HDPE Piping Spec

FORMATION DEVELOPMENT FEED
WORLEYPARSONS
LIMITED 2 PROJECT,
Doc. title SPECIFICATION FOR HDPE PIPING Rev.: 00 Status: AFD
COMPANY No.: 8015-0152-WP05-00-000-PI-SP-12017
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DOCUMENT REVISION HISTORY SHEET
REV STATUS DATE ISSUED UPDATE / AMENDMENT DETAILS
A IDC 02-10-2014 INTER DISCIPLINE CHECK
B IFR 12-10-2014 ISSUED FOR REVIEW
C IFA 30-11-2014 ISSUED FOR APPROVAL
00 AFD 18-12-2014 APPROVED FOR DESIGN
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Uncontrolled copy, if printed.
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CONTENT
1 INTRODUCTION .......................................................................................................... 6
1.1 Purpose ........................................................................................................................... 6
1.2 Scope ............................................................................................................................... 6
1.3 Definitions and Abbreviations ....................................................................................... 6
1.4 Units of Measurements ................................................................................................... 8

2 REFERENCE DOCUMENTS ....................................................................................... 9
2.1 Order of Precedence ....................................................................................................... 9
2.2 Project Reference Documents ........................................................................................ 9
2.3 International Codes and Standards ............................................................................... 9

3 TECHNICAL REQUIREMENTS ............................................................................... 12
3.1 General ......................................................................................................................... 12
3.2 Service Conditions ........................................................................................................ 12
3.3 Bill of Material ............................................................................................................. 12
3.4 SUPPLIER’s Responsibility ......................................................................................... 12
3.5 Site Condition ............................................................................................................... 14

4 MATERIALS ............................................................................................................... 15
4.1 Ultraviolet (UV) Protection .......................................................................................... 15
4.2 Gaskets.......................................................................................................................... 15
4.3 Valves (Supplied by Others) ........................................................................................ 15
4.4 Bolting ........................................................................................................................... 15

5 DESIGN ........................................................................................................................ 16
5.1 Standard Dimension Ratio (SDR) ................................................................................ 16
5.2 Ovality / Out of Roundness .......................................................................................... 16
5.3 Dimensions and Tolerances.......................................................................................... 16
5.4 Pipes .............................................................................................................................. 16
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5.5 Flanges .......................................................................................................................... 16
5.6 Fittings .......................................................................................................................... 16
5.7 Process of Manufacture................................................................................................ 17
5.8 Types of Connections ................................................................................................... 17

6 FABRICATION ........................................................................................................... 18
6.1 Heat Fusion Joining...................................................................................................... 18
6.2 Mechanical Joining....................................................................................................... 18
6.3 Branch Connections ..................................................................................................... 18

7 INSTALLATION ......................................................................................................... 19
7.1 General ......................................................................................................................... 19
7.2 Mechanical Joint and Flange Installation ................................................................... 19
7.3 Pipe Handling ............................................................................................................... 19

8 QUALITY PROGRAMME ......................................................................................... 20
8.1 Quality Manual ............................................................................................................ 20
8.2 Process and Quality Control Requirements ................................................................ 20
8.3 Quality Control Equipment ......................................................................................... 20

8.3.1 General ....................................................................................................................... 20
8.3.2 Dimensional Measuring Equipment ............................................................................ 20
8.3.3 Pressure Measuring Devices ....................................................................................... 20
8.4 Quality Control Tests ................................................................................................... 20

8.4.1 Conditioning ............................................................................................................... 20
8.4.2 Retest and Rejection ................................................................................................... 20
8.5 Test, Examination, Inspection, Rejection and Compliance ........................................ 21

8.5.1 General ....................................................................................................................... 21
8.5.2 Inspection by the COMPANY .................................................................................... 21
8.5.3 Manufacturing Test ..................................................................................................... 21
8.5.4 Site Visual Examination.............................................................................................. 21
8.5.5 Butt Fusion Testing..................................................................................................... 22
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8.5.6 Hydrostatic Test.......................................................................................................... 22

8.5.7 Rejection .................................................................................................................... 23
8.5.8 Compliance................................................................................................................. 23
8.6 Quality Control Records Requirements ...................................................................... 23

8.6.1 Purpose ....................................................................................................................... 23
8.6.2 QA / QC Plan ............................................................................................................. 23
8.6.3 QC Records ................................................................................................................ 24
9 PREPARATION FOR SHIPMENT ............................................................................ 25
9.1 Packing ......................................................................................................................... 25
9.2 Identification ................................................................................................................ 25

10 DOCUMENTATION ................................................................................................... 26
10.1 Manufacturer’s Drawings ............................................................................................ 26
10.2 Installation Manual ...................................................................................................... 26
10.3 Safety Precautions ........................................................................................................ 26

