Petronas STD

PTS 31.40.30.
34
January 2011
Page 3
PREFACE
PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication, of
PETRONAS OPUs/Divisions.
They are based on the experience acquired during the involvement with the design, construction,
operation and maintenance of processing units and facilities. Where appropriate they are based on,
or reference is made to, national and international standards and codes of practice.
The objective is to set the recommended standard for good technical practice to be applied by
PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical
plants, marketing facilities or any other such facility, and thereby to achieve maximum technical and
economic benefit from standardisation.
The information set forth in these publications is provided to users for their consideration and
decision to implement. This is of particular importance where PTS may not cover every requirement
or diversity of condition at each locality. The system of PTS is expected to be sufficiently flexible to
allow individual operating units to adapt the information set forth in PTS to their own environment and
requirements.
When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the
quality of work and the attainment of the required design and engineering standards. In particular, for
those requirements not specifically covered, it is expected of them to follow those design and
engineering practices which will achieve the same level of integrity as reflected in the PTS. If in
doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility,
consult the owner.
The right to use PTS rests with three categories of users:
1) PETRONAS and its affiliates.

2) Other parties who are authorised to use PTS subject to appropriate contractual
arrangements.
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users
referred to under 1) and 2) which requires that tenders for projects, materials
supplied or - generally - work performed on behalf of the said users comply with the
relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users,
PETRONAS disclaims any liability of whatsoever nature for any damage (including injury or death)
suffered by any company or person whomsoever as a result of or in connection with the use,
application or implementation of any PTS, combination of PTS or any part thereof. The benefit of this
disclaimer shall inure in all respects to PETRONAS and/or any company affiliated to PETRONAS that
may issue PTS or require the use of PTS.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual
arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by users
to any company or person whomsoever and the PTS shall be used exclusively for the purpose they
have been provided to the user. They shall be returned after use, including any copies which shall
only be made by users with the express prior written consent of PETRONAS.
The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe custody
and PETRONAS may at any time require information satisfactory to PETRONAS in order to ascertain
how users implement this requirement.
PTS 31.40.30.34
January 2011
Page 4
TABLE OF CONTENTS
1. INTRODUCTION ........................................................................................................ 6
1.1 SCOPE........................................................................................................................ 6
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 6
1.3 DEFINITIONS ............................................................................................................. 6
1.4 ABBREVIATIONS ....................................................................................................... 8
1.5 CROSS-REFERENCES ............................................................................................. 9
2. MATERIALS ............................................................................................................. 10
2.1 GENERAL ................................................................................................................. 10
2.2 THERMOPLASTIC LINER MATERIALS .................................................................. 11
2.3 MATERIAL SELECTION GUIDE .............................................................................. 18
2.4 MATERIAL TESTING ............................................................................................... 19
2.5 END CONNECTORS ................................................................................................ 23
3. DESIGN .................................................................................................................... 24
3.1 INTRODUCTION ...................................................................................................... 24
3.2 MINIMUM LINER THICKNESS................................................................................. 25
3.3 LINER DESIGN PROCEDURE................................................................................. 26
3.4 VENT POINT DESIGN .............................................................................................. 32
3.5 PULL-IN LOADS AND INSERTION LENGTH .......................................................... 34
3.6 DESIGN OF END CONNECTORS ........................................................................... 35
4. MANUFACTURE OF THE THERMOPLASTIC LINER ............................................ 37
4.1 PROCESS OF MANUFACTURE .............................................................................. 37
4.2 FINISH AND WORKMANSHIP ................................................................................. 37
4.3 DIMENSIONS, WEIGHTS AND TOLERANCES ...................................................... 38
4.4 QUALITY PROGRAMME .......................................................................................... 38
4.5 EQUIPMENT MARKING ........................................................................................... 41
4.6 HANDLING AND STORAGE .................................................................................... 42
5. LINER INSTALLATION ............................................................................................ 43
5.1 GENERAL - INSTALLATION TECHNIQUES ........................................................... 43
5.2 PREPARATION PHASE ........................................................................................... 45
5.3 LINER FABRICATION PHASE ................................................................................. 47
5.4 LINER INSTALLATION ............................................................................................. 49
5.5 END FLANGES AND IN-LINE FLANGED JOINTS .................................................. 51
5.6 TESTING................................................................................................................... 52
6. OPERATION ............................................................................................................. 53
6.1 START-UP ................................................................................................................ 53
6.2 DE-PRESSURISING ................................................................................................. 53
6.3 PIGGING ................................................................................................................... 53
6.4 FLOW VELOCITY ..................................................................................................... 53
6.5 VENTING .................................................................................................................. 53
6.6 MAINTENANCE ........................................................................................................ 53
6.7 REPAIR ..................................................................................................................... 54
6.8 OPERATIONAL PROCEDURE FOR A LINED PIPELINE ....................................... 54
7. DOCUMENTATION .................................................................................................. 55
7.1 INFORMATION TO BE SUBMITTED BY THE PRINCIPAL ..................................... 55
7.2 INFORMATION TO BE SUBMITTED BY THE CONTRACTOR .............................. 55
8. REFERENCES ......................................................................................................... 56
APPENDICES
APPENDIX 1 CURRENT RANGE OF SERVICE EXPERIENCE .......................................... 59
APPENDIX 2 EXAMPLE OF OPERATIONAL PROCEDURE ............................................... 61
APPENDIX 3 LINER DESIGN DATA SHEET ........................................................................ 63
PTS 31.40.30.34
January 2011
Page 5
APPENDIX 4 MATERIAL PROPERTIES............................................................................... 65

APPENDIX 5 PURCHASE ORDER INFORMATION ............................................................ 66
PTS 31.40.30.34
January 2011
Page 6
1. INTRODUCTION
1.1 SCOPE
This PTS specifies requirements and gives recommendations for the selection, design,
manufacture, installation and operation of thermoplastic liners in carbon steel pipelines and
flowlines. It covers both the retro-fitting of thermoplastic liners inside existing carbon steel
pipelines and flowlines as well as new pipelines and flowlines.
In the context of this PTS, a liner consists of a number of thermoplastic pipe lengths which
are fused together into sections of up to approximately 1 km. After pressure testing, the
section of liner is inserted into a pre-welded carbon steel pipeline or flowline section. The
carbon steel pipe provides the pressure containment and the liner the internal corrosion
protection. At the ends of the section the liner is terminated in a thermoplastic flange or
other (usually mechanical) connection system, to enable sections to be joined together.
Onshore, offshore, buried and above-ground applications are considered. Within certain
limitations, thermoplastic lined pipelines and flowlines may be used in oil, gas or water
service. Although the scope is directed towards thermoplastic liners for carbon steel
pipelines and flowlines, much of the content is also relevant for liners inserted in flexible
flowlines and risers.
The liners covered in this PTS are based both on currently applied thermoplastic materials
and on those materials that have the potential to be applied in future, more demanding
applications.
This PTS only gives requirements for the thermoplastic liner. It is assumed that the carbon
steel pipeline or flowline into which the liner is to be inserted has been designed and
constructed in accordance with PTS 31.40.00.20.
Amended per
Circular 05/02
Factory-applied liners inside steel pipe and fittings are covered by PTS 31.38.01.11-Gen.
Hose lining techniques, using polyester materials with fibre tubes and epoxy to bond these
to the pipe wall, are not covered by this PTS. Pipelines lined with thermoset materials such
as GRE (Glass fibre Reinforced Epoxy) are not covered by this PTS either.
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by PETRONAS, the distribution of this PTS is confined to
companies forming part of PETRONAS or managed by a Group company, and to
Contractors and Manufacturers/Suppliers nominated by them.
This PTS is intended for use in the design, procurement, manufacturing, transport and
installation of thermoplastic liners for pipelines for oil and gas production, oil refineries,
chemical plants, gas plants and supply/marketing installations.
If national and/or local regulations exist in which some of the requirements may be more
stringent than in this PTS, the Contractor shall determine by careful scrutiny which of the
requirements are more stringent and which combination of requirements will be acceptable
as regards safety, environmental, economic and legal aspects. In all cases the Contractor
shall inform the Principal of any deviation from the requirements of this PTS which is
considered to be necessary in order to comply with national and/or local regulations. The
Principal may then negotiate with the Authorities concerned with the object of obtaining
agreement to follow this PTS as closely as possible.
1.3 DEFINITIONS
1.3.1 General definitions

The Contractor is the party which carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project, or operation or
PTS 31.40.30.34
January 2011
Page 7
maintenance of a facility. The Principal may undertake all or part of the duties of the
Contractor.
The Manufacturer/Supplier is the party which manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party which initiates the project and ultimately pays for its design and
construction. The Principal will generally specify the technical requirements. The Principal
may also include an agent or consultant to act for, and on behalf of, the Principal.
The word shall indicates a requirement.
The word should indicates a recommendation.
1.3.2 Specific definitions

Acceptance criteria Defined limits placed on characteristics of materials,
products or services.
Annulus Space between thermoplastic liner and the carbon steel
outer pipe.
Bell hole Excavated area allowing access to a buried carbon steel
pipeline e.g. for insertion of a section of thermoplastic
liner.
Butt fusion welding A process of fusing thermoplastic materials that entails
squaring and aligning the pipe materials, heating the pipe
ends, bringing the two aligned pipe ends together under
pressure and a predetermined cooling time resulting in a
fused joint having a hydrostatic strength equal to the
parent pipe.
Crude oil service Fluids in which the volume fraction of crude oil is at least
1%
End connector A device used to provide a leak-tight structural
connection between two sections of lined pipe. The lining
is terminated inside the end connector.
Flanges Face flanges with a bolt circle according to ASME B 16.5
or ASME B16.47, including thermoplastic flanges with
metallic backup rings.
Grout porosity Voids in grout, which allow the transport of gas through
the grout to venting ports.
Hot plate welding Technique whereby thermoplastic pipe is fused by
smelting and re-solidification.
In-line compression joint System of terminating lined pipelines by compression of
the liner between an internal ring and a CRA material.
Inspectors Individuals designated by the Principal to act on behalf of
the Principal for monitoring Contractor's quality control
testing and technical acceptance.
Lot number Assignment of a unique code to each lot of pipes to
maintain traceability. A lot is defined as being all pipes
produced from the same base polymer batch with the
same diameter and wall thickness, up to a maximum
number of 50 pipes.
Modulus Elastic modulus: proportionality constant between applied
stress and strain.
Ovality This is a measurement of the deflected set in a cross-
section of pipe and is expressed as a percentage. It is
PTS 31.40.30.34
January 2011
Page 8
measured by taking the maximum measured diameter

minus the minimum measured diameter (the out-of-
roundness value) and dividing that sum by the average
measured diameter and multiplying that result by 100.
PA liner Liner based on Polyamide in combination with fillers and
plasticisers.
PE liner Liner based on Polyethylene in combination with fillers
and plasticisers.
PK liner Liner based on Polyketone in combination with fillers and
plasticisers.
Point of fusion The end of a liner which is available for trimming, heating
and pressing together during the heat fusion process.
PP liner Liner based on Polypropylene in combination with fillers
and plasticisers.
PPS liner Liner based on Polyphenylene Sulphide in combination
with fillers and plasticisers.
PTFE liner Liner based on Polytetrafluoroethylene in combination
with fillers and plasticisers.
PVC liner Liner based on Polyvinylchloride in combination with
fillers and plasticisers.
PVDF liner Liner based on Polyvinylidenefluoride in combination with
fillers and plasticisers.
Permeation Gradual diffusion of liquid and gas through a
thermoplastic layer under the influence of pressure.
Records Retrievable information.
Standard Dimension Ratio A specific ratio of the average specified outside diameter
(SDR) to the minimum specified wall thickness (OD/t) for outside
diameter-controlled plastic pipe.
Thermoplastic materials Plastic materials which retain their mechanical properties
after heating and cooling.
Vent connection or point Hole in the carbon steel outer pipe to allow the release of
gas accumulated in the annulus between the liner and
the carbon steel pipe.
Venting The release of gas accumulated in the annulus between
the thermoplastic liner and the carbon steel pipeline.
Water service Fluids in which the volume fraction of crude oil is less
than 1%
1.4 ABBREVIATIONS
CRA Corrosion Resistant Alloy
ESC Environmental Stress Cracking
ID Nominal internal diameter
HDPE High Density Polyethylene
MDPE Medium Density Polyethylene
OD Nominal outside diameter
PA Polyamide
PTS 31.40.30.34
January 2011
Page 9
PE Polyethylene
PK Polyketone
PP Polypropylene
PPS Polyphenylene Sulphide
PTFE Polytetrafluoroethylene
PVC Polyvinylchloride
PVDF Polyvinylidenefluoride
SDR Standard Dimension Ratio
UV Ultra violet light
XLPE or PEX Cross-linked Polyethylene consisting of long polymer chains in
a 3-dimensional structure.
1.5 CROSS-REFERENCES
Where cross-references to other parts of this PTS are made, the referenced section
number is shown in brackets. Other documents referenced in this PTS are listed in (8).
PTS 31.40.30.34
January 2011
Page 10
2. MATERIALS
2.1 GENERAL
The Contractor shall be responsible for the selection and supply of all materials required to
meet the specified installation and service conditions (7). The Contractor shall have either
measured test data (preferred) or documented methods for predicting the thermoplastic
liner material properties for the specified service conditions. For the predictive methods, the
Contractor shall have available, for review by the Principal, records of tests and
evaluations, which demonstrate that the predictive method yields conservative results. If the
conveyed fluid contains gas, it shall be demonstrated by testing or documented evidence of
standard testing that the thermoplastic will not blister or degrade during service, i.e. start-
up, continuous operation or shut-down (rapid de-pressurisation).
The Contractor shall also be responsible for documenting the mechanical, thermal, fluid
compatibility and permeability properties of the thermoplastic liner material (2.4).
PTS 31.40.30.34
January 2011
Page 11
2.2 THERMOPLASTIC LINER MATERIALS

