technical manual - Flexpipe Systems

Transcription

TECHNICAL MANUAL
TECHNICAL MANUAL
06-1876 R4.3
Composite Production Systems
shawcor.com
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TECHNICAL MANUAL
Contents
List of Tables ...................................................................................................... v
List of Figures .................................................................................................... v
1 Introduction ................................................................................................... 1
2 Pipe ................................................................................................................ 1
2.1 Product Lines............................................................................................. 1
2.2 Design ....................................................................................................... 2
2.3 Materials .................................................................................................... 4
2.4 Manufacturing ............................................................................................ 5
2.4.1 Liner ..................................................................................................... 5
2.4.2 Reinforcement ...................................................................................... 5
2.4.3 Pipe ...................................................................................................... 6
2.4.4 Quality Control ..................................................................................... 6
3 Fittings ........................................................................................................... 7
3.1 Fitting Configurations ................................................................................. 7
3.2 Design ....................................................................................................... 8
3.3 Materials .................................................................................................. 10
3.4 Manufacturing .......................................................................................... 11
3.5 Corrosion Protection ................................................................................ 11
4 Qualification ................................................................................................ 12
4.1 Introduction to Standards and Regulations .............................................. 12
4.2 Standards ................................................................................................ 12
4.2.1 American Petroleum Institute (API) .................................................... 12
4.2.2 Canadian Standards Association (CSA) ............................................ 13
4.3 Regulations.............................................................................................. 14
4.3.1 Canadian Provincial Regulatory Bodies ............................................. 14
4.3.2 United States Regulatory Bodies ....................................................... 14
4.3.3 Australia Regulatory Bodies ............................................................... 15
4.3.4 Latin America Regulatory Bodies ....................................................... 15
4.4 Testing ..................................................................................................... 15
5 Performance ................................................................................................ 16
5.1 Applications & Chemical Compatibility .................................................... 16
5.1.1 Application Evaluations ...................................................................... 16
5.1.2 Gas .................................................................................................... 17
5.1.3 Oil ....................................................................................................... 17
5.1.4 Water ................................................................................................. 17
5.1.5 H2S ..................................................................................................... 18
5.1.6 CO2 .................................................................................................... 18
5.1.7 Aromatic and Cycloalkane Hydrocarbons .......................................... 18
5.1.8 Chemical Injection .............................................................................. 19
5.1.9 Methanol and Ethanol ........................................................................ 19
5.2 Pressure and Temperature Ratings......................................................... 19
5.2.1 Maximum and Minimum Allowable Operating Temperature ............... 19
5.2.2 Maximum Allowable Operating Pressures.......................................... 20
5.2.3 Calculations for Determining Maximum Allowable Operating Pressure21
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5.3 Cyclic Pressure........................................................................................ 23
5.3.1 FPLP Cyclic Capabilities .................................................................... 24
5.3.2 FPLP HT Cyclic Capabilities .............................................................. 24
5.3.3 FCLP Cyclic Capabilities .................................................................... 24
5.3.4 Pump Jacks........................................................................................ 25
5.4 Flow Characteristics ................................................................................ 26
5.4.1 Pipe Flow ........................................................................................... 26
5.4.2 Fittings ............................................................................................... 28
5.5 Durability ................................................................................................. 28
5.6 Corrosion ................................................................................................. 29
5.7 Erosion .................................................................................................... 29
5.8 Ultra-Violet Protection .............................................................................. 29
5.9 Bend Radius ............................................................................................ 29
5.10 Permeation .............................................................................................. 30
5.11 Expansion/Contraction and Axial Growth ................................................ 31
5.12 External Load and Internal Vacuum Capability ........................................ 32
5.13 Thermal Conductivity ............................................................................... 33
6 Installation ................................................................................................... 33
6.1 Field Services Support ............................................................................ 33
6.2 Transportation ......................................................................................... 34
6.3 Trenching ................................................................................................ 34
6.4 Plowing .................................................................................................... 35
6.5 Insertion as a Freestanding Liner ............................................................ 35
6.6 Surface Installation .................................................................................. 36
6.7 Support Spacing ...................................................................................... 38
6.8 Buoyancy and Pipe Weights .................................................................... 38
6.9 Crossings ................................................................................................ 40
6.10 Risers ...................................................................................................... 40
6.11 Tracer Wire .............................................................................................. 41
6.12 Cold Temperature Installation.................................................................. 41
6.13 Heat Tracing ............................................................................................ 41
6.14 Fitting Installation..................................................................................... 42
6.15 Cathodic Protection ................................................................................. 42
6.16 Tying into Steel – Welding ....................................................................... 43
6.17 Tying into Plastic ..................................................................................... 43
6.18 Field Pressure Testing of New Pipelines ................................................. 43
7 Accessories ................................................................................................. 45
7.1 A-frames .................................................................................................. 45
7.2 Turn Table and Lifting device for Coiled pipe .......................................... 45
7.3 Riser Support Trays................................................................................. 45
7.4 Pull Tools ................................................................................................. 45
7.5 Sacrificial Anodes .................................................................................... 45
8 Operations ................................................................................................... 46
8.1 Startup ..................................................................................................... 46
8.2 Pigging .................................................................................................... 46
8.3 Hot Oiling ................................................................................................. 47
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8.4 Static Electricity ....................................................................................... 47
8.5 Secondary Excavations ........................................................................... 47
8.6 Field Pressure Testing of Existing Pipelines ............................................ 48
8.7 Shutdown Procedures ............................................................................. 48
9 Reliability ..................................................................................................... 49
9.1 History ..................................................................................................... 49
9.2 Leak Testing ............................................................................................ 49
9.3 Cut-outs ................................................................................................... 49
9.4 Reliability Management ........................................................................... 50
9.5 Integrity Verification ................................................................................. 51
10 Appendix ..................................................................................................... 53
Product Data Sheets ....................................................................................... 53
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List of Tables
Table 1: Product Lines .................................................................................................... 2
Table 2: Standard Fittings ............................................................................................... 7
Table 3: Custom Fittings ................................................................................................. 8
Table 4: Shawcor Fitting Material List ........................................................................... 10
Table 5: Links for Specific CSA Z662 Requirements .................................................... 14
Table 6: Pipe and Fitting Tests and Applicable Standards ............................................ 16
Table 7: Allowable Aromatic and Cycloalkane Hydrocarbon Content ........................... 19
Table 8: Maximum and Minimum Allowable Operating Temperatures .......................... 20
Table 9: Maximum Allowable Operating Pressure ........................................................ 21
Table 10: Flow Coefficients for Shawcor Spoolable Products ....................................... 28
Table 11: K Factor for Shawcor Spoolable Products Coupling Fittings ......................... 28
Table 12: Minimum Bend Radius for Operation, Transport and Handling ..................... 29
Table 13: Permeability Coefficients for HDPE ............................................................... 30
Table 14: Representative Permeation Rates for Shawcor Spoolable Products............. 31
Table 15: FPLP and FPLP HT Thermal Conductivity and Resistivity ............................ 33
Table 16: Conduit Compatibility for Shawcor Spoolable Products Insertion .................. 36
Table 17: Maximum Allowable Pull Forces for Shawcor Spoolable Products................ 36
Table 18: Recommended Pipe Support Spacing for Shawcor Spoolable Products ...... 38
Table 19: Recommended Sand Bag Weight for Weighting Shawcor Spoolable Products
...................................................................................................................................... 39
Table 20: New Pipeline Hydrostatic Test Pressures and Durations .............................. 43
Table 21: Custom Polyurethane Disk Pigs .................................................................... 46
Table 22: Shawcor Pig Dimensions for Shawcor Spoolable Products .......................... 47
List of Figures
Figure 1: FPLP and FPLP HT Three-layer Design .......................................................... 3
Figure 2: FCLP Design .................................................................................................... 4
Figure 3: Cutaway View of Shawcor Fitting ..................................................................... 9
Figure 4: Procedure for Determining MPR and MAOP .................................................. 22
Figure 5: Representative Pressure Drop Comparison: Water at Various Flow Rates ... 27
Figure 6: Representative Pressure Drop Comparison: Methane at Various Flow Rates27
Figure 7: Sandwich Type Insulated Barrier Configuration ............................................. 42
Figure 8: Cut-out Burst Test Results ............................................................................. 50
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In an effort to provide useful product information, Shawcor makes
available a three part document:
Part 1 – Technical Manual
This part is mainly addressed to engineers, supervisors and procurement
personnel. It is intended to present a general description of Shawcor
products’ 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 Shawcor products’ handling, joining, installing and
testing.
Part 3 – Operators Guide
This part is mainly addressed to pipeline operations and is intended to
provide general guidance on the compatibility of Shawcor products.
Each of the three parts emphasizes particular aspects of the Shawcor
product application. Familiarity with the three 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 Shawcor 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 Shawcor,
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 Shawcor is prohibited.
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1 Introduction
Shawcor has designed, tested, and manufactured high pressure, corrosion-resistant,
coiled, continuous pipeline systems utilizing new and exciting engineering technologies
intended primarily for the Oil and Gas and Utility industries. Typical applications include
oil and gas gathering, oilfield water transferring, disposal and injection, gas distribution
and transmission lines.
Shawcor has also developed an innovative crimp fitting technology that allows efficient
joining directly to steel lines, standard flanged connections, or other Shawcor Spoolable
products pipelines. Shawcor holds patents for its unique pipe and fitting designs1.
2 Pipe
2.1
Product Lines
Shawcor currently offers three product lines:



