To prevent emission or reduce it to acceptable levels, a thermoplastic welded thermoplastic composite or “threaded and glued” or adhesive bonded thermoset composite joint should be used. The pipe manufacturer should select a suitable adhesive to seal threaded connections, and demonstrate that it can be applied in the field without hampering joining operations, and produce an emission-tight joint at ‘maximum pressure and temperature. The pipe-to-pipe couplings shall be swaging or crimping. When one swaging or crimping coupling cannot connect two RTP together, the swaging or crimping coupling shall be with short pipe to weld with another swaging or crimping coupling. Flange for pipe-to- pipe connection is not accepted. The required material for fittings shall be Alloy 825 as the minimum, and the minimum length is 200mm. VENDOR shall consider the heat effect of welding when determining the final length of the fitting, especially the temperature limits close to the RTP pipe body during swaging or crimping with short pipe welding, and a field construction instruction shall be prepared. The end-fttings shall be swaging or crimping with flange. The required material for fittings shall be Alloy 825 as the minimum also. Materials for fitting components for sour service applications in contact with conveyed fluids shall be selected in accordance with NACE MRO175/ISO 15156. QUALIFICATION PROGRAM General The qualification program consists of standard methods for quantifying component performance with respect to static intemal pressure, elevated temperature, tensile load, bending, vacuum, cyclic pressure performance, and leak-tightness of joints to be used in hydrocarbon and very toxic services.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV. A PAGE 10 OF 19 All tests shall be carried out, or witnessed and certified by an independent third party approved by the COMPANY. The qualification shall be documented in a qualification report. Qualification requirements for the pipe bodies, end-fitfings, couplers, and general characteristics are specified in this Section. The manufacturer is responsible for demonstrating compliance with the provisions of this specification. A qualification test report shall be kept on file by the manufacturer and a copy shall be available on request to the PURCHASER. PURCHASER may make any additional investigation deemed necessary to prove compliance by the manufacturer. ‘Where it is necessary to introduce joints of any type into the manufactured pipe, samples containing joints shall either be employed in the full qualification procedure or be treated as a product variants. ‘Thermoplastic liner butt welds are exempt from this provided the appropriate procedures are followed to ensure consistent high weld quality as described in Section 4.2.1.1 of API SPEC 158. For an introduction to terminology used in this section, refer to Annex H of API SPEC 153. Unless otherwise specified, the test specimen length shall be in accordance with ASTM D1599, Nonmetallic reinforcement has significant regression properties. For this reason, the MPR shall be based on a design factor applied to the long-term hydrostatic pressure of the pipe. ‘The MPR of the PFR and all product variants shall be confirmed by long-term hydrostatic pressure testing in accordance with 53 of API SPEC 15S, which shall be verified and certified by an independent third-party agency that conforms to ISO 17020 and/or ISO 17065 or shall be conducted at an ISO 17025 accredited laboratory. All failed samples, including any that fail by modes other than the PM, shall be reported in the qualification report. Long-term hydrostatic pressure shall be developed and reported adhering to the methodology of ASTM D2992-12, Procedure B. A product family size range may extend in nominal diameter -51 mm/+102 mm from the PFR and between 1/2 and 2 of the nominal pressure rating of the PFR. Size and/or pressure rating changes outside these ranges require full qualification as a new PFR in accordance with Section 5 of API SPEC 15S. Changes within these ranges require qualification as PV. APER shall have a nominal diameter of at least 51 mm in accordance with section 7.1 of API SPEC 15S and shall be tested in accordance with Section 5.3.3 of API SPEC 15S to determine the regression slope for the product family.