A liner is made from a mix of a thermoplastic polymer material, colouring agent, anti-oxidant
and plasticiser. Currently there are several thermoplastic polymer materials that are used
for liners in pipelines or for similar applications in flexible flowlines and risers: Polyethylene
(PE), Polyamide (PA), and Polyvinylidenefluoride (PVDF). Other polymers such as
Polypropylene (PP), Polyvinylchloride (PVC), Polytetrafluoroethylene (PTFE),
Polyphenylene Sulphide (PPS) and Polyketone (PK) have the potential to be used but are
not in use at present.
These thermoplastic polymer materials are produced in numerous grades and qualities.
The differences in material properties between grades of the same polymer may be as
great as the difference between different polymers.
The following presents a limited introduction to the generic thermoplastic material types and
commonly applied grades. In particular, for each polymer, it specifies the:
Application envelope (in terms of maximum operating temperature as a function of fluid
composition);
Typical material properties at ambient conditions;
Appropriate testing standards.
The typical material properties (un-aged) are listed for guidance only, based on an
assumed lifetime of twenty years. They should be considered as minimum values at
ambient un-aged conditions. Specific material data relating to actual service conditions
(temperature, life-time) and fluid composition shall always be used in design and installation
requirement analyses.
The minimum design temperature for all thermoplastic materials covered in this PTS is
minus 20 C. Lower temperatures may be tolerated but only provided that specific low
temperature material data are available and the operating temperature does not fall below
the brittleness temperature of the thermoplastic material.
For a more complete specification of polymer properties, refer to PTS 30.10.02.13-Gen.
2.2.1 Polyethylene (PE)

PE is the most commonly applied liner material. PE liners shall not be exposed to operating
temperatures above 60 C in water service. In hydrocarbon service (combined liquid and
gas phases), the recommended maximum operating temperature is lower and depends on
the fluid composition but shall not exceed 50 C. If only a liquid phase or a dry gas phase is
present, then a higher temperature (>50C) can be tolerated, but the maximum operating
temperature shall be specified and agreed by the Principal. This reduction in operating
temperature results from small organic compounds diffusing into the PE, causing swelling
and softening. (Table 2.2.1a) lists the recommended maximum operating temperature as a
function of fluid composition.
Table 2.2.1a Maximum operating temperature for PE as a function of fluid
composition
Fluid Composition Temperature (C)
Oil/gas/water mixture 50
Oil/water mixture 50
Gas and condensate 50
Dry gas 60
Water 60
Numerous PE grades are available. The differences between them primarily result from the
polymerisation processes for the production of the base polymer, chemical modifications or
enhancements with additives. Base polymer density is used to indicate PE type. Low,
medium and high-density grades are distinguished as LDPE, MDPE and HDPE. This
PTS 31.40.30.34
January 2011
Page 12
characterisation applies to most vendor data. For lining applications, three types of PE are
used; in increasing order of strength and chemical resistance, they are:
MDPE, used in low-pressure water and gas distribution applications;
HDPE, used in all types of service;
Ultra High Molecular Weight (UHMW-HDPE) used in demanding applications.
MDPE (or PE 80) is a relatively soft grade and is used in (low) pressure applications at
ambient conditions. It has good 50-year creep-rupture performance and is easy to
manufacture (extrude) and install.
HDPE (or PE 100) is the basic engineering grade of PE. Compared to MDPE, it has a
higher yield and ultimate strength, a higher modulus and better chemical resistance. These
improved properties come with the penalty of slightly more difficult extrusion and
installation. However, HDPE is more sensitive to notches and has a lower environmental
stress cracking (ESC) resistance than MDPE.
UHMW-HDPE is developed for aggressive chemical environments and high toughness.
Compared to HDPE it has a higher yield and ultimate strength, a higher modulus and better
chemical resistance. This results in reduced swelling in crude oil and an increased
capability of bridging pinhole leaks in the carbon steel outer pipe. However, these improved
properties come with a penalty of considerably more difficult extrusion and installation.
The above description is for general information only. There is a general trend away from
merely specifying PE grades, and it is recommended to specify the material properties of
PE listed in (Table 2.2.1b) instead.
A summary of typical material properties of PE in ambient conditions is presented in (Table
2.2.1b). This Table is for comparison purposes only. Manufacturers shall submit the
relevant (minimum) material property specifications at the specific service conditions.
Table 2.2.1b "Typical" material properties of PE
Typical properties PE (MD) PE (HD) PE (UHMW)
Density (g/cm3) 0.926-0.94 0.941-0.965 0.989
Tensile properties at
23 C
Yield strength (MPa) 18 25 32
Stress at break (MPa) 20 20 25
Elongation at break >400 >400 >400
(%)
Modulus (MPa) 400 700 1100
Thermal conductivity 0.35 0.4 0.4
(W/m.K)
Coefficient of thermal 200 x 10-6 200 x 10-6 200 x 10-6
expansion
1
(K )
Mechanical properties 23 C 40 C 60 C 23 C 40 C 60 C 23 C 40 C 60 C
(function of
temperature)
Modulus (MPa) 400 250 130 700 450 250 1100 600 400
Poisson ratio 0.35 0.38 0.4 0.35 0.38 0.4 0.35 0.38 0.4
All PE pipe and fittings supplied to this PTS shall be stabilised against degradation by UV-
light in accordance with standard practices by a minimum of 2% (by mass) of Carbon Black
(ASTM D 3350).
A UV stabiliser as specified by ASTM D 3350, code C or D shall be added.
PTS 31.40.30.34
January 2011
Page 13
2.2.2 Polyamide (PA)

PA is a commodity engineering plastic that is more expensive than PE. Therefore, it should
only be considered for application outside the range of PE. PA has excellent resistance to
hydrocarbons but limited resistance to water at elevated temperatures. (Table 2.2.2a) lists
the recommended maximum operating temperature as a function of fluid composition.
Because of the molecular structure of PA, different grades e.g. PA-6 and PA-11, can
essentially be considered as different materials. PA-11 is used as a liner in conventional
flexible flowlines and risers transporting gas and crude with low water cuts. It has good
material properties for liner applications, high modulus and strength, with relatively high
strain to failure in its un-aged condition. It has been used to line carbon steel pipelines at
temperatures up to 75 C.
Table 2.2.2a Maximum operating temperature for PA-11 as a function of fluid
composition
Dry gas 80
Water 75
A summary of typical material properties of PA is presented in (Table 2.2.2b). This Table is

for comparison purposes only. Manufacturers shall submit the relevant (minimum) material
property specifications at the specified service conditions.
Table 2.2.2b "Typical" material properties of PA-11
Typical properties PA-11
Density (g/cm3) 1.04
Tensile properties at 23 C
Yield strength (MPa) 40-60
Stress at break (MPa) 80
Elongation at break (%) >30
Modulus (MPa) 650-1400
Thermal conductivity (W/m.K) 0.25
Coefficient of thermal expansion 100 x 10-6
1
(K )
Mechanical properties (function 23 C 40 C 60 C 80 C
of temperature)
Modulus (MPa) 650 500 400 300
Poisson ratio 0.35 0.36 0.37 0.38
PA liners shall comply with the requirements of ASTM D 4066 and ASTM F 1733.
2.2.3 Polyvinylidenefluoride (PVDF)

PVDF is a fluoropolymer that is more expensive than both PE and PA. Therefore it should
only be considered for applications outside the range of PE and PA, i.e. for hydrocarbon
applications above 80 C and water applications above 60 C. PVDF has excellent
chemical resistance. Superior thermal stability implies that the application envelope in
terms of temperature for PVDF extends well beyond that of PA, up to 120 C for all
applications. (Table 2.2.3a) lists the recommended maximum operating temperature as a
PTS 31.40.30.34
January 2011
Page 14
Table 2.2.3a Maximum operating temperature for PVDF as a function of fluid

composition
Fluid composition Temperature (C)
Dry gas 120
Water 120
PVDF has good mechanical properties. The modulus and yield strength are high but the
yield strain is low. The pure polymer is difficult to extrude and to overcome this, plasticised
grades (both homopolymer and co-polymer) are used, for example as pressure sheaths in
flexible flowlines and risers. Only co-polymer grades of PVDF should be used to minimise
problems associated with leaching out of the plasticiser.
A summary of typical material properties of PVDF is presented in (Table 2.2.3b). This Table
is for comparison purposes only. Manufacturers shall submit the relevant (minimum)
material property specifications at the specified service conditions.
Table 2.2.3b "Typical" material properties of PVDF
Typical properties PVDF (homopolymer) PVDF (co-polymer)
Density (g/cm3) 1.78 1.78
Tensile properties at
23 C
Yield strength (MPa) 55 25
Stress at break (MPa) 40 35
Elongation at break (%) >20 >50
Modulus (MPa) 2200 1000
Thermal conductivity 0.19 0.18
(W/m.K)
Coefficient of thermal 130 x 10-6 140 to 180 x 10-6
1
expansion (K )
Mechanical properties 23 C 40 C 75 C 90 C 120C 23 C 40 C 75 C 90 C 120C
(function of
temperature)
Modulus (MPa) 2200 1750 1000 750 400 1000 650 250 150 110
Poisson ratio 0.35 0.35 0.40 0.45 0.5 0.35 0.35 0.40 0.45 0.5
PVDF liners shall comply with the requirements of ASTM D 3222 and ASTM F 491.
2.2.4 Polypropylene (PP)

PP is a commodity engineering plastic. It is not currently used as a thermoplastic liner
material but has the potential for such use in the future. Although chemically similar to PE,
PP has important mechanical property differences. It can tolerate a higher operating
temperature than PE, and it is not susceptible to ESC. PP has excellent resistance to water
and liquid hydrocarbons, but limited resistance to aromatics. (Table 2.2.4a) lists the
maximum recommended operating temperature as a function of fluid composition.
Table 2.2.4a Maximum operating temperature for PP as a function of fluid
composition
Dry gas 85
Water 85
In general, the mechanical properties of PP, i.e. high modulus and high yield strength with
sufficient strain to failure, are sufficient for liner installations. A summary of typical material
PTS 31.40.30.34
January 2011
Page 15
properties of PP is presented in (Table 2.2.4b). This Table is for comparison purposes only.
Manufacturers shall submit the relevant (minimum) material property specifications at the
specified service conditions.
Table 2.2.4b "Typical" material properties of PP
Typical properties PP
Density (g/cm3) 0.9
Yield strength (MPa) 35
Stress at break (Mpa) 40
Modulus (MPa) 1200
1
(K )
PP liners shall comply with the requirements of the ASTM D 2657, ASTM D 4101 and
ASTM F 492.
2.2.5 Polyphenylene Sulphide (PPS)

PPS is an engineering plastic with a price similar to that of PVDF. It is not currently used as
a thermoplastic liner but has the potential for such use in the future. It has excellent high
temperature properties and should only be considered for applications in the temperature
range of PDVF and beyond. It has good chemical resistance to water, dry gas and most
hydrocarbons, except aromatics. (Table 2.2.5a) lists the recommended maximum operating
temperature as a function of fluid composition.
Table 2.2.5a Maximum operating temperature for PPS as a function of fluid
composition
Dry gas 180
Water 180
There are many different grades of PPS available but because of its molecular structure
PPS shall be plasticised to enable extrusion and to provide the flexibility required to enable
insertion as a liner.
PPS has good mechanical properties, high modulus and strength but a limited strain to
failure. A summary of typical material properties of PPS is presented in (Table 2.2.5b). This
Table is for comparison purposes only. Manufacturers shall submit the relevant (minimum)
material property specifications for the liner material at the specified service conditions.
PTS 31.40.30.34
January 2011
Page 16
Table 2.2.5b "Typical" material properties of PPS
Typical properties PPS

Elongation at break (%) 5
Modulus (MPa) 3800
Coefficient of thermal expansion (K1) 90 x 10-6
Specifications for PPS liners shall be agreed between the Contractor and the Principal.
2.2.6 Cross-linked Polyethylene (PEX)

PEX is an engineering plastic manufactured by cross-linking PE. It is more expensive than
PE. PEX has excellent resistance to hydrocarbons and water at elevated temperatures up
to 85 C. (Table 2.2.6a) lists the recommended maximum operating temperature as a
Table 2.2.6a Maximum operating temperature for PEX as a function of fluid
composition
Dry gas 85
Water 85
The cross-linking of PE implies that PEX is stiffer than PE with a corresponding reduction in
flexibility. For liner applications the material properties, modulus and yield strength are
good, with a strain-to-failure strength sufficient for insertion.
A summary of typical material properties of PEX is presented in (Table 2.2.6b). This Table
is for comparison purposes only. Manufacturers shall submit the relevant (minimum)
material property specifications for the liner material at the specified service conditions.
Table 2.2.6b "Typical" material properties of PEX
Typical properties PEX
Modulus (MPa) 800
1
(K )
Specifications for PEX liners shall be agreed between the Contractor and the Principal.
2.2.7 Polyketone (PK)

Polyketone (PK) is a relatively new thermoplastic polymer. It has good chemical resistance
to both water and hydrocarbons. However, it is susceptible to oxidation and stabilisers shall
PTS 31.40.30.34
January 2011
Page 17
be used to limit degradation. (Table 2.2.7a) presents the recommended maximum

operating temperature as a function of fluid composition.
Table 2.2.7a Maximum operating temperature for PK as a function of fluid
composition
Dry gas 105
Water 105
A summary of typical material properties of PK is presented in (Table 2.2.7b). This Table is

for comparison purposes only. Manufacturers shall submit the relevant (minimum) material
property specifications at the specified service conditions.
Table 2.2.7b "Typical" material properties of PK
Typical properties PK
Elongation at break (%) 350
Modulus (MPa) 1600
Coefficient of thermal expansion (K1) 110 x 10-6
Specifications for PK liners shall be agreed between the Contractor and the Principal.
2.2.8 Other materials