FlexPipe Linepipe (FPLP)
FlexPipe Linepipe High Temperature (FPLP HT)
FlexCord Linepipe (FCLP)
FPLP and FPLP HT are intended for static or mild cyclic applications with service
temperatures up to 60°C and 82°C, respectively. FCLP is suited for severe cyclic
applications with service temperatures up to 60°C.
The product range for each product line is as shown in Table 1:
1
Fiber reinforced pipe: US patent number 6,889,716 (May 10, 2005); Canadian patent number 2,513,506 (August
3, 2010); International patents pending.
Compression-style fitting: US patent number 6,902,205 (June 7, 2005); Canadian patent number 2,513,468
(February 1, 2011); International patents pending.
Crimp-style fitting: US patent numbers 7,946,629 B2 (May 24, 2011) and 8,042,252 B2 (October 25, 2011);
Canadian patent number 2,562,823 (May 22, 2012).
High temperature pipe: US patent number 12/712,060 (pending); Canadian patent number 2,753,024 (pending);
International patents pending.
Steel cord pipe: US patent number 12/763,506 (pending); Canadian patent number 2,755,289 (pending);
International patents pending.
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Table 1: Product Lines
Pressure Rating
Shawcor Grade
2,068 kPa
(300 psi)
150
5,171 kPa
(750 psi)
10,342 kPa
(1,500 psi)
13,790 kPa
(2,000 psi)
301
601
801
Product Line
FlexPipe Linepipe
(FPLP)
Nominal Size (inches)
3”, 4”
FlexPipe Linepipe
High Temperature
(FPLP HT)
2”, 3”, 4”
2”, 3”, 4”
2”, 3”, 4”
2”, 3”, 4”
FlexCord Linepipe
(FCLP)
3”, 4”
FPLP and FCLP are available in a standard white jacket, and FPLP HT is available in a
standard grey jacket. All product lines provide a minimum of 20 years protection against
exposure to ultraviolet (UV) light.
All three product lines will hereafter be collectively referred to as Shawcor Spoolable
Products.
The product data sheets in the appendix list the Shawcor Spoolable Products
dimensions and parameters.
2.2
Design
Shawcor Spoolable Products are manufactured at the state-of-the-art Shawcor facility in
Calgary, Alberta, Canada. Shawcor Spoolable Products are patented three-layer
designs constructed from a thermoplastic liner (liner), helically wrapped continuous high
strength reinforcement and an external thermoplastic jacket (jacket). FPLP and FPLP
HT product lines are reinforced with high strength glass fibers, while the FCLP product
line is reinforced with high strength galvanized steel cords.
The liner acts as a bladder, the reinforcement provides strength, and the jacket protects
the load-bearing layer. This construction is unique and has the following advantages:
 The reinforcement is not encased in a thermosetting matrix and is therefore flexible,
avoiding potential micro-cracking or over-straining of the matrix material. Shawcor
Spoolable Products are very rugged, durable and easy to handle.
 The simplicity of construction reduces the manufacturing costs.
 The high strength reinforcement enables design for high-pressure applications.
 The liner ensures that the pipeline system is immune to corrosion and eliminates the
need for inspections.
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


