Flexpipe Technical Manual English

FLEXPIPE SYSTEMS
TECHNICAL INFORMATION MANUAL

FlexPipe Linepipe
Toll Free: 888-FLX-PIPE (888-359-7473)

Toll Free Fax: 888-359-7479
Website: www.flexpipesystems.com
Flexpipe Systems 06-1876 R3.2
ShawCor Ltd., 2010
Contents
List of Tables ........................................................................................................................... iv
List of Figures .......................................................................................................................... iv
1 Introduction ...................................................................................................................... 1
2 Pipe ................................................................................................................................... 1
2.1 Product Lines ...................................................................................................................... 1
2.2 Design.................................................................................................................................. 1
2.3 Materials ............................................................................................................................. 3
2.4 Manufacturing .................................................................................................................... 3
2.4.1 Liner .............................................................................................................................. 4
2.4.2 Fiber Reinforcement ..................................................................................................... 4
2.4.3 Pipe ............................................................................................................................... 4
2.4.4 Quality Control ............................................................................................................. 5
3 Fittings .............................................................................................................................. 5
3.1 Product Lines ...................................................................................................................... 6
3.2 Design.................................................................................................................................. 7
3.3 Materials ............................................................................................................................. 8
3.4 Manufacturing .................................................................................................................... 9
3.5 Corrosion Protection ........................................................................................................... 9
4 Qualification .................................................................................................................... 10
4.1 Introduction to Standards and Regulations ...................................................................... 10
4.2 Standards .......................................................................................................................... 11
4.2.1 American Petroleum Institute (API) ............................................................................ 11
4.2.2 Canadian Standards Association (CSA)....................................................................... 11
4.3 Regulations ....................................................................................................................... 13
4.3.1 Canadian Provincial Regulatory Bodies ...................................................................... 13
4.3.2 United States Regulatory Bodies ................................................................................ 13
4.4 Testing ............................................................................................................................... 13
5 Performance .................................................................................................................... 15
5.1 Applications & Chemical Compatibility............................................................................. 15
5.1.1 Application Evaluations .............................................................................................. 15
5.1.2 Gas .............................................................................................................................. 15
5.1.3 Oil ............................................................................................................................... 16
5.1.4 Water .......................................................................................................................... 16
5.1.5 H2S .............................................................................................................................. 16
5.1.6 CO2 .............................................................................................................................. 17
5.1.7 Aromatic and Cycloalkane Hydrocarbons .................................................................. 17
5.1.8 Chemical Injection ...................................................................................................... 17
5.1.9 Methanol and Ethanol ................................................................................................ 18
5.2 Pressure and Temperature Ratings .................................................................................. 18
5.2.1 Minimum Allowable Operating Temperature ............................................................ 18
5.2.2 Maximum Allowable Operating Temperatures and Pressures ................................... 18
ShawCor Ltd., 2010
5.2.3 Calculations for Determining Maximum Allowable Operating Pressure .................... 19

5.3 Cyclic Pressure .................................................................................................................. 20
5.3.1 Pump Jacks ................................................................................................................. 22
5.4 Flow Characteristics .......................................................................................................... 23
5.4.1 Pipe Flow .................................................................................................................... 23
5.4.2 Fittings ........................................................................................................................ 25
5.5 Durability........................................................................................................................... 25
5.6 Corrosion........................................................................................................................... 26
5.7 Erosion .............................................................................................................................. 26
5.8 Ultra-Violet Protection ...................................................................................................... 26
5.9 Bend Radius ...................................................................................................................... 26
5.10 Permeation ....................................................................................................................... 27
5.11 Expansion/Contraction and Axial Growth ........................................................................ 28
5.12 External Load and Internal Vacuum Capability ................................................................. 28
5.13 Thermal Conductivity ........................................................................................................ 29
6 Installation ...................................................................................................................... 30
6.1 Field Services Support ....................................................................................................... 30
6.2 Transportation .................................................................................................................. 30
6.3 Trenching .......................................................................................................................... 31
6.4 Plowing.............................................................................................................................. 31
6.5 Insertion as a Freestanding Liner ...................................................................................... 31
6.6 Surface Installation ........................................................................................................... 33
6.7 Support Spacing ................................................................................................................ 34
6.8 Buoyancy and Pipe Weights.............................................................................................. 34
6.9 Crossings ........................................................................................................................... 36
6.10 Risers ................................................................................................................................. 37
6.11 Tracer Wire ....................................................................................................................... 37
6.12 Cold Temperature Installation .......................................................................................... 37
6.13 Heat Tracing ...................................................................................................................... 38
6.14 Fitting Installation ............................................................................................................. 39
6.15 Cathodic Protection .......................................................................................................... 39
6.16 Tying into Steel Welding ................................................................................................ 39
6.17 Tying into Plastic ............................................................................................................... 39
6.18 Field Pressure Testing of New Pipelines ........................................................................... 39
7 Accessories ...................................................................................................................... 40
7.1 A-frames............................................................................................................................ 41
7.2 Riser Support Trays ........................................................................................................... 41
7.3 Pull Tools ........................................................................................................................... 41
7.4 Sacrificial Anodes .............................................................................................................. 41
8 Operations....................................................................................................................... 41
8.1 Startup .............................................................................................................................. 41
8.2 Pigging ............................................................................................................................... 42
8.3 Hot Oiling .......................................................................................................................... 43
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8.4 Static Electricity................................................................................................................. 43

8.5 Secondary Excavations ...................................................................................................... 43
8.6 Field Pressure Testing of Existing Pipelines ...................................................................... 44
9 Reliability ........................................................................................................................ 44
9.1 History ............................................................................................................................... 44
9.2 Leak Testing ...................................................................................................................... 45
9.3 Cut-outs............................................................................................................................. 45
9.4 Integrity Verification ......................................................................................................... 46
10 Appendix ............................................................................................................................ I
Product Data Sheets ...................................................................................................................... I
ShawCor Ltd., 2010
iii
List of Tables
Table 1: Flexpipe Fittings ................................................................................................................ 6
Table 2: Flexpipe Flow Joints .......................................................................................................... 6
Table 3: Flexpipe Fitting Material List ............................................................................................. 9
Table 4: Links for Specific CSA Z662 Requirements ...................................................................... 12
Table 5: FlexPipe Linepipe and Fitting Tests and Applicable Standards ....................................... 14
Table 6: Allowable Aromatic and Cycloalkane Hydrocarbon Content for FPLP ........................... 17
Table 7: Maximum Allowable Operating Pressure for FPLP ......................................................... 19
Table 8: Flow Coefficients for FPLP ............................................................................................... 25
Table 9: K Factor for Flexpipe Coupling Fittings ........................................................................... 25
Table 10: Minimum Bend Radius for Operation, Transport and Handling of FPLP ...................... 26
Table 11: Permeability Coefficients for HDPE............................................................................... 27
Table 12: Representative Permeation Rates for FPLP .................................................................. 28
Table 13: FlexPipe Linepipe Thermal Conductivity and Resistivity............................................... 29
Table 14: Conduit Compatibility for FPLP Insertion ...................................................................... 32
Table 15: Maximum Allowable Pull Forces for FPLP ..................................................................... 32
Table 16: Recommended Pipe Support Spacing for FPLP ............................................................. 34
Table 17: Recommended Sand Bag Weight for Weighting FPLP .................................................. 36
Table 18: Custom Urethane Disk Pigs for FPLP ............................................................................. 42
Table 19: Flexpipe Pig Dimensions for FPLP ................................................................................. 43
List of Figures
Figure 1: FlexPipe Linepipe Three-layer Design .............................................................................. 2
Figure 2: Cutaway View of Flexpipe Fitting..................................................................................... 7
Figure 3: Procedure for Determining MPR and MAOP ................................................................. 20
Figure 4: Representative Pressure Drop Comparison: Water at Various Flow Rates .................. 24
Figure 5: Representative Pressure Drop Comparison: Methane at Various Flow Rates .............. 24
Figure 6: Sandwich Type Insulated Barrier Configuration ............................................................ 38
Figure 7: Cut-out Burst Test Results ............................................................................................. 46
ShawCor Ltd., 2010
iv
In an effort to provide useful product information, Flexpipe Systems makes

available a two part document:
Part 1 Technical Information Manual
This part is mainly addressed to engineers, supervisors and procurement
personnel. It is intended to present a general description of FlexPipe Linepipe
materials, construction, qualification, performance, installation, operation and
reliability.
Part 2 Installation Guide
This part is mainly addressed to field personnel and is intended to provide
general guidance on FlexPipe Linepipe handling, jointing, installing and testing.
Each of the two parts emphasizes particular aspects of the Flexpipe product
application. Familiarity with both parts is recommended for a broader
perspective.
This document is intended solely as a reference for use by persons of technical
competence. It is the responsibility of the pipeline operator to ensure the
suitability of Flexpipe products for any specific pipeline application. While the
information contained in this document is believed to be correct as of the date
of issue, under no circumstances will Flexpipe Systems Inc, or any of its
subsidiaries, be liable in any way for any loss, damage or injury of any kind
(whether direct, consequential, punitive or otherwise) incurred as a result of
any omissions in this document or as a result of reliance on any information
contained in this document. This document does not contain any warranty,
express or implied.
All rights reserved. Any reproduction of this document in part or as a whole
without the written permission of Flexpipe Systems Inc is prohibited.
ShawCor Ltd., 2010
1 Introduction
Flexpipe Systems Inc (Flexpipe) has designed, tested, and manufactured a high pressure,
corrosion-resistant, coiled, continuous pipeline system utilizing new and exciting engineering
technologies for the Oil and Gas and Utility industries. Applications include oil and gas
gathering, water disposal and injection pipelines for the Oil and Gas industry and transmission
and distribution pipelines for the Gas Utility industry.
Flexpipe has also developed original crimp fittings that allow efficient joining directly to steel
lines, standard flanged connections, or other FlexPipe lines. Flexpipe holds patents for its
unique pipe and fitting designs1.
2 Pipe
2.1
Product Lines
Flexpipe Systems currently offers three product lines of FlexPipe Linepipe (referred to as
FlexPipe or FPLP), identified by the color of the pipe jacket. Black jacket pipe is the standard line
pipe intended for buried or slips lining applications; white jacket pipe is supplied for surface
applications and yellow jacket pipe is used for buried gas distribution service. All product lines
provide a minimum of 20 years protection against exposure to ultraviolet (UV) light. All product
lines are available in 2, 3 and 4 sizes, and classes FP150, FP301 and FP601 with pressure
ratings of 2,068 kPa (300 psi), 5,171 kPa (750 psi), and 10,342 kPa (1500 psi) respectively.
Flexpipe makes use of ANSI 150, 300 and 600 flanges for FP150, 301 and 601 products
respectively. FP301 has superseded the FP300 and RS155-H products.
The product data sheets in the appendix list the FPLP dimensions and parameters.
2.2
Design
FPLP is manufactured at the state-of-the-art Flexpipe facility in Calgary, Alberta, Canada. FPLP is
a fully patented three-layer design constructed from a thermoplastic liner (liner), helically
wrapped continuous high-strength fiber reinforcement (fiber) and an external thermoplastic
jacket (jacket).
Fiber reinforced pipe: US patent number 6,889,716 (May 10, 2005); Canadian patent number 2,513,506 (August
3, 2010); European patent number 1592908 (April 7, 2010).
Compression-style fitting: US patent number 6,902,205 (June 7, 2005); Canadian patent pending
Crimp-style fitting: Canadian patent pending; US patents pending.
2010 Flexpipe Systems Inc
The liner acts as a bladder, the fibers provide strength, and the jacket protects the load-bearing
fibers. This construction is unique and has the following advantages:
The fiber reinforcement is not encased in a thermosetting matrix and is therefore flexible,
avoiding potential micro-cracking or over-straining of the matrix material.
FPLP is very rugged, durable and easy to handle.
The simplicity of construction reduces the manufacturing costs.
The fiber reinforcement enables design for high-pressure applications.
The liner ensures that the FPLP is immune to corrosion and eliminates the need for
inspections.
The continuous, long-length FPLP spools facilitate fast and easy installation with fewer
connections and less disturbance to impacted parties.
Environmental impact and soil disturbance can be reduced since FPLP can be trenched with
a narrower trench and right of way than steel line pipe, or plowed in without trenching.
The low weight minimizes handling equipment requirements leading to lower installation
costs when compared to stick and other spoolable products.
Figure 1: FlexPipe Linepipe Three-layer Design
The pipe has been designed using a sophisticated mathematical model that was developed
specifically for the unique construction of this product. The mathematical model was used to
design the fiber-reinforcement configuration and optimize pressure capacity and strain. The
strength of FPLP depends on the thickness and configuration of the fiber reinforcement layer,
so traditional pipe design models based on wall thickness are not applicable. The validity of the
mathematical model and the material properties used by this model has been verified through
extensive physical testing.
The design and manufacturing of FPLP is in accordance with standards and guidelines regarding
qualification, quality control and testing of composite pipe and accessories. Please refer to
Section 4 in this document for additional information on these standards, and Section 5.2 for a
summary of the design methods and calculations.
2.3
Materials
The materials used in FPLP have been widely used in the oil and gas industry for many years.
FPLP liner and jacket are manufactured using bimodal pressure-pipe-grade high density
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 low-friction internal surface for decreased pressure losses. Colorant
and an ultra-violet (UV) stabilizer are blended with the thermoplastic pellets during the
extrusion process, providing resistance to weathering.
The fiber reinforcement is constructed from a series of continuous glass fiber rovings which
have been manufactured in accordance with ASTM D5784. The fiber chemistry and coatings are
specifically selected to optimize long-term performance.
Flexpipe Systems is committed to maintaining high standards of quality and reliability. Each
individual supplier is qualified by Flexpipe, in accordance with API RP 15S5, to ensure that
quality inspections, physical testing, and material traceability meet Flexpipes quality standards.
Each specific material is qualified by Flexpipe through rigorous physical testing, prior to
manufacturing and in finished Flexpipe products.
2.4
Manufacturing
Flexpipe is equipped to manufacture all components of FPLP in-house. Each step of the
manufacturing process is closely monitored, resulting in direct control over the quality of all
FPLP.
2
PPI TR-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
4
ASTM D578 Standard Specification for Glass Fiber Strands
5
API RP 15S Recommended Practice for the Qualification of Spoolable Reinforced Plastic Line Pipe
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 D25136. Each
liner is 100% inspected for diameter, wall thickness, and
concentricity by online ultrasonic measurement.
2.4.2 Fiber Reinforcement

