ISSUED FOR

USE (IFU)
26-MAY-2011
 WEST QURNA I SPECIFICATION-PLASTIC AND
PLASTIC-LINED PIPE

SCOPE

[I] This Project Engineering Specification covers the materials, design, fabrication, inspection, and
testing of plastic and plastic-lined piping. It covers thermoplastic pipe such as high density
polyethylene pipe (HDPE) and Polypropylene (PP), as well as thermoplastic-lined ferrous metal
piping.
Note: This Project Engineering Specification does not contain requirements for Reinforced
Thermosetting Resin Pipe (RTRP).

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TABLE OF CONTENTS

SCOPE .............................................................................................................................................2

1.0 REQUIRED REFERENCES ................................................................................................4

1.1 Project Engineering Specifications ....................................................................4

1.2 ASME–American Society of Mechanical Engineers..........................................4
1.3 ASTM–American Society for Testing and Materials..........................................4
1.4 AWWA–American Water Works Association.....................................................4
1.5 NFPA – National Fire Protection Association....................................................4

2.0 DEFINITIONS......................................................................................................................5

3.0 DOCUMENTATION.............................................................................................................6

4.0 DESIGN AND LIMITATIONS..............................................................................................7

5.0 INSTALLATION ..................................................................................................................9

6.0 INSPECTION AND TESTING .......................................................................................... 10

7.0 PREPARATION FOR SHIPMENT ................................................................................... 11

ATTACHMENT: PURPOSE CODE DEFINITIONS ..................................................................... 12

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1.0 REQUIRED REFERENCES

This Section lists the Project Engineering Specifications, codes, standards, and publications that
shall be used with this document. Unless otherwise specified herein, use the latest edition.

1.1 Project Engineering Specifications

IQWQ-FT-LSPDS-00-030101 Upstream Piping Component Selection and System Design

IQWQ-FT-LSPDS-00-032002 Upstream Piping Classification - Line Classes Atmospheric
and 125

1.2 ASME–American Society of Mechanical Engineers

ASME B31.3 Process Piping

1.3 ASTM–American Society for Testing and Materials

ASTM D 2563 Standard Practice for Classifying Visual Defects in Glass-Reinforced

Plastic Laminate Parts
ASTM D 2657 Standard Practice for Heat Fusion Joining of Polyolefin Pipe and
Fittings
ASTM D 2846/D 2846M Standard Specification for Chlorinated Poly(Vinyl Chloride) (CPVC)
Plastic Hot- and Cold-Water Distribution Systems
ASTM D 3035 Standard Specification for Polyethylene (PE) Plastic Pipe (DR-PR)
Based on Controlled Outside Diameter
ASTM F 1545 Standard Specification for Plastic-Lined Ferrous Metal Pipe, Fittings,
and Flanges

1.4 AWWA–American Water Works Association

AWWA C901 Polyethylene (PE) Pressure Pipe and Tubing, 1/2 in. (13 mm) Through 3 in.
(76 mm), for Water Service
AWWA C906 Polyethylene (PE) Pressure Pipe and Fittings, 4 in. (100 mm) Through 63 in.
(1,575 mm), for Water Distribution and Transmission
AWWA M55 PE Pipe - Design and Installation

1.5 NFPA – National Fire Protection Association

NFPA 24 Standard for the Installation of Private Fire Service Mains and Their
Appurtenances

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2.0 DEFINITIONS

Term [I] Description

Combustible High flash liquids [flash points 38C (100F) or higher] when handled at
Liquids temperatures 8C (15F) below their flash point and lower.
Flammable Low flash liquids [flash point below 38C (100F)] and high flash liquids
Liquids [flash point 38C (100F) or higher] when handled at temperatures
above or within 8C (15F) of their flash points.
Flammable Flammable liquids; hydrocarbon vapors; and other vapors, such as
Materials hydrogen and carbon disulfide, that are readily ignitable when released
to atmosphere.
Reliability Critical Piping and Equipment that has a credible failure mode with an assigned
Equipment Consequence of Level I or Level II per the Company Risk Matrix.
Safety, Health and Any device (mechanical, pneumatic, hydraulic, electrical, or electronic),
Environment system, or subsystem functioning as the last line of defense to prevent,
(SHE) Critical or as vital in mitigating, one or more of the following potential scenarios:
Equipment
 An uncontrolled major breach of containment of flammable or toxic
materials
 A process-related incident with the potential for severe injuries or
death
 A release of materials that could have a serious environmental
impact
 A breach of security access that has the potential for sabotage or
other serious consequences
Toxic For the definition of Toxic, refer to IQWQ-FT-LSPDS-00-030101 Section
titled "Terms"

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3.0 DOCUMENTATION

1) [O] [R] Temperature, pressure, and fluid service conditions will be supplied by Purchaser.
2) [S] [A] [R] As part of the proposal, the following data shall be submitted to Purchaser for
approval by the Owner's Engineer.
a) Product information including pipe specifications, Material Safety Data Sheets (MSDS),
installation instructions, and detailed joining procedures
b) Verification that the pipe is suitable for the service
c) Pipe inspection and testing procedures
d) Pipe transportation and storage information and details
e) Pipe systems installation precautions and recommendations

