Scope - American Petroleum Institute



DRAFT for DISCUSSIONStandard Specification for Thermoplastic Liners for Oilfield Tubular GoodsScope – This specification provides the requirements for the selection, design, manufacture, installation and operation of unbonded thermoplastic liner pipes that are inserted into existing pressure rated host pipes for the primary purpose of internal corrosion and abrasion mitigation, and the end connections or terminations of those lined pipelines. This specification also provides the requirements for operation and inspection of the lined pipeline. The liners of this specification are not intended to contribute to the pressure rating of the lined pipe. This standard does not apply to inserted pipes that become the primary pressure containment element of the lined system. The liners of this specification are used in onshore and offshore upstream oil and gas production system pipelines and downstream product transfer pipelines. Upstream Ppipelines include produced water lines, water injection lines, hot water transfer, slurry lines, hydrocarbon production lines, multiphase production lines and gas production lines. Hot water transfer lines are also covered. PDownstream pipelines also include refined liquid product pipelines and natural gas (fuel gas) pipelines. This specification is confined to liner and end connections, and the procedures for installation and operation of the lined system. It does not relate to other system components and appurtenances. Where other system components (e.g. risers, valves, fittings, etc.) are of conventional construction they will be governed by other applicable codes and practices.Note: Thermoplastic liners are in common use in new pipelines and in pipelines that have already been in service provided that the host pipe meets the pressure requirements of the service. Normative References (essential references)PPI TR4PPI TR19ISO 23936-1 NORSOK M-710API 17J-2014ISO 24033:2009API 17 TR2NACE RP 0304API 15LEGlossary (Terms, Definitions and Abbreviations)Annulus: The interstitial space between the liner outer walsurface and the inside wall surface of the host pipe.Buckling: The onset of elastic instability of the liner which can usually be calculated using known materials properties. Collapse may follow quickly after buckling.Collapse: The large-scale deformation of a liner usually resulting in reduced flow capacity and damage to the liner. Collapse often results in a U-shaped cross-section of the liner.Critical buckling pressure (Pcrit): The external pressure applied to a liner sufficient to initiate structural buckling. Expansion: Increasing the diameter of the inserted liner so that it is in contact with the interior surface of the host pipe.Fusion: The process of joining lengths of liner by melting the plastic at the joint. It also refers to the fusion joint. Host pipe: The existing rigid pipe which may be steel or composite.Installer: A contractor specializing in liner insertion and termination.Interference fit: See Tight fit.Joint: A length of liner when it is provided as straight pieces.Liner: The plastic pipe inserted into the host pipe.Liner manufacturer: The party that converts thermoplastic polymer material into liner pipe to be used by the installer.Loose fit: A liner design case in which the pre-insertion liner outside diameter (OD) is smaller than the host pipe inside diameter (ID). A description can be found in “Pipeline Rehabilitation by Sliplining with Polyethylene Pipe.”2Material supplier: The party that manufactures the polymer material used to make the liner supplied to the installer. In some cases the liner extrusion company serves in the materials supplier role, as described in this standard.Neutral fit: A liner design case in which the pre-insertion liner OD is the same as the host pipe ID.Owner: The party ultimately contracting with the installer for the liner, and who has long-term responsibility for the lined pipeline.Pull head: A special piece of equipment, usually made from the same polymer as the liner, containing a secure attachment point.Sizing plate: A pipeline inspection device with an accurate known OD, that is normally pulled through the host pipeline prior to liner insertion, for the purpose of determining the minimum ID within the host pipe.Liner – Composed of thermoplastic tubularSee NACE SRP 304, Sect. 2Liner Materials (Long, Mason, Walsh, Fullmer, Cox, Boros, Ziera, Kato, Craster, Langston)What properties are needed for the design process, long term performance, manufacturability and installation???The selection of an appropriate liner material is a critical part of the liner design process. Not all thermoplastic polymer materials are suitable for use as liners in oilfield pipelines because of the variety of fluids and operating conditions. Of the materials