The fiber reinforcements for each product are constructed from a
single type of input strand, purchased from qualified suppliers.
Flexpipes roving construction process combines these strands into
custom packages for use in the construction of FPLP. Each package
is specially configured for the individual finished product in which it
will be used.
Flexpipe has developed extensive expertise in this area through critical evaluation and physical
testing of various materials, coatings, and processing methods. State-of-the-art roving
machines are used with tensioning systems designed in-house specifically for this process.
2.4.3 Pipe
Each reel of FPLP is manufactured in a single continuous production run that combines liner,
fiber reinforcement, and jacket into the finished product. The liner length is sufficient to
complete an entire pipe production run without fusions.
The first step in the process is cleaning and drying the incoming liner. A laser measurement
system inspects the diameter and roundness of the liner. If needed, multi-directional rounding
rollers are applied to correct the roundness.
The fiber reinforcement is applied by sequential custom-designed
winding machines, which wrap fiber reinforcement rovings from
multiple bobbins around the liner in a tightly controlled process. An
automated control system directly measures the line speed, and
maintains the correct wrap angle by controlling the speed of each
individual winding machine. Each bobbin of fiber is individually
braked to maintain the correct fiber tension.
ASTM D2513 Standard Specification for Thermoplastic Gas Pressure Pipe, Tubing, and Fittings
The jacket is applied over the fiber reinforcement with a customized cross-head extrusion die,
and immediately cooled. Computerized laser and ultrasonic measurement systems are used to
ensure that strict quality standards are maintained as the protective jacket is applied. The
jacket is marked with identifying information by an inline printer. Finally, the finished product
is coiled directly onto a transportation reel.
2.4.4 Quality Control

Quality control (QC) is critical to the FPLP manufacturing process. Flexpipe Systems is an ISO
9001:2008 certified manufacturing facility. From supplier evaluation and approval to the
qualification of every reel of finished FPLP, quality control data is diligently reviewed and
evaluated. Flexpipe is committed to using suppliers that provide material-composition data
and maintain certification and QC test results for all raw products. Material certification and
traceability is critical to the Flexpipe quality assurance program that cohesively links raw
materials with production records and serial markings on pipe and fittings. Flexpipe routinely
verifies and audits the QC programs of its suppliers.
The manufacturing process is designed with many levels of quality monitoring. Sophisticated
instrumentation systems, lasers, ultra-sonics and production operators continually monitor the
production line at specific intervals. Corrective action is implemented according to the
established non-conformance reporting (NCR) system if design parameters are not within the
specified tolerance limits.
Every finished reel of FPLP is tested in accordance with the Flexpipe Production Qualification
Testing (PQT) Standards, and in accordance with API RP 15S. Samples are taken from the
beginning and the end of every pipe production run. The samples are subjected to destructive
burst testing. The results from these tests must meet or exceed stringent QC requirements.
In addition, Flexpipe tests raw materials to ensure compliance with material specifications.
Flexpipes testing equipment includes burst chambers, ovens, a cold chamber, an Instron tensile
testing machine, stress-rupture testing machines, density test equipment and numerous
custom jigs and fixtures.
3 Fittings
The Flexpipe fitting is a metallic device that mechanically fastens to the pipe. The fitting can
terminate the pipe with a standard ASME B16.57 lap-joint flange or a weld neck transition. The
weld neck fitting allows direct connection to steel. The end of the FPLP from one reel can be
ASME B16.5 Pipe Flanges and Flanged Fittings
attached to the beginning of the FPLP from a second reel with a pipe-to-pipe coupling, thus
eliminating an underground flanged connection.
3.1
Product Lines
The three types of fittings that are used with FPLP are shown in
Table 1. Each of these fittings is available for each pipe size and grade. Flexpipe also offers preassembled flow joints in the configurations shown in
Table 2.
Table 1: Flexpipe Fittings
Flanged End Fitting
Compatible with standard raised face
flanges. Flange is free to spin until bolts
are tightened, allowing easy connection
without stressing existing flanges.
Coupling Fitting
Used to connect two pieces of FPLP
together.
Dimensional
drawings
available upon
request.
Weld Neck Fitting

Used to connect FPLP to steel pipe, using
standard field welding procedures.
Table 2: Flexpipe Flow Joints
90 Degree Elbow Flow Joint

Dimensional
drawings
available upon
request.
T Flow Joint
True Y Flow Joint

Dimensional
drawings
available upon
request.
Y-Lateral Flow Joint
3.2
Design
The fitting consists of a mandrel that is inserted into the pipe, and a sleeve that is crimped
around the pipe. The mandrel and sleeve are both equipped with uni-directional teeth that
securely grip the liner and jacket of the pipe. Crimping the sleeve creates very high permanent
clamping pressure, which holds the fiber reinforcement securely in place. The fitting system
does not require the application of heat or adhesives in order to bond components together.
Figure 2: Cutaway View of Flexpipe Fitting
The mandrel is sealed to the liner by the clamping pressure. For additional security, the
mandrel is equipped with two o-rings that provide an additional seal.
The vent hole in the sleeve allows the annulus of the pipe (the space between the liner and
jacket which contains the fiber reinforcement layer) to vent freely at each fitting. This allows
any gases that may have permeated through the liner to escape, and prevents any pressure
buildup in the annulus.
Flexpipe fittings are installed in a two-step process, using portable installation equipment. In
the first step, the mandrel is inserted into the liner. In the second step, the sleeve is crimped to
the pipe. The fitting is supplied with the sleeve already welded to the mandrel to hold it in the
correct position. Flexpipe fittings can be installed in the field in about 20 to 30 minutes. To
view a simulation of the fitting installation process, visit the Flexpipe website at
www.flexpipesystems.com. For more information on fitting installation, see Section 6.14.
Flexpipe fittings have been tested together with FPLP as a complete system in long-term, high
pressure tests, and have undergone rigorous testing to verify their performance in field
conditions. More information on qualification testing is presented in Section 4.4.
The inside diameter of the mandrel in the fitting is smaller than the inner diameter of the
pipeline. However, the restriction is minimal, and results in negligible pressure loss (see Section
5.4 for further information). Fittings are compatible with pigging programs as detailed in
Section 8.2.
3.3
Materials
Standard Flexpipe fittings are manufactured from seamless steel that meets the requirements
of NACE MR01758 for sour service. See Table 3 for a full list of materials used in Flexpipe
fittings. Material certificates are reviewed by Flexpipe prior to manufacture of the fittings, and
are retained as part of Flexpipes 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.
NACE MR0175 Petroleum and Natural Gas IndustriesMaterials for Use in H2S-Containing Environments in Oil
and Gas Production
The steel used in 4 Flexpipe fitting mandrels and flanges meet the low-temperature notchtoughness requirements of Category II of CSA Z245.119. Whenever required, custom made
mandrels and flanges in 2 and 3 sizes meeting the low-temperature notch-toughness
requirements can also be supplied.
Table 3: Flexpipe Fitting Material List
Part
Material type
Material grade(s)
a
Mandrel
Alloy steel
AISI 4130 or 4140
a
Sleeve
Carbon steel
ASTM A106, A333, A513, or A519
Flange (flanged fittings only) Carbon steel
ASTM A105 or ASTM A350 LF2
a
Weld neck fitting welding Carbon steel
ASTM A106 or A333
end
Flow joints
Carbon steela
ASTM A234 WPB or ASTM A420 WPL6
O-rings
Vitonb
75 Durometer
c
Coatings
Electroless Nickel or uncoated
a
Meets requirements of NACE MR0175 for sour service
b
Special o-rings are available for high-pressure CO2 service
c
Weld neck fittings are not coated
3.4
Manufacturing
Flexpipe fittings are manufactured, coated, assembled, and labeled according to Flexpipe
specifications by suppliers whose processes have been qualified by Flexpipe. Flexpipe routinely
verifies and audits the QC programs of these suppliers.
All welding required for the manufacture of Flexpipe fittings is performed in shop conditions, by
suppliers qualified to Flexpipes weld procedures in accordance with CSA Z662. These
procedures are specific to the materials used, and include appropriate heat treatments and
inspections.
3.5
Corrosion Protection
Standard fittings are supplied with high-phosphorus electroless nickel plating with a
fluoropolymer sealer on all wetted surfaces of the fitting. This plating protects the fitting from
corrosion and erosion for many applications. Additional information on electroless nickel
plating is available upon request.
CSA Z245.11 Steel Fittings
Weld neck fittings are not coated or plated, since the coating or plating would be destroyed by
the heat input during welding. Prefabricated flow joints can be coated, since no welding is
required at installation. All fittings are also available with no coating.
External corrosion control of Flexpipe fittings is achieved by the application of the Denso
Petrolatum Tape Anti-Corrosion System. Denso paste is applied to the exposed reinforcement
fibers at the end of the pipe prior to installing the fitting, to protect the fibers from moisture.
The fitting is wrapped in Denso tape after installation. When applied according to the product
data sheet supplied with the tape, the system meets AWWA C21710.
Polyken tape is used to protect the Denso tape on each fitting from being damaged or
removed. White Polyken tape is also required to be applied over couplings in surface lines to
prevent excessive heating due to solar radiation and to prevent external moisture from
entering the fitting.
Additional corrosion control via cathodic protection is available. Cathodic protection
requirements for buried steel fittings are covered in Clause 13.1.5 of CSA Z662-07. Flexpipe has
developed a ribbon anode kit for buried steel fittings that provides external corrosion
protection for a 50 year life in soil resistivities ranging between 1500 to 3000 ohm/cm. This is
based on a fitting external coating efficiency of 95%. Anode test posts and monitoring for
buried steel couplings in composite pipelines are not required.
The anode kit consists of a zinc ribbon anode connected to a copper lead wire, along with a roll
of cloth tape to fix the anode to the Flexpipe and a stainless steel hose clamp to secure the lead
wire to the fitting. Flexpipes anode kit can be readily installed in the field by attaching a clamp
around the fitting and taping the ribbon along the pipe. Fittings with anodes attached are
compatible with installation by trenching or plowing. Please refer to the Flexpipe Systems
Installation Guide for more information.
4 Qualification
4.1
Introduction to Standards and Regulations
According to industry terminology, Flexpipe Systems line pipe is classified as a reinforced