11 APPENDICES .............................................................................................................. 27
APPENDIX-1: DESIGN CONDITION AND FLUID SERVICE (NOTE-1)........................ 28
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1 INTRODUCTION
( ), in partnership with the Company of , is
developing its upstream production facilities and infrastructure to meet a target of 1.2MMBOPD
of production in the 2 oil field in . The field consists of two primary
reservoirs, and , which are developed as separate projects. It is envisaged that
the reservoir will produce 650MBOPD of the 1.2MMBOPD targeted from the entire
field.
WorleyParsons has been contracted to execute the FEED phase of the Development
Project. The development includes well pads, gathering systems, water injection facilities, gas
and water treatment, a gas turbine power plant, a light oil export pipeline and tank farm
upgrades, tie-ins to LPG and gas export systems and further expansion of supporting facilities
such as accommodation camps, security systems and expansion of the infrastructure as
necessary.
The Project aims to produce a comprehensive FEED Package in order to allow the progression of
the Project to the EPC (Execute) Phase.
1.1 Purpose
The purpose of this document is to define the minimum technical requirements for project
specification for HDPE Piping for the Development Feed Project for 2.
1.2 Scope
This specification along with referenced applicable project documents (specifications,
datasheets, design drawings) and codes/standards defines the minimum requirements for the
design, materials, manufacture, testing and inspection, quality assurance and quality control,
documentation, preparation for shipment, field installation and testing of HDPE Piping for the
Development Feed Project for 2 project.
This specification is intended to cover HDPE piping for utility services. It does not cover HDPE
for natural gas service.
1.3 Definitions and Abbreviations
1.3.1 Definitions:
COMPANY ( )
CONTRACTOR The Organization selected to carry out the work described under
the contract with the COMPANY
Inspector COMPANY nominated third party or COMPANY designated

Representative
PROJECT Formation Development FEED 2 Project,
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Shall and must Indicate mandatory requirements
Should indicate that the provision is not mandatory, but recommended

as a good practice/ guidelines
SUPPLIER/ The Organization selected to manufacture or supply the

equipment and services
MANUFACTURER
SUB-SUPPLIER The Organization selected by the SUPPLIER to supply the part

of the equipment and services
1.3.2 Abbreviations:
API American Petroleum Institute

ASME American Society of Mechanical Engineers
ASTM American Society for Testing for Materials
DR Dimension Ratio
DSF Design Service Factor
EPC Engineering, Procurement and Construction
FEED Front End Engineering Design
FFJ Field Fit Joint
GRP Glass-fiber Reinforced Plastic
GRE Glass-fiber Reinforced Epoxy
GRV Glass-fiber Reinforced Vinylester
HDB Hydrostatic Design Basis
HDPE High Density Polyethylene
HDS Hydrostatic Design Stress
HSE Health, Safety and Environment
ISO International Organization for Standardization
ITP Inspection and Test Plan
MBOPD Thousand Barrels of Oil per Day
MMBOPD Million Barrels of Oil per Day
NDE Non-Destructive Examination
NPS Nominal Pipe Size
PE Polyethylene
PPI Plastics Pipe Institute
SDR Standard Dimension Ratio
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1.4 Units of Measurements

All units of measurement are to be in SI units and in-line with Document number 8015-0152-
WP05-00-000-PC-BD-12001: Basic Engineering Design Data.
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2 REFERENCE DOCUMENTS
2.1 Order of Precedence
The precedence applying for use of the Codes, Standards, and Specification and Statutory
requirements for this project is as follows:
• Statutory Requirements, Local applicable laws and Regulation in
• Standards
• Project Datasheets
• Project Specifications and Standards
• International Standards
• Service Authority Standards
In the event of an inconsistency, conflict or discrepancy between any of the Standards,
Specifications and Statutory requirements, the most stringent and safest requirement applicable
to the project will prevail to the extent of the inconsistency, conflict or discrepancy. Any
inconsistencies, critical to the design, shall be brought to the attention of for resolution.
2.2 Project Reference Documents
Document Number Description

8015-0152-WP05-00-000-PC-BD-12001 Basic Engineering Design Data (BEDD)
8015-0152-WP05-00-000-MT-RP-12001 Material Selection Report - Plant
8015-0152-WP05-00-000-PI-BD-12001 Piping Design Criteria
8015-0152-WP05-00-000-PI-SP-12001 Piping Material Specification
8015-0152-WP05-00-000-PI-SP-12013 Specification for Gaskets
8015-0152-WP05-00-000-PI-SP-12014 Specification for Stud Bolts
2.3 International Codes and Standards

Reference to any standard or code shall mean latest edition of that standards or code including
addenda, supplements or revisions, unless otherwise stated.