that can be used as a liner, no single material is suited to all operating conditions. Several thermoplastic polymers have been used as liners in oilfieldservice in different environments GeneralThe liner material is normally selected by the installer in consultation with the owner. Materials shall be selected based on mechanical properties and chemical resistance information supplied by the thermoplastic polymer material supplier such that they meet the specified service and installation requirements.Polymeric compounds shall be specified using a cell classification system appropriate to the polymer type or specified as compliant with the minimum properties listed in Table 1. If a polymer pipe standard is used the dimensional requirements shall not apply. Fitness for purpose shall be established based upon tests as specified in Table 2 using extruded liner pipe specimens.Fusion joints in the liner are permitted provided that they are performed by a qualified operator using a qualified procedure according to a recognized standard. The liner shall maintain its integrity for the specified fluids under the given service conditions.Table 1 – Minimum Properties for Polyethylene Liner PipeProperty Test Method Minimum RequirementDensity (g/cm3)ASTM D1505 > 0.941Melt index (g/10min; 190°C, 2160 gr load)ASTM D1238 < 0.15Modulus of Elasticity (MPa; 50 mm/min.)ASTM D638 > 750Tensile Strength at Yield (MPa; 50 mm/min.)ASTM D638 > 18ESCR (Condition C, 192 hours)ASTM D1693 Failure less than 20%Hydrostatic design basis (MPa at 23°C, 20 years)ASTM D2837 > 8.62Oxygen Induction Temperature (at 200°C)ASTM D3895 > 150 minutesThe liner shall maintain its integrity for the specified fluids under the given service conditions.Do all of the properties have to be confirmed for the specific fluids (not defined) under unspecified service conditions/times? How will this be done? … and who will perform the testing (pipe manufacturer?)Table 1 – Minimum Properties for Polyethylene Liner PipeProperty Test Method Minimum RequirementDensity (g/cm3)ASTM D1505 > 0.941Melt index (g/10min; 190°C, 2160 gr load)ASTM D1238 < 0.15Modulus of Elasticity (MPa; 50 mm/min.)ASTM D638 > 750For the applications, might need to be a bit higher … maybe 1000 MPa … or 1,200 MPaTensile Strength at Yield (MPa; 50 mm/min.)ASTM D638 > 18ESCR (Condition C, 192 hours)ASTM D1693 Failure less than 20%Why is there a need to use ESCR? I would think that specifying a PENT value > 500 hours would be more in line with the pressure resin specifications that is being sought.Hydrostatic design basis (MPa at 23°C, 20 years)ASTM D2837 > 8.62Seems like a strange/unique HDB.Oxygen Induction Temperature (at 200°C)ASTM D3895 > 150 minutesWhat is the basis for this value? Why is the API looking at such a high number? I doubt that there will be a need for all the extra antioxidants … and the potential to drive up costs. I would think that something in the range of 100-120 minutes would be very adequate.Polymer Properties – see RP 304 appendix BRefer to table 1 These properties may change with exposure so the measurements should be measured at thermal and chemical environmental equilibrium.Table 2 – Testing Requirements for Extruded Polymer LinersCharacteristicTestsStandardMechanical / Physical PropertiesResistance to CreepASTM D2990Yield Strength/ElongationASTM D638Ultimate Strength/ElongationASTM D638Stress Relaxation PropertiesASTM E328Modulus of Elasticity (Young’s Modulus)ASTM D638Compression StrengthASTM D695Impact StrengthASTM D256DensityASTM D792 or D1505Notch SensitivityASTM D256Thermal PropertiesBrittleness (or Glass Transition) TemperatureASTM D746 or ASTM E1356Glass Transition Temperature and Melting PointASTM D3418-12e1or ISO 11357Permeation CharacteristicsFluid PermeabilityAPI 17J-2014 Paragraph 6.2.3.1Blistering ResistanceSection 4.4 of this document or API 17J-2014 Paragraph 6.2.3.2Compatibility and AgingFluid CompatibilityAging TestsWeathering ResistanceASTM D2565 Chemical Resistance and AgingThe liner manufacturer or installer shall document the effects of the chemical components of the service environment at the design temperature on the liner materials. An engineering assessment shall be conducted to verify that the liner will retain integrity and fitness for purpose at the design conditions. The assessment shall be based on testing and experience and shall predict the aging or deterioration of the polymer under the influence of environment. As a minimum, polymer aging estimates shall consider temperature, water cut, and pH. Special attention should be given to deplasticization, loss and/or degradation of additive formulation components, fluid absorption, and changes of dimensions.Materials used in liners covered by this standard shall be demonstrated to remain stable for the design life of the product, retaining the