thermoplastic pipe (RTP). Various standards deal with this type of product, and cover topics
such as materials, testing, manufacture, and installation. Standards are guidelines that are
generally accepted throughout an industry as appropriate, usually on the basis of industry-wide
experience. They are often referenced by regulations, which may adopt some or all of the
10
AWWA C217 Cold-Applied Tape Coatings for the Exterior of Special Sections, Connections, and Fittings for
Buried/Submerged Steel Water Pipelines
10
guidelines, or even introduce more stringent requirements. Regulations are requirements that
must be followed by law.
Standards that apply to Flexpipe products are primarily performance-based. This means that
they emphasize the demonstration of a products capabilities through repeated testing, rather
than relying only on theoretical design calculations. A detailed theoretical design model serves
as a starting point for Flexpipe product designs. The designs are validated through extensive
long term testing in accordance with accepted test standards.
4.2
Standards
4.2.1 American Petroleum Institute (API)

The American Petroleum Institute (API) was the first North American standards body to develop
a recommended practice specific to the spoolable composite pipe industry. API RP 15S,
Recommended Practice for the Qualification of Spoolable Reinforced Plastic Line Pipe, includes
guidelines for determining material properties, pressure ratings, safety factors and service
factors, and minimum performance requirements.
It also includes guidelines for
manufacturing, quality control tests, and typical installation methods. This recommended
practice applies to RTP and spoolable thermosetting composite pipe.
API 15S is based on expert knowledge of the materials involved, extensive experience with
related applications and related products used in other applications, and detailed research on
related knowledge used in other countries. It uses proven ASTM testing methods, such as
ASTM D299211, for establishing long-term performance.
This recommended practice is the basis for the Flexpipe pipe qualification program. All Flexpipe
products meet or exceed the stringent qualification requirements established by API 15S.
4.2.2 Canadian Standards Association (CSA)

CSA provides standards to which manufacturers should comply. CSA does not certify or
approve pipeline products.
CSA Z662-07, Oil and Gas Pipeline Systems, covers the design, construction, operation, and
maintenance of oil and gas industry pipeline systems. FPLP falls under Clause 13.1 of this
standard, which specifically addresses design, manufacturing and installation requirements for
fiber-reinforced composite pipelines.
11
ASTM D2992 Standard Practice For Obtaining Hydrostatic or Pressure Design Basis For Fiberglass (GlassFiber-Reinforced Thermosetting Resin) Pipe And Fittings
11
FPLP is fully compliant with CSA Z662-07 Clause 13. Some of the specific requirements are
discussed below. Other requirements are discussed in more detail elsewhere in this document,
as referenced in Table 4.
According to Clause 13.1.1.3, FPLP and all other reinforced composite pipelines may be used in
low vapor pressure (LVP)12, gas gathering, and oilfield water pipelines. High vapor pressure
(HVP)13 pipelines are excluded by this clause. FPLP also meets the requirements of Clause
12.5.4 for gas distribution systems.
Design pressure calculations for RTP are outlined in Clause 13.1.2.8. This clause refers to API
15S as the industry standard according to which FPLP must be qualified. It uses the
qualification methods given in API 15S, and specifies the values to be used for derating factors
used in these methods. These factors are a minimum requirement; in some cases, Flexpipe has
chosen service fluid factors (Ffluid) which are more conservative than required by CSA. These
factors are already included in the Maximum Allowable Operating Pressures (MAOP) published
for FPLP, as shown in the design pressure calculations in Section 5.2.3.
Clause 5.2.3 of CSA Z662 requires that steel fittings 4 and larger meet the notch toughness
requirements of CSA Z245.1114 and Z245.1215. Flexpipe 4 fitting mandrels and flanges meet
these requirements.
Table 4: Links for Specific CSA Z662 Requirements
Requirement
Gas service design pressure limit
Sour gas limits
Cyclic service
Tracer wire
Cathodic protection
Crossings and casing
Freestanding liner insertion
Pressure testing new installations
CSA Z662 clause

13.1.1.4
13.1.1.4
13.1.2.10
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
Discussed in
Section 5.1.2
Section 5.1.5
Section 5.3
Section 6.11
Section 6.15
Section 6.9
Section 6.5
Section 6.18
12
Includes oilfield water, multiphase fluids, or liquid hydrocarbon mixtures with vapour pressure of 110 kPa
(absolute) or less at 38C.
13
Hydrocarbons or hydrocarbon mixtures in the liquid or quasi-liquid state with a vapour pressure greater than 110
kPa (absolute) at 38 C.
14
15
CSA Z245.11 Steel Fittings

CSA Z245.12 Steel Flanges
12
Pressure testing repairs/replacements

Static electricity
Maximum external pressure
4.3
13.1.8.2
13.1.8.3
13.1.2.11
Section 8.6
Section 8.4
Section 5.12
Regulations
4.3.1 Canadian Provincial Regulatory Bodies

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

The United States Department of Transportation (DOT) considers the use of FPLP in regulated
areas through special permit applications submitted to the Office of Pipeline Safety. Currently,
Flexpipe Systems is working with the Department of Transportation to include Reinforced
Thermoplastic Pipes as an approved material in 49 CFR Part 192 Transportation of Natural and
Other Gas by Pipeline.
4.4
Testing
Flexpipe Systems is committed to ensuring that its products are rugged, reliable, and safe. FPLP
is tested together with fittings as a complete system. This system has undergone extensive
testing to demonstrate that it meets and exceeds the strict requirements of API 15S. Flexpipes
13
test procedures have been audited by an independent laboratory16 to validate compliance with
API RP 15S.
Flexpipe strongly believes that its products should perform as well under field conditions as in
the laboratory. Therefore, Flexpipe has gone beyond the strict requirements of the applicable
standards, and has developed its own procedures to test field handling of FPLP and related
equipment.
Some of the specific tests in Flexpipe Systems testing program are listed in Table 5. These tests
have resulted in a comprehensive base of knowledge about product performance under a wide
variety of service conditions.
Table 5: FlexPipe Linepipe and Fitting Tests and Applicable Standards
Test description
Applicable standard(s)
ASTM D2992 Procedure B
Regression pressure testing
API RP 15S Section 5.1.2.3
Elevated temperature pressure testing
API RP 15S Section 5.2.1
Low temperature pressure testing
ASTM D159917 Procedure A
Minimum bend radius pressure testing
Installation pressure testing samples retrieved after
liner insertion
Installation pressure testing samples retrieved after ASTM D1599 Procedure A
plowing
Flexpipe 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
Thermal cycle testing
External load testing
ASTM D241218
16
Jana Laboratories Inc. (Aurora, Ontario)

ASTM D1599 Standard Test Method for Resistance to Short-Time Hydraulic Pressure of Plastic Pipe, Tubing,
and Fittings
17
14
5 Performance
5.1
Applications & Chemical Compatibility
It is the responsibility of the pipeline operator to understand the suitability of Flexpipe products
for specific pipeline applications. The information in this section is intended to provide an
understanding of the suitability of Flexpipe products for a wide range of common applications.
For these or other applications, Flexpipes engineering team will be pleased to evaluate the
application and advise regarding compatibility of Flexpipe products.
5.1.1 Application Evaluations

Flexpipe has established a process to evaluate any proposed applications that exceed the
normal operational limits given in the following sections. These limits are intended to provide a
consistent and conservative approach to potential applications. While FPLP performs well in
many applications that exceed these limits, it may not be appropriate for certain combinations
of factors when one or more of the limits are exceeded.
Application evaluations are intended as a service to clients, provided by the Flexpipe
Engineering team. Each evaluation assesses the details of a proposed application to identify
potential risks and determine specific measures that can be taken to eliminate or minimize
them. Recommendations resulting from these evaluations have allowed many projects to
successfully take advantage of the full capabilities of FPLP. Flexpipe believes that this approach
reflects its commitment to public safety and has contributed to its outstanding service record,
while allowing it to meet the unique needs of its clients.
5.1.2 Gas
FPLP has a strong historical record in gas gathering applications, which account for the majority
of FPLP currently in operation. There is no requirement to further de-rate the FPLP MAOP in
gas applications (see Section 5.2 for determination of pressure ratings). Suitable environments
include natural gas, solution gas, exhaust gas, and fuel gas. See Section 5.1.6 for information on
CO2 applications.
For gas applications in which condensates can form, a suitable pigging program should be
implemented to prevent condensate buildup at low points along the pipeline.
Clause 13.1.1.4 of CSA Z662 limits the allowable design pressure for FPLP gas pipelines to a
maximum of 9930 kPa (1440 psi).
18
ASTM D2412 Standard Test Method for Determination of External Loading Characteristics of Plastic Pipe by
Parallel-Plate Loading
15
FPLP 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
FPLP is suitable for oil effluent or oil emulsion (two- or three-phase) applications. FPLP is
entirely corrosion resistant, fully piggable, and is an excellent option for production with high
water-cut. For applications with high wax content, suitable pigging programs should be in
place. Please refer to Section 5.3 for more information on cyclic pressure applications. Please
refer to Section 8.2 for more information on pigging.
5.1.4 Water
FPLP is a corrosion resistant product that is an excellent option for oilfield water applications
such as water transfer and disposal lines. FPLP may also be used for water injection and similar
systems. However, these applications often involve cyclic pressure variations, and should be
evaluated for compatibility. Please refer to Section 5.3 for more information on cyclic pressure
applications.
5.1.5 H2S
H2S (hydrogen sulphide, also known as sour gas) is a toxic and potentially lethal substance
commonly found in oilfield media. Accordingly, a greater risk exists in routine pipeline
inspection or maintenance, or in the event of fluid release due to pipeline damage.
Non-metallic pipelines such as FPLP may allow small amounts of the transported fluids to
permeate through the pipeline materials (see Section 5.10), accumulate within the materials or
fitting system, and/or be released through the outer surface of the pipeline (please refer to the
Flexpipe Systems Sour Service Pipeline Bulletin, available from the Flexpipe Systems website, for
more information). These risks should be controlled by consistent and conservative limits on
sour content.
Sour applications must comply with the regulatory requirements of specific regional authorities.
FPLP is compatible with an H2S content of 5% by volume in liquids (oil and/or water), gas or
multiphase19.
19
CSA Z 662-07 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
16
5.1.6 CO2
FPLP can be used for gases or liquids containing up to 100% CO2 by volume. FPLP suitability for
CO2 service has been confirmed by a rapid decompression testing. Flexpipe standard 75
Durometer Vition o-rings are suited for a wide range of CO2 applications. For applications
having higher than 10% CO2 and operating at pressures above 750 psig, Flexpipe recommends
the use of special o-rings that provide superior performance for these conditions. Refer to
Section 3.5 for further information on the fittings corrosion resistance and coating.
5.1.7 Aromatic and Cycloalkane Hydrocarbons

