Saep-387 2021

Engineering Procedure 02 June 2021
SAEP-387
Thermoplastic Liners for New and Existing Pipelines
Document Responsibility: Nonmetallic Standards Committee
Previous Revision: 22 January 2019 Next Revision: 02 June 2026

Contact: (ASIRAY0A) Page 1 of 26
© Saudi Arabian Oil Company, 2021
Saudi Aramco: Company General Use

Document Responsibility: Nonmetallic Standards Committee SAEP-387
Issue Date: 02 June 2021
Next Revision: 02 June 2026 Thermoplastic Liners for New and Existing Pipelines
Contents
SUMMARY OF CHANGES.................................................................................................................... 3
I SCOPE .............................................................................................................................................. 5
II CONFLICTS AND DEVIATIONS ................................................................................................... 5
III REFERENCES ................................................................................................................................. 5
IV DETAILED MODIFICATIONS OF NACE SP0304 .................................................................. 7
V. DOCUMENTATION [ADDITION] ............................................................................................. 23
VI. QUALITY PROGRAM [ADDITION] ............................................................................................ 25
VII. DRAWING [ADDITION]................................................................................................................ 25
VIII. STORAGE AND HANDLING [ADDITION] ................................................................................ 26
DOCUMENT HISTORY........................................................................................................................ 26
© Saudi Arabian Oil Company, 2021 Page 2 of 26

Summary of Changes
Paragraph Number
Change Type Technical Change(s)
(Addition, Modification, Deletion,
Previous Revision Current Revision New)
(22 January 2019) (02 June 2021)
Added reference to 01-

SAMSS-025 for in-plant piping
1 I Addition
systems with PTFE/fluorinated
polymer lining
Qualification requirements for
IV.3.11 Addition
PERT material
Clarification between the
Section 4. 3.12 IV.3.13 Modification cases for smooth liner and
grooved liner utilization
The design of liner system
shall be carried out by the liner
NA IV.4.5 Addition
installer for the approved
engineering contractor
Clarification on the
requirement of re-injection
Section 4. 5.5 IV.5.6 Modification
system for systems in sour
service
Hydrostatic testing
Section 4. 6.3 IV. 6.3 Modification requirements for steel pipes
before liner insertion
Steel pipe assessment
IV. 6.3 Addition requirements for rehabilitation
projects as per SAEP-326
Clarification on the use of
raised face flanges for high
Section 4. 6.6 IV. 6.6 Modification pressure lined pipelines (Class
900 and higher) as allowed
per SAES-L-109
− Marking requirements
moved to IV.7.7.
Section 4. 6.3 IV.7.7 Modification Surface markers is newly
required in addition to pipeline
marking.
− New conditions and
requirements for the use of
extrusion welding of stub-
end flanges
NA IV.6.6 Addition
− New requirements for the
steel flanges internal
diameter and bend radius to
avoid sharp corners in

contact with the

thermoplastic liner
Existing flange insulation kits
at the flange connections shall
not be disturbed by the
installation of the liner.
Hydrostatic testing
NA IV.6.7 Modification
requirements for lined pipe
− Any damage to the
internal/external coating of
the steel flanges at the
termination sides shall be
repaired per para 9.6 of
SAES-H-001.
− Requirement to replace the
vent/re-injection tubing, for all
NA IV.7.6 Addition
breached lined pipe.
− Inclusion of circular economy
requirement:
“If the pipeline failed, beyond
repair or when it reaches its
end-life, the nonmetallic liner
shall be recycled or
repurposed as appropriate.”
Deletion of the Commentary
Section 4.5.8 NA Deletion
Note
Deleted requirement for
Section 4. 6.6 NA Deletion washers between the nut and
the flange

I Scope
This document establishes the minimum technical requirements for the material
selection, specification, design, manufacture, installation, and operation of
thermoplastic internal liners. This procedure is an addendum to all parts of
NACE SP0304:2004 which covers Thermoplastic Liners for Oilfield Pipelines to
be used in pressurized systems as listed in SAES-L-132.
The use of these internal liners is for rehabilitating existing carbon steel
pipelines and flowlines as well as for new pipelines and flowlines. Lining with
thermoplastic material is applicable to aboveground, buried and sub-sea
pipelines.
Internally lined piping systems for transporting corrosive fluids including acids
and alkaline solutions are the scope of 01-SAMSS-025 Plastic-lined Ferrous
Metal Pipe, Fittings and Flanges.
II Conflicts and Deviations