Other thermoplastic materials, e.g. PVC, PTFE or co-extruded liners, i.e. multiple layered
liners made from more than one thermoplastic material, can be considered for liner
applications. If such materials are proposed, the material data supplied by the Contractor
shall at least comprise the data listed in (Tables 2.2.1a and 2.2.1b) and also satisfy the
requirements of (2.4).
PTS 31.40.30.34
January 2011
Page 18
2.3 MATERIAL SELECTION GUIDE

Material selection is a procedure of matching system requirements to the property data of
available materials. The loading conditions should be systemically identified and could
comprise combinations of temperature, pressure, axial load and environment as a function
of time. They are matched to materials property acceptance criteria in the design analysis.
The following strategy facilitates thermoplastic polymer material selection by identifying
acceptance criteria in a structured manner:
1. Define pipeline function and requirements.
2. Identify fixed boundary conditions.
3. Design system and/or analyse design.
4. Define function of the individual components.
5. Identify service conditions of individual components.
6. Identify material requirements to maintain function throughout service life.
7. Identify acceptance criteria.
(Table 2.3) gives an example of the applied loads acting on a thermoplastic liner from
transport from the manufacturing plant through to operation.
Table 2.3 Applied loads acting on the liner system
Mechanical Thermal Environment Duration
loading loading
Transport Handling Ambient, Ambient Weeks
- 40 C /+ 50 C
Storage Stack weight Ambient Ambient Weeks, months
Construction Pull-in, reduction Ambient + friction Lubricant Minutes, hours
Operation Hydrostatic Fluid, operating Fluid, slugs Years
pressure temp.
Mis-operation Vacuum Rapid cool-down Air Days
Removal Pull-out Ambient Residue Hours, days
The material selection process involves matching the material properties of the candidate
thermoplastic liner materials to the loads and boundary conditions listed in (Table 2.3) to
provide the most appropriate material option.
PTS 31.40.30.34
January 2011
Page 19
2.4 MATERIAL TESTING

A full material qualification programme is required to the satisfaction of the Principal, before
the Contractor can start production of the liner. Thermoplastic pipe material shall be
qualified according to API Spec 15 LE. Thermoplastic pipe material qualified to ISO 4427
may also be supplied provided that the following requirements are met: equivalent strength
grade to API Spec 15 LE and elevated temperature characteristics to ISO 4427, Section
4.4, Type A. Changes in the method of manufacture will require additional qualification
tests.
NOTE: API Spec 15 LE and ISO 4427 are specific to PE. However, the general principles of material testing
outlined in both API Spec 15 LE and ISO 4427 are also applicable to other thermoplastics. Specific
temperatures for elevated temperature tests shall be proposed by the Contractor and agreed with the
Principal.
The following list of tests (mechanical, thermal, permeation, compatibility and ageing tests)
represents a complete material qualification programme (Table 2.4). For most applications
only a restricted qualification programme will be required. Additional tests, specific to the
unique operating conditions, shall be agreed between the Contractor and the Principal.
Other standard test procedures may replace those listed in (Table 2.4) on agreement
between the Contractor and the Principal. (Table 2.4) also indicates for which applications
the tests are required along with the purpose of the tests.
A chemical analysis of the compounds comprising the thermoplastic pipe material shall be
available for review by the Principal.
PTS 31.40.30.34
January 2011
Page 20
Table 2.4 Standard test procedures required in the materials qualification procedure
Characteristic Applications Tests Test Purpose Comments
procedure
Mechanical/ All applications Creep modulus ASTM D2990 Collapse calculation
physical properties
Yield strength/elongation ASTM D 638 Installation requirement
Ultimate strength/elongation ASTM D 638 Installation requirement
Stress relaxation properties ASTM E 328 Installation requirement or ISO 527 R
Modulus of elasticity ASTM D 790 Collapse calculation or ISO 868
Hardness ASTM D 2240 QA/QC or ISO 180
Impact strength ASTM D 256 QA/QC
Abrasion resistance ASTM D 4060 Flow conditions or ASTM D 1044
Density ASTM D 792 QA/QC or ASTM D 1505
Notch sensitivity ASTM D 256 Defect assessment and QA/QC
Thermal properties All applications Coefficient of thermal expansion ASTM E 831 Installation requirement and collapse
assessment
Melt flow index ASTM D 1238 QA/QC ISO 1133
Heat distortion temperatures ASTM D 648 QA/QC upper temperature limit Method A
Brittleness temperature ASTM D 746 QA/QC lower temperature limit Or glass transition temperature
(ASTM E 1356)
Permeation/ Only if gas phase present Fluid permeability See (2.4.1) Collapse calculation venting rates For gas phase components at
Characteristics design conditions
Blistering resistance See (2.4.2) No blistering for gas phase At design conditions
components
Compatibility and Only if gas phase present Ageing test See (2.4.3) Degradation in modulus collapse
ageing calculation
All applications Swelling test See (2.4.4) Collapse calculation
Environmental stress cracking ASTM D 1693 QA/QC durability Method C. For PE only
Weathering resistance ISO 4427 QA/QC only if liner exposed Effectiveness of UV stabiliser
PTS 31.40.30.34
January 2011
Page 21
2.4.1 Fluid permeability test

The following conditions shall apply as a minimum for the fluid permeability test:
a) Test sample shall be taken from the extruded polymer.
b) Minimum sample thickness is 1 mm.
c) Minimum sample diameter is 50 mm.
d) A sufficient number of tests shall be performed to allow for linear interpolation of the
results as a function of temperature.
The procedure for the fluid permeability test may be to pressurise one side of the
specimen and measure fluid flow at the other side when steady state flow conditions are
reached. Alternatively, the test can be performed with the same absolute pressure on both
sides using the partial pressure of the component gas as the driving force.
The purpose of the permeability test is to provide an estimate of the gas permeation rate
into the annulus and is for information only. Therefore this test is only necessary if a gas
phase is present.
2.4.2 Blistering resistance test

Blistering resistance tests shall reflect the design requirements along with fluid conditions,
pressure, temperature, and number of decompressions and decompression rate. As a
minimum, the following conditions shall apply:
a) Only gas components of the specified environment shall be used.
b) Conditioning time shall be sufficient to ensure full saturation.
c) Number of decompressions should be a minimum of 20 cycles or the number expected
in practice.
d) The decompression rate should be the expected rate, otherwise a minimum 70 bar per
minute should be used (from design pressure to zero).
e) Sample thickness shall be the same as the wall thickness of the liner.
f) The expected decompression temperature shall be used.
g) The design pressure shall be used as a minimum.
The test procedure is that after each depressurisation the sample shall be examined at a
magnification of 20 times for signs of blistering, swelling and slitting. The acceptance
criterion is that no blister formation or slitting is observed.
2.4.3 Ageing test

The Contractor shall have either documented test data of the samples aged in the service
environment according to ASTM C 581, or ageing prediction models for the thermoplastic
polymer. The fluid used in ageing tests shall be representative of the service conditions
fluid. Materials that will be subjected to tensile or compressive loads in service shall be
tested under equivalent stress conditions.
The ageing model shall be based on testing and experience and shall predict the ageing or
deterioration of the polymer under the influence of environmental and load conditions that
represent the service conditions. As a minimum, polymer-ageing models shall consider
temperature, chemical environment and mechanical load. Special attention should be
given to de-plasticisation, fluid adsorption and changes in dimensions. Creep and stress
relaxation shall be investigated on aged and un-aged samples.
Ageing may be determined from changes in either specified mechanical properties or in
specified physico-chemical characteristics which includes reduction in the plasticiser (if
relevant) content of the material.
The purpose of the ageing test to provide the elastic modulus and yield strength and strain
for the material aged in the flow conditions.
2.4.4 Swelling test

The following conditions shall apply for the swell test procedure:
PTS 31.40.30.34
January 2011
Page 22
5 cubic specimens, each approximately 125 mm3, shall be machined from a sample of
the actual thermoplastic liner.
Specimen dimensions shall be recorded to the nearest 0.01 mm.
Specimen weight shall be recorded to the nearest 0.001 g.
3
The samples shall be exposed to 500 cm of the liquid hydrocarbon mixture of the pipeline
fluid for 500 h and at the design temperature in a sealed container.
After exposure, the dimensions and weights shall be recorded to the same accuracy as the
pre-expose samples.
Linear swell of the liner, swell (%), is related to the volumetric swell and shall be calculated
as follows;
where the volumetric swell of the sample, Vswell, is defined as:

PTS 31.40.30.34
January 2011
Page 23
2.5 END CONNECTORS

Steel flange material shall comply with the requirements of PTS 31.40.21.34-Gen.
Thermoplastic flange material shall be the same as the liner.
Retainer rings shall be made from ASTM A 106 grade B or equivalent material. Bolts shall
be ASTM A 193 grade B7. Nuts shall be ASTM A 194 grade 2H.
PTS 31.40.30.34
January 2011
Page 24
3. DESIGN
3.1 INTRODUCTION
The Contractor shall be responsible for the design of the liner system and shall take into
account the selected installation method and service requirements.
Thermoplastic liners in carbon steel pipelines can fail due to (in no order of preference):
Environmental stress cracking.
Collapse of the liner due to pressure build-up in the annulus between the liner and the
carbon steel pipe. Gases can permeate through certain thermoplastics and can
accumulate in the annulus. During depressurisation of the pipeline, expansion of this
accumulated gas may cause collapse of the liner.
Excessive material shrinkage.
Buckling due to excessive swelling.
Lack of strength (short term but also long term after ageing).
Cracks due to lack of liner impact resistance or prior exposure to UV light.
Material defects.
Construction defects (gouges, scores).
End termination failures due to creep.
Factors that influence such failures include:
Choice of liner material (amounts and type of thermoplastic, fillers and plasticisers,
anti-oxidants, UV stabilisers).
Thickness of liner.
Quality assurance and control during manufacturing, fabrication and installation.
Exposure to UV light prior to installation.
Installation method used and tightness of fit inside the carbon steel pipe line.
Fluid composition (incl. inhibitors, chemicals, etc.).
Minimum and maximum operating temperatures.
Rate of depressurisation.
Spacing of vent points.
Frequency of venting.
For liners in hydrocarbon service, factors such as stress relaxation, loss of plasticiser,
permeation and absorption of gases and liquids into the polymer should be taken into
account.
The design procedure for a thermoplastic liner consists of determining the thickness to limit
both stress and strain to acceptable levels and to prevent collapse. Factors such as creep
rate, permeation rate and ESC should also be considered, particularly in terms of how they
are affected by liner wall thickness. The outside diameter of the liner shall be determined
taking into account the inside diameter of the carbon steel pipe, the requirements of the
installation technique and handling and storage requirements. Thermoplastic liners often
have to be tailor-made to the application implying that often non-standard dimensions are
used.
PTS 31.40.30.34
January 2011
Page 25
3.2 MINIMUM LINER THICKNESS

For water service the minimum thickness shall be 5 mm to avoid difficulties in installation
and fusion bonding. For hydrocarbon service a thicker liner shall be used as determined by
the procedure given in (3.3).
PTS 31.40.30.34
January 2011
Page 26
3.3 LINER DESIGN PROCEDURE

The calculation for the required wall thickness of the liner is determined from three
conditions: handling and storage (A), installation (B) and collapse (C). The greatest
thickness calculated from requirements (A), (B) and (C) is taken as the design wall
thickness. For requirement (C) it is conservatively assumed that the pressure in the
annulus is the same as the bore pressure.
A flow diagram visualising the design process is presented in (Figure 3.3). The Contractor
shall supply to the Principal the liner design sheet in Appendix 3 as part of the tender
documentation.
The liner design procedure for determining wall thickness is described in the following
steps:
1. Determine the liner outer diameter taking into account both the inside diameter of the
carbon steel pipe and the requirements of the installation technique.
2. Determine the wall thickness from handling and storage requirements (3.3.1).
3. Determine the wall thickness from installation requirements (3.3.2).
4. Select the larger wall thickness from steps 2 and 3.
5. Select the modulus of the thermoplastic material and swelling strain for the service
conditions.
6. Calculate the liner fit depending on the chosen installation technique (3.3.3.1).
If no gases are present, then go to step 9.
7. Calculate the collapse pressure from (3.3.3.2), (3.3.3.3) or (3.3.3.4) as appropriate,
depending on liner fit. Include liner swell if appropriate.
8. Determine the design pressure (including safety factor) and maximum operating
pressure for either the "intrinsically safe" or "allowance for gas expansion" design
procedure (3.3.4).
If no liquids are present, then go to step 10.