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV. A PAGE 11 OF 19 62 6.2.1 6.2.2 6.23 624 Qualification of the Product Family Representative Test Requirements All qualification tests shall be carried out on spool pieces comprising the basic pipe body, together with one or more types of end-fitting All tests shall be conducted with unrestrained ends. Laboratory test fitings are allowed. Preconditioning of Samples The test samples shall either be preconditioned or shall pass the tests described in section 5.5.2 of API SPEC 15S. If preconditioning is deemed necessary in accordance with section .5.2 of API SPEC 15S, the test samples shall be preconditioned to the stated allowable handling MBR or the stated allowable number of respooling cycles (or both if both tests are unsuccessful in section 5.5.2 of API SPEC 15S) prior to performing PFR qualification testing Permissible Failure Modes ‘The permissible mode of failure shall be tensile rupture of the reinforcement. If there is a failure mode other than the permissible mode during qualification testing, then that test result shall be discarded in computing averages or plotting the data. NOTE: An example of a non-permissible failure mode is ejection of the pipe from the fitfing or coupler. Determination of MPR The MPR of the PFR shall be determined by a series of creep rupture tests under constant pressure at the qualification test temperature. The procedure as described in ASTM D292, Procedure B shall be used. No data points below 10 hours shall be included in regression calculations. The qualification test temperature shall be selected by the manufacturer and shall be greater than or equal to the maximum service temperature in any application for which the product is employed. Water is typically used as the pressurizing fluid. If an alternate fluid is used it shall be specified in the qualification report. The MPR shall be calculated as follows: MPR = LCLpoar Fy a) A maximum design factor, Fy = 0.67 shall be employed and is based upon the following: b) Maximum service temperature is equal to or less than the qualification temperature, the maximum service temperature is 85°C at least; ©) Fluid service is water, Fius=1, (Fass=0.80 or less for multiphase services, which is suitable for this project);BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV. A PAGE 12 OF 19 63 64 d) Loading is static (for cyclic loading, refer to Annex G of API SPEC 1S, cyclic loading shall be considered for this project); and ) Installed in full compliance with manufacturer's recommendations and requirements (refer to Annex D of API SPEC 15S for guidance on handling, installation and operation practices). If operating conditions are outside these baseline conditions, additional testing or analysis shall be considered. Short-term Burst Tests ‘The short-term burst strength in bar shall be determined by testing five replicate samples, with minimum test length of 5 times pipe diameter and unrestrained ends, in accordance with ASTM D199. The STHP of the product family representative shall be taken as the lower deviated (two standard deviaticns) value of the five replicate samples. Testing shall be at SLT. For nonmetallic reinforced pipe, each test specimen's short-term burst pressure shall be greater than or equal to 90 % of the 97.5 % lower prediction bound value as calculated in ASTM D2992-12. 1000 Hours Qualification Tests To demonstrate long-term strength performance, i.e., minimum design life, two replicate samples (pipe + joint) of the product sector representative shall be selected at random and pressure tested with unrestrained ends according to test method ASTM D1598. ‘The test pressure shall be at 85 “C. The product sector representative (pipe + joint) is qualified if it survives the test duration, i.e., does not leak, lose pressure, or structural integrity during the test duration. The test duration shall be 1000h, and the test pressure shall be related to the manufacturer's rominal pressure rating by the following equation: TP acon = 2.2 x NPR (up to 85 °C) ‘The manufacturer shall determine the nominal pressure rating, by means of short-term burst strength testing with a safety factor of at least 3.75. The nominal pressure rating is defined by the following: NPR = STHP/3.75 Before starting the 1000h qualification test, the test samples shall be pre-conditioned at ‘SLT by a combination of bending cycles followed by tensile loading. The number of bending cycles used to pre-condition the samples will directly determine the qualification level for maximum number of spooling cycles in service. The VENDOR shall determine the number of bending cycles used to pre-condition the samples. The recommended number of bending cycles should be at least 40, whilst the minimum number shall be 10. The chosen number of bending cycles shall be included within the test report. Bending shall be performed using either of the following methods to replicate a minimum bending radius of 2m; a) Bending around a mandrel with a maximum diameter of 4m, orBASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV. A PAGE 13 OF 19 67 b) Four points bend test using an outer