Any conflicts between this document and other applicable Mandatory Saudi
Aramco Engineering Requirements (MSAERs) shall be addressed to the
EK&RD Coordinator.
Any deviation from the requirements herein shall follow internal company
procedure SAEP-302.
III References
All referenced specifications, standards, codes, drawings, and similar material
are considered part of this engineering procedure to the extent specified,
applying the latest version, unless otherwise stated.
III.1 Saudi Aramco References
Saudi Aramco Engineering Procedures

SAEP-302 Waiver of a Mandatory Saudi Aramco Engineering
Requirements
SAEP-306 Assessment of Pipelines Defects
SAEP-326 Inspection Requirements for In-service Pipelines
Saudi Aramco Engineering Standards
SAES-H-001 Coating Selection and Application Requirements for

Industrial Plants and Equipment
SAES-L-109 Selection of Flanges, Stud Bolts and Gaskets

SAES-L-132 Materials Selection for Pipelines, Piping and Process

Equipment
SAES-L-410 Design of Pipelines
SAES-L-150 Pressure Testing of Plant Piping and Pipelines
Saudi Aramco Material System Specification
01-SAMSS-051 High Density Polyethylene (HDPE) Pipe and Fittings.
III.2 Industry Codes and Standards
American Society for Testing and Materials

ASTM D4066 Standard Classification System for Nylon Injection and
Extrusion Materials (PA)
ASTM F491 Standard Specification for Poly Vinylidene Fluoride (PVDF)
Plastic-lined Ferrous Metal Pipe and Fittings
ASTM F2620 Standard Practice for Heat Fusion Joining of Polyethylene
Pipe and Fittings
ASTM F1733 Standard Specification for Butt Heat Fusion Polyamide
(PA) Plastic Fitting for Polyamide (PA) Plastic Pipe and
Tubing
American Society of Mechanical Engineers
ASME B16.5 Steel Pipe Flanges, Flanged Valves, and Fittings
ASME B31.4 Pipeline Transportation Systems for Liquids and Slurries
Canadian Standards Association
CSA Z662-03 Oil & Gas Pipeline Systems
German Institute for Standardization
DVS-2207-4 Welding Thermoplastic Materials- Hot-gas extrusion
welding of pipes, piping parts, fittings and panels
International Organization for Standardization
ISO 22391-1 Plastic Piping Systems for Hot and Cold Water
Installations-Polyethylene of Raised Temperature
Resistance (PE-RT) –Part 1: General

ISO 24033 Polyethylene of raised temperature resistance (PE-RT)

pipes — Effect of time and temperature on the expected
strength
National Association of Corrosion Engineers
NACE SP0304 Design, Installation and Operation of Thermoplastic Liners
for Oilfield Pipelines
IV Detailed modifications of NACE SP0304
The following paragraph numbers refer to NACE SP0304, which is part of this
procedure. The text in each paragraph below is an addition, exception,
modification, or deletion to NACE SP0304 as noted. Paragraph numbers not
appearing in NACE SP0304 are new addition to the document.
Summary of modifications of NACE SP0304 “Design, Installation, and

Operation of Thermoplastic Liners for Oilfield Pipelines”
NACE
Section
SP0304 Title Remarks
Number
2004 Edition
Section 1 General…………………………………… No Change
Section 2 Definitions………………......................... Addition
Section 3 Liner material
Subs. 3.2 Modification
Subs. 3.3 Exception
Subs. 3.4 Modification
Subs. 3.11 Addition
Subs. 3.12 Addition
Subs. 3.13 Addition
Subs. 3.14 Guidelines to selecting liners…………. Addition
Subs. 3.15 End connectors......................……........ Addition
Subs. 3.16 Manufacture of the liner.………............ Addition
Subs. 3.17 Rotationally molded spools................... Addition
Subs. 3.18 Ovality………………….….......…............ Addition
Subs. 3.19 Dimensions and tolerances................... Addition
Subs. 4.1 (d) Pressure cycles……….......................... Addition
Subs. 4.1 (f) Pipeline repair………………................. Addition
Subs. 4.1 (j) Scraping/Pigging……............................. Addition
Subs. 4.5 Liner design responsibilities Modification

Subs. 5.1.2 Liner design types....................………. Modification

Subs. 5.6 Vent point and venting………………..... Addition
Subs. 5.7 Spacing between vent points..........….. Addition
Subs. 5.8 Other design aspects............................ Addition
Subs. 5.9 Design of end connectors……………… Addition
Subs. 6.3 Preparation………………………………. Addition
Subs. 6.4 Bead cleaning…………………………… Addition
Subs. 6.5 Joints testing……………………………. Addition
Subs. 6.6 End flanges and in-line flanged joints Addition
Subs. 6.7 Testing……………………………………. Addition
Subs. 7.4 Operational procedure………………….. Addition
Subs. 7.5 Maintenance…………………………..…. Addition
Subs. 7.6 Repair………………………….…………. Addition
Subs. 7.7 Marking…………………………………… Addition

