Flexpipe Technical Manual English

FLEXPIPE SYSTEMS TECHNICAL INFORMATION MANUAL FlexPipe Linepipe

Toll Free: 888-FLX-PIPE (888-359-7473) Toll Free Fax: 888-359-7479 Website: www.flexpipesystems.com

Flexpipe Systems 06-1876 R3.2

© ShawCor Ltd., 2010

Contents List of Tables ........................................................................................................................... iv List of Figures .......................................................................................................................... iv 1 Introduction ...................................................................................................................... 1 2 Pipe ................................................................................................................................... 1 2.1 Product Lines ......................................................................................................................1 2.2 Design.................................................................................................................................. 1 2.3 Materials ............................................................................................................................. 3 2.4 Manufacturing ....................................................................................................................3 2.4.1 Liner .............................................................................................................................. 4 2.4.2 Fiber Reinforcement ..................................................................................................... 4 2.4.3 Pipe ............................................................................................................................... 4 2.4.4 Quality Control ............................................................................................................. 5 3 Fittings .............................................................................................................................. 5 3.1 Product Lines ......................................................................................................................6 3.2 Design.................................................................................................................................. 7 3.3 Materials ............................................................................................................................. 8 3.4 Manufacturing ....................................................................................................................9 3.5 Corrosion Protection ........................................................................................................... 9 4 Qualification .................................................................................................................... 10 4.1 Introduction to Standards and Regulations ...................................................................... 10 4.2 Standards ..........................................................................................................................11 4.2.1 American Petroleum Institute (API) ............................................................................ 11 4.2.2 Canadian Standards Association (CSA) ....................................................................... 11 4.3 Regulations .......................................................................................................................13 4.3.1 Canadian Provincial Regulatory Bodies ...................................................................... 13 4.3.2 United States Regulatory Bodies ................................................................................ 13 4.4 Testing ............................................................................................................................... 13 5 Performance .................................................................................................................... 15 5.1 Applications & Chemical Compatibility ............................................................................. 15 5.1.1 Application Evaluations .............................................................................................. 15 5.1.2 Gas .............................................................................................................................. 15 5.1.3 Oil ............................................................................................................................... 16 5.1.4 Water .......................................................................................................................... 16 5.1.5 H2S .............................................................................................................................. 16 5.1.6 CO2 .............................................................................................................................. 17 5.1.7 Aromatic and Cycloalkane Hydrocarbons .................................................................. 17 5.1.8 Chemical Injection ...................................................................................................... 17 5.1.9 Methanol and Ethanol ................................................................................................ 18 5.2 Pressure and Temperature Ratings .................................................................................. 18 5.2.1 Minimum Allowable Operating Temperature ............................................................ 18 5.2.2 Maximum Allowable Operating Temperatures and Pressures................................... 18



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5.2.3 Calculations for Determining Maximum Allowable Operating Pressure.................... 19 5.3 Cyclic Pressure .................................................................................................................. 20 5.3.1 Pump Jacks ................................................................................................................. 22 5.4 Flow Characteristics .......................................................................................................... 23 5.4.1 Pipe Flow .................................................................................................................... 23 5.4.2 Fittings ........................................................................................................................ 25 5.5 Durability ........................................................................................................................... 25 5.6 Corrosion........................................................................................................................... 26 5.7 Erosion .............................................................................................................................. 26 5.8 Ultra-Violet Protection ......................................................................................................26 5.9 Bend Radius ......................................................................................................................26 5.10 Permeation .......................................................................................................................27 5.11 Expansion/Contraction and Axial Growth ........................................................................ 28 5.12 External Load and Internal Vacuum Capability ................................................................. 28 5.13 Thermal Conductivity ........................................................................................................29 6 Installation ...................................................................................................................... 30 6.1 Field Services Support .......................................................................................................30 6.2 Transportation .................................................................................................................. 30 6.3 Trenching ..........................................................................................................................31 6.4 Plowing.............................................................................................................................. 31 6.5 Insertion as a Freestanding Liner ...................................................................................... 31 6.6 Surface Installation ........................................................................................................... 33 6.7 Support Spacing ................................................................................................................ 34 6.8 Buoyancy and Pipe Weights .............................................................................................. 34

6.9 Crossings ........................................................................................................................... 36 6.10 Risers ................................................................................................................................. 37 6.11 Tracer Wire .......................................................................................................................37 6.12 Cold Temperature Installation .......................................................................................... 37 6.13 Heat Tracing ......................................................................................................................38 6.14 Fitting Installation ............................................................................................................. 39 6.15 Cathodic Protection .......................................................................................................... 39 6.16 Tying into Steel – Welding ................................................................................................ 39 6.17 Tying into Plastic ............................................................................................................... 39 6.18 Field Pressure Testing of New Pipelines ........................................................................... 39 7 Accessories ...................................................................................................................... 40 7.1 A-frames ............................................................................................................................ 41 7.2 Riser Support Trays ........................................................................................................... 41 7.3 Pull Tools ........................................................................................................................... 41 7.4 Sacrificial Anodes .............................................................................................................. 41 8 Operations....................................................................................................................... 41 8.1 Startup .............................................................................................................................. 41 8.2 Pigging ............................................................................................................................... 42 8.3 Hot Oiling ..........................................................................................................................43



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8.4 Static Electricity ................................................................................................................. 43 8.5 Secondary Excavations ......................................................................................................43 8.6 Field Pressure Testing of Existing Pipelines ...................................................................... 44 9 Reliability ........................................................................................................................ 44 9.1 History ............................................................................................................................... 44 9.2 Leak Testing ......................................................................................................................45 9.3 Cut-outs............................................................................................................................. 45 9.4 Integrity Verification ......................................................................................................... 46 10 Appendix ............................................................................................................................I Product Data Sheets ...................................................................................................................... I



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List of Tables Table 1: Flexpipe Fittings ................................................................................................................ 6 Table 2: Flexpipe Flow Joints .......................................................................................................... 6 Table 3: Flexpipe Fitting Material List ............................................................................................. 9 Table 4: Links for Specific CSA Z662 Requirements ...................................................................... 12 Table 5: FlexPipe Linepipe and Fitting Tests and Applicable Standards ....................................... 14 Table 6: Allowable Aromatic and Cycloalkane Hydrocarbon Content for FPLP ........................... 17 Table 7: Maximum Allowable Operating Pressure for FPLP ......................................................... 19 Table 8: Flow Coefficients for FPLP ............................................................................................... 25 Table 9: K Factor for Flexpipe Coupling Fittings ........................................................................... 25 Table 10: Minimum Bend Radius for Operation, Transport and Handling of FPLP ...................... 26 Table 11: Permeability Coefficients for HDPE ............................................................................... 27 Table 12: Representative Permeation Rates for FPLP .................................................................. 28 Table 13: FlexPipe Linepipe Thermal Conductivity and Resistivity............................................... 29 Table 14: Conduit Compatibility for FPLP Insertion ...................................................................... 32 Table 15: Maximum Allowable Pull Forces for FPLP ..................................................................... 32 Table 16: Recommended Pipe Support Spacing for FPLP ............................................................. 34 Table 17: Recommended Sand Bag Weight for Weighting FPLP .................................................. 36 Table 18: Custom Urethane Disk Pigs for FPLP ............................................................................. 42 Table 19: Flexpipe Pig Dimensions for FPLP ................................................................................. 43

List of Figures Figure 1: FlexPipe Linepipe Three-layer Design .............................................................................. 2 Figure 2: Cutaway View of Flexpipe Fitting..................................................................................... 7 Figure 3: Procedure for Determining MPR and MAOP ................................................................. 20 Figure 4: Representative Pressure Drop Comparison: Water at Various Flow Rates .................. 24 Figure 5: Representative Pressure Drop Comparison: Methane at Various Flow Rates .............. 24 Figure 6: Sandwich Type Insulated Barrier Configuration ............................................................ 38 Figure 7: Cut-out Burst Test Results ............................................................................................. 46



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In an effort to provide useful product information, Flexpipe Systems makes available a two part document: Part 1 – Technical Information Manual This part is mainly addressed to engineers, supervisors and procurement personnel. It is intended to present a general description of FlexPipe Linepipe materials, construction, qualification, performance, installation, operation and reliability. Part 2 – Installation Guide This part is mainly addressed to field personnel and is intended to provide general guidance on FlexPipe Linepipe handling, jointing, installing and testing. Each of the two parts emphasizes particular aspects of the Flexpipe product application. Familiarity with both parts is recommended for a broader perspective. This document is intended solely as a reference for use by persons of technical competence. It is the responsibility of the pipeline operator to ensure the suitability of Flexpipe products for any specific pipeline application. While the information contained in this document is believed to be correct as of the date of issue, under no circumstances will Flexpipe Systems Inc, or any of its subsidiaries, be liable in any way for any loss, damage or injury of any kind (whether direct, consequential, punitive or otherwise) incurred as a result of any omissions in this document or as a result of reliance on any information contained in this document. This document does not contain any warranty, express or implied. All rights reserved. Any reproduction of this document in part or as a whole without the written permission of Flexpipe Systems Inc is prohibited.



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1

Introduction

Flexpipe Systems Inc (Flexpipe) has designed, tested, and manufactured a high pressure, corrosion-resistant, coiled, continuous pipeline system utilizing new and exciting engineering technologies for the Oil and Gas and Utility industries. Applications include oil and gas gathering, water disposal and injection pipelines for the Oil and Gas industry and transmission and distribution pipelines for the Gas Utility industry. Flexpipe has also developed srcinal crimp fittings that allow efficient joining directly to steel lines, standard flanged connections, or other FlexPipe lines. Flexpipe holds patents for its 1 unique pipe and fitting designs .

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Pipe

2.1

Product Lines

Flexpipe Systems currently offers three product lines of FlexPipe Linepipe (referred to as FlexPipe or FPLP), identified by the color of the pipe jacket. Black jacket pipe is the standard line pipe intended for buried or slips lining applications; white jacket pipe is supplied for surface applications and yellow jacket pipe is used for buried gas distribution service. All product lines provide a minimum of 20 years protection against exposure to ultraviolet (UV) light. All product lines are available in 2”, 3” and 4” sizes, and classes FP150, FP301 and FP601 with pressure ratings of 2,068 kPa (300 psi), 5,171 kPa (750 psi), and 10,342 kPa (1500 psi) respectively. Flexpipe makes use of ANSI 150, 300 and 600 flanges for FP150, 301 and 601 products respectively. FP301 has superseded the FP300 and RS155-H products. The product data sheets in the appendix list the FPLP dimensions and parameters.

2.2

Design

FPLP is manufactured at the state-of-the-art Flexpipe facility in Calgary, Alberta, Canada. FPLP is a fully patented three-layer design constructed from a thermoplastic liner (liner), helically wrapped continuous high-strength fiber reinforcement (fiber) and an external thermoplastic jacket (jacket).

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Fiber reinforced pipe: US patent number 6,889,716 (May 10, 2005); Canadian patent number 2,513,506 (August 3, 2010); European patent number 1592908 (April 7, 2010). Compression-style fitting: US patent number 6,902,205 (June 7, 2005); Canadian patent pending Crimp-style fitting: Canadian patent pending; US patents pending.


©2010 Flexpipe Systems Inc

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The liner acts as a bladder, the fibers provide strength, and the jacket protects the load-bearing fibers. This construction is unique and has the following advantages: The fiber reinforcement is not encased in a thermosetting matrix and is therefore flexible, avoiding potential micro-cracking or over-straining of the matrix material. FPLP is very rugged, durable and easy to handle. The simplicity of construction reduces the manufacturing costs. The fiber reinforcement enables design for high-pressure applications. The liner ensures that the FPLP is immune to corrosion and eliminates the need for inspections. The continuous, long-length FPLP spools facilitate fast and easy installation with fewer connections and less disturbance to impacted parties. Environmental impact and soil disturbance can be reduced since FPLP can be trenched with a narrower trench and right of way than steel line pipe, or plowed in without trenching. The low weight minimizes handling equipment requirements leading to lower installation costs when compared to stick and other spoolable products.