FPLP is compatible with aromatic and cycloalkane hydrocarbons (e.g. benzene, toluene, ethyl
benzene, xylene, naphthalene and cyclohexane) in gas or liquids. Table 6 lists the allowable
aromatic and cycloalkane concentrations for FPLP at normal operating pressures, based on
Flexpipe test data. Interpolation between temperatures is acceptable.
Table 6: Allowable Aromatic and Cycloalkane Hydrocarbon Content for FPLP
Operating temperature
20C (68F) or below
40C (104F)
60C (140F)
Maximum allowable aromatic

cycloalkane content (by volume)
25%
5%
1%
and
For gas applications in which condensates can form, a suitable pigging program should be
implemented to prevent aromatic and cycloalkane hydrocarbon buildup at low points along the
pipeline.
See also: Section 5.1.8 Chemical Injection.
5.1.8 Chemical Injection

Common injection chemicals used in the oil gathering industry, such as corrosion inhibitors,
biocides, paraffin dispersants, surfactants, scale inhibitors, defoamers, and demulsifiers, are not
considered problematic to the HDPE liner in FPLP. Flexpipe recommends that chemical
injection programs use dilute concentrations or batch treatments, as per the standard practice
for HDPE applications as set out by the chemical manufacturing company.
Injection chemicals which are made up from aromatic and cycloalkane hydrocarbons are
acceptable for use with the HDPE liner in FPLP provided the concentration of the injection
chemicals is controlled such that the aromatic and cycloalkane concentration stays within the
limits listed in Table 6 as applicable for the pipe service temperature. Any higher concentration
17
batch treatment process should be of limited duration as recommended by the injection

chemical manufacturer for use in HDPE pipe.
This section addresses only the more common injection chemicals used in the oil gathering
industry. Due to the variety of injection chemicals available, however, Flexpipe recommends
that the oil field operating company develop an injection program in conjunction with the
chemical manufacturing company to ensure there are no chemical compatibility concerns with
HDPE.
5.1.9 Methanol and Ethanol

HDPE has good resistance to concentrated methanol and ethanol at temperatures up to 60C
(140F). Alcohols are routinely used in FPLP in continuous and batch programs, and are also
commonly used during hydrotests to prevent freezing.
5.2
Pressure and Temperature Ratings
5.2.1 Minimum Allowable Operating Temperature

The Minimum Allowable Operating Temperature for all FPLP is -460C (-50F). This has been
proven by the successful completion of the qualification testing required by a major oil and gas
producer. The testing indicated that FPLP has excellent impact resistance properties and does
not become brittle at temperatures of -460C (-50F). In addition, the product performance at
low temperatures is further ascertained by the positive track record of field applications in the
northern United States and Canada, where low ambient temperatures are common during
winter. Please refer to Section 3.3 for fittings material selection, Section 6.12 for minimum
installation temperatures, and Section 8.1 for starting up pipelines at low temperatures.
5.2.2 Maximum Allowable Operating Temperatures and Pressures

The Maximum Allowable Operating Pressure (MAOP) ratings for FPLP at temperatures up to
60C (140F) are shown in Table 7. Flexpipe supplies tags for installation on risers to notify
operators of the temperature limitations of the pipe.
18
Table 7: Maximum Allowable Operating Pressure for FPLP
Maximum
Maximum Allowable Operating Pressure*
Allowable
Operating
FP150
FP301
FP601
Temperature
(C)
(F)
(kPa)
(psi)
(kPa)
(psi)
(kPa)
(psi)
60
140
2068
300
5171
750
10,342
1500
*Check your local regulations to verify the maximum allowable operating
pressure does not exceed the maximum allowable design pressure.
Insulation or white Polyken tape is required for protecting aboveground portions of black or
yellow FPLP (for example at risers) from exceeding the maximum allowable operating
temperature as a result of heating due to solar radiation.
5.2.3 Calculations for Determining Maximum Allowable Operating Pressure

The MAOPs listed in Table 7 have been determined by the following calculation:
MAOP
MPR F fluid
The Maximum Pressure Ratings (MPR) has been determined at the maximum design
temperatures and design life of the pipeline in accordance with API RP 15S20 and CSA Z662-07.
The procedure is illustrated in Figure 3, 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.
The Pressure Service Factor (PSF) is a derating factor that is intended to account for small
variations in materials, installation, or operating parameters, to ensure that these variations do
not cause the pipes actual capabilities to be exceeded. The PSF is applied to the Lower
Confidence Limit at the Design Life to determine the MPR at the qualification temperature.
Flexpipe uses PSF=0.67, as recommended by API 15S.
20
API RP 15S Recommended Practice for the Qualification of Spoolable Reinforced Plastic Line Pipe
19
Figure 3: Procedure for Determining MPR and MAOP
21
The Service Fluid Factor (Ffluid) is an additional derating factor that is intended to account for the
effects of the transported fluid on the pipe materials, to ensure that the fluid does not reduce
the pipelines capability of maintaining the MAOP over the design life. This factor is applied to
the MPR to determine the MAOP at the qualification temperature.
Flexpipe has chosen to use Ffluid=0.67 for all types of fluid. This value allows a consistent MAOP
for all types of fluids. It meets the CSA Z662 requirements for gas, and is more conservative
than its requirements for other services. Flexpipe believes that this conservative approach, has
contributed to FPLPs outstanding track record. Other spoolable product suppliers may be using
a less conservative fluid service factor.
Because FPLPs MAOP already includes derating factors for pressure and fluid, no additional
deratings are required. FPLPs MAOP is based on a 50-year design life.
5.3
Cyclic Pressure
Water transfer, disposal or injection applications and oil gathering applications are typically
quite corrosive and are a natural fit for FPLPs corrosion resistance properties. However, to
ensure the optimal performance and reliability of FPLP in these applications, consideration
must be given to the cyclic pressure characteristics of the system design and the operating
regime.
As part of Flexpipes commitment to quality and customer satisfaction, Flexpipe offers an
application evaluation process. The pipeline end user provides the operation parameters as per
21
Based on Figure 1 of API RP 15S (2006).
20
the Application Review Form for Flexpipe to assess. Flexpipe Systems application engineering
specialists can provide project specific recommendations regarding selection of the best
product, optimal system design, and operational considerations for the intended application.
Flexpipe recommends that an application review be completed for all cyclic service applications
to ensure optimal performance of the FPLP and the overall system. Flexpipe cyclic service
application review recommendations are based on a minimum 20 years service life.
The key parameters that must be considered when evaluating the suitability of FPLP for a cyclic
service application include:
Type of pump: The pump type plays a major role in determining the cyclic
characteristics of a pipeline system. Typical pumps used in the oil and gas industry are
centrifugal pumps and piston pumps.
Flexpipe recommends using single stage or multistage centrifugal pumps (e.g. REDA
pumps). This type of pump provides a steady pressure free of high frequency pressure
pulsations or excessive vibration; therefore, no cyclic service factor derating is required.
Accordingly, pipes used with centrifugal pumps can take advantage of the full FPLP
pressure rating.
Applications with piston pumps (e.g. Triplex, Quintuplex) generate substantial highfrequency pressure pulsations and vibration in the pipeline. These operational
characteristics can be detrimental to many pipeline materials, including FPLP. To protect
this type of pipeline system from progressive damage, a cyclic service derating factor of
0.5 is required. This mirrors the requirements of CSA Z662 Oil and Gas Pipeline
Systems clause 13.1.2.10. Accordingly, pipes used with piston pumps are limited to half
the maximum allowable pressure values published in Flexpipe data sheets.
For applications where piston pumps are used, Flexpipe recommends the following
precautions in addition to the 0.5 cyclic service factor:
o Effective pulsation dampeners at the pump inlet and outlet which are selected,
installed, operated and maintained as per the pump and pulsation dampener
manufacturers recommendations.
o A minimum of 100 feet of steel pipe between the pump and the FPLP to assist
with vibration dissipation.
For pumps such as screw pumps, progressive cavity pumps and diaphragm pumps,
please contact a Flexpipe representative for project specific recommendations. Duplex
pumps operating at reduced pressures may also be a suitable alternative. Please
21
contact your Flexpipe representative to discuss having an application review for your
specific scenario. This review may be required to evaluate the feasibility of using
Flexpipe products on your project and provide guidance on how to safely operate your
pipeline in severe cyclic pressure conditions.
Pressure fluctuations: Pressure fluctuations may either be the result of:
o 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.
FPLP is not intended for severe cyclic applications, with pressure cycling in excess of +/20% of the normal operating pressure, with an average frequency of once per day over
a 20 year period. In order to eliminate the pressure fluctuations resulting from pump
on/off cycles, Flexpipe recommends using a variable frequency drive (VFD) to regulate
the flow rate while maintaining a continuous operation of the pump.
Depending on their magnitude and frequency, pressure pulsations and fluctuations could be
detrimental to the pipe performance. Contact your Flexpipe representative for a project specific
application evaluation.
5.3.1 Pump Jacks

FPLPs corrosion resistance properties are a natural fit for corrosive oil emulsion production.
However, to ensure the optimal performance and reliability of FPLP in pump jack applications,
consideration must be given to the cyclic pressure characteristics of the system design and the
operating regime.
In general, using sound system design and good industry operating practices will optimize the
integrity and life of all production equipment. The pressure differential between the upstroke
and down stroke pressures generated by the operation of the pump jack is of critical
importance to the long term integrity of the FPLP.
Some of the design and operational factors that can affect the magnitude of the pressure
differential in the flow line include:
Length and diameter of the flow line
Production volumes
Production fluid properties
22
Down hole pump integrity

Wax build-up
Flow line check valve integrity
Hot oiling and pigging practices
For applications with an upstroke pressure above 150 psi, Flexpipe Systems recommends
limiting the amplitude of the pressure differential between the routine upstroke and down
stroke pressures to 50 psi for FP301 and 75 psi for FP601. For example, if the normal upstroke
pressure in a FP301 flow line is 175 psig, the minimum pressure during the down stroke should
be no less than 125 psig. Infrequent pressure excursions beyond these limits are generally
acceptable.
These recommendations are based on both qualification test results and field experience. They
provide safe operating limits using a design life of 20 years. In order to ensure the long term
integrity of the piping system, Flexpipe Systems recommends:
Installing and maintaining a pressure switch (such as a Presco switch) set at a maximum
of 100 psi above the upstroke pressure to limit the possibility of subjecting the pipeline
to excessive pressure swings for extended time durations.
Routinely monitoring the upstroke and down stroke pressure values using a calibrated
pressure gauge mounted between the well head and the flow line.
Implementing a suitable pigging program to ensure the upstroke pressure does not
increase as a result of wax build up.
5.4
Flow Characteristics
5.4.1 Pipe Flow