9. If the liquid service conditions result in liner swell, then calculate the collapse
resistance of the liner (3.3.5).
10. Correct the wall thickness to compensate for any reduction of liner wall thickness
during installation.
11. If the collapse resistance of the liner is not sufficient then repeat steps 5 to 10 with an
increased liner wall thickness.
The output of successful completion of steps 1 to 11 is the required liner wall thickness,
sufficient to withstand the requirements of handling and storage, installation and collapse.
Once the required liner wall thickness has been determined, a final check shall be made to
ensure that the resulting liner internal diameter does not have an unacceptable impact on
the pipeline hydraulics i.e. pressure drop and fluid velocities (6.4).
In this design procedure it is assumed that the annular volume is not vented.
(Table 3.3) summarises the design procedure for determining the thickness of a liner as a
function of fluid type and tightness of liner fit.
PTS 31.40.30.34
January 2011
Page 27
FIGURE 3.3 LINER DESIGN PROCESS

PTS 31.40.30.34
January 2011
Page 28
Table 3.3 Design procedure as a function of fluid type and tightness of fit
Fluid type Tightness of fit Design procedure
Water Loose, partially Liner thickness determined from maximum of
loose, tight handling or storage (3.3.1) and installation (3.3.2)
requirements
Liquid Loose, partially Liner thickness determined from maximum of
hydrocarbons loose, tight handling and storage (3.3.1) or installation (3.3.2)
requirements or swelling (3.3.5)
Gas, liquid Loose Liner thickness determined from maximum of
hydrocarbons handling and storage (3.3.1) or installation (3.3.2)
and water requirements or collapse (3.3.3.2)
mixtures
Gas, liquid Partially loose Liner thickness determined from maximum of
mixtures
Gas, liquid Tight Liner thickness determined from maximum of
mixtures
3.3.1 Liner thickness - handling and storage
To maintain roundness of the liner and dimensional stability during storage, possibly for
several months and to minimise distortion during handling, Manufacturers recommend a
minimum Standard Dimension Ratio (SDR) ranging from 26 to 17.
A minimum SDR of 26 is recommended for less onerous applications, although in
consultation with the Manufacturer a thinner liner may be used. For all other applications
an SDR of 17 is recommended.
3.3.2 Liner thickness installation

Liners are installed by pulling a pre-fabricated length of thermoplastic pipe into the carbon
steel outer pipe.
The axial stress carried by the liner shall be limited to 50% of the tensile yield strength of
the thermoplastic polymer. The pulling load consists of the friction load of dragging the
liner into the carbon steel pipe, the deformation load, which is a function of the installation
technique, plus friction loads due to pipe bends etc. (3.5).
3.3.3 Liner thickness - collapse
3.3.3.1 Liner fit

Collapse of a liner can occur if, during normal operation, gases within the bore of the
pipeline permeate into the annulus volume between the liner and the host carbon steel
pipe. Depressurising the pipeline, e.g. for maintenance, can cause the liner to collapse if
the wall thickness is not sufficient. If only liquids are present in the pipeline, e.g. in water
injection lines, then collapse due to gas expansion cannot occur. However, liquids can be
absorbed in the liner causing swelling. Excessive swelling can also cause the liner to
collapse.
The pressure required to cause collapse of the liner is dependent on the installation
technique or more precisely the liner fit within the outer steel pipe. (Table 3.3.3.1)
distinguishes liner fit for the different installation techniques into three categories: loose,
partially loose and tight.
PTS 31.40.30.34
January 2011
Page 29
Table 3.3.3.1 Categories of liner fit as a function of installation technique

Installation technique Category of liner fit
Slip lining (no grout) Loose
Folded pipe, Slip lining (with grout) Partially loose
Swagelining, Roll-down, Tite liner Tight
The definition of liner fit is based on the constant, C, defined as:
where (mm) is the difference between the inner radius of the carbon steel pipe and the
outer radius of the thermoplastic liner. The following inequalities define the liner fit:
where,
t= liner wall thickness (mm)
R= average radius of the liner (mm) defined as
where the subscripts o and i refer to the outer and inner radius of the thermoplastic liner
pipe.
3.3.3.2 Loose fitting liners

When the outer steel pipe provides no restraint during collapse, the fit of the liner is
defined as loose and the collapse pressure, Pc (bar), is given by:
where,
E= liner Youngs modulus (MPa)
= liner Poisson ratio
3.3.3.3 Partially loose fitting liners

When the outer steel pipe provides partial restraint during collapse, the fit of the liner is
defined as partially loose and the collapse pressure, Pc (bar), is given by:
3.3.3.4 Tight fitting liners

When the outer steel pipe provides restraint during collapse, the fit of the liner is defined as
tight and the collapse pressure, Pc (bar), in the absence of swell is given by:
If liquids present in the service conditions cause swelling of the liner, then the collapse
pressure, Pc (bar), is given by:
PTS 31.40.30.34
January 2011
Page 30
where,
swell = Liner swell (%), (refer 2.4.4)
NOTES: 1. Liner swell is defined as the average swell across the liner thickness.
2. The modulus used in the above Sections should be representative of the thermoplastic polymer
material at the design temperature and include allowance for any possible reductions or
increases due to chemical absorption or de-absorption. The visco-elastic nature of some
polymers may also need to be considered.
3.3.4 Design pressure of pipeline

The design pressure, Pdes, of the pipeline is defined as the maximum operating pressure,
Pmop, multiplied by a safety factor, J:
A safety factor, J, of 1.33 is recommended.
3.3.4.1 Intrinsically safe

If the collapse pressure, Pc, of the liner calculated from (3.3.3.1) to (3.3.3.4), is less than
the design pressure, Pdes, of the pipeline, then the liner wall thickness is not sufficient to
prevent collapse. If it is greater, then the liner will not collapse. The following inequality
defines the intrinsically safe design pressure procedure:
3.3.4.2 Allowance for gas expansion

In (3.3.4.1) it is implicitly assumed that there is an infinite supply of gas to the annulus to
drive the collapse process. In reality there is a finite volume of gas in the annulus. It is
possible to account for the expansion of the gas during collapse. However, the initial
volume of the annulus is required. It may not be possible to accurately determine this initial
volume.
The following provides a simplified guide to determining initial annular volume as a function
of the liner fit.
For a loose fitting liner the initial volume, Vinit (mm3/mm), is:
where,
Rs = Inside radius of the steel pipe (mm)
For a partially loose fitting liner, the initial volume is;
For a tight fitting liner it is conservatively assumed that the annulus volume is proportional
to the surface roughness of the outer steel pipe. The initial volume is given by:
where,
= Surface roughness of the steel pipe (mm).
NOTE: Determining the initial volume is imprecise due to the uncertainties in the actual situation. It is
therefore recommended that conservative estimates of Vinit be taken if gas expansion is allowed for
in this way.
The volume of annulus at collapse Vc (mm3/mm) is given by:

PTS 31.40.30.34
January 2011
Page 31
During the collapse process the product of annulus pressure times annulus volume
remains constant. If the collapse pressure, Pc, calculated from (3.3.3.1) to (3.3.3.4), times
the annulus volume at collapse, Vc, is less than the design pressure, Pdes, of the pipeline
times the initial annulus volume at collapse, Vinit, then the liner wall thickness is not
sufficient to prevent collapse. If the product is greater then the liner will not collapse. The
following inequality defines the allowance for gas expansion procedure:
3.3.5 Swelling
If the pipeline fluids are liquid then a possible collapse mechanism can be driven through
swelling of the liner. For example, PE can swell by up to 10% in certain hydrocarbon
environments (aromatics). To prevent the liner from collapsing due to swelling only, then
the following design inequality formula shall be used to determine if the liner wall thickness
is sufficient to prevent liner collapse (refer 2.4.4):
NOTE: Swell is defined as the average swell across the liner thickness.
If there is a possibility of the liner swelling while gas is present in the pipeline fluids, then
(3.3.3) shall be used to determine the collapse pressure.
PTS 31.40.30.34
January 2011
Page 32
3.4 VENT POINT DESIGN

All thermoplastic lined pipelines shall incorporate vent points unless otherwise agreed by
the Principal. The vent point assembly shall ensure venting of gases from the annulus
throughout the service life of the pipeline. The assembly shall include a valve to allow
closure of the vent. The design of the vent point assembly shall be proposed by the
Contractor and agreed with the Principal. The minimum number of vent points shall be one
at each flanged end of a section of lined pipe. The vent points have three functions:
To vent (ambient) gas and/or fluids from the annulus during installation.
To vent the permeated gas accumulated in the annulus to prevent collapse.
To allow monitoring of the liners integrity.
Vents can be designed to be:
Continuously closed (plugged)
Valved (closed or open during normal operation)
For water injection lines venting during operation is not necessary and therefore vents are
normally plugged. Lines transporting multi-phase hydrocarbons with H2S concentrations
3
lower than 50 ml/m can have continuously open vents (vents shall be valved in order to
be able to close the annulus in case of liner leakage or collapse). For gas transport and for
H2S concentrations of 50 ml/m3 and higher, vents will have to be opened and closed on a
periodic basis after consultation with the local HSE regulator.
There are two strategies to determine the spacing between vent points:
1. Minimum vent point spacing - determined from the lined pipe section length, i.e. one
vent at each flanged end. This vent point spacing is suitable for:
- intrinsically safe designed liners (3.3.4.1);
- water service;
- stabilised dead crude oil or oil/water mixture service.
2. Calculated vent point spacing - determined from (3.4.1). This spacing is required for
critical applications defined as:
- gas service;
- live crude service;
- multiphase service.
NOTE: Due to uncertainties in estimating the initial annulus volume it is recommended when calculating the
vent spacing to choose the most conservative gap between the liner and the outer steel pipe.
3.4.1 Vent point spacing

The requirement for additional vent points shall be determined as follows.
During the collapse sequence, the instantaneous product of annulus volume, V, and
pressure, P, remains constant (assuming the annulus temperature remains constant), i.e.:
where Pinit is the initial pressure in the annulus. The other terms are defined in (3.3). The
units for pressure and volume are (bar) and (mm 3) respectively.
The initial volume may be difficult to accurately determine. (3.3.4.2) provides a guide for
estimating this initial volume as a function of liner fit. Summarising (3.3.4.2), the initial
volume per unit length of the lined pipe (mm3/mm) is given by;
where = gap between the liner and the steel pipe (mm).
The initial annulus volume, Vinit (mm3), is determined from the product of the vent point
spacing, Lvent (mm), and the initial volume per unit length, Vinit/L, (3.3.4.2) and is given by:
The annulus volume at collapse per unit length Vc/L (mm3/mm), is given by:
PTS 31.40.30.34
January 2011
Page 33
To calculate the collapse volume, Vc (mm3) at collapse, the following assumptions are
made to determine the axial collapse length, Lc:
axial profile of the collapsed liner is triangular;

radial liner profile remains similar;
collapse length, Lc (mm), extends over 5 times the diameter of the liner, i.e.
Under these assumptions the total critical volume at collapse, Vc (mm3), is:
Using values of Pinit, Vinit, Pc and Vc, defined above, the vent point spacing, Lvent (mm), is
given by:
It is assumed (conservatively) that the initial pressure in the annulus, Pinit is equal to the
bore pressure.
A sensitivity analysis with respect to the influence of initial annulus gap size, (mm), on
the vent point spacing, Lvent, shall be performed.
PTS 31.40.30.34
January 2011
Page 34
3.5 PULL-IN LOADS AND INSERTION LENGTH

The pull-in load, Fpull (N), for a thermoplastic liner is calculated from the sum of three force
components: Ffriction, the friction load from dragging the liner into the steel pipe, Fbend, the
additional friction loads caused by bends etc. and Freduce, the load applied to the liner from
the installation technique:
The calculation procedure for determining the maximum loads and stresses acting on the
liner during installation shall be as outlined in this Section. If the Contractor wishes to use
an alternative procedure this shall be submitted to the Principal for agreement.
3.5.1 Friction load, Ffriction
The friction load contribution to the overall liner pull-in load is derived from two
components. One component is due to the weight of the liner and the associated friction
factor, the other is due to superficial damage to the outside of the thermoplastic liner, i.e.:
where Lliner is the length of liner (m) to be installed and W is the weight of the liner per unit
length (N/m). f is the friction factor and for new pipelines is taken as 0.4. For retro-fitting,
higher friction factors may be required to simulate the surface roughness of the pipe. If the
installation procedure includes liner lubrication then f should be reduced to 0.1.
Fscore is generally zero, unless otherwise quoted by the installer.
3.5.2 Bending load, Fbend
The bending load is defined as a function of the pull-in load, the friction factor and the
angle of the bend:
where f is the friction factor, Fpull (N) is the pull-in load and is the bend angle (radians).
3.5.3 Reduction load, Freduce
The reduction load, Freduce (N) is a function of the installation technique. For each
installation technique a reduction pressure, Preduce (MPa), is quoted and the reduction load
is derived by multiplying this pressure by the cross-sectional area of the liner:
where t (mm) is the liner wall thickness and D (mm) is the internal diameter of the steel
pipe. For the different installation techniques (Table 3.5.3) lists the reduction pressure.
Table 3.5.3 Reduction pressure as a function of installation technique
Installation technique Reduction pressure
(MPa)
Slip-lining 0
Roll-down 0
Tite-lining 5
Swage-lining 5
3.5.4 Total pull-in load and maximum installation length
The total pull-in load, Fpull (N), is calculated from the individual load components described
in (3.5.1) to (3.5.3).
The maximum allowable tensile load on the liner is limited to 50% of the tensile yield
strength, yield (MPa).
PTS 31.40.30.34
January 2011
Page 35
3.6 DESIGN OF END CONNECTORS
3.6.1 General
The Contractor shall select the end connection and shall submit this for approval to the
Principal. The Contractor shall demonstrate by means of a qualification test that the end
connections meet the same operational requirements as the thermoplastic liner. The
design shall account for shrinkage, creep, ageing of the thermoplastic material and
operational pressure fluctuations.
In general, only flanged connections shall be considered for termination at the ends of
pipeline sections, see (Figure 3.6.2) for typical arrangement. Screwed connectors shall not
be allowed. Compression-type fittings may be allowed for in-situ retro-fitting. An example
of a compression type fitting is presented in (Figure 3.6.1).
FIGURE 3.6.1 TYPICAL THERMOPLASTIC LINER COMPRESSION JOINT
3.6.2 Flange type connections

The carbon steel parts of flanged type connections shall comply with the general
requirements of PTS 31.40.21.34.Gen.
PTS 31.40.30.34
January 2011
Page 36
FIGURE 3.6.2 TYPICAL THERMOPLASTIC LINER FLANGE CONNECTION
The inside diameter of the steel flange shall be identical to that of the carbon steel pipeline.
The outside diameter of the thermoplastic flange face shall have the same diameter as the
raised face of the carbon steel flange.
The liner weld shall be made by butt fusion welding. If the liner has been pulled in from the
other end, then the flange shall be welded to the liner before the axial tension is released.
The thermoplastic flange shall be made from the same material as the liner and have the
same internal diameter as the liner. The minimum length of the flange shall be 150 mm.
The steel retainer rings shall be such that they fit between the thermoplastic flange and
inside the bolt circle of the steel flanges.
PTS 31.40.30.34
January 2011
Page 37
4. MANUFACTURE OF THE THERMOPLASTIC LINER
4.1 PROCESS OF MANUFACTURE