The continuous, long-length spools facilitate fast and easy installation with fewer
connections and less disturbance to impacted parties.
Environmental impact and soil disturbance can be reduced since Shawcor Spoolable
Products 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: FPLP and FPLP HT Three-layer Design
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Figure 2: FCLP Design
Shawcor Spoolable Products have been designed using a sophisticated mathematical
model that was developed specifically for the unique construction of these products.
The mathematical model was used to design the reinforcement configuration and
optimize pressure capacity and strain. The strength of Shawcor Spoolable Products
depend on the thickness and configuration of the reinforcement layer, thus 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 Shawcor Spoolable Products are 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 Shawcor Spoolable Products have been widely used in the oil
and gas industry for many years. The liner and jacket are manufactured using bimodal
pressure-pipe-grade high density polyethylene (HDPE) thermoplastic resin. This
material is designated PE4710 by PPI TR-32, in accordance with ASTM D33503. 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
2
PPI TR-3 Policies and Procedures for Developing Hydrostatic Design Basis, Pressure Design Basis, Strength
Design Basis, and Minimum Required Strength Ratings for Thermoplastic Piping Materials or Pipe
3
ASTM D3350 Standard Specification for Polyethylene Plastics Pipe and Fittings Materials
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low-friction internal surface for decreased pressure losses. Colorant and a ultra-violet
(UV) stabilizer are blended with the thermoplastic pellets during the extrusion process,
providing resistance to weathering.
The glass fiber reinforcement utilized in FPLP and FPLP HT is constructed from a
series of continuous glass fiber rovings which have been manufactured in accordance
with ASTM D5784. The fiber chemistry and coatings are specifically selected to
optimize long-term performance.
The high-strength steel cords utilized in FCLP are constructed from a series of stranded
wires and galvanized for optimum performance and corrosion resistance.
Shawcor is committed to maintaining high standards of quality and reliability. Each
individual supplier is qualified by Shawcor, in accordance with API RP 15S5 and API
17J6, to ensure that quality inspections, physical testing, and material traceability meet
Shawcor’ quality standards. Each specific material is qualified by Shawcor through
rigorous physical testing, prior to use in manufacturing and in finished products.
2.4
Manufacturing
Shawcor is equipped to manufacture all components of
Shawcor Spoolable Products in-house. Each step of the
manufacturing process is closely monitored, resulting in direct
control over the quality of the products.
2.4.1 Liner
The liner is manufactured and inspected by highly experienced
operators using state-of-the art equipment, in accordance with stringent dimensional
requirements defined by ASTM D25137. Each liner is 100% inspected for diameter, wall
thickness, and concentricity by online ultrasonic measurement.
2.4.2 Reinforcement
Glass Fiber Reinforcement
The fiber reinforcements for each product are constructed from
a single type of input strand, purchased from qualified
suppliers. Shawcor roving construction process combines
these strands into custom packages for use in the construction
of Shawcor Spoolable Products. Each package is specially configured for the individual
finished product in which it will be used. Shawcor has developed extensive expertise in
this area through critical evaluation and physical testing of various materials, coatings,
4
ASTM D578 Standard Specification for Glass Fiber Strands
API RP 15S Recommended Practice for the Qualification of Spoolable Reinforced Plastic Line Pipe
6
API RP 17J Specification for Unbonded Flexible Pipe
7
ASTM D2513 Standard Specification for Thermoplastic Gas Pressure Pipe, Tubing, and Fittings
5
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and processing methods. State-of-the-art roving machines are used with tensioning
systems designed in-house specifically for this process.
Galvanized Steel Cord Reinforcement
The galvanized steel cord reinforcements are applied directly as purchased from
qualified suppliers.
2.4.3 Pipe
Each reel of pipe is manufactured in a single continuous production run that combines
liner, 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 reinforcement is applied by sequential custom-designed
winding machines, which wrap the reinforcement 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
reinforcement is individually braked to maintain the correct
tension.
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 either onto a reel or a pallet for
transportation.
2.4.4 Quality Control
Quality control (QC) is critical to the manufacturing process. Shawcor is an ISO
9001:2008 certified manufacturing facility. From supplier evaluation and approval to the
qualification of every finished product, quality control data is diligently reviewed and
evaluated. Shawcor 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 Shawcor quality assurance program that
cohesively links raw materials with production records and serial markings on pipe and
fittings. Shawcor 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
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implemented according to the established non-conformance reporting (NCR) system if
design parameters are not within the specified tolerance limits.
Every finished product is tested in accordance with the Shawcor Production
Qualification Testing (PQT) Standards, and in accordance with API RP 15S or the
applicable requirements of API 17J. Samples are taken from the beginning and the end
of every pipe reel. The samples are subjected to destructive burst testing. The results
from these tests must meet or exceed stringent QC requirements.
In addition, Shawcor tests raw materials to ensure compliance with material
specifications. Shawcor testing equipment includes burst chambers, ovens, a cold
chamber, a cyclic testing station, an Instron tensile testing machine, stress-rupture
testing machines, density test equipment and numerous custom jigs and fixtures.
3 Fittings
The Shawcor fitting is a metallic device that mechanically fastens to the pipe. The fitting
can terminate the pipe with a standard ASME B16.58 lap-joint flange or a weld neck
transition. The weld neck fitting allows direct connection to steel pipe. The end of the
Shawcor product from one coil can be attached to the beginning of the Shawcor product
from a second coil with a pipe-to-pipe coupling, thus eliminating an underground flanged
connection.
3.1
Fitting Configurations
The three types of fittings that are used with FPLP are shown in Table 2. Each of these
fittings is available for each pipe size and grade.
Shawcor fittings come in two lengths, a standard length for use with FPLP and an
Extended Length (EL) for use with FPLP HT and FCLP. Refer to the installation manual
document number 14-1096 for guidance on the installation of both types of fittings.
Shawcor also offers pre-assembled flow joints in the configurations shown in Table 3.
Table 2: Standard 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.
8
ASME B16.5 Pipe Flanges and Flanged Fittings
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Dimensional
drawings available
upon request.
TECHNICAL MANUAL
Coupling Fitting
Used to connect two pieces
of FPLP together.
Weld Neck Fitting
Used to connect FPLP to
steel pipe, using standard
field welding procedures.
Table 3: Custom Fittings
90 Degree Elbow Flow Joint
Tee Flow Joint
Dimensional
drawings available
upon request.
True Y Flow Joint
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 unidirectional teeth that securely grip the liner and jacket of the pipe. Crimping the sleeve
creates very high permanent clamping pressure, which holds the reinforcement securely
in place. The fitting system does not require the application of heat or adhesives in
order to bond components together.
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Figure 3: Cutaway View of Shawcor Fitting
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 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.
Shawcor 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. Shawcor fittings can be installed in the
field in about 20 to 30 minutes. To view a simulation of the fitting installation process,
visit the Shawcor website at www.shawcor.com. For more information on fitting
installation, see Section 6.14.
Shawcor fittings have been tested together with our products 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.
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3.3
Materials
Standard Shawcor fittings are manufactured from seamless steel that meets the
requirements of NACE MR01759 for sour service. See Table 4 for a full list of materials
used in Shawcor fittings. Material certificates are reviewed by Shawcor prior to
manufacture of the fittings, and are retained as part of Shawcor 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.
The steel used in 4” Shawcor fitting mandrels and flanges meet the low-temperature
notch-toughness requirements of Category II of CSA Z662-11 with a minimum design
temperature of -45°C. Whenever required, custom made mandrels and flanges in 2”and
3” sizes with proven low-temperature notch-toughness properties can also be supplied.
In addition, custom made crimp fittings with a stainless steel mandrel can also be
supplied whenever specifically requested.
Table 4: Shawcor Fitting Material List
Part
Mandrel
Sleeve
Material type
Alloy steela
or
Stainless
Steela
Carbon steela
Flange (flanged fittings Carbon steela
only)
Weld neck fitting welding Carbon steela
end
Flow joints
Carbon steela
O-rings
Material grade(s)
AISI 4130, 4140 or equivalent
or
Duplex 2205
ASTM A106, A333, A519, or
equivalent
ASTM A105 or ASTM A350 LF2
Class 1
ASTM A106, A333 or equivalent
ASTM A234 WPB or ASTM A420
WPL6
75 Durometer
FKM/FPM
Fluorocarbon
Elastomerb
Coatingsc
Electroless Nickel or uncoated
a
Meets requirements of NACE MR0175 for sour service
b
Special o-rings are available for high-pressure CO2 service
c
Weld neck and Stainless Steel fittings are not coated
9
ANSI / NACE MR0175 / ISO 15156 Petroleum and Natural Gas Industries—Materials for Use in H2S-Containing
Environments in Oil and Gas Production
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3.4
Manufacturing
Shawcor fittings are manufactured, coated, assembled, and labeled according to
Shawcor specifications by suppliers whose processes have been qualified by Shawcor.
Shawcor routinely verifies and audits the QC programs of these suppliers.
All welding required for the manufacture of Shawcor fittings is performed in shop
conditions, by suppliers qualified to Shawcor 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 about
electroless nickel plating is available upon request. 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 during installation.
All fittings are also available with no coating.
Although the sleeves may be coated with electroless nickel plating, it is not intended for
corrosion protection as the crimping process will damage the surface of the nickel
plating. Flash surface rust may occasionally be present on the sleeves surface.
External corrosion control of Shawcor 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 data sheet supplied with the tape, the system meets
AWWA C21710. A high temperature version of the Denso products is available for use
with the FPLP HT product line.
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 Z662-11.
Shawcor 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.
10
AWWA C217 Cold-Applied Tape Coatings for the Exterior of Special Sections, Connections, and Fittings for
Buried/Submerged Steel Water Pipelines
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The anode kit consists of a magnesium ribbon anode connected to a copper lead wire,
along with a roll of cloth tape to fix the anode to the Shawcor and a stainless steel hose
clamp to secure the lead wire to the fitting. Shawcor 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 Shawcor Installation Guide for more information.
4 Qualification
4.1
Introduction to Standards and Regulations
According to industry terminology, Shawcor 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 guidelines, or even introduce more stringent requirements.
Regulations are requirements that must be followed by law.
Standards that apply to Shawcor 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 Shawcor 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 RP 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 ASTM D299211, for establishing long-term
performance.
11
ASTM D2992 Standard Practice For Obtaining Hydrostatic or Pressure Design Basis For “Fiberglass” (GlassFiber-Reinforced Thermosetting Resin) Pipe And Fittings
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API 17J, “Specification for Unbonded Flexible Pipe”, is a standard created for the design
of flexible pipe primarily for the offshore industry. The FCLP product line has been
designed following the requirements of API 17J that are applicable to onshore
applications.
All Shawcor products meet or exceed the stringent qualification requirements
established by API RP 15S or applicable requirements of API 17J.
4.2.2 Canadian Standards Association (CSA)
CSA provides standards to which manufacturers should comply. CSA Z662-11, Oil and
Gas Pipeline Systems, “covers the design, construction, operation, and maintenance of
oil and gas industry pipeline systems”. Shawcor Spoolable Products fall under Clause
13.1 of this standard, which specifically addresses design, manufacturing and
installation requirements for reinforced composite pipelines.
Shawcor is fully compliant with CSA Z662-11 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 5.
According to Clause 13.1.1.3, reinforced composite pipelines may be used in low vapor
pressure (LVP)12, gas gathering, and oilfield water pipelines. High vapor pressure
(HVP)13 pipelines are excluded by this clause. FPLP and FPLP HT also meet the
requirements of Clause 12.4.6.3 for gas distribution systems14.
Design pressure calculations for RTP are outlined in Clause 13.1.2.8. This clause
refers to API RP 15S as the industry standard according to which FPLP and FPLP HT
must be qualified. This clause also refers to API 17J as the industry standard according
to which FCLP must be qualified. It uses the qualification methods given in the product
standards and specifies the values to be used for derating factors used in these
methods. These factors are a minimum requirement; in some cases, Shawcor 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 Shawcor Spoolable Products, as shown in the design pressure
calculations in Section 5.2.3.
Shawcor fittings are engineered for suitable low-temperature notch toughness. The
material properties meet CSA Z662 Category II requirements with a minimum design
temperature of -45°C.
12
Includes oilfield water, multiphase fluids, or liquid hydrocarbon mixtures with vapor pressure of 110 kPa
(absolute) or less at 38˚C.
13
Hydrocarbons or hydrocarbon mixtures in the liquid or quasi-liquid state with a vapor pressure greater than 110
kPa (absolute) at 38°C.
14
Based on a design life of 50 years at a design temperature of 40ºC (104ºF).
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Table 5: Links for Specific CSA Z662 Requirements
Requirement
CSA Z662 clause
Gas service design pressure limit
13.1.1.4
Sour gas limits
Cyclic service
Tracer wire
Cathodic protection
13.1.1.4
13.1.2.9
13.1.4.1
13.1.5 and 9.1
13.1.4.2
13.1.4.6
13.1.4.7
13.1.4.8
13.1.6
13.1.8.2
13.1.8.3
Crossings and casing
Freestanding liner insertion
Pressure testing – new installations
Pressure testing –
Static electricity
Maximum external pressure
4.3
13.1.2.12
Reference
in
manual
Section 5.1.2
this
Section 5.1.5
Section 5.3
Section 6.11
Section 6.15
Section 6.9
Section 6.5
Section 6.18
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. Cross provincial installations are licensed under the National Energy Board (NEB)
in a similar manner.
The ERCB allows Shawcor Spoolable Products applications to be processed as routine
for fresh water, salt water, multiphase, crude oil/LVP, and natural gas service. Shawcor
has developed a positive history with the ERCB through provision of data on design,
manufacturing, testing, installation and in-service evaluations. More information on the
results of these evaluations can be found in Section 9. Shawcor 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 Shawcor website. Examples are given for a new pipe line and as a
freestanding liner.
4.3.2 United States Regulatory Bodies
Shawcor Spoolable Products are extensively used in unregulated areas in the United
States. In regulated areas, the United States Department of Transportation (DOT)
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considers the use of Shawcor Spoolable Products through special permit applications
submitted to the Office of Pipeline Safety. Currently, Shawcor is working with the
Department of Transportation to eventually include Reinforced Thermoplastic Pipes as
an approved material in 49 CFR Part 192 “Transportation of Natural and Other Gas by
Pipeline”.
4.3.3 Australian Regulatory Bodies
FPLP and FPLP HT have been accepted by regulatory bodies in South Australia and
Queensland, in accordance with AS 2885.1 “Pipelines – Gas and liquid petroleum” for
use as emulsion and oil pipe lines.
4.3.4 Latin American Regulatory Bodies
Shawcor Spoolable Products have been certified by ABS Group Services de Mexico.
FPLP and FPLP HT comply with NRF-185-PEMEX-2008 “Tubería Plástica Reforzada
Enrollable para recolección y Transporte de Hidrocarburos Líquidos y Gaseosos”15 and
FCLP complies with P.2.0730.01 “Tubería Plástica Reforzada Enrollable para
recolección y Transporte de Hidrocarburos Líquidos y Gaseosos” third edition.
Shawcor is currently in the final stages of qualifying its products with several oil and gas
operators in the Latin American Region.
4.4
Testing
Shawcor is committed to ensuring that its products are rugged, reliable, and safe.
Shawcor Spoolable Products are 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 or the applicable requirements of API 17J. Shawcor’
test procedures have been audited and accepted by an independent laboratory16.
Shawcor strongly believes that its products should perform as well under field conditions
as in the laboratory. Therefore, Shawcor has gone beyond the strict requirements of
the applicable standards, and has developed its own procedures to test field handling of
Shawcor Spoolable Products and related equipment.
Some of the specific tests in Shawcor’ testing program are listed in Table 6. These
tests have resulted in a comprehensive base of knowledge about product performance
under a wide variety of service conditions.
15
16
Spoolable Reinforced Plastic Pipe to collect and transport liquid and gaseous hydrocarbons
Jana Laboratories Inc. (Aurora, Ontario)
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Table 6: Pipe 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
Installation pressure testing – samples retrieved
after liner insertion
Installation pressure testing – samples retrieved
after plowing
Shawcor Test Procedure 10-0942
Short term burst pressure testing
Cyclic pressure testing
Pressure testing - samples subjected to reverse
bending
Axial load testing
Vent testing - gases venting from annulus
Impact resistance testing
Thermal expansion & pressure-expansion testing API RP 15S Sections 5.5.4 and 5.5.5
Kink testing
Fitting gas leak testing
Flexpipe Systems Test Procedure 10Thermal cycle testing
0945
External load testing
ASTM D241218
Corrosion Testing - for steel cords
API 17J / ISO 13628‐2
5 Performance
5.1
Applications & Chemical Compatibility
It is the responsibility of the pipeline operator to understand the suitability of Shawcor
Spoolable Products for specific pipeline applications. The information in this section is
intended to provide an understanding of the suitability of the products for a wide range
of common applications. For these or other applications, Shawcor’ engineering team
will be pleased to evaluate the application and advice regarding compatibility of
Shawcor Spoolable Products.
5.1.1 Application Evaluations
Shawcor has established a systematic process to evaluate proposed applications in
order to verify compliance with the normal operational limits given in the following
sections. These limits are intended to provide a consistent and conservative basis to
17
ASTM D1599 Standard Test Method for Resistance to Short-Time Hydraulic Pressure of Plastic Pipe, Tubing,
and Fittings
18
ASTM D2412 Standard Test Method for Determination of External Loading Characteristics of Plastic Pipe by
Parallel-Plate Loading
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potential applications. While Shawcor Spoolable Products may perform well in
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 provided by Shawcor Engineering team as a service to
clients. Each evaluation assesses the details of a proposed application to identify
potential risks and determines 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 Shawcor Spoolable
Products. Shawcor 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
Shawcor has a strong historical record in gas gathering applications. There is no
requirement to further de-rate the Shawcor 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 Z662-11 limits the allowable design pressure for RTP gas
pipelines to a maximum of 9930 kPa (1440 psi).
Shawcor Spoolable Products can also be used in sour (H2S) applications, but limits
apply. Please refer to Section 5.1.5 for more details.
5.1.3 Oil
Shawcor Spoolable Products are suitable for oil effluent or oil emulsion (two- or threephase) applications. The product lines are corrosion resistant, fully piggable, and are 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
Shawcor Spoolable Products are corrosion resistant and an excellent option for oilfield
water applications such as water transfer, disposal and injection lines. 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.
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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 Shawcor Spoolable Products 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 Shawcor Sour Service Pipeline Bulletin,
available from the Shawcor website, for more information). Similar to other components
in sour gas service, due consideration should be given to the potential accumulation of
H2S around the vent hole of the Shawcor fittings.
Sour applications must comply with the regulatory requirements of specific regional
authorities.
FPLP and FPLP HT are compatible with H2S. Shawcor chooses to limit H2S content of
up to 10% by mol in the gas phase of liquids (oil and/or water) or multiphase19.
Applications above 10% are evaluated on a case by case basis. FCLP is suitable for
the transport of liquids (oil and/or water), gas or multiphase with up to 3000 ppm of H2S.
This limit has been established by extensive corrosion testing on the steel cord
reinforcements of the FCLP product and has been approved by an independent third
party engineering firm as well as the ERCB (Energy Resources Conservation Board) of
Alberta.
5.1.6 CO2
Shawcor Spoolable Products can be used for gases or liquids containing up to 100%
CO2 by volume. The suitability for CO2 service has been confirmed by a rapid
decompression testing. The standard 75 Durometer Vition o-rings are suited for a wide
range of CO2 applications. For applications having higher than 10% CO2 and operating
at pressures above 750 psi, Shawcor 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
Shawcor Spoolable Products are compatible with aromatic and cycloalkane
hydrocarbons (e.g. benzene, toluene, ethyl benzene, xylene, naphthalene and
cyclohexane) in gas or liquids. Table 7 lists the allowable aromatic and cycloalkane
concentrations for normal operating pressures, based on Shawcor test data.
19
CSA Z 662-11 Clause 13.1.1.4 limits the partial pressure of H2S 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
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Table 7: Allowable Aromatic and Cycloalkane Hydrocarbon Content
Product Line
Operating temperature
FPLP and
FCLP
FPLP HT
60˚C (140˚F) or below
82˚C (180˚F) or below
Maximum allowable
aromatic and cycloalkane
content (by volume)
25%
25%
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. Shawcor 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 provided the concentration of the injection
chemicals is controlled such that the aromatic and cycloalkane concentration stays
within the limits listed in Table 7 as applicable for the pipe service temperature. Any
higher concentration 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,
Shawcor 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 may be used in Shawcor Spoolable Products during hydrotests
to prevent freezing. They may also be used in FPLP and FPLP HT in continuous and
batch programs. Due to the possible introduction of oxygen with alcohols, continuous
injection of alcohols in FCLP is not recommended.
5.2
Pressure and Temperature Ratings
5.2.1 Maximum and Minimum Allowable Operating Temperature
The Maximum Allowable Operating Temperatures (MAOT) and minimum allowable
operating temperatures for Shawcor Spoolable Products are indicated in Table 8.
These temperatures have been proven by the successful completion of the required
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qualification testing and the positive track record of field applications in the northern
United States and Canada.
Shawcor supplies tags for installation on risers to notify operators of the temperature
limitations of the pipe.
Table 8: Maximum and Minimum Allowable Operating Temperatures
Product Line
FPLP
FPLP HT
FCLP
Maximum Allowable
Operating Temperature
(°C)
(°F)
60
140
82
180
60
140
Minimum Allowable
Operating Temperature
(°C)
(°F)
-46
-50
-25
-13
0
32
Shawcor Spoolable Products have excellent impact resistance properties and do not
become brittle at low temperatures. Shawcor Spoolable Products can be installed at
temperatures lower than 0˚C (32˚F). Refer to Section 6.12 for cold temperature
installation limits, Section 3.3 for fittings materials selection and Section 8.1 for starting
up pipelines at low temperatures.
During hot oiling applications using FPLP HT, it is allowable for excursions to exceed
the pipe maximum allowable operating temperature of 82°C (180°F) for a brief period.
The hot oiling temperature is allowed to reach up to a maximum of 93°C (200°F) for a
cumulative maximum duration of 500 hours over the lifetime of the pipeline. It is
recommended to limit the amplitude of the temperature differential between the
maximum and minimum operating temperatures to 87°C / 156°F or lower. Contact your
Shawcor Account Manager to discuss applications with extreme temperature swings.
Insulation or white Polyken tape is required for protecting aboveground portions of
Shawcor Spoolable Products (for example at risers) from exceeding the maximum
allowable operating temperature as a result of heating due to solar radiation.
5.2.2 Maximum Allowable Operating Pressures
The Maximum Allowable Operating Pressures (MAOP) is shown in Table 9. These
pressures have been established by performing the qualification testing at the MAOT of
each product line.
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Table 9: Maximum Allowable Operating Pressure
Maximum Allowable Operating Pressure*
Produc
t Line
150
301
601
801
(kPa)
(psi) (kPa) (psi)
(kPa)
(psi)
(kPa)
(psi)
FPLP
2,068
300
5,171
750
10,342 1500
FPLP
2,068
300
5,171
750
10,342 1500
HT
FCLP
13,790
2,000
*Check your local regulations to verify the maximum allowable operating pressure
does not exceed the maximum allowable design pressure.
5.2.3 Calculations for Determining Maximum Allowable Operating Pressure
The MAOPs listed in Table 9 have been determined by the following equation:
MAOP  MPR  F fluid  Fcyclic
Where
MAOP = Maximum Allowable Operating Pressure
MPR = Maximum Pressure Rating
Ffluid = Service Fluid Factor
Fcyclic = Cyclic Pressure Service Factor
The Maximum Pressure Ratings (MPR) have been determined at the maximum design
temperatures and minimum 20 years design life of the pipeline in accordance with API
RP 15S20 or API 17J21 as applicable, and include the required Pressure Service Factor
(PSF).
The Service Fluid Factor (Ffluid) is a service 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.
The procedure utilized to establish the MAOP of FPLP and FPLP HT is illustrated in
Figure 4, where data from multiple long-term pressure tests are plotted on a log-log
graph. The MPR is derived using statistical calculations, and includes a Pressure
Service Factor (PSF) which is the service factor 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
20
21
API RP 15S Recommended Practice for the Qualification of Spoolable Reinforced Plastic Line Pipe
API 17J Specification for Unbonded Flexible Pipe
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Confidence Limit (LCL) at the Design Life to determine the MPR at the qualification
temperature. Shawcor uses PSF=0.67, as recommended by API 15S.
Figure 4: Procedure for Determining MPR and MAOP22
FPLP and FPLP HT have been designed using an Ffluid=0.67 for all types of fluids. This
value allows a consistent MAOP for all types of fluids. It meets the CSA Z662-11
requirements for gas, and is more conservative than CSA Z662-11 requirements for
other services. Shawcor believes that this conservative approach has contributed to its
outstanding track record.
The FCLP Maximum Pressure Rating is determined in accordance with API 17J / ISO
13628-2. Table 9, includes the use of the required design factors, and considers the
effects of the transported medium on the material properties. Accordingly, and in line
with CSA Z662-11 clause 13.1.2.8, FCLP’s MAOP has been determined using a Fluid
Factor (Ffluid) of 1.0 for all service fluids shown in Table 13.1 of CSA Z662-11.
Because Shawcor’ MAOP already includes the required design and fluid factors,
Shawcor Spoolable Products can be operated in the field at pressures up to the MAOP
published by Shawcor.
The effect of pressure cycling (i.e. cyclic pressure service factor Fcyclic of CSA Z662-11
section 13.1.2.8) is taken into account during the application evaluation conducted by
Shawcor on a project by project basis. The amplitude of the pressure fluctuations that
the system will see under typical operating conditions is compared to the cyclic test data
generated by Shawcor during laboratory testing, and a safe cycling frequency is
determined. A Cyclic Pressure Service Factor (Fcyclic) of 1.0 has been used to determine
the MAOP values shown in Table 9.
22
Based on Figure 1 of API RP 15S (2006).
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5.3
Cyclic Pressure
Water transfer, disposal or injection applications and oil gathering applications are
typically quite corrosive and are a natural fit for Shawcor Spoolable Products corrosion
resistance properties. However, to ensure the optimal performance and reliability of the
products in these applications, consideration must be given to the cyclic pressure
characteristics of the system design and the operating regime.
As part of Shawcor’s commitment to quality and customer satisfaction, an application
evaluation process is offered. The pipeline end user provides the operating parameters
as per the Application Review Form for assessment. Shawcor applications engineers
can provide project specific recommendations regarding selection of the best product,
optimal system design, and operational considerations for the intended application.
Shawcor requires that an application review be completed for all liquid applications to
ensure optimal performance of the product and the overall system. The
recommendations of an application review are based on a minimum 20 year service life.
The key parameters that influence the selection of the pipe type for a cyclic service
application are:

Type of pump: The pump type plays a major role in determining the cyclic
characteristics of a pipeline system. Pumps can be generally divided into
pulsating and non-pulsating types. All pulsating pumps are of the reciprocating
positive displacement type, such as Triplex, Quintuplex and Diaphragm pumps.
These pumps generate a pulsating flow and pressure output as a result of their
back and forth mechanical action. Non-pulsating pumps such as centrifugal,
progressive cavity, screw, and gear, are characterized by their rotating
mechanical action resulting in a smooth flow and pressure output. Pump Jacks
are a unique type of positive displacement pumps and will be treated separately
in Section 5.3.4.

Pressure fluctuations: Pressure fluctuations may either be the result of:
o Pump start/stop cycles where the pressure in the pipeline system cycles
between the operating pressure and the shut off pressure, or
o Modifications to the system operation or layout, such as operating an
additional pump or injecting into a different well.
Depending on their magnitude and frequency, pressure pulsations and fluctuations
could be detrimental to the pipe performance. Contact your Shawcor representative for
a project specific application evaluation. The Application Review process evaluates the
feasibility of using Shawcor Spoolable Products on your project and provides guidance
on how to safely operate the pipeline.
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5.3.1 FPLP Cyclic Capabilities
Applications with non-pulsating pumps can be operated at the full FPLP pressure rating,
as this type of pump provides a steady pressure output free of high frequency pressure
pulsations or excessive vibration. Additionally, FPLP can handle mild pressure
fluctuations and these applications need to be evaluated on a case-by-case basis using
Shawcor’ application review process.
Applications with pulsating pumps can be detrimental to many pipeline materials. It is
required to maintain the peak-to-peak amplitude of the high-frequency pressure
pulsations below 15 psi for FP301 and below 25 psi for FP601. To protect FPLP from
progressive damage, effective pulsation dampeners are required at the pump inlet and
outlet, designed to limit peak to peak amplitude to 3%. As the industry practice
estimates the peak-to-peak amplitude of high-frequency pulsations to be 10% of the
mean pressure value, this translates into a maximum service pressure of 150 psi for
FP301 and 250 psi for FP601. This does not affect the capability of the pipe to handle
infrequent pressure excursions up to the pipe MAOP as shown in Table 9. In addition, a
minimum of 100 feet of steel pipe between the pump and the FPLP is recommended to
assist with vibration dissipation.
For all application types and in order to eliminate large amplitude pressure fluctuations
resulting from pump on/off cycles, Shawcor recommends using a variable frequency
drive (VFD) to regulate the flow rate while maintaining continuous operation of the
pump, and provide a soft start/stop whenever the pump shuts down.
5.3.2 FPLP HT Cyclic Capabilities
Applications with non-pulsating pumps can be operated at the full FPLP HT pressure
rating, as this type of pump provides a steady pressure output free of high frequency
pressure pulsations or excessive vibration. Additionally, FPLP HT can handle mild
pressure fluctuations and these applications need to be evaluated on a case-by-case
basis using Shawcor’ application review process.
For all application types and in order to eliminate large amplitude pressure fluctuations
resulting from pump on/off cycles, Shawcor recommends using a variable frequency
drive (VFD) to regulate the flow rate while maintaining a continuous operation of the
pump, and provide a soft start/stop whenever the pump shuts down.
It is not recommended to utilize FPLP HT with pumps generating a pulsating pressure
output, such as Duplex, Triplex, Quintuplex, Diaphragm, Hydra-Cell, etc.
5.3.3 FCLP Cyclic Capabilities
FCLP is suitable for service in systems subject to severe cyclic pressure conditions-with
either pulsating (piston, diaphragm) or non-pulsating (centrifugal, gear, screw,
progressive cavity) pumps. FCLP is adequate for use with pulsating pumps operating at
pressures up to 13,790 kPa (2,000 psi) and peak-to-peak pressure pulsations of up to
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1,380 kPa (200 psi). Pulsating pumps can generate large peak-to-peak pulsations well
in excess of 200 psi. Properly designed, operated and maintained pulsation dampeners
at the pump suction and discharge of pulsating pumps are required. A typical maximum
peak-to-peak design value for pulsation dampeners is 3% of the operating pressure.
FCLP is also suitable for applications with large amplitude pressure cycles of up to 10
cycles per day of 0 – 10,342 kPa (0 - 1,500 psi) or 1 cycle per day of 0 – 13,790 kPa
(2,000 psi) based on a minimum service life of 20 years.
5.3.4 Pump Jacks
Shawcor Spoolable Products corrosion resistant properties are a natural fit for corrosive
oil emulsion production. However, to ensure the optimal performance and reliability 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
Down hole pump integrity
Wax build-up
Flow line check valve integrity
Hot oiling and pigging practices
For FPLP applications with an upstroke pressure above 150 psi, Shawcor 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.
FPLP HT is a very good fit for applications with pump jacks. For pump jacks with an
upstroke pressure above 150 psi, Shawcor recommends limiting the amplitude of the
pressure differential between the routine upstroke and down stroke pressures to 30 psi
for FP301 HT and 50 psi for FP601 HT. Infrequent pressure excursions beyond this limit
are generally acceptable.
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FCLP is suitable for use in pump jack applications with severe pressure cycling
parameters, with consistent upstroke pressures of up to 3,450 kPa (500 psi).
These recommendations are based on both qualification test results and field
experience. They provide safe operating limits based on a minimum design life of 20
years. In order to ensure the long term integrity of the piping system, Shawcor
recommends:



5.4
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.
Flow Characteristics
5.4.1 Pipe Flow
Relative to steel pipe, the smooth internal surface of Shawcor Spoolable Products
polyethylene liner provides favorable flow rates and reduced pressure losses as a result
of reduced friction. Figure 5 and Figure 6 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 the product
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 the
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 Shawcor Spoolable
Products.
For other flow scenarios, the pressure drop can be calculated using any of the flow
coefficients listed in Table 10.
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800
700
Pressure Drop (PSI)
600
500
400
300
200
100
2" Flexpipe
2" Sch 40 Steel
3" Flexpipe
3" Sch 40 Steel
4" Flexpipe
4" Sch 40 Steel
0
0
5000
10000
15000
20000
25000
30000
35000
Flow Rate (bbls/day)
Figure 5: Representative Pressure Drop Comparison: Water at Various Flow Rates
*Calculations based on 1 mile of pipe length, with fresh water at 30˚C (86˚F)
500
450
Pressure Drop (PSI)
400
350
300
250
200
150
100
50
2" Flexpipe
2" Sch 40 Steel
3" Flexpipe
3" Sch 40 Steel
4" Flexpipe
4" Sch 40 Steel
0
0
5000
10000
15000
20000
25000
30000
35000
40000
Flow Rate (Mcf/day)
Figure 6: Representative Pressure Drop Comparison: Methane at Various Flow Rates
*Calculations based on 1 mile of pipe length, with methane at 20˚C (68˚F) compressed
to 500 PSI
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Table 10: Flow Coefficients for Shawcor Spoolable Products
150
Hazen & Williams
Darcy Weisbach
0.0015 mm (0.000005 ft)
Manning
0.009
5.4.2 Fittings
The inside diameter of the mandrel of the 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 Shawcor coupling fittings can be used to
calculate the loss in pressure or pressure head due to the flow constriction.
Pressure loss:
Pressure head loss:
Pfitting  K
h fitting
V 2
Where:
 = fluid density
2
V = fluid velocity
g = acceleration due to gravity
K = factor from Table 11
V2
K
2g
Table 11: K Factor for Shawcor Spoolable Products Coupling Fittings
Fitting size
K factor
2”
0.56
3”
0.55
4”
0.33
5.5
Durability
Shawcor Spoolable Products are a durable, rugged product. The high-strength, pipegrade thermoplastic used in the jacket protects the reinforcement from the environment.
The jacket is highly resistant to cracking, and will not bruise, chip, or flake under normal
handling. Shawcor Spoolable Products can be installed over rocks and rough terrain, or
pulled into failed pipelines.
Impact testing according to API RP 15S Section 5.5.2 at -25◦C (-13◦ F) has
demonstrated a high level of resistance to impact loading from normal handling and
installation activities.
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5.6
Corrosion
Shawcor Spoolable Products liner and jacket will not corrode. External corrosion
control of the 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).
FCLP is intended for applications where lined steel is typically specified and is expected
to perform corrosion free.
5.7
Erosion
Shawcor Spoolable Products 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. Shawcor
Spoolable Products may not be suitable for dry slurry applications. Please contact your
Shawcor representative to conduct an application evaluation for your project in this
case.
5.8
Ultra-Violet Protection
Shawcor adds a UV stabilizer to the jacket material during the extrusion process. The
outer jackets of all Shawcor Spoolable Products provide a minimum of 20 years
protection against UV exposure.
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 12.
Table 12: Minimum Bend Radius for Operation, Transport and Handling
Minimum bend radius
Minimum bend radius
Shawcor
OPERATION
TRANSPORT & HANDLING
Spoolable
Products
(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.
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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.
Shawcor Spoolable Products have a self-venting design which allows permeated gases
to vent at the fittings. This prevents pressure from building up within the annulus (the
space between the liner and jacket that contains the reinforcement layer), thereby
avoiding the risk of liner collapse during line depressurization. Wherever it is desired to
avoid venting permeated gas above grade, Shawcor offers a flange option where the
vent hole has been plugged. In such installations, a coupling should be located within
300 meters from the plugged flange to provide the pipeline with adequate venting
capability.
Field testing has shown that the actual rates of gas release from pipeline 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 13, which
are experimentally determined from testing conducted on unreinforced polyethylene.
The following example provides a representative illustration of the extent of permeation
in Shawcor Spoolable Products.
Table 13: Permeability Coefficients for HDPE
Permeability coefficient at 40°C
Permeant
Methane
H2S
CO2
(cm /cm-secMPa)
1 x 10-7
1 x 10-7
5.5 x 10-7
3
(104°F)
(inch3/inch-secpsi)
1.07 x 10-10
1.07 x 10-10
5.88 x 10-10
Shawcor Spoolable Products liner has a similar SDR (Standard Dimension Ratio) in all
sizes, which results in the same permeation rate for all sizes. Table 14 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. The values
listed in Table 14 have been determined by the following equation:
q
PA( p ' p" )
t
Where:
q = Volume of gas permeating per unit length per unit time
P = Permeability coefficient from Table 13
A = Surface area per unit length of pipe
P’ = Internal partial pressure
P” = External partial pressure
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t = Wall thickness
Table 14: Representative Permeation Rates for Shawcor Spoolable Products
Pipe at 10°C
(50°F)
Pipe at 40°C
(104°F)
Pipe at 60°C
(140°F)
Pipe at 82°C
(180°F)
Pipe
pressure
89% methane
1% H2S
10% CO2
Total mixture
89% methane
1% H2S
10% CO2
Total mixture
89% methane
1% H2S
10% CO2
Total mixture
89% methane
1% H2S
10% CO2
Total mixture
Permeation rate
of pipe/day (in3/ft of pipe/day)
689 kPa
5171 kPa
10,342 kPa
(100 psi)
(750 psi)
(1500 psi)
6 (0.1)
46 (0.9)
93 (2)
0.1 (0.001)
0.5 (0.01)
1 (0.02)
4 (0.07)
29 (0.5)
57 (1)
10.2 (0.2)
76 (1.4)
151 (3)
30 (0.6)
224 (4)
447 (8)
0.3 (0.006)
3 (0.05)
5 (0.09)
18 (0.3)
138 (3)
276 (5)
48 (0.9)
365 (7)
728 (13)
85 (2)
639 (12)
1277 (24)
1 (0.02)
7 (0.13)
14 (0.3)
53 (1)
395 (7)
789 (15)
139 (3)
1041 (19)
2080 (39)
270 (5)
2025 (38)
4051 (75)
3 (0.06)
23 (0.4)
46 (0.8)
167 (3)
1252 (23)
2503 (47)
440 (8)
3300 (61)
6599 (123)
cm3/m
5.11 Expansion/Contraction and Axial Growth
Shawcor Spoolable Products have been engineered to significantly minimize axial strain
as a result of pressure or temperature changes in operation. When pressurized,
expansion and contraction of the product is governed by the mechanics of the
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, the product 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.
*When Shawcor Spoolable Products are used as free standing liners (see Section 6.5),
it is required to terminate the liner pull underground and provide 7 meters of uncased
buried length before bringing the pipe to surface. This ensures any expansion or
contraction concentrated inside the existing failed line is restrained by ground friction
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before coming to surface. The entry and exit points of the Shawcor Spoolable Product
should also be protected as per Section 6.9.
5.12 External Load and Internal Vacuum Capability
When the pressure outside the pipe 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 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 the products 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 .
Shawcor Spoolable Products external pressure resistance for buried applications has
been measured according to ASTM D241223, in accordance with Clause 13.1.2.12 of
CSA Z662-11. The maximum net external load that the pipe 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 clay24. If the total combination of dead
loads, live loads, and internal vacuum will exceed this, the pipe 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, the pipe can withstand a net vacuum pressure of 101 kPa (14.7 psi) at 23˚C
(73˚F), the maximum vacuum pressure that will be created due to gravity flow down
slopes.
Higher temperatures or long term exposure to liquid hydrocarbons may reduce the net
external load that the pipe can withstand. Shawcor Spoolable Products are not
23
ASTM D2412 Standard Test Method for Determination of External Loading Characteristics of Plastic Pipe by
Parallel-Plate Loading
24
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.).
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intended for subsea applications. In case of shallow water applications (e.g. 30 meters
water depth) an application review can be conducted to determine feasibility.
5.13 Thermal Conductivity
Shawcor Spoolable Products thermal conductivity properties result from the properties
of the polyethylene and the reinforcement materials. Accordingly, Shawcor Spoolable
Products is a good thermal insulator with higher resistivity than metallic pipes. Table 15
lists the thermal conductivity and resistivity values of the FPLP and FPLP HT products.
FCLP will have somewhat higher values than listed below. Contact Shawcor for
guidance.
Table 15: FPLP and FPLP HT Thermal Conductivity and Resistivity
Item
Units
Pipe Size
Values
Units
2" FP150
3"
FP150
4" FP150
Values
2" FP150
3" FP150
4" FP150
Wall
Thicknes
s
R'-value
K'-value
mm
n/a
9.14
11.30
in
n/a
0.36
0.45
m*K/W
W/m*K
n/a
n/a
0.15
6.80
0.14
6.97
hr*ft*F/Btu
Btu/hr*ft*F
n/a
n/a
0.25
3.93
0.25
4.03
Item
Units
Pipe Size
Values
Units
2"
FP301/HT
3"
FP301/HT
4"
FP301/HT
Values
2"
FP301/HT
3"
FP301/HT
4"
FP301/HT
Wall
Thicknes
s
R'-value
K'-value
mm
7.75
9.91
12.57
in
0.31
0.39
0.50
m*K/W
W/m*K
0.28
3.53
0.25
4.04
0.25
4.07
hr*ft*F/Btu
Btu/hr*ft*F
0.49
2.04
0.43
2.33
0.43
2.35
Item
Units
Units
3"
FP601/HT
4"
FP601/HT
mm
9.40
11.94
15.37
m*K/W
W/m*K
0.47
2.14
0.41
2.45
0.42
2.40
Pipe Size
Wall
Thicknes
s
R'-value
K'-value
Values
2"
FP601/HT
Values
2"
FP601/HT
3"
FP601/HT
4"
FP601/HT
in
0.37
0.47
0.61
hr*ft*F/Btu
Btu/hr*ft*F
0.81
1.24
0.71
1.41
0.72
1.38
6 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 Shawcor Field Services Department provides support services for the installation of
Shawcor Spoolable Products, including training courses, project coordination services,
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equipment rentals, onsite inspectors, and installation supervisors.
Experienced
managers and project coordinators are on call 24 hours per day, 7 days per week.
Shawcor strives to ensure successful installation of its products on every project.
Fitting installation equipment is available from Shawcor for sale or rental. Information
on this equipment can be found in the Shawcor Installation Guide. In addition, Shawcor
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 Shawcor Installation Guide.
6.2
Transportation
Shawcor Spoolable Products are spooled 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 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
Shawcor representative for more information and for Shawcor recommended
disassembly procedure.
Shawcor also offers a reel-less/coiled version of its products.
The pipe is coiled in different lengths and is placed on to a
wooden pallet for transportation. The coil is handled by using a
Shawcor custom designed lifting device and is deployed using
a Shawcor custom designed turn table. Please see the
Shawcor Installation Manual and Technical Bulletin 06-4013
for detailed information about the installation of reel-less/coiled
pipe.
6.3
Trenching
Shawcor Spoolable Products can
easily be un-spooled and placed into
a trench or ditch. The pipe is
handled and installed much like
coiled HDPE pipe. The bending
stiffness of the two is very similar,
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but Shawcor Spoolable Products have less “memory” than HDPE pipe and will lay flat
more readily. Soil condition and padding requirements for the pipe are typically similar
to those for steel pipelines
The flexibility of Shawcor Spoolable Products allows it to 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 single-pass operation, a pipeline plow can trench, install the pipe 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. Plowing also
reduces the safety hazards associated with lifting and open trench installations.
Recommended plow chute dimensions are available in the Shawcor Installation Manual.
6.5
Insertion as a Freestanding Liner
In situations where an existing pipeline has failed, Shawcor Spoolable Products can be
pulled inside the failed pipeline as a remedial line. The pipe is a freestanding liner, and
does not depend on the existing pipeline for any structural support.
In pipeline remediation applications there must be adequate clearance between the
outer diameter of the product and the inner diameter of the existing conduit.
Table 16 shows the general compatibility of various conduits for 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 Shawcor Spoolable Products, provided that enough pipe is
removed to avoid bending the pipe tighter than the minimum radius for operation given
in Table 12. Pipe must be suitably restrained at conduit exits. Refer to Section 5.11 for
guidance.
Shawcor fittings can be pulled along with the Shawcor Spoolable Products. A
centralizing collar or sleeve may be used before each fitting to prevent the fitting from
catching on weld beads or other discontinuities inside the conduit. The maximum
allowable pull forces for Shawcor lines are shown in Table 17, and should not be
exceeded with any type of pull tool.
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Please see the Shawcor Installation Guide for information on pull tools available from
Shawcor.
Table 16: Conduit Compatibility for Shawcor Spoolable Products Insertion
Conduit
3" Steel
4" Steel
6" Steel
0.188 0.120 Sch 0.188" 0.125 Sch. Sch 0.188" 0.156
FPLP
" wall " wall . 40
wall
" wall
80
. 40
wall
" wall
2"
P
FP301/HT
2"
N
FP601/HT
N
3" FP150
3"
N
FP301/HT
3"
N
FP601/HT
N
3” FC801
N
4" FP150
4"
N
FP301/HT
4"
N
FP601/HT
N
4” FC801
N = Not compatible
coupling fittings
0.125
" wall
P
PF
PF
PF
PF
PF
PF
PF
PF
P
PF
PF
PF
PF
PF
PF
PF
PF
N
P
P
P
PF
PF
PF
PF
PF
N
N
P
P
PF
PF
PF
PF
PF
N
N
N
P
PF
PF
PF
PF
PF
N
N
N
N
N
N
P
N
PF
P
PF
P
PF
PF
PF
PF
PF
PF
N
N
N
N
P
P
PF
PF
PF
N
N
N
N
P
P
PF
PF
PF
N
N
N
N
P
P
PF
PF
PF
P = Compatible for pipe without fittings
PF = Compatible for pipe with
Note: The above table is based on 0.15” clearance on diameter between Shawcor Spoolable Products
and the steel pipe weld bead, and a steel pipe weld bead allowance of 0.125”on diameter.
Table 17: Maximum Allowable Pull Forces for Shawcor Spoolable Products
Pipe Size
(nominal)
(in)
2
3
4
6.6
Maximum pull force
(kgf)
1000
2040
2720
(lbf)
2200
4500
6000
Surface Installation
Where permitted by the appropriate regulatory body, Shawcor Spoolable Products 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 may be more susceptible to external damage than metallic
pipelines. External forces, both during installation and during future disturbance or
construction in the area, are additional potential causes of external damage to pipelines.
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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 Shawcor 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. Shawcor Spoolable
Products with black jacket readily absorbs solar radiation and can reach excessively
high temperatures very quickly when exposed to direct sunlight. This may be damaging
and detrimental to the pipe. Shawcor Spoolable Products with white or grey jacket
reduces solar heating and is required for surface lines. The operating temperature of
the pipe, including the effect of solar heating, must be prevented from exceeding 60˚C
(140˚F) for FPLP and FCLP and 82˚C (180˚F) for FPLP HT
When used as a temporary surface line, Shawcor Spoolable Products can be unwound
onto the surface and rewound back onto the reel. It is very important to adequately
control the spooling and unspooling process to avoid damaging the pipe, such as by
kinking, cutting, scraping, and abrading. Unspooling and re-using a damaged pipeline
can result in pipeline failure. It is recommended to limit the re-spooling and re-using of
Shawcor Spoolable Products up to a maximum of 5 deployment cycles (unspooling and
re-spooling sets) per pipeline.
Shawcor Spoolable Products are designed to vent gases that permeate from the
transported fluid through the liner. Permeated gases travel via the annulus containing
the reinforcement layers and are released at the fittings through a vent hole in each
fitting. A fraction of the permeated gases may also be released across the outer jacket
along the length of the pipeline.
Operational experience has shown that unrestrained Shawcor Spoolable 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, Shawcor recommends
implementation of some measures during the pipeline installation. These measures
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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 Shawcor Installation Guide for
further recommendations on the installation of surface lines.
6.7
Support Spacing
For elevated support of Shawcor Spoolable Products, a continuous tray which is wide
enough to allow for the expected thermal expansion and snaking is recommended.
Shawcor Spoolable Products 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, Shawcor recommends spacing the
supports no farther than the distances given in Table 18.
Table 18: Recommended Pipe Support Spacing for Shawcor Spoolable Products
Recommended maximum support spacing
Liquid service
Gas service
(m)
(ft)
(m)
(ft)
2”
1.1
3.5
1.2
4
3”
1.2
4
1.5
5
4”
1.5
5
1.7
5.5
6.8
Buoyancy and Pipe Weights
Shawcor Spoolable Products will float in water or muskeg if not weighted or buried in a
clay base. If conditions are suitable, the pipeline 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 Shawcor or plow installation contractors.
If there is a concern that the pipe may float, the pipe can be weighted during installation.
The weights should not have sharp edges that could point-load or cut the protective
jacket of the product. 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.
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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 required per unit length of pipe  Net buoyancyper unit length of pipe  1.1
Shawcor recommends multiplying by 1.1 to ensure the pipeline is adequately weighted
to remain submerged.
Weight of fluid displaced by sand bag  Volume of fluid displaced by sand bag  Fluid density
Submerged weight of sand bag  Weight of sand bag in air - Weight of fluid displaced by 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 19 for each type of Shawcor
Spoolable Products. These results are based on muskeg with a fluid density of 1121
kg/m3 (70 lb/ft3).
Table 19: Recommended Sand Bag Weight for Weighting Shawcor Spoolable Products
Pipe weight
per length
Recommended
Weightsa
Pipe OD
(kg/m) (lbs/ft) (mm)
(in)
3”
2.5
1.7
95
3.75
FP15
4”
4.0
2.7
122
4.80
0
2”
1.7
1.1
69
2.73
FP30
3”
3.0
2.0
97
3.80
1/HT
4”
4.9
3.3
124
4.89
2”
2.5
1.7
73
2.86
FP60
3”
4.3
2.9
101
3.96
1/HT
4”
6.9
4.6
130
5.11
3”
4.3
2.9
101
3.96
FC80
4”
6.9
4.6
130
5.11
1
aDry sandbag weight. These weights already include
ensure the pipe remains submerged.
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Recommended
Maximum
Spacing
(kg)
(lb)
(m)
100
220
8.9
100
220
5.3
27
60
5.2
100
220
9.1
100
220
5.6
27
60
5.9
100
220
10.3
200
440
12.1
100
220
10.3
200
440
12.1
the recommended safety factor
(ft)
29.2
17.4
17.1
29.9
18.4
19.4
33.8
39.7
33.8
39.7
of 1.1 to
TECHNICAL MANUAL
6.9
Crossings
Shawcor Spoolable Products are 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.
Shawcor 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 pickup 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).
Each bore is unique and therefore it is the responsibility of the installation contractor to
assess the soil conditions and the need for casing (see Section 5.12). Steel casings
may be required by regulations.
Please see the Installation Guide for information on installations involving crossings.
Centering spacers are not required for isolating Shawcor Spoolable Products from the
metal casing. Allowing the pipe to snake inside the casing can accommodate minor
thermal length changes of the pipeline in the casing. Pipe must be suitably restrained at
conduit exits. Refer to Section 5.11 for guidance.
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
Shawcor Spoolable Products 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 pipe that could be caused by settling
of backfill and earth movement. Sand bagging or other suitable protection should be
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TECHNICAL MANUAL
provided at the horizontal transition of the pipe 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. Shawcor Spoolable Products
should be protected from mechanical
damage similar to other piping
materials above ground, depending
on expected hazards in the area.
Shawcor Spoolable Products is a
ductile material and can withstand
reasonable impact even at low
temperatures.
6.11 Tracer Wire
Shawcor Spoolable Products are 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
Shawcor Spoolable Products 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 and
the actual pipe temperature. Shawcor Spoolable Products have
very low thermal conductivity, which means that it cools down or heats up very slowly.
As a result, if pipe is stored outside overnight, 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 Shawcor
Installation Guide for recommended precautions for installing pipe at temperatures
below freezing.
6.13 Heat Tracing
Shawcor Spoolable Products 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.
Shawcor recommends a sandwich type insulated barrier with an insulation/heattrace/insulation configuration, as shown in Figure 7. Because the pipe jacket material is
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TECHNICAL MANUAL
a very poor thermal conductor, concentrated hot spots will appear directly below the
heat tracing wire if an insulated barrier is not used.
The maximum operating temperature of FPLP and FCLP is 60°C (140°F). Therefore, it is
very important to select the insulation thickness and the amount of heat tracing per unit
length of pipe accordingly.
Figure 7: Sandwich Type Insulated Barrier Configuration
6.14 Fitting Installation
Shawcor 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.
Shawcor
works
with
contractors
and
customers to provide certification training so that certified third-party contractors can
provide the fitting installation service. Alternatively, Shawcor can provide certified fitting
installation technicians. Fitting installation equipment is engineered and designed
specifically for Shawcor Spoolable Products, and is available from Shawcor on a rental
basis.
The link ed image cannot be display ed. The file may hav e been mov ed, renamed, or deleted. Verify that the link points to the correct file and location.
6.15 Cathodic Protection
Shawcor Spoolable Products are corrosion resistant and do not require cathodic
protection. Wherever regulations require cathodic protection for buried metallic fittings,
Shawcor can make available ribbon anode kits tailored for Shawcor fittings. Further
information is available in Section 3.5.
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6.16 Tying into Steel – Welding
Shawcor 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 Shawcor Spoolable Products 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 Shawcor fittings by means of welding or standard flanged
connections as appropriate. For example, a poly-to-steel transition fitting can be welded
to a Shawcor weld neck fitting to form a poly-to-Shawcor Spoolable Product transition
fitting.
6.18 Field Pressure Testing of New Pipelines
Shawcor Spoolable Products are designed to accommodate the pressure-testing
requirements specified by regulatory standards and codes. Due to the safety factors
built into the pipeline 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 Shawcor Spoolable Products depend on whether the pipeline
is a new installation or a tie-in or repair job.
Shawcor recommends that new pipelines that have not been placed in operation be
subjected to a hydrostatic hold test at 1.25 x MAOP as shown in Table 20. Refer to
Section 8.6 for hydrostatic testing of pipelines that have already been placed in
operation.
Table 20: New Pipeline Hydrostatic Test Pressures and Durations
Pressure Rating
Flexpipe Systems
Grade
Product Line
FlexPipe Linepipe
(FPLP)
2,068 kPa
(300 psi)
5,171 kPa
(750 psi)
10,342 kPa
(1,500 psi)
13,790 kPa
(2,000 psi)
150
301
601
801
Hydrostatic test pressure and duration
2,586 kPa (375
psi) / 24 hrs.
FlexPipe Linepipe High
Temperature (FPLP
HT)
6,467 kPa (938
psi) / 24 hrs.
6,467 kPa (938
psi) / 24 hrs.
12,928 kPa
(1,875 psi) / 24
hrs.
12,928 kPa
(1,875 psi) / 24
hrs.
17,237 kPa
(2,500 psi) / 8
hrs.
FlexCord Linepipe
(FCLP)
Check with local regulations to ensure required hydrostatic test pressures are met.
Shawcor requires monitoring the system carefully to ensure that the pipeline
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TECHNICAL MANUAL
does not exceed 1.5 x MAOP at any point along the pipeline including low points
at any time during the hydrostatic test.
Suggested procedures for pressure testing new pipelines are given in the Shawcor
Installation Guide.
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. For safety reasons, pressure testing with
a gas medium is acceptable for test pressures up to 2900 kPa (420 psi), provided that
the below conditions are considered. Pressure testing with air or gas above 2900 kPa
(420 psi) is at the discretion of the engineering resources of the pipeline operating
company, but must also consider the conditions listed below:


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 Shawcor 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.
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 Shawcor Spoolable Products
and is commonly used as an additive to prevent water from freezing at low
temperatures.
Where new Shawcor pipelines have been hydrotested in sections or require repair after
a successful hydrotest prior to operation, retesting of the entire pipeline system is not
required after tying in provided:
 Pipe sections used for tie-ins, repairs, or replacement are pre-tested as per Table
20 where required by local regulations or standards.
 Joints of the tie-ins, repairs, or replacements are 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.
Note: Pressure testing pipelines to a pressure greater than MAOP is generally only
appropriate after original construction and prior to a pipeline being put in operation.
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7 Accessories
The following sections cover some of the tools and equipment that are commonly used
for the installation of Shawcor Spoolable Products. For more detailed information on
tools and accessories, please refer to the Shawcor Installation Guide.
7.1
A-frames
A-frames are steel structures used to hold the reel while the pipe is being deployed and
are available on a rental basis. Please contact your Shawcor representative for more
information.
The following reference drawings are available from Shawcor upon request:
 8FT A-Frame Drawing
 4FT A-Frame Drawing
7.2
Turn Table and Lifting device for Coiled pipe
Turn tables and lifting devices are steel structures required to handle and deploy coiled
Shawcor Spoolable Products and are available either on a rental basis or drawings can
be provided upon request. Please contact your Shawcor representative for more
information.
7.3
Riser Support Trays
Riser trays support the pipe as it comes out of the ground to connect to surface pipe
(see Section 6.10). Shawcor offers 45°, 90° and S-bend 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 Shawcor upon request:
 45° Riser Drawing
 90° Riser Drawing
 S-bend Riser Drawing
7.4
Pull Tools
Shawcor offers several types of pull tools for the installation of Shawcor Spoolable
Products. Please refer to the Installation Guide for further information on the available
pull tools.
7.5
Sacrificial Anodes
Shawcor anode kits consist of a magnesium ribbon anode connected to a copper lead
wire, along with a roll of cloth tape to fix the anode to the pipe 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.
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8 Operations
8.1
Startup
In the case of large temperature differences between the pipeline and the conveyed
fluid, startup procedures for Shawcor Spoolable Products should include a gradual or
stepped flow increase to allow for gradual temperature and pressure changes in the
system.
8.2
Pigging
Shawcor Spoolable Products are suitable for pigging. However, Shawcor Spoolable
Product 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 Shawcor disc (cleaning) pig is
required. Use of a pig not approved by Shawcor could result in the pig becoming stuck
in a fitting. Shawcor supplies tags for installation on risers to warn operators of the
temperature limitations of the pipe and pigging restrictions of the fittings.
Shawcor recommends medium-density (5 lb) foam bullet pigs for dewatering and
Shawcor polyurethane disk pigs for removing wax build-up. The foam bullet pigs are
also available with a polyurethane coated tip, which provides protection against damage
during pigging operations. Ball pigs and brush pigs must not be used.
Shawcor polyurethane disk pigs are designed specifically for
Shawcor Spoolable Products, 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.
Polyurethane pigs are available from Shawcor in a variety of
durometers to suit different pigging requirements (see Table 21).
Table 21: Custom Polyurethane Disk Pigs
Size
2”
3”
4”
Durometer
80
70
80
70
60
70
60
Color
Yellow
Green
Yellow
Green
Purple
Green
Purple
Shawcor polyurethane 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 (45° or 90°). If a pigging program is required on a
Shawcor line joining another line, Shawcor 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
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TECHNICAL MANUAL
bottom of the Y. Pig launchers must be sized to accommodate the Shawcor pig
dimensions as indicated in Table 22.
Table 22: Shawcor Pig Dimensions for Shawcor Spoolable Products
Shawcor
Shawcor
Required pressure
polyurethane pig
polyurethane pig
differentiala
diameter
length
(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
4”
104.9
4.13
165.1
6.5
276
40
a
Required pressure differential is approximate and assumes the line is lubricated.
Pipe Size
(nominal)
8.3
Hot Oiling
Shawcor Spoolable Products can be hot oiled. The maximum allowable operating
pressure and temperature of Shawcor Spoolable Products listed in Section 5.2.1 must
not be exceeded at any time during the hot oiling procedure. Contact Shawcor to
discuss the details of your hot oiling program.
8.4
Static Electricity
Standard operating and maintenance procedures for handling non-conductive pipe and
dissipation of static electricity apply when working with Shawcor Spoolable Products.
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 of scale, rust, or
dirt can generate static electricity. Other causes of static charge include gas flow
disrupters such as pipe elbows, valves, neck-downs, 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
Shawcor Spoolable Products due to the potential for external damage. The preferred
method for excavating buried pipe is hydro-excavation (hydrovac).
The following practices are recommended to minimize the risk of external damage to
the pipe:
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TECHNICAL MANUAL









