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Fiber Glass Systems (Pipex)

Navy overview

Royal Australian Navy, Australia, October 2017

Advanced design

Delivering first-class engineering solutions

Subsea 7, Seven Atlantic Diving Support Vessel 3D laser scan

For over 40 years Pipex px® have been the industry leader in engineering, expert technical services & design consultancy of GRE piping systems, FRP composite structures & thermoplastic drainage & civils, providing high-performance products with reduced weight & corrosion resistance.

Our expert engineering team provides first-class solutions, uniting Advanced Design & Advanced Manufacturing for prestigious projects across the globe.

3

Phenolic FRP HVAC access structure, BP Clair Ridge

Structural design solutions - Subsea

• Combined design & manufacturing to produce high-quality structures of strength, corrosion resistance, low-weight & extended operational life

• Engineering includes mechanical, FEA, advanced laminate design, weight optimization, deployment & retrieval analysis

4

Anode ICCP Frames

Seabox Treatment unit

Structural design solutions – Offshore

5

• MARRS® OFFSHORE phenolic FRP handrail system, a patented proprietary product designed & engineered for offshore topside applications

• MARRS® OFFSHORE handrails have undergone rigorous testing & regulatory acceptance, including load testing, extreme temperature, salt exposure, fire testing, wear testing & NORSOK compliance

• 700+ tonnes weight saved with FRP handrails, structures, gates & ladders, grating, piping, and pressure vessels

BP Clair Ridge Platform, UK North Sea

MARRS® OFFSHORE handrail

Finite element analysis (FEA)

• Utilised for complex geometry & laminate design

• Provides behavioral evaluation for optimization of designs in both static & dynamic environments

• More complex designs may require Computational Fluid Dynamics (CFD)

6

Dover Sea Wall, replacement hybrid footbridge

Subsea Anode ICCP skid frame

Piping design, assistance & verification

• General arrangements

• Developing pipe specifications

• Pipe routing & coordination

• Isometrics – fabrication & installation

• Spool details

• Support design

• Verification of customer designs

7

All photos: BP API sandfilters

Caesar II piping stress analysis

• The most widely used pipe flexibility & stress analysis software for optimal design

• Evaluates & confirms structural & operational integrity of process piping systems to ensure compliance/accordance to international piping codes & standards

• Loads to enable pipe support design

• Direct link between CAESAR II and CadWORX plant BP Grangemouth – replacement 8” oily water line from 36 diameter tank. 3D Laser Scanned > Overlayed with CADWorx> Output to Caesar II.

8

Composite pressure vessel design

9

• Includes design, test, qualification, manufacture & supply up to 40” diameter` & 80 barg

• Design standards ASME X, BS EN 13923, BS EN 13121, OS DNV C501

• Application examples - sea water reverse osmosis (SWRO), ultra filtration, coarse filters

FEA of composite pressure vessel section

Large diameter ASME X pressure vessels

Surveys - including 3D laser & dimensional control

Offshore surveys• Trained personnel can be mobilized offshore at short

notice to survey or repair GRE piping issues & FRP structures

3D laser surveys• Cutting edge scanning equipment & interpretation

software• Highly accurate & detailed drawings produced

10

Nexen Buzzard drip trays

BP Kinneil pipe layout

Innovation, research & development

• From concept to prototype manufacture to final product – all completed in-house

• Includes laminate design, 3D printing & prototyping, optimization, & final product

• Commitment to ADAM, providing sustainable, high-performance one-stop-shop solutions

• Rich portfolio of project examples including SWRO pressure vessels, DSW footbridge, PLA HUMP, railway platform composite coper stone & specialist subsea structures

11

Dover Sea Wall Hybrid Footbridge

Static Gap Filler Coper

Bespoke tooling designl, Type 26

Advanced manufacturing

Continuous reinvestment into our factory facilities has created a space of Advanced Design & Advanced Manufacturing (“ADAM”) under one roof offering clients unique precision engineering & problem solving. We combine expertise & cutting-edge engineering techniques to turn customer concepts into reality. Facilities include:

• Resin Infusion Composite Engineering (R.I.C.E.) facility – 140,000 sq foot state-of-the-art space dedicated to large off-site manufacturing for bespoke shapes & structures

• R.I.C.E. is home to one of the UK’s largest 5-axis CNC machines• Specialist manufacturing equipment, designed & built in-house• Multi-skilled fabricators, with 24/7 production available• Testing facilities (dropped impact etc.) and In-house quality assurance system

Resin Infusion Composite Engineering

• Numerous international recognised accreditations held across all business divisions and UK Manufacturing facilities, including third party accreditations ISO 9001, ISO 14001 and OHSAS 18001

• Additional accreditations held & maintained in line with various industry requirements within Oil & Gas and Nuclear market sectors

• Products are manufactured in accordance with various industry specific standards including NORSOK & ASME X

• Official recognised NVQ training and assessment centre via ECITB - Engineering Construction Institute Training Board

• Leaders in the advancement of composite and thermoplastic solutions, research & development, specialist fabrications and engineering services

• Committed to producing first-class products, services & problem solving, including numerous world firsts

Compliance & Competence

Composite pipe systems

Bondstrand® GRE pipe systems provide long-term cost savings with their superior corrosion resistance & low-weight, typically weighing 1/6th the weight of traditional metallic equivalents. Available with standard or bespoke fittings, they provide flexible, fit & forget solutions for the harshest of environments. Features include:

Sizes 1” to 40” (60”)Maximum design pressure Full vacuum to 50bar+Maximum design temperature -40ºC to 121ºCConductive & Non Conductive GRE/GRV SystemsFire Rating IMO L3 to L1 productsApprovals Lloyds, DNV, RINA, BV, etc….Jointing types Bonded, mechanical, laminated

Bondstrand® GRE pipe systems

FRP composite structures

Phenolic FRP gratingPipex px®

Advantages:

• Weight (less than 1/3 that of steel).• Low maintenance (tough and corrosion resistant).• Fast install time (easy to fabricate).• Improved safety (tough anti-slip surface).

= Reduced costs for Installer & Owner

Fire properties:

Duradek Polyester: Fire Retardant GratingDuragrid Phenolic: Fire Integrity Grating

Approvals:

• USCG Approval PFM 164.040/1/1• Lloyds, DNV, Bureau Veritas, ABS

Phenolic FRP gratingPipex px®

Ellen Platform: 38 year Case History !1979 2012

MARRS® Offshore handrailsPipex px®

Testing & regulatory acceptance, including:

• Load testing• Extreme temperature• Salt exposure

MARRS® = “Multi Angled Rapid Railing System” Offshore Phenolic FRP Handrail

A Patented Proprietary Product, designed and engineered for Offshore Topside Applications.

MARRS® can be used in most areas throughout an offshore installation except in specific areas where post-fire integrity may be required (such as L1 & L2 designated safety escape routes).

Pipex MARRS® TRCU

Innovative FRP Top Rail Connection Unit (TRCU)

Pipex MARRS® ACU

Advanced FRP Articulated Corner Unit (ACU)


High Structural performance:

Low weight – 1/3rd weight of steel 0.74kN to 1.5kN p/m horizontal loads available as

standard (x5 SF @0.74kN.) 1.0kN point load Highly robust Minimal deflection (BS EN Specs) Uses proven materials technology Minimal maintenance Suitable for new-build & for brownfield retrofit


• Modular construction• Optimised post & rail profiles• Robust design

Easy to configure to requirements:

Meets Offshore Standards:

NORSOK International Offshore Standards ISO BS EN 14122-3 BS EN 10204 3.1 certification Phenolics for low smoke / fumes Multi-rail arrangement Lloyds and BP witness test

Access StructuresPipex px®

Designed & developed in-house, Pipex px® FRP structures meet the required strength, toughness and fire reaction performance for offshore oil & gas installations. Enhanced health & safety benefits are also provided as no hot works are required. Products include:

• MARRS® handrails, gates & ladders• FRP structures & walkways• Stairs, hop-overs & ramps

Advantages include:

Lower Lifetime Costs No marine corrosion (BP Clair Ridge – 40 years to first major maintenance)

Lower Costs to replace corroded steel Ease of handling & onsite modification

Increased SafetyCorroded steel can be major safety issue - not so with Pipex px® FRP

Reduced Worries Pipex px® FRP eliminates the worry of deciding when to replace steel!

• FRP platforms• FRP phenolic structures• Phenolic Grating

Pipex px®

FRP ladders

Design:

• Comprehensive Ladder and Safety Cage designs• BS or OSHA dimensions and standards• Stringer fixing centres 2.5M or 5.0M• Top front or side cage entry arrangements • Utilises MARRS profiles and components• Self closing hinges with adjustable force• Configure to suit project requirements

Materials:

• Uses proven Pipex phenolic FRP technology• Phenolics for low smoke and fumes• Minimal maintenance

Pipex px®

FRP platforms & stairs

Design:

• Structural FRP Profiles and mechanical fasteners.• Loading and layout to project standards. • MARRS Handrails & Duragrid Grating

Low weight:

• FRP structures weigh 1/3 of steel equivalent• Numerous FRP tertiary platforms of varying sizes

and applications were designed and supplied by Pipex for use on BP Clair Ridge.