The thermoplastic liner shall be manufactured by extrusion. Extrusion involves melting,
converging and forming the thermoplastic into a tubular product.
Other manufacturing processes shall not be used by the Manufacturer to produce the
thermoplastic liner unless agreed by the Principal.
Only virgin polymers shall be used for the production of the liner, with a maximum of
0.2% wt of additives. Use of reworked (or re-cycled) materials shall not be permitted. The
use of colouring agents should be avoided. A larger quantity of additives may be added if
electrically conductive properties are required.
Manufacturing of the liner shall not proceed until the material qualification programme has
been completed to the full satisfaction of the Principal.
The Contractor shall be responsible for the manufacturing of the liner
The Contractor shall complete the data sheets in Appendix 4 and supply these as part of
the tender documentation. The data provided by the Contractor shall be used as baseline
data for the QC requirements (Section 4.4.4.3)
4.1.1 Flange material

Flanges shall be moulded or machined from extruded material and shall be from the same
material as the pipe. The wall thickness of the flanges shall be equal to the wall thickness
of the pipe. Flared flanges may be used only for limited lengths which cannot be fitted with
fused flanges, and only with the approval of the Principal.
4.1.2 Rotational moulded spools

Rotational moulded spools may be used only with the approval of the Principal. The
material used shall have minimum material properties provided by the Contractor as listed
in Appendix 4 unless otherwise agreed with the Principal.
The wall thickness of the liner in the spools should be equal to the minimum wall thickness
determined in (Section 3.3)
NOTE: There is a maximum wall thickness which can be rotationally moulded.
There shall be no reliance on adhesion of the polymer to the steel surface. For live crude
or gas service, vents shall be provided on the spool pieces.
4.2 FINISH AND WORKMANSHIP
4.2.1 Pipe ends

Pipe ends shall be plain and square. Cut pipe ends shall be clean without ledges, shaving
tails, burrs or cracks. The interior of the pipe shall be blown or washed clean of cuttings
and shavings.
4.2.2 Finish
The internal and external surfaces of the plastic liner shall be free from defects such as
blisters, cracks, scratches, dents, nicks or sharp tool marks which can affect the
performance of the liner. Absence of these defects shall be determined visually or with a
liquid penetrant.
4.2.3 Microscopic examination

Microscopic examination at 10 times magnification or visual examination by means of
transmitted light shall show no voids, foreign inclusions or other internal defects which
affect the performance of the liner. For alternative non-destructive testing techniques the
Principal shall be consulted.
PTS 31.40.30.34
January 2011
Page 38
4.3 DIMENSIONS, WEIGHTS AND TOLERANCES
4.3.1 Size, tolerances

Pipe furnished to this PTS shall comply with the dimensions and tolerances given in Table
3 of API Spec 15 LE or Tables 3 to 6 of ISO 4427.
The Contractor shall specify nominal values of liner outside diameter and wall thickness.
Tolerances on the outside diameter are listed in (Table 4.3.1):
Table 4.3.1 Tolerances on liner outside diameter
Liner Nominal Diameter Minimum diameter Maximum diameter
(ND)
ND 60 mm - 0 mm + 0.5 mm
60 < ND 114 mm - 0 mm + 1 mm
ND > 114 mm - 0 mm + 0.01*ND
The tolerance on the liner wall thickness shall be -0%/+5% of the specified value.
4.3.2 Length of liner pipe joints

The length of individual joints of liner pipe shall be as long as possible, to minimise the
number of field welds, consistent with transportation, handling and any other project
constraints.
No jointers (two pieces fused together to make a length) shall be permitted.
The average, maximum and minimum liner joint lengths shall be agreed between the
Contractor and the Principal.
4.3.3 Ovality and out-of-roundness

The ovality of the pipe shall not exceed 5% when measured in accordance with
ASTM D 2513.
During production both ovality and out-of-roundness shall be monitored and recorded at
the frequencies specified in (Table 4.4.4.3).
4.4 QUALITY PROGRAMME
4.4.1 Quality Manual

The Manufacturer shall maintain a Quality Manual which describes the quality programme.
All prior revisions shall be retained for a period of not less than five years.
4.4.2 Process and quality control requirements

The Quality Manual shall include a documentation programme to assure communication of
approved manufacturing and inspection procedures to qualified receiving, manufacturing
and quality control personnel. The Quality Manual shall be submitted to the Principal for
review and approval, and shall cover at least the following aspects:
raw material acceptance;
extrusion procedures;
pipe manufacturing practices;
welding procedures and qualifications;
inspection and test procedures;
acceptance criteria;
repair procedures.
4.4.3 Quality control equipment

Equipment used to inspect, test or examine material shall be calibrated at specified
intervals in accordance with the Manufacturers Quality Manual and consistent with
referenced industry standards.
PTS 31.40.30.34
January 2011
Page 39
4.4.4 Quality control tests
4.4.4.1 Conditioning
Unless otherwise specified, all Quality Control (QC) specimens shall be conditioned for a
minimum of 4 hours prior to test in air or 1 hour in water at 23 C 2 C.
When conditioning is required for witness tests the specimens shall be conditioned in
accordance with Procedure A of ASTM D 618 at 23 C 2 C and at an agreed level of
relative humidity and conditioning time.
4.4.4.2 Test conditions

Tests shall be conducted at the Standard Laboratory temperature of 23 C 2 C unless
otherwise specified in the test methods.
4.4.4.3 Material property requirements and frequency

This PTS adopts periodic sampling to determine batch quality control. The Manufacturer
shall be responsible for ensuring that all pipes meet the specified requirements.
Acceptable QC shall be demonstrated by successfully completing the tests listed in (Table
4.4.4.3) of API Spec 15 LE at the specified frequency. Where the Manufacturer has agreed
to the supply of pipe produced to ISO 4427, the equivalent quality control tests prescribed
by ISO 4427 shall be applied.
NOTE: API Spec 15 LE and ISO 4427 are specific to PE. However, the general principles of quality control
through material testing outlined in both API Spec 15 LE and ISO 4427 are also applicable to other
thermoplastics. Minimum strength and specific temperatures for elevated temperature tests shall be
proposed by the Contractor and agreed with the Principal.
The melt flow rate shall not deviate by more than 30% from the value specified by the
Manufacturer. The change in melt flow rate caused by processing, i.e. the difference
between the measured value for material from the pipe and the measured value for the
compound, shall not be more than 25%.
PTS 31.40.30.34
January 2011
Page 40
(Table 4.4.4.3) lists the quality control tests that are required along with the appropriate
standard test procedure, testing frequency and acceptance criterion. The total number of
QC tests shall be agreed between the Contractor and the Principal.
Table 4.4.4.3 QC requirements on material properties during production
Property ASTM Acceptance criteria Frequency
Outside diameter D 2122 API Spec 15 LE, Table 3 Once every hour or once
Wall thickness D 2122 API Spec 15 LE, Table 3 every coil, whichever is
Burst pressure (up D 1599 To be agreed between less frequent
to 100 mm diameter) Contractor and Principal
Strength (Over 100 D 2122 To be agreed between
mm diameter) Contractor and Principal
Hydro-test See 4.4.4.4 Once every coil
Out of roundness D 2122 < 5% of quoted value Once per lot (production
Ovality D 2122 < 5% of quoted value run)
Density D 1505 < 2% of quoted value
Melt flow rate D 1238 < 30% of quoted value
Modulus D 638 < 5% of quoted value
ESC resistance D 1693 < 5% of quoted value
Carbon black D 1603 2% min. unless otherwise
agreed.
For quoted values refer to (Section 4.1)
4.4.4.4 Hydro-testing
Liner pipe sections shall not show any sign of leakage (burst or weep) or ballooning when
subjected to a hydrostatic pressure test. The hydrostatic test pressure shall be agreed
between the Principal, Contractor and Manufacturer and is maintained for at least 3
minutes. As a guide the test pressure should be 1.5 times the rated pressure for the
stand-alone thermoplastic pipe.
Failure is defined as:
Ballooning Any abnormal localised expansion of a pipe specimen while under
internal hydraulic pressure.
Burst Failure by a break in the pipe with immediate loss of test liquid and
continual leakage of test liquid independent of applied pressure.
Weep Failure that occurs through microscopic breaks in the pipe wall,
frequently only at or near the test pressure. At lower pressures, the
pipe may maintain its integrity.
4.4.4.5 Retest and rejection

If a sample fails to meet any of the QC requirements, additional tests shall be made on the
previously produced samples back to the previous acceptable sample. Pipes produced in
the interim that do not pass the requirements shall be rejected. Testing frequency shall be
every 10th pipe back to the previously acceptable sample.
4.4.5 Inspection and rejection
4.4.5.1 Inspection by the Principal

All Quality Control tests shall be witnessed by an Inspector approved by the Principal at
the start of production and monitored thereafter at the Principals discretion.
4.4.5.2 Significant defects

Significant defects are those which adversely affect the service life of the liner pipe, e.g.
inclusions, bends, dents, scratches, visible cracks, foreign material contaminants or any
other imperfection reducing the wall thickness below minimum acceptable limits (4.3.1).
Material which contains significant defects on inspection shall be rejected.
Significant defects include:
PTS 31.40.30.34
January 2011
Page 41
Scratches in pipe: Surface scratches and nicks in thermoplastic liner may not exceed a
depth of 5% of the nominal wall thickness.
Scratches in flanges: thermoplastic flange surfaces shall be free of scratches and nicks.
Bends: bend angles in thermoplastic liner pipes shall not exceed 5. Bend radii shall not be
less than 5 times the nominal liner diameter.
Dents: The maximum depth shall be the lower of 6.5 mm or 2% of the pipe OD.
4.4.5.3 Repair of defects

Repair of defects is not permitted.
4.4.6 Quality control records requirements
4.4.6.1 Purpose
Quality control records are necessary to substantiate that all pipe manufactured to this
PTS conforms to the specified requirements.
4.4.6.2 Records control

Quality control records required by this PTS shall be legible, identifiable, retrievable
and protected from damage, deterioration or loss.
Quality control records required by this PTS shall be retained by the pipe supplier and
Contractor for a minimum of five years following the date of manufacture.
All quality control records required by this PTS shall be signed and dated by the pipe
supplier's designated authorised person.
4.4.6.3 The following records shall be maintained and supplied by pipe supplier:
1. Quality manual in accordance with (Section 4.4.1).
2. Quality control test results in accordance with (Section 4.4.4).
3. Design and material qualification data in accordance with (Section 3.1) and
(Section 4.1).
4. All procedures utilised by the pipe supplier in the process of fulfilling the order
5. Quality assurance records for all materials supplied by the pipe supplier.
4.5 EQUIPMENT MARKING

Pipe shall be marked by the Manufacturer as follows:
The markings on each length of pipe or fitting shall include in any sequence:
Manufacturer's name or trademarks;
base specification shown on purchase order, e.g. API Spec 15 LE or ISO 4427;
nominal pipe size;
date of manufacture;
SDR;
appropriate material code;
Manufacturer's lot number;
additional markings, as agreed between the Manufacturer, Contractor and Principal.
Pressure rating shall not be marked on the pipe.
The markings on pipe shall be paint stencilled or printed on the outside surface at intervals
of not more than 1.5 m or on each fitting. Indentation marking may be used provided:
The marking does not reduce the wall thickness to less than the minimum value.
The marking has no effect on the long-term strength.
PTS 31.40.30.34
January 2011
Page 42
4.6 HANDLING AND STORAGE
4.6.1 Storage
Coils shall be stored stacked flat one on top of another. Straight lengths shall be stored on
horizontal racks and given support to prevent damage. In either storage form, pipe shall
not come into contact with hot water or steam and shall be kept away from hot surfaces.
Coils containing pipes of diameters greater than 1.5 inches (38 mm) and larger shall not be
stored on edge.
Pipe shall be covered with adequate protection from direct sunlight. If the pipe has to be
stored in the open air before, during or after shipment, it shall be protected from
environmental contamination.
Pipe end covers shall be used to prevent ingress of moisture or dirt to the inside of the
pipe.
4.6.2 Handling
All pipes shall be cleaned, dried and packed before handling and transportation.
Thermoplastic pipe can be susceptible to damage by abrasion and by sharp objects.
Dragging pipe sections or coils over rough ground shall not be permitted. If, due to
unsatisfactory storage or handling, a pipe is damaged it shall be rejected.
4.6.3 Transportation
The minimum requirements for transportation shall be as specified in the following:
API RP 5L1 for railroad transportation;
API RP 5LW for marine transportation.
Pipe transported by sea shall not be shipped as deck cargo.
4.6.4 Coiling
Coil diameter should be sufficiently large to prevent excessive strain being applied to the
pipe. The minimum recommended inside coil diameter shall be determined by:
Coiling diameters are based on maximum allowable axial strain. For thin-walled pipes,
buckling could induce extra axial strain and therefore, before coiling thin-walled pipe, the
Manufacturer should be consulted for recommendations.
PTS 31.40.30.34
January 2011
Page 43
5. LINER INSTALLATION
5.1 GENERAL - INSTALLATION TECHNIQUES