Section 2: Definitions
[Addition]
Batch: A lot supplied by the compound manufacturer having an
individual identification number or code.
SDR: Standard Dimension Ratio; Nominal outside diameter of liner /
Nominal wall thickness
CRA: Corrosion Resistant Alloy
ID: Nominal internal diameter
OD: Nominal outside diameter
UV: Ultra violet light
Liner installer: The party that conduct all or part of the project design,
engineering, liner procurement, construction, commissioning, or
management of a project.
Bell hole: Excavations made at a section joints of a pipeline for the
purpose of pulling of a thermoplastic liner section.
Butt fusion welding: A method of joining plastic pipe wherein the two
ends to be joined are heated to the molten state for a period of time
under pressure. After the cooling period, the joint exhibits strength
either similar/higher than the pipe.
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.
Inspector: Professional assigned to ensure a project's compliance
with its specifications and statutory requirements.
Ovality: Ovality is the deviation from roundness as a result of
extrusion, coiling, handling, or installation.
Permeation: Diffusion of liquid and gas through a plastic layer under
the influence of pressure and temperature. Permeation is a
physiochemical mass transfer phenomenon involving diffusion of a
solute through a porous medium. The driving force for mass transfer
is the presence of an activity (e.g., concentration) gradient with respect
to the solute.
Smooth wall liner: Liner that is manufactured with a uniform wall
cross section with no grooves.
Grooved liner: Liner that is manufactured with grooves on the outside
surface. Grooves shall be uniform and the minimum wall thickness will
not consider the depth of the groove.

Vent connection or point: A vent in a lined pipeline system is a hole

that is drilled through the steel pipe to allow passage of any permeated
gases or liquids or, to monitor pressure build-up in the liner annulus.
The liner integrity is determined by monitoring any pressure
accumulations at the vent hole.
Venting: Release of permeated gas accumulated in the annulus at a
constant interval.
Annulus: Space between thermoplastic liner and the host outside
carbon steel pipe.
Flanges face: ASME B16.5 code requires that the flange face (raised
face and flat face) has a specific roughness to ensure that this surface
be compatible with the thermoplastic flange and provide a high quality
seal.
Hot plate welding technique: The process of hot plate welding uses
a heated platen to melt the joining surfaces of the two halves of a
thermoplastic pipe. The pipe ends are brought into contact with a
precisely heated platen for a predetermined period.
Elastic modulus: The ratio of the stress applied on a body to the
strain that results in the body in response to it. The modulus of
elasticity of a material is a measure of its stiffness and for most
materials remains constant over a range of stress.
Section 3: Liner materials
3.2 [Modification] Liner material
High Density Polyethylene (HDPE)
Product manufacturer shall utilize HDPE; PE-100 material only as
specified in 01-SAMSS-051. Liner manufacturing, qualification, and
procurement shall also comply with 01-SAMSS-051. HDPE shall be
used as a base case liner material for water injection and disposal lines
with a maximum operating temperature up to 70ºC (158ºF).
3.3 [Exception] Liner material
Medium Density Polyethylene (MDPE)
Medium-density polyethylene (MDPE) is not acceptable as a liner
material for water disposal, injection, and hydrocarbon lines.
3.4 [Modification] Liner material
Polyamide (PA)
Polyamide such as PA12 and PA6-12, in addition to PA11, shall be
used as a liner for hydrocarbon services provided that the crude is free