American Petroleum Institute (API)
API 15 LE Specification for Polyethylene Line Pipe
American Society of Mechanical Engineers (ASME)
ASME B16.5 Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24
ASME B16.47 Large Diameter Steel Flanges NPS 26 Through NPS 60
ASME B16.48 Line blanks
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ASME B31.3 Process piping
American Society for Testing and Materials (ASTM)
ASTM A536 Standard Specification for Ductile Iron Castings
ASTM D638 Standard Test Method for Tensile Properties of Plastics
Standard Test Methods for Density and Specific Gravity (Relative
ASTM D792
Density) of Plastics by Displacement
Standard Test Method for Melt Flow Rates of Thermoplastics by
ASTM D1238
Extrusion Plastometer
Standard Test Method for Density of Plastics by the Density-
ASTM D1505
Gradient Technique
Standard Test Method for Time-to Failure of Plastic Pipe Under
ASTM D1598
Constant Internal Pressure
Standard Test Method for Resistance to Short-Time Hydraulic
ASTM D1599
Failure Pressure of Plastic Pipe, Tubing and Fittings
ASTM D1600 Standard Terminology for Abbreviated Terms Relating to Plastics
ASTM D1603 Standard Test Method for Carbon Black Content in Olefin Plastics
Standard Test Method for Determining Dimensions of
ASTM D2122
Thermoplastic Pipe and Fittings
Standard Test Method for Apparent Hoop Tensile Strength of Plastic
ASTM D2290
or Reinforced Plastic by Split Disk Method
Standard Specification for Polyethylene Gas Pressure Pipe, Tubing
ASTM D2513
and Fittings
Standard Specification for Socket-Type Polyethylene Fittings for
ASTM D2683
Outside Diameter—Controlled Polyethylene Pipe and Tubing
Standard Test Methods for Determination of Gel Content and Swell
ASTM D2765
Ratio of Crosslinked Ethylene Plastics
Standard Practice for Underground Installation of Thermoplastic
ASTM D2774
Pressure Piping
Standard Test Method for Obtaining Hydrostatic Design Basis for
ASTM D2837 Thermoplastic Pipe Materials or Pressure design basics for
Thermoplastic pipe products.
Standard Specification for Polyethylene (PE) Plastic Pipe (DR-PR)
ASTM D3035
Based on Controlled Outside Diameter
Standard Specification for Butt Heat Fusion Polyethylene (PE)
ASTM D3261
Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing
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Standard Specification for Polyethylene Plastics Pipe and Fittings
ASTM D3350
Materials
Standard Test Method for Determination of Carbon Black Content in
ASTM D4218
Polyethylene Compounds by the Muffle-Furnace Technique
ASTM F412 Standard Terminology Relating to Plastic Piping Systems
Standard Specification for Polyethylene (PE) Plastic Pipe (DR-PR)
ASTM F714
Based on Outside Diameter
Standard Specification for Electrofusion Type Polyethylene Fittings
ASTM F1055
for Outside Diameter Controlled Polyethylene Pipe and Tubing
Standard Test Method for Notch Tensile Test to Measure the
ASTM F1473
Resistance to Slow Crack Growth of Polyethylene Pipes and Resins
Standard Specification for Fabricated Fittings of Butt-Fused
ASTM F2206 Polyethylene (PE) Plastic Pipe, Fittings, Sheet Stock, Plate Stock, or
Block Stock
Standard Practice for Heat Fusion Joining of Polyethylene Pipe and
ASTM F2620
Fittings
British Standards Institute (BSI)
BS EN 12201 Part 1 Plastics piping systems - Polyethylene (PE) pipes and fittings for
water supply - General
water supply – Pipes
water supply – Fittings
water supply – Valves
water supply- Fitness for purpose of the system
BS EN 10204 Metallic Product Types of Inspection Documents
International Organization for Standardization
ISO 9000 Quality Management Systems - Fundamentals and Vocabulary
ISO 9001 Quality management systems — Requirements
National Sanitation Foundation (NSF) International
NSF Standard No.61 Drinking Water Systems Components – Health Effects
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If SUPPLIER will use any other standard not listed herein, then it shall be clearly mentioned in
their proposal for CONTRACTOR/ COMPANY approval.
3 TECHNICAL REQUIREMENTS
3.1 General
a) The HDPE Manufacturer shall have a suitable and accredited quality system in
accordance with ISO 9001.
b) The Manufacturer shall identify fabrication processes and activities that affect component
performance and shall ensure that these processes and activities are adequately controlled
in accordance with ISO 9001.
c) HDPE Piping shall be in accordance with API Spec.15LE, BS ISO 4427 Parts 1 thru 3 as
a minimum.
d) The materials selected for all parts of the installations shall have an expected operating
life of at least 25 years in their relevant operating service.
e) HDPE piping for potable water service shall conform to the requirements of NSF
Standard 61.
f) Pipes shall be furnished in minimum lengths of 12m.
3.2 Service Conditions

Service fluid and design condition shall be as per the relevant piping class covered under Piping
Material Specification document no. 8015-0152-WP05-31-750-PI-SP-12001.
3.3 Bill of Material

a) SUPPLIER shall provide Bill of Materials of any additional auxiliary fittings like
couplings, nipples, any other item etc. based on CONTRACTOR’s documents/ isometrics
as per SUPPLIER’s HDPE Piping Material’s connection details or any other reason.
b) SUPPLIER shall submit cross sectional dimensional drawings for all sizes of pipes,
fittings and flanges depicting thickness, OD, end to end dimensions etc. Catalogues
detailing offered items shall also be submitted with the offer.
3.4 SUPPLIER’s Responsibility