Figure 1: FlexPipe Linepipe Three-layer Design

The pipe has been designed using a sophisticated mathematical model that was developed specifically for the unique construction of this product. The mathematical model was used to design the fiber-reinforcement configuration and optimize pressure capacity and strain. The



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strength of FPLP depends on the thickness and configuration of the fiber reinforcement layer, so traditional pipe design models based on wall thickness are not applicable. The validity of the mathematical model and the material properties used by this model has been verified through extensive physical testing. The design and manufacturing of FPLP is in accordance with standards and guidelines regarding qualification, quality control and testing of composite pipe and accessories. Please refer to Section 4 in this document for additional information on these standards, and Section 5.2 for a summary of the design methods and calculations.

2.3

Materials

The materials used in FPLP have been widely used in the oil and gas industry for many years. FPLP liner and jacket are manufactured using bimodal pressure-pipe-grade high density 2 polyethylene (HDPE) thermoplastic resin. This material is designated PE4710 by PPI TR-3 , in 3 accordance with ASTM D3350 . This leading-edge material meets rigorous standards for high strength and resistance to slow crack growth. It also provides excellent wear resistance and impact toughness, and a low-friction internal surface for decreased pressure losses. Colorant and an ultra-violet (UV) stabilizer are blended with the thermoplastic pellets during the extrusion process, providing resistance to weathering. The fiber reinforcement is constructed from a series of continuous glass fiber rovings which 4 have been manufactured in accordance with ASTM D578 . The fiber chemistry and coatings are specifically selected to optimize long-term performance. Flexpipe Systems is committed to maintaining high standards of quality and reliability. Each 5 individual supplier is qualified by Flexpipe, in accordance with API RP 15S , to ensure that quality inspections, physical testing, and material traceability meet Flexpipe’s quality standards. Each specific material is qualified by Flexpipe through rigorous physical testing, prior to manufacturing and in finished Flexpipe products.

2.4

Manufacturing

Flexpipe is equipped to manufacture all components of FPLP in-house. Each step of the manufacturing process is closely monitored, resulting in direct control over the quality of all FPLP. 2

PPI TR-3Policies

and Procedures for Developing Hydrostatic Design Basis, Pressure Design Basis, Strength Design Basis, and Minimum Required Strength Ratings for Thermoplastic Piping Materials or Pipe ASTM D3350Standard Specification for Polyethylene Plastics Pipe and Fittings Materials 4 ASTM D578Standard Specification for Glass Fiber Strands 5 API RP 15SRecommended Practice for the Qualification of Spoolable Reinforced Plastic Line Pipe 3



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2.4.1 Liner The liner is manufactured and inspected by highly experienced operators using state-of-the art equipment, in accordance with 6 stringent dimensional requirements defined by ASTM D2513 . Each liner is 100% inspected for diameter, wall thickness, and concentricity by online ultrasonic measurement.

2.4.2 Fiber Reinforcement The fiber reinforcements for each product are constructed from a single type of input strand, purchased from qualified suppliers. Flexpipe’s roving construction process combines these strands into custom packages for use in the construction of FPLP. Each package is specially configured for the individual finished product in which it will be used. Flexpipe has developed extensive expertise in this area through critical evaluation and physical testing of various materials, coatings, and processing methods. State-of-the-art roving machines are used with tensioning systems designed in-house specifically for this process.

2.4.3 Pipe Each reel of FPLP is manufactured in a single continuous production run that combines liner, fiber reinforcement, and jacket into the finished product. The liner length is sufficient to complete an entire pipe production run without fusions. The first step in the process is cleaning and drying the incoming liner. A laser measurement system inspects the diameter and roundness of the liner. If needed, multi-directional rounding rollers are applied to correct the roundness. The fiber reinforcement is applied by sequential custom-designed winding machines, which wrap fiber reinforcement rovings from multiple bobbins around the liner in a tightly controlled process. An automated control system directly measures the line speed, and maintains the correct wrap angle by controlling the speed of each individual winding machine. Each bobbin of fiber is individually braked to maintain the correct fiber tension.

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ASTM D2513Standard Specification for Thermoplastic Gas Pressure Pipe, Tubing, and



Fittings

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The jacket is applied over the fiber reinforcement with a customized cross-head extrusion die, and immediately cooled. Computerized laser and ultrasonic measurement systems are used to ensure that strict quality standards are maintained as the protective jacket is applied. The jacket is marked with identifying information by an inline printer. Finally, the finished product is coiled directly onto a transportation reel.

2.4.4 Quality Control Quality control (QC) is critical to the FPLP manufacturing process. Flexpipe Systems is an ISO 9001:2008 certified manufacturing facility. From supplier evaluation and approval to the qualification of every reel of finished FPLP, quality control data is diligently reviewed and evaluated. Flexpipe is committed to using suppliers that provide material-composition data and maintain certification and QC test results for all raw products. Material certification and traceability is critical to the Flexpipe quality assurance program that cohesively links raw materials with production records and serial markings on pipe and fittings. Flexpipe routinely verifies and audits the QC programs of its suppliers. The manufacturing process is designed with many levels of quality monitoring. Sophisticated instrumentation systems, lasers, ultra-sonics and production operators continually monitor the production line at specific intervals. Corrective action is implemented according to the established non-conformance reporting (NCR) system if design parameters are not within the specified tolerance limits. Every finished reel of FPLP is tested in accordance with the Flexpipe Production Qualification Testing (PQT) Standards, and in accordance with API RP 15S. Samples are taken from the beginning and the end of every pipe production run. The samples are subjected to destructive burst testing. The results from these tests must meet or exceed stringent QC requirements. In addition, Flexpipe tests raw materials to ensure compliance with material specifications. Flexpipe’s testing equipment includes burst chambers, ovens, a cold chamber, an Instron tensile testing machine, stress-rupture testing machines, density test equipment and numerous custom jigs and fixtures.

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Fittings

The Flexpipe fitting is a metallic device that mechanically fastens to the pipe. The fitting can 7 terminate the pipe with a standard ASME B16.5 lap-joint flange or a weld neck transition. The weld neck fitting allows direct connection to steel. The end of the FPLP from one reel can be

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ASME B16.5Pipe

Flanges and Flanged Fittings



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attached to the beginning of the FPLP from a second reel with a pipe-to-pipe coupling, thus eliminating an underground flanged connection.

3.1

Product Lines

The three types of fittings that are used with FPLP are shown in Table 1. Each of these fittings is available for each pipe size and grade. Flexpipe also offers preassembled flow joints in the configurations shown in Table 2. Table 1: Flexpipe Fittings Flanged End Fitting Compatible with standard raised face flanges. Flange is free to spin until bolts are tightened, allowing easy connection without stressing existing flanges. Coupling Fitting Used to connect two pieces of FPLP together.

Dimensional drawings available upon request.

Weld Neck Fitting Used to connect FPLP to steel pipe, using standard field welding procedures.

Table 2: Flexpipe Flow Joints

90 Degree Elbow Flow Joint Dimensional drawings available upon request.

T Flow Joint



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True Y Flow Joint Dimensional drawings available upon request.

Y-Lateral Flow Joint

3.2

Design

The fitting consists of a mandrel that is inserted into the pipe, and a sleeve that is crimped around the pipe. The mandrel and sleeve are both equipped with uni-directional teeth that securely grip the liner and jacket of the pipe. Crimping the sleeve creates very high permanent clamping pressure, which holds the fiber reinforcement securely in place. The fitting system does not require the application of heat or adhesives in order to bond components together.

Figure 2: Cutaway View of Flexpipe Fitting



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The mandrel is sealed to the liner by the clamping pressure. For additional security, the mandrel is equipped with two o-rings that provide an additional seal. The vent hole in the sleeve allows the annulus of the pipe (the space between the liner and jacket which contains the fiber reinforcement layer) to vent freely at each fitting. This allows any gases that may have permeated through the liner to escape, and prevents any pressure buildup in the annulus. Flexpipe fittings are installed in a two-step process, using portable installation equipment. In the first step, the mandrel is inserted into the liner. In the second step, the sleeve is crimped to the pipe. The fitting is supplied with the sleeve already welded to the mandrel to hold it in the correct position. Flexpipe fittings can be installed in the field in about 20 to 30 minutes. To view a simulation of the fitting installation process, visit the Flexpipe website at www.flexpipesystems.com. For more information on fitting installation, see Section 6.14. Flexpipe fittings have been tested together with FPLP as a complete system in long-term, high pressure tests, and have undergone rigorous testing to verify their performance in field conditions. More information on qualification testing is presented in Section 4.4. The inside diameter of the mandrel in the fitting is smaller than the inner diameter of the pipeline. However, the restriction is minimal, and results in negligible pressure loss (see Section 5.4 for further information). Fittings are compatible with pigging programs as detailed in Section 8.2.

3.3

Materials

Standard Flexpipe fittings are manufactured from seamless steel that meets the requirements 8 of NACE MR0175 for sour service. See Table 3 for a full list of materials used in Flexpipe fittings. Material certificates are reviewed by Flexpipe prior to manufacture of the fittings, and are retained as part of Flexpipe’s QC System. Weld neck fittings are manufactured using the same alloy steel material as flange and coupling fittings, with a short carbon steel pup welded to the end of the mandrel. This pup makes the weld neck fitting suitable for field-welding to standard carbon steel pipe and fittings of various pipe schedules, with no special weld procedures required.

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NACE MR0175Petroleum and Natural Gas Industries—Materials for Use in H2S-Containing Environments in Oil and Gas Production



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The steel used in 4” Flexpipe fitting mandrels and flanges meet the low-temperature notch9 toughness requirements of Category II of CSA Z245.11 . Whenever required, custom made mandrels and flanges in 2” and 3” sizes meeting the low-temperature notch-toughness requirements can also be supplied. Table 3: Flexpipe Fitting Material List

Part

Material type

Material grade(s)

Mandrel Alloy steela AISI 4130 or 4140 a Sleeve Carbon steel ASTM A106, A333, A513, or A519 Flange (flanged fittings only) Carbon steel ASTM A105 or ASTM A350 LF2 a Weld neck fitting welding Carbon steel ASTM A106 or A333 end Flow joints Carbon steela ASTM A234 WPB or ASTM A420 WPL6 b O-rings Viton 75 Durometer c Coatings Electroless Nickel or uncoated a Meets requirements of NACE MR0175 for sour service b Special o-rings are available for high-pressure CO 2 service c Weld neck fittings are not coated

3.4

Manufacturing

Flexpipe fittings are manufactured, coated, assembled, and labeled according to Flexpipe specifications by suppliers whose processes have been qualified by Flexpipe. Flexpipe routinely verifies and audits the QC programs of these suppliers. All welding required for the manufacture of Flexpipe fittings is performed in shop conditions, by suppliers qualified to Flexpipe’s weld procedures in accordance with CSA Z662. These procedures are specific to the materials used, and include appropriate heat treatments and inspections.

3.5

Corrosion Protection

Standard fittings are supplied with high-phosphorus electroless nickel plating with a fluoropolymer sealer on all wetted surfaces of the fitting. This plating protects the fitting from corrosion and erosion for many applications. Additional information on electroless nickel plating is available upon request.