from water, or at very low levels, and within its limited maximum
operating temperatures.
Liner manufacturers shall submit the relevant PA (minimum) material
specification at the specified operating conditions. This procedure
shall comply with the requirements of ASTM D4066 and/or ASTM
F1733 or equivalent ISO Standard.
3.11 [Addition] Liner material
Polyethylene Raised Temperature (PE-RT)
Polyethylene raised temperature (PE-RT) shall be used as a base case
liner material for water injection and disposal lines when the design
temperature of the thermoplastic lined pipe exceeds 70ºC (158ºF) and
up to maximum operating temperature 82ºC (180ºF).
PE-RT resin shall be type II per ISO 24033 and/or ISO 22391-2 or
equivalent ASTM standard. The mechanical and physical test reports
as per ISO 22391-2 shall be submitted.
Liner manufacturer selected by the liner installer shall perform fitness
for purpose 1,000 hr. internal pressure test for pipe + butt-welded joint
specimens at 95°C (203ºF) and a pressure corresponding to a
hydrostatic hoop stress of 3.6 MPa. At least 3 specimens shall be
submitted. Minimum size for initial approval shall be 200 mm (8”). For
approval of additional sizes, 165 hr. pressure tests are acceptable
following the same parameters as above.
Polyvinylidene Fluoride (PVDF)
For liner applications, unplasticized PVDF copolymer based on
vinylidene fluoride (VF2) and chlorotrifluoroethylene (CTFE) shall be
used in water and hydrocarbon applications. Other grades of
copolymer or unplasticized PVDF shall be assessed by the CSD Non-
metallic Engineering Group before acceptance.
Manufacturers shall submit the relevant PVDF (minimum) material
specification at the specified operating conditions. This procedure
shall comply with the requirements of ASTM F491 or equivalent ISO
standards.
Table 1 lists recommended maximum operating temperature for the
use of thermoplastic liner as a function of fluid composition. However,
unless otherwise specified in SAES-L-132, the maximum operating
temperature and intended application shall be specified and agreed
with the CSD

Non-metallic Engineering Group before approval of the material for

lining.
Table 1 – Recommended liner material as a function

of maximum operating temperature and fluid composition
Temperature °F or (°C)
Water injection and
Materials Multiphase Crude Oil Gas Gas Condensate
Disposal service
HDPE 158ºF (70ºC)-Base Case 140ºF (60ºC) 140ºF (60ºC) Not Applicable
PE-RT 180ºF (82ºC)-Base Case 180ºF (82ºC) 180ºF (82ºC) Not Applicable
PA Not Applicable 185ºF (82ºC) 185ºF (82ºC) Not Applicable
PVDF Overdesign 250ºF (120ºC) 250ºF (120ºC) Not Applicable

Note:
Smooth liner system shall be selected for all water injection and disposal systems (including
sour water).
For multiphase hydrocarbon applications, grooved liner or smooth liner system may be used.
Smooth liners shall demonstrate collapse resistance and sufficient stiffness to withstand Total
Dissolved Gas Pressure
3.14 [Addition] Guidelines to selecting thermoplastic liners

The liner installer shall be responsible for selecting and supplying of all
materials required to meet the specified service design conditions and
installation requirements. The selection of materials shall be based on
actual test data or documented methods (field-proven) predicting the
liner material properties for the specified service conditions. For any new
application not referred to SAES-L-132, the liner installer shall submit a
report incorporating the test results and records to the CSD Non-metallic
Engineering Group for review.
This procedure is not restrictive to the materials mentioned herein,
however any new polymeric liner materials (e.g., POK, PEEK) or any
new applications (hydrocarbon including oil, gas and gas condensate)
shall be evaluated against the following criteria with the consultation of
the CSD Non-metallic Engineering Group. Till date, HDPE, and PE-
RT have been field proven for water injection and disposal applications.
Liner material selection for pipelines shall consider the fluid(s) being
carried; its chemical constituents and concentrations, abrasiveness,
flow rates, the long term effect of the fluid(s) on the liner, resistance to
pressure change while leading to blistering and collapse of the liner,
operating conditions (flow, temperature, pressure), compatibility with

pigging operations, and swelling. Other general characteristics that

need to be evaluated during the liner materials selection include:
expected life and economics. The liner manufacturer is usually
consulted to determine the long-term compatibility with the intended
service.
A qualification and quality control testing program for the selected
thermoplastic shall be established. This program shall include the
following properties:
a) Liner material selection; fluid compatibility, temperature rating,
physical/mechanical and thermal properties; case studies
submitted by the liner installer will replace the laboratory testing
requirement of the liner.
b) Liner material field application; pulling capability, weldability and
ability to maintain its tight fit property.
c) Trial test for at least 6 months or otherwise specified for the
selected application; Duration of testing shall be determined
based on the saturation level of the liner in conveyed fluid or
anticipated steady-state permeation; Additionally, the liner
installer shall provide adequate support in determining the
associated venting mechanism and frequency.
3.15 [Addition] End connectors and vent/re-injection tubing
The material of the thermoplastic flange shall be the same as the liner
material to avoid incompatibility and failure at the joint. The wall
thickness of the flanges shall be equal to the wall thickness of the liner.
The retaining rings shall be made from carbon steel. Other materials
recommended by the liner installer are acceptable upon review and
submittal of the retaining ring materials used in the field for similar
applications.
The vent tubings shall be made from corrosion-resistant materials such
as stainless steel or braided hose, provided that they can meet the
same hydrotesting pressure as the host pipe. For near shore
applications, vent/re-injection tubing shall be made of Super Duplex
Stainless Steel.
3.16 [Addition] Manufacture of the liner
The manufacturing of thermoplastic liner shall be similar to thermoplastic
pipe manufacture using extrusion machines. Only 100% prime virgin
materials shall be used for the production of the liner.
The liner installer shall be responsible for the procurement and
manufacturing of the liner per the approved specification and inspection
and test plan (ITP). In case of already established 9COM (e.g., 9COM