Pipex px®

FRP bespoke structures

Phenolic FRP structures & walkways FRP minehunter stanchion posts

Subsea protection systems include the Cocoon & Shroud® Well-head protection system, impact protection systems, cable protection systems plus large complex bespoke subsea structures. Key advantages include:

• Significant weight reduction

• No cathodic protection required

• Minimal maintenance

Composite Structures - SubseaPipex px®

Subsea protection systems key benefits:

• Easier and faster deployment offshore

• Lower cost vessels with smaller cranes required for installation

• Reduced requirement for buoyancy

• Larger one-piece structures in FRP – provide significantly improved access to subsea equipment for faster maintenance interventions.

• Low weight hatches & covers opened using airbags (no compensated tugger lines from overhead vessels)

• Facilitate diverless operations, using ROV only

Composite Structures - SubseaPipex px®

Pipex px®

Testimonial

BP Clair Ridge Testimonial:

Pipex px® innovative Phenolic FRP MARRS® Offshore handrails, access structures, ladders, safety gates and grating have been designed, supplied, and installed extensively throughout the BP Clair Ridge project, all performing beyond expectations throughout fabrication, and passing Lloyds Class Project testing.

The Pipex px® FRP products successfully provided a cost effective, corrosion resistant alternative solution to steel equivalents and made a significant contribution towards critical weight saving objectives.

BP Lead Topside Structural Engineer, London

Pipex px® Navy Case History’s

Royal Fleet Auxiliary OilerPipex px®

• Ballast System in Ameron Bondstrand 7000M (conductive system) – BAE Prime Contractor

• System designed, prefabricated, supplied and installed by Pipex Limited

• Wave Ruler & Wave Knight pictured at launch from BAE Barrow in Furness

HMS ArgusPipex px®

• Replacement GRE pipe for seawater cooling

• Bondstrand 2000M non conductive, lined pipe and fittings with quick lock adhesive bonded joints

• Spools were hydro tested at 15 bar pressure for 1 hour

Type 22/23 RefitsPipex px®

• HMS Cumberland refit – Devonport 7000M Ballast System 1996

• HMS Sheffield refit – Devonport 7000M Ballast System 1996,1997

• HMS Cambeltown refit – Devonport 7000M Ballast System 1997

• HMS Coventry refit – Rosyth 7000M Ballast System 1995

• HMS Intrepid, HMS Fearless 35 years ago

• HMS Invincible

HMS InvinciblePipex px®

• Work carried out December 1999 - February 2000 at HMNB Portsmouth by Pipex

• Work carried out for MoD via Fleet Support Limited – David Porter (0797 00 73 449): note Pipex/Ameron were specified

• Pipex conducted onsite fabrication & replacement by two man installation team of existing sewage treatment pipework system

• Seriously degraded 3” & 2” Galvanised Carbon Steel replaced with Ameron Bondstrand 2000M pipe, fittings and flanges

• Work on Sierra Deck Compartment 274-232

HMS Albion / HMS BulwarkPipex px®

• HMS Albion refit – Devonport 7000M Ballast System 2009

• HMS Cumberland refit – Devonport 7000M Ballast System 2010

• Application - Bilge and Ballast Water to 10 bar pressure

• Scope of Work included fabrication and installation of 75 M of specialist BONDSTRAND® 2000M non conductive 10” & 12” GRE pipes and fittings with Quick Lock adhesive joints

• GRE pipe systems were used as part of the ballast and cooling water systems and offer superior corrosion resistance compared to traditional materials

RFA Fort Austin & RosaliePipex px®

• Pipex px® supplied & fabricated 24 no. GRE spools in diameters of 3” – 8” for the new ballast water treatment system of RFA Austin, 23 no. spools were supplied for RFA Rosalie

• The piping system was installed in conjunction with the installation of a Hyde Marine BWT unit to meet requirements of International Maritime Organisation (IMO)

• Hydro testing was completed on all spools prior to delivery

RFA Fort Austin & Rosalie - StructuresPipex px®

• 53 no. FRP phenolic grating panels were supplied for the walkways on RFA Fort Austin

• 54 no. FRP phenolic grating panels were supplied for the walkways on RFA Fort Rosalie

HMS OceanPipex px®

• HMS Ocean CuNi pipe work replacement

• 3D laser survey carried out by Pipex px engineers

• All spools prefabricated off site.

Landing craft utliltyPipex px®

• Ameron 2000M Ballast System installed at Ailsa Troon by Pipex Limited

• Initial 2 vessels have GRE piping onboard

Type 45 Anti Air Warfare Destroyers Pipex px®

BAE – Gold AwardSupplier Excellence

• First of Class Astute Submarines for BAE Systems, MOD

• Bondstrand® 2000M GRE Pipes & fittings supplied and installed for systems including Chilled water flow & return, sounding, magazine drains, deck drains and air escapes

• Pipex px® scope included site survey, design, project management, fabrication of bespoke angle fittings, prefabrications of spools, field service and commissioning of pipework

Type 45 weight & running cost savings

• GRE Estimated Running Costs Savings Per Vessel Per Ton = £50,000

• 15 Ton Saving v’s Cuni = £750,000 TLC• 23 Ton Saving v’s Carbon Steel = £1,150,000 TLC

9,312

24,13032,596

0

5000

10000

15000

20000

25000

30000

35000

GRE Cuni Sch 40

Pipe Material WeightsKg

First of Class Astute SubmarinePipex px®

Client Ministry of Defence

Project £2 billion Astute Prime Contract is for three next generation submarines

Pipe system Bondstrand 2000M GRE Pipes & Fittings

Scope of Work Site survey, design assistance (Caesar 2 stress analysis to confirm allowable loadings, support types and support locations), fabrication of bespoke angle fittings, prefabrication of spools, installation and commissioning of pipework, all completed in a critical 2 month window

First of Class Astute SubmarinePipex px®

Fabricate & Install

• Pipex fabricated spools months/years ahead of required by dates, after Boat 1 which was all critical path• Pipex stored and delivered spools to Bae• Pipex installed all spools and site ran small bore lines with assistance from Bae site teams• Very proactive working relationship with site teams• Pipex manufactured spools well in advance (currently storing boat 6 and 7 at Plymouth)

Queen Elizabeth Class (QEC) Aircraft Carriers Pipex px®

• 3828 No. BONDSTRAND® GRE pipe spools were supplied for chilled water, waste heat water, ballast water, and seawater cooling systems for BAE systems, MOD

• Over 7000 fittings per vessel, and over 5,300 metres of pipe systems supplied per vessel• Diameters from 2” to 28”• Pipe xpx® provided detailed design & fabrication drawings• Installation and field service team based on-site for 6 years• Innovative bulkhead penetration trims provided to maintain water integrity and fire resistance• Combined weight saving of over 390 tonnes with innovative composite materials

The information contained in this document is CONFIDENTIAL and PROPRIETARY to BAE Systems and

ACA Document Identifier Number Functional Maturity Code Version

CVF-10080631 F03 1

Title Equipment Specification (ES) for Glass Reinforced Epoxy Pipework

State REL

Issue Date 22-09-2008

Ship Applicability Type Organisation Area Perspective Category PBS

000 ACA-ENGR KCKH4 EN 0 CON N/A

Applicable for review only:

Reviewer Signature Print Name

Review Date DD-MM-YYYY

C ACCEPTED – NO COMMENTS

R ACCEPTED WITH COMMENTS. INCORPORATE COMMENTS AND SUBMIT FOR APPROVAL. WORK MAY PROCEED WITH CAUTION


Pipe systems design spec:

• Chilled Water Distribution System (Supply & Return) 8 bar 50°C 4” to 12”

• Waste Heat Water 8 bar 80°C 4” to 12”• Ballast Water 3.6 bar 50°C 4” to 12”• Seawater Cooling 3.6 bar 80°C 4” to 28”

Not Protectively Marked

Commercial in Confidence

ACA Document Identifier

Number

Functional Maturity Code

Version

CVF-10080631

F03

1

Title

Equipment Specification (ES) for Glass Reinforced Epoxy Pipework

State

REL

Issue Date

22-09-2008

Ship Applicability

Type

Organisation

Area

Perspective

Category

PBS

000

ACA-ENGR

KCKH4

EN

0

CON

N/A

Applicable for review only:

Reviewer

Signature

Print Name

Review Date

DD-MM-YYYY

C

ACCEPTED – NO COMMENTS

R

ACCEPTED WITH COMMENTS. INCORPORATE COMMENTS AND SUBMIT FOR APPROVAL. WORK MAY PROCEED WITH CAUTION

N

UNACCEPTABLE – MAJOR COMMENTS. REVISE AND RESUBMIT FOR FURTHER REVIEW. WORK SHALL NOT PROCEED IN THE AFFECTED AREAS UNTIL COMMENTS ARE RESOLVED

Amendment History

Version

Author

Date

Comments; including affected pages

1

J.Grimmond

22-09-2008

Requirements extracted for CVF-10047191 to this document for individual contract placement.