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CSA Z245.11Steel Fittings



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Weld neck fittings are not coated or plated, since the coating or plating would be destroyed by the heat input during welding. Prefabricated flow joints can be coated, since no welding is required at installation. All fittings are also available with no coating. External corrosion control of Flexpipe fittings is achieved by the application of the Denso Petrolatum Tape Anti-Corrosion System. Denso paste is applied to the exposed reinforcement fibers at the end of the pipe prior to installing the fitting, to protect the fibers from moisture. The fitting is wrapped in Denso tape after installation. When applied according to the product 10 data sheet supplied with the tape, the system meets AWWA C217 . Polyken tape is used to protect the Denso tape on each fitting from being damaged or removed. White Polyken tape is also required to be applied over couplings in surface lines to prevent excessive heating due to solar radiation and to prevent external moisture from entering the fitting. Additional corrosion control via cathodic protection is available. Cathodic protection requirements for buried steel fittings are covered in Clause 13.1.5 of CSA Z662-07. Flexpipe has developed a ribbon anode kit for buried steel fittings that provides external corrosion protection for a 50 year life in soil resistivities ranging between 1500 to 3000 ohm/cm. This is based on a fitting external coating efficiency of 95%. Anode test posts and monitoring for buried steel couplings in composite pipelines are not required. The anode kit consists of a zinc ribbon anode connected to a copper lead wire, along with a roll of cloth tape to fix the anode to the Flexpipe and a stainless steel hose clamp to secure the lead wire to the fitting. Flexpipe’s anode kit can be readily installed in the field by attaching a clamp around the fitting and taping the ribbon along the pipe. Fittings with anodes attached are compatible with installation by trenching or plowing. Please refer to the Flexpipe Systems Installation Guide for more information.

4

Qualification

4.1

Introduction to Standards and Regulations

According to industry terminology, Flexpipe Systems line pipe is classified as a reinforced thermoplastic pipe (RTP). Various standards deal with this type of product, and cover topics such as materials, testing, manufacture, and installation. Standards are guidelines that are generally accepted throughout an industry as appropriate, usually on the basis of industry-wide experience. They are often referenced by regulations, which may adopt some or all of the 10

AWWA C217Cold-Applied Tape Coatings for the Exterior of Special Sections, Connections, and Fittings for Buried/Submerged Steel Water Pipelines



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guidelines, or even introduce more stringent requirements. Regulations are requirements that must be followed by law. Standards that apply to Flexpipe products are primarily performance-based. This means that they emphasize the demonstration of a product’s capabilities through repeated testing, rather than relying only on theoretical design calculations. A detailed theoretical design model serves as a starting point for Flexpipe product designs. The designs are validated through extensive long term testing in accordance with accepted test standards.

4.2

Standards

4.2.1 American Petroleum Institute (API) The American Petroleum Institute (API) was the first North American standards body to develop a recommended practice specific to the spoolable composite pipe industry. API RP 15S, Recommended Practice for the Qualification of Spoolable Reinforced Plastic Line Pipe , includes guidelines for determining material properties, pressure ratings, safety factors and service factors, and minimum performance requirements. It also includes guidelines for manufacturing, quality control tests, and typical installation methods. This recommended practice applies to RTP and spoolable thermosetting composite pipe. API 15S is based on expert knowledge of the materials involved, extensive experience with related applications and related products used in other applications, and detailed research on related knowledge used in other countries. It uses proven ASTM testing methods, such as 11 ASTM D2992 , for establishing long-term performance. This recommended practice is the basis for the Flexpipe pipe qualification program. All Flexpipe products meet or exceed the stringent qualification requirements established by API 15S.

4.2.2 Canadian Standards Association (CSA) CSA provides standards to which manufacturers should comply. CSA does not ‘certify’ or ‘approve’ pipeline products. CSA Z662-07, Oil and Gas Pipeline Systems, “covers the design, construction, operation, and maintenance of oil and gas industry pipeline systems”. FPLP falls under Clause 13.1 of this standard, which specifically addresses design, manufacturing and installation requirements for fiber-reinforced composite pipelines.

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ASTM D2992Standard Practice For Obtaining Hydrostatic or Pressure Design Basis For “Fiberglass” (GlassFiber-Reinforced Thermosetting Resin) Pipe And Fittings



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FPLP is fully compliant with CSA Z662-07 Clause 13. Some of the specific requirements are discussed below. Other requirements are discussed in more detail elsewhere in this document, as referenced in Table 4. According to Clause 13.1.1.3, FPLP and all other reinforced composite pipelines may be used in 12 low vapor pressure (LVP) , gas gathering, and oilfield water pipelines. High vapor pressure 13 (HVP) pipelines are excluded by this clause. FPLP also meets the requirements of Clause 12.5.4 for gas distribution systems. Design pressure calculations for RTP are outlined in Clause 13.1.2.8. This clause refers to API 15S as the industry standard according to which FPLP must be qualified. It uses the qualification methods given in API 15S, and specifies the values to be used for derating factors used in these methods. These factors are a minimum requirement; in some cases, Flexpipe has chosen service fluid factors (Ffluid) which are more conservative than required by CSA. These factors are already included in the Maximum Allowable Operating Pressures (MAOP) published for FPLP, as shown in the design pressure calculations in Section 5.2.3. Clause 5.2.3 of CSA Z662 requires that steel fittings 4” and larger meet the notch toughnes s 14 15 requirements of CSA Z245.11 and Z245.12 . Flexpipe 4” fitting mandrels and flanges meet these requirements. Table 4: Links for Specific CSA Z662 Requirements

Requirement Gas service design pressure limit Sour gas limits Cyclic service Tracer wire Cathodic protection Crossings and casing Freestanding liner insertion Pressure testing new – installations 12 13

CSA Z662 clause Discussed in 13.1.1.4 Section 5.1.2 13.1.1.4 Section 5.1.5 13.1.2.10 Section 5.3 13.1.4.1 Section 6.11 13.1.5 and 9.1 Section 6.15 13.1.4.2 13.1.4.6 Section 6.9 13.1.4.7 13.1.4.8 Section 6.5 13.1.6 Section 6.18

Includes oilfield water, multiphase fluids, or liquid hydrocarbon mixtures with vapour pressure of 110 kPa (absolute) or less at 38˚C. Hydrocarbons or 38 hydrocarbon mixtures in the liquid or quasi-liquid state with a vapour pressure greater than 110 kPa (absolute) at °C.

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CSA Z245.11Steel Fittings CSA Z245.12Steel Flanges



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Pressure testing repairs/replacements – Static electricity Maximum external pressure

4.3

13.1.8.2 13.1.8.3 13.1.2.11

Section 8.6 Section 8.4 Section 5.12

Regulations

4.3.1 Canadian Provincial Regulatory Bodies The Energy Resources Conservation Board (ERCB) is a regulatory body that oversees the development of Alberta’s energy resources, including oilfield pipelines. Any oilfield pipeline in Alberta must be approved by the ERCB before installation, in accordance with its regulations. Other provinces in Canada have regulatory bodies with a similar role. The ERCB allows FPLP applications to be processed as routine for fresh water, salt water, multiphase, crude oil/LVP, and natural gas service. Flexpipe has developed a positive history with the ERCB through provision of data on design, manufacturing, testing, installation and inservice evaluations. More information on the results of these evaluations can be found in Section 9. Flexpipe has also established relationships with the corresponding regulatory bodies in British Columbia, Saskatchewan, and Manitoba, and installations have been completed in each of these provinces. Full instructions for completing Directive 56 – Schedule 3 for ERCB applications are available from the Flexpipe Systems website. Examples are given for FPLP as a new pipe line and for FPLP as a freestanding liner.

4.3.2 United States Regulatory Bodies The United States Department of Transportation (DOT) considers the use of FPLP in regulated areas through special permit applications submitted to the Office of Pipeline Safety. Currently, Flexpipe Systems is working with the Department of Transportation to include Reinforced Thermoplastic Pipes as an approved material in 49 CFR Part 192 “Transportation of Natural and Other Gas by Pipeline”.

4.4

Testing

Flexpipe Systems is committed to ensuring that its products are rugged, reliable, and safe. FPLP is tested together with fittings as a complete system. This system has undergone extensive testing to demonstrate that it meets and exceeds the strict requirements of API 15S. Flexpipe’s



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test procedures have been audited by an independent laboratory API RP 15S.

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to validate compliance with

Flexpipe strongly believes that its products should perform as well under field conditions as in the laboratory. Therefore, Flexpipe has gone beyond the strict requirements of the applicable standards, and has developed its own procedures to test field handling of FPLP and related equipment. Some of the specific tests in Flexpipe Systems’ testing program are listed in Table 5. These tests have resulted in a comprehensive base of knowledge about product performance under a wide variety of service conditions. Table 5: FlexPipe Linepipe and Fitting Tests and Applicable Standards Test description Applicable standard(s) ASTM D2992 Procedure B Regression pressure testing API RP 15S Section 5.1.2.3 Elevated temperature pressure testing API RP 15S Section 5.2.1 Low temperature pressure testing ASTM D159917 Procedure A Minimum bend radius pressure testing API RP 15S Section 5.3.2 Installation pressure testing – samples retrieved after ASTM D1599 Procedure A liner insertion Installation pressure testing – samples retrieved after ASTM D1599 Procedure A plowing Flexpipe Test Procedure 10-0942 ASTM D1599 Procedure A Short term burst pressure testing API RP 15S Section 5.1.2.3 API RP 15S Section 5.1.5.1 Cyclic pressure testing Flexpipe Test Procedure 10-0941 Pressure testing - samples subjected to reverse API RP 15S Section 5.1.2.1 bending Axial load testing API RP 15S Section 5.3.3 Vent testing - gases venting from annulus API RP 15S Section 5.3.1 Impact resistance testing API RP 15S Section 5.5.2 Thermal expansion & pressure-expansion testing API RP 15S Sections 5.5.4 and 5.5.5 Kink testing Flexpipe Test Procedure 10-0940 Fitting gas leak testing API RP 15S Section 5.3.1 Thermal cycle testing Flexpipe Test Procedure 10-0945 External load testing ASTM D241218

16

Jana Laboratories Inc. (Aurora, Ontario) ASTM D1599Standard Test Method for Resistance to Short-Time Hydraulic Pressure of Plastic Pipe, Tubing, and Fittings 17



14

5 5.1

Performance Applications & Chemical Compatibility

It is the responsibility of the pipeline operator to understand the suitability of Flexpipe products for specific pipeline applications. The information in this section is intended to provide an understanding of the suitability of Flexpipe products for a wide range of common applications. For these or other applications, Flexpipe’s engineering team will be pleased to evaluate the application and advise regarding compatibility of Flexpipe products.

5.1.1 Application Evaluations Flexpipe has established a process to evaluate any proposed applications that exceed the normal operational limits given in the following sections. These limits are intended to provide a consistent and conservative approach to potential applications. While FPLP performs well in many applications that exceed these limits, it may not be appropriate for certain combinations of factors when one or more of the limits are exceeded. Application evaluations are intended as a service to clients, provided by the Flexpipe Engineering team. Each evaluation assesses the details of a proposed application to identify potential risks and determine specific measures that can be taken to eliminate or minimize them. Recommendations resulting from these evaluations have allowed many projects to successfully take advantage of the full capabilities of FPLP. Flexpipe believes that this approach reflects its commitment to public safety and has contributed to its outstanding service record, while allowing it to meet the unique needs of its clients.

5.1.2 Gas FPLP has a strong historical record in gas gathering applications, which account for the majority of FPLP currently in operation. There is no requirement to further de-rate the FPLP MAOP in gas applications (see Section 5.2 for determination of pressure ratings). Suitable environments include natural gas, solution gas, exhaust gas, and fuel gas. See Section 5.1.6 for information on CO2 applications. For gas applications in which condensates can form, a suitable pigging program should be implemented to prevent condensate buildup at low points along the pipeline. Clause 13.1.1.4 of CSA Z662 limits the allowable design pressure for FPLP gas pipelines to a maximum of 9930 kPa (1440 psi).

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ASTM D2412Standard Test Method for Determination of External Loading Characteristics of Plastic Pipe by Parallel-Plate Loading



15

FPLP can also be used in sour (H 2S) applications, but limits apply. Please refer to Section 5.1.5 for more details.