There are several commercially available liner installation techniques. An overview of the
generic types is given below and is illustrated by specific examples. The scope of this PTS
covers lining technologies that involve pulling a discrete length of thermoplastic pipe into a
host steel pipe. All technologies require an insertion clearance between the liner and the
host pipeline. The scope covers both onshore and offshore installation cases.
There are three generic liner installation techniques:
undersizing;
consecutive reduction and pull-in;
simultaneous reduction and pull-in.
The following summarises these three main types of installation techniques currently
available and is for information only. The Contractor shall propose a specific installation
technique and submit it to the Principal for approval.
5.1.1 Undersizing
Undersized liner installation involves inserting a liner of outside diameter less than the
inside diameter of the host pipe. The difference in diameter is the insertion clearance. It is
the simplest technique for lining pipes and has been applied for many years in oilfield
applications.
5.1.1.1 Slip-lining
Slip-lining is a technique where the undersized liner is simply pulled into the host steel
pipe. The liner is expanded in place by internal pressure, with or without heating, to yield
the liner while the annulus is vented. There is always a remaining annular gap. Internal
pressure, creep and swell are relied upon to obtain a tight liner fit, often after weeks of
operation. This time period depends strongly on the insertion clearance, liner material
properties and service conditions. If the pipeline is not pressurised for long periods then
there is a risk of the liner reverting to its original undersized dimensions.
5.1.1.2 Grouting
Grouting is a technique where an undersized liner is pulled into the steel host pipe, as in
slip-lining. The insertion clearance is filled with a liquid grout that solidifies, e.g. Bentonite
based systems (concrete-type materials). To ensure complete filling of the annulus, the
initial insertion clearance has to be comparatively large. The consequence of this is that
liner installation is simple but a significant reduction in pipe inside diameter results.
5.1.2 Consecutive reduction and pull-in

Consecutive reduction and pull-in techniques reduce or deform the liner to generate the
insertion clearance. The reduction step shall be stable, to allow subsequent liner
installation.
During the pressure expansion stage the annulus shall be continuously vented.
5.1.2.1 Folded pipe

Two manufacturing options of folded pipe are available: hot-forming or cold-forming.
In hot-forming, the liner is hot folded into a flat ribbon shape after leaving the extrusion die.
It is then reeled and can be installed using slip-lining. As the liner is hot-formed, it shall be
heated (usually using steam) to above its softening point during the pressure expansion
stage or else it will revert to its original flat shape.
In cold-forming, the liner is mechanically folded into shape using a die. The deformed
shape is tied up with a wrap to maintain the insertion clearance. Installation is by slip-lining
and internal pressure is used to break the wrap and yield the liner to fit the host pipe.
5.1.2.2 Diameter reduction by deformation

The diameter reduction by deformation technique involves an oversized liner being
reduced in diameter by cold-forming through a die. The liner is plastically deformed and is
PTS 31.40.30.34
January 2011
Page 44
therefore stable in its reduced state. The diameter reduction results in a wall thickness
increase. Installation is by slip-lining, with the pressure expansion step applied to achieve
the initial fit with the annulus continuously vented. As the liner has been plastically
deformed its yield strength is lowered. This implies that the initial liner fit is tighter than with
standard slip-lining. Also the time to establish a stable fit is much shorter with little risk of
reversion to initial liner diameter.
5.1.3 Simultaneous reduction and pull-in

Simultaneous reduction and pull-in techniques reduce the liner diameter elastically through
a die during the installation process. The immediate elastic recovery forces the liner into a
tight fit inside the host pipe. However, to maintain the insertion clearance during pull-in the
liner shall remain under tension at all times, implying that the liner shall be fed through the
die and straight into the host steel pipe in one continuous pull.
5.1.3.1 Reduction forming (with die)

Reduction forming or swageing (with die) is a British Gas proprietary lining system,
designed to maximise remaining bore diameter. Using a simple die, diameter reduction is
converted into an axial length increase. When the tension is released, the elastic recovery
is immediate with the liner length reducing as the liner diameter increases. The annulus is
continuously vented with the end result being a very tight interference fit between the liner
and the host pipe. This technique provides the tightest possible liner fit but is the most
demanding in terms of engineering tolerances.
5.1.3.2 Reduction forming (with rollers)

Reduction forming (with rollers) is similar to reduction forming (with die), where instead of a
static die, a set of profiled rollers is used to forge the reduced diameter in several stages,
with the reduction deformation imposed more gradually on the liner than by reduction
forming (with die). The last set of rollers is powered.
By controlling both the pull-in and roller loads an optimum conversion of length and wall
thickness is achieved. Alternatively the rollers may not be powered, in which case the liner
is pushed through the rollers.
5.1.4 Summary
(Table 5.1.4) summarises the pros and cons in terms of liner fit, installation length and
internal pipe dimensional tolerances of the various installation techniques, where + is
defined as a strength, 0 as neutral and a weakness.
Table 5.1.4 Pros and cons of liner installation techniques
As-installed Installed Dimensional
liner fit section length tolerances
Undersized + +
Consecutive 0 + 0
reduction
Simultaneous + 0
reduction
PTS 31.40.30.34
January 2011
Page 45
5.2 PREPARATION PHASE
5.2.1 General
Whether the liner is to be installed in a new pipeline or retro-fitted into an existing pipeline
will influence the preparation of the inside surface of the carbon steel pipeline. An accurate
assessment of the condition of the host pipeline is critical to ensure a successful lining
operation.
For rehabilitation of existing pipelines, the preparation considerations shall include:
corrosion damage;
presence of leaks;
internal deposits;
diameter variations and mismatches;
weld protrusions and misalignment;
general lay-out with bends, road, river crossings, pig traps, manifolds etc.
In particular, the following checks should be performed.
The condition of the steel pipe should be assessed to determine that sufficient
mechanical strength is retained to meet the design pressure rating for the proposed
service, based on hydrotest and/or inspection survey data. This test should be carried
out at a minimum test pressure of 1.25 times the design pressure with the aim to reach
a stress level as defined by PTS 31.40.00.10-Gen.
The internal condition and dimensions of all lines should be evaluated to ensure that
the liner can be pulled through each segment without significant damage e.g. due to
excessive local weld penetration (icicles). These should be checked by gauging
pigs/plates and/or by pulling a test sample of liner through every flanged pipe section.
Locations for cutting and flanging of the line and any requirement for separate spooled
sections should to be determined. The longest continuous length of liner which can be
installed in straight pipe depends on diameter and wall thickness, but is generally
reduced in practice by local curvature of the line. Breaks are also required at road
crossings, changes in ID and any bends of radius less than 20D, (recommended
minimum where possible is 40D).
Flanges welded to the steel line should be of matching bore and with a minimum
radius at the inside edge of about 6 mm. Vents shall be welded to the line in
accordance with (Section 3.4) of this PTS.
For lining existing buried pipelines, bellholes should be placed at the ends of the line and
at any other locations where breaks in the liner need to be made. In addition to the normal
safety considerations in excavating, sizing and ensuring stability of the bellholes, the
following factors should also be considered:
The working area within the bellhole should be of sufficient size to accommodate the
pipe fusion machine and operator.
The entry slope should be sufficiently shallow to enable the liner pipe to bend
smoothly from ground level to the pipeline depth without severe abrasion against the
steel flange during pull-through. (Provision may also be required for pulling from two
directions within a single bellhole).
Provision of sufficient length and width to enable the pipe ends to be offset for flange
welding and pulling in of the liner.
For new installations, preparation consideration shall include:
site conditions;
steel material selection (surface roughness);
weld specification.
For both a new or existing pipeline, the pipe inner surface shall be thoroughly cleaned
before liner installation.
Particularly for offshore liner installation, special attention shall be paid to ensuring that
there are sufficient space, weight and anchoring provisions (e.g. for pull-in winch) for all
the equipment required for the installation and testing of the liner.
PTS 31.40.30.34
January 2011
Page 46
5.2.2 Liner unloading and stockpiling

Unloading and stockpiling of the liner pipes and reels shall be done in accordance with
Manufacturer's recommendations.
When the liner pipe is cut from a coil, it should be supported to minimise stresses during
installation. The pipe should not be subjected to reverse curvature. Plastic pipe hangers
may be used to support the pipe. Care shall be taken not to over-tighten and cause the
hanger clamps to cut into the pipe. Pipe hangers should be correctly aligned and should
provide a flat smooth surface for contact with the pipe. Supports having sharp edges shall
not be used.
5.2.3 Inspection of liner materials
5.2.3.1 General
Material which shows injurious defects on site inspection shall be marked and rejected and
the Contractor so notified.
5.2.3.2 Defects
a) In pipe, surface scratches and nicks shall not exceed a depth of 5% of the nominal
liner wall thickness.
b) Flange surfaces shall be free of scratches and nicks
c) The maximum depth of dents shall be the smaller of 6.5 mm or 2% of the pipe OD.
5.2.3.3 Repair of defects

Defects in any form shall not be repaired. Pipe lengths with defects exceeding the
acceptance criteria of this PTS in (Section 5.2.3.2) shall be discarded and marked as
rejects.
5.2.4 Vent point assemblies

Vent point assemblies shall be installed in accordance with the design and shall be
installed prior to installation of the liner.
The design of the vent point assembly shall be agreed with the Principal.
Every lined pipeline and flowline should incorporate vent points. The minimum number of
vent points should be one on each flanged end of a section of lined pipe. Vent holes
should be designed such that no extrusion of the liner will occur. For larger diameter lines,
vent discs with multiple holes or wire screens may be used. Vent holes should not be
larger than 3 mm in diameter. All vents should be valved (except for water service where
vents can be plugged) and should have a "snorkel" to prevent ingress of dirt, moisture
and/or air.
PTS 31.40.30.34
January 2011
Page 47
5.3 LINER FABRICATION PHASE
5.3.1 General
The thermoplastic liner pipe shall be joined using the butt fusion welding process, as
defined in ASTM D 2657, Technique II. Any proposal by the Contractor to use a different
technique, e.g. hand welding, shall be subject to agreement by the Principal.
Contractor personnel performing the butt fusion welding shall be certified by the liner
Manufacturer in the liner joining procedure.
Joining of liners with a wall thickness difference of more than 2 mm shall not be permitted.
Procedures requiring the introduction of additional filler may also be used where
appropriate. Measures to avoid oxidation and thermal degradation of the liner shall be
taken.
After completion of the fusion weld, the internal and external bead of the weld shall be
trimmed. After trimming, the surface of the joint shall be visually examined for evidence of
good fusion. Nicks, gouges or undercuts caused by bead trimming are not acceptable and
shall be removed or cut-out.
5.3.2 Butt fusion welding procedure

The Contractor shall prepare a detailed procedure for each type and size of joint and fitting
to be welded. Separate procedures shall be prepared for shop and site welding.
Each butt fusion welding procedure shall detail the following information:
welding equipment type and model;
material grade and Manufacturer;
pipe/fitting dimensions at the joint;
welding sequence.
Essential parameters to be controlled as detailed in the welding equipment operating
manual for both the pre-heat and fusion stages include:
temperatures, times, pressures, hot plate condition in terms of roughness and
cleanliness;
weld dimensions and tolerances.
For each pipe butt fusion welding procedure to be used a test spool shall be prepared and
welded. This shall consist of three pipe sections butt fusion welded together with a flange
welded at each end, i.e. 4 circumferential welds in total. The assembly shall be tested as
follows:
weld dimensions - within tolerances of approved welding procedure;
visual inspection - no visible defects;
ultrasonic and/or radiographic examination when specified by the Principal -
acceptance criteria to be agreed;
pressure test using water at the maximum design temperature and at a pressure
agreed with the Principal or 1.5 times the equivalent rated pressure for the stand-
alone thermoplastic pipe - no leakage after 2 hours.
For each material grade and weld type, four additional test samples shall be prepared from
the largest diameter represented. The test samples shall be tested to short-term burst
pressure according to ASTM D 1599. The acceptance criterion is that the pipe shall not fail
at the weld.
All butt fusion welding operators who successfully complete the above welding procedure
qualification shall be considered qualified for butt fusion welds of the same type, material
grade and diameter range as represented by the procedure.
All qualified welders shall wear an ID card including a pass photo and stating name,
validity (end date of project) diameter range, wall thickness and material grade for which
they are qualified. The ID card shall be signed by the Principal.
5.3.3 Testing
The Contractor shall conduct an air test on the fused liner section prior to installation of the
liner. A maximum pressure of 0.3 bar shall be applied for a duration of not more than 3
PTS 31.40.30.34
January 2011
Page 48
hours unless otherwise specified by the Principal. The pipe should be anchored at 5 to 7
metre intervals with back-fill material before pressuring. A vacuum should not be pulled. All
fusion joints shall be soap-tested in the presence of an Inspector, approved by the
Principal.
Alternatively a water test may be performed. The pressure of the water test shall be 1.5
times the equivalent pressure rated (stand-alone) thermoplastic pipe. This test pressure
shall be agreed between the Principal and the Contractor.
PTS 31.40.30.34
January 2011
Page 49
5.4 LINER INSTALLATION
5.4.1 General
All equipment and material required for the installation and testing of the liner shall be
provided by the Contractor unless otherwise agreed.
Procedures to cover the installation of the thermoplastic liner inside the carbon steel
pipeline shall be prepared by the Contractor and submitted to the Principal for approval.
5.4.2 Preparation
5.4.2.1 Pre-installation communications

The Contractor shall establish communication procedures between the ends of the pull
section prior to the start of the liner pull-in.
5.4.2.2 Pull wire

The pull wire shall be certified to a load of at least four times the anticipated maximum pull
load.
5.4.2.3 Pipe cleaning

Before installation, the Contractor shall clean the pipeline and demonstrate that the bore of
the carbon steel pipeline is free from obstructions (e.g. excessive weld penetration, dents,
etc.) that could interfere with or damage the liner during pull-in. A gauging plate shall be
used to assess the internal diameter variations within the carbon steel pipeline.
5.4.2.4 Pull head and winch

The design of the pull head shall be such that sufficient clearance between the pull head
and the pipe shall be maintained.
The winch shall contain as a minimum a distance indicator and recorder and a calibrated
load indicator and recorder.
5.4.2.5 Wireline and pig train