CONTRACTOR/ COMPANY will issue preliminary dimensioned isometric drawings for pipe
sizes NPS 2 & above and isometric
a) The rating, design and dimensions to be used for pipe, fittings and flanges shall be as per
Piping Material Specification document no. 8015-0152-WP05-31-750-PI-SP-12001.
b) Flange drilling shall be as per ASME B16.5.
c) CONTRACTOR/ COMPANY will issue preliminary dimensioned isometric drawings for
pipe sizes NPS 2 & above and isometric sketches with overall dimensions for pipe size
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NPS 1½ and below. SUPPLIER shall review these drawings and revise them, if
necessary to suit his design and range of products.
d) SUPPLIER scope includes detail design/ design verification, inclusive of the HDPE
piping stress analysis and supporting, material supply for HDPE system. Fabrication,
installation and testing shall be done by CONTRACTOR personnel trained by
SUPPLIER and under supervision of SUPPLIER. CONTRACTOR scope also includes
approval of the SUPPLIER submissions and transfer of performance guarantee of the
HDPE system from SUPPLIER to CONTRACTOR.
e) The SUPPLIER shall calculate the thickness of the pipes, flanges and fittings as per
design conditions specified in project Line List and Piping Material Specification and
shall be suitable for the specified surge conditions. The SUPPLIER shall prepare
specification for piping fabrication, installation and testing; this specification will be sent
to CONTRACTOR/ COMPANY for review and approval.
f) The SUPPLIER must review the isometric sketch and BOM to verify that the listed item
type and description suit their product. The SUPPLIER must inform CONTRACTOR the
changes, if any necessary, to suit their design and range of product.
g) SUPPLIER shall provide the expansion data, pressure temperature rating charts for pipes
fittings and flanges with increase in temperature.
h) SUPPLIER to submit detail drawings for HDPE pipe supports, minimum support span
details, saddle details etc. The SUPPLIER must identify, wherever required collars for
pipe supports and for special thickness pipes/ elbows/ tees identified based on stress
analysis.
i) The SUPPLIER shall guarantee the overall performance of the system to suit the
pressure, temperature, service and environmental conditions for a design life of 25 years.
j) The SUPPLIER shall furnish maximum recommended bolt torque for flanges in order to
achieve proper sealing without causing distress to the flanges and to the piping system
k) SUPPLIER/MANUFACTURER shall supply all necessary documentation for
receiver/approval covering information mentioned as below
• Minimum allowable bend radius.
• Installation Procedures.
• Maximum allowable distortion to bring piping in alignment.
• Jointing procedures.
• Visual inspection procedures and acceptances criteria for electro fusion welding.
• SUPPLIER shall be responsible for all of the required storage, handling and
transportation.
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3.5 Site Condition

a) HDPE pipe will be laid underground. Above ground HDPE piping is not envisaged for
this project.
b) Design pressure / temperature and fluid service are specified in Appendix 1 of this
document.
c) The civil work and data required for the Design and Installation of pipe shall be done as
per 8015-0152-WP05-00-000-CI-DC-12001 Civil/ Structural Design Criteria, 8015-
0152-WP05-00-000-CI-SP-12004 Specification for Earthworks, Roads and Drainage
System, 8015-0152-WP05-00-000-CI-PH-12001Drainage Philosophy.
d) Vendor shall take into account the nature of soil, External loads (Soil Load, Wheel load)
etc. as per the above said document.
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4 MATERIALS
a) All HDPE pipes and pipe components shall be produced by the same manufacturer. Pipes
and fittings from different manufacturers shall not be interchanged.
b) The SUPPLIER shall ensure that the material is compatible with the service fluids to
which it is exposed over the full design temperature range so that the mechanical,
physical, and chemical properties of the HDPE piping satisfy the design requirements
throughout the intended lifetime.
c) It is the responsibility of the SUPPLIER to review the materials proposed in this
specification and guarantee their suitability to service fluids/ design conditions stated
under Section 3.2 above and Appendix 1 of this document.
d) All basic materials shall be new, fresh and free from all deleterious defects and
imperfections.
e) HDPE material designation for pipes and injection molded fittings shall be PE 100 in
accordance with BS EN 12201.
4.1 Ultraviolet (UV) Protection

HDPE pipes, fittings and flanges shall be provided with long term UV protection (2.0%
to 3.0% carbon black content).
4.2 Gaskets
a) Gasket shall be in accordance with the requirements of Piping Material Specification
document no. 8015-0152-WP05-31-750-PI-SP-12001 (HPDE pipe classes) and
Specification for Gaskets document no. 8015-0152-WP05-31-750-PI-SP-12013 as
applicable.
b) Gasket Material shall match the pressure, temperature and chemical resistance of the
piping system.
4.3 Valves (Supplied by Others)

Valves shall be in accordance with Piping Material Specification, Document no. 8015-0152-
WP05-00-000-PI-SP-12001.
4.4 Bolting
Bolting including washers shall be in accordance with Piping Material Specification document
no. 8015-0152-WP05-00-000-PI-SP-12001 and Specifications for Stud Bolts document no.
8015-0152-WP05-00-000-PI-SP-12014
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5 DESIGN
5.1 Standard Dimension Ratio (SDR)

HDPE (PE 100) pipe and injection moulding fittings shall be designed in considering SDR
11.
5.2 Ovality / Out of Roundness