5.1.3 Oil FPLP is suitable for oil effluent or oil emulsion (two- or three-phase) applications. FPLP is entirely corrosion resistant, fully piggable, and is an excellent option for production with high water-cut. For applications with high wax content, suitable pigging programs should be in place. Please refer to Section 5.3 for more information on cyclic pressure applications. Please refer to Section 8.2 for more information on pigging.

5.1.4 Water FPLP is a corrosion resistant product that is an excellent option for oilfield water applications such as water transfer and disposal lines. FPLP may also be used for water injection and similar systems. However, these applications often involve cyclic pressure variations, and should be evaluated for compatibility. Please refer to Section 5.3 for more information on cyclic pressure applications.

5.1.5 H2S H2S (hydrogen sulphide, also known as sour gas) is a toxic and potentially lethal substance commonly found in oilfield media. Accordingly, a greater risk exists in routine pipeline inspection or maintenance, or in the event of fluid release due to pipeline damage. Non-metallic pipelines such as FPLP may allow small amounts of the transported fluids to permeate through the pipeline materials (see Section 5.10), accumulate within the materials or fitting system, and/or be released through the outer surface of the pipeline (please refer to the Flexpipe Systems Sour Service Pipeline Bulletin , available from the Flexpipe Systems website, for more information). These risks should be controlled by consistent and conservative limits on sour content. Sour applications must comply with the regulatory requirements of specific regional authorities. FPLP is compatible with an H 2S content of 5% by volume in liquids (oil and/or water), gas or 19 multiphase .

19

CSA Z 662-07 Clause 13.1.1.4 limits the partial pressure of H 2S in gas to 50 kPa (7.25 psi) for all composite pipe used in sour gas applications. The ERCB (Directive 71) requires calculation of H2S release volumes for multi-phase pipelines



16

5.1.6 CO2 FPLP can be used for gases or liquids containing up to 100% CO 2 by volume. FPLP suitability for CO2 service has been confirmed by a rapid decompression testing. Flexpipe standard 75 Durometer Vition o-rings are suited for a wide range of CO 2 applications. For applications having higher than 10% CO 2 and operating at pressures above 750 psig, Flexpipe recommends the use of special o-rings that provide superior performance for these conditions. Refer to Section 3.5 for further information on the fittings corrosion resistance and coating.

5.1.7 Aromatic and Cycloalkane Hydrocarbons FPLP is compatible with aromatic and cycloalkane hydrocarbons (e.g. benzene, toluene, ethyl benzene, xylene, naphthalene and cyclohexane) in gas or liquids. Table 6 lists the allowable aromatic and cycloalkane concentrations for FPLP at normal operating pressures, based on Flexpipe test data. Interpolation between temperatures is acceptable. Table 6: Allowable Aromatic and Cycloalkane Hydrocarbon Content for FPLP

Operating temperature 20˚C (68˚F) or below 40˚C (104˚F) 60˚C (140˚F)

Maximum allowable aromatic cycloalkane content (by volume) 25% 5% 1%

and

For gas applications in which condensates can form, a suitable pigging program be implemented to prevent aromatic and cycloalkane hydrocarbon buildup at low pointsshould along the pipeline. See also: Section 5.1.8 Chemical Injection.

5.1.8 Chemical Injection Common injection chemicals used in the oil gathering industry, such as corrosion inhibitors, biocides, paraffin dispersants, surfactants, scale inhibitors, defoamers, and demulsifiers, are not considered problematic to the HDPE liner in FPLP. Flexpipe recommends that chemical injection programs use dilute concentrations or batch treatments, as per the standard practice for HDPE applications as set out by the chemical manufacturing company. Injection chemicals which are made up from aromatic and cycloalkane hydrocarbons are acceptable for use with the HDPE liner in FPLP provided the concentration of the injection chemicals is controlled such that the aromatic and cycloalkane concentration stays within the limits listed in Table 6 as applicable for the pipe service temperature. Any higher concentration



17

batch treatment process should be of limited duration as recommended by the injection chemical manufacturer for use in HDPE pipe. This section addresses only the more common injection chemicals used in the oil gathering industry. Due to the variety of injection chemicals available, however, Flexpipe recommends that the oil field operating company develop an injection program in conjunction with the chemical manufacturing company to ensure there are no chemical compatibility concerns with HDPE.

5.1.9 Methanol and Ethanol HDPE has good resistance to concentrated methanol and ethanol at temperatures up to 60˚C (140˚F). Alcohols are routinely used in FPLP in continuous and batch programs, and are also commonly used during hydrotests to prevent freezing.

5.2

Pressure and Temperature Ratings

5.2.1 Minimum Allowable Operating Temperature 0

The Minimum Allowable Operating Temperature for all FPLP is -46 C (-50˚F). This has been proven by the successful completion of the qualification testing required by a major oil and gas producer. The testing indicated that FPLP has excellent impact resistance properties and does 0 not become brittle at temperatures of -46 C (-50˚F). In addition, the product performance at low temperatures is further ascertained by the positive track record of field applications in the northern United States and Canada, where low ambient temperatures are common during winter. Please refer to Section 3.3 for fittings material selection, Section 6.12 for minimum installation temperatures, and Section 8.1 for starting up pipelines at low temperatures.

5.2.2 Maximum Allowable Operating Temperatures and Pressures The Maximum Allowable Operating Pressure (MAOP) ratings for FPLP at temperatures up to 60ºC (140ºF) are shown in Table 7. Flexpipe supplies tags for installation on risers to notify operators of the temperature limitations of the pipe.



18

Table 7: Maximum Allowable Operating Pressure for FPLP

Maximum Maximum Allowable Operating Pressure* Allowable Operating FP150 FP301 FP601 Temperature (˚C) (˚F) (kPa) (psi) (kPa) (psi) (kPa) (psi) 60 140 2068 300 5171 750 10,342 1500 *Check your local regulations to verify the maximum allowable operating pressure does not exceed the maximum allowable design pressure. Insulation or white Polyken tape is required for protecting aboveground portions of black or yellow FPLP (for example at risers) from exceeding the maximum allowable operating temperature as a result of heating due to solar radiation.

5.2.3 Calculations for Determining Maximum Allowable Operating Pressure The MAOPs listed in Table 7 have been determined by the following calculation:

MAOP

MPR F fluid

The Maximum Pressure Ratings (MPR) has been determined at the maximum design 20 temperatures and design life of the pipeline in accordance with API RP 15S and CSA Z662-07. The procedure is illustrated Figure 3, is where datausing fromstatistical multiple long-term pressure tests area plotted on a log-log graph. inThe MPR derived calculations, and includes Pressure Service Factor. The Pressure Service Factor (PSF) is a derating factor that is intended to account for small variations in materials, installation, or operating parameters, to ensure that these variations do not cause the pipe’s actual capabilities to be exceeded. The PSF is applied to the Lower Confidence Limit at the Design Life to determine the MPR at the qualification temperature. Flexpipe uses PSF=0.67, as recommended by API 15S.

20

API RP 15SRecommended Practice for the


Qualification of Spoolable Reinforced Plastic Line Pipe


19

Figure 3: Procedure for Determining MPR and MAOP

21

The Service Fluid Factor (Ffluid) is an additional derating factor that is intended to account for the effects of the transported fluid on the pipe materials, to ensure that the fluid does not reduce the pipeline’s capability of maintaining the MAOP over the design life. This factor is applied to the MPR to determine the MAOP at the qualification temperature. Flexpipe has chosen to use Ffluid=0.67 for all types of fluid. This value allows a consistent MAOP for all types of fluids. It meets the CSA Z662 requirements for gas, and is more conservative than its requirements for other services. Flexpipe believes that this conservative approach, has contributed to FPLP’s outstanding track record. Other spoolable product suppliers may be using a less conservative fluid service factor. Because FPLP’s MAOP already includes derating factors for pressure and fluid, no additional deratings are required. FPLP’s MAOP is based on a 50-year design life.

5.3

Cyclic Pressure

Water transfer, disposal or injection applications and oil gathering applications are typically quite corrosive and are a natural fit for FPLP’s corrosion resistance properties. However, to ensure the optimal performance and reliability of FPLP in these applications, consideration must be given to the cyclic pressure characteristics of the system design and the operating regime. As part of Flexpipe’s commitment to quality and customer satisfaction, Flexpipe offers an application evaluation process. The pipeline end user provides the operation parameters as per

21

Based on Figure 1 of API RP 15S (2006).



20

the Application Review Form for Flexpipe to assess. Flexpipe Systems application engineering specialists can provide project specific recommendations regarding selection of the best product, optimal system design, and operational considerations for the intended application. Flexpipe recommends that an application review be completed for all cyclic service applications to ensure optimal performance of the FPLP and the overall system. Flexpipe cyclic service application review recommendations are based on a minimum 20 years service life. The key parameters that must be considered when evaluating the suitability of FPLP for a cyclic service application include: Type of pump: The pump type plays a major role in determining the cyclic characteristics of a pipeline system. Typical pumps used in the oil and gas industry are centrifugal pumps and piston pumps. Flexpipe recommends using single stage or multistage centrifugal pumps (e.g. REDA pumps). This type of pump provides a steady pressure free of high frequency pressure pulsations or excessive vibration; therefore, no cyclic service factor derating is required. Accordingly, pipes used with centrifugal pumps can take advantage of the full FPLP pressure rating. Applications with piston pumps (e.g. Triplex, Quintuplex) generate substantial highfrequency pressure pulsations and vibration in the pipeline. These operational characteristics can be detrimental to many pipeline materials, including FPLP. To protect this type of pipeline system from progressive damage, a cyclic service derating factor of 0.5 is required. This mirrors the requirements of CSA Z662 “Oil and Gas Pipeline Systems” clause 13.1.2.10. Accordingly, pipes used with piston pumps are limited to half the maximum allowable pressure values published in Flexpipe data sheets. For applications where piston pumps are used, Flexpipe recommends the following precautions in addition to the 0.5 cyclic service factor: o

o

Effective pulsation dampeners at the pump inlet and outlet which are selected, installed, operated and maintained as per the pump and pulsation dampener manufacturer’s recommendations. A minimum of 100 feet of steel pipe between the pump and the FPLP to assist with vibration dissipation.

For pumps such as screw pumps, progressive cavity pumps and diaphragm pumps, please contact a Flexpipe representative for project specific recommendations. Duplex pumps operating at reduced pressures may also be a suitable alternative. Please



21

contact your Flexpipe representative to discuss having an application review for your specific scenario. This review may be required to evaluate the feasibility of using Flexpipe products on your project and provide guidance on how to safely operate your pipeline in severe cyclic pressure conditions. Pressure fluctuations: Pressure fluctuations may either be the result of: o

o

Pump start/stop cycles where the pressure in the pipeline system cycles between the operating pressure and the shut off pressure, or Modifications to the system operation or layout, such as operating an additional pump or injecting into a different well.

FPLP is not intended for severe cyclic applications, with pressure cycling in excess of +/20% of the normal operating pressure, with an average frequency of once per day over a 20 year period. In order to eliminate the pressure fluctuations resulting from pump on/off cycles, Flexpipe recommends using a variable frequency drive (VFD) to regulate the flow rate while maintaining a continuous operation of the pump. Depending on their magnitude and frequency, pressure pulsations and fluctuations could be detrimental to the pipe performance. Contact your Flexpipe representative for a project specific application evaluation.