necessary performance characteristics required to meet the original design specification. The fluid used in ageing-resistance tests should be representative of the specified pipeline fluid. Materials that are tensile- or compressive-loaded in service should be tested with similar stresses induced.NOTEPPI TR-19 may be used as a screening tool for evaluating fluid compatibility. ISO 23936-1 and NORSOK M-710 provide a methodology for performing fluid compatibility testing.Swelling TestThe following procedure shall be followed to determine the amount of swelling of liner polymer caused by absorption of pipeline fluids.At least 3 test specimens shall be machined from extruded polymer of the same type as the liner. The minimum dimensions of the samples shall be: Thickness: 5 mmLength:10 mmWidth: 10 mmMeasure the linear dimensions and record them to the nearest 0.01 mm.Weigh the specimens and record the weight to the nearest 0.001 g.Immerse the specimens in at least 500 ml of fluid representative of the anticipated pipeline contents. Raise the temperature to the design temperature of the pipeline to be lined.Expose the specimens at the design temperature for a minimum of 2 weeks.Periodically remove the specimens, wipe them dry, weigh them and record the weight with the same accuracy as the initial weighing. Replace the specimens into the test fluid.When the weight stabilizes for three successive measurement intervals, wait for the specimens to return to room temperature, then measure the linear dimensions and record them with the same accuracy as the initial pre-exposure measurements.Calculate the volumetric swell of the specimens using Equation 1.?Vswell = Vexposed-Vpre-exposureVpre-exposure Eq. 1Calculate the linear swell using Equation 2.εswell= ?Vswell2 × 100 Eq.2 Blister ResistanceBlistering resistance tests shall reflect the design requirements, relating in particular to fluid conditions, pressure, temperature, number of decompressions and decompression rate. The following conditions shall apply as a minimum.Samples:Samples shall be taken from extruded linerFluid mixtures:Use gas components of specified environment as documented in the test procedure.Soak time:Use sufficient to ensure saturation.Test cycles:If available, use expected number of decompressions, or else use 20?cycles as a minimum.Decompression rate:If available, use expected decompression rate, or else use as a minimum 7?MPa/min (1015?psi/min).Thickness:Liner wall thickness as a minimum.Temperature:Use the expected decompression temperature.Pressure:Use design pressure as a minimum.Procedure:After each depressurization the sample shall be examined at a magnification of 20x for signs of blistering, swelling and slitting. If the liner is a multilayer or coextruded structure, the adhesion between layers shall not be compromised during the blistering test.Table 3 - Polymer Material StandardsPolymerStandardTitlePolyethylene (PE)ASTM D2513-14, Section 4 - MaterialsorStandard Specification for Polyethylene (PE) Gas Pressure Pipe, Tubing, and FittingsASTM F2619-13, Section 4 - MaterialsorStandard Specification for High-Density Polyethylene (PE) Line PipeAPI 15LE, Sections 2 & 5.1.1orSpecification for Polyethylene Line Pipe (PE)ISO 4437-1:2014Plastics piping systems for the supply of gaseous fuels - Polyethylene (PE)Polyamide 11Polyamide 12Other PolymersASTM D4000Standard Classification System for Specifying Plastic MaterialsLiner Polymer TypesLiner polymers must be able to be extruded into the desired shape and dimensions, have sufficient resistance to weathering and UV damage so prevent degradation in storage and shipment, be able to be joined in the field, inserted in to the host pipe by the installer’s method, be terminated using the installer’s preferred terminations and resist the service environment for the design life.PolyethylenesPolyethylenes suitable for use as liners covered by this standard shall have a long term hydrostatic strength rating listed in PPI TR-4. If a materials is not listed in TR-4 the materials supplier shall demonstrate that the material has met all the requirements to be listed in TTR-4 High Density Polyethylenes shall be classified as PE4710 or PE100. Polyethylenes of Raised Temperature are permitted provided that have an HDB at 180F listed in PPI TR-4, and they are designated as PE-RT Type II according to ISO 24033:2009. ??Polyamides (nylons)Because polyamide materials age by hydrolysis, polyamide (nylon) materials for use as liners covered by this standard shall be described by an aging model developed consistent with API 17 TR2, including the effects of temperature and pH on the aging rate.Polyamide 11Polyamide 12Other PolymersQualification using Table 1 test methods shall be required together with an aging model And ??d…….Liner Design for Interference Tight Fit Liners (Fullmer, Baron, Compton, Kneller, Svetlik, Lauzon??)5.1The design procedure for a thermoplastic liner consists of determining the thickness that limits both stress and strain to acceptable levels and is sufficient to prevent collapse or other mechanical failure. Factors such as creep rate, permeation rate, and environmental stress cracking also should be considered, particularly in terms of how they are affected by liner wall thickness. The outside diameter of the liner shall be determined, considering the inside diameter of the carbon steel pipe, the requirements of the installation technique and handling, and storage requirements. Thermoplastic liners often must be tailor made to the application therefore nonstandard dimensions are frequently used.Specifically, the liner design shall consider and account for the effects of the following general pipeline design and operating factors on the liner material, structural design of the liner, installation method, and operation of the lined pipeline:(a) Current or proposed method of operating the pipeline(b) Pipeline length, ID, and condition (new, pitted, abraded, scaled, etc.)(c) Operating pressure range (minimum, average, maximum)(d) Pressure-cycling magnitude and frequency(e) Operating temperature range (f) Pipeline repair points and methods of repair(g) Flow requirements(h) Pipeline service fluid components, including chemical additives, and frequency of chemical additions(i) Pipeline geometry (fittings, bends, terrain, right-of-way, location, and accessibility)(j) Pigging frequency and type of pigs used(k) Local regulatory and code requirements(l) Methods of liner diameter reduction and insertion (m) Termination and end connections5.2The liner design also shall consider and account for the behavior of the liner under the influence of the operating conditions once installed. The following liner behaviors shall be considered and analyzed.(a) Differential thermal expansion of the liner,(b) Potential for collapse (critical buckling pressure),(c) Dimensional and mechanical properties changes caused by exposure to the pipeline service fluid, including any chemical additives.(d) Presumed erosion (wall loss) and its effect on critical buckling pressure.5.3The liner design also shall account for and consider the requirements of insertion and termination:(a) Termination of each lined segment(b) Connection of adjacent segments and any future access required for maintenance(c) Tensile loading of the liner during pull-in(d) Residual stresses as a result of insertion by diameter reduction and termination. Method used should minimize stresses for diameter reduction and installation.5.4The design shall specify the following characteristics of the liner:(a) Outside diameter average, minimum, and maximum(b) Nominal wall thickness, minimum, and maximum allowed thickness(c) Maximum ovality(d) Outer wall surface geometry, e.g., smooth or grooved(e) Maximum deviation from straightness for each joint of liner(f) Print line text (markings printed onto liner)(g) Packaging and delivery form(h) Duration and conditions of required storage time(i) Maximum allowable “toe-in” at ends of each joint5.5It shall be the responsibility of the installer to be sure that the dimensions of the liner delivered to the job site meet the specified design requirements for the project.Section 5: Liner Design Aspects6.1Installed Stress State6.1.1The design process uses the information provided by the owner and the liner material supplier to make decisions about the selection of a liner material, the dimensions of the liner, and the installed stress state of the liner.6.1.2This specification shall be limited to tight-fit liners only installed by a method of diameter reduction using roller reduction or powered roller reduction. Tight fitting liners, also called compression or interference fit liners, occur when the liner OD is initially larger than the ID of the host pipe and after temporary mechanical diameter reduction and insertion, reverts to a compressive state against the steel pipe wall. Tight fit liners operate in a hoop-compressive state. Liners that are shaped in a “U” configuration prior to insertion are not consider in this specification.6.1.3The insertion condition can be quantitatively defined. Percent tightness or looseness, denoted by the symbol " QUOTE " shall be defined as the percent difference between the ID of the host and the OD of the liner, and calculated using Equation (1).6.2Collapse Considerations6.2.1Liner collapse can be radial or axial. Both types of collapse can occur in the same liner. Radial collapse occurs when the critical buckling pressure has been exceeded. Radial collapse is realized as the formation of a collapse lobe, usually running parallel to the liner longitudinal axis, reducing the interior diameter of the liner. Radially collapsed liners may, in extreme cases, assume a U-shaped cross-section. The "U" cross-section does not have to be present to consider the liner to have collapsed. Axial collapse may be realized as compaction at the end fitting or as inversion of the liner into the adjacent segment of pipeline. Axial collapse has been observed to have followed severe radial collapse at the end fitting. 