Relative to steel pipe, the smooth internal surface of FPLPs polyethylene liner provides
favorable flow rates and reduced pressure losses as a result of reduced friction. Figure 4 and
Figure 5 show representative pressure drops at various flow rates for fresh water and methane,
respectively. The results shown are based on calculation of the pressure drop for the given
fluid in each size of FPLP using the Darcy-Weisbach method, repeated in each case for standard
steel pipe of the same nominal size. As the charts show, the pressure drop for a given flow rate
in a FPLP line will be significantly lower than for the corresponding steel pipe. Conversely, a
higher flow rate can be attained for a given pressure drop using FPLP.
For other flow scenarios, the pressure drop can be calculated using any of the flow coefficients
listed in Table 8.
23
Pressure Drops of Flexpipe and Steel Pipe at Various Flow Rates

(Calculations based on 1 mile of pipe length, with 30C fresh water)
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 4: Representative Pressure Drop Comparison: Water at Various Flow Rates
Pressure
and Steel
Various
*Calculations based
on 1Drops
mile of
of Flexpipe
pipe length,
withPipe
freshatwater
atFlow
30CRates
(860 F)
(Calculations based on 1 mile of pipe length, with 20C Methane compressed to 500 PSI)
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 5: Representative Pressure Drop Comparison: Methane at Various Flow Rates
*Calculations based on 1 mile of pipe length, with methane at 20C (680 F) compressed to 500
PSI
24
Table 8: Flow Coefficients for FPLP
Hazen & Williams
150
Darcy Weisbach
0.0015 mm (0.000005 ft)
Manning
0.009
5.4.2 Fittings
The inside diameter of the mandrel of the FPLP pipe fitting is smaller than the inner diameter of
the pipeline (see Section 3.2). However, the restriction is minimal, and very few fittings are
required even for very long lengths of pipe. The associated pressure loss is negligible compared
to the pipe friction discussed above.
The following equations and K factors for Flexpipe coupling fittings can be used to calculate the
loss in pressure or pressure head due to the flow constriction.
V2
Pfitting K
2
Pressure loss:
h fitting
Pressure head loss:
V2
2g
Where:
= fluid density
V = fluid velocity
g = acceleration due to gravity
K = factor from Table 9
Table 9: K Factor for Flexpipe Coupling Fittings
Fitting size
K factor
2
0.16
3
0.15
4
0.12
5.5
Durability
FPLP is a durable, rugged product. The high-strength, pipe-grade thermoplastic used in the
jacket protects the fiber from the environment. The jacket is highly resistant to cracking, and
will not bruise, chip, or flake under normal handling. FPLP can be unspooled over rocks and
rough terrain, or pulled into failed pipelines.
The impact resistance of FPLP has been demonstrated by impact testing according to API RP
15S Section 5.5.2 at -25 C (-130 F).
25
5.6
Corrosion
FPLP liner and jacket will not corrode. External corrosion control of FPLP fittings is achieved by
the application of moisture resistant tape, and internal corrosion control by standard coatings
on the fittings (see Section 3.5). Additional corrosion control via cathodic protection is an
available option (see Section 6.15) and may be required by local regulations (i.e.: Energy
Resources Conservation Board ERCB of Alberta).
5.7
Erosion
FPLP will experience less erosion than steel in wet slurry applications (ie solid particles carried
in a liquid) due to the elasticity and toughness of the liner material. However, a sufficient flow
velocity should be maintained to prevent solid particles from settling out of the carrying liquid.
Settled particles that slide along the bottom of the pipe may cause wear to the bottom surface.
Dry slurry applications (ie solid particles carried by a gas) may cause excessive static electricity
build-up and/or heating due to dry particles sliding on the surface. FPLP may not be suitable for
dry slurry applications. Please contact your Flexpipe representative to conduct an application
evaluation for your project in this case.
5.8
Ultra-Violet Protection
Flexpipe adds a UV stabilizer to the jacket material during the extrusion process. FPLPs black,
white and yellow jacket options provide a minimum of 20 years protection against UV
exposure. The blue jacket on some existing FPLP provides a minimum of 2 years UV protection
and is no longer produced.
5.9
Bend Radius
The minimum allowable bend radius of FPLP differs in operation (pressurized) and
transport/handling (un-pressurized) conditions, as shown in Table 10.
Table 10: Minimum Bend Radius for Operation, Transport and Handling of FPLP
Minimum bend radius
Minimum bend radius
FP150, FP301,
OPERATION
TRANSPORT & HANDLING
and FP601
(ft)
(ft)
(m)
(m)
2
1.2
4.0
0.8
2.5
3
1.8
6.0
1.0
3.3
4
2.1
7.0
1.3
4.2
Note: The minimum radius does not apply to fittings/couplings. These joints
need to be kept straight to avoid point loading at the end of the fitting. Typically
there should be no bends within 1.8 meters (6 feet) from a fitting.
26
5.10 Permeation
Gas molecules are able to travel very slowly through pipe walls by moving through the spaces
between the molecules of the pipe material. This is known as permeation of the gas. All piping
materials allow gases to permeate to some extent, but composite materials allow more than
steel pipes do.
FPLP has 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 fiber reinforcement layer), thereby avoiding the risk of liner collapse during
line depressurization.
Field testing has shown that the actual rates of gas release from FPLP are generally insignificant
(see Section 9.2). This is supported by calculations based on a conservative model, in which the
gases in the pipe permeate through the liner and then permeate through the jacket or travel
along the annulus to exit through the vent hole at the fitting. The calculations use the
permeability coefficients given in Table 11, which are experimentally determined from testing
conducted on unreinforced polyethylene. The following example provides a representative
illustration of the extent of permeation in FPLP.
Table 11: Permeability Coefficients for HDPE
Permeant
Methane
H2S
CO2
Permeability coefficient at 40C (104F)

(cm3/cm-sec-MPa)
(inch3/inch-sec-psi)
1 x 10-7
1.07 x 10-10
1 x 10-7
1.07 x 10-10
-7
5.5 x 10
5.88 x 10-10
FPLP liner has a similar SDR (Standard Dimension Ratio) in all sizes, which results in the same
permeation rate for all sizes. Table 12 shows expected permeation rates for a gas mixture of
89% methane, 1% H2S, and 10% CO2. To obtain expected permeation rates at different
temperatures, it can be approximated that a 5C (9F) increase in temperature results in a 30%
increase in permeation rate.
27
Table 12: Representative Permeation Rates for FPLP
Permeation rate
3
cm3/m of pipe/day (in /ft of pipe/day)
Pipe pressure
Pipe at 10C
(50F)
Pipe at 40C
(104F)
Pipe at 60C
(140F)
89% methane
1% H2S
10% CO2
Total mixture
89% methane
1% H2S
10% CO2
Total mixture
89% methane
1% H2S
10% CO2
Total mixture
689 kPa
(100 psi)
6 (0.1)
0.1 (0.001)
4 (0.07)
10.2 (0.2)
30 (0.6)
0.3 (0.006)
18 (0.3)
48 (0.9)
85 (2)
1 (0.02)
53 (1)
139 (3)
5171 kPa
(750 psi)
46 (0.9)
0.5 (0.01)
29 (0.5)
76 (1.4)
224 (4)
3 (0.05)
138 (3)
365 (7)
639 (12)
7 (0.13)
395 (7)
1041 (19)
10,342 kPa
(1500 psi)
93 (2)
1 (0.02)
57 (1)
151 (3)
447 (8)
5 (0.09)
276 (5)
728 (13)
1277 (24)
14 (0.3)
789 (15)
2080 (39)
5.11 Expansion/Contraction and Axial Growth

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

When the pressure outside FPLP may exceed the pressure inside the pipe, the pipes ability to
withstand collapse should be considered. External pressure arises from factors such as ground
water pressure and the weight of soil above the pipe. Additional loads (such as the weight of
28
water or live loads due to moving vehicles) must be considered if the pipe runs through a bore
below a creek, roadway, etc. Internal vacuums may result from gravity flow of liquid down a
slope when the pipeline is unpressurized.
The ability of FPLP to withstand collapse is based on the total difference in pressure between
the outside and inside of the pipe. When the external pressure exceeds the internal pressure,
the difference can be considered as a net external pressure (or equivalently, a net internal
vacuum). The net external pressure can be calculated as follows:
Pnet,external Pexternal Pinternal

where Pinternal is a negative number for an internal vacuum, thus increasing Pexternal .
FPLPs external pressure resistance for buried applications has been measured according to
ASTM D241222, in accordance with Clause 13.1.2.11 of CSA Z662, based on a 50-year design life.
The maximum net external load that FPLP can withstand at 23C (73F) 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
clay23. If the total combination of dead loads, live loads, and internal vacuum will exceed this,
the FPLP should be protected by a steel casing (see Section 6.9).
When on the surface, there is no support from surrounding soil. Under these conditions, FPLP
can withstand a net vacuum pressure of 101 kPa (14.7 psi) at 23C (73F), 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 FPLP can withstand. FPLP is not intended for subsea applications.
5.13 Thermal Conductivity

FPLP thermal conductivity properties result from the properties of the polyethylene and
fiberglass materials. Accordingly, FPLP is a good thermal insulator with higher resistivity than
metallic pipes. Table 13 lists the thermal conductivity and resistivity values of the FPLP product
range.
Table 13: FlexPipe Linepipe Thermal Conductivity and Resistivity
22
ASTM D2412 Standard Test Method for Determination of External Loading Characteristics of Plastic Pipe by
Parallel-Plate Loading
23
The soil modulus is typically 1000 psi or greater for backfill embedment materials consisting of manufactured
angular granular materials, coarse grained soils with little or no fines with a Proctor density greater than 70%, or
coarse grained soils with fines with a Proctor density greater than 85%; the soil modulus is not typically greater than
1000 psi for fine-grained or organic soils (muck, clay, etc.).
29
Item
Pipe Size
Wall Thickness
R'-value
K'-value
Units
Item
Pipe Size
Wall Thickness
R'-value
K'-value
Units
Item
Pipe Size
Wall Thickness
R'-value
K'-value
Units
mm
m*K/W
W/m*K
mm
m*K/W
W/m*K
mm
m*K/W
W/m*K
2" FP150
n/a
n/a
n/a
Values
3" FP150
9.14
0.15
6.80
4" FP150
11.30
0.14
6.97
Units
2" FP301
7.75
0.28
3.53
Values
3" FP301
9.91
0.25
4.04
4" FP301
12.57
0.25
4.07
2" FP601
9.40
0.47
2.14
Values
3" FP601
11.94
0.41
2.45
4" FP601
15.37
0.42
2.40
in
hr*ft*F/Btu
Btu/hr*ft*F
2" FP150
n/a
n/a
n/a
Values
3" FP150
0.36
0.25
3.93
4" FP150
0.45
0.25
4.03
2" FP301
0.31
0.49
2.04
Values
3" FP301
0.39
0.43
2.33
4" FP301
0.50
0.43
2.35
2" FP601
0.37
0.81
1.24
Values
3" FP601
0.47
0.71
1.41
4" FP601
0.61
0.72
1.38
Units
in
hr*ft*F/Btu
Btu/hr*ft*F
Units
in
hr*ft*F/Btu
Btu/hr*ft*F
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 Flexpipe Systems Field Services Department provides support services for the installation of
Flexpipe products, including training courses, project coordination services, equipment rentals,
onsite inspectors, and installation supervisors. Experienced managers and project coordinators
are on call 24 hours per day, 7 days per week. Flexpipe strives to ensure successful installation
of its products on every project.
Fitting installation equipment is available from Flexpipe for sale or rental. Information on this
equipment can be found in the Flexpipe Systems Installation Guide. In addition, Flexpipe offers
a variety of specialized installation accessories, including A-frames for carrying pipe reels, riser
support trays, pull tools, custom cleaning pigs, moisture resistant Denso products, Polyken tape
and sacrificial anode kits for cathodic protection. For more information on these accessories,
see the Installation Guide.
6.2
Transportation
FPLP is coiled onto 3.66-meter (12 ft)-diameter, custom engineered transport reels that have
either 1.22-meter (4 ft) or 2.44-meter (8 ft) widths. Multiple reels can be transported on a
30
standard flat-deck trailer, or a single reel can be transported on a