5.3.1 Pump Jacks FPLP’s corrosion resistance properties are a natural fit for corrosive oil emulsion production. However, to ensure the optimal performance and reliability of FPLP in pump jack applications, consideration must be given to the cyclic pressure characteristics of the system design and the operating regime. In general, using sound system design and good industry operating practices will optimize the integrity and life of all production equipment. The pressure differential between the upstroke and down stroke pressures generated by the operation of the pump jack is of critical importance to the long term integrity of the FPLP. Some of the design and operational factors that can affect the magnitude of the pressure differential in the flow line include: Length and diameter of the flow line Production volumes Production fluid properties



22

Down hole pump integrity Wax build-up Flow line check valve integrity Hot oiling and pigging practices For applications with an upstroke pressure above 150 psi, Flexpipe Systems recommends limiting the amplitude of the pressure differential between the routine upstroke and down stroke pressures to 50 psi for FP301 and 75 psi for FP601. For example, if the normal upstroke pressure in a FP301 flow line is 175 psig, the minimum pressure during the down stroke should be no less than 125 psig. Infrequent pressure excursions beyond these limits are generally acceptable. These recommendations are based on both qualification test results and field experience. They provide safe operating limits using a design life of 20 years. In order to ensure the long term integrity of the piping system, Flexpipe Systems recommends: Installing and maintaining a pressure switch (such as a Presco switch) set at a maximum of 100 psi above the upstroke pressure to limit the possibility of subjecting the pipeline to excessive pressure swings for extended time durations. Routinely monitoring the upstroke and down stroke pressure values using a calibrated pressure gauge mounted between the well head and the flow line. Implementing a suitable pigging program to ensure the upstroke pressure does not increase as a result of wax build up.

5.4

Flow Characteristics

5.4.1 Pipe Flow Relative to steel pipe, t he smooth internal surface of FPLP’s polyethylene liner provides favorable flow rates and reduced pressure losses as a result of reduced friction. Figure 4 and Figure 5 show representative pressure drops at various flow rates for fresh water and methane, respectively. The results shown are based on calculation of the pressure drop for the given fluid in each size of FPLP using the Darcy-Weisbach method, repeated in each case for standard steel pipe of the same nominal size. As the charts show, the pressure drop for a given flow rate in a FPLP line will be significantly lower than for the corresponding steel pipe. Conversely, a higher flow rate can be attained for a given pressure drop using FPLP. For other flow scenarios, the pressure drop can be calculated using any of the flow coefficients listed in Table 8.



23

800 700 600 I) S P500 ( p o r D

400

e r u s s e 300 r P

200 100

2" Flexpipe

2" Sch40Steel

3" Flexpipe

3" Sch40Steel

4" Flexpipe

4" Sch40Steel

0 0

5000

10000

15000

20000

25000

30000

35000

Flow Rate (bbls/day)

Figure 4: Representative Pressure Drop Comparison: Water at Various Flow Rates 0

*Calculations based on 1 mile of pipe length, with fresh water at 30˚C (86 F) 500 450 400 )I 350 S (P

300

p o r

D250 e r u s 200 s e r P150

100 50

2"Flexpipe

2"Sch40Steel

3"Flexpipe

3"Sch40Steel

4"Flexpipe

4"Sch40Steel

0 0

5000

10000

15000

20000

25000

30000

35000

40000

Flow Rate (Mcf/day)

Figure 5: Representative Pressure Drop Comparison: Methane at Various Flow Rates

*Calculations based on 1 mile of pipe length, with methane at 20 ˚C (68 0 F) compressed to 500 PSI



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Table 8: Flow Coefficients for FPLP

Hazen & Williams

150

Darcy Weisbach

0.0015 mm (0.000005 ft)

Manning

0.009

5.4.2 Fittings The inside diameter of the mandrel of the FPLP pipe fitting is smaller than the inner diameter of the pipeline (see Section 3.2). However, the restriction is minimal, and very few fittings are required even for very long lengths of pipe. The associated pressure loss is negligible compared to the pipe friction discussed above. The following equations and K factors for Flexpipe coupling fittings can be used to calculate the loss in pressure or pressure head due to the flow constriction. Pressure loss:

Pfitting

K

h fitting Pressure head loss:

V2 2

K

V2 2g

Where: = fluid density V = fluid velocity g = acceleration due to gravity K = factor from Table 9 Table 9: K Factor for Flexpipe Coupling Fittings Fitting size K factor 2” 0.16 3” 0.15 4” 0.12

5.5

Durability

FPLP is a durable, rugged product. The high-strength, pipe-grade thermoplastic used in the jacket protects the fiber from the environment. The jacket is highly resistant to cracking, and will not bruise, chip, or flake under normal handling. FPLP can be unspooled over rocks and rough terrain, or pulled into failed pipelines. The impact resistance of FPLP has been demonstrated by impact testing according to API RP 0 15S Section 5.5.2 at -25 C (-13 F).



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5.6

Corrosion

FPLP liner and jacket will not corrode. External corrosion control of FPLP fittings is achieved by the application of moisture resistant tape, and internal corrosion control by standard coatings on the fittings (see Section 3.5). Additional corrosion control via cathodic protection is an available option (see Section 6.15) and may be required by local regulations (i.e.: Energy Resources Conservation Board – ERCB of Alberta).

5.7

Erosion

FPLP will experience less erosion than steel in wet slurry applications (ie solid particles carried in a liquid) due to the elasticity and toughness of the liner material. However, a sufficient flow velocity should be maintained to prevent solid particles from settling out of the carrying liquid. Settled particles that slide along the bottom of the pipe may cause wear to the bottom surface. Dry slurry applications (ie solid particles carried by a gas) may cause excessive static electricity build-up and/or heating due to dry particles sliding on the surface. FPLP may not be suitable for dry slurry applications. Please contact your Flexpipe representative to conduct an application evaluation for your project in this case.

5.8

Ultra-Violet Protection

Flexpipe adds a UV stabilizer to the jacket material during the extrusion process. FPLP’s black, white and yellow jacket options provide a minimum of 20 years protection against UV exposure. The blue jacket on some existing FPLP provides a minimum of 2 years UV protection and is no longer produced.

5.9

Bend Radius

The minimum allowable bend radius of FPLP differs in operation (pressurized) and transport/handling (un-pressurized) conditions, as shown in Table 10. Table 10: Minimum Bend Radius for Operation, Transport and Handling of FPLP Minimum bend radius Minimum bend radius FP150, FP301, OPERATION TRANSPORT & HANDLING and FP601 (ft) (ft) (m) (m) 2” 1.2 4.0 0.8 2.5 3” 1.8 6.0 1.0 3.3 4” 2.1 7.0 1.3 4.2 Note: The minimum radius does not apply to fittings/couplings. These joints

need to be kept straight to avoid point loading at the end of the fitting. Typically there should be no bends within 1.8 meters (6 feet) from a fitting.



26

5.10 Permeation Gas molecules are able to travel very slowly through pipe walls by moving through the spaces between the molecules of the pipe material. This is known as permeation of the gas. All piping materials allow gases to permeate to some extent, but composite materials allow more than steel pipes do.

FPLP has pressure a self-venting design up which allows permeated vent atthe the fittings. This prevents from building within the annulus (the gases space to between liner and jacket that contains the fiber reinforcement layer), thereby avoiding the risk of liner collapse during line depressurization. Field testing has shown that the actual rates of gas release from FPLP are generally insignificant (see Section 9.2). This is supported by calculations based on a conservative model, in which the gases in the pipe permeate through the liner and then permeate through the jacket or travel along the annulus to exit through the vent hole at the fitting. The calculations use the permeability coefficients given in Table 11, which are experimentally determined from testing conducted on unreinforced polyethylene. The following example provides a representative illustration of the extent of permeation in FPLP. Table 11: Permeability Coefficients for HDPE

Permeant Methane H2S CO2

Permeability coefficient at 40˚C (104˚F) (cm3/cm-sec-MPa) (inch3/inch-sec-psi) -7 -10 1 x 10 1.07 x 10 -7 -10 1 x 10 1.07 x 10 -7 -10 5.5 x 10 5.88 x 10

FPLP liner has a similar SDR (Standard Dimension Ratio) in all sizes, which results in the same permeation rate for all sizes. Table 12 shows expected permeation rates for a gas mixture of 89% methane, 1% H2S, and 10% CO2. To obtain expected permeation rates at different temperatures, it can be approximated that a 5˚C (9 ˚F) increase in temperature results in a 30% increase in permeation rate.



27

Table 12: Representative Permeation Rates for FPLP

Permeation rate 3

3

cm /m of pipe/day (in /ft of pipe/day)

Pipe pressure Pipe at 10˚C (50˚F)

Pipe at 40˚C (104˚F)

Pipe at 60˚C (140˚F)

89% methane 1% H2S 10% CO2 Total mixture 89% methane 1% H2S 10% CO2 Total mixture 89% methane 1% H2S 10% CO2 Total mixture

689 kPa (100 psi) 6 (0.1) 0.1 (0.001) 4 (0.07) 10.2 (0.2) 30 (0.6) 0.3 (0.006) 18 (0.3) 48 (0.9) 85 (2) 1 (0.02) 53 (1) 139 (3)

5171 kPa (750 psi) 46 (0.9) 0.5 (0.01) 29 (0.5) 76 (1.4) 224 (4) 3 (0.05) 138 (3) 365 (7) 639 (12) 7 (0.13) 395 (7) 1041 (19)

10,342 kPa (1500 psi) 93 (2) 1 (0.02) 57 (1) 151 (3) 447 (8) 5 (0.09) 276 (5) 728 (13) 1277 (24) 14 (0.3) 789 (15) 2080 (39)

5.11 Expansion/Contraction and Axial Growth FPLP has been engineered to significantly minimize axial strain as a result of pressure or temperature changes in operation. When pressurized, expansion and contraction of FPLP is governed by the mechanics of the fiber reinforcement layer, and axial expansion due to temperature or pressure changes is minimal. Radial expansion will occur, but will be far less than in unreinforced polyethylene. When unpressurized, FPLP will display approximately the same amount of growth or contraction with temperature changes as unreinforced polyethylene. However, the low modulus and viscoelastic properties of the pipe allow it to shift and relax, thereby minimizing any loads exerted at end connections. Therefore, expansion loops and special consideration for end loads at termination points are not required. Sudden temperature and pressure changes should be avoided. Gradual or stepped flow increases should be used on very hot or very cold days to allow for gradual temperature and pressure changes in the system.

5.12 External Load and Internal Vacuum Capability When the pressure outside FPLP may exceed the pressure inside the pipe, the pipe’s ability to withstand collapse should be considered. External pressure arises from factors such as ground water pressure and the weight of soil above the pipe. Additional loads (such as the weight of



28

water or live loads due to moving vehicles) must be considered if the pipe runs through a bore below a creek, roadway, etc. Internal vacuums may result from gravity flow of liquid down a slope when the pipeline is unpressurized. The ability of FPLP to withstand collapse is based on the total difference in pressure between the outside and inside of the pipe. When the external pressure exceeds the internal pressure, the difference can be considered as a net external pressure (or equivalently, a net internal vacuum). The net external pressure can be calculated as follows:

Pnet,external

Pexternal

Pinternal

where Pinternal is a negative number for an internal vacuum, thus increasing Pexternal . FPLP’s external pressure resistance for buried applications has been measured according to 22 ASTM D2412 , in accordance with Clause 13.1.2.11 of CSA Z662, based on a 50-year design life. The maximum net external load that FPLP can withstand at 23˚C (73˚F) is 214 kPa (31 psi), when installed in backfill embedment material with a soil modulus of 1000 psi or greater. This includes most soils, with the exception of very fine-grained or organic soils such as muck and 23 clay . If the total combination of dead loads, live loads, and internal vacuum will exceed this, the FPLP should be protected by a steel casing (see Section 6.9).

When on the surface, there is no support from surrounding soil. Under these conditions, FPLP can withstand a net of 101flow kPa down (14.7 psi) at 23˚C (73˚F), the maximum vacuum pressure that will bevacuum created pressure due to gravity slopes. Higher temperatures or long term exposure to liquid hydrocarbons may reduce the net external load that FPLP can withstand. FPLP is not intended for subsea applications.