6.2.2Liners should be designed to be collapse-resistant. Tolerance to risk of collapse shall be determined by the owner/operator at the start of the design process and a safety factor against collapse should be agreed upon between the owner and the installer prior to liner design.6.2.3Liners deform under the pressure of the annulus relative to the pipeline pressure. Buckling occurs when the force required to deform the liner ceases to increase with increasing deformation. The critical buckling pressure is the pressure in the annulus at the radial buckling point. Collapse may rapidly ensue after buckling, as less additional force is required to continue the liner wall motion than before buckling.6.2.3.1Collapse-resistant liners have a radial critical buckling pressure (Pcrit) that is higher than the maximum anticipated annulus pressure. The intent of a collapse-resistant design is to prevent radial buckling as a means of preventing irreversible deformation or rupture of the liner.6.2.4The Pcrit decreases with decreasing tightness, decreasing liner thick? ness, and decreasing liner material modulus. The effects of chemical exposure on the material's properties shall be included in calculation of the critical buckling pressure resulting in an equilibrium value of Pcrit that accounts for changes in properties and fit during use.6.2.5Calculation of Pcrit may be done by finite element analysis or by any of the several published closed-form methods for calculating the buckling pressure of a rigidly encased pipe. Several reviews have been published by NACE. Because of uncertainties in knowing the actual operating conditions and material properties at any particular time during service, such calculations of Pcrit are only estimates. The designer shall describe the calculation assumptions and method in sufficient detail so that the end user understands the basis of the design. A factor of safety, consistent with standard engineering practice, should be incorporated into the design basis related to Pcrit. 6.2.5.1In the tight-fitting liner case, the steel host pipe provides sup? porting restraint during collapse. The initial critical buckling pressure Pcrit in kPa can be estimated by Equation (2). QUOTE where: QUOTE = liner material Young’s Modulus (MPa)t = liner wall thickness (mm)R = average radius of liner (mm) defined as QUOTE If fluids in the service conditions cause swelling of the plastic liner material, this estimate required modification. Swelling changes, the dimensions and the Young's Modulus (E). In that case, the designer should use the Young's Modulus of the saturated or swollen material at the operating temperature and use the swollen material thickness (t) and average radius (R).6.2.6The pressure in the annulus is usually attributed to the presence of permeated gases from the flowing pipeline contents. During steady-state operation, the annulus pressure is balanced by the pipeline pressure. The annulus gas has a finite volume at operating pressure because the annulus is a closed space. As the pipeline is depressurized without first venting off the annulus gas pressure, the liner may deform under the pressure of the expanding annulus gases. The increase in annular volume results in a proportional decrease of annular pressure. The ratio of the annulus volume before depressurization to the pre-buckling volume after depressurization defines the maximum permissible annulus pressure for collapse-resistant liners. Elastic deformation upon depressurization should not be exclusively relied on to prevent collapse. Migration of annulus gases, presence of local large volumes caused by corrosion pits, or other locally larger volumes at high pressure may initiate collapse at lower pressures than the annulus pressure-volume product might suggest.6.2.7Tight fitting liners have a higher Pcrit value and considering the small micro annular space the liner wall thickness can be designed to resist collapse. 