support span of 2m and an inner span (loading jig) of 1m. Bending shall be performed at a minimum mid-span deflection of 204 mm, equivalent to a bending radius of 2 m. Following completion of the full number of bending cycles, the pre-conditioning of the samples shall be completed by tensile loading. The samples shall be loaded in accordance with ASTM D2105 to the pre-determined TLR. The TLR used to pre- condition the samples shall be included within the test report. The 1000 hours tests shall be carried out, or witnessed and certified by an independent third party authority for this project. Vacuum Tests ‘The manufacturer shall demonstrate the ability of spoolable pipe to withstand vacuum by full-vacuum testing two replicate, 1000-hour tested samples of each product family at 85 °C. The product family representatve is qualified if it survives the test duration, ie., collapse of pipe or liner shall not be permitted. The test duration shall be at least 1h Test pipes with a length of at least 5 times the pipe diameter. and not more than 3000mm, shall be used. For hydrocarbon services, additional full-vacuum testing shall be performed. Vacuum testing shall be performed after 1000 hours internal exposure testing to pentane fluid at 85°C Collapse of pipe or liner, or liner blistering, shall not be permitted. Hydrocarbon Permeation Tests For hydrocarbon service, the manufacturer shall provide coefficients for permeability, diffusivity and solubility. The permeation rate at the rated temperature shall be determined according to EN 14125 with Pentane, Toluene and a 50/50% by volume mixture of Pentane/Toluene as test fluids. Results of the hydrocarbon permeation test must demonstrate that the pipe exhibits a lower permeation rate than a full internal liner pipe of equal total wall thickness. Elevated Temperature Test for End Fitting ‘An elevated temperature test procedure in accordance with API SPEC 15S shall be employed to ensure that non-permissible failure modes relating to polymeric components of the pipe do not occur at times between the end of the regression test period and the end of the design life, eg., stress relaxation resulting in loss of grip within the fitting, or liner strain rupture. ‘The manufacturer shall subject test samples, with end fittings or couplers, to a constant pressure survival test, at a temperature in excess of the qualification test temperature, for a test period corresponding to the required lifetime. For PE lined products, the test shall be carried out with a 20 °C temperature shift for 1000 hours or a 25 °C temperature shift for 250 hours. The test pressure shall be the LCL. These tests may be carried out inBASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV. A PAGE 14 OF 19 ‘a temperature-controlled oven or water bath. For each fitting or coupler type to be qualified, at least 2 end fittings or couplers shall be tested, and the length of spool piece between the two shall be at least 5 times the nominal diameter. All specimens shall survive without leakage for the full test period. Following the elevated temperature test, each test-piece shall be de-pressurized and stored at ambient for at least 24 hours in air. The test-pieces shall then be pressurized to 1.0 MPa (150 psi) at SLT and examined for leakage. There shall be no visible leakage over a 24-hour period Changes of End-fitting that affect fit or ‘unction shall require requalification. 68 Minimum Bend Radius/Re-spooling Tests Minimum bend radius/re-spooling test procedure in accordance with API SPEC 15S shall be employed. 69 Ten: Strength Tests The teneile strength in KN chall be determined by teeting five replicate eamplee in accordance with ASTM D2105. The TS of the product family representative shall be taken as the lower deviated (two standard deviations) value of the five replicate samples. Testing shall be at SLT. 6.10 External Load Performance External load performance shall be characterized using ASTM D2412. 6.11 Minimum Allowable Operating Temperature Tests The manufacturer shall specify the minimum allowable operating temperature. The ‘manufacturer shall also conduct tests on the highest pressure class of the product family using two samples of the smallest and two samples of the largest pipe diameter. Test procedure shall be in accordance with API SPEC 158. 612 Requalification Requalifcation shall be required when the manufacturer makes changes to the materials and/or manufacturing process used in any product family. Test procedure shall be in accordance with API SPEC 15. Changes to a spoolable pipe component, to an extent beyond that agreed with the COMPANY, shall invalidate the component's previous qualification. 