Authorisation

Name

Signature

Role

Date

Prepared by:

Jon Grimmond

Author

Authorised by:

Martin Hails

DDA

Released by:

Jim Bennett

P&P Director

Contents List

iiAmendment History

iiAuthorisation

iiiContents List

iiiTable of Tables

31Glass Reinforced Epoxy Pipework

31.1Overview

31.2Scope of Supply

31.3General Requirements

31.4Detailed Requirements

31.4.1Pipework Classifications

31.4.2Pipe performance

31.4.3Pipe Fitting Performance

31.4.4Glass Reinforced Epoxy System Perfomance

31.4.5Identification

31.4.6Weight budget

31.5Acceptance

31.6Standards

31.7Acronyms & Abbreviations

3ANNEX 1 - Glass Reinforced Epoxy Pipes

3ANNEX 2 - Glass Reinforced Epoxy Fittings

Table of Tables

3Table 1‑1 Glass Reinforced Epoxy Pipe/Fitting System Requirements

3Table 1‑2 Acceptance Matrix

3Table 1‑3 List of Standards

3Table 1‑4 Acronyms and Abbreviations

3Table 2-1 Details for Glass Reinforced Epoxy Pipes

3Table 2-2 Details of 90˚ Elbow




3Table 2-6 Details of 22.5˚ Elbow

3Table 2-7 Details of Equal Tee

3Table 2-8 Details of Reducing Tee

3Table 2-9 Details of Concentric Reducer

3Table 2-10 Details of Eccentric Reducer

3Table 2-11 Details of 45˚ equal Lateral

3Table 2-12 Details of 45˚ Reducing Lateral

3Table 2-13 Details of Heavy Duty Flange (BS EN 1092 PN16)

3Table 2-14 Details of Heavy Duty Flange (BS EN 1092 PN10)

3Table 2-15 Details of Orifice Flange (BS EN 1092 PN16/BS EN ISO 228-1)

3Table 2-16 Details of Bellmouth with Heavy Duty Flange (BS EN 1092 PN16)

3Table 2-17 Details of Saddle Reducing Flange (BS EN 1092 PN16)

3Table 2-18 Details of Saddle Reducing Bush (BS EN ISO 228-1)

3Table 2-19 Details of Double O-Ring Assembly Joint

3Table 2-20 Details of Coupling

3Table 2-21 Details of Standard Nipple

3Table 2-22 Details of Large Bore Nipple

1 Glass Reinforced Epoxy Pipework

1.1 Overview

1. This Equipment Specification (ES) defines the technical requirements for Glass Reinforced Epoxy Pipework on the Future Aircraft Carrier (CVF) for the Ministry of Defence.

2. Safety arrangements shall be provided to reduce hazards as much as reasonably practicable. This in no way detracts from the Sub-Contractor’s statutory duties under the Health and Safety Regulations.

1.2 Scope of Supply

3. The scope of supply is for various different types and sizes of Glass Reinforced Epoxy Pipework for use on the Aircraft Carrier Systems. These Glass Reinforced Epoxy Pipework quantities have been collated in a list at Annex 1 and 2. These are the quantities required for one shipset. The total quantity is subject to change and growth/reduction as each system design that the Glass Reinforced Epoxy Pipework serves develops.

4. To ensure adherence to Lloyds Register Type Approval certification any pipe fitting that is required to be procured with a particular type of Pipe to form a Pipe System shall be included in this Equipment Specification.

5. The following are the main types of Pipe that shall be required:

· Glass Reinforced Epoxy Pipes.

6. The following are the main types of Pipe Fittings that shall be required:

· Glass Reinforced Epoxy Type Fittings.

1.3 General Requirements

7. The specified Glass Reinforced Epoxy Pipework shall be manufactured in accordance with:

a) The applicable requirements of Lloyds Register Rules and Regulations for Classification of Ships (S1) for design, functional and operational performance, design appraisal / type approval, including construction under survey, unless otherwise stated.

1.4 Detailed Requirements

1.4.1 Pipework Classifications

8. Pipework has been classified in accordance with Lloyd’s Register Rules and Regulations for the Classification of Naval Ships (S2) Vol 2, Part 7, Chapter 1, Section 2.3. The classification for each material has been defined using the worst case system demand for a given material. The classification of each material is defined in Section 1.4.2 and 1.4.3 of this document.

1.4.1.1 Lloyds Register Class III Pipe Materials

9. All Lloyds Register Class III pipework is to be manufactured and tested in accordance with requirements of the standards stated in section 1.4.2. and 1.4.3.

10. All Lloyds Register Class III pipework shall be supplied with a Manufacturers Materials Test Certificate. This shall be a Type 3.1 (replaces Type 3.1B) Inspection Certificate in accordance with BS EN 10204 (S5) – hereinafter known as a Type 3.1

1.4.1.2 Equivalent Pipework Standards

11. If a Contractor offers an alternative Pipework Specification to that specified to widen the scope of supply, then the Contractor is required to highlight any variation from the specification, including dimensional/physical property variations and, if possible, supply a copy of the proposed alternate specification.

1.4.2 Pipe performance

1.4.2.1 Glass Reinforced Epoxy Pipes (Lloyds Register Class III)

12. The Purchaser has selected Glass Reinforced Epoxy Pipes which shall be manufactured in accordance with BS EN ISO 14692-2 (S3). Wall thicknesses are determined in accordance with ASTM D2996.

13. In accordance with Lloyds Register Rules and Regulations for Classification of Ships (S1) Part 2 - Rules for the Manufacture, Testing and Certification of Materials Chapter 14, Section 4.3.1, Glass Reinforced Epoxy Pipes shall be manufactured at facilities approved by Lloyds Register, using materials approved by LR.

14. Every consignment of Glass Reinforced Epoxy Type Fittings shall be supplied with a Type 3.1 certificate in hard copy, this is to be either an original or a red stamped copy.

15. The Glass Reinforced Epoxy Pipes shall be approved to Fire Endurance L3 according to IMO Resolution A.753 (18) (S4).

16. Glass Reinforced Epoxy Pipes shall satisfy the requirements shown in Annex 1.

1.4.3 Pipe Fitting Performance

17. The quantities in Annex 2 are estimates based on the current available system designs and are subject to growth/reduction.

1.4.3.1 Glass Reinforced Epoxy Type Fittings (Lloyds Register Class III)

18. The Purchaser has selected Glass Reinforced Epoxy Type Fittings which shall be manufactured in accordance with BS EN ISO 14692-2 (S3). Wall thicknesses are determined in accordance with ASTM D2996.

19. In accordance with Lloyds Register Rules and Regulations for Classification of Ships (S1) Part 2 - Rules for the Manufacture, Testing and Certification of Materials Chapter 14, Section 4.3.1, Glass Reinforced Epoxy Fittings shall be manufactured at facilities approved by Lloyds Register, using materials approved by Lloyds Register.

20. Every consignment of Glass Reinforced Epoxy Type Fittings shall be supplied with a Type 3.1 certificate in hard copy, this is to be either an original or a red stamped copy.

21. The Glass Reinforced Epoxy Type Fittings shall be approved to Fire Endurance L3 according to IMO Resolution A.753 (18) (S4).

22. All flanges on Glass Reinforced Epoxy Fittings shall be compatible with BS EN 1092-1 (S9) flanges PN 10 or PN16 designation.

23. All metallic threads on Glass Reinforced Epoxy Fittings shall be compatible with BS EN ISO 228-1 (S8) threads and are to be composed of Aluminium Bronze alloy CuAl10Ni5Fe4 to BS EN 12167 (S10).

24. Glass Reinforced Epoxy Pipes shall satisfy the requirements shown in Annex 2.

1.4.4 Glass Reinforced Epoxy System Perfomance

25. The strategy for the design, construction and installation of the Glass Reinforced Epoxy Pipe work on CVF is as follows:

(a) The majority of the Glass Reinforced Epoxy Pipe work (100 – 400 DN) will be made up of pipe and fittings in spool form that are to be constructed by the Contractor and delivered to the various CVF build sites. The spool drawings will be designed by detail design offices (representing the Purchaser) utilising the Glass Reinforced Epoxy pipe and fittings shown in Annex 1 + 2. These spools drawings will be sent to the Contractor in hard or soft copy and are to be approved by the Contractor before the spool is constructed. These spools are to be pressure tested before delivery.