The ovality of the pipe shall be within limits as specified in para 6.2 of BS EN 12201 Part 2.
The out of roundness of the fittings shall be within the limits as specified in para 6.2.3 of BS
EN 12201 Part 3.
5.3 Dimensions and Tolerances

Line pipe dimensions and tolerances shall be in accordance with BS EN 12201 Part 2.
Fittings dimension and tolerances shall be in accordance to BS EN 12201 Part 3.
5.4 Pipes
a) Pipe outside diameter sizing system shall be as per Table 1 of BS EN 12201 Part 2.
b) HDPE pipes shall be in accordance with thermoplastic material designation PE 100 and
shall be designed considering SDR 11 in accordance with BS EN 12201 Part 2.
5.5 Flanges
a) Flanges shall consist of an HDPE adapter (or stub end) and a Ductile Iron (DI) back-up
ring.
b) The HDPE flange adapters shall be provided with a serrated sealing surface.
c) HDPE flange adapters shall conform to ASTM D3261. The material grade shall be the
same as the pipe it is attached to.
d) The DI back-up ring dimensions and drilled bolt holes shall be in accordance with ASME
B16.5 for sizes up to NPS 24 or B16.47 Series A for sizes NPS 26 and larger.
e) One edge of the inner diameter of DI back-up ring shall be chamfered such that it fits
with the back of the HDPE flange adapter.
f) Unless otherwise specified, spectacle blinds, blanks and spacers shall confirm to ASME
B16.48 shall be quoted with PE from both sides.
5.6 Fittings
a) Fittings under this specification are elbows, reducers, tees, adaptors and couplers.
b) All pipe fittings molded or fabricated shall meet the full pressure rating specified in the
piping class.
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c) As far as possible all branch connections shall be achieved either by equal tees or
reducing tees only. The use of saddles shall be limited to where reducing tees are not
available in SUPPLIER's range.
d) Fitting shall be of same material and shall have at least the same chemical and
mechanical properties as the pipe on which they are intended to be fitted.
g) The effective total wall thickness, calculated in accordance with the requirement of
ASME B31.3 Chapter VII, shall be suitable for the specified pressure and temperature
conditions.
h) HDPE pipe fittings shall conform to ASTM D3261.
5.7 Process of Manufacture

All pipes and fittings shall be manufactured in accordance with BS EN 12201 and suitable
for the design conditions mentioned in Appendix 1.
5.8 Types of Connections

a) The piping connections shall be either of the following acceptable joining system:
• Thermal heat fusion
o Electrofusion
• Mechanical fittings
o Flanged connection - Flange adapter and stub ends
o Mechanical couplings that are fully thrust-restrained
b) Mechanical couplings that are not fully thrust-restrained by design are not permitted.
c) SUPPLIER shall confirm that joints will not degrade and suitable for 25 years design life.
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6 FABRICATION
6.1 Heat Fusion Joining

a) Thermal fusion joining (electro-fusion) shall be in accordance with ASTM F2620 and the
Manufacturer’s detailed written procedure.
b) Thermal fusion joining procedures shall be submitted for COMPANY review and
approval.
c) The CONTRACTOR shall ensure that all personnel performing heat fusion joints have
received training in the Manufacturer’s recommended procedure.
d) Joints between plain end pipes and fittings shall be made by butt fusion or electro-fusion,
and joints between the main and saddle branch fittings shall be made by saddle fusion.
e) Butt fusion joining between pipe/fitting ends with same outside diameter and unequal
wall thickness is permitted only if the difference in standard dimension ratio (SDR) of the
two pieces is two SDRs or less.
f) Component ends to be joined shall be clean, dry and free of detrimental surface defects.
g) Transitions between the same outside diameters and unequal wall thicknesses greater
than two standard dimension ratios (DRs) shall be made with transition nipple (a short
length of the heavier wall pipe with one end machined to the lighter wall) or by
mechanical means.
h) The EPC CONTRACTOR shall be responsible to verify that the fusion equipment is in
good operating condition and that the operator has been trained within the past twelve
(12) months. The fusion equipment shall be equipped with a data logger. Records of the
welds (heater temperature, fusion pressure, and a graph of the fusion cycle) shall be
maintained for five (5) years. Fusion beads shall not be removed.
6.2 Mechanical Joining

a) HDPE pipe and fittings may be joined together or joined to other materials by either
flange connections (flange adapters and back-up rings) or mechanical couplings designed
for joining HDPE pipe or for joining HDPE pipe to another material.
b) Mechanical couplings shall be fully pressure-rated and fully thrust-restrained such that
when installed in accordance with Manufacturer’s recommendations, a longitudinal load
applied to the mechanical coupling will cause the pipe to yield before the mechanical
coupling disjoins.
c) External joint restraints shall not be used in lieu of fully restrained mechanical couplings.
6.3 Branch Connections

a) Branch connections to the main shall be made with saddle fittings or tees.
b) HDPE saddle fittings shall be saddle-fused to the main pipe.
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7 INSTALLATION
7.1 General
a) Installation shall be in accordance with the Manufacturer’s recommendations and this
specification.
7.2 Mechanical Joint and Flange Installation

a) Flange faces shall be centered and aligned to each other before assembling and tightening
bolts. In no case shall the flanged bolts used to draw the flanges into alignment.
b) Bolt threads shall be lubricated and flat washers shall be fitted under the flange nuts.
Bolts shall be evenly tightened to the torque step recommendations of the Manufacturer.
c) Gasket and flange sealing surfaces must be clean and free of significant cuts or gouges,
d) 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
recommended.
7.3 Pipe Handling

a) When lifting with slings, only wide fabric choker slings shall be used to lift, move or
lower pipe and fittings. The use of wire rope or chain is not permitted.
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8 QUALITY PROGRAMME
8.1 Quality Manual