5.2.8Swelling of the liner because of fluid uptake increases both the axial and radial compressive stresses. Similarly, a liner may shrink because of extraction of fugitive components such as plasticizers, low molecular-weight polymer fractions, and stabilizer additives. If the liner material is expected to change dimensions in the expected service, the magnitude of the change should be estimated and accounted for in the design to prevent radial and/or axial buckling of the liner.6.3Differential Thermal Expansion6.3.1Thermoplastic liners are normally operated at or above the temperature of installation. Thermoplastic polymers have higher linear thermal expansion coefficients than metals. The result is that the liner normally grows in length and diameter relative to the steel host pipe. Axial extension caused by thermal expansion can be prevented with a tight fit liner with sufficient surface friction at the interface between the liner and the host pipe. 6.3.2The liner design should account for the effect of differential thermal expansion. Differential thermal expansion effects may be negligible in cases in which there is sufficient liner-host pipe friction to prevent axial motion of the liner. 6.4Liner Pipe Profile6.4.1Liiner pipes have a smooth outer surface and a smooth inner sur? face. The annulus formed after insertion of these liners is intended to be small during operation. Movement of gases and liquids along the annulus of smooth-sur? face liners is likely and is beneficial for monitoring and in some cases venting of annular pressure along the entire lined segment length. 6.5Abrasion6.5.1Some lined pipelines transport abrasive slurries or contain entrained abrasive particles such as sand in gas or liquids. Thermoplastic liners are subject to wall thickness loss caused by the abrasive pipeline contents. In consultation with the owner, the installer shall determine if abrasion damage is possible and account for abrasion-caused wall thickness loss in the design.6.6 Monitoring Vent Point & VentingThe design of the vent point assembly shall be proposed by the Liner Installer and agreed with the Owner. Venting is used to monitor the integrity of the liner. The vent point shall include a valve to allow open/close of the vent. The design of the vent point assembly shall be proposed by the Liner Installer and agreed with the Owner. The minimum number of vent points shall be one at each flanged end of a section of lined pipe. Venting can be operated by installing valve to be closed or opened during normal operation. Venting can also be used to monitor the integrity of the liner. Monitoring can be done manual at the valve location or remotely. Lines transporting water and multi-phase hydrocarbons with H2S, or other hazardous gasses, may have a provision of a re-injection system to transport the permeated gas to the bore. The Liner Installer shall submit the re-injection system design to the Owner for review. Note:Venting procedure provided by the liner installer shall be strictly followed.6.7 Spacing between Vent PointsVent point is usually installed at each flanged end particularly for water service, stabilized crude oil and oil/water mixture.Liner Installer shall consider the length of the pipeline and determine the number of lined sections that can be connected using an annular vent jumper before connecting with a re-injection system or to an exit to the atmosphere.?Caution should be taken to ensure that vents are not plugged. 6.8 Design of End ConnectorsThe Liner Installer shall select the end connection and submit this for approval to the Owner. The Liner Installer shall demonstrate that the end connection meets the same operational requirements as the thermoplastic liner. The design shall account for shrinkage, creep, aging of the thermoplastic material and operational pressure fluctuations. In general, flanged connections are considered for termination at the ends of pipeline mentary:If flangeless jointing systems are the preferred jointing system for the lined pipeline the liner installer shall submit the qualification of their specific flangeless jointing system to the Owner for review. 6.9 Annular EnvironmentThe annular environment that will exist during operation should be evaluated to ensure that it is not detrimental to the steel host pipe. Any product in the pipeline prior to liner insertion should be considered in addition to any products that may permeate through the liner during operation.Edit notes:It was discussed that the above sections 4 and 5 might be better merged into one section on Design.It was discussed that the above format was excessively “descriptive” and that perhaps it would be simplified if much of the description was moved to a definitions section.Design ObjectivesThe function of the liner is to separate the host pipe wall from the corrosive pipeline contents while minimizing the reduction in inside diameter compared to the unlined pipe. As a minimum, the liner should be designed with the thickness necessary to: a. retain its shape in handling and storageb. permit high quality fusion jointsc. be installed correctlyd. resist collapseDesign ProcedureThe design process includes an assessment of the service conditions, materials, chemical compatibilities of liner materials with any service fluids and