5.13 Thermal Conductivity FPLP thermal conductivity properties result from the properties of the polyethylene and fiberglass materials. Accordingly, FPLP is a good thermal insulator with higher resistivity than metallic pipes. Table 13 lists the thermal conductivity and resistivity values of the FPLP product range. Table 13: FlexPipe Linepipe Thermal Conductivity and Resistivity 22

ASTM D2412Standard Test Method for Determination of External Loading Characteristics of Plastic Pipe by Parallel-Plate Loading

23

The soil modulus is typically 1000 psi or greater for backfill embedment materials consisting of manufactured angular granular materials, coarse grained soils with little or no fines with a Proctor density greater than 70%, or coarse grained soils with fines with a Proctor density greater than 85%; the soil modulus is not typically greater than 1000 psi for fine-grained or organic soils (muck, clay, etc.).



29

Item Pipe Size Wall Thickness R'-value K'-value

Units


Units


Units

6

mm m*K/W W/m*K

mm m*K/W W/m*K

mm m*K/W W/m*K

2" FP150 n/a n/a n/a

Values 3" FP150 9.14 0.15 6.80

4" FP150 11.30 0.14 6.97

Units

2" FP301 7.75 0.28 3.53

Values 3" FP301 9.91 0.25 4.04

4" FP301 12.57 0.25 4.07

2" FP601 9.40 0.47 2.14

Values 3" FP601 11.94 0.41 2.45

4" FP601 15.37 0.42 2.40

in hr*ft*F/Btu Btu/hr*ft*F

2" FP150 n/a n/a n/a

Values 3" FP150 0.36 0.25 3.93

4" FP150 0.45 0.25 4.03

2" FP301 0.31 0.49 2.04

Values 3" FP301 0.39 0.43 2.33

4" FP301 0.50 0.43 2.35

2" FP601 0.37 0.81 1.24

Values 3" FP601 0.47 0.71 1.41

4" FP601 0.61 0.72 1.38

Units in hr*ft*F/Btu Btu/hr*ft*F

Units in hr*ft*F/Btu Btu/hr*ft*F

Installation

This section provides a general overview of the installation of FPLP. Please refer to the Installation Guide for further information.

6.1

Field Services Support

The Flexpipe Systems Field Services Department provides support services for the installation of Flexpipe products, including training courses, project coordination services, equipment rentals, onsite inspectors, and installation supervisors. Experienced managers and project coordinators are on call 24 hours per day, 7 days per week. Flexpipe strives to ensure successful installation of its products on every project. Fitting installation equipment is available from Flexpipe for sale or rental. Information on this equipment can be found in the Flexpipe Systems Installation Guide. In addition, Flexpipe offers a variety of specialized installation accessories, including A-frames for carrying pipe reels, riser support trays, pull tools, custom cleaning pigs, moisture resistant Denso products, Polyken tape and sacrificial anode kits for cathodic protection. For more information on these accessories, see the Installation Guide.

6.2

Transportation

FPLP is coiled onto 3.66-meter (12 ft)-diameter, custom engineered transport reels that have either 1.22-meter (4 ft) or 2.44-meter (8 ft) widths. Multiple reels can be transported on a



30

standard flat-deck trailer, or a single reel can be transported on a special reel trailer. The reel capacities and weights are provided on the Product Data Sheets in the Appendix. Some reels can be disassembled in the field and stacked to reduce space requirements, which allows up to five times as many empty reels to fit on a truck deck. Please contact your Flexpipe representative for more information and for Flexpipe’s recommended disassembly procedure.

6.3

Trenching

FPLP can easily be un-spooled and placed into a trench or ditch. FPLP is handled and installed much like coiled HDPE pipe. The bending stiffness of the two is very similar, but FPLP has less “memory” than HDPE pipe and will lay flat more readily. Soil condition and padding requirements for FPLP are typically similar to those for steel pipelines The flexibility of FPLP allows it be easily threaded underneath existing lines for easy line crossings. This eliminates the need to cut the pipe and install extra fittings at line crossings.

6.4

Plowing

In a singlepass operation, a pipeline plow can trench, install FPLP and couplings, and cover the trench. This method is most beneficial when long continuous lengths of pipe are to be installed, and minimizes disturbance to the environment.

6.5

Insertion as a Freestanding Liner

In situations where an existing pipeline has failed, FPLP can be pulled inside the failed pipeline as a remedial line. FPLP is a freestanding liner, and does not depend on the existing pipeline for any structural support.



31

In pipeline remediation applications there must be adequate clearance between the outer diameter of the FPLP and the inner diameter of the existing conduit. Table 14 shows the general compatibility of various conduits for FPLP insertion. The existing conduit must be free of obstructions that could damage the pipe (fittings, wax, scale, etc.). Excavating and removing any fittings is often a simple way to make a line compatible for insertion of FPLP, provided that enough pipe is removed to avoid bending the FPLP tighter than the minimum radius for operation given in Table 10. Flexpipe fittings can be pulled along with the FPLP. A centralizing collar or sleeve is required before each fitting to prevent the fitting from catching on weld beads or other discontinuities inside the conduit. The maximum allowable pull forces for FPLP are shown in Table 15, and should not be exceeded with any type of pull tool. Please see the Installation Guide for information on pull tools available from Flexpipe. Table 14: Conduit Compatibility for FPLP Insertion Conduit FPLP 2" FP301 2" FP601

3" Steel 0.188" 0.120" wall wall P P N P

3" FP150 3" FP301 3" FP601 4" FP150 4" FP301 4" FP601

Sch. 40 PF PF

4" Steel 0.188" 0.125" wall wall PF PF PF PF

Sch. 80 PF PF

Sch. 40 PF PF

6" Steel 0.188" 0.156" wall wall PF PF PF PF

0.125" wall PF PF

N N N

N N N

P N N

P P N

P P P

PF PF PF

PF PF PF

PF PF PF

PF PF PF

PF PF PF

N N N

N N N

N N N

N N N

N N N

P P P

P P P

PF PF PF

PF PF PF

PF PF PF

N = Not compatible

P = Compatible for pipe without fittings

PF = Compatible for pipe with coupling fittings

Note: The above table is based on 0.15” clearance on diameter between FPLP and the steel pipe weld bead, and a steel pipe weld bead allowance of 0.125”on diameter.

Table 15: Maximum Allowable Pull Forces for FPLP

Pipe Size (nominal) (in) 2 3 4

Maximum pull force (kgf) 1000

(lbf) 2200

2040 2720

4500 6000



32

6.6

Surface Installation

Where permitted by the appropriate regulatory body, FPLP can be used above ground for permanent and temporary surface flowlines. Appropriate hazard control measures should be implemented in consideration of the elevated risk of injury or property damage inherent in surface installations.

Non-metallic pipelines both may be more External forces, duringsusceptible to external damage than metallic pipelines. installation and during future disturbance or construction in the area, are additional potential causes of external damage to pipelines. By their nature, surface pipelines are exposed to an uncontrolled environment and are exposed to greater risk of damage than buried pipelines. Examples of surface damage risks include sharp rocks, existing and growing foliage, fire, earth slides, flooding, vehicular traffic, weapon discharge, vandalism, and lightning strikes. Damage to or misuse of Flexpipe products may result in uncontrolled release of the product being transported, which may result in serious injury or death. The energy stored in a pressurized compressible gas is significant, and may result in a highly explosive failure mode with the potential to cause significant property damage, serious injury, or death. Surface pipelines are subject to heating by solar radiation. FPLP with black jacket readily absorbs solar radiation and can reach excessively high temperatures very quickly when exposed to direct sunlight. This is damaging and detrimental to the pipe. FPLP with white jacket reduces solar heating and is required for FPLP surface lines. The operating temperature of the pipe, including the effect of solar heating, must be prevented from exceeding 60˚C (140˚F). When used as a temporary surface line, FPLP can be unwound onto the surface and rewound back onto the reel. Use only Flexpipe-certified contractors or have a Flexpipe field personnel on site when rewinding FPLP back onto reels. If done improperly, this process can cause damage to the pipe, including kinking, cutting, scraping, and abrading. If the FPLP is subsequently unwound for further pipeline use, this damage can result in pipeline failure. FPLP is designed to vent gases that permeate from the transported fluid through the liner. Permeated gases travel via the annulus reinforcement layer and are released at the fittings



33

through a vent hole in each fitting. Permeated gases may also be released along the length of the pipeline. Operational experience has shown that unrestrained Flexpipe products installed in surface line applications may experience undesirable pipe movement during operation. Excessive pipe movement may increase the risk of damage and/or reduced integrity. In order to reduce the risk of undesirable pipe movement, Flexpipe recommends implementation of some measures during the pipeline installation. These measures include hydro testing the line with a loose end, and securing the line at all corners or bends by trenching or sand bagging. Please refer to the Flexpipe Systems Installation Guide for further recommendations on the installation of surface lines.

6.7

Support Spacing

For elevated support of FPLP, a continuous tray which is wide enough to allow for the expected thermal expansion and snaking is recommended. FPLP may also be supported using individual (non-continuous) pipe supports or hangers, as long as the expected thermal expansion can be accommodated. . The pipe should be allowed to rest in a rounded cradle, with a length approximately equal to or greater than the nominal diameter of the pipe being supported. Supports should have rounded edges that will not cut into the pipe. In order to prevent excessive sag between supports, Flexpipe recommends spacing the supports no farther than the distances given in Error! Reference source not found.. Table 16: Recommended Pipe Support Spacing for FPLP Recommended maximum support spacing FP150, FP301, Liquid service Gas service and FP601 (m) (ft) (m) (ft) 2” 1.1 3.5 1.2 4 3” 4”

6.8

1.2 1.5

4 5

1.5 1.7

5 5.5

Buoyancy and Pipe Weights

FPLP will float in water or muskeg if not weighted or buried in a clay base. If conditions are suitable, FPLP may be plowed into muskeg without weighting. The suitability of the conditions may be evaluated based on existing pipelines in the area and consultation with Flexpipe or plow installation contractors.



34

If there is a concern that the pipe may float, FPLP can be weighted during installation. The weights should not have sharp edges that could point-load or cut the protective jacket of the FPLP. Sand-filled saddlebag weights are recommended. When weights are used, it is extremely important that the pipe is handled and lowered into the ditch by lifting on the weights directly. Lifting on the pipe may cause the pipe to kink or be damaged by the weights. The following formulas can be used to calculate the pipe buoyancy per unit length (note that some unit conversions may be required). To keep the pipe submerged, the sand bag weight per unit length must be slightly more than the buoyancy force per unit length. Note that there will also be a buoyancy force on the sand bags themselves, which is compensated for in the formulas below. Pipe cross - sectional area OD 2

4

Weight of fluid displaced per unit length of pipe Pipe cross - sectional area Fluid density Net buoyancy per unit length of pipe Weight of fluid displaced per unit length - Pipe weight per unit length

Note that the pipe will sink if the net buoyancy is less than 0.

Submergedsand bag weight requiredper unit length of pipe Net buoyancyper unit length of pipe 1.1 Flexpipe recommends multiplying by 1.1 to ensure the pipeline is adequately weighted to remain submerged.

Weight of fluid displacedby sand bag Volumeof fluid displacedby sand bag Fluid density Submergedweightof sand bag Weight of sand bag in air - Weight of fluid displacedby sand bag Submerged weight of sand bag Sand bag spacing Submerged sand bag weight required per unit length of pipe Note: The sand bag spacing should be small enough to prevent the unrestrained pipe between sand bags from rising too far.

The recommended dry sand bag weight is shown in Table 17 for each type of FPLP. These 3 3 results are based on muskeg with a fluid density of 1121 kg/m (70 lb/ft ).