special reel trailer. The reel capacities and weights are provided on
the Product Data Sheets in the Appendix.
Some reels can be disassembled in the field and stacked to reduce
space requirements, which allows up to five times as many empty
reels to fit on a truck deck. Please contact your Flexpipe
representative for more information and for Flexpipes recommended disassembly procedure.
6.3
Trenching
FPLP can easily be un-spooled and

placed into a trench or ditch. FPLP is
handled and installed much like coiled
HDPE pipe. The bending stiffness of the
two is very similar, but FPLP has less
memory than HDPE pipe and will lay
flat more readily. Soil condition and
padding requirements for FPLP are typically similar to those for steel pipelines
The flexibility of FPLP allows it be easily threaded underneath existing lines for easy line
crossings. This eliminates the need to cut the pipe and install extra fittings at line crossings.
6.4
Plowing
In a singlepass
operation,
a pipeline
plow can
trench,
install FPLP
and couplings, and cover the trench. This method is most beneficial when long continuous
lengths of pipe are to be installed, and minimizes disturbance to the environment.
6.5
Insertion as a Freestanding Liner
In situations where an existing pipeline has failed, FPLP can be pulled inside the failed pipeline
as a remedial line. FPLP is a freestanding liner, and does not depend on the existing pipeline for
any structural support.
31
In pipeline remediation applications there must be adequate clearance between the outer
diameter of the FPLP and the inner diameter of the existing conduit.
Table 14 shows the general compatibility of various conduits for FPLP insertion. The existing
conduit must be free of obstructions that could damage the pipe (fittings, wax, scale, etc.).
Excavating and removing any fittings is often a simple way to make a line compatible for
insertion of FPLP, provided that enough pipe is removed to avoid bending the FPLP tighter than
the minimum radius for operation given in Table 10.
Flexpipe fittings can be pulled along with the FPLP. A centralizing collar or sleeve is required
before each fitting to prevent the fitting from catching on weld beads or other discontinuities
inside the conduit. The maximum allowable pull forces for FPLP are shown in Table 15, and
should not be exceeded with any type of pull tool.
Please see the Installation Guide for information on pull tools available from Flexpipe.
Table 14: Conduit Compatibility for FPLP Insertion
Conduit
FPLP
2" FP301
2" FP601
3" FP150
3" FP301
3" FP601
4" FP150
4" FP301
4" FP601
3" Steel
0.188" 0.120"
wall
wall
P
P
N
P
N
N
N
N
N
N
N
N
N
N
N
N
N = Not compatible
4" Steel
0.188" 0.125"
wall
wall
PF
PF
PF
PF
P
P
P
P
N
P
N
N
N
N
N
N
Sch.
40
PF
PF
P
N
N
N
N
N
P = Compatible for pipe without fittings
Sch.
80
PF
PF
PF
PF
PF
P
P
P
Sch.
40
PF
PF
PF
PF
PF
P
P
P
6" Steel
0.188" 0.156"
wall
wall
PF
PF
PF
PF
PF
PF
PF
PF
PF
PF
PF
PF
PF
PF
PF
PF
0.125"
wall
PF
PF
PF
PF
PF
PF
PF
PF
PF = Compatible for pipe with coupling fittings
Note: The above table is based on 0.15 clearance on diameter between FPLP and the steel pipe weld bead, and a
steel pipe weld bead allowance of 0.125on diameter.
Table 15: Maximum Allowable Pull Forces for FPLP
Pipe Size
(nominal)
(in)
2
3
4
Maximum pull force

(kgf)
1000
2040
2720
(lbf)
2200
4500
6000
32
6.6
Surface Installation
Where permitted by the appropriate regulatory body, FPLP can be used above ground for
permanent and temporary surface flowlines. Appropriate hazard control measures should be
implemented in consideration of the elevated risk of injury or property damage inherent in
surface installations.
Non-metallic pipelines 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.
By their nature, surface pipelines are
exposed
to
an
uncontrolled
environment and are exposed to greater risk of damage than buried pipelines. Examples of
surface damage risks include sharp rocks, existing and growing foliage, fire, earth slides,
flooding, vehicular traffic, weapon discharge, vandalism, and lightning strikes.
Damage to or misuse of Flexpipe products may result in uncontrolled release of the product
being transported, which may result in serious injury or death. The energy stored in a
pressurized compressible gas is significant, and may result in a highly explosive failure mode
with the potential to cause significant property damage, serious injury, or death.
Surface pipelines are subject to heating by solar radiation. FPLP with black jacket readily
absorbs solar radiation and can reach excessively high temperatures very quickly when exposed
to direct sunlight. This is damaging and detrimental to the pipe. FPLP with white jacket reduces
solar heating and is required for FPLP surface lines. The operating temperature of the pipe,
including the effect of solar heating, must be prevented from exceeding 60C (140F).
When used as a temporary surface line, FPLP can be unwound onto the surface and rewound
back onto the reel. Use only Flexpipe-certified contractors or have a Flexpipe field personnel on
site when rewinding FPLP back onto reels. If done improperly, this process can cause damage
to the pipe, including kinking, cutting, scraping, and abrading. If the FPLP is subsequently
unwound for further pipeline use, this damage can result in pipeline failure.
FPLP is designed to vent gases that permeate from the transported fluid through the liner.
Permeated gases travel via the annulus reinforcement layer and are released at the fittings
33
through a vent hole in each fitting. Permeated gases may also be released along the length of
the pipeline.
Operational experience has shown that unrestrained Flexpipe products installed in surface line
applications may experience undesirable pipe movement during operation. Excessive pipe
movement may increase the risk of damage and/or reduced integrity.
In order to reduce the risk of undesirable pipe movement, Flexpipe recommends
implementation of some measures during the pipeline installation. These measures include
hydro testing the line with a loose end, and securing the line at all corners or bends by
trenching or sand bagging. Please refer to the Flexpipe Systems Installation Guide for further
recommendations on the installation of surface lines.
6.7
Support Spacing
For elevated support of FPLP, a continuous tray which is wide enough to allow for the expected
thermal expansion and snaking is recommended. FPLP may also be supported using individual
(non-continuous) pipe supports or hangers, as long as the expected thermal expansion can be
accommodated. . The pipe should be allowed to rest in a rounded cradle, with a length
approximately equal to or greater than the nominal diameter of the pipe being supported.
Supports should have rounded edges that will not cut into the pipe.
In order to prevent excessive sag between supports, Flexpipe recommends spacing the
supports no farther than the distances given in Error! Reference source not found..
Table 16: Recommended Pipe Support Spacing for FPLP
Recommended maximum support spacing
FP150, FP301,
Liquid service
Gas service
and FP601
(m)
(ft)
(m)
(ft)
2
1.1
3.5
1.2
4
3
1.2
4
1.5
5
4
1.5
5
1.7
5.5
6.8
Buoyancy and Pipe Weights
FPLP will float in water or muskeg if not weighted or buried in a clay base. If conditions are
suitable, FPLP may be plowed into muskeg without weighting. The suitability of the conditions
may be evaluated based on existing pipelines in the area and consultation with Flexpipe or plow
installation contractors.
34
If there is a concern that the pipe may float, FPLP can be weighted during installation. The
weights should not have sharp edges that could point-load or cut the protective jacket of the
FPLP. Sand-filled saddlebag weights are recommended.
When weights are used, it is extremely important that the pipe is handled and lowered into the
ditch by lifting on the weights directly. Lifting on the pipe may cause the pipe to kink or be
damaged by the weights.
The following formulas can be used to calculate the pipe buoyancy per unit length (note that
some unit conversions may be required). To keep the pipe submerged, the sand bag weight per
unit length must be slightly more than the buoyancy force per unit length. Note that there will
also be a buoyancy force on the sand bags themselves, which is compensated for in the
formulas below.
Pipe cross - sectional area OD 2
Weight of fluid displaced per unit length of pipe Pipe cross - sectionalarea 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
Flexpipe recommends multiplying by 1.1 to ensure the pipeline is adequately weighted to

remain submerged.
Weight of fluid displaced by sand bag Volumeof fluid displaced by sand bag Fluid density
Submergedweight 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 17 for each type of FPLP. These
results are based on muskeg with a fluid density of 1121 kg/m3 (70 lb/ft3).
35
Table 17: Recommended Sand Bag Weight for Weighting FPLP

Recommended
Maximum
FPLP
Spacing
(kg/m) (lbs/ft)
(mm)
(in)
(kg)
(lb)
(m)
(ft)
3
2.5
1.7
95
3.75
100
220
8.9
29.2
FP150
4
4.0
2.7
122
4.80
100
220
5.3
17.4
2
1.7
1.1
69
2.73
27
60
5.2
17.1
3
3.0
2.0
97
3.80
100
220
9.1
29.9
FP301
4
4.9
3.3
124
4.89
100
220
5.6
18.4
2
2.5
1.7
73
2.86
27
60
5.9
19.4
3
4.3
2.9
101
3.96
100
220
10.3
33.8
FP601
4
6.9
4.6
130
5.11
200
440
12.1
39.7
a
Dry sandbag weight. These weights already include the recommended safety factor of 1.1 to ensure the
pipe remains submerged.
Pipe weight per
length
6.9
Pipe OD
Recommended
Weightsa
Crossings
FPLP is well-suited to a variety of crossings. Design of road, railway,

and highway crossings must be in accordance with the regulations
of the governing body, local authority, railway company, or highway
department. Where applicable, depth of cover shall not be less than
the applicable requirements listed in Table 4.9 of CSA Z662 Clause
4.11.
Flexpipe recommends casings for:
Crossings of all public roads, highways and railways.
Crossings of lease roads and general areas where only light weight traffic is expected
(cars and pick up trucks) wherever the minimum burial depth is shallower than 1.2
meters (4 ft).
Crossings of lease roads and general areas where heavy weight traffic is expected (heavy
trucks, cranes) wherever the minimum burial depth is shallower than 2 meters (6.6 ft).
Bores more than 150 meters (500 ft) in length.
Steel casings may be required by regulations. For uncased bores, the suitability of the soil
conditions should be verified (see Section 5.12).
Please see the Installation Guide for information on installations involving crossings.
36
Centering spacers are not required for isolating FPLP from the metal casing. Allowing the pipe
to snake inside the casing can accommodate minor thermal length changes of the FPLP in the
casing.
Clause 13.1.4.7 of CSA Z662 requires protection to be provided for the pipe at entry and exit
points of the casing to prevent unacceptable shear and bending loads that could develop from
settlement and embedment consolidation. A well-compacted trench bottom and bedding, exit
and entry sand bagging, or other suitable protection should be provided. Cathodic Protection
(CP) of the steel casing is not required unless requested by the local authority, railway company
or highway department. If it is required, CP can be provided by installing sacrificial anodes on
the casing
6.10 Risers
FPLP may be terminated underground
with either a flange or weld neck fitting.
Alternatively, it can be brought to
surface and supported by a metal
support tray (riser support) mounted
onto pilings. The purpose of the riser
support is to prevent unnecessary shear
or tensile loads on the FPLP that could be caused by settling of backfill and earth movement.
Sand bagging or other suitable protection should be provided at the horizontal transition of the
FPLP to the riser support. For further information regarding risers see the Installation Guide.
The aboveground portion of the riser must be covered with insulation or white Polyken tape.
FPLP should be protected from mechanical damage similar to other piping materials above
ground, depending on expected hazards in the area. FPLP is a ductile material and can
withstand reasonable impact even at low temperatures.
6.11 Tracer Wire