The wireline unit should be suitably instrumented with footage and weight indicators, an
overload control set to a maximum of 100% of the calculated maximum allowable pulling
force and fitted with a speed controllable reel with cable spooling and braking facility.
The Contractor should provide suitable pigs and launching equipment to propel the
wireline and pig train through the pipeline
A typical pig train should include:
Sizing pig
Cleaning pig
Cup pig
Wegment of liner pipe (for loose liner)
Once the wireline has been passed through the pipeline section, the pig train is pulled
through, the pulling force being continuously monitored to determine the location of any
constrictions.
For loose fitting liners, the disc plate diameter should generally be about midway between
the OD of the liner and the ID of the steel pipe. For tight liners, the disc plate should be of
sufficient diameter to verify that internal weld beads do not protrude excessively, taking
into account the dimensional tolerances of the steel pipe.
The outer diameter of the liner pipe segment should be such that any excess weld
penetration which could result in liner puncture during normal operation is detected. For
loose liners this could imply that a larger diameter liner pipe may be necessary for test
purposes than during operation.
PTS 31.40.30.34
January 2011
Page 50
The liner test segment attached to the pig train should emerge without serious damage.
Scuffing of the liner surface is permissible but sharp longitudinal scars or other penetration
damage exceeding 0.5 mm or 5% of the wall thickness, which ever is larger, is
unacceptable and would require rectification by further pigging using a breaker pig or by
other means before continuing with liner installation. After rectification another liner test
segment should be pulled through.
5.4.3 Insertion
5.4.3.1 General
Liner insertion techniques depend on the method of installation chosen as outlined in (5.1).
Installation methods and procedures proposed shall include as a minimum:
description of equipment used;
length of sections;
maximum allowable and planned axial pull load. The maximum allowable axial stress
in the liner should be limited to 50% of the tensile yield stress;
type of lubrication - Lubricants can be water or bentonite. The use of grease is not
allowed unless by testing it is proven to be compatible with the thermoplastic liner and
will not lead to stress cracking;
pull-in rate;
methods for continuous load monitoring with calibrated equipment;
precautions shall be taken to ensure that no debris is introduced into the line on the
external or internal surface of the liner.
5.4.3.2 Pull-in load

The actual pull-in load shall be continuously monitored during pull-in. It shall not be
allowed to exceed the maximum allowable pull-in load (3.5.4).
5.4.4 Expansion
5.4.4.1 General
For all methods, with exception of grouting, the liner shall be expanded. The Contractor
shall propose procedures for this to the Principal.
Thermoplastic polymers have a thermal coefficient of expansion greater than that of
carbon steel. Consequently, allowance for thermal expansion and contraction after pull-in
and during service should be made during the liner expansion phase of installation. A
practical allowance is 20 mm per 10 m of pipe for each 10 C change in temperature. For
fully constrained pipe, a detailed stress analysis shall be performed by the Contractor.
5.4.4.2 Grouted liners

For liners that are grouted into place, an external extruded or machined anchor pattern
should be considered.
Before grouting the annulus gap should be at least 5 mm.
The pipeline should be pressurised during grouting to prevent collapse. The grout pressure
should be 1 bar below pipeline pressure.
The liner should be centred before inserting the grout, using spacers. Grouting should start
from the first vent point until it emerges from the second point. Upon completion this
second vent point becomes insertion point. A quality check of grout (density) at emergence
at vent points should be performed.
The shear strength of the grout should be at least 5 MPa.
For cementitious grouts, entrapment of air in grout should be between 1% and 2% to allow
porosity and permeability of gas through the grout to the vent holes.
PTS 31.40.30.34
January 2011
Page 51
5.5 END FLANGES AND IN-LINE FLANGED JOINTS

Connections between thermoplastic lined pipes and metallic piping shall be flanged. No
other joining methods (e.g. flared or screwed connections) shall be permitted, except for
in-situ retro-fitting where compression-type fittings may be used. The design of the
thermoplastic lined flanges shall be proposed by the Contractor and agreed with the
Principal. The design of the lined flanges should be raised face with spacer/backing rings.
When the liner has been pulled in, flange adapters should be fusion welded to each end.
The method should be detailed by the Contractor but will generally involve the following
steps:
Welding a flange adapter to the liner segment trailing end and pulling in to the steel
flange.
Clamping and stretching the liner from the leading end, sufficient to trim to required
length and butt the second flange adapter. (Normally a minimum 100 m segment
length is required for this technique to accommodate the necessary elastic strain).
Releasing the clamp to allow the liner to contract on to the steel flange face.
Fitting metal retaining rings around the liner flanges. These are designed to a
controlled thickness to limit compression of the flanges to a pre-determined value
when bolting adjacent segments and to prevent spreading of the flange material under
load.
Flange bolts shall be tightened with a torque wrench, using greased bolts and nuts, in
sequence and to the torque values as specified by the Manufacturer. Too great a bolt
loading may damage the plastic facing on the flanges. Appropriate spring washers should
be used between the nut and the flange. Bolts should be re-torqued after an initial service
period of 24 hours.
PTS 31.40.30.34
January 2011
Page 52
5.6 TESTING
The complete lined pipeline system shall be hydro-tested with water at ambient
temperature at the lower of 1.5 times the maximum operating pressure or the pressure of
the pipeline strength test for a period of 24 hours. For the duration of the test all vent points
shall remain open (refer to Section 5.2.3).
The pressure may fluctuate due to variations in ambient temperature, and care shall be
taken that the test pressure does not exceed the lowest rated element in the system.
During hydrotesting, temperature and pressure shall be recorded continuously unless
otherwise agreed with The Principal.
During the hydrotest the pressure shall be increased first to 3 times the liner pipe free-
standing pressure rating with all vents open to allow annular fluids to escape. If all fluids
have escaped or after one hour, which ever takes longer, the pressure shall be increased
to the required hydrotest pressure.
All end terminations and vents shall be visually inspected.
Acceptance criterion shall be that no weeping at flanges or through vent holes, if present,
is witnessed during the test.
At the end of the hydrotest the vents shall all be closed whilst the line is still under
pressure. Two to four weeks after commissioning all vents should be opened and closed
again to allow fluids which may have permeated through the annulus to the vents to
escape as well as to check whether any liner defects have developed.
PTS 31.40.30.34
January 2011
Page 53
6. OPERATION
6.1 START-UP
Immediately prior to starting up lined pipeline systems in gas service, any accumulated
pressure shall be bled off at all the vents. As soon as the pipeline is up to operating
pressure, the pressure at each vent point shall be checked and recorded. This should be
repeated after 48 hours' operation.
6.2 DE-PRESSURISING
Before de-pressurising the pipeline the vent points should opened for at least one hour.
The rate at which the vent point can relieve the gas trapped in the annulus should be
estimated to ensure that the venting rate, during de-pressurisation, is sufficient to prevent
a positive pressure difference between the annulus and the pipeline, i.e. at no time during
de-pressurisation should the annulus pressure be greater than the line pressure.
6.3 PIGGING
Pipelines with liners do not usually require pigging. However, if the line requires pigging to
remove fluids, then only foam pigs shall be used.
6.4 FLOW VELOCITY

(Table 6.4) presents the maximum recommended flow velocities for lined carbon steel
pipelines.
Table 6.4 Maximum recommended flow velocity
Service Normal flow (m/s) Maximum Maximum intermittent
condition continuous flow flow (m/s)
(m/s)
Liquid 1-8 10 15
Gas 5-15 20 40
NOTE: The above velocities are based on the assumption that no hard particles are present in the flow. Hard
particles can be tolerated but the potential erosion rate shall then be assessed.
6.5 VENTING
Venting procedures are required to prevent liner collapse during process upset conditions
(large pressure fluctuations) or shutdowns. Venting is required when gases are present in
the pipeline fluids. Venting is not required for liquid lines.
Vents shall be opened for the following conditions:
before changes in the operating conditions;
before shutdown;
at least monthly to evacuate the permeated gas accumulated in the annulus.
Venting operations shall be recorded in a log and include: date, length of time vent
remained open, vent pressure, volume of gas vented and other general observations. The
requirement for monthly venting may be revised according to experience using the log
entries to justify revising the venting frequency.
Alternatively it may be decided to operate the pipelines with the vents open (assuming
approval from the appropriate Health, Safety and Environment authority), i.e. continuously
venting the annulus. Open vents shall be inspected at least monthly to check integrity of
the thermoplastic liner and blockage of the vent points.
6.6 MAINTENANCE
Vent points shall be kept free from paint or other deposits. Blocked vent points, pipes and
fittings should be cleaned with low-pressure water only. The use of rods, steam jets or
sharp tools for cleaning shall not be permitted.
PTS 31.40.30.34
January 2011
Page 54
The vent holes and flange bolt torques shall be checked regularly.
Amended per
Circular 39/08
If very toxic gases (see PTS 01.00.01.30-Gen.) are present the local HSE authority shall
be consulted before venting operations.
6.7 REPAIR
Lined pipes and fittings shall not be repaired by welding, since heat could cause damage
to the liner. If damage occurs to a component of an installed lined piping system, the
damaged component shall be replaced.
Consideration may be given to returning damaged pipes to the Contractor for relining.
Leakage at flanged connections shall be remedied by the measures in the following
sequence:
Re-torquing of flange bolts to the specified values. Care shall be taken that these
values are not exceeded.
Replacement of the pipe spool having the suspect flange face.
6.8 OPERATIONAL PROCEDURE FOR A LINED PIPELINE

An operational procedure shall be developed for all lined pipelines and flowlines. This
procedure shall as a minimum address the following aspects:
system description;
operating envelope;
venting;
pigging;
start-up procedure;
routine operations;
de-pressuring.
An example of an Operational Procedure is given in (Appendix 2).
PTS 31.40.30.34
January 2011
Page 55
7. DOCUMENTATION
7.1 INFORMATION TO BE SUBMITTED BY THE PRINCIPAL

The following information should be supplied by the Principal:
Internal/external diameter of carbon steel pipeline.
Length of pipeline.
Right-of-Way access.
Location (onshore/offshore, buried/above ground).
Elevation profile of pipeline.
Location, radius and angle of all bends.
Location of any valves and fittings (e.g. tees) installed in the pipeline.
Condition of internal surface of the carbon steel pipeline (new/used, roughness,
penetration of welds, etc.)
Fluid composition (incl. inhibitors, chemicals etc.).
Expected minimum/maximum ambient temperatures during installation.
Minimum/maximum operating temperature of the system.
Minimum/maximum operating pressure of the system.
Maximum rate of de-pressurisation of the system.
Indication of likelihood of large pressure fluctuations.
Preferred type of liner material and thickness (if known).
Possibility and frequency of local venting. If nothing is specified it can be assumed that
the venting frequency is once per one to three months.
Requirements for valves at gas venting points, requirements for gas monitoring,
limitations on gas venting rates and any restrictions on venting locations.
Design life.
Appendix 5 lists the data that the Principal should provide in the Purchase order.
7.2 INFORMATION TO BE SUBMITTED BY THE CONTRACTOR

The Contractor shall submit information on the liner system to be used. This information
shall contain as a minimum:
Liner system identification.
Manufacturer's material data.
Material pre-qualification information.
Type and thickness of liner material.
Expected short-term and long-term volumetric swelling or shrinkage for the range of
operating conditions.
Expected thermal deformations due to operating temperatures.
Liner manufacturing procedure.
Liner installation procedure.
Anticipated insertion forces for each liner section in relation to liner strength.
Bend limitations for the steel pipe.
Maximum allowable weld penetration of carbon steel pipeline girth welds.
Vent connection details and spacing.
PTS 31.40.30.34
January 2011
Page 56
8. REFERENCES
In this PTS, reference is made to the following publications:
NOTE: Unless specifically designated by date, the latest edition of each publication shall be used, together
with any amendments/supplements/revisions thereto.
Amended per
Circular 05/02
PETRONAS STANDARDS
Index to PTS publications and standard PTS 00.00.05.05
specifications
Amended per
Circular 39/08
Definition of temperature, pressure and toxicity PTS 01.00.01.30
levels
Piping - general requirements PTS 31.38.01.11
Pipeline and riser engineering PTS 31.40.00.20
Carbon and low alloy steel pipeline flanges for use in PTS 31.40.21.34
oil and gas operations (amendments/supplements to
MSS SP-44)
Non-metallic materials selection and application PTS 30.10.02.13
AMERICAN STANDARDS
Pipe flanges and flanged fittings NPS 1/2 through ASME B 16.5
NPS 24
Large diameter steel flanges NPS 26 through NPS ASME B 16.47
60
Issued by:
American Society of Mechanical Engineers
345 East 47th Street
New York NY 10017
USA
Specification for polyethylene line pipe (PE) API Spec 15 LE

Recommended practice for railroad transportation of API RP 5L1
line pipe
Recommended practice for transportation of line API RP 5LW
pipe on barges and marine vessels
Issued by:
American Petroleum Institute
Publications and Distribution Section
1220 L Street Northwest
Washington DC. 20005
USA
Standard specification for seamless carbon steel ASTM A 106

pipe for high-temperature service
Standard specification for alloy-steel and stainless ASTM A 193
steel bolting materials for high-temperature service
Standard specification for carbon and alloy steel ASTM A 194
nuts for bolts for high-pressure or high-temperature
service, or both
Standard practice for determining chemical ASTM C 581
resistance of thermosetting resins used in glass-
fiber-reinforced structures intended for liquid service
Standard test methods for determining the Izod ASTM D 256
pendulum impact resistance of plastics
Standard practice for conditioning plastics for testing ASTM D 618
PTS 31.40.30.34
January 2011
Page 57
Standard test method for tensile properties of ASTM D 638

plastics
Standard test method for deflection temperature of ASTM D 648
plastics under flexural load
Standard test method for brittleness temperature of ASTM D 746
plastics and elastomers by impact
Standard test methods for flexural properties of ASTM D 790
unreinforced and reinforced plastics and electrical
insulating materials
Standard test methods for density and specific ASTM D 792
gravity (relative density) of plastics by displacement
Standard test method for resistance of transparent ASTM D 1044
plastics to surface abrasion
Standard test method for flow rates of ASTM D 1238
thermoplastics by extrusion plastometer
Standard test method for density of plastics by the ASTM D 1505
density- gradient technique
Standard test method for short-time, hydraulic failure ASTM D 1599
pressure of plastic pipe, tubing and fittings
Standard test method for carbon black in olefin ASTM D 1603
plastics
Standard test method for environmental stress- ASTM D 1693
cracking of ethylene plastics
Standard test method for determining dimensions of ASTM D 2122
thermoplastic pipe and fittings
Standard test method for rubber property ASTM D 2240
Durometer hardness
Standard specification for thermoplastic gas ASTM D 2513
pressure pipe, tubing and fittings
Standard practice for heat fusion joining of polyolefin ASTM D 2657
pipe and fittings
Standard test methods for tensile, compressive, and ASTM D 2990
flexural creep and creep-rupture of plastics
Standard specification for unmodified ASTM D 3222
polyvinylidenefluoride (PVDF) molding extrusion and
coating materials
Standard Specification for polyethylene plastic pipe ASTM D 3350
and fitting materials
Standard test method for oxidative-induction time of ASTM D 3895
polyolefins by differential scanning calorimetry
Standard test method for abrasion resistance of ASTM D 4060
organic coatings by the taber abraser
Standard classification system for nylon injection ASTM D 4066
and extrusion materials (PA)
Standard specification for propylene plastic injection ASTM D 4101
and extrusion materials
Standard test methods for stress relaxation tests for ASTM E 328
materials and structures
Standard test method for linear thermal expansion of ASTM E 831
solid materials by thermomechanical analysis
Standard test method for assignment of the glass ASTM E 1356
transition temperatures by differential scanning
PTS 31.40.30.34
January 2011
Page 58
calorimetry or differential thermal analysis