35

Table 17: Recommended Sand Bag Weight for Weighting FPLP

Pipe weight per length

FPLP

Pipe OD

Recommended a Weights

Recommended Maximum Spacing

(kg/m)

(lbs/ft)

(mm)

(in)

(kg)

(lb)

(m)

(ft)

FP150

3” 4”

2.5 4.0

1.7 2.7

95 122

3.75 4.80

100 100

220 220

8.9 5.3

29.2 17.4

FP301

2” 3” 4”

1.7 3.0 4.9

1.1 2.0 3.3

69 97 124

2.73 3.80 4.89

27 100 100

60 220 220

5.2 9.1 5.6

17.1 29.9 18.4

2.5 1.7 73 2.86 27 60 5.9 19.4 2” 3” 4.3 2.9 101 3.96 100 220 10.3 33.8 4” 6.9 4.6 130 5.11 200 440 12.1 39.7 a Dry sandbag weight. These weights already include the recommended safety factor of 1.1 to ensure the pipe remains submerged.

FP601

6.9

Crossings

FPLP is well-suited to a variety of crossings. Design of road, railway, and highway crossings must be in accordance with the regulations of the governing body, local authority, railway company, or highway department. Where applicable, depth of cover shall not be less than the applicable requirements listed in Table 4.9 of CSA Z662 Clause 4.11. Flexpipe recommends casings for: Crossings of all public roads, highways and railways. Crossings of lease roads and general areas where only light weight traffic is expected (cars and pick up trucks) wherever the minimum burial depth is shallower than 1.2 meters (4 ft). Crossings of lease roads and general areas where heavy weight traffic is expected (heavy trucks, cranes) wherever the minimum burial depth is shallower than 2 meters (6.6 ft). Bores more than 150 meters (500 ft) in length. Steel casings may be required by regulations. For uncased bores, the suitability of the soil conditions should be verified (see Section 5.12).

Please see the Installation Guide for information on installations involving crossings.



36

Centering spacers are not required for isolating FPLP from the metal casing. Allowing the pipe to snake inside the casing can accommodate minor thermal length changes of the FPLP in the casing. Clause 13.1.4.7 of CSA Z662 requires protection to be provided for the pipe at entry and exit points of the casing to prevent unacceptable shear and bending loads that could develop from settlement and embedment consolidation. A well-compacted trench bottom and bedding, exit and entry sand bagging, or other suitable protection should be provided. Cathodic Protection (CP) of the steel casing is not required unless requested by the local authority, railway company or highway department. If it is required, CP can be provided by installing sacrificial anodes on the casing

6.10 Risers FPLP may be terminated underground with either a flange or weld neck fitting. Alternatively, it can be brought to surface and supported by a metal support tray (riser support) mounted onto pilings. The purpose of the riser support is to prevent unnecessary shear or tensile loads on the FPLP that could be caused by settling of backfill and earth movement. Sand bagging or other suitable protection should be provided at the horizontal transition of the FPLP to the riser support. For further information regarding risers see the Installation Guide. The aboveground portion of the riser must be covered with insulation or white Polyken tape. FPLP should be protected from mechanical damage similar to other piping materials above ground, depending on expected hazards in the area. FPLP is a ductile material and can withstand reasonable impact even at low temperatures.

6.11 Tracer Wire FPLP is non-metallic. Therefore, tracer wire is required for buried installations to allow for future location of the pipe. The tracer wire should be installed simultaneously with the pipe and checked for electrical continuity immediately after installation. The wire termination points should be secured and clearly marked at readily accessible locations above ground.

6.12 Cold Temperature Installation FPLP can be installed in cold, winter conditions, provided that precautions are taken. The precautions are based on the temperature of the pipe; therefore, wind-chill conditions do not apply. Consideration must also be given to the difference between the ambient temperature



37

and the actual pipe temperature. FPLP has very low thermal conductivity, which means that it cools down or heats up very slowly. As a result, if pipe is stored outside over night, the pipe may be much cooler than the ambient temperature the next day. When necessary, the entire reel of pipe must be pre-heated to a temperature above -25˚C (- 13˚F) prior to deploying (unspooling) or plowing. Please refer to the Flexpipe Systems Installation Guide for recommended precautions for installing pipe at temperatures below freezing.

6.13 Heat Tracing FPLP may be heated by means of a heat tracer wire to prevent freezing. However, the heat tracer must be separated from the pipe by an insulation barrier to prevent concentrated hot spots or over-heating of the jacket. Flexpipe recommends a sandwich type insulated barrier with an insulation/heattrace/insulation configuration, as shown in Figure 6. Because the FPLP jacket material is a very poor thermal conductor, concentrated hot spots will appear directly below the heat tracing wire if an insulated barrier is not used. 0

0

The maximum operating temperature of FPLP is 60 C (140 F). Therefore, it is very important to regulate the amount of heat tracing per unit length of pipe accordingly.

Figure 6: Sandwich Type Insulated Barrier Configuration



38

6.14 Fitting Installation Flexpipe’s proprietary fittings can be installed in the field in 20 to 30 minutes by an experienced technician, and must be installed by certified technicians with specialized tools and equipment. Flexpipe works with

contractors and customers to provide certification training so that certified thirdparty contractors can provide the fitting installation service. Alternatively, Flexpipe can provide certified fitting installation technicians. Fitting installation equipment is engineered and designed specifically for Flexpipe products, and is available from Flexpipe on a rental basis.

6.15 Cathodic Protection FPLP is corrosion resistant pipeline system and does not require cathodic protection. Wherever regulations require cathodic protection for buried metallic fittings, Flexpipe can make available ribbon anode kits tailored for Flexpipe fittings. Further information is available in Section 3.5.

6.16 Tying into Steel – Welding Flexpipe Systems has designed a weld neck fitting to accommodate tying into existing steel lines, or steel risers. This fitting eliminates the need for a buried flanged connection. See Section 3.3 for more details on the materials used in weld neck fittings.

6.17 Tying into Plastic Transitions from FPLP to poly or other pipeline materials can be achieved by using transition fittings designed for the other pipeline material. These fittings can be connected to Flexpipe fittings by means of welding or standard flanged connections as appropriate. For example, a poly-to-steel transition fitting can be welded to a Flexpipe weld neck fitting to form a poly-toFPLP transition fitting.

6.18 Field Pressure Testing of New Pipelines FPLP is designed to accommodate the pressure-testing requirements specified by regulatory standards and codes. Due to the safety factors built into the FPLP design, there is no need to upgrade to a higher pressure-rated pipe if testing is required above the stated MAOP. Field pressure testing requirements and recommendations for FPLP depend on whether the pipeline is a new installation or a tie-in or repair job. Flexpipe recommends that new FPLP pipelines be subjected to a 24 hour hold test at 1.25xMAOP. Check with local regulations to ensure required hydrotest pressures are met. Where necessary (e.g. low points in hilly terrain) and to account for unexpected pressure



39

fluctuations, FPLP can be allowed to reach a maximum pressure of 1.5 x MAOP at the lowest point in the line during the pressure test. Suggested procedures for pressure testing new pipelines are given in the Flexpipe Systems Installation Guide. To minimize the potential risk of injury or property damage in the unlikely event of a pressure test failure, a relatively incompressible liquid such as water is recommended as the pressurizing medium. Methanol is compatible with FPLP and is commonly used as an additive to prevent freezing when pressure testing at low temperatures. Pressure test failures involving compressible media such as air result in the sudden uncontrolled release of a great deal of energy, with the potential for property damage, personal injury, or death. Pressure testing with a gas medium is acceptable for test pressures up to 2900 kPa (420 psi) only, provided that: it is not prohibited by local regulations or standards; appropriate precautions are taken to protect the pipeline from damage and minimize the risks associated with a pressure test failure. Under no circumstances will Flexpipe Systems be liable in any way for any loss, damage or injury of any kind (whether direct, consequential, punitive or otherwise) incurred as a result of the use of a gas medium for pressure testing. Flexpipe recommends tie-ins, repaired and replaced sections of pipelines be left exposed as the pipeline is brought into service and visually monitored for leaks for at least four hours, at the highest available operating pressure. Re-testing of the entire pipeline is not recommended. Pressure testing pipelines to a pressure greater than MAOP is generally only appropriate prior to a pipeline being in operation. Pre-testing of the tie-in and/or replacement pipe is also not necessary.

7

Accessories

For complete information on tools and accessories required to install Flexpipe products, please refer to the Flexpipe Systems Installation Guide.



40

7.1

A-frames

A-frames are available on a rental basis for carrying spools of FPLP during deployment. Please contact your Flexpipe representative for more information. The following reference drawings are available from Flexpipe Systems upon request:

8FT A-Frame Drawing 4FT A-Frame Drawing

7.2

Riser Support Trays

Riser trays support FPLP from shear forces as the pipe comes out of the ground to connect to surface pipe (see Section 6.10). Flexpipe offers 45º and 90º riser support trays for each pipe size, as well as hardware for securing the pipe to the tray. The following reference drawings are available from Flexpipe Systems upon request: 45° Riser Drawing 90° Riser Drawing S-bend Riser Drawing

7.3

Pull Tools

Flexpipe Systems offers four types of pull heads for FPLP. Please refer to the Installation Guide for further information on the available pull tools.

7.4

Sacrificial Anodes

Flexpipe anode kits consist of a zinc ribbon anode connected to a copper lead wire, along with a roll of cloth tape to fix the anode to the FPLP and a stainless steel hose clamp to secure the lead wire to the fitting. Please refer to Section 3.5 for more information on performance and installation.

8 8.1

Operations Startup

On very hot or very cold days, start up procedures for FPLP should include a gradual or stepped flow increase to allow for gradual temperature and pressure changes in the system.



41

8.2

Pigging

FPLP is suitable for pigging. However, Flexpipe fittings have an ID that is smaller than the ID of the pipe. To ensure proper pigging, the use of a medium-density foam bullet pig, or a Flexpipe disc (cleaning pig) is required. Failure to use a Flexpipe-approved pig could result in the pig becoming stuck in a fitting. Flexpipe supplies tags for installation on risers to warn operators of the temperature limitations of the pipe and pigging restrictions of the fittings. Flexpipe recommends medium-density (5 lb) foam bullet pigs for dewatering and Flexpipe urethane disk pigs for removing wax build-up. The foam bullet pigs are also available with a urethane coated tip, which provides protection against damage during pigging operations. Ball pigs and brush pigs must not be used. Flexpipe urethane disk pigs are designed specifically for FPLP, and offer more aggressive cleaning. However, a greater pressure differential is required to move them through fittings, and they require the presence of some liquid in the pipeline to provide lubrication. Urethane pigs are available from Flexpipe Systems in a variety of durometers to suit different pigging requirements (see Table 18). Table 18: Custom Urethane Disk Pigs for FPLP

Size 2”

3”

4”

Durometer 80 70 80 70 60 70 60

Color Yellow Green Yellow Green Purple Green Purple

Flexpipe urethane pigs cannot be used for threaded fittings, and are not recommended for any T fittings or welded thin-wall elbows. They may be used with schedule 40 or 80 welded elbows (45º or 90º). If a pigging program is required on a FlexPipe line joining another line, Flexpipe recommends a y-lateral joint (see Section 3.1), oriented to allow the pig to enter the joint from one of the arms and exit from the bottom of the Y. Pig launchers must be sized to accommodate the Flexpipe pig dimensions as indicated in Table 19.



42

Table 19: Flexpipe Pig Dimensions for FPLP

Pipe Size Flexpipe urethane pig Flexpipe urethane pig Required pressure (nominal) diameter length differentiala (in) (mm) (in) (mm) (in) (kPa) (psi) 2” 57.2 2.25 101.6 4.0 138 20 3” 82.6 3.25 139.7 5.5 207 30 104.9 4.13 165.1 6.5 276 40 4” aRequired pressure differential is approximate and assumes the line is lubricated.

8.3

Hot Oiling

FPLP can be hot oiled. Flexpipe Systems recommends that the procedures and safety guidelines provided by the hot oiling service provider and the operator’s production engineers be followed. The maximum allowable operating pressure and temperature of FPLP listed in Section 5.2.2 must not be exceeded at any time during the hot oiling procedure. Only Flexpipe-approved pigs may be used for FPLP (see Section 8.2).

8.4

Static Electricity

Standard operating and maintenance procedures for handling non-conductive pipe and dissipation of static electricity apply when working with FPLP. Static charge on a plastic pipe can be generated by friction during the physical handling of the pipe in storage, shipping, installation, and repairing operations. Also, flowing gas in an operational plastic pipe containing particulate matter in the form scale, rust, or dirt can elbows, generatevalves, static neck-downs, electricity. Other causes of static charge include gas flowofdisrupters such as pipe and leaks. Discharge of static electricity in the presence of a flammable gas-air mixture may cause an explosion or fire and result in property damage and/or personal injury. When conditions exist such that a flammable gas-air mixture may be encountered and static charges may be present, all company (pipeline operator, utility, contractor, etc.) procedures for static electricity safety and control should be followed, including procedures for discharging static electricity and personal protection. Information on handling static electricity in plastic pipelines is available in Occupational Safety and Health Administration Hazard Information Bulletin dated September 30, 1988.

8.5

Secondary Excavations

Excavation near installed pipe is the most common risk to the integrity of operational FPLP due to the potential for external damage. The preferred method for excavating buried FPLP is hydro-excavation (hydrovac).



43

The following practices are recommended to minimize the risk of external damage to the pipe: Identify the location of the FPLP using the tracer wire installed with the pipe. Follow hydro-excavation procedures that comply with industry best practices for excavation of thermoplastic piping, including: o Use of protective tips (eg rubber, neoprene, etc) on spray nozzles and suction hoses. o Use of multi-jet nozzles with diverging spray patterns; not oscillating, rotating, or converging pattern nozzles. o Continuous movement of the spray wand while excavating. o A distance of at least 12 ” between the spray nozzle and the pipe. o Spray pressures as low as practical and not above 2000 psi. o Water temperatures below 60˚C (140˚F). Inspect the exposed pipe thoroughly after the excavation is complete. Support the weight of exposed pipe at intervals of not greater than 6m (20 feet). Take appropriate precautions to avoid impact or sustained pressure from sharp or heavy objects. Exercise care during any mechanical excavation near FPLP. Inspect all exposed FPLP for external damage prior to backfilling. Replace any sections of FPLP that are damaged during excavation. Use proper backfill procedures.

8.6

Field Pressure Testing of Existing Pipelines

When a cut out is replaced, a failure is repaired or a tie-in is connected to a previously operating pipeline, the new pipe and the connections used to join or repair the pipe should undergo a service test. Flexpipe recommends the repaired, replaced or connected section be left exposed as the pipeline is brought into service and visually monitored for leaks for at least four hours, at the highest available operating pressure. Re-testing of the entire pipeline is not recommended. Pressure testing pipelines to a pressure greater than MAOP is generally only appropriate prior to a pipeline being in operation. Pre-testing of the tie-in and/or replacement pipe is also not necessary.

9 9.1

Reliability History

As of 2009, over 7 million meters (23 million feet) of FPLP and 20 thousand fittings have been installed throughout Western Canada, the United States, and internationally. FPLP is currently in service carrying a wide range of liquid and gas media, at various operational temperatures and pressures up to and including the published limits. A number of different installation methods have been employed over a wide range of climate, soil, and terrain conditions.



44

Flexpipe products continuously meet the extensive challenges of operation in demanding applications, and have earned an excellent record as high quality and dependable products in the field. This has been demonstrated through numerous evaluations of operating pipelines in a variety of applications.

9.2

Leak Testing

Approximately 53 km (174,000 feet) of in-service gas gathering pipelines, including over 140 coupling and end fittings, have been tested for gas leaks by an independent emission detection company. No gas was detected along any of the pipelines and only trace amounts of gas were detected at the surface end fitting vent holes, as expected. In fact, the only high gas concentrations detected during leak testing were discovered to be leaks in the threaded connections of nearby steel piping.

9.3

Cut-outs

In order to satisfy Canadian regulatory requirements, Flexpipe Systems has cut out and tested a number of pipe samples after two years of service to validate the long-term performance of FPLP. In all cases, destructive burst testing results of the cut-out samples exceeded the minimum acceptable levels. In addition, detailed dissections were carried out and none of the samples showed any indications of degradation. The results of the destructive burst testing are found in Figure 7. These results demonstrate that there is no degradation of pipe performance after two years of service. The most significant risk to the integrity of FPLP is external damage. The risk of external damage during operation most commonly arises due to excavation near installed FPLP. Recommended practices to minimize this risk are given in Section 8.5. Other operational considerations important to maintaining the integrity of FPLP include: Ensuring the maximum temperature and pressure limits are not exceeded at any time. Ensuring liquids do not freeze inside of the pipe. Ensuring the cyclic service recommendations in Section 5.3 are not exceeded. Avoiding fluid hammer due to rapid opening or closing of valves, water surge due to abrupt pump starts and stops etc. Following Flexpipe’s recommendations regarding hot oiling and chemical treatment. Utilizing appropriate hazard controls for prevention of external damage to surface pipelines.



45

Figure 7: Cut-out Burst Test Results

9.4

Integrity Verification

Many operators elect to limit their integrity verification activities to an initial pressure test after installation. In line with their risk management strategies, some operating companies may choose to exceed normal industry practice by incorporating one or more of the activities listed below into their integrity verification activities. It would typically be appropriate for an operating company to make use of the options that are matched most closely to their current practices for other pipeline materials (whether steel, composite, or plastic). Likewise, sample sizes and inspection frequencies could parallel those used for other pipeline materials.



46

Integrity verification options for FPLP include: Cut-out testing. A method for confirming pipe integrity is to remove a sample of pipe approximately 10-15 feet in length and have it tested. Flexpipe offers integrity assessment testing and analysis of such samples. Pressure testing. To verify the integrity of the pipe after a period of operation a pressure test may be conducted over a duration of 4 hours at the lesser of the maximum allowable operating pressure and 1.25 times the normal operating pressure. Visual inspection for corrosion of metallic fittings. The external condition of a fitting can be inspected by removing the denso tape. The condition of the interior coating of a flanged fitting can be inspected visually after unbolting the flanged connection. It is recommended that new gaskets and denso tape be used during reassembly. Visual inspection of jacket. Where pipe is exposed above surface the jacket can be inspected for discoloration that may indicate UV degradation. Gas detection testing. Fittings can be checked for leaks during operation using gas detection equipment. Flexpipe has performed this type of inspection on numerous buried and surface fittings in Canada in accordance with requirements of the local regulatory authority (see Section 9.2).



47

10 Appendix Product Data Sheets



I

FlexPipe Linepipe 600 A N S I- F P 60 1

Maximum Operating Pressure @ 60°C or 140°F No m inaSl iz e

Metric(mm)

Outside Diameter

Imperial (inches) Metric(mm)

Inside Diameter

Imperial (inches) Metric(kg/m)

Weight

Min. Bend Radius (operational)

Reel Diameter

Reel Width*

Reel Weight – Full*

Reel Weight – Empty*

Fitting Outside Diameter

Fitting Inside Diameter

10,342 kPa / 1500 psi 3” 4” 2”

73

101

2.86 54

3.02 4.3

1.7 1.2 4

69

99 3.90

2.9

4.6

4

1000

700

600

Imperial (ft)

3281

2297

1968

Metric(m)

3.7

3.7

3.7

Imperial(ft)

12

12

12

Metric(m) Imperial(ft)

1.2 4

1.2

2.4

4

8

6 1000 3281 3.7

4

4

1.7

6

7

2461

12

8

750

2461 3.7 12

2.4 4

12

1.2 8

3175

3719

5261

2359

7000

8200

11600

5200

Metric(kg)

680

680

1134

Imperial (lbs)

1500

1500

2500

1500

1500

2500

1500

2500

Metric (mm)

80.5

108.5

139.2

75.9

103.1

131.8

101.6

129.3

Imperial (inches)

3.17

4.27

5.48

2.99

Metric (mm)

44.5

63.5

85.9

44.5

Imperial (inches)

1.75

2.50

3.38

1.75

630

4.06 63.5 2.50

10600 1134

5.19 85.9 3.38

2631

2.4

Metric (kg)

6500

4808

2461 3.7

Imperial (lbs)

680

2948

2.7 2.1

750

3.7

1.2

3.90 4.0

1.8

750

2461

12

1.2

3.3

7

3.7

12

3.02 2.6

2.1

750

4.80

99

3.90 4.9

2.0 1.8

122 3.75

77

3.02 3.0

2,068 kPa / 300 psi 4”

95

4.89 99

2.12

1.2

Metric(m)

124

3.80 77

1.1

2.1 7

97

1.7

1 5 0 A N S I - FP 1 5 0

5,171 kPa / 750 psi 4” 3”

2.73 54

6.9

1.8 6

3”

5.11

77

2.12

Metric(m)

130

3.96

2.5

Imperial(lbs/ft)

Imperial(ft) Length / Reel*

2”

300 A N S I- F P 301

5800 680

4.00 63.5 2.50

4128 9100 1134

5.09 85.9 3.38

Flow Coefficients Hazen Williams &

150

DarcyWeisbach

e=0.000005ftor0.0015mm

Manning

0.009

*Double length reels are available as a custom order. Please contact your Account Manager for more information. Product Data is subject to change without notice. Flexpipe is not responsible for variations in data presented. Flexpipe products are protected by US Patents: 6,889,716 and 6,902,205.

888-FLX-PIPE / 888-359-7473

www.flexpipesystems.com

FlexCord Linepipe FC601

60 A0NSI

Maximum Operating Pressure @ 55°C or 131°F FC601 NominaSlize

10,342 kPa / 1500 psi 3” 4”

Metric(mm)

Outside Diameter

99

Imperial(inches) Metric(mm)

Inside Diameter

77

Imperial(inches) Metric(kg/m)

Weight

Imperial(lbs/ft)

Min. Bend Radius (operational) Length / Reel

Metric(m)

Reel Width Reel Weight – Full Reel Weight – Empty Fitting Outside Diameter* Fitting Inside Diameter*

128 5.03 99

3.02

3.90

5.1

8.6

3.5 1.8

5.8 2.1

Imperial(ft)

6

7

Metric(m)

615

525

Imperial(ft)

Reel Diameter

3.91

2018

1722

Metric(m)

3.7

3.7

Imperial(ft)

12

12

Metric(m) Imperial(ft)

1.2 4

2.4 8

Metric(kg)

3855

5669

Imperial(lbs)

8500

12500

680

1134

Metric(kg) Imperial(lbs)

1500

2500

Metric(mm)

107.1

136.5

Imperial(inches) Metric(mm)

4.22 63.5

Imperial(inches)

2.50

5.38 85.9 3.38

Flow Coefficients Hazen Williams &

150

DarcyWeisbach Manning

e=0.000005ftor0.0015mm 0.009

*Fitting dimensions do not include O.D. of flange provided for Flanged End Fittings. Fitting O.D. and I.D. apply to Flanged End, Weld-Neck, and Pipe-to-Pipe Coupling fittings. Product Data is subject to change without notice. Flexpipe is not responsible for variations in data presented.

888-FLX-PIPE / 888-359-7473

www.flexpipesystems.com

Head Office and Manufacturing Facility th 3501 - 54 Avenue S.E. Calgary, Alberta T2C 0A9 Tel: 403-503-0548 Fax: 403-503-0547 Canada Solution Centers Lampman, SK Tel: 306-861-0509 Grand Prairie, AB Tel: 780-882-1213 Drayton Valley, AB Tel: 780-514-5430 US Sales Office Houston, TX Tel: Fax:

281-227-2050 281-227-2084

US Solution Centers Grand Junction, CO Tel: 970-243-0067 Fax: 970- 243-7962 Midland, TX Tel: 432-685-0865 Fax: 432-685-0857

Toll Free: 888-FLX-PIPE (888-359-7473) Toll Free Fax: 888-359-7479 Website: www.flexpipesystems.com

Flexpipe Technical Manual English

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