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

FPLP can be installed in cold, winter conditions, provided that precautions are taken. The
precautions are based on the temperature of the pipe; therefore, wind-chill conditions do not
apply. Consideration must also be given to the difference between the ambient temperature
37
and the actual pipe temperature. FPLP has very low thermal
conductivity, which means that it cools down or heats up very
slowly. As a result, if pipe is stored outside over night, the pipe
may be much cooler than the ambient temperature the next day.
When necessary, the entire reel of pipe must be pre-heated to a
temperature above -25C (-13F) prior to deploying (unspooling) or
plowing. Please refer to the Flexpipe Systems Installation Guide for recommended precautions
for installing pipe at temperatures below freezing.
6.13 Heat Tracing

FPLP may be heated by means of a heat tracer wire to prevent freezing. However, the heat
tracer must be separated from the pipe by an insulation barrier to prevent concentrated hot
spots or over-heating of the jacket.
Flexpipe recommends a sandwich type insulated barrier with an insulation/heattrace/insulation configuration, as shown in Figure 6. Because the FPLP jacket material is a very
poor thermal conductor, concentrated hot spots will appear directly below the heat tracing
wire if an insulated barrier is not used.
The maximum operating temperature of FPLP is 600C (1400F). Therefore, it is very important to
regulate the amount of heat tracing per unit length of pipe accordingly.
Figure 6: Sandwich Type Insulated Barrier Configuration
38
6.14 Fitting Installation

Flexpipes proprietary fittings can be installed
in the field in 20 to 30 minutes by an
experienced technician, and must be installed
by certified technicians with specialized tools
and equipment.
Flexpipe works with
contractors and customers to provide
certification training so that certified thirdparty contractors can provide the fitting installation service. Alternatively, Flexpipe can provide
certified fitting installation technicians. Fitting installation equipment is engineered and
designed specifically for Flexpipe products, and is available from Flexpipe on a rental basis.
6.15 Cathodic Protection

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

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

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

FPLP is designed to accommodate the pressure-testing requirements specified by regulatory
standards and codes. Due to the safety factors built into the FPLP design, there is no need to
upgrade to a higher pressure-rated pipe if testing is required above the stated MAOP. Field
pressure testing requirements and recommendations for FPLP depend on whether the pipeline
is a new installation or a tie-in or repair job.
Flexpipe recommends that new FPLP pipelines be subjected to a 24 hour hold test at
1.25xMAOP. Check with local regulations to ensure required hydrotest pressures are met.
Where necessary (e.g. low points in hilly terrain) and to account for unexpected pressure
39
fluctuations, FPLP can be allowed to reach a maximum pressure of 1.5 x MAOP at the lowest
point in the line during the pressure test.
Suggested procedures for pressure testing new pipelines are given in the Flexpipe Systems
Installation Guide.
To minimize the potential risk of injury or property damage in the unlikely event of a pressure
test failure, a relatively incompressible liquid such as water is recommended as the pressurizing
medium. Methanol is compatible with FPLP and is commonly used as an additive to prevent
freezing when pressure testing at low temperatures.
Pressure test failures involving compressible media such as air result in the sudden
uncontrolled release of a great deal of energy, with the potential for property damage, personal
injury, or death.
Pressure testing with a gas medium is acceptable for test pressures up to 2900 kPa (420 psi)
only, provided that:
it is not prohibited by local regulations or standards;
appropriate precautions are taken to protect the pipeline from damage and minimize the
risks associated with a pressure test failure.
Under no circumstances will Flexpipe Systems be liable in any way for any loss, damage or
injury of any kind (whether direct, consequential, punitive or otherwise) incurred as a result of
the use of a gas medium for pressure testing.
Flexpipe recommends tie-ins, repaired and replaced sections of pipelines be left exposed as the
pipeline is brought into service and visually monitored for leaks for at least four hours, at the
highest available operating pressure. Re-testing of the entire pipeline is not recommended.
Pressure testing pipelines to a pressure greater than MAOP is generally only appropriate prior
to a pipeline being in operation. Pre-testing of the tie-in and/or replacement pipe is also not
necessary.
7 Accessories
For complete information on tools and accessories required to install Flexpipe products, please
refer to the Flexpipe Systems Installation Guide.
40
7.1
A-frames
A-frames are available on a rental basis for carrying spools of FPLP during deployment. Please
contact your Flexpipe representative for more information.
The following reference drawings are available from Flexpipe Systems upon request:
8FT A-Frame Drawing
4FT A-Frame Drawing
7.2
Riser Support Trays
Riser trays support FPLP from shear forces as the pipe comes out of the ground to connect to
surface pipe (see Section 6.10). Flexpipe offers 45 and 90 riser support trays for each pipe
size, as well as hardware for securing the pipe to the tray.
The following reference drawings are available from Flexpipe Systems upon request:
45 Riser Drawing
90 Riser Drawing
S-bend Riser Drawing
7.3
Pull Tools
Flexpipe Systems offers four types of pull heads for FPLP. Please refer to the Installation Guide
for further information on the available pull tools.
7.4
Sacrificial Anodes
Flexpipe anode kits consist of a zinc ribbon anode connected to a copper lead wire, along with a
roll of cloth tape to fix the anode to the FPLP and a stainless steel hose clamp to secure the lead
wire to the fitting. Please refer to Section 3.5 for more information on performance and
installation.
8 Operations
8.1
Startup
On very hot or very cold days, start up procedures for FPLP should include a gradual or stepped
flow increase to allow for gradual temperature and pressure changes in the system.
41
8.2
Pigging
FPLP is suitable for pigging. However, Flexpipe fittings have an ID that is smaller than the ID of
the pipe. To ensure proper pigging, the use of a medium-density foam bullet pig, or a Flexpipe
disc (cleaning pig) is required. Failure to use a Flexpipe-approved pig could result in the pig
becoming stuck in a fitting. Flexpipe supplies tags for installation on risers to warn operators of
the temperature limitations of the pipe and pigging restrictions of the fittings.
Flexpipe recommends medium-density (5 lb) foam bullet pigs for dewatering and Flexpipe
urethane disk pigs for removing wax build-up. The foam bullet pigs are also available with a
urethane coated tip, which provides protection against damage during pigging operations. Ball
pigs and brush pigs must not be used.
Flexpipe urethane disk pigs are designed specifically for FPLP, and
offer more aggressive cleaning. However, a greater pressure
differential is required to move them through fittings, and they
require the presence of some liquid in the pipeline to provide
lubrication. Urethane pigs are available from Flexpipe Systems in a
variety of durometers to suit different pigging requirements (see
Table 18).
Table 18: Custom Urethane Disk Pigs for FPLP
Size
2
3
4
Durometer
80
70
80
70
60
70
60
Color
Yellow
Green
Yellow
Green
Purple
Green
Purple
Flexpipe urethane pigs cannot be used for threaded fittings, and are not recommended for any
T fittings or welded thin-wall elbows. They may be used with schedule 40 or 80 welded elbows
(45 or 90). If a pigging program is required on a FlexPipe line joining another line, Flexpipe
recommends a y-lateral joint (see Section 3.1), oriented to allow the pig to enter the joint from
one of the arms and exit from the bottom of the Y. Pig launchers must be sized to
accommodate the Flexpipe pig dimensions as indicated in Table 19.
42
Table 19: Flexpipe Pig Dimensions for FPLP
Pipe Size
Flexpipe urethane pig Flexpipe urethane pig
Required pressure
(nominal)
diameter
length
differentiala
(in)
(mm)
(in)
(mm)
(in)
(kPa)
(psi)
2
57.2
2.25
101.6
4.0
138
20
3
82.6
3.25
139.7
5.5
207
30
4
104.9
4.13
165.1
6.5
276
40
a
Required pressure differential is approximate and assumes the line is lubricated.
8.3
Hot Oiling
FPLP can be hot oiled. Flexpipe Systems recommends that the procedures and safety guidelines
provided by the hot oiling service provider and the operators production engineers be
followed. The maximum allowable operating pressure and temperature of FPLP listed in
Section 5.2.2 must not be exceeded at any time during the hot oiling procedure.
Only Flexpipe-approved pigs may be used for FPLP (see Section 8.2).
8.4
Static Electricity
Standard operating and maintenance procedures for handling non-conductive pipe and
dissipation of static electricity apply when working with FPLP. Static charge on a plastic pipe
can be generated by friction during the physical handling of the pipe in storage, shipping,
installation, and repairing operations. Also, flowing gas in an operational plastic pipe containing
particulate matter in the form 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 FPLP due
to the potential for external damage. The preferred method for excavating buried FPLP is
hydro-excavation (hydrovac).
43
The following practices are recommended to minimize the risk of external damage to the pipe:
Identify the location of the FPLP using the tracer wire installed with the pipe.
Follow hydro-excavation procedures that comply with industry best practices for excavation
of thermoplastic piping, including:
o Use of protective tips (eg rubber, neoprene, etc) on spray nozzles and suction hoses.
o Use of multi-jet nozzles with diverging spray patterns; not oscillating, rotating, or
converging pattern nozzles.
o Continuous movement of the spray wand while excavating.
o A distance of at least 12 between the spray nozzle and the pipe.
o Spray pressures as low as practical and not above 2000 psi.
o Water temperatures below 60C (140F).
Inspect the exposed pipe thoroughly after the excavation is complete.
Support the weight of exposed pipe at intervals of not greater than 6m (20 feet).
Take appropriate precautions to avoid impact or sustained pressure from sharp or heavy
objects.
Exercise care during any mechanical excavation near FPLP.
Inspect all exposed FPLP for external damage prior to backfilling.
Replace any sections of FPLP that are damaged during excavation.
Use proper backfill procedures.
8.6
Field Pressure Testing of Existing Pipelines
When a cut out is replaced, a failure is repaired or a tie-in is connected to a previously