The Manufacturer shall maintain a quality manual, which describes the quality program and shall
be submitted to client for review.
8.2 Process and Quality Control Requirements

The Manufacturer shall institute and maintain a documentation programme to assure
communication of approved manufacturing and inspection procedures to qualified receiving,
manufacturing and quality control personnel, and their respective supervisory personnel. The
following procedures shall be submitted to the COMPANY for review and approval:
a) Raw material acceptance
b) Pipes manufacturing procedures
c) Welding procedures and qualifications
d) Inspection and test procedures
8.3 Quality Control Equipment
8.3.1 General
Equipment used to inspect, test or examine material or other equipment shall be identified,
controlled, calibrated and adjusted at specified intervals and accordance with documented
Manufacturer instructions, and consistent with referenced industry standards to maintain the
accuracy required by this specification.
8.3.2 Dimensional Measuring Equipment

Dimensional measuring equipment shall be controlled and calibrated by the Manufacturer’s
written specification / procedures.
8.3.3 Pressure Measuring Devices

a) Test pressure measuring devices shall be either pressure gauges or pressure transducers.
b) All pressure measuring devices shall be calibrated to a certified standard annually.
8.4 Quality Control Tests
8.4.1 Conditioning
Unless otherwise specified by the applicable test method, the test pieces shall be conditioned at
(23 ± 2 ⁰C) before testing in accordance with Table 5 of BS EN 12201 Part 2.
Test description and frequency shall be as per BS EN 12201 Part 2 and this specification.
8.4.2 Retest and Rejection

When the pipe fail to meet the specification requirements of any test, additional test shall be mad
on the products produced, back to the previous acceptable results. The pipe produced in the
interim that do not pass the requirements shall be rejected.
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8.5 Test, Examination, Inspection, Rejection and Compliance
8.5.1 General
a) Quality control of raw materials, finished products, and physical properties examination
are determined from test methods according to referenced codes, specifications, and
standards as mentioned in Section 2.
b) Testing and controlling can be witnessed by the CONTRACTOR.
c) Test result will be reported in test reports submitted by SUPPLIER.
8.5.2 Inspection by the COMPANY

a) All Quality Control tests shall be witnessed by a COMPANY-appointed representative at
the start of production and monitored thereafter at the discretion of the COMPANY.
b) Where the inspector representing the COMPANY desires to inspect the pipes or witness
quality control tests, a minimum of 48 hours notice by the Manufacturer shall be given of
the time at which the run is to be made.
c) Manufacturing or testing procedures required to be reviewed by the COMPANY shall be
submitted a minimum of two weeks prior to the commencement of production unless an
earlier date is specified in the Purchase Order.
8.5.3 Manufacturing Test

a) The pipe manufacturer shall perform and give evidence of the relevant ASTM testing of
materials and/ or components used in the manufacture of the HDPE pipes and fittings.
Test reports shall be traceable to the lot of pipe furnished and correctly listed and
identified in inspection reports.
b) The following tests are for proof of design only and need not be made on pipe
manufactured specifically for this project. Report is to be certified by independent
authorities.
• Density in accordance with ASTM D1505.
• Melt index in accordance with ASTM D1238
• Flexural modulus in accordance with ASTM D790.
• Tensile strength at yield in accordance with ASTM D638.
• Slow crack growth resistance in accordance with ASTM D1693 or ASTM F1473
• Hydrostatic strength classification in accordance with ASTM D2837
8.5.4 Site Visual Examination

Butt fusion joints shall be visually examined to ensure joint quality. The inspection and
acceptance criteria shall be in accordance with the Manufacturer’s recommendation and as a
minimum shall be as follows.
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a) The width of double bead of the butt fusion shall be 2 to 2.5 times the height of the bead
from the pipe surface.
b) The depth of V-groove between the beads shall not be more than half the bead height.
c) The double bead shall be uniform in size and shape all around the joint.
d) The above visual examination shall apply to both outside and inside fusion beads and
inside fusion beads. Inside fusion beads shall be examined when accessible, such as at a
flange adapter, the first fission of an elbow, and first and second fusion at a tee.
8.5.5 Butt Fusion Testing

