FuturePipe Installation Manual 18-7-05

8/11/2019 FuturePipe Installation Manual 18-7-05

1/25

FUTURE PIPE INDUSTRIES

Spoolable Reinforced Composite Line Pipe

Installation Guide

July 2005


2/25

Spoolable Reinforced Composites(SRC) Line Pipe

INSTALLATION GUIDE

January 2005

Table of Contents

SECTION 1

1

SECTION 2

3

SECTION 3

8

SECTION 4

15

SECTION

5

16

SECTION

6

21

SECTION 7

22

Spoolable Reinforced Composite Line Pipe

INSTALLATION GUIDE

July 2005

Table of Contents

SECTION 1

Introduction

SECTION 2

Transport, Handling and Storage

SECTION 3

Installation Techniques

SECTION 4

End Connections

SECTION 5

Installing Lap Joint Flanges

SECTION 6

Field Testing

SECTION 7

Line Pipe Repairs

i


3/25

This symbol identifies instructions specific to SRC line pipe in cold weather.

CAUTION:This bullet-and-title identifies instructions relating to safety of personnel and equipment in the installation of SRC

line pipe.

NOTE:This bullet-and-title identifies instructions relating to speed and efficiency in the installation of SRC line pipe.

FPI reserves the right to incorporate improvements into our products continually, and make changes in specifications and de

scriptions contained in this publication as conditions warrant. The information in this publication is general in nature, and does

not intend to be engineering advice. FPI products are provided subject to FPIs General Terms and Conditions, and nothing

herein modifies or expands said General Terms and Conditions.

ii


4/25

This guide provides recommended practices for the installa-

tion of Future Pipe Industries Spoolable Reinforced Compos-

ite (SRC) line pipe in upstream oil and gas applications.

Line pipe is a general industry term that refers to horizontal

pipe applications and includes flow lines, production lines,

gas-gathering systems, disposal lines and injection lines.

Following these guidelines is essential to a successful installa-

tion and to a long service life. The end user is encouraged to

read and understand these recommended procedures prior to

installing SRC.

NOTE:FPIs Trainers are available to train contractors con-

cerning the proper procedures for installing SRC. All installa-

tion contractors must be trained prior to installing SRC. Con-

tact FPI for scheduling.

GENERAL PRODUCT DESCRIPTION

SRC line pipe includes the following structural elements:

Extruded thermoplastic liner on the ID of the pipe

Composite laminate consisting of carbon and/or E-glass

fibers in an enhanced amine cured epoxy matrix

Optional damage tolerance layer of E-glass fibers in

an enhanced amine cured epoxy on the OD of the pipe

PRODUCT SPECIFICATIONS

Each SRC line pipe product has a specification detailing the

physical characteristics. FPIS SRC line pipe is an engineered

product, so special products can be produced to meet specific

applications.

STANDARD LINE PIPE PRODUCTS

Cobra is the product name used to describe line pipe with

an HDPE liner. Python is the product name used to describe

line pipe with a PEX liner. Boa is the product name used to

describe line pipe with a PA-11 liner (see Table 1-1).

1

SECTION 1: INTRODUCTION

Table 1-1: STANDARD FPI LINE PIPE PRODUCTS

ProductThermoplastic

Liner

MaximumOperating

Temperature F (C)Typical Applications

CobraTMHigh Density

Polyethylene (HDPE)140 (60) Water lines, limited hydrocarbons

PythonTMCrosslinked

Polyethylene (PEX)180 (82) Same as HDPE, but for higher working temps

BoaTM Polyamide-11 (PA-11) 210 (99) Hydrocarbons, limited water*

*In applications with water, the maximum operating temperature is 165 F (74 C).


5/252

PRODUCT IDENTIFICATION

As shown in Figure 1-1, SRC line pipe is marked in epoxy

based ink with the following data:

Nominal Pipe Size (inches)

Maximum Operating Pressure (psig)

Product Name (liner material)

Footage Mark (feet and meters)

Serial Number (uniquely identifies the pipe)

NOTE: It is approximately 5 feet between the first vertical bar

of the F in FPI to the equivalent point on the next footage

mark.

CAUTION:Be sure to consult the appropriate Product Speci-

fication to verify mechanical properties before installation.

LINER MATERIALS

Thermoplastic liner materials for SRC line pipe should be se

lected on the basis of chemical compatibility with flow media

and the required operating temperature. All liners are pres

sure tested before being processed. Liners are not used in

design calculations of the finished product. Consult FPI fo

product recommendations for your application.

STRUCTURAL LAMINATE

The structural composite laminate is constructed from carbon

and/or E-glass fibers in an enhanced amine cured epoxy ma

trix. The laminate is designed with FPIs proprietary design

software. The enhanced amine cured epoxy formulation is

selected to provide the corrosion resistance and resistance

to hot/wet degradation necessary for oil and gas industry

applications.

Figure 1-1: Typical marks on SRC line pipe every five feet.

Nominal Pipe Size: 4 (100 mm) Serial Number: 00369

Footage Marks: 4,855 ft (1,479.8 m)

Maximum Operating Pressure:3,000 psig (200 bars)

Product Name:Cobra (HDPE liner)


6/253

SRC line pipe is packaged on steel or wooden reels for trans-

port, storage and deployment. Smaller reels can usually be

shipped upright, but may require a drop-deck trailer to be

shipped without a permit. Larger reels (greater than 120 or

3,000 mm flange diameter) are usually shipped horizontally

on wooden strips (see Figure 2-1).

Generally, SRC line pipe is spooled so that there is a minimum

gap of 1-3 inches (25-75 mm) between the outer wrap of pipe

and the outer rim of the reel. For North American transporta-

tion, no protection for the outer layer is generally required.

For export shipments, a ring of wooden planks can be placed

on the outside of the reel to protect the pipe.

All SRC line pipe is 100% hydrotested at the factory to 1.5

times the maximum operating pressure. After hydrotesting at

the factory, test water is chased from the pipe with foam pig

and several gallons of alcohol antifreeze to reduce the chance

of water pockets, which could freeze and damage the pipe.

Both ends of the pipe are plugged before shipping.

CAUTION:While SRC line pipe is very flexible, it will still

retain a small amount of stored elastic energy when wound

on the reel. Care should be taken to insure that the free end

of the spooled pipe is restrained or under tension during all

operations to avoid injury to personnel or damage to pipe

and equipment.

CAUTION:Improper handling of reels can cause injury to

personnel as well as damage to the product. Insure that the

lifting equipment used, including straps, slings and spreade

bars, is adequate for the load and conditions. Insure tha

equipment operators have received the proper training in

handling SRC.

NOTE:Handling equipment (e.g. forklift tines, lifting slings

and chains) must not be allowed to contact SRC line pipe

during handling.

NOTE:SRC line pipe is designed for reels with a specified

minimum bend radius, which is documented in the specifica

tion sheet for each product. SRC line pipe MUST NOT BEND

BEYOND THE MINIMUM BENDING RADIUS AT ANY TIME!

Typical shipping reel sizes and capacities are shown in Figure

2-2, Table 2-1 and Table 2-2.

SECTION 2: TRANSPORT, HANDLING AND STORAGE

Figure 2-1: Shipment of reel in horizontal position.

Figure 2-2: Reel nomenclature.

OuterFlange

Diameter

OverallWidth

Drive Holes(inboard)

Lifting Holes(outboard)


7/254

Table 2-1: FPI SHIPPING REEL INFORMATION (Imperial)

NominalPipe Size

(ID)

Typical Reel DimensionsTypical

Length ofPipe on

Reel

Total Weight of Pipe and Reel

Reels perTruck

OuterFlange

Diameter

OverallWidth

EmptyWeight

750 psiMOP

1500 psiMOP

2250 psiMOP

(in) (in) (in) (lb) (ft) (lb) (lb) (lb) (-)

1 138 80 2,100 10,000 5,400 5,400 6,500 4

1 1/2 138 80 2,100 10,000 6,600 7,900 7,900 4

2 138 80 2,100 9,000 8,300 10,200 11,900 4

2 1/2 166 96 6,100 8,000 14,400 15,900 17,400 3

3 166 96 6,100 6,500 14,400 15,800 17,200 3

3 1/2 202 102 7,100 6,000 16,600 18,100 19,700 2

4 202 102 7,100 4,500 16,400 17,900 19,400 2

4 1/2 210 102 7,800 3,200 16,900 18,500 21,500 2

Notes:

Table 2-2: FPI SHIPPING REEL INFORMATION (Metric)

NominalPipe Size

(ID)

Typical Reel DimensionsTypical

Length ofPipe on

Reel

Total Weight of Pipe and Reel

Reels perTruck

OuterFlange

Diameter

OverallWidth

EmptyWeight

50 barMOP

100 barMOP

150 barMOP

(mm) (mm) (mm) (kg) (m) (kg) (kg) (kg) (-)

25 3,505 2,030 950 3,000 2,400 2,400 3,000 438 3,505 2,030 950 3,000 3,000 3,500 3,500 4

50 3,505 2,030 950 2,700 3,700 4,600 5,300 4

63 4,216 2,440 2,770 2,400 6,500 7,200 7,800 3

75 4,216 2,440 2,770 2,000 6,600 7,200 7,900 3

88 5,130 2,590 3,220 1,800 7,500 8,100 8,800 2

100 5,130 2,590 3,220 1,400 7,500 8,200 8,900 2

155 5,335 2,590 3,540 1,000 7,650 8,400 9,750 2

Notes:

1. All values are estimates.

2. Specific lengths and/or custom reels can be supplied for special project needs.

1. All values are estimates.2. Specific lengths and/or custom reels can be supplied for special project needs.


8/25

STANDARD STEEL REELS

Standard FPI reels are radial-spoke steel reels equipped with

heavy steel drive plates on the sides as shown in Figure 2-3.

There are seven to nine holes in the drive plate:

One center shaft hole is 4 (101mm) diameter

Four inboard drive holes are 3 (76mm) diameter on a

20 (508mm) diameter circle

Two or four outboard lifting holes are 3 (76mm)

diameter on a 41 (1,041mm) diameter circle

RECEIVING & INSPECTION

Check the Bill of Lading and Certificate of Conformance

for any discrepancies between the Purchase Order, re-

ceived pipe, end connections and equipment.

Visually inspect all exposed surfaces of the pipe and the

reel upon arrival.

Inspect the pipe for bruises, light spots or rough

resulting from impact, and damage to the reel indicate

damage during transportation.

Note any discrepancies or observed damage to the pipe

on the delivery receipts before accepting or signing for

products.

UNLOADING UPRIGHT REELS

Smaller reels of SRC line pipe may be received in the up-

right position and can be unloaded using one of the following

methods:

With an appropriately rated forklift with widely spaced

tines, slide the tines under the radius of one flange, chain

the top of the flange to the top of the forklift mast, and lif

the reel.

A steel bar or pipe of the appropriate size and strength

is passed through the central hole. A forklift is placed on

either side of the truck and the reel is lifted by both forklifts

simultaneously.

A steel bar or pipe is placed through the center hole of

the reel and a crane using slings attached to the bar lifts

the reel. A spreader bar is recommended to space ou

the slings.

With any lifting method, the reel should be lifted only enough

to clear the truck bed, and then the truck is driven slowly from

under the reel.

UNLOADING HORIZONTAL REELS

Reels shipped horizontally are typically unloaded by one o

the following methods:

Two forklifts are placed on either side of the trailer to lif

the reel under the flanges.

A crane using a bar or pipe lifts the fixture in the cente

hole.

A crane using slings attached to the reel structure lifts

the reel. A spreader bar is recommended to space ou

the slings.

The trailer is driven slowly away from under the reel.

With any lifting method, the reel should be lifted only enough

to clear the truck bed.

UPRIGHTING REELS

Reels that are horizontal may be lifted upright using a suitably

sized crane or two suitably sized forklifts working together

The following techniques have been found to be suitable:

A crane using slings attached to the flange rims (or to

the lifting holes in the drive flange), picks up the reel to

upright it. See Figure 2-4.

One forklift lifts the reel from one side and the second

fork lift is on the opposite side to catch the reel and

lower it to the ground.

The installer should consider local conditions and available

equipment to develop suitable alternative approaches.

5

Figure 2-3: Typical drive plate configuration.


9/256

NOTE: Reels in the upright position should always be chocked

to prevent rolling. Be sure to chock ONLY on the reel flange.

DO NOT CHOCK ON SRC LINE PIPE.

FIELD TRANSPORT

Transport should be on a trailer that is as close to the ground

as practical. The speed of the transport should be carefully

controlled, especially during turns.

CAUTION:Upright reels are top-heavy loads that are easily

overturned. The reel and frame should be mounted as close

to the ground as possible and the frame chained tight to the

trailer. During transport, speed should be reduced and turnshandled with care.

MOVING THE REELS

Reels may be moved short distances using one or two forklifts,

gin pole truck, steel track backhoe, or a crane and sling. The

method is the same as described for unloading.

CAUTION:MOVING REELS BY ROLLING IS NOT RECOM-

MENDED. Rolling reels may become unstable and roll out ofcontrol. Upright reels are top heavy and may tip over when

rolling.

STORAGE

Reels of SRC line pipe should be stored on level stabilized

ground with no protruding objects that might contact and

damage the pipe on the outermost layer. Chock or anchor the

reel to be sure it can not roll. Do not chock on pipe.

ULTRAVIOLET STORAGE

If SRC line pipe is to be stored for an extended period of time

it should be protected from ultraviolet (UV) exposure by being

covered with a tarpaulin.

THERMAL STORAGE

SRC utilizes a design philosophy that involves use of a ther

moplastic liner that serves as a fluid containment element and

a composite laminate that serves as a structural element. The

thermoplastic liner has a large coefficient of thermal expan

sion, relatively low strength and modulus, and large elonga

tion at the break point. The composite structural element on

the other hand has a very small coefficient of thermal expan

sion, relatively high strength and modulus and relatively low

elongation at the breakpoint.

As temperatures decrease, the modulus and strength of both

the composite and thermoplastic components increase while

the elongation at the break point decreases. Additionally, as

temperatures decrease, the thermoplastic liner contracts in

diameter and length, with respect to the composite, by the ef

fects of thermal expansion/contraction. When the liner is wel

bonded to the composite such that its expansion/contraction

is limited by the strength of the composite, an increased stress

on the thermoplastic liner will result.

When SRC stored on a reel at 3.5% spooling strain is ad

ditionally subjected to extremely low temperatures, the in

creased thermal stresses can result in circumferential breaks

in the liner (a loss of fluid containment). Forces resultant from

removal of SRC from the reel in extremely cold temperatures

can have the same effect. The thermoplastic liner material se

lected limits storage temperatures as indicated in Table 2-3.

SRC, like steel pipe, is subject to bursting when a slug o

water is trapped in the pipe and the temperature drops to

freezing. Special precautions are taken at the factory to mini

mize water entrapment following hydrotest. If excess water is

found to be in the SRC line pipe, from whatever source, efforts

should be made to remove it, protect the water from freezing

by adding anti-freeze, or to keep the spool of pipe above the

freezing temperature.

Figure 2-4: Righting and lifting a reel.


10/25

SRC line pipe should be protected from freezing

water damage by insuring that no water has en-

tered/can enter the pipe.

Table 2-3: Minimum storage temperatures


LinerMinimum

Storage Temperature

CobraTMHigh DensityPolyethylene

(HDPE)-29 F (-34 C)

PythonTMCrosslinked

Polyethylene (PEX)-29 F (-34 C)

BoaTMPolyamide-11

(PA-11)-55 F (-48 C)

7


11/25

FPIs SRC line pipe is designed to be stored, handled, de-

ployed and installed using a reel. The pipe can be deployed

using an A frame, winch truck, picker, crane and/or side

boom. The flexibility, long continuous lengths, and reduced

sensitivity to impact/wear dictate installation techniques thatdiffer substantially from methods used to install jointed steel

or fiberglass pipe.

This section discusses the installation techniques that have

been successfully used in the past. A brief discussion of some

of the essential tools required for installations are included in

this section. Specific installation techniques may require tools

not listed or discussed.

DEPLOYMENT

SRC utilizes a design philosophy that involves use of a ther-

moplastic liner that serves as a fluid containment element and

a composite laminate that serves as a structural element. The

thermoplastic liner has a large coefficient of thermal expan-

sion, relatively low strength and modulus, and large elonga-

tion at the break point. The composite structural element on

the other hand has a very small coefficient of thermal expan-

sion, relatively high strength and modulus and relatively lowelongation at the breakpoint.

As temperatures decrease, the modulus and strength of both

the composite and thermoplastic increase while the elonga-

tion at the break point decreases. At extremely low tempera-

tures, (temperatures below the minimum installation temper-

ature) both the composite and thermoplastic can buckle or

fracture when attempts are made to deploy the pipe from the

reel. Table 3-I provides suggestions for minimum installationtemperatures for the various liner materials.

Table 3-1: Minimum installation temperatures


Liner

MinimumInstallation

Temperature

CobraTMHigh Density

Polyethylene (HDPE)-20 F (-29 C)

PythonTMCrosslinked

Polyethylene (PEX)-20 F (-29 C)

BoaTMPolyamide-11

(PA-11)-30 F (-35 C)

NOTE: It is STRONGLY RECOMMENDED that contractors

and construction crews have a FPI Field Service Technician o

Certified Representative train their personnel before their firs

installation of SRC line pipe. Please contact FPI for additiona

information and scheduling.

NOTE:It is recommended that all contractor and construction

crews be briefed on the installation procedures to be followed

and the difference between SRC line pipe and other types o

products. Individuals that plan to install FPI end connections

on SRC line pipe MUST be trained and certified by FPI prior

to installation.

A person with training in composites piping should visually

examine the pipe as it is deployed from the reel to identify

anomalies in the product that may result from shipping, han

dling or deployment. If damage is discovered, it should be

repaired or removed prior to field-testing or burial. Always

document and mark the location of the damaged area for

future reference.

As a general rule, SRC line pipe should not be un

spooled or respooled if the pipe itself is at tempera

tures below -20 F (-29 C). Certain high-perform

ance polymer liners may have different minimum installation

temperature limits (see Table 3-1).

SECTION 3: INSTALLATION TECHNIQUES

8


12/25

DEPLOYMENT METHODS

Several different methods have been used to deploy and in-

stall SRC line pipe:

Spooling frame or A frame

Steel track backhoe with a spreader bar

Winch truck with a spreader bar

Cherry picker with a spreader bar

Crane with spreader bar

Side boom with spreader bar

Spooling trailer

SPOOLING FRAMES

A spooling frame suitable for supporting and controlling the

reel of pipe is recommended. Insure that the reel will physi-

cally fit into the spooling frame (including the shaft diameter

and spacing of the drive holes). The frame must hold the reel

such that it can rotate in a controlled fashion to deploy pipe

(see Figure 3-1).

Ideally, the frame should:

Support the reel off the ground allowing it to rotate in a

controlled fashion

Have an integral braking device that allows the operator

to maintain tension on the pipe as it is pulled off the reel

(adequately sized friction brakes have been used success-

fully)

Be positioned as close to the ground as possible to

minimize the overturning moment of the top-heavy reel

For respooling operations, a fairlead mechanism is

recommended to insure even spooling

NOTE:Hydraulically powered frames such as those used in

coiled tubing operations have been used successfully, when

properly employed

STEEL TRACK BACKHOE, WINCH TRUCK, CHERRY

PICKER, CRANE OR SIDE BOOM

Many types of equipment have been used to deploy SRC line

pipe. All equipment must have the load capabilities to safely

lift and handle the reel of pipe being installed. In most lifting

cases, the cable or wire rope attached to the reel must be

spread in order to prevent placing a collapse force at the top

of the reel. This can be prevented by using a spreader bar

The spreader bar must be wider than the width of the reel to

prevent damage to the reel when lifting and placing tension

on the cable or wire rope.

SPOOLING TRAILER

A spooling trailer is a specifically built trailer for hauling, de

ploying and respooling SRC line pipe.

UNSPOOLING FROM A STATIONARY POSITION

To install SRC line pipe from a stationary position, the reel is

secured at one position and the pipe is pulled off the reel. This

is the preferred method for installation of SRC in areas with

soil that is not excessively rocky or abrasive; that is, where

the pipe will not be damaged by being dragged over the

ground.

The equipment used to pull SRC line pipe must have sufficien

power. Experience has shown that estimating the force (in

pounds) for dragging SRC line pipe across dry level soil is:

0.5 X Line Pipe Weight (lb/ft) X Length (ft) X = Axial Pulling

Load (lb)

Experience has shown that SRC line pipe may be pulled by a

pickup truck, tractor, backhoe or similar piece of construction

equipment. See Figure 3-2.

The maximum pulling load must not exceed the maximum

allowable tensile of the pipe being deployed. See Produc

Specification for tensile allowable.Figure 3-1: Reel mounted into a spooling frame.

9


13/25

A load indicator should be fitted between SRC line pipe and

the pulling equipment so that the axial load on the pipe is

monitored. If the maximum pull load exceeds the products

tensile rating, multiple pulling devices spaced along the length

of the pipe should be used to insure that the maximum allow-

able pull load is not exceeded. However, these multiple unitsmust be operated at exactly the same speed to avoid buckling

of the pipe.

CAUTION: Tension should be maintained on the pipe at

the reel at all times (preferably with a brake on the spooling

frame, to prevent bird nesting of several layers of spooled

pipe). Bird nesting results when unrestrained pipe is free to

change spooling diameter and there is a rapid, uncontrolled

release of stored energy. Care must be exercised when re-

moving a bird nest of crossed pipe. Applying tension to pipes

that are crossed may result in pipe damage.

CAUTION:Do not cut the pipe until the ends are securely

restrained, due to the residual elastic energy in the spooled

pipe.

PULLING DEVICES

Pulling devices must be capable of pulling the predicted load

and have a rated working load approximately equal to the

maximum allowable tensile strength of the pipe being in-

stalled. A steel cable pulling sleeve (finger puzzle) which is at

least ten pipe diameters in length is recommended, as shown

in Figure 3-3.

It is recommended that the portion of the pipe at and near the

pulling device be cut off and discarded after use.

Another method of pulling SRC line pipe is with an interna

expandable mandrel type pulley. Contact FPI for details.

UNSPOOLING FROM A MOVING REEL

SRC line pipe can also be unspooled by anchoring one end

of the pipe at the starting point (using a pulling device as

described above) and hauling, lifting or pulling the reel away

from the starting point with an A-frame on a trailer or truck

bed, steel track backhoe, winch truck or cherry picker (see

Figure 3-4). This is the preferred method for installation in

areas with rocky or very abrasive soil, as this approach mini

mizes the opportunity for abrasion damage to the pipe during

installation. This is also a preferred method for lines that are

not straight.

Figure 3-2: Unspooling of pipe from stationary spooling frame, using atruck hitch to pull pipe alongside a trench.

10

Figure 3-3: Steel cable pulling sleeve (finger puzzle) on SRC.

Figure 3-4: Unspooling SRC line pipe from a trailer mounted spoolingframe.


14/2511

CAUTION:All equipment must have sufficient load capabili-

ties to SAFELY handle the weight of the reel.

CAUTION:The reel of pipe represents a top-heavy load that

may be prone to overturning when crossing rough terrain. An

overturned load can result in injury to personnel and/or dam-

age to equipment and the pipe. Be sure to evaluate the center

of gravity of the equipment with the reel and insure that the

track of the vehicle is adequately smooth, wide, and level to

prevent overturning along the intended route.

BURIED INSTALLATIONS

SRC line pipe can be buried either by conventional trench &

backfill methods using conventional trenching equipment or

plowing-in with specialized trenching plows.

For buried installations, consideration must be given to the

method of attachment to surface equipment. This is particu-

larly critical in areas subject to soil movement or heave. The

transition from ditch to riser must be on a gentle slope with

mechanical support. Contact FPI for recommendations.

If future recovery of the pipe is a potential issue, SRC line pipe

can be installed inside a conduit, such as corrugated HDPE or

steel pipe, to facilitate retrieval.

TRENCH & BACKFILL: EXCAVATION & BEDDING

Proper construction of trenches is important. Trenches should

be constructed according to the following guidelines:

Trenches must be wide and deep enough to accommo-

date the SRC line pipe and other lines.

The trench should be as straight as possible.

Avoid sharp bends and abrupt changes in elevation in

the line.

When changes in direction are required, trenches

should be made with gentle, gradual turns which have a

radius greater than the minimum operating radius of SRC

line pipe product being installed (see Product Specifica-

tions for minimum operating bend radius).

The bottom of the trench should be as UNIFORM as

possible and provide a smooth, firm bearing surface to

support the bottom quarter of the pipe circumference. This

is often accomplished by healing the bottom of the trench

with a hoe bucket. High spots in the trench bottom can

cause uneven bearing on the pipe, damage due to local

ized stress during backfill, and unnecessary wear at these

points.

It is important to remove all sharp rocks and othe

abrasive material from the trench bottom.

The pipe should be properly supported to prevent low

spots, traps or sumps.

If the trench is excavated through rock or shale ledges

or through unstable soil, make the trench slightly deeper

Use a minimum of six inches of river sand or other clean

backfill such as pea-gravel in the bottom of the trench and

over the pipe to protect the pipe from rocks.

If bedding is used it should be in place before the pipe

is placed into the trench.

If multiple lines are installed in the same trench, they

should be separated by a distance of at least four to six

inches (100 - 150 mm) or one pipe diameter, which eve

is greater. This is particularly important if any lines in the

trench will experience pulsation or movement.

At road crossings, SRC line pipe is typically laid through

a conduit. See recommendations under Relining Applica

tions section for installing SRC line pipe inside a conduit

If it is not possible to use a conduit, see Table 3-2 for rec

ommended burial depths beneath typical unpavedgravel

asphalt or concrete roads.

NOTE:The depth of the trench affects the installation method

SRC line pipe should be deployed beside the trench and low

ered into the trench manually.

CAUTION:Safe work practices must be followed when work

ing inside an open trench, including but not limited to the use

of adequate shoring of the sides of the trench. Local regula

tions regarding shoring requirements should be consulted.


15/2512

TRENCH & BACKFILL: BACKFILLING

Before backfilling the trench, check to be sure that the pipe

is properly positioned and that any tools or positioning jigs

used during installation are removed from the trench. Flange

connections and splices should be left exposed for inspection

during testing.

NOTE:Prior to hydrotesting, the trench should be backfilled

every 30 feet (10 meters) to surface. The trench should be

backfilled as soon as possible after hydrostatic testing to elimi-

nate the chance of damage to the pipe, floating if the trench

floods, or shifting due to collapse of the sides of the trench.

It is recommended that the material used as backfill for SRC

line pipe be free from rocks, boulders, large clods of dirt,

frozen dirt and other objects that could damage the pipe.

Caution should be taken to prevent voids (areas that do not

contain backfill) under or around the pipe. See Table 3-2 for

recommended backfill depths.

If frozen earth is used as backfill, it will eventually thaw and

contract, leaving the pipe with insufficient supports and voids

around the pipe. Remove frozen lumps from all backfill ma-

terials before backfilling. Compaction of the material to at

least the same density as the surrounding undisturbed soil is

recommended.

For trenches excavated in roads or under structures, place

backfill in 6 inch (150 mm) layers to top of trench, and com

pact each layer to at least 95% of maximum density. When

compacting, avoid causing damage to the pipe. Vibrating

tampers should not be used until there is at least one foot of

backfill over the pipe.

PLOW-IN

A variation of the moving reel installation involves the use

of a plow to trench, install and cover the trench in a single

pass operation (see Figure 3-5). The plow must have sufficien

capacity to bury SRC line pipe to the required depth and be

equipped with a shoe with a radius that is equal to or greate

than the minimum operating bend radius of SRC line pipe.

In a plow-in installation, consideration must be given to the

method of feeding the pipe into the shoe. The orientation and

location of the reel and equipment, and the feeding of the

pipe should minimize bending of the pipe. Reversal of the

direction of bending should be avoided.

Table 3-2: RECOMMENDED BACKFILL DEPTHS

(For soil modulus over 1,000 psi; see ASTM D 3839 or AWWA C 950)

NominalLine pipe

SizeSurface Condition

Minimum Burial Depth to

Top of Line pipe

Minimum Sand or Pea-Gravel

Above Top of Line pipe

2 (50mm)

Un-Paved 17 in. 432 mm 12 in. 305 mm

Asphalt Paving, Min. 4 (100mm) 12 in. 305 mm 8 in. 203 mm

Concrete Paving, Min. 4 (100mm) 9 in. 229 mm 5 in. 127 mm

3 (75mm)

Un-Paved 20 in. 508 mm 14 in. 356 mm

Asphalt Paving, Min. 4 (100mm) 13 in. 330 mm 9 in. 127 mm

Concrete Paving, Min. 4 (100mm) 11 in. 279 mm 7 in. 178 mm

Refer to ASTM D 3839 or AWWA C 950 for details. Soil modulus depends on soil type and compaction. For example, pea gravel typically has modulus o

1,000 psi with no compaction, while sand requires slight compaction for the same modulus.


16/2513

SURFACE INSTALLATIONS

For surface installations, SRC line pipe is laid either on the sur-

face, directly at grade or on fabricated stands (usually steel)

above grade. For pipe laid at grade, the surface should be

free of rocks and other sharp objects that could damage the

pipe.

System design must evaluate the coefficient of thermal expan-

sion and anticipated temperature swings (including black-

body absorption of the line pipe). Adequate expansion loops,

expansion joints or changes in direction should be provided.

Contact FPI for assistance.

When desirable, the pipe may be placed on supports above

the ground. Spacing and construction requirements of aboveground supports will vary according to application. SRC line

pipe should not come in direct contact with steel. Consult FPI

for above ground support and spacing recommendations (see

Figure 3-6).

SRC line pipe, when installed on the surface, must be re

strained horizontally with thrust blocks or anchored to exist

ing structures whenever it changes direction, and periodically

anchored vertically to piles, foundations, or other supports

Bends in the pipe should always be made with gentle, gradu

al turns, which have a radius greater than the minimum operating bend radius of the SRC line pipe product being installed

(see Product Specifications).

CAUTION:SRC line pipe, which is installed on the surface,

must be properly restrained BEFORE HYDROTESTING.

RELINING APPLICATIONS

Relining or insertion is a technique used to replace failed lines

by pulling or inserting SRC pipe into an existing line.

NOTE:Relining steel with SRC line pipe does result in a re-

duction of ID cross-sectional area. Flow may be less affected

than expected, since the thermoplastic liner of the SRC line

pipe is much smoother than steel line pipe. The Hazen-Wil

liams flow coefficient of SRC line pipe is 150. Contact FPI to

assist in single or multi-phase flow calculations.

In relining applications, there must be adequate clearance between the outside diameter of SRC line pipe and the inside di

ameter of the existing steel line. There must be no obstructions

in the steel pipeline. Obstructions in the line include any sharp

turns, dents or kinks in the pipe, and internal weld-splatter. Al

of these can reduce the effective ID of the steel line and dam

age the pipe being installed. A pig with sizing plates should

be run through the old steel a few times to insure a successfu

installation of SRC.

Figure 3-6: SRC installed aboveground on fabricated steel stands.

Figure 3-5: Plow installation of SRC line pipe inside an HDPE tile conduit up a grade at approximately 1 km per hour.


17/25

It is recommended that the drift or ID of the steel pipe be

checked by pulling a 30 foot (10 meter) length of SRC line

pipe through the line using a pulling line with swivel joints

attached to both ends. If this test segment of pipe successfully

passes through the entire steel line, the rest of the pipe can be

attached to the pull line and pulled into place. If the test pipe

becomes stuck, the trailing pull line can be used to retrieve

the drift segment. Then, the steel pipe can be prepared as

required for the application.

NOTE: If laid wire rope is used as the pull line, a swivel must

be installed between the pull line and SRC line pipe to prevent

the laid wire rope from applying torque to SRC line pipe as it

is pulled during installation.

It is recommended that both ends of the pipe be capped dur-

ing pulling or insertion to prevent a build up of foreign mate-

rial in the line.

Whenever the pipe passes through a conduit, be sure that the

pipe is properly bedded at the points of entry to and exit from

the conduit to prevent stress, wear or damage to the pipe.

If there is any possibility that the pipe will touch the edges

of the conduit, pad the pipe and conduit to prevent rubbing

against the conduit. Concentric rubber boots, which are prop-

erly sized, are recommended at entries and exits after SRC

is in place.

Pull lines should be sized for the maximum weight of the length

of pipe being pulled into the existing line as a minimum. Ac-

tual pulling force shall be limited to the products maximum

allowable tensile rating. A powered winch with controlled

take up speeds is recommended for pulling SRC line pipe.

Pull speeds should be limited to a maximum of 60 feet/minute

(18 meter/minute).

A load indicator system which provides real-time axial

weight/tension during installation is REQUIRED. The system

should also provide a record of the axial force applied. For

hydraulic winch systems, the hydraulic fluid pressure at the

winch is proportional to the axial pull of the winch with the

wire on a particular wrap.

RELINING BY INSERTION

An alternative means to reline existing lines is to insert SRC

line pipe using a conventional coiled tubing (CT) injector

head, as shown in Figure 3-7. This method can be effective, i

the existing line is known to be free of obstructions.

This insertion method is rarely employed due to the cost as

sociated with mobilizing a CT injector, but it can be an ap

propriate technique for particular jobs.

Because SRC has low stiffness, FPI should be consulted before

a relining job by insertion is planned, due to the risk of buck

ling the line pipe under a compressive axial load.

NOTE:When SRC line pipe is passed through a steel condui

or casing, as in a road crossing, the pipe must be supported

on padding material to prevent vibration induced wear. Con

centric rubber boots, which are properly sized, are recom

mended. Care must be taken to insure that there are no bends

in the pipe within 6 feet (2 meters) of the conduit opening.

Figure 3-7: SRC line pipe is conveying pipeline survey tools (note horizon-tal injector head).

14


18/25

The standard end connection for SRC line pipe is FPIs ANSI

Lap Joint Flange (LJK) with a raised face (RF) seal, as shown in

Figure 4-1 (US Patent #6,361,080). The LJK has the following

advantages:

Installs in the field in about one hour with common GRP

pipe tools plus one hour for cure/cooling prior to test-

ing.

Mates to standard ANSI RF flanges.

The Lap Joint Flange rotates to facilitate make-up.

Provides 100% pigging, with full-bore connection.

No flow wetted metal parts.

Uses the swaged thermoplastic liner as the primary

sealing gasket, eliminating seals between the end connec-

tion and the liner.

The internal/external advanced composite connection

provides a high safety factor and fatigue-resistance.

Available in ANSI 300 through ANSI 900 pressure

classes.

Installation Kits include all materials required for field

installation.

Installation Kits are available with or without the ANSI

flange.

NOTE:End connections installed but not approved by FPI in

writing are not the responsibility of FPI.

NOTE: SRC line pipe must not be used to support heavy

equipment such as flanges, valves, or steel risers. Both the

steel equipment and SRC must be supported independently,

and in such a way as to reduce relative motion between the

two.

When bolting FPIs ANSI Lap Joint Flanges to one another o

to standard ANSI raised face (RF) flanges, the swaged liner

is sufficient gasket material. The sequence for tightening the

bolts shall be in accordance with published standards. Please

see Figure 4-2. Care should be taken to avoid over-torquing

the bolts, as this will tend to excessively extrude the plastic

liner.

LINE PIPE TO LINE PIPE SPLICES

FPI supplies a Splice Kit for splicing Cobra line pipe up to

750 psig (50 bars) working pressure only. Splicing SRC line

pipe requires the following:

Standard HDPE pipe fusion equipment

Qualified HDPE pipe fitter

FPIs line pipe Splice Kit

FPI Tool Kit for installing ANSI Lap Joint Flanges

CAUTION:Pipe-to-pipe splices result in a slight increase in

OD (i.e. an external upset) and an increase in pipe bending

stiffness at the splice.

CAUTION:Pipe-to-pipe splices must be made on two straight

ened sections of pipe, which have been arranged coaxially

and with no angular misalignment.

CAUTION: Pipe-to-pipe splices MUST NOT be respooled be

cause of the increased stiffness at the splice.

Figure 4-2: Flange bolt tightening sequence.

15

Figure 4-1: Field installed ANSI Lap Joint Flange (note swaged HDPE linerserves as sealing surface).

SECTION 4: END CONNECTIONS


19/25

A LJ Flange Kit or LJ Kit is required for each installation. All materi-

als included in the LJ Kit shall be provided by FPI. No substitution

of materials is permitted without prior written approval from FPI.

The typical components of a LJ Kit are depicted in Figure 5-1 and

listed in Table 5-1. The LJ Flange Kit is identical to the LJ Kit except

it also includes a modified ANSI B16.5 Lapped Flange

NOTE:If flanges are to be supplied by the end user, the end user

MUST consult FPI for assistance in proper flange selection.

NOTE:LJ Kits should be stored in a clean, dry location at a tem-

perature of 75 25 F (24 14 C). When LJ Kits are stored in

these conditions, a shelf life of 1 year can be expected.

Table 5-1: COMPONENTS OF A LJ KIT

A Protective gloves

B Coated stub end

C Glass and/or carbon braided sleeves

D Plastic mixing beaker

E FPI SP Field Resin Part A

F FPI SP Field Resin Part B

G Tow of glass fiberH 2-part quickset epoxy

I Roll of shrink tape

J Resin stopping gasket

K Wooden mixing sticks

n.s. Isopropyl alcohol wipers (not shown)

n.s. Modified lapped flange (not shown)

NOTE:All end connections installed on FPI products must be

installed by crew members who have been trained and certified

by FPI.

Table 5-2: TOOLS FOR INSTALLATION OF LJ KIT

A Hacksaw

B Tapering tool

C Tapering tool mandrel (size specific)

D Tapering tool collet (size specific)

E* Tapering blade

F* Pre-swage (size specific)

G* Swage reaction tool (size specific)

H Hot plate

I High temperature dry silicone lubricant

J Pipe cutter (size specific)

K* Final-swage (size specific)

L High temperature tape

M Coarse sand paper

N Manual drive

O Tapering tool adapter to square head

P Square head adapter, Ridgid700 or equivalent

Q Power drive, Ridgid700 or equivalentR Spray bottle

S Heat gun

n.s. Soft jaw pipe vise (not shown)

n.s.Temperature indicating crayonsor thermometer (not shown)

n.s.* Heating blanket (size specific, not shown)

* Indicates items only available through FPI

SECTION 5: INSTALLING LAP JOINT (LJ) FLANGES

16

Figure 5-1: Components of a LJ kit.

Figure 5-2: Tools for installation of LJ Kit.


20/25

PIPE END PREPARATION

Assemble the necessary materials, tools and equipment at the

point of installation. When environmental conditions include

wind in excess of 5 mph (8 km/h), blowing sand, rain, snow or

temperatures less than 50 F (10 C) a shelter should be erected

around the pipe end.

Select a pre-swage and a final-swage (shown in Figure 5-3) that

correspond to the nominal pipe size and begin heating them. Thisheating process is usually completed on a hot plate.

Clamp the pipe end in a soft jaw pipe vise with approximately

6 (150 mm) of pipe extending beyond the vise. Always protect

the clamped area of the pipe with two 180 pieces of plastic or

gasket material.

Use a pipe or tubing cutter to cut the end of the pipe square and

smooth.

NOTE:A hacksaw may be used to finish the cut if necessary. If a

hacksaw is substituted for a pipe cutter, extra care must be taken

to get a smooth square cut.

PIPE TAPERING

NOTE:Do not begin this operation unless preparation has been

made to complete the flange installation. Once tapered, the in-stallation must be completed within two hours of the process must

start over.

The pipe must be carefully tapered to provide the proper bond-

ing surface. Select the proper size tapering machine collet for the

SRC product to be tapered and install the collet on the tapering

machine.

Insert the collet into the SRC liner (ID of the pipe) and position the

cutter such that it overhangs the pipe by approximately 0.25

(5 mm). Tighten the tapering collet screw until the collet is snug

within the pipe.

Rotate the taper depth screw clockwise until the tapering blade

contacts the composite pipe surface. Mount the RidgidMode

700 Power Drive and Square Drive Adapter to the tapering ma

chine and begin to rotate the tool clockwise. As the taper tool isrotated, adjust the taper depth screw approximately 1/8th of a

turn clockwise for each revolution.

Continue tapering until approximately 1.25 (30 mm) of liner is

exposed beyond the composite overwrap at the end of the pipe

When the proper amount of liner is exposed, rotate the tape

tool 6 to 10 additional revolutions without adjusting the tape

depth screw to cleanup the taper area. Remove the drive, back

off the tapering collet screw and remove the tapering tool from

the pipe.

Use a powered brush, grinding wheel or coarse sandpaper to

cleanup the liner/composite interface and the exposed liner as

necessary. Then, degloss and roughen the outside surface of the

SRC pipe for a length of 6 (150 mm) more than the longest

braided sleeve beyond the end of the tapered area. The surface

should be free of the gloss associated with an epoxy-rich surface

Wipe the surfaces with a clean dry cloth to remove all dust and

debris. Visually inspect the surface for uniformity.

Always use isopropyl alcohol to clean all tapered and prepared

(deglossed and roughened) surfaces. In each LJ Kit, FPI provideswipers that are presaturated with isopropyl alcohol for this pur

pose. Diluted isopropyl alcohol may be used if the only diluen

is distilled water. If diluted isopropyl alcohol is used, care should

be taken to ensure that all of the water has evaporated before

proceeding with stub end bonding.

CAUTION:Tapering and sanding SRC can create dust that may

be irritating to the skin, eyes and respiratory system. Good venti

lation is recommended to prevent this irritation. A dust breathing

mask is strongly recommended when working in poorly ventilated

areas. Long sleeve shirts and eye protection are strongly recommended for all installers.

STUB END BONDING

Begin this process immediately after isopropyl alcohol cleaning

to avoid contamination of the tapered and roughened surfaces

Avoid touching any bonding surface since natural oils from hu

man skin can inhibit bonding. Protect the bonding surfaces from

moisture and other contaminants.

17

Figure 5-3: Pre-swage and final-swage.


21/25

CAUTION:Prior to handling epoxy, the installer must become fa-

miliar with the proper procedures for safe handling and disposal

of epoxies. Appropriate personal protective equipment should be

worn during all operations (gloves, safety glasses, etc.).

Check the fit of the stub end over the tapered area of the pipe.

A proper fit is identified as 1.0 to 1.25 (25-30 mm) of liner ex-

tending beyond the stub end, and the back of the stub end within

1/8 (3 mm) of the crest.

If the fit is too tight (less than 1 of liner exposed beyond the stub

end) additional tapering is required. If the fit is too loose, cut the

piece of glass fiber (provided in LJ Kit) into three equal lengths to

make positioning bundles. The bundles should be positioned and

taped to the OD and face of the stub end so that they are uni-

formly spaced around the circumference as shown in Figure 5-4.

Position the braided sleeves, resin-stopping gasket and flange on

the pipe end. The initial configuration is shown in Figure 5-5.Certified installers should contact FPI with questions regarding the

proper order of these components.

Squeeze the contents of the two-part epoxy tube onto a clean

dry surface and stir thoroughly using the supplied wooden mix-

ing stick. The epoxy will have a thick consistency and a uniform

creamy white color when it is properly mixed.

Using the mixing stick, apply the mixed epoxy to the middle o

the tapered area in a circumferential direction. Spread the epoxy

from the middle of the area out to the root and crest of the taper

with the mixing stick. The whole tapered surface should have a

layer of at least 0.125 (3 mm) of epoxy. Be careful not to apply

the epoxy on the plastic liner.

Slowly slide the stub end onto the pipe and rotate it as it slides

into position. The small end of the stub end must be within 0.125(3 mm) of the crest of the taper.

Using another mixing stick and/or dry, clean rags, remove ex

cess epoxy from each end of the stub end. No excess epoxy is

permitted on either side of the flange surface.

The epoxy will harden quickly (within 10 minutes) when mixed

properly and applied at 60 - 80 F (15 -25 C). If the temperature

is lower, a heat gun may be used to speed the hardening of the

two-part epoxy. Do not allow the pipe surfaces to exceed 200 F

(90 C) during this heating process.

SWAGE THE LINER

Swaging the liner is the process of forming the liner into a gas

ket using a combination of heat and pressure. When swaging a

Cobra (HDPE) liner into the flange gasket, heat the swages to

200 - 250 F (90 120 C). For a Python (PEX) liner, heat the

swages to 225 - 275 F (110 135 C). For other liners, please

contact FPI. Confirm that both swages have reached the prope

temperature with a thermometer or temperature indicating cray

ons. Using a high temperature dry silicone lubricant, spray the

contact faces of each swage. Do not spray the stub end.

Insert the swaging collet into the liner to a depth of approximately

5 (125 mm) from the stub end flange and tighten the collet nu

with the swaging wrench. The threaded collet shaft will extend

beyond the end of the liner.

NOTE:The collet shaft should be lubricated with an anti-seize

lubricant prior to use.

Start the pre-swage on the collet shaft with the brass washer and

swaging nut. Tighten the swaging nut until the swage contacts theliner. Slowly tighten the swaging nut until the swage bottoms out

The rate of tightening should be approximately 2 rpm.

When the swage bottoms out as shown in Figure 5-6, allow it to

cool without further movement of the swage. Cooling may be ex

pedited by spraying the swaged liner and swage face with a wa

ter mist. When the mist stops steaming on contact and the swage

is cool to the touch, it is safe to proceed with the next step.

18

Figure 5-4: Glass fibers used to position stub end.

Figure 5-5: Initial configuration of braided sleeves, resin-stopping gasket,flange and stub end.


22/25

Remove the pre-swage from the pipe. Confirm that the final-swage

is heated to the proper temperature and repeat the swaging proc-

ess with the final-swage. The final-swage should bottom out as

shown in Figure 5-7.

Remove the swage from the pipe end after it cools. The diameter

of the swaged liner should match the diameter of the stub end

face as shown in Figure 5-8. Axially, the liner gasket should relax

no more than 0.375 (9 mm) from the stub end face. The swaged

liner face should be smooth with no cracks.

REINFORCE THE CONNECTION

The stub end shall be reinforced with braided sleeves of E-glass

and/or carbon fiber to ensure that the connection is as strong as

the pipe body.

Slide the properly rated flange over the stub end until it bottoms

against the stub end flange. Position the resin stopping gaske

against the pipe side face of the flange. Clean the roughened

pipe and stub end with isopropyl alcohol. Avoid touching anybonding surface since natural oils from human skin can inhibi

bonding. Protect the bonding surface from moisture and othe

contaminants.

Begin mixing the two parts of the FPI Spoolable Pipe Field Resin

immediately after the isopropyl alcohol cleaning to avoid contam

ination of the tapered and roughened surfaces. To mix the epoxy

empty each bottle of into the mixing container supplied. Mix thor

oughly with the provided wooden mixing stick. When properly

mixed, the epoxy should be of uniform color and consistency.

CAUTION: Prior to handling epoxy, the installer must become

familiar with the proper procedures for safe handling and dispos

al of epoxies. Appropriate personal protective equipment should

be worn during all operations (gloves, safety glasses, etc.).

NOTE:FPI Field Resin is a prone to crystallization at tempera

tures below 122 F (50 C). If the appearance of the resin is

hazy or the consistency is thicker than syrup, crystallization has

occurred. To return the resin to its original state, gently warm the

container and its contents above 122 F (50 C). The recom-

mended procedure is to hold the resin at 140 F (60 C) for onehour. The resin should be cooled to 100 F (38 C) before using

in a LJ Flange installation. Upon cooling, the resin regains all of

its original physical properties.

After putting on a clean pair of latex gloves, pour enough resin on

the stub end to fully coat the stub end and tapered surfaces with

a layer of resin. Gently pull the longest braided sleeve over the

stub end up to the resin-stopping gasket. Impregnate the sleeve

with resin by pouring resin directly onto the sleeve and manually

kneading it into the fibers as shown in Figure 5-9. Take care not

to twist the sleeve around the pipe. Ensure that the sleeve is fullywet with resin including the bottom of the pipe.

19

Figure 5-6: Using the pre-swage to form the liner into a gasket.

Figure 5-7: Final-swage inserted fully into the end of the pipe.

Figure 5-8: Acceptable liner gasket formed by swaging process.


23/25

Pull the next braided sleeve over the wetted sleeve and up to

the resin stopping gasket. Repeat the impregnation process.

If additional sleeves remain, pull them into place and impreg-

nate them one at a time. Use most or all of the resin provided.

Excess resin will be squeezed out by the shrink tape.

Wrap the whole sleeve area with the shrink tape provided

starting at the flange end and working toward the pipe end.

The shrink tape should be placed on the reinforcement with

the exposed side of the tape adjacent to the reinforcement.

Placement should be such that each wrap overlaps approxi-

mately 50% of the preceding wrap of tape. Use high tempera-

ture tape to secure the loose end of the shrink tape.

The resin shall be cured by one of the methods listed below. Heat gun

1) Move the heat gun slowly over all of the wet resin areas

until all surfaces reach 250 F (121 C).

2) Maintain this temperature on all wet resin surfaces for

atleast 30 minutes.

3) Allow the pipe to cool for at least one hour before

hydro testing the line.

Heating blanket

1) Wrap and secure the blanket over the wet resin area.2) Allow the blanket to reach the preset temperature of

250 F (121 C).

3) Maintain this temperature for at least 30 minutes.

4) Allow the pipe to cool for at least one hour before

hydro testing the line.

NOTE:Cure temperatures above 300 F (150 C) will impai

the pipes performance. Precaution should be taken (especial

ly with the heat gun) to not exceed this maximum allowable

cure temperature.

After completion of the curing procedure, the flange should

rotate freely. A completed LJ Flange end connection is shown

in Figure 5-10. It is recommended to allow at least one hour

to elapse between the end of the curing procedure and the

beginning of the hydrotest.

NOTE:If after installing a LJ Kit, the end will not be placed in

service or bolted to a companion flange in a short period o

time, FPI recommends bolting a cover on the LJ Flange. Stand

ard blind flanges, light gauge steel plates or flat plywood

can be used to assure the gasket remains flat and the piping

system remains closed.

QUALITY REQUIREMENTS

Upon completion of the LJ Flange installation, the certified

installer shall permanently label the flange with his/her initials

and the date of installation. The labeling shall be completed

with a low stress steel stamp or a paint marker.

If possible, the installer should take photographs of the com

pleted LJ Flange end connection. Records of each LJ Flanges

installation date, installers name, and location in the piping

system should be maintained with the pipeline data.

20

Figure 5-9: Impregnation of braided sleeve with epoxy.

Figure 5-10: Completed LJ Flange end connection.


24/2521

All FPIs SRC line pipe is pressure tested two ways before

delivery:

Short-time failure pressure test

Two samples from each batch

Method per ASTM D 1599

Hydrostatic test on a reel150% of products Maximum Operating Pressure (MOP)

Charts ship with the pipe

After installation of SRC line pipe, FPI STRONGLY RECOM-

MENDS a hydrotest before placing the line into service. All

testing should be performed in accordance with local, state

and federal laws.

CAUTION:Testing with fluids under pressure can be hazard-

ous. Personnel injury and/or equipment damage is possible.Follow safety precautions.

CAUTION:Testing with compressible fluids such as air or gas

is NOT RECOMMENDED, as the potential energy developed

during such a test can be dangerous if a failure occurs.

In cold climates, hydrotest fluid must be protected

against freezing.

FILLING THE PIPE FOR FIELD TESTINGThe recommended test fluid is water with antifreeze added

as necessary.

Fill the system by pumping a soft foam pig through the line in

front of the test fluid to help force the air out of the system. Test

fluid should enter the system at the lowest available point and

air should be vented from the highest point or points.

Allow the test fluid to flow through the vents until there is no

evidence of air (sputtering) coming from the system. When allair is removed, seal the vents and prepare for testing. Blind

flanges may be used for to isolate the line.

CAUTION:Trapped air is a compressible gas. Use care to

ensure that all of the air is removed.

RECOMMENDED TESTING PROCEDURE

It is recommended that testing be conducted on each run o

pipe as it is completed. Complex piping systems should be

broken into smaller runs for testing.

At a minimum, lines shall be covered with dirt to the top ofthe trench every 30 feet (10 meters) prior to hydrotesting

Aboveground lines shall also be secured against movemen

with dirt or sandbags.

The recommended hydrotest procedure is:

Apply pressure slowly up to 50% of the test pressure.

Hold pressure for 5 minutes for each 1,000 (15 minutes

for each 1,000 m) being tested.

During hold, walk the line and inspect for leaks

particularly at end connections. After initial pressure stabilizes, increase no faster than

20% of MOP/minute to the final test pressure.

Walk the line and inspect for leaks, particularly at end

connections

After final pressure stabilizes, hold pressure for desired

test period.

If there is an indication of a leak, stop the test, bleed-off

pressure and make repairs. After repairing the leak, refil

the pipe with hydrotest fluid and restart the testing proce

dure.

Test pressure should be held for a minimum of thirty minutes

while the line is checked for leaks. The customer and/or ap

plicable regulations may require longer testing periods.

NOTE:Maximum hydrostatic test pressure should not exceed

150% of the products MOP.

CAUTION:Notify all site personnel before pressure testing

Maintain a safe distance from the pressurized piping systemDO NOT STRADDLE THE PIPE or CLIMB INTO THE TRENCH

while the pipe is pressurized.

NOTE:Pressure may not remain constant during a long pe

riod (such as 24 hours) due to changes in temperatures, expo

sure to sunlight, changes in wind, etc. Temperature changes

will cause the test fluid to expand or contract leading to fluc

tuations in pressure.

SECTION 6: FIELD TESTING


25/25

This section describes the recommended and approved meth-

ods for repair of SRC line pipe and end connections.

NOTE:External sleeves, patches and bolted couplings are

NOT RECOMMENDED for repairs to SRC line pipe. In gener-

al, these products are not sized properly to fit SRC line pipe.

LJ FLANGES

Leaks across flange faces are often caused by uneven torque

applied to the flange studs and nuts. To correct this type of

leak, apply even torque to the nuts following the sequence

shown in Figure 4-2. Care should be taken to avoid over-

torquing the bolts, as this will tend to excessively extrude the

plastic liner.

If a swaged liner gasket is pinched, cracked and/or dam-aged, the entire connection must be replaced. Cut the pipe

behind the braided sleeves and have a FPI certified installer

construct a new LJ flange following the procedure in Section 5.

PIPE BODY DAMAGE

If a pipe body leak occurs, the piping system should be evalu-

ated to determine the type of failure involved and probable

cause of the failure. The two most common SRC line pipe

failure modes are burst and weeping.

Burst failures are localized pressure failures that breach the

pipe body wall. Burst failures are typically the result of local-

ized mechanical damage from impact, crushing or abrasion

of the pipe. A burst failure will typically be confined to a short

area (usually less than 12 inches or 300 mm long) and will

exhibit an obvious, axially oriented breach through the entire

thickness of the pipe wall. The area adjacent to the burst must

be examined for damage and evidence of the cause of the

burst, such as impact or abrasion from a foreign object. Ex-

amine the area near the burst for evidence of bruises or lightcolored areas that could indicate mechanical damage.

Since burst failures are normally associated with mechanical

damage, the burst pipe typically needs to be cut back a short

distance, at least 5 feet (1.5 meters) on each side of the area

of the damage.

Weeping failures are characterized slow seepage of fluid

through the laminate wall. The weeping usually appears as a

multitude of tiny high pressure streams around the circumfer

ence of the pipe which resembles a sprinkler hose. There usu

ally is not a distinct, visually detectable breach in the compos

ite laminate. Examine the area of the weeping for evidenceof bruises or light colored areas that could indicate damage

Weeping can only occur if the liner is damaged or cracked

and the composite laminate is still intact.

In weeping failures, the location of the leak may be a consid

erable distance from the actual liner damage point. It is rec-

ommended that at least 50 feet (15 meters) of pipe on each

side of the weeping area be cut back.

The recommended repair method for either type of failure isto remove the recommended length of pipe and replace with

a length of SRC line pipe with LJ Flanges on each end. If

possible, hydrotest the replacement piece before installation

Connect the replacement piece by installing new LJ Flanges

on the existing line. After repairs, repeat the hydrotest proce

dure outlined in Section 6.

SECTION 7: LINE PIPE REPAIRS

FuturePipe Installation Manual 18-7-05

Documents