Identify the location of the Shawcor Spoolable Product 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 1500 psi.
o Water temperatures below 40˚C (104˚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 Shawcor Spoolable Products.
Inspect all exposed Shawcor Spoolable Products for external damage prior to
backfilling.
Replace any sections of Shawcor Spoolable Products 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 integrity of the new pipe section and the connections used to join
or repair the pipeline is ensured as follows:


Pipe sections used for tie-ins, repairs, or replacement are pre-tested as per Table
20 where required by local regulations or standards.
Joints of the tie-ins, repairs, or replacements are 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.
Note: Pressure testing pipelines to a pressure greater than MAOP is generally only
appropriate after original construction and prior to a pipeline being put in operation.
8.7
Shutdown Procedures
Shawcor Products containing high pressure gas or CO2 (including multiphase or liquid
content, water, oil, CO2 dense phase, etc) have the unique characteristic of having a
high rate of gas permeation that is typical of a gas service. Accordingly, it is
recommended to depressurize these lines slowly, at a rate similar to what is typical for
gas pipelines. This is to allow enough time for the gas that has permeated through the
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TECHNICAL MANUAL
liner and into the annular space to vent out to the atmosphere via the vent hole provided
on each fitting, thus reducing the external pressure that may result in a liner collapse.
It is recommended to slowly depressurize the pipeline (i.e. no more than 100 psi per
hour) to 50 psi and hold for 24 hours to allow the permeated gas to vent out. The same
recommendation applies to gas pipelines rich in CO2.
9 Reliability
9.1
History
As of 2013, over 16 million meters (53 million feet) of Shawcor Spoolable Products and
70 thousand fittings have been installed throughout Western Canada, the United States,
and internationally. Shawcor Spoolable Products are 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.
Shawcor Spoolable 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.
9.3
Cut-outs
In order to satisfy Canadian regulatory requirements, Shawcor has cut out and tested a
number of pipe samples after two years of service to validate the long-term performance
of Shawcor Spoolable Products.
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 8. These
results demonstrate that there is no degradation of pipe performance after two years of
service.
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Sample Burst Test Results
5000
Burst pressure at time of manufacture
Burst pressure after service
4500
4000
Burst Pressure (psi)
3500
3000
2500
2000
Test Pressure
(937 psi)
1500
1000
500
MAOP
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Sample Number
Figure 8: Cut-out Burst Test Results
9.4
Reliability Management
The reliability of Shawcor Spoolable Products is dependent on the proper engineering,
installation and operation of the pipeline system. The following steps are crucial in
assuring the pipeline system will operate as intended:

Material Selection:
o Shawcor offers an application evaluation process for all pipeline systems.
o Make certain the pipeline end user provides accurate operating
parameters to Shawcor for assessment.
o Ensure Shawcor provides project specific recommendations regarding
selection of the best product, optimal system design, and operational
considerations for the intended application.

Pipeline Installation:
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o Shawcor offers an Installation Guide for use by pipeline end users and
third party installation contractors.
o Make certain the installation crew is in compliance with Shawcor
comprehensive installation program documented by a currently valid
individual ticket number certification.
o Ensure the installation of risers and other transition locations are properly
supported per the Installation Guide and best engineering practice.

9.5
Operational Considerations: The following considerations are important to
maintaining the integrity of Shawcor Spoolable Products.
o Ensuring the pipeline is being operated within the parameters provided
during the application evaluation. Contact Shawcor to discuss any
observed variances.
o Ensuring liquids do not freeze inside of the pipe.
o Avoiding fluid hammer due to rapid opening or closing of valves, or water
surge due to abrupt pump starts and stops etc.
o Following Shawcor recommendations regarding hot oiling and chemical
treatment.
o Ensuring an adequate pigging program is in place to avoid wax build up.
o Utilizing appropriate hazard controls for prevention of external damage to
surface pipelines. The most significant risk to the integrity of Shawcor
Spoolable Products is external damage. The risk of external damage
during operation most commonly arises due to excavation near installed
Shawcor Spoolable Products. Recommended practices to minimize this
risk are given in Section 8.5.
Integrity Verification
Many operators elect to limit their integrity verification activities to an initial pressure test
after installation. 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, in line with their risk management strategies. It would typically be
appropriate for an operating company to make use of the options below.
Integrity verification options for Shawcor Spoolable Products include:
 Visual inspection of jacket. Where pipe is exposed above surface the jacket can be
inspected for discoloration that may indicate UV degradation.
 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.
 Gas detection testing. Fittings can be checked for leaks during operation using gas
detection equipment. Shawcor 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).
06-1876 R4.3
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TECHNICAL MANUAL


Integrity 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 either the maximum allowable operating pressure or 1.25 times the normal
operating pressure.
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. Shawcor offers integrity
assessment testing and analysis of such samples. Refer to Section 8.6.
The extent and frequency of the integrity testing program is to be determined by the
operating company on a case by case basis, as required by pipeline modifications
implemented to the equipment, service type, and/or operating conditions.
06-1876 R4.3
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TECHNICAL MANUAL
10 Appendix
Product Data Sheets
06-1876 R4.3
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53
PRODUCT DATA BULLETIN
Maximum Operating Pressure @ 60°C or 140°F
Nominal Size
Outside Diameter
Inside Diameter
Weight
Min. Bend Radius (operational)
Length / Reel*
Reel Diameter
Reel Width
Reel Weight – Full*
Reel Weight – Empty
Fitting Outside Diameter**
Fitting Inside Diameter**
Metric (mm)
Imperial (inches)
Metric (mm)
Imperial (inches)
Metric (kg/m)
Imperial (lbs/ft)
Metric (m)
Imperial (ft)
Metric (m)
Imperial (ft)
Metric (m)
Imperial (ft)
Metric (m)
Imperial (ft)
Metric (kg)
Imperial (lbs)
Metric (kg)
Imperial (lbs)
Metric (mm)
Imperial (inches)
Metric (mm)
Imperial (inches)
FP150
FP301
FP601
2,068 kPa / 300 psi
5,171 kPa / 750 psi
10,342 kPa / 1,500 psi
3"
4"
2"
3"
4"
2"
3"
4"
95
3.75
77
3.02
2.6
1.7
1.8
6
760
2495
3.7
12
1.2
4
2760
6100
680
1500
110.7
4.36
63.5
2.50
122
4.80
99
3.90
4.0
2.7
2.1
7
750
2460
3.7
12
2.4
8
4283
9430
1150
2530
139.7
5.50
85.9
3.38
69
2.73
54
2.12
1.7
1.1
1.2
4
1100
3610
3.7
12
1.2
4
2635
5800
680
1500
80.5
3.21
44.5
1.75
97
3.80
77
3.02
3.0
2
1.8
6
760
2495
3.7
12
1.2
4
3100
6800
680
1500
110.7
4.36
63.5
2.50
124
4.89
99
3.90
4.9
3.3
2.1
7
735
2410
3.7
12
2.4
8
5013
11030
1150
2530
139.7
5.50
85.9
3.38
73
2.86
54
2.12
2.4
1.6
1.2
4
1100
3610
3.7
12
1.2
4
3450
7600
680
1500
85.1
3.35
44.5
1.75
101
3.96
77
3.02
4.3
2.9
1.8
6
700
2300
3.7
12
1.2
4
3820
8400
680
1500
115.6
4.55
63.5
2.50
130
5.11
99
3.90
6.9
4.6
2.1
7
570
1870
3.7
12
2.4
8
5493
12130
1150
2530
144.3
5.68
85.9
3.38
Flow Coefficients
Hazen & Williams
150
Darcy Weisbach
e=0.000005 ft or 0.0015 mm
Manning
0.009
*Length and reel weights are approximate as they may vary depending on the manufacturing run.
**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. Shawcor's products are patented by US Patents 6,889,716, 6,902,205, 7,946,629 B2
and 8,042,252 B2 by Canada Patents 2,513,506, 2,513,468 and 2,562,823 and by European Patent 1592908. Additional patents are pending.
©ShawCor Ltd., 2015.
Rev #003: 11/17/2015
FlexPipe Linepipe High Temperature (FPLP HT)
FlexPipe Linepipe High Temperature (FPLP H
FP301 HT
FP601 HT
5,171 kPa / 750 psi
10,342 kPa / 1,500 psi
Nominal Size
Outside Diameter
Inside Diameter
Weight
Length / Reel*
Reel Diameter
Reel Width
Metric (mm)
Imperial (inches)
Metric (mm)
Imperial (inches)
Metric (kg/m)
Imperial (lbs/ft)
Metric (m)
Imperial (ft)
Metric (m)
Imperial (ft)
Metric (m)
Imperial (ft)
Metric (m)
Imperial (ft)
Metric (kg)
Imperial (lbs)
Metric (kg)
Imperial (lbs)
Metric (mm)
Imperial (inches)
Metric (mm)
Imperial (inches)
2"
3"
4"
2"
3"
4"
69
2.73
54
2.12
1.7
1.1
1.2
4
1120
3675
3.7
12
1.2
4
2635
5800
680
1500
8105
3.21
44.5
1.75
97
3.80
77
3.02
3.0
2.0
1.8
6
760
2495
3.7
12
1.2
4
3100
6800
680
1500
110.7
4.36
63.5
2.50
124
4.89
99
3.90
4.9
3.3
2.1
7
735
2410
3.7
12
2.4
8
5013
11030
1150
2530
139.7
5.5
85.9
3.38
73
2.86
54
2.12
2.4
1.6
1.2
4
1120
3675
3.7
12
1.2
4
3450
7600
680
1500
85.1
3.35
44.5
1.75
101
3.96
77
3.02
4.3
2.9
1.8
6
700
2300
3.7
12
1.2
4
3820
8400
680
1500
115.6
4.55
63.5
2.50
130
5.11
99
3.90
6.9
4.6
2.1
7
570
1870
3.7
12
2.4
8
5493
12130
1150
2530
144.3
5.68
85.9
3.38
Flow Coefficients
Hazen & Williams
Darcy Weisbach
Manning
150
e=0.000005 ft or 0.0015 mm
0.009
Rev #003: 11/17/2015
FlexCord Linepipe (FCLP)
FlexCord Linepipe (FCLP) - 800 ANSI
FC801
13,790 kPa / 2,000 psi
Nominal Size
Outside Diameter
Metric (mm)
Inside Diameter
Metric (mm)
Imperial (inches)
Weight
Length / Reel*
3"
4"
99
128
3.91
5.03
77
99
Imperial (inches)
3.02
3.90
Metric (kg/m)
5.1
8.6
Imperial (lbs/ft)
3.5
5.8
Metric (m)
1.8
2.1
Imperial (ft)
6
7
Metric (m)
575
485
Imperial (ft)
1890
1590
Metric (m)
3.7
3.7
Imperial (ft)
12
12
Reel Width
Metric (m)
1.2
2.4
Imperial (ft)
4
8
Metric (kg)
3817
7036
Imperial (lbs)
8415
15479
Metric (kg)
680
1150
Imperial (lbs)
1500
2530
Metric (mm)
115.6
144.3
Imperial (inches)
4.55
5.68
Metric (mm)
63.5
85.9
Imperial (inches)
2.50
3.38
Reel Diameter
Flow Coefficients
Hazen & Williams
150
Darcy Weisbach
e=0.000005 ft or 0.0015 mm
Manning
0.009
Rev #003: 11/17/2015
TECHNICAL MANUAL
Head Office and Manufacturing Facility
3501 - 54th Avenue S.E.
Calgary, Alberta
Canada T2C 0A9
Tel: 403-503-0548
Fax: 403-503-0547
Manufacturing Facility
195, 1820 – 100 Ave. NE
Calgary, Alberta
Canada T3J 0P7
Tel: 403-503-0548
Fax: 403-567-5452
Australia Solution Center
1517 Lytton Road
Hemmant, QLD
Australia 4174
Mobile: +61 439390081
U.S. Head Office
1155 Dairy Ashford, Suite 450
Houston, Texas
United States 77079
Tel: 281‐670‐2105
Fax: 281‐670‐2164
Asia Pacific
101 Thomson Road,
#17-01 and 02,
United Square
Singapore 307591
DID: +65-6477-5331
Mobile: +65-8522-8729
Canada Solution Centers
 Estevan, SK
Tel: 306-402-7196
 Grand Prairie, AB
Tel: 780-882-1213
U.S. Solution Centers
 Grand Junction, CO
Tel: 970-243-0067
 Midland, TX
Tel: 432-685-0865
 Big Wells, TX
Tel: 956-857-4665
 Dickinson, ND
Tel: 970-243-0067
06-1876 R4.3
shawcor.com
U.S. Deployment Centers
 Canadian, TX
Tel: 432-685-0865
 Myton, UT
Tel: 970-243-0067
 Bakersfield, CA
Tel: 970-243-0067
 Big Wells, TX
Tel: 281-670-2108
 Ennis, TX
Tel: 281-670-2108
54

technical manual - Flexpipe Systems

Transcription

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