a) A trial fusion test for each fusion operator shall be conducted first on each day of work.
b) The trial fusion shall be allowed to cool completely, then fusion test straps shall be cut
out.
c) Butt fusion welds shall be tested by cutting a 300 mm long ring section of the HDPE pipe
with the butt fusion weld area centered. Four strips 90° apart, shall be cut out for visual
examination and a bend test. The width of the test bend strips shall be equal to the
thickness of the pipe or 25 mm whichever is greater.
d) The cross section of the fusion weld shall be examined visually, and shall contain no
voids or discontinuities.
e) The bend test consists of the following steps:
• Each test strip is clamped in a vise 25 mm under the weld bead.
• A steel extension pipe of appropriate diameter and length is then slipped over the free
end of the specimen to 25 mm above the weld bead.
• The bend test is performed by bending the test specimen a minimum of 90° in the
direction that places the concave interior surface surface/root of the pipe wall weld in
tension. No failures in the butt fusion area are permitted for the four test strips.
f) If the fusion fails at the joint , a new trial fusion shall be made, cooled completely and
tested
g) Butt fusion of pipe to be installed shall not commence until trial fusion has passed the
bending test.
8.5.6 Hydrostatic Test

a) The completed piping systems shall be fully hydrostatically tested at a pressure as stated
on the applicable isometric drawing at ambient temperature after erection.
b) Hydrostatic testing shall be in accordance with Hydrostatic Test Specification, document
no. 8015-0152-WP05-00-000-PI-SP-12020.
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8.5.7 Rejection
Material that shows injurious defects on plant inspection or subsequent to acceptance at the
Manufacturer’s works or which proves to be defective when properly applied in service may be
marked and rejected and the Manufacturer so notified.
8.5.8 Compliance
The Manufacturer is responsible for complying with all of the provisions of this specification.
The Principal may make any investigation necessary to satisfy himself of compliance by the
Manufacturer and may reject any material that does not comply with the specification.
8.6 Quality Control Records Requirements
8.6.1 Purpose
The quality records required by this specification are necessary to substantiate that all materials
and products made to meet this specification do conform to the specified requirements.
8.6.2 QA / QC Plan
The SUPPLIER is required to prepare/ submit along with his bid document a proposed “Quality
Assurance/ Quality Control Plan” including the following as a minimum:
a) General quality policies, procedures and practices of the SUPPLIER and its Sub-
SUPPLIER, if any.
b) The organization structure, responsibilities, activities, resources and events that together
provide organized procedures and method of implementation to ensure the capability of
the organization to meet quality requirements.
c) A particular QA/ QC plan defining the specific quality procedures and practices,
resources and activities for the implementation of the Project Works. This QA/ QC plan
should cover as a minimum:
• Origin and traceability of SUPPLIER supplied material,
• Qualification of personnel,
• Quality control of the work (welding procedures, inspection, test, acceptance
certificates, non-conformity report, etc.)
d) Equipment used to inspect, test or examine material or other equipment shall be
identified, controlled, calibrated and adjusted at specified intervals in accordance with
documented Manufacturer instructions, and consistent with referenced industry standards
to maintain the accuracy required by this specification.
e) Dimensional measuring equipment shall be controlled and calibrated by the
Manufacturer’s written specification / procedures.
f) Test pressure measuring devices shall be either pressure gauges or pressure transducers.
All pressure measuring devices shall be calibrated to a certified standard annually.
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g) When pipe fail to meet the specification requirements of any test, additional tests shall be
made on the products produced, back to the previous acceptable results. The pipe
produced in the interim that do not pass the requirements shall be rejected.
8.6.3 QC Records
Quality Control records shall be prepared and submitted by the SUPPLIER to the
CONTRACTOR at the proper time during the execution of the works, and a record file shall be
maintained and issued with the final SUPPLIER documentation on completion of the work.
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9 PREPARATION FOR SHIPMENT
9.1 Packing
a) Pipes, fittings, etc. shall be packed in a manner which will ensure arrival at destination in
a satisfactory condition and which will be acceptable. Crates will be constructed in the
most economical manner and are provided with skids to facilitate handling by forklift
truck. In case of nesting, pipes will be provided with suitable fillers between pipe walls.
b) Socket weld ends shall be protected by polyethylene covered straw mats.
c) Shipments from the works are made in wooden cases or in special containers.
d) Each layer of pipes is separated from the next layer by planks not more than 2m apart.
Planks thickness must be such that the bell ends do not touch other pipes or pipe ends.
e) Prior to packing, the SUPPLIER shall ensure that all the items shall be marked with
identification number for identification at site yard.
f) Any damage resulting from the poor packing will be to the account of SUPPLIER and
shall be replaced at no extra cost within the construction period.
g) Coil may be stored either on edge or stacked flat one on top of the other, but in either
case, they should be allowed to come into contact with hot water or steam pipes and
should be kept away from hot surfaces. Coils of large diameter, i.e. 1 1/2 (38 mm) and
larger, should not be stored on edge.
h) Supplier shall be responsible for the storage of finished goods, or parts thereof, for the
full period (till completion of the project) at Supplier’s works. Polyethylene pipe or coils
shall not be dragged over rough ground resulting in any damage by abrasion and by
objects with a cutting edge. In case of any damage or kink formation, the damaged
portion shall be cut out completely.
9.2 Identification
a) All pipes, flanges, and fittings must be permanently marked by the Manufacturer with the
following information:
• Name of Manufacturer and name of product
• Class of material according to standards (if any)
• Nominal diameter
• Date of fabrication (year, month, day) in clear
b) The Inspection AGENCY:
• Must also affix its mark on the pipes, flanges, and fittings it has inspected in
conformity with this specification and which it has accordingly accepted
• An indelible “Rejected” mark must be applied to defective parts.
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10 DOCUMENTATION
10.1 Manufacturer’s Drawings