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4.0 DESIGN AND LIMITATIONS

1) Thermoplastic and plastic-lined pipe shall conform to the referenced standards. Polyethylene
(PE) pipe shall be in accordance with ASTM D 3035 and AWWA C906.
2) [S] Plastic piping (excluding plastic-lined piping) shall not be used in aboveground flammable
materials or combustible liquid services. Plastic pipe shall not be used in any other
aboveground application where the piping meets the definition of SHE Critical equipment.
3) [R] [A] Plastic pipe shall not be used in aboveground application where the piping meets the
definitions of Reliability Critical equipment unless approved by the Owner's Engineer.
4) [R] Plastic piping in aboveground applications shall be provided with ultraviolet (UV)
protection by use of a resin additive for thermoplastic pipe (such as HDPE). UV protection for
transportation and storage shall also be considered for underground applications.
5) [I] To determine the external design pressure for plastic pipe installed under ground, under
water, or in other situations that cause external pressure, a safety factor of four must be
applied to the critical buckling pressure considering all imposed loads.
6) [O] Flanged joints used in plastic-lined piping shall be per the following:
a) Nonflammable or noncombustible service—The liner shall be molded or shaped (lapped
over the flange faces) to provide the gasket for the joint.
b) Flammable materials, combustible liquid, or hazardous liquid service—The flanged joint
shall be designed to prevent leakage under exposure to heat sufficient to destroy or melt
the lining material.
7) [O] [R] Maximum allowable deflection of thermoplastic pipe, at maximum operating pressure,
shall be defined by pipe Manufacturer, taking into account applicable live and dead loads.
8) [O] [R] Temperature limits for plastic and plastic-lined pipe shall be per Manufacturer's
recommendations and per Table 1 below.

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Table 1: Temperature Limits for Plastic Pipe

Temperature Limitation(1)

Material(3) Minimum Maximum(2)

F C F C

CPVC Chlorinated Polyvinyl Chloride 50 10 140 60

PP (Polypropylene) 30 –1 210 99
PVDC (Polyvinylidene Chloride) 40 5 160 71
PTFE (Polytetrafluoroethylene) –20 –29 400 205
FEP (Perfluoro (Ethylene-Propylene) –20 –29 300 149
Copolymer)
ETFE (Ethylene-tetrafluoroethylene) –20 –29 300 149
HDPE (High Density Polyethylene) –20 –29 140 60
PFA (Perfluoroalkoxy) –20 –29 500 260
PVDF (Polyvinylidene Fluoride) 0 –18 275 135
Notes:
(1) For exposure to corrosive environments, the recommendation of the pipe
Manufacturer shall be submitted for review by the Owner's Engineer.
(2) Values represent maximum design temperature of contained fluid.
(3) For materials not listed, temperature limitations shall be per Manufacturer's
recommendations.

9) [O] [R] Pipe lengths shall not exceed six (6) meters (20 feet) for plastic linings in order to limit
differential thermal expansion between the pipe and the lining.
10) [O] [M] As-Built drawings shall be furnished by Purchaser.
11) For applicable standards and additional information on piping material classification
requirements, on Chlorinated Poly Vinyl Chloride (CPVC) and High Density Polyethylene
(HDPE), refer to IQWQ-FT-LSPDS-00-032002.
12) [R] Non-metallic piping systems design and installation shall meet with the requirements of
ASME B31.3, AWWA Manual M 55 for PE, and ASTM D 2846/D 2846M for CPVC piping
systems.
13) [R] Piping stress analysis shall be carried out as applicable to the installation, to verify
systems performance per the requirements of ASME B31.3 and AWWA M55, taking into
account all operating and upset conditions, e.g., seismic, surge, vacuum, etc.

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5.0 INSTALLATION

1) [O] Installation (including joint makeup) shall be in accordance with Manufacturer's

specification.
2) [O] [R] Plastic pipe shall be installed only by qualified personnel approved by the pipe
Manufacturer.
3) [*] [O] Plastic spacers are permitted between plastic-lined pipe and other types of flanged
equipment in nonflammable or noncombustible service. Spacers longer than thirteen (13)
millimeters (1/2 in.) shall be armored. Spacer locations shall be indicated on As-Built
drawings.
4) [A] [O] [R] PE and PP piping shall be joined by heat fusion welding only. Heat fusion
welding procedures and welders shall be qualified per the Bonding Procedure Specifications
(BPS) requirements for Normal Service per Section A328.2.1 of ASME B31.3 and per ASTM
D 2657. These shall be reviewed and approved by the Owner's Engineer prior to plastic pipe
installation. Each qualified bonder shall be identified by a unique certification number.
5) Flanges shall be used, as required, to connect dissimilar systems. Flange bolts shall be
tightened as recommended by thermoplastic manufacturer.
6) [A] A piping system installation procedure shall be developed and submitted for Company
approval. This procedure shall include, but not be limited to, material handling,
transportation, storage, and spool fabrication. For buried piping, trenching, bedding, and
backfill requirements shall be included.