operating pipeline, the new pipe and the connections used to join or repair the pipe should
undergo a service test. Flexpipe recommends the repaired, replaced or connected section be
left exposed as the pipeline is brought into service and visually monitored for leaks for at least
four hours, at the highest available operating pressure. Re-testing of the entire pipeline is not
recommended. Pressure testing pipelines to a pressure greater than MAOP is generally only
appropriate prior to a pipeline being in operation. Pre-testing of the tie-in and/or replacement
pipe is also not necessary.
9 Reliability
9.1
History
As of 2009, over 7 million meters (23 million feet) of FPLP and 20 thousand fittings have been
installed throughout Western Canada, the United States, and internationally. FPLP is currently
in service carrying a wide range of liquid and gas media, at various operational temperatures
and pressures up to and including the published limits. A number of different installation
methods have been employed over a wide range of climate, soil, and terrain conditions.
44
Flexpipe products continuously meet the extensive challenges of operation in demanding

applications, and have earned an excellent record as high quality and dependable products in
the field. This has been demonstrated through numerous evaluations of operating pipelines in
a variety of applications.
9.2
Leak Testing
Approximately 53 km (174,000 feet) of in-service gas gathering pipelines, including over 140
coupling and end fittings, have been tested for gas leaks by an independent emission detection
company. No gas was detected along any of the pipelines and only trace amounts of gas were
detected at the surface end fitting vent holes, as expected. In fact, the only high gas
concentrations detected during leak testing were discovered to be leaks in the threaded
connections of nearby steel piping.
9.3
Cut-outs
In order to satisfy Canadian regulatory requirements, Flexpipe Systems has cut out and tested a
number of pipe samples after two years of service to validate the long-term performance of
FPLP.
In all cases, destructive burst testing results of the cut-out samples exceeded the
minimum acceptable levels. In addition, detailed dissections were carried out and none of the
samples showed any indications of degradation. The results of the destructive burst testing are
found in Figure 7. These results demonstrate that there is no degradation of pipe performance
after two years of service.
The most significant risk to the integrity of FPLP is external damage. The risk of external
damage during operation most commonly arises due to excavation near installed FPLP.
Recommended practices to minimize this risk are given in Section 8.5.
Other operational considerations important to maintaining the integrity of FPLP include:
Ensuring the maximum temperature and pressure limits are not exceeded at any time.
Ensuring liquids do not freeze inside of the pipe.
Ensuring the cyclic service recommendations in Section 5.3 are not exceeded.
Avoiding fluid hammer due to rapid opening or closing of valves, water surge due to abrupt
pump starts and stops etc.
Following Flexpipes recommendations regarding hot oiling and chemical treatment.
Utilizing appropriate hazard controls for prevention of external damage to surface pipelines.
45
Figure 7: Cut-out Burst Test Results
9.4
Integrity Verification
Many operators elect to limit their integrity verification activities to an initial pressure test after
installation. In line with their risk management strategies, some operating companies may
choose to exceed normal industry practice by incorporating one or more of the activities listed
below into their integrity verification activities. It would typically be appropriate for an
operating company to make use of the options that are matched most closely to their current
practices for other pipeline materials (whether steel, composite, or plastic). Likewise, sample
sizes and inspection frequencies could parallel those used for other pipeline materials.
46
Integrity verification options for FPLP include:

Cut-out testing. A method for confirming pipe integrity is to remove a sample of pipe
approximately 10-15 feet in length and have it tested. Flexpipe offers integrity assessment
testing and analysis of such samples.
Pressure testing. To verify the integrity of the pipe after a period of operation a pressure
test may be conducted over a duration of 4 hours at the lesser of the maximum allowable
operating pressure and 1.25 times the normal operating pressure.
Visual inspection for corrosion of metallic fittings. The external condition of a fitting can be
inspected by removing the denso tape. The condition of the interior coating of a flanged
fitting can be inspected visually after unbolting the flanged connection. It is recommended
that new gaskets and denso tape be used during reassembly.
Visual inspection of jacket. Where pipe is exposed above surface the jacket can be
inspected for discoloration that may indicate UV degradation.
Gas detection testing. Fittings can be checked for leaks during operation using gas
detection equipment. Flexpipe has performed this type of inspection on numerous buried
and surface fittings in Canada in accordance with requirements of the local regulatory
authority (see Section 9.2).
47
10 Appendix
Product Data Sheets
ShawCor Ltd., 2010
FlexPipe Linepipe
Maximum Operating Pressure @ 60C or 140F

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
600 ANSI-FP601
300 ANSI-FP301
150 ANSI-FP150
10,342 kPa / 1500 psi
5,171 kPa / 750 psi
2,068 kPa / 300 psi
Metric (mm)
73
101
130
69
97
124
95
122
Imperial (inches)
2.86
3.96
5.11
2.73
3.80
4.89
3.75
4.80
Metric (mm)
54
77
99
54
77
99
77
99
Imperial (inches)
2.12
3.02
3.90
2.12
3.02
3.90
3.02
3.90
Metric (kg/m)
2.5
4.3
6.9
1.7
3.0
4.9
2.6
4.0
Imperial (lbs/ft)
1.7
2.9
4.6
1.1
2.0
3.3
1.7
2.7
Metric (m)
1.2
1.8
2.1
1.2
1.8
2.1
1.8
2.1
Imperial (ft)
Metric (m)
1000
700
600
1000
750
750
750
750
Imperial (ft)
3281
2297
1968
3281
2461
2461
2461
2461
Metric (m)
3.7
3.7
3.7
3.7
3.7
3.7
3.7
3.7
Imperial (ft)
12
12
12
12
12
12
12
12
Metric (m)
1.2
1.2
2.4
1.2
1.2
2.4
1.2
2.4
Imperial (ft)
Metric (kg)
3175
3719
5261
2359
2948
4808
2631
4128
Imperial (lbs)
7000
8200
11600
5200
6500
10600
5800
9100
Metric (kg)
680
680
1134
680
630
1134
680
1134
Imperial (lbs)
1500
1500
2500
1500
1500
2500
1500
2500
Metric (mm)
80.5
108.5
139.2
75.9
103.1
131.8
101.6
129.3
Imperial (inches)
3.17
4.27
5.48
2.99
4.06
5.19
4.00
5.09
Metric (mm)
44.5
63.5
85.9
44.5
63.5
85.9
63.5
85.9
Imperial (inches)
1.75
2.50
3.38
1.75
2.50
3.38
2.50
3.38
Flow Coefficients
Hazen & Williams
150
Darcy Weisbach
e=0.000005 ft or 0.0015 mm
Manning
0.009
*Double length reels are available as a custom order. Please contact your Account Manager for more information.
Product Data is subject to change without notice. Flexpipe is not responsible for variations in data presented.
Flexpipe products are protected by US Patents: 6,889,716 and 6,902,205.
888-FLX-PIPE / 888-359-7473
www.flexpipesystems.com
FlexCord Linepipe
FC601
600 ANSI
Maximum Operating Pressure @ 55C or 131F
10,342 kPa / 1500 psi
FC601 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)
99
128
Imperial (inches)
3.91
5.03
Metric (mm)
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)
Metric (m)
615
525
Imperial (ft)
2018
1722
Metric (m)
3.7
3.7
Imperial (ft)
12
12
Metric (m)
1.2
2.4
Imperial (ft)
Metric (kg)
3855
5669
Imperial (lbs)
8500
12500
Metric (kg)
680
1134
Imperial (lbs)
1500
2500
Metric (mm)
107.1
136.5
Imperial (inches)
4.22
5.38
Metric (mm)
63.5
85.9
Imperial (inches)
2.50
3.38
Flow Coefficients
Hazen & Williams
150
Darcy Weisbach
e=0.000005 ft or 0.0015 mm
Manning
0.009
*Fitting dimensions do not include O.D. of flange provided for Flanged End Fittings.
Fitting O.D. and I.D. apply to Flanged End, Weld-Neck, and Pipe-to-Pipe Coupling fittings.
Product Data is subject to change without notice. Flexpipe is not responsible for variations in data presented.
888-FLX-PIPE / 888-359-7473
www.flexpipesystems.com
Head Office and Manufacturing Facility

3501 - 54th Avenue S.E.
Calgary, Alberta
T2C 0A9
Tel: 403-503-0548
Fax: 403-503-0547
Canada Solution Centers
Lampman, SK
Tel: 306-861-0509
Grand Prairie, AB
Tel: 780-882-1213
Drayton Valley, AB
Tel: 780-514-5430
US Sales Office
Houston, TX
Tel: 281-227-2050
Fax: 281-227-2084
US Solution Centers
Grand Junction, CO
Tel: 970-243-0067
Fax: 970- 243-7962
Midland, TX
Tel: 432-685-0865
Fax: 432-685-0857
Toll Free: 888-FLX-PIPE (888-359-7473)

Toll Free Fax: 888-359-7479
Website: www.flexpipesystems.com

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FLEXPIPE SYSTEMS

TECHNICAL INFORMATION MANUAL

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Flexpipe Systems 06-1876 R3.2

ShawCor Ltd., 2010

Flexpipe Systems 06-1876 R3.2

ShawCor Ltd., 2010

5.2.3 Calculations for Determining Maximum Allowable Operating Pressure .................... 19

Flexpipe Systems 06-1876 R3.2

ShawCor Ltd., 2010

8.4 Static Electricity................................................................................................................. 43

Flexpipe Systems 06-1876 R3.2

ShawCor Ltd., 2010

Flexpipe Systems 06-1876 R3.2

ShawCor Ltd., 2010

In an effort to provide useful product information, Flexpipe Systems makes

Flexpipe Systems 06-1876 R3.2

ShawCor Ltd., 2010

Flexpipe Systems 06-1876 R3.2

2010 Flexpipe Systems Inc

Figure 1: FlexPipe Linepipe Three-layer Design

Flexpipe Systems 06-1876 R3.2

2010 Flexpipe Systems Inc

Flexpipe Systems 06-1876 R3.2

2010 Flexpipe Systems Inc

2.4.2 Fiber Reinforcement

Flexpipe Systems 06-1876 R3.2

2010 Flexpipe Systems Inc

2.4.4 Quality Control

ASME B16.5 Pipe Flanges and Flanged Fittings

Flexpipe Systems 06-1876 R3.2

2010 Flexpipe Systems Inc

Weld Neck Fitting

Table 2: Flexpipe Flow Joints

90 Degree Elbow Flow Joint

Flexpipe Systems 06-1876 R3.2

2010 Flexpipe Systems Inc

True Y Flow Joint

Figure 2: Cutaway View of Flexpipe Fitting

Flexpipe Systems 06-1876 R3.2

2010 Flexpipe Systems Inc

Flexpipe Systems 06-1876 R3.2

2010 Flexpipe Systems Inc

CSA Z245.11 Steel Fittings

Flexpipe Systems 06-1876 R3.2

2010 Flexpipe Systems Inc

Introduction to Standards and Regulations

According to industry terminology, Flexpipe Systems line pipe is classified as a reinforced

Flexpipe Systems 06-1876 R3.2

2010 Flexpipe Systems Inc

4.2.1 American Petroleum Institute (API)

4.2.2 Canadian Standards Association (CSA)

Flexpipe Systems 06-1876 R3.2

2010 Flexpipe Systems Inc

CSA Z662 clause

CSA Z245.11 Steel Fittings

Flexpipe Systems 06-1876 R3.2

2010 Flexpipe Systems Inc

Pressure testing repairs/replacements

4.3.1 Canadian Provincial Regulatory Bodies

4.3.2 United States Regulatory Bodies

Flexpipe Systems 06-1876 R3.2

2010 Flexpipe Systems Inc

Jana Laboratories Inc. (Aurora, Ontario)