The manufacturer shall supply to the COMPANY, certified drawings with the dimensions and
tolerances of the materials subject to the purchase requisition.
10.2 Installation Manual

The SUPPLIER will supply to the COMPANY its installation manual describing the
recommended methods for:
a) Transport and storage of finished products (loading, unloading, handling)
b) Storage of base materials,
c) Jointing and preparation methods for adhesive bounded joint, flanged joint, mechanical
coupler, etc. (method statement)
d) Tools and tackles required for field fabrication
10.3 Safety Precautions

The manufacturer will supply to the COMPANY its safety manual describing the precautions to
be exercised when processing HDPE piping products.
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11 APPENDICES
Appendix-1 : Design Condition and Fluid Service
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Appendix-1: Design Condition and Fluid Service (NOTE-1)
ASME B16.5 Flange

Design Temp. (°C)
Design Pressure.
Max. Size NPS
Base Material
Pipe Material
ASME Class
Design Code
Piping Class
CA (mm)
Service
Group
(barg)
(Underground Service)
Manufacture Standard
Potable Water,
ASME B31.3
(NOTE-1)
7 to 50
HDPE
150 FF
HDPE
10
36
0
NOTE-1: EPC CONTRACTOR to advise, subject to COMPANY approval.
8015-0152-WP05-00-000-PI-SP-12017_ 00.docx

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FORMATION DEVELOPMENT FEED

DOCUMENT REVISION HISTORY SHEET

REV STATUS DATE ISSUED UPDATE / AMENDMENT DETAILS

A IDC 02-10-2014 INTER DISCIPLINE CHECK

B IFR 12-10-2014 ISSUED FOR REVIEW

C IFA 30-11-2014 ISSUED FOR APPROVAL

00 AFD 18-12-2014 APPROVED FOR DESIGN

1.1 Purpose ........................................................................................................................... 6

1.2 Scope ............................................................................................................................... 6

1.3 Definitions and Abbreviations ....................................................................................... 6

1.4 Units of Measurements ................................................................................................... 8

2.1 Order of Precedence ....................................................................................................... 9

2.2 Project Reference Documents ........................................................................................ 9

2.3 International Codes and Standards ............................................................................... 9

3.1 General ......................................................................................................................... 12

3.2 Service Conditions ........................................................................................................ 12

3.3 Bill of Material ............................................................................................................. 12

3.4 SUPPLIER’s Responsibility ......................................................................................... 12

3.5 Site Condition ............................................................................................................... 14

4.1 Ultraviolet (UV) Protection .......................................................................................... 15

4.3 Valves (Supplied by Others) ........................................................................................ 15

4.4 Bolting ........................................................................................................................... 15

5.1 Standard Dimension Ratio (SDR) ................................................................................ 16

5.2 Ovality / Out of Roundness .......................................................................................... 16

5.3 Dimensions and Tolerances.......................................................................................... 16

5.4 Pipes .............................................................................................................................. 16

5.5 Flanges .......................................................................................................................... 16

5.6 Fittings .......................................................................................................................... 16

5.7 Process of Manufacture................................................................................................ 17

5.8 Types of Connections ................................................................................................... 17

6.1 Heat Fusion Joining...................................................................................................... 18

6.2 Mechanical Joining....................................................................................................... 18

6.3 Branch Connections ..................................................................................................... 18

7.1 General ......................................................................................................................... 19

7.2 Mechanical Joint and Flange Installation ................................................................... 19

7.3 Pipe Handling ............................................................................................................... 19

8.1 Quality Manual ............................................................................................................ 20

8.2 Process and Quality Control Requirements ................................................................ 20

8.3 Quality Control Equipment ......................................................................................... 20

8.4 Quality Control Tests ................................................................................................... 20

8.5 Test, Examination, Inspection, Rejection and Compliance ........................................ 21

8.5.6 Hydrostatic Test.......................................................................................................... 22

8.6 Quality Control Records Requirements ...................................................................... 23

9.1 Packing ......................................................................................................................... 25

9.2 Identification ................................................................................................................ 25

10.1 Manufacturer’s Drawings ............................................................................................ 26

10.2 Installation Manual ...................................................................................................... 26

10.3 Safety Precautions ........................................................................................................ 26

1.3 Definitions and Abbreviations

Inspector COMPANY nominated third party or COMPANY designated

PROJECT Formation Development FEED 2 Project,

Shall and must Indicate mandatory requirements

Should indicate that the provision is not mandatory, but recommended

SUPPLIER/ The Organization selected to manufacture or supply the

SUB-SUPPLIER The Organization selected by the SUPPLIER to supply the part

API American Petroleum Institute

1.4 Units of Measurements

2.2 Project Reference Documents

Document Number Description

2.3 International Codes and Standards

Document Number Description

Document Number Description

Document Number Description