(b) Six metre lengths of plain ended Glass Reinforced Epoxy Pipe (100 – 400 DN) will be delivered to the various CVF build sites. This pipe will be used to connect Glass Reinforced Epoxy spools together by the use of axial grip type couplings. This pipe does not need pressure testing.

(c) If upon delivery to the build site for installation by the shipyard staff (representing the Purchaser) the Glass Reinforced Epoxy spools (100 – 400 DN) are found to have incorrect geometry for integration due to incorrect drawings, spool construction or build tolerances then the spool will, were possible, be modified by the use of axial grip type couplings or, if the build yard has the capability, adhesive joints. If this is not possible it is to be uplifted and returned to the Contractor for modification.

(d) The large bore Glass Reinforced Epoxy Pipe work (450 – 700 DN) will be constructed entirely in spool form, in most cases, from the Glass Reinforced Epoxy pipe and fittings shown in Annex 1 + 2. As this Glass Reinforced Epoxy Pipe work is considered to be lock out pipework (i.e. it has to be installed at the unit construction phase) its design and installation procedure is to be reviewed and agreed by both the detail design office/shipyard staff (representing the Purchaser) and the Contractor. Any adhesive jointing of the large bore Glass Reinforced Epoxy Pipe work at ship is to be carried out by the Contractor and kept to a minimum however it may be required for “Field Fits” where the exact dimensions of the ship may not be known until after structural construction.

(e) In order to meet the construction/geometric constraints of CVF a limited amount of Glass Reinforced Epoxy Pipe work is required to be constructed in spool format that does not meet the dimensions of pipe and fittings shown in Annex 1 +2. These special spools will be designed by detail design offices (representing the Purchaser) and drawings will be supplied to the Contractor for review in hard or soft copy. The special spools method of construction is to be determined by the Contractor however the interface geometry and interface method (i.e. flanges/plain ends) is to be adhered to. The Contractor is to return a manufactures drawing to the Purchaser for approval prior to construction. These spools will require pressure testing.

26. The contractor shall confirm that they can supply the Glass Reinforced Epoxy pipe/spools and that they can supply the large bore Glass Reinforced Epoxy pipe work/special spool for which they must be able to supply specialists to carry out any onsite modification/repair or adhesive bonding work at ship when required.

27. The Contractor shall supply details for all tooling (manual and powered), consumables, training and processes required to install the Glass Reinforced Epoxy pipe and spools (using the build yard personnel) that are supplied from the Contractor in accordance with the classification society type approval certificate. This is to be taken as each of the build yards below installing the following percentages of the Glass Reinforced Epoxy System:

· BVT Surface Fleet (North) – Glasgow – 41%

· BAE System Submarine Solutions – Barrow in Furness – 31%

· BVT Surface Fleet (South) – Portsmouth – 22%

· Babcock Engineering Services – Rosyth – 6%

28. The Contractor shall supply an approval letter from Lloyds Register, or equivalent classification society, stating that axial grip type couplings are approved to connect the Glass Reinforced Epoxy pipe offered.

29. The MoD has specified that a number of critical systems aboard CVF must be operable after a shock event. These systems utilise the Glass Reinforced Epoxy System and therefore the pipework must maintain its integrity during and after a shock event. The Contractor shall supply an acceptance letter from the MoD stating that the Glass Reinforced Epoxy System offered is suitable for use on Royal Navy ships. As this acceptance letter covers the use of Glass Reinforced Epoxy pipework and connectors for use aboard all Royal Navy ships it is not project specific therefore any and all costs associated with obtaining this letter of approval from the MoD will be at the Contractors cost. The MoD has advised that to be able to issue an approval letter to the Contractor the Glass Reinforced Epoxy pipework and connectors are to be tested in a standard configuration to levels of Grade AB in accordance with DEF STAN 08-120 (S6), detailed in guidance document BR 8470 (S7). The Glass Reinforced Epoxy pipework and connectors are to be pressurised to, and maintain, their maximum working pressure during and for 5 minutes after the test. The MoD has agreed a test configuration with the ACA that satisfies the above criteria/standards and have nominated a test centre that has a suitable testing machine. In order to arrange approval testing and obtain the test configuration the Contractor is to contact both:

ACA Shock Engineer: Phil Bayley BrownE-mail: [email protected]

ACA Shock Manager: John KirkwoodE-mail: [email protected]

30. The Table below specifies the requirements of the Glass Reinforced Epoxy Pipe/Fitting System. The Contractor shall complete columns 7, 8, 9, 10 and return the completed table to the Purchaser with the requested Approval Certification.

1

2

3

4

5

6

7

8

9

10

System Name

Working Medium

Working Pressure (Bar)

Working Temp. (oC)

Lloyds Class

Pipe Sizes (DN)

Lloyds Approval Certificate for System (Yes/No)

Other Classification Society Certificate for System (Yes/No)

If Yes State Society

State Lloyds/other Classification Society Certificate Number

(I, II or III)

Chilled Water Distribution System (Supply and Return)

Fresh Water

8

50

III

100-300

Waste Heat Hot Water

Fresh Water

8

80

III

100-300

Ballast

Sea Water

3.6

50

III

100-300

Sea Water Cooling

Sea Water

3.6

80

III

100-700

Table 1‑1 Glass Reinforced Epoxy Pipe/Fitting System Requirements

1.4.5 Identification

31. Glass Reinforced Epoxy Pipework shall have the following identification. Standard and large bore pipe spools are to be permanently identified by their spool/line number that will be present on the Purchasers drawings. Plain-ended pipes are to be permanently identified by their part number that can be found in Annex 1. Special spools are to be permanently identified by their occurrence and part number that will be present on the Purchasers drawings and must be shown on the returned Contractors manufacturers drawing.

1.4.6 Weight budget

32. Glass Reinforced Epoxy Pipework shall comply with the weight shown in the Annex 1 and 2.

Acceptance

Performance Requirement

Acceptance Method

Para 7

Design documentation

Para 14


Para 15


Para 16


Para 20


Para 21


Para 22


Para 23


Para 24


Para 26


Para 27


Para 28


Para 29


Para 30


Para 31


Para 32


Table 1‑2 Acceptance Matrix

Standards

33. This section provides full details of all standards referenced in the foregoing sections.

Ref. No.

Standard No. (including Part No.)

Title of Standard

Date

Issue Status

S1

LRS

Lloyd's Register Rules and Regulations for the Classification of Ships

Jan 2003

Full

S2

LRNS

Lloyd’s Register Rules and Regulations for the Classification of Naval Ships

July 2005

Full

S3

BS EN ISO 14692-2

Petroleum and natural gas industries Glass-reinforced plastics (GRP) piping Part 2: Qualification and manufacture

August 2006

Full

S4

IMO Resolution A.753 (18)

Guidelines for the application of plastic pipes on ships

November 1993

Full

S5

BS EN 10204

Metallic products Types of inspection documents

October 2004

Full

S6

DEF STAN 08-120

Requirements for determining the shock strength of equipment (Restricted – Unavailable from ACA)

April 2000

Full

S7

BR 8470

Shock and vibration manual (Restricted – Unavailable from ACA)

September 1989

Full

S8

BS EN ISO 228-1

Pipe threads where pressure-tight joints are not made on the threads Part 1: Dimensions, tolerances and designation

February 1993

Full

S9

BS EN 1092-1

Flanges and their joints — Circular flanges for pipes, valves, fittings and accessories, PN designated — Part 1: Steel flanges

October 2007

Full

S10

BS EN 12167

Copper and copper alloys. Profiles and rectangular bar for general purposes

September 1998

Full

Table 1‑3 List of Standards

34. Reference to a particular Defence Standard should not be taken to imply that compliance with any of its embedded standards is required, unless this is explicitly stated.

Acronyms & Abbreviations

Acronym/ Abbreviation

Description

ACA

Aircraft Carrier Alliance

HSE

Health and Safety Executive

DDA

Designated Design Authority

DN

Nominal Size

ES

Equipment Specification

GRE

Glass Reinforced Plastic

BS

British Standard

EN

European Standards

ACA

Aircraft Carrier Alliance

LR

Lloyds Ship Rules

MPa

Mega Pascal

MoD

Ministry of Defence

LRNS

Lloyds Naval Ship Rules

ISO

International Standard

Table 1‑4 Acronyms and Abbreviations

ANNEX 1 - Glass Reinforced Epoxy Pipes

DN

Outside diameter (mm)

Wall thickness (mm)

Max working pressure (bar)

Mass per unit length (kg/m)

Part Number (per metre)

Quantity (m)

100

113.4

4.1

14

3.1

40018252

160

125

140.1

4.1

14

3.5

40018285

787

150

167.2

4.2

14

4.6

40018288

293

200

219.8

5.5

14

7.4

40018350

1,380

250

276.9

7

14

12

40018352

1,191

300

330.3

8.3

14

17

40018359

926

350

355.6

9

14

19

40018370

94

400

406.4

10.3

14

25

40018371

213

450

456.8

11.5

14

32

40018373

63

500

507.7

12.8

14

39

40018378

97

600

609.4

15.4

14

56

40018388

33

700

737.4

18.7

14

75

40018389

7

Total

5,244

Table 2-1 Details for Glass Reinforced Epoxy Pipes

ANNEX 2 - Glass Reinforced Epoxy Fittings

90˚ ELBOW

PIPE SIZE

WEIGHT KG

PART NO.