7.0 OTHER REQUIRED TESTING 74 Chemical Resistance ‘The manufacturer shall supply chemical resistance data for the relevant service fluids for all materials applied in the pipe systems e.g., liner, matrix, reinforcement materials andBASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV. A PAGE 15 OF 19 interface layers such as bonding layers and diffusion or permeant), including the highest known service temperature that the material has been subjected to and, if available, the service life that has been achieved under the service conditions. The chemical resistance information shall state whether the material has been laboratory tested according to ASTM C581 (or equivalent standard) and shall state the life expectancy for the intended service. ‘The assessment shall be based on testing and experience and shall predict the aging or deterioration of the polymer under the influence of environment. As a minimum, polymer aging estimates shall consider temperature, water cut, and pH. Special attention should be given to deplasticization, loss and/or degradation of additive formulation components, fluid absorption, and changes of dimensions. Materials used by products covered by this standard shall be demonstrated to remain stable for the design life of the product, retaining the necessary performance characteristics required to meet the original design specification. 7.2 Solar Radiation Resistance Tests If PE is used for the cover, the UV resistance for transportation and short-term storage shall be Code C or Code E as defined in ASTM D3360 or ISO 4437. The UV resistance of other cover materials for transportation and short-term storage should be documented and agreed upon between the manufacturer and the PURCHASER. For pipe used in surface applications, the UV resistance should be documented and agreed upon between the manufacturer and the PURCHASER. 7.3 Impact Resistance Test The manufacturer shall quote the impact energy resistance of the pipe at minimum installation temperature. Two pipe samples shall be impacted according to the applicable sections of ASTM D244 using Tup B or an equivalent test method. Following impact testing, the impact energy resistance of the pipe shall be confirmed by means of 1000- hour testing. The manufacturer shall also conduct a two-sample test on the smallest and largest pipe diameter for the highest pressure class of each product family. Following impact testing, the cover shall provide adequate protection to the reinforcement from the extemal environment 7.4 Thermal Expansion Coefficient The manufacturer shall measure and quote the axial thermal expansion coefficient of the pipe measured over a temperature range of at least 28 °C. The pipe test sample shall be a minimum length of 6x the pipe diameter. Measurements shall be conducted unpressurized and at the NPR. For applications where OD clearance is critical the hoop thermal expansion coefficient shall also be determined. The manufacturer shall also conduct a two-sample test on the smallest and largest pipe diameter for the highest pressure class of each product family.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV. A PAGE 16 OF 19 ws 8.0 84 8.2 83 Growth and Shrinkage on Application of Pressure The manufacturer shall measure and quote changes in pipe length and diameter which takes place as the pipe is pressurized from ambient pressure up to and including hydrotest pressure. The manufacturer shall also conduct a two-sample test on the ‘smallest and largest pipe diameter for the highest pressure class of each product family. QUALITY ASSURANCE AND CONTROL REQUIREMENTS: Short-term Burst Test ‘Two samples of pipe body per batch (one cut off from each end) shall be tested. The short-term burst test shall follow ASTM D159, Procedure A or Procedure B. Each test specimen’s short-term burst pressure shall be greater than or equal to 90 % of the 97.5 % lower prediction bound value as calculated by ASTM D2992. Reusable end-fttings, different in design to those used in the field, may be employed for these tests Hydrostatic Test After manufacturing, the spootable pipe components shall be hydrostatically tested at a pressure of 1.5 times the qualified NPR. Testing of shorter lengths is required, the minimum test length shall be 5 times pipe diameter. Hydrostatic test pressure shall be maintained for a minimum of two minutes in order to ascertain there is no leakage. If pracicable, test components shall have unrestrained ends. Test temperature shall be ambient. Dimensions All dimensions shall be compared with the baseline values determined for the qualified product family representative. The following dimensions shall be determined in accordance with ASTM D3567 for at least 1 % of continuous production: a) Internal diameter, b) Outside diameter; c) Mass; d) Liner thickness; ) Minimum liner thickness; f) Reinforced wall thickness. The measurement location on the component shall be the same as that used to determine the baseline value for the qualified product. Any out-of-tolerance components shall be rejected. The dimensions shall satisfy the requirements in Section 7.1 of API SP 158.