additives, pipeline geometry,and risk analysis.The design procedure consists of determining the thickness necessary to limit loads on the liner to acceptable levels and to prevent collapse. The liner OD shall be determined by taking into account the ID of the host pipe, the installation method and desired tightness. The wall thickness shall be determined by handling and storage requirements, fusion joint quality, and critical radial buckling pressure differential (collapse resistance). General Pipeline Design FactorsThe liner design shall consider and account for the effects of the following general pipeline design and operating factors on the liner material, structural design of the liner, installation method, and operation of the lined pipeline:Current or proposed method of operating the pipelinePipeline length, ID, and condition (new, pitted, abraded, scaled, etc.)Operating pressure range (minimum, average, maximum)Pressure-cycling magnitude and frequencyOperating temperature range (minimum, normal, maximum)Pipeline repair points and methods of repairFlow requirementsPipeline service fluid components, including chemical additives, and frequency of chemical additionsPipeline geometry (fittings, bends, terrain, right-of-way, location, and accessibility)Pigging frequencyLocal regulatory and code requirementsOperating Condition FactorsInsertion and Termination RequirementsEffect of Tightness Essential Design Equations – provide in appendixVenting End FittingsLiner Manufacturing and Quality Requirements (Boros, Dyer/Casteel, KatoPomante, MasonPonda, Langston, Svetlik, Ziera, Doyle)Polymer GradeRework requirementsClean rework materials of the same grade and commercial designation, generated from the manufacturer’s own pipe and fitting production may be used by the same manufacturer as long as the pipe and fittings produced meet all of the requirements of this specificationDimensional RequirementsDo we need to provide a minimum liner wall thickness table??MarkingQuality TestingMelt flow; O.D.; wall thickness; out of round (ovality); Toe-In; Joint length; Busrt pressure; Sustained pressure; Workmanship; DocumentationPackaging and TransportationLiner Installation and Flanging (Compton, Kneller, Baron, Fullmer) – NACE RP 304, Sect. 6General Installation Parameters8.1.1Liner installation is the process of inserting a liner into an existing pipeline. The installation step is accomplished by skilled contractors assisted by representatives of the owner. The roles of the owner and contractor are complementary. Neither party is in possession of all the information and skills necessary for a successful liner project. The liner is an engineered product with many related installation and performance parameters. The following checklist outlines some pertinent criteria that should be considered for each project. This checklist is not all inclusive because of the specialized circumstances of each individual project. Based on the liner design, the installer shall evaluate the following aspects of the project in consultation with the owner before beginning work on the line.(a) Previous, present, and future pipeline service(b) Previous inspection reports on the condition of the pipeline(c) Current pipeline pressure rating(d) Type of pipeline connections(e) Pipeline profile/geometry(f) Future service/connections used(g) Flow-rate capacity(h) Minimum/maximum pressures(i) Annular clearance(j) Insertion forces(k) Flange design(l) Vent design(m) Pipeline fittings and bend radii and possible replacement to accommodate the liner8.2Installation Techniques: Common Considerations6.2.1The liner installer, in conjunction with the owner representative, shall determine locations for break flanges along the pipeline to be lined.8.2.2Flanges or other suitable terminations modified for liner applications, and threaded vent-outlet adapters shall be welded at each end of each section to be lined.8.2.3Before the liner is installed, excessive internal scale and/or other debris shall be removed from the pipeline by pigging or chemical cleaning.8.2.4Pressure testing or other integrity assessment and any necessary re- pairs of the host pipe should be performed before the liner is inserted.8.2.5Dehydration of the host pipe before the installation of the liner may be necessary.8.2.6Application of a chemical corrosion inhibitor to the pipeline steel after cleaning and before liner insertion should be considered.8.2.7Butt fusion procedures shall be documented by the installer. Fusion personnel should be trained and qualified by the installer or by an independent certifying body. The installer shall certify that only properly trained fusion personnel are used. A copy of the fusion records and fusion technician qualifications shall be provided to the owner upon request.8.2.8Fusion technicians must complete pre-job trial fusions to qualify the procedure as well as themselves. Field quality tests should be conducted on the trial fusions to verify that quality meets industry-accepted standards and the results shall be reported to the owner and entered a job log. Fusion joints may be tested by any of a variety of commonly used methods such as the "bend-back test" outlined in ASTM F2620-13.8.2.9A pig-mounted sizing plate should be passed through the host pipe segment to identify potentially damaging internal features. The diameter of the sizing plate should be agreed between the liner installer and the owner. If any scratch or gouge in the proofing of the line is determined to cause a gouge in the liner pipe that exceeds 10% of the liner wall thickness, then the internal feature shall be sufficiently remediated. 8.2.10The installation method to obtain an interference tight fit liner requires that the diameter reduction of the liner pipe limit the stress on the liner. This requires the low friction method of roller reduction and power roller reduction. Liner insertion must be accomplished with a combination of diameter reduction and pulling.8.2.11The loads on the liner during insertion should not exceed the liner manufacturer's recommended maximum. Deviations from this requirement shall be documented in detail and provided to the owner.8.2.12The installer shall maintain documented procedures for insertion and termination of the liner and shall provide such documents to the owner upon re? quest.8.2.13After the insertion, sufficient time should be allowed for the liner to relax and recover to a near-neutral axial stress state to minimize the amount of tension left in the liner before termination. Relaxation times depend on liner fit, temperature, loading history, and material properties.8.2.14If pigging of the lined pipeline is anticipated, the installer should be instructed to remove the internal fusion bead at the liner joint before installation. If the internal fusion bead has not been removed, these beads may be torn away during pigging operations using any type of pig. The beads are then able to travel and may cause operating problems with down-stream equipment such as valves.8.2.15After the completion of the liner installation process, and before returning the lined pipeline to service, the installer shall subject the lined pipeline to an integrity verification using compressed air with the annulus vents open. The lined pipeline must pass the air pressure integrity check before being returned to service. The presence of a continuous air flow as determined by the installer at the vents during the test is an indication of a likely breach in the liner and shall be investigated and repaired by the installer before retesting and returning to service. Local codes and regulations may require a pressure test before the pipeline is returned to service. If required, a hydrostatic test should be done after a successful air pressure integrity verification check.8.2.16Connections between lined segments shall not be disassembled after the final pressure integrity test. Any untested connections should be left exposed for an appropriate period to allow for direct observation of the connection for detection of leaks.Based on the liner design, the installer shall evaluate the following aspects of the projectin consultation with the owner before beginning work on the line.(a) Previous, present, and future pipeline service(b) Previous inspection reports on the condition ofthe pipeline(c) Current pipeline pressure rating(d) Type of pipeline connections(e) Pipeline profile/geometry(f) Future service/connections used(g) Flow-rate capacity(h) Minimum/maximum pressures(i) Annular clearance(j) Insertion forces(k) Flange design(l) Vent design(m) Pipeline fittings and bend radii and possiblereplacement to accommodate the linerHost Pipeline Preparation Preparing an existing pipelineDesigning a new pipeline intended for use with a liner.Material Handling and StorageMethods JoiningFlange BoltingPull lengthsEnd fittingsQuality testingCommissioningOperation (Cox, Compton, Mason, Kneller, Knapp) – NACE RP 304, Sect. 7Routine ProceduresVentingStart-upShut-downPiggingChemical AdditionUpset ConditionsRepair and MaintenanceIntegrity Management of Liner And Host PipeDocumentation To Be Supplied By the BuyerTo Be Supplied By the DesignerTo Be Supplied By the InstallerQuality API Q1 ???API Q2 ??? Packaging, Handling and Storage (Svetlik, Dyernames?)Annex A (Informative)Design EquationsAnnex B (Informative)Typical Properties of Thermoplastic Liner MaterialsAnnex B (Informative)Test Procedures for Thermoplastic Liner MaterialsAnnex C (Informative)API Monogram Program ................
................

In order to avoid copyright disputes, this page is only a partial summary.

Google Online Preview   Download