QUANTITY

DN

OD

W/T

100

113.4

4.1

1.6

40024324

21

125

140.1

4.1

2.7

40024325

298

150

167.2

4.2

3.6

40024326

196

200

219.8

5.5

6.8

40024327

274

250

276.9

7

11

40024328

113

300

330.3

8.3

18

40024329

36

350

355.6

9

26

40024330

2

400

406.4

10.3

31

40024331

90

450

456.8

11.5

53

40024332

6

500

507.7

12.8

65

40024334

2

600

609.4

15.4

122

40024335

2

700

737.4

18.7

205

40024336

2

Table 2-2 Details of 90˚ Elbow

60˚ ELBOW

PIPE SIZE

WEIGHT KG

PART NO.

QUANTITY

DN

OD

W/T

100

113.4

4.1

1.29

40033366

3

125

140.1

4.1

2.13

40033367

25

150

167.2

4.2

3.16

40033368

6

200

219.8

5.5

6.36

40033369

28

250

276.9

7

11.81

40033370

14

300

330.3

8.3

17.14

40033371

19

350

355.6

9

21.73

40033372

2

400

406.4

10.3

30.91

40033373

4

450

456.8

11.5

33.74

40033374

1

500

507.7

12.8

59.66

40033375

2

600

609.4

15.4

71.31

40033376

1

700

737.4

18.7

169.13

40033377

0


45˚ ELBOW

PIPE SIZE

WEIGHT KG

PART NO.

QUANTITY

DN

OD

W/T

100

113.4

4.1

1.1

40024357

16

125

140.1

4.1

1.8

40024358

180

150

167.2

4.2

2.4

40024359

76

200

219.8

5.5

4.2

40024360

238

250

276.9

7

7.3

40024361

103

300

330.3

8.3

11

40024362

60

350

355.6

9

17

40024363

0

400

406.4

10.3

20

40024364

14

450

456.8

11.5

33

40024365

5

500

507.7

12.8

40

40024366

2

600

609.4

15.4

82

40024367

0

700

737.4

18.7

140

40024368

2


30˚ ELBOW

PIPE SIZE

WEIGHT KG

PART NO.

QUANTITY

DN

OD

W/T

100

113.4

4.1

0.95

40033383

0

125

140.1

4.1

1.09

40033384

6

150

167.2

4.2

1.94

40033385

14

200

219.8

5.5

3.8

40033386

4

250

276.9

7

8.11

40033387

15

300

330.3

8.3

12.82

40033388

4

350

355.6

9

13.89

40033389

2

400

406.4

10.3

21.41

40033390

3

450

456.8

11.5

21.34

40033391

0

500

507.7

12.8

43.76

40033392

4

600

609.4

15.4

30.61

40033393

3

700

737.4

18.7

76.15

40033394

0


22.5˚ ELBOW

PIPE SIZE

WEIGHT KG

PART NO.

QUANTITY

DN

OD

W/T

100

113.4

4.1

1

40024436

1

125

140.1

4.1

1.4

40024437

74

150

167.2

4.2

1.9

40024439

26

200

219.8

5.5

3.9

40024440

83

250

276.9

7

5.9

40024441

64

300

330.3

8.3

10.4

40024442

19

350

355.6

9

12

40024443

0

400

406.4

10.3

14

40024444

16

Table 2-6 Details of 22.5˚ Elbow

EQUAL TEE

PIPE SIZE

WEIGHT KG

PART NO.

QUANTITY

DN

OD

W/T

100

113.4

4.1

2.5

40024296

0

125

140.1

4.1

5

40024297

25

150

167.2

4.2

6.7

40024298

16

200

219.8

5.5

10

40024299

71

250

276.9

7

18

40024300

5

300

330.3

8.3

29

40024301

16

350

355.6

9

37

40024302

0

400

406.4

10.3

56

40024312

6

450

456.8

11.5

69

40024313

3

500

507.7

12.8

92

40024314

0

600

609.4

15.4

168

40024315

0

700

737.4

18.7

285

40024317

2

Table 2-7 Details of Equal Tee

REDUCING TEE

PARENT PIPE SIZE

BRANCH PIPE SIZE

WEIGHT KG

PART NO.

QUANTITY

DN

OD

W/T

DN

OD

W/T

100

113.4

4.1

50

59.2

3.1

2.1

40024540

0

100

113.4

4.1

80

88

3.1

2.3

40024541

0

125

140.1

4.1

50

59.2

3.1

3.4

40024542

0

125

140.1

4.1

80

88

3.1

4

40024543

87

125

140.1

4.1

100

113.4

4.1

4.6

40024544

62

150

167.2

4.2

50

59.2

3.1

6.2

40024545

0

150

167.2

4.2

80

88

3.1

5.7

40024546

7

150

167.2

4.2

100

113.4

4.1

5.9

40024547

0

150

167.2

4.2

125

140.1

4.1

6.2

40024548

4

200

219.8

5.5

80

88

3.1

9.1

40024549

24

200

219.8

5.5

100

113.4

4.1

9.7

40024550

0

200

219.8

5.5

125

140.1

4.1

10.6

40024551

8

200

219.8

5.5

150

167.2

4.2

11.4

40024552

20

250

276.9

7

100

113.4

4.1

14.8

40024553

5

250

276.9

7

125

140.1

4.1

15.2

40024554

0

250

276.9

7

150

167.2

4.2

15.5

40024555

15

250

276.9

7

200

219.8

5.5

16.5

40024556

10

300

330.3

8.3

100

113.4

4.1

21

40024557

0

300

330.3

8.3

150

167.2

4.2

22

40024558

13

300

330.3

8.3

200

219.8

5.5

23

40024559

11

300

330.3

8.3

250

276.9

7

24

40024560

0

350

355.6

9

100

113.4

4.1

31

40029394

0

350

355.6

9

150

167.2

4.2

29

40024561

0

350

355.6

9

200

219.8

5.5

30

40024562

0

350

355.6

9

250

276.9

7

32

40024563

0

350

355.6

9

300

330.3

8.3

34

40024564

0

400

406.4

10.3

100

113.4

4.1

37

40029395

4

400

406.4

10.3

150

167.2

4.2

37

40024565

1

400

406.4

10.3

200

219.8

5.5

38

40024566

14

400

406.4

10.3

250

276.9

7

41

40024567

12

400

406.4

10.3

300

330.3

8.3

45

40024568

1

400

406.4

10.3

350

355.6

9

49

40024569

0

450

456.8

11.5

100

113.4

4.1

38

40029396

0

450

456.8

11.5

150

167.2

4.2

45

40029397

0

450

456.8

11.5

200

219.8

5.5

53

40024570

0

450

456.8

11.5

250

276.9

7

60

40024571

0

450

456.8

11.5

300

330.3

8.3

67

40024572

0

450

456.8

11.5

350

355.6

9

66

40024573

2

450

456.8

11.5

400

406.4

10.3

69

40024574

0

500

507.7

12.8

100

113.4

4.1

43

40029398

4

500

507.7

12.8

150

167.2

4.2

50

40028295

6

500

507.7

12.8

250

276.9

7

77

40024575

8

500

507.7

12.8

300

330.3

8.3

82

40024576

0

500

507.7

12.8

350

355.6

9

85

40024577

0

500

507.7

12.8

400

406.4

10.3

85

40024578

2

500

507.7

12.8

450

456.8

11.5

89

40024579

1

600

609.4

15.4

100

113.4

4.1

61

40029399

0

600

609.4

15.4

150

167.2

4.2

69

40029400

0

600

609.4

15.4

200

219.8

5.5

77.9

40024580

0

600

609.4

15.4

250

276.9

7

85

40024581

0

600

609.4

15.4

300

330.3

8.3

85

40024582

0

600

609.4

15.4

350

355.6

9

101

40024585

0

600

609.4

15.4

400

406.4

10.3

99

40024586

1

600

609.4

15.4

450

456.8

11.5

137

40024587

0

600

609.4

15.4

500

507

12.8

156

40024588

0

Table 2-8 Details of Reducing Tee

CONCENTRIC REDUCER

PARENT PIPE SIZE

BRANCH PIPE SIZE

WEIGHT KG

PART NO.