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6.0 INSPECTION AND TESTING

1) [R] Prior to start of work, a successful mockup of the joining process for plastic pipe shall be
completed and inspected as follows:
a) [*] Mockup shall use the same type and largest size of pipe to be used on the job. For
pipe sizes larger than one hundred fifty (150) millimeters (6 inches), two mockups are
required, utilizing the smallest and the largest size pipe or as otherwise specified by
Company. The acceptance criteria for bonds shall meet the requirements of ASME
B31.3, Section A341.3.2 titled "Acceptance Criteria."
b) [A] Thermoplastic pipe mockups, including fusion bonders qualification joints, shall be
hydrostatically tested per ASME B31.3, Section A328.2.5.c) titled "Qualification Tests." A
hydrotest procedure shall also be submitted for Company approval.
c) [A] Mockups shall be witnessed and documented by the Owner's Inspector, with
documentation reflecting satisfactory completion of the mockup(s) submitted to the
Owner for approval.
2) [O] Inspection of thermoplastic-lined pipe and fittings shall be per ASTM F 1545.
3) [R] Inspection of the fusion joining process for thermoplastic pipe (such as HDPE) shall
include verification of pipe alignment, heater temperature, heating time, fusion pressure, and
cool times. These parameters shall be documented in individual weld joint field reports and
shall be in compliance with the BPS.
4) [R] Inspection of plastic pipe fabricated by adhesive bonding shall include verification of
correct adhesive, cleanliness of surfaces to be joined, ambient conditions required by
adhesive Manufacturer, amount of adhesive applied, visibility of excess adhesive on internal
and external surfaces, and adhesive cure time dictated by ambient temperature.
5) [O] After installation, plastic piping shall not be hydrostatically tested until all fusion joints
have cooled to ambient temperature and all solvent cemented joints or adhesive bonded
joints have fully cured.
6) [A] A hydrostatic test procedure for the installed piping system shall be developed, per the
requirements of ASME B31.3, Section A345 titled "Testing," and submitted for approval. The
procedure shall include the following requirements:
a) Hydrostatic test pressure shall be as stated in project line list.
b) Prior to the hydrostatic testing of buried installation, piping shall be partially backfilled
(straight pipe only) between joints to restrain the pipe during the test.
c) The hydrotest hold time after pressure stabilization shall be a minimum of 2 hours or time
required to inspect all exposed joints. No leakage at bonded joints is permitted.
d) Hydrostatic testing of Fire Water piping shall include requirements of NFPA 24.
e) Any leakage detected during hydrotest must be cut out and replaced.

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7.0 PREPARATION FOR SHIPMENT

[O] After completion of inspection, all pipe and fittings shall be prepared for shipment as follows:
1) Flanges shall be protected over the entire gasket surface with wood and hardboard
protectors bolted hand tight with at least four bolts.
2) Socket welding-end connections shall be fitted with wood or plastic plugs or caps.
3) Thermoplastic pipe shall be shipped on racks or an equivalent that will give continuous
support and prevent sagging or draping.

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ATTACHMENT: PURPOSE CODE DEFINITIONS

Code Description

* Assigned to paragraphs that require the Owner's Engineer to provide additional information or
make a decision.
A Assigned to paragraphs that require approval from the Owner's Engineer before the work may
proceed or the design is finalized.
C Assigned to paragraphs whose primary purpose is reduced costs. Reduced cost in this
context refers to initial investment cost and does not include life cycle cost considerations. Life
cycle cost considerations are captured under reliability, maintainability, or operability purpose
codes.
E Assigned to paragraphs whose primary purpose is driven by environmental considerations.
Environmental considerations typically include specifications intended to protect against
emissions/leakage to the air, water, and/or soil. Deviations from the specifications contained in
such paragraphs require formal review and approval according to local environmental policy.
I Assigned to paragraphs that provide only clarifying information, such as Scope statements,
definitions of terms, etc.
M Assigned to paragraphs whose primary purpose is to provide for maintainability of equipment
or systems. Maintainability provisions are those that facilitate the performance of maintenance
on equipment/systems either during downtimes or during onstream operations.
O Assigned to paragraphs whose primary purpose is to assure operability of equipment or
systems. Operability is the ability of the equipment/system to perform satisfactorily even
though conditions are off-design, such as during start-ups, process swings, subcomponent
malfunction, etc.
R Assigned to paragraphs whose primary purpose is to improve or assure the reliability of
equipment or systems. Reliability is a measure of the ability of equipment/systems to operate
without malfunction or failure between planned maintenance interventions.
S Assigned to paragraphs containing specifications/guidance where the primary purpose is the
avoidance of incidents impacting personnel safety, operational safety, and the public in
general and/or involving responses to emergency situations. Any deviation from the
specifications contained in such designated paragraphs requires formal review and approval
according to local safety policy.
Personnel Safety: Refers to incident-related personnel injuries or illness, e.g., burns, cuts,
abrasions, inhalation of or exposure to dangerous substances, etc., that
could result in medical treatment, restricted work, lost-time incidents, or
fatalities.
Operational Refers to the prevention and control of process releases, fires, and/or
Safety: explosions that could result in damage to equipment, process disruption,
or personnel injury or illness.

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