Standard specification for polyvinylidenefluoride ASTM F 491
(PVDF) plastic-lined ferrous metal pipe and fittings
Standard specification for propylene and ASTM F 492
polypropylene (PP) plastic-lined ferrous metal pipe
and fittings
Standard specification for butt heat fusion polyamide ASTM F 1733
(PA) plastic fitting for polyamide (PA) plastic pipe
and tubing
Issued by:
American Society for Testing and Materials
1916 Race Street,
Philadelphia Pa 19103
USA
INTERNATIONAL STANDARDS
Plastics Determination of Izod impact strength ISO 180
Plastics Determination of tensile properties ISO 527 R
Plastics and ebonite Determination of indentation ISO 868
hardness by means of a durometer (Shore
hardness)
Plastics Determination of the melt mass-flow rate ISO 1133

(MFR) and the melt volume-flow rate (MVR) of
thermoplastics
Polyethylene (PE) pipes for water supply - ISO 4427

Specifications
Thermoplastics pipes Determination of ring ISO 9969

stiffness
Issued by:
International Organisation for Standardisation
1, Rue de Varemb
CH-1211 Geneva 20
Switzerland
Copies can also be obtained from national standards

organizations.
PTS 31.40.30.34
January 2011
Page 59
APPENDIX 1 CURRENT RANGE OF SERVICE EXPERIENCE
The Shell Group has more than 10 years of favourable operating experience with
thermoplastic liners in water injection, gas and crude oil applications in moderate operating
conditions.
FIGURE A.1 GROUP EXPERIENCE OF THERMOPLASTIC LINED PIPELINES IN
TERMS OF PRESSURE - DIAMETER RANGE
(Figure A.1) presents the broad range of application currently in Group service in terms of
pressure-diameter range. (Figure A.2) presents the current usage as a function of fluid
transported.
FIGURE A.2 GROUP EXPERIENCE OF THERMOPLASTIC LINED PIPELINES AND
FLOWLINES IN TERMS OF FLUID TRANSPORTED
PTS 31.40.30.34
January 2011
Page 60
The bulk of liner applications are for water transport, although several long low-pressure
gas transport lines are also in service.
Polyethylene (PE) is the most commonly used thermoplastic polymer material to date. The
bulk of current applications are limited to operating temperatures below 60 C. It is
anticipated that this service temperature will rise as the application envelope of lined
carbon steel pipelines and flowlines is broadened, implying that other thermoplastic
polymer materials will have to be considered.
PTS 31.40.30.34
January 2011
Page 61
APPENDIX 2 EXAMPLE OF OPERATIONAL PROCEDURE
The following example is taken from the Shell Canada, Waterton 24 inch gas pipeline.
A.2.1 Scope
Due to excessive internal corrosion on the existing Waterton 24-inch steel pipeline, a
31.5 mm polyethylene liner has been installed.
PE liners do not corrode therefore no corrosion inhibitor injection is required.
The maximum operating pressure of the pipeline has been de-rated to 99.30 bar.
The high-pressure setting on check valves at the upstream and downstream end of the line
has been set to 90 bar to provide additional protection.
A.2.2 Vents
The liner has been pulled into the pipeline in six segments. These segments are joined by
flanges which are buried underground. On each side of the flange a half-inch vent pipe
rises to surface, isolated with a valve. A 1/8" hole has previously been drilled through the
steel pipeline only to vent any annular gas which may permeate through the plastic liner
and migrate up into the vent pipes.
Vents are also required to check the integrity of the liner.
When checking the vents for pressure or bleeding-off the pressure, they shall be dealt with
in the same manner as breaking the integrity of any system:
2 men are required;
1 safety person;
self-contained breathing apparatus shall be worn by worker performing task;
safety person shall be upwind and a safe distance away;
record the vent pressure on the venting log sheet;
annular pressure should be kept below 50 bar at all times;
vents are to be left in the closed position at all times;
during normal operation the pipeline vents will be filled with 100% glycol. This will
reduce the volume of H2S that can accumulate in the vent lines.
CAUTION: Do not use pressure to fill vent lines.
A.2.3 Temperature
If the gas in the line reaches high temperatures the liner could soften. This can cause
weakening of the liner and collapse.
At no time should the temperature of the fluid entering the liner be greater than 45 C.
The upstream heater shall be set to maintain a temperature at 40 C with the high-
temperature alarm set at 45 C.
A.2.4 Pigging
Pipelines with liners do not usually require pigging. However, if the line requires pigging to
remove fluids then it can be pigged with the following restrictions:
- 3 lb (psi) density foam pigs to be used;
- do not pig with ball or hard style pigs. There are signs located at each end to alert
operators to this.
A.2.5 Start-up procedure
Immediately prior to start-up bleed the pressure off all the vents.
Introduce gas into the pipeline.
As soon as the pipeline is up to operating pressure, check and record all vent pressures.
Maintain/record each vent pressure after first 2 days on venting log sheet.
PTS 31.40.30.34
January 2011
Page 62
A.2.6 Operation/routine
Check liner pressure and record on venting log sheet once per month. If time to bleed off
annulus pressure is very short (<10 s) leave closed and continue to check on monthly
basis.
A.2.7 De-pressuring pipeline

Immediately (within 1 hour) before de-pressuring the pipeline, the pressure on all the vents
shall be bled off and then closed. Following de-pressuring of the pipeline the vents shall be
left open for 1 hour, then closed.
CAUTION: Failure to remove pressure from vents before pipeline de-pressurisation could
lead to collapse of the liner.
A.2.8 Drop in normal operating pressures

A drop in normal operating pressure of greater than 7.5 bar for extended periods of time
could cause a collapse of the liner. Therefore, the maximum differential pressure should
not exceed 7.5 bar.
PTS 31.40.30.34
January 2011
Page 63
APPENDIX 3 LINER DESIGN DATA SHEET
The following information shall be provided by the Contractor during the tender:
Installation technique to be used:
Step 1 Units Value

OD (liner outside diameter) mm
h (liner wall thickness) mm
R = 0.5 * (IDsteel - h) mm
Step 2 handling and storage requirements
SDR ratio
h mm
Step 3 installation requirements
Maximum allowable stress during pulling MPa
Maximum load during pulling N
h mm
Step 4
Maximum h from Steps 2 and 3 mm
Step 5
Service (water, crude oil or multiphase)
Maximum design temperature C
Maximum linear swell, swell
Modulus, E at service conditions MPa

Step 6
Liner fit, C calculate from (Section 3.3.3.1)
Step 7 only for multi-phase or gas applications
Collapse pressure, Pc calculate from (Sections 3.3.3.2, bar
3.3.3.3, 3.3.3.4) depending on liner fit using maximum h
(Step 4)
Step 8 only for multi-phase or gas applications
Design pressure, Pdes (Section 3.3.4) bar
Choose operational procedure, intrinsically safe or
allowance for gas expansion
For intrinsically safe procedure, is Pdes > Pc (Section
3.3.4.1)
If yes, increase liner wall thickness and return to Step 6
If no, go to Step 10
For allowance for gas expansion procedure calculate 3
mm /mm
initial annulus volume, Vinit (Section 3.3.4.2)
For allowance for gas expansion procedure calculate 3

mm /mm
critical volume, Vc (Section 3.3.4.2)
For allowance for gas expansion procedure, is Pdes > Pc*

Vc/ Vinit (Section 3.3.4.2)
PTS 31.40.30.34
January 2011
Page 64

Step 9 only for liquid applications
Critical swell, crit, calculate from (Section 3.3.5)
swell > crit (Section 3.3.5)
Step 10
Minimum liner wall thickness mm
PTS 31.40.30.34
January 2011
Page 65
APPENDIX 4 MATERIAL PROPERTIES
The following information shall to be provided by the Contractor during the tender for:
- Pipe material
- Flange material
- Lined spools
Property Test Method Manufacturer

data
Pipe, flange or spool? -
Raw Material manufacturer -
Material type and grade (unique -
identification as used by manufacturer)
Pipe supplier -
Poisson ratio -
-1 -
Coefficient of thermal expansion (K )
Carbon black content (only for PE) ASTM D 3350
3 ASTM D 1505
Density (g/cm )
Melt index (g/10min at 190 C, 2160 g load) ASTM D 1238
Modulus (MPa) at 20 C ISO 9969
Modulus (MPa) at design temperature ISO 9969
Tensile strength (MPa at 50 mm/min) ASTM D 638
Environmental stress crack resistance ASTM D 1693
(Condition C for 192 hours)
Oxygen Induction Temperature ASTM D 3895
(at 200 oC)
Burst pressure (MPa) ASTM D 1599
PTS 31.40.30.34
January 2011
Page 66
APPENDIX 5 PURCHASE ORDER INFORMATION
The following information shall be provided by the Principal in the purchase documents:
Process design data Unit Value
Tmax, Maximum design temperature C
Tmin, Minimum design temperature C
Minimum ambient temperature C

Maximum ambient temperature C
Minimum pressure bar
Maximum design pressure bar
Pressure fluctuation during normal operation bar
Pressure fluctuation frequency 1/s
Gross throughput 3
m /day
Watercut %
For crude oil lines:
Bubble point bar
GOR (gas/oil recovery) at normal conditions 3 3
m /m
Partial pressure of H2S in gas phase bar
Well stimulation chemicals
Well lift mechanism (ESP, beam pump, etc.)
CITHP (closed in tubing head pressure) bar
FTHP (flowing tubing head temperature) C
Carbon steel line details
ID carbon steel line mm
Internal condition (corroded/new)
Internal condition (max weld penetration) mm
Design life years
Buried or above ground
Coating (presence/colour/type)
Liner supply data
Pipeline length m
Specified length or coil size m
Delivery/shipping instructions

Petronas STD

Uploaded by

Copyright:

Available Formats

You might also like

Petronas STD

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Petronas STD

Uploaded by

Copyright:

Available Formats

PTS 31.40.30.

The right to use PTS rests with three categories of users:

1) PETRONAS and its affiliates.

APPENDIX 4 MATERIAL PROPERTIES............................................................................... 65

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

1.3.1 General definitions

1.3.2 Specific definitions

measured by taking the maximum measured diameter

2.2 THERMOPLASTIC LINER MATERIALS

2.2.1 Polyethylene (PE)

Density (g/cm3) 0.926-0.94 0.941-0.965 0.989

2.2.2 Polyamide (PA)

A summary of typical material properties of PA is presented in (Table 2.2.2b). This Table is

2.2.3 Polyvinylidenefluoride (PVDF)

Table 2.2.3a Maximum operating temperature for PVDF as a function of fluid

2.2.4 Polypropylene (PP)

2.2.5 Polyphenylene Sulphide (PPS)

Table 2.2.5b "Typical" material properties of PPS

Typical properties PPS

2.2.6 Cross-linked Polyethylene (PEX)

2.2.7 Polyketone (PK)

be used to limit degradation. (Table 2.2.7a) presents the recommended maximum

A summary of typical material properties of PK is presented in (Table 2.2.7b). This Table is

2.2.8 Other materials

2.3 MATERIAL SELECTION GUIDE

2.4 MATERIAL TESTING

2.4.1 Fluid permeability test

2.4.2 Blistering resistance test

2.4.3 Ageing test

2.4.4 Swelling test

where the volumetric swell of the sample, Vswell, is defined as:

2.5 END CONNECTORS

3.2 MINIMUM LINER THICKNESS

3.3 LINER DESIGN PROCEDURE

If no liquids are present, then go to step 10.

FIGURE 3.3 LINER DESIGN PROCESS

3.3.2 Liner thickness installation

3.3.3 Liner thickness - collapse

3.3.3.1 Liner fit

Table 3.3.3.1 Categories of liner fit as a function of installation technique

3.3.3.2 Loose fitting liners

3.3.3.3 Partially loose fitting liners

3.3.3.4 Tight fitting liners

3.3.4 Design pressure of pipeline

A safety factor, J, of 1.33 is recommended.

3.3.4.1 Intrinsically safe

3.3.4.2 Allowance for gas expansion

For a partially loose fitting liner, the initial volume is;

The volume of annulus at collapse Vc (mm3/mm) is given by:

3.4 VENT POINT DESIGN

3.4.1 Vent point spacing

axial profile of the collapsed liner is triangular;

3.5 PULL-IN LOADS AND INSERTION LENGTH

3.5.1 Friction load, Ffriction

3.5.2 Bending load, Fbend

3.5.3 Reduction load, Freduce

3.6 DESIGN OF END CONNECTORS

3.6.2 Flange type connections