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV. A PAGE 17 OF 19 9.0 10.0 10.4 10.2 10.3 MARKING Components manufactured shall be marked by the manufacturer. Additional project related markings as desired by the manufacturer or as requested by the COMPANY should be included. Markings shall be applied by paint or ink stencil, decal, or both as agreed upon between the COMPANY and manufacturer. Markings shall be permanent, shall not overlap, and shall be applied in such manner as not to damage the pipe. Markings shall be applied on the pipe components within one meter of the end. All pipes and fittings shall be permanently marked with: a) Manufacturer's name; b) Liner Material c) Rated pressure, tensile load and temperature; 4) Nominal diameter; e) Manufacturer's identification code; f) Date of manufacture. HANDLING, STORAGE AND TRANSPORTATION Handling All pipes shall be cleaned, dried and packed before handling and transportation Thermoplastic pipe is susceptible to damage by abrasion and by sharp objects. Spools of pipe tend to be top-heavy loads, and shall be handled with care to avoid ‘overturning the spool and damaging to the pipe and/or spool. A spreader bar and non-metallic slings, e.g., nylon, should be used when moving spools with a crane. Moving the spool by “rolling” shall not be permitted. Storage Pipe end covers shall be used to prevent ingress of moisture or dirt to the inside of the Pipe. Pipe spools should be stored on level flat surfaces with no protruding objects that may contact and damage the pipe on the external layer. During long-term storage, the pipe should be protected from freezing water that still may be present in the pipe, e.g., from hydrotesting, Transportation During field transport, e.g., for deployment, the spool shall be mounted in a suitable spooling frame. Transport should be on a trailer that is as close to the ground as practical. ‘Space constraints and obstacles, especially at a development site, may pose a problem during transportation. Alternative safe methods should be consideredBASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV. A PAGE 18 OF 19 11.0 14 n2 13 14 DOCUMENTATION Certification of Conformance ‘The manufacturer shall have available certification that the product was manufactured and tested in accordance with this specification Quality Assurance Test Reports The manufacturer shall have available a report which documents the results of quality assurance tests. Record Retention ‘The manufacturer shall keep on file for 10 years all documentation pertaining to the pipe manufacture, including manufacturing records, certificates, inspection, and quality assurance test documentation. Qualification Test Report The manufacturer shall prepare a qualification test report demonstrating conformance to this specification and it shall be made available for review on request.An i> o_o = BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0024 REV. A PAGE 19 OF 19 APPENDIX-1 PROJECT INFORMATION CHECKLIST Guidance for information that may be provided by the PURCHASER for a project is provided as follows: Basie Design Data ‘Nominal Pipe Diameter inches or milimeters Pipeline Length, feet or meters ‘Anticipated Service Life, years ‘MaxiMin Design Temperature, For © ‘Normal Operating Temperature, F or ‘MaxiMin System Design Pressure, MPa ‘Normal and Maximum Operating Pressures, MPa Pressure Fluctualions (size and frequency) Extemal Pressure, MPa ‘Soil Loading “Thermal Insulation Requirements Endfiting and Connector Metallurgy Fluid Service: ‘GaclWateriCainliphase (Please Specify) Productionvinjection (Please Specify) Fluid Composition, including Aromatie Content ‘CO,/H,S Content ‘Solids Content (Other Fluids, e.g. Production Chemicals ‘Quality Assurance: Required Batch and Hydrotest Procedures ‘Operational Requirements Tnspection Requirements — Internaliexternal Pigging Requirements ‘Reparabilty Requirements Impact Resistance Requirements ‘External Wear Requirements. Corrosion Protection Requirements (CP, etc, Including end-fitings/eouplings outer material) installation Details ‘Desorption of instalation (above/below ground) ‘Ground Conditions, ‘Extemal Environment (lemperalure, Sun, 16) ‘Extemal interference Hazards installation Procedure. Routing and Spatial Limitations Future Tien Requirements Delivery/Shipping Instructions Eng-fiting Interface Requirements, Min/Max Ambient Temperature, F or ©