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Fiber Glass Systems (Pipex)
Navy overview
Royal Australian Navy, Australia, October 2017
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Advanced design
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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.
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Phenolic FRP HVAC access structure, BP Clair Ridge
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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
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Anode ICCP Frames
Seabox Treatment unit
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Structural design solutions – Offshore
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• 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
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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)
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Dover Sea Wall, replacement hybrid footbridge
Subsea Anode ICCP skid frame
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Piping design, assistance & verification
• General arrangements
• Developing pipe specifications
• Pipe routing & coordination
• Isometrics – fabrication & installation
• Spool details
• Support design
• Verification of customer designs
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All photos: BP API sandfilters
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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.
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Composite pressure vessel design
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• 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
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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
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Nexen Buzzard drip trays
BP Kinneil pipe layout
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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
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Dover Sea Wall Hybrid Footbridge
Static Gap Filler Coper
Bespoke tooling designl, Type 26
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Advanced manufacturing
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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
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• 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
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Composite pipe systems
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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
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FRP composite structures
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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
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Phenolic FRP gratingPipex px®
Ellen Platform: 38 year Case History !1979 2012
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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)
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MARRS® Offshore handrailsPipex px®
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
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MARRS® Offshore handrailsPipex px®
• 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
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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
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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
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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.
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Pipex px®
FRP bespoke structures
Phenolic FRP structures & walkways FRP minehunter stanchion posts
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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®
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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®
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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
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Pipex px® Navy Case History’s
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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
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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
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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
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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
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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
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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
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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
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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
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HMS OceanPipex px®
• HMS Ocean CuNi pipe work replacement
• 3D laser survey carried out by Pipex px engineers
• All spools prefabricated off site.
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Landing craft utliltyPipex px®
• Ameron 2000M Ballast System installed at Ailsa Troon by Pipex Limited
• Initial 2 vessels have GRE piping onboard
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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
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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
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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
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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)
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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
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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
Queen Elizabeth Class (QEC) Aircraft Carriers Pipex px®
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 2-3 Details of 60˚ Elbow
3Table 2-4 Details of 45˚ Elbow
3Table 2-5 Details of 30˚ 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
Design documentation
Para 15
Design documentation
Para 16
Design documentation
Para 20
Design documentation
Para 21
Design documentation
Para 22
Design documentation
Para 23
Design documentation
Para 24
Design documentation
Para 26
Design documentation
Para 27
Design documentation
Para 28
Design documentation
Para 29
Design documentation
Para 30
Design documentation
Para 31
Design documentation
Para 32
Design documentation
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
Table 2-3 Details of 60˚ Elbow
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
Table 2-4 Details of 45˚ Elbow
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
Table 2-5 Details of 30˚ Elbow
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
-
Queen Elizabeth Class (QEC) Aircraft Carriers Pipex px®
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
-
Queen Elizabeth Class (QEC) Aircraft Carriers Pipex px®
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
-
BONDSTRAND® GRE - Testing
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 - Testing
-
BONDSTRAND® GRE – Weight comparison
-
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
Product Overall Cost Comparison
176145
267480
Sheet1
GRECuniferGRECunifer
£176,145£267,4807,96019,335
Sheet1
£GB
Product Overall Cost Comparison
Sheet2
Kg
Product Overall Weight Comparison
Sheet3
Chart3
GRE
Cunifer
Kg
Product Overall Weight Comparison
7960
19335
Sheet1
GRECuniferGRECunifer
£176,145£267,4807,96019,335
Sheet1
£GB
Product Overall Cost Comparison
Sheet2
Kg
Product Overall Weight Comparison
Sheet3
-
BONDSTRAND® GRE v cunifer comparison
-
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!