QUANTITY

DN

OD

W/T

DN

OD

W/T

100

113.4

4.1

50

59.2

3.1

1.1

40024619

0

100

113.4

4.1

80

88

3.1

0.9

40024620

0

125

140.1

4.1

80

88

3.1

1.4

40024621

25

125

140.1

4.1

100

113.4

4.1

1.5

40024622

87

150

167.2

4.2

80

88

3.1

1.8

40024623

2

150

167.2

4.2

100

113.4

4.1

1.8

40024624

4

150

167.2

4.2

125

140.1

4.1

1.8

40024625

19

200

219.8

5.5

100

113.4

4.1

2.9

40024626

0

200

219.8

5.5

125

140.1

4.1

2.8

40024627

4

200

219.8

5.5

150

167.2

4.2

2.7

40024628

115

250

276.9

7

150

167.2

4.2

3.7

40024629

20

250

276.9

7

200

219.8

5.5

3.6

40024630

5

300

330.3

8.3

200

219.8

5.5

5

40024631

11

300

330.3

8.3

250

276.9

7

4.6

40024632

3

350

355.6

9

250

276.9

7

7.2

40024633

2

350

355.6

9

300

330.3

8.3

7.3

40024634

0

400

406.4

10.3

300

330.3

8.3

8.9

40024635

13

400

406.4

10.3

350

355.6

9

9

40024636

1

450

456.8

11.5

300

330.3

8.3

48.9

40033485

0

450

456.8

11.5

400

406.4

10.3

12.7

40024637

0

500

507.7

12.8

400

406.4

10.3

22.6

40024638

2

500

507.7

12.8

450

456.8

11.5

18.9

40024639

0

600

609.4

15.4

400

406.4

10.3

48.4

40024640

3

600

609.4

15.4

450

456.8

11.5

44.3

40024641

0

600

609.4

15.4

500

507.7

12.8

38.5

40024642

0

700

737.4

18.7

400

406.4

10.3

72

40024643

2

700

737.4

18.7

500

507.7

12.8

69

40024644

2

700

737.4

18.7

600

609.4

15.4

67.3

40024650

0

Table 2-9 Details of Concentric Reducer

ECCENTRIC REDUCER

PARENT PIPE SIZE

BRANCH PIPE SIZE

LL

OL

X

WEIGHT KG

PART NO.

QUANTITY

DN

OD

WT

DN

OD

WT

100

113.4

4.1

50

59.2

3.1

200

292

27

1.1

40035384

0

100

113.4

4.1

80

88

3.1

93

185

12

0.9

40035385

0

125

140.1

4.1

100

113.4

4.1

101

204

14

1.5

40035386

0

150

167.2

4.2

80

88

3.1

293

396

39

1.8

40035387

0

150

167.2

4.2

100

113.4

4.1

200

303

27

1.8

40035388

0

150

167.2

4.2

125

140.1

4.1

100

214

13

1.8

40035389

0

200

219.8

5.5

100

113.4

4.1

390

500

52

2.9

40035390

0

200

219.8

5.5

150

167.2

4.2

190

311

25

2.7

40035391

6

250

276.9

7

150

167.2

4.2

392

519

53

3.7

40035392

0

250

276.9

7

200

219.8

5.5

202

336

27

3.6

40035393

6

300

330.3

8.3

200

219.8

5.5

390

530

53

5

40035394

0

300

330.3

8.3

250

276.9

7

190

336

26

4.6

40035395

0

350

355.6

9

250

276.9

7

308

467

42

7.2

40035396

0

350

355.6

9

300

330.3

8.3

118

283

16

7.3

40035397

0

Table 2-10 Details of Eccentric Reducer

45˚ EQUAL LATERAL

PIPE SIZE

WEIGHT KG

PART NO.

QUANTITY

DN

OD

W/T

100

113.4

4.1

3.9

40024526

0

125

140.1

4.1

5.8

40024527

0

150

167.2

4.2

6.8

40024528

2

200

219.8

5.5

12

40024529

0

250

276.9

7

21

40024530

0

300

330.3

8.3

30

40024531

0

350

355.6

9

39

40024532

0

400

406.4

10.3

54

40024533

0

Table 2-11 Details of 45˚ equal Lateral

45˚ REDUCING LATERAL

PARENT PIPE

BRANCH PIPE

WEIGHT KG

PART NO.

QUANTITY

DN

OD

W/T

DN

OD

W/T

100

113.4

4.1

50

59.2

3.1

3.5

40024658

0

100

113.4

4.1

80

88

3.1

3.7

40024659

0

150

167.2

4.2

80

88

3.1

4

40024660

0

150

167.2

4.2

100

113.4

4.1

4.5

40025661

0

200

219.8

5.5

100

113.4

4.1

9

40024662

0

200

219.8

5.5

150

167.2

4.2

11

40024664

0

250

276.9

7

150

167.2

4.2

16

40024665

0

250

276.9

7

200

219.8

5.5

18

40024666

0

300

330.3

8.3

200

219.8

5.5

25

40024667

0

300

330.3

8.3

250

276.9

7

28

40024668

0

Table 2-12 Details of 45˚ Reducing Lateral

HEAVY DUTY FLANGE (BS EN 1092 PN16)

PIPE SIZE

PCD

O/D

NO OFF HOLES

HOLE DIA

WEIGHT KG

PART NO.

QUANTITY

DN

OD

W/T

100

113.4

4.1

180

220

8

18

2.7

40025082

13

125

140.1

4.1

210

250

8

18

4

40025083

25

150

167.2

4.2

240

285

8

22

4.9

40025085

185

200

219.8

5.5

295

340

12

22

6.9

40025086

190

250

276.9

7

355

405

12

26

9.8

40025087

123

300

330.3

8.3

410

460

12

26

12.7

40025088

21

350

355.6

9

470

520

16

26

20.5

40025089

46

400

406.4

10.3

525

580

16

30

27.4

40025090

148

450

456.8

11.5

585

640

20

30

32

40025091

39

500

507.7

12.8

650

715

20

33

40

40025092

24

600

609.4

15.4

770

840

20

36

58

40025093

3

700

737.4

18.7

840

910

24

36

73

40025094

11

Table 2-13 Details of Heavy Duty Flange (BS EN 1092 PN16)

HEAVY DUTY FLANGE (BS EN 1092 PN10)

PIPE SIZE

PCD

O/D

NO OFF HOLES

HOLE DIA

WEIGHT KG

PART NO.

QUANTITY

DN

OD

W/T

200

219.8

5.5

295

340

8

22

6.9

TBC

20

250

276.9

7

350

395

12

22

9.8

TBC

6

300

330.3

8.3

400

445

12

22

12.7

TBC

10

350

355.6

9

460

505

16

22

20.5

TBC

0

400

406.4

10.3

515

565

16

30

27.4

TBC

0

Table 2-14 Details of Heavy Duty Flange (BS EN 1092 PN10)

ORIFICE FLANGE (BS EN 1092 PN16/ BS EN ISO 228-1)

PIPE SIZE

PCD

O/D

NO OFF HOLES

HOLE DIA

WEIGHT KG

0.5” BSP BUSH PART NO.

QUANTITY

DN

OD

W/T

150

167.2

4.2

240

285

8

22

4.9

TBC

10

200

219.8

5.5

295

340

12

22

7.43

TBC

10

250

276.9

7

355

405

12

26

13.5

TBC

10

300

330.3

8.3

410

460

12

26

20.8

TBC

4

350

355.6

9

470

520

16

26

27.3

TBC

2

400

406.4

10.3

525

580

16

30

34.6

TBC

8

Table 2-15 Details of Orifice Flange (BS EN 1092 PN16/BS EN ISO 228-1)

BELLMOUTH WITH HEAVY DUTY FLANGE (BS EN 1092 PN16)

PIPE SIZE

WEIGHT KG

PART NO.

QUANTITY

DN

OD

W/T

250

276.9

7

39.1

40030566

16

Table 2-16 Details of Bellmouth with Heavy Duty Flange (BS EN 1092 PN16)

SADDLE REDUCING FLANGE (BS EN 1092 PN 16)

PARENT

BRANCH

B

L

THK

MASS KG

PART NO.