6000000039 for HDPE material), liner shall be procured from the

approved vendor list.
3.17 [Addition] Rotationally molded spools
Rotationally molded lined carbon steel spools are acceptable in tees,
bends, etc. The material used shall meet the minimum material
properties as requested by the liner installer. In the case of the spools
not being able to be fabricated with the identical liner material as the
host pipe, a higher grade polymer shall be selected. For PA lined pipe,
molded spools shall be fabricated with PVDF material. The lining
thickness for rotomolded spools shall be as per manufacturer
capabilities and recommendations.
3.18 [Addition] Ovality

During liner manufacturing, ovality/out-of-roundness shall be
monitored and recorded and the ovality of the pipe shall not exceed
5% when measured in accordance with ASTM D2513 or the standard
specified in the agreed Inspection Test Plant.
3.19 Dimensions and tolerances
Liner, manufactured to this specification shall comply with the
dimensions and tolerances specified by the liner installer in the
submitted Inspection Test Plan. The tolerance on the liner wall
thickness shall be within -0%/+10% of the specified value.
4 Liner design
4.1 (d) [Addition]
Pressure cycles are permitted if they are within the pressure surge
allowance (e.g., surge stem from valve and pump shut on/of).
Conversely, lining shall not be utilized in applications that will include
continuous pressure cycling while utilizing duplex and multiplex
pumps.
4.1 (f) [Addition]
When using thermoplastic liner for pipeline rehabilitation applications,
the damaged steel pipes shall be repaired for any leaks or metal loss
and they shall pass the hydrostatic pressure testing as specified in 6.3.
4.1 (j) [Addition]
If the pipeline requires scraping facility as per SAES-L-410, it shall be
noted that the utilization of any scraping (e.g., foam pig) or inspection

tool (e.g., modified MFL) shall be reviewed by the liner installer. Scraping
procedure shall also strictly adhere to the liner installer recommendation.
4.5 [Modification]
The design of liner system shall be carried out by the liner installer for
the approved engineering contractor.
5 Liner design aspects
5.1.2 [Modification]
This procedure shall be limited to tight fit liners only. Loose fit, neutral,
and perforated liners are not allowed.
5.6 [Addition] Vent point and venting
For grooved liner pipelines, the vent point shall include a valve to allow
open / close of the vent. The design of the vent point assembly shall be
proposed by the liner installer. The minimum number of vent points shall
be one at each flanged end of a section of lined pipe. Venting can be
operated by installing valve to be closed or opened during normal
operation. Venting can also be used to monitor the integrity of the liner.
Pressure gauges needs to be installed to monitor the pressure inside
the annulus.
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 operators 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 needs to be kept below 50 psig (3.4 barg)
at all times;
• Vents are to be left in the closed position at all times;
Note:
Venting procedure provided by the liner installer shall be strictly complied.
For smooth liner pipelines in non-sour service, such as water injection
lines, the vent point shall be plugged. venting during operation are
normally plugged.

Lined pipelines in sour service, such as sour water disposal and multi-
phase hydrocarbons with H2S, shall have a system to transport the
permeated gas to the bore.
5.7 [Addition] Spacing between vent points
Vent/passive re-injection point is usually installed at each flanged end
particularly for water service, stabilized crude oil and oil/water mixture.
Flangeless connections can be designed with or without vent points.
For critical applications such as multiphase system, gas and
unstabilized crude oil additional vents shall be needed. The liner
installer is responsible for determining the spacing between the vent
points.
The steel contractor shall install weld O’let fittings a maximum of 75 –
100 mm (3” – 4”) distance from flange weld to serve as part of the liner
vent piping system. The weld O’let shall be installed to each flange
end, at the 12 o’clock position. Following the installation of the vent
weld O’let on the pipe, drilling out of the vent hole shall be performed
by the steel contractor at the size of maximum 3.2 mm (⅛ in). Vent
tubing shall be connected with the host pipe by utilizing a thread-o-let
connection and it shall be inspected through a non-destructive testing
before the insertion of the liner as per the liner installer recommended
procedure.
The vent tubing shall include a pressure gauge able to read from a
minimum of 3.4 barg (50 psig) to the maximum allowable operating
pressure of the