QUANTITY

DN

I/D (mm)

DN

O/D (mm)

200

219.8

50

59.2

244

152

22

4.5

40036043

26

200

219.8

80

88

244

241

22

6.6

40036045

34

200

219.8

100

113

257

305

22

8

40036046

46

250

276.9

50

59.2

270

152

22

5.3

40036047

32

250

276.9

80

88

270

241

22

7.8

40036048

38

250

276.9

100

113

282

305

22

9.5

40036049

24

300

330.3

50

59.2

302

152

22

6

40036050

33

300

330.3

80

88

302

241

22

8.9

40036051

31

300

330.3

100

113

302

305

22

10.9

40036052

24

400

406.4

50

59.2

343

152

22

7.2

40036053

3

400

406.4

80

88

343

241

22

10.8

40036054

2

400

406.4

100

113

343

305

22

13.3

40036055

0

Table 2-17 Details of Saddle Reducing Flange (BS EN 1092 PN16)

SADDLE REDUCING BUSH (BS EN ISO 228-1)

PIPE DN

I/D (mm)

WEIGHT (kg)

0.5” BSP BUSH

QUANTITY

0.75” BSP BUSH

QUANTITY

1” BSP BUSH

QUANTITY

100

113.4

0.8

40036027

16

125

140.1

0.9

40036028

79

150

167.2

1.1

40036029

29

200

219.8

1.3

40036030

138

250

276.9

1.6

40036031

119

40036033

24

40036035

30

300

330.3

1.8

40034655

93

40034662

19

40034669

23

350

355.6

1.9

40036032

9

40036034

2

40036036

2

400

406.4

2.1

40034656

21

40034663

4

40034670

5

450

456.8

1.3

40034657

6

40034664

1

40034671

2

500

507.7

1.4

40034658

10

40034665

2

40034672

2

600

609.4

1.7

40034659

3

40034666

1

40034673

1

700

737.4

2

40034660

1

40034667

0

40034674

0

PIPE DN

I/D (mm)

WEIGHT (kg)

1” BSP BUSH

QUANTITY

1.25” BSP BUSH

QUANTITY

1.5” BSP BUSH

QUANTITY

250

276.9

1.6

40036035

40

40036037

8

40036039

12

300

330.3

1.8

40034669

31

40034676

6

40036040

9

350

355.6

1.9

40036036

3

40036038

1

40036041

1

400

406.4

2.1

40034670

7

40034677

1

40036042

2

450

456.8

1.3

40034671

2

40034678

500

507.7

1.4

40034672

3

40034679

600

609.4

1.7

40034673

1

40034680

700

737.4

2

40034674

0

40034681

Table 2-18 Details of Saddle Reducing Bush (BS EN ISO 228-1)

DOUBLE O-RING EXPANSION JOINT

PIPE SIZE

WEIGHT KG

PART NO.

QUANTITY

DN

OD

WT

100

113.4

4.1

3.5

40033607

0

125

140.1

4.1

4.6

40033608

0

150

167.2

4.2

6.6

40033609

0

200

219.8

5.5

15.4

40033610

0

250

276.9

7

19.9

40033611

0

300

330.3

8.3

21

40033612

0

350

355.6

9

25

40033613

0

400

406.4

10.3

32

40033614

0

450

456.8

11.5

27

40033615

0

500

507.7

12.8

32

40033616

0

600

609.4

15.4

52

40033617

0

700

737.4

18.7

99

40033618

0

Table 2-19 Details of Double O-Ring Assembly Joint

COUPLING

PIPE SIZE

WEIGTH KG

PART NO.

QUANTITY

DN

OD

W/T

100

113.4

4.1

0.6

40024449

1

125

140.1

4.1

0.9

40024450

3

150

167.2

4.2

1.1

40024451

1

200

219.8

5.5

1.7

40024452

6

250

276.9

7

2.3

40024453

5

300

330.3

8.3

2.8

40024454

4

350

355.6

9

4.6

40024456

0

400

406.4

10.3

7.2

40024473

1

450

456.8

11.5

10.7

40024479

0

500

507.7

12.8

13

40024480

0

600

609.4

15.4

24.2

40024481

0

700

737.4

18.7

23.5

40024482

0

Table 2-20 Details of Coupling

STANDARD NIPPLE

PIPE SIZE

WEIGHT KG

PART NUMBER

QUANTITY

DN

O/D

W/T

100

113.4

4.1

0.2

40024488

11

125

140.1

4.1

0.3

40024489

52

150

167.2

4.2

0.4

40024490

20

200

219.8

5.5

0.6

40024491

92

250

276.9

7

0.9

40024492

79

300

330.3

8.3

1.1

40024493

62

350

355.6

9

3.1

40024494

6

400

406.4

10.3

4.4

40024499

14

Table 2-21 Details of Standard Nipple

LARGE BORE NIPPLE

PIPE SIZE

WEIGHT KG

PART NUMBER

QUANTITY

DN

O/D

W/T

450

456.8

11.5

5.9

40024519

4

500

507.7

12.8

7.8

40024520

6

600

609.4

15.4

11.7

40024521

4

700

737.4

18.7

21.1

40024522

2

Table 2-22 Details of Large Bore Nipple

The information contained in this document is CONFIDENTIAL and PROPRIETARY to BAE Systems and Thales Naval Limited, who are members of the Aircraft Carrier Alliance. No part of this document or the information contained in it may be copied, disclosed or used except as expressly agreed in writing by both BAE Systems and Thales Naval Limited as copyright owners. The UK Secretary of State for Defence has Error! Unknown document property name. Rights of use as defined in Contract Nos. CBCVF/00102-00107. Other members of the Aircraft Carrier Alliance, (Babcock Support Services Limited, Kellogg Brown & Root Limited and VT Shipbuilding Limited) also have rights of use under the CVF Alliance Agreement dated 13 April 2006.

Not Protectively Marked

Commercial in Confidence

Template Ref: CVF-10051442-F04-01UNCONTROLLED IF PRINTED


The Pipex px® Product Advantages:

• Full compliance with stringent MoD technical specifications for use on Naval ships

• Low operating and significant through life cost savings with minimal maintenance

• Quick, safe and cost effective installation

• Light weight, GRE Pipe is on average 1/6th the weight of comparable steel pipe

• Corrosion resistant, internally and externally corrosion resistant to salt water, chemicals and organic matter

• Unprecedented technical expertise and support gained from working on similar projects such as the Royal Navy Type 45 Anti-Air Warfare Destroyers and the Royal Navy Astute Class Submarines


Fabrication video

QEC gratingPipex px®

• Pipex px® supplied, fabricated & installed 1,400² metres of phenolic FRP flight-deck walkways, and 200² metres for the forward and aft island walkways

QEC platformsPipex px®

• Design, fabrication & delivery of phenolic FRP platforms for HMS Queen Elizabeth & HMS Prince of Wales

• Structures were delivered flat packed and assembled on site by Pipex px® field service engineers

• Pipex px® engineering department developed a concept design solution from FRP materials in accordance with the clients requirements

Pipex px®

Pipex px® innovative GRE pipe systems & FRP structures provided

a combined weight saving of over 390 tonnes!

Queen Elizabeth Class (QEC) Aircraft Carriers

*Weight saving in comparison to metallic equivalents

SEA 5000 Potential Pipe SystemsPipex px®

DrawingsSystem System Fluid Pipe Sizes System Design Pressure Bar

Working Temperature °C

ADFB - Air escape and Vents (from tanks: Fresh and Tech. water, Grey water, Ballast water,

Urea, Bio sludge, Sea inlets, Sewage treat. plants, Chilled water plants and from cofferdams and

void spaces)

Air 50-200 Static pressure max 1 Bar -2 to 55

AFDC - Sea Inlets and Overboard Discharge (sh4) Sea Water 50-200 4 -2 to 55

CCDC - Fresh Water Filling and transfer Fresh Water 80 4 0 to 80

CCEB & CCEZ - Chilled Water Fresh Water 80-150 7 -2 to 55

CCSC - Chilled Water Sea Water Sea Water 80-200 4 -2 to 55

CCKA - External scuppers and drains Sea Water 50- Static pressure max 1 Bar -2 to 55

CCKB - Magazine and Internal deck drains Sea Water 50- Static pressure max 1 Bar -2 to 55

CCPZ - Prewetting Sea Water 50 11 -2 to 55

CCSA - Propulsion Sea Water Cooling Sea Water 80-125 3.5 -2 to -55

CCSB - Low Pressure Sea Water Cooling Sea Water 80-150 4 -2 to 55

CFHB - Grey Water Gray Water 50-125 Static pressure max1Bar -2 to 55

Pipex px® Marine & Offshore Case History’s

• The Seven Atlantic is one of the world’s largest diving support vessels• Corroded metallic pipework causing fouling & blockages, effecting the heating & cooling of the seawater

supply to diver's suits. Composite replacement required• One of our engineers performed 98 onboard 3D laser scans offshore North Sea over 4 days to capture the

corroded pipework route, spanning 6 decks port & starboard sides• Scans were amalgamated into one model, isometrics produced in-house• Pipex px® also conducted spool fabrication & testing• Specialist installation team attended onboard for 3 day, fast track, perfect fit installation

The Seven Atlantic – 3D laser scans & GRE pipe

• GRE pipe fabrication, specialist installation and training for the Belanak FPSO, West Natuna Field, Indonesia • 3,500 metres Bondstrand® series 7000M & 2416C GRE pipework with Taper/Taper adhesive bonded joints &

conductive fittings• Diameters supplied 2 inch through to 16 inch• Training of local workforce in Bondstrand® handling and installation techniques• Pipex px® field service engineers conducted all jointing of critical pressure systems and installation of all

mechanical joints • Inspection of all completed pipework systems with ZERO testing failure rate• Engineering services included design assistance and verification, stress analysis, specialist on-site advisory

role and project management• Pipex px® awarded the Gold Award for Supplier Excellence by Conoco Phillips

Belanak Gold AwardDeliverer of Excellence

Belanak FPSO – pipe systems & training

• Exhaust gas scrubbing installation, GRE pipe, fabrication and specialist installation• 290 metres Bondstrand®, 1 inch to 14 inch diameter pipe and fittings supplied, fabricated and installed by

Pipex px®• Corrosion resistant solution ideal for the containment of acidic waster water produced through the scrubbing

process, together with the seawater supply lines to the scrubber• Bespoke mitred joint design and fabrication to enable retrofit in severely restrictive areas• 30% of the DNV Class approved pipework pre-fabricated off-site to enable fast track installation• Team of 8 Pipex px® Filed Service Engineers based on-board the ferry 24/7 for 14 days to accommodate strict

client scheduling

Commodore Clipper ferry – Scrubber solution

• Bespoke spool design, GRE pipe, fabrication and specialist installation• GRE solutions provided by Pipex px® have included, sea chests, engine room piping, exhaust outlets,

transducer housings, seawater outlet & inlet manifolds, and discharge stacks• Material selection & approval compliance, 2D & 3D isometric drawing production, spool fabrication and onsite

installation assistance• Recent projects include Sunseeker 37 metre Tri-Deck Yacht, Bondstrand® 2000M conductive GRE pipe and

fittings. 1 inch to 20 inch quick lock adhesive joints and 4 inch to 6 inch special fabrication laminated joints• Pipex px® conducted in-house 100% hydro testing of spools to 1.5 times design pressure for 1 hour duration

Luxury Yacht Supply – Sunseeker & Princess Yachts

Pipe System:

• Bondstrand 2400 conductive GRE Pipe & Fittings 2” – 10” Taper/Taper adhesive bonded joints

Design Criteria:

• 16 ½ bar operating pressure 25 bar test pressure for 24 hour

Offshore Sea Water Filtration

Technical details –Piping

BONDSTRAND® GRE designPipex px®

• Valves & equipment should be supported separately at the flanges• Supports should not be placed underneath fittings, except flanges• Use maximum support span• Anchor connections of GRE to steel pipes• Use support saddles for sliding supports• Avoid Load points• Always use protective material between pipe wall and steel supports (rubber, saddle, etc)

BONDSTRAND® MOD designPipex px®

• Lloyds Register – Naval Rules• ISO 14692-2• WT = ASTM 2996• Safety Factor of 4:1 • Hydrostatic Test 1.5 x design pressure• Fire = IMO Resolution A.753 L3 Fire rating (30 min wet)

(+ further options)• Other approvals (DNV, ABS, BV)• 25 + year design life

Pipex px®

Shock test comments:

• Design critical – Pipex design capability as per drawings pictured right. Caesar II Stress Analysis available.

• Pipex have Two Shock Test Reports sponsored by Netherlands Ministry of Defence (Navy) in 1995.TNO Report 95-MAR-RO748TNO Report 95-MAR-RO755Available for view upon request. Product has passed RN tests this year – report issue due soon

• AMAT Final Report Project 201 “Fire Water Pipes in Composites” covers simulated shock and jet fire tests reference offshore platforms – available on request.

• Material & jointing is now proven for T45 project

• Qinetiq Report specific to T45: “Shock tests on GRP pipework: Phase 2A (UC) “ Reference Qinetiq/FST/CR030198/1.0 – UK RESTRICTED

BONDSTRAND® GRE - Testing

4.unknown

PIPEX HOUSE,

PIPEX LIMITED,

AUTOCAD

LOWMAN WAY,

FAX : 01884 253 285

TEL: 01884 255 405

TIVERTON, DEVON.

PIPEX

PIPEX HOUSE,

PIPEX LIMITED,

AUTOCAD

LOWMAN WAY,

FAX : 01884 253 285

TEL: 01884 255 405

TIVERTON, DEVON.

PIPEX


1. Bondstrand GRE piping is suitable for use in in shock grade zone AB, C and D as defined below and be Shock Class 1.

2. Bondstrand GRE piping will function without degradation in performance when subjected to the shock motions at the foundation (i.e. Ship structure), as described in MAP 01-470, for their applicable Shock Grade, as modified by Parameter Fraction 1.0 (for Class 1).

3. Bondstrand GRE Pipe & Fittings when subjected to the shock motions specified in MAP 01-470, for their applicable Shock Grade (with a Parameter Fraction of 1.0) will:

a. remain captive;

b. not release any projectiles;

c. not pose a hazard to personnel or other equipment.

4. Bondstrand GE Pipework Systems Shock Class 1 is vital for maintaining watertight integrity, lifesaving, damage control and fire-fighting, and escape and evacuation.

ConclusionThe sample of Ameron GRP pipe, submitted for the fire tests detailed in this report achieved the following results:

Property Test Method Result

Smoke index Def Stan 02 – 711 74.9

Oxygen index ISO 4589 – 2 25.6%

Temperature index ISO 4589 – 3Annex A

226°C

Halogen Content Lassaigne Sodium Fusion

Toxicity Index Def Stan 02 – 713 1.47 / 100g

Spread of Flame BS 476 Part 7 Class 2

Nitrogen | NegativeChloride | NegativeBromide | NegativeFluoride | NegativeSulphur | Negative


BONDSTRAND® GRE – Weight comparison

BONDSTRAND® GRE – Cost comparison

GRE Cunifer

£176,145£267,480

050000

100000150000200000250000300000350000400000

£GB

Product Overall Cost Comparison

GRECunifer

7,960

19,335

0

5000

10000

15000

20000

Kg

Product Overall Weight Comparison

Chart2

GRE

Cunifer

£GB


176145

267480

Sheet1

GRECuniferGRECunifer

£176,145£267,4807,96019,335

Sheet1

£GB


Sheet2

Kg


Sheet3

Chart3

GRE

Cunifer

Kg


7960

19335

Sheet1

GRECuniferGRECunifer

£176,145£267,4807,96019,335

Sheet1

£GB


Sheet2

Kg


Sheet3

BONDSTRAND® GRE v cunifer comparison

Thank You!

Fiber Glass Systems (Pipex) Advanced �designSlide Number 3Slide Number 4Slide Number 5Slide Number 6Slide Number 7Slide Number 8Slide Number 9Slide Number 10Slide Number 11Advanced manufacturingResin Infusion Composite EngineeringCompliance & CompetenceComposite pipe systemsBondstrand® GRE pipe systemsFRP composite structuresPhenolic FRP gratingPhenolic FRP gratingMARRS® Offshore handrailsMARRS® Offshore handrailsMARRS® Offshore handrailsAccess StructuresSlide Number 24Slide Number 25Slide Number 26Slide Number 27Slide Number 28Slide Number 29Pipex px® Navy �Case History’s Royal Fleet Auxiliary OilerRoyal Fleet Auxiliary OilerHMS ArgusType 22/23 RefitsHMS InvincibleHMS Albion / HMS BulwarkRFA Fort Austin & RosalieRFA Fort Austin & Rosalie - StructuresHMS OceanLanding craft utlilty Type 45 Anti Air Warfare Destroyers Type 45 weight & running cost savingsFirst of Class Astute Submarine First of Class Astute Submarine Queen Elizabeth Class (QEC) Aircraft Carriers Queen Elizabeth Class (QEC) Aircraft Carriers Queen Elizabeth Class (QEC) Aircraft Carriers Queen Elizabeth Class (QEC) Aircraft Carriers QEC gratingQEC platformsSlide Number 51SEA 5000 Potential Pipe SystemsPipex px® �Marine & Offshore �Case History’s The Seven Atlantic – 3D laser scans & GRE pipeBelanak FPSO – pipe systems & trainingCommodore Clipper ferry – Scrubber solutionLuxury Yacht Supply – Sunseeker & Princess YachtsOffshore Sea Water FiltrationTechnical details – �PipingBONDSTRAND® GRE designBONDSTRAND® MOD designSlide Number 62BONDSTRAND® GRE - TestingBONDSTRAND® GRE - TestingBONDSTRAND® GRE – Weight comparisonBONDSTRAND® GRE – Weight comparisonBONDSTRAND® GRE – Cost comparisonBONDSTRAND® GRE v cunifer comparisonBONDSTRAND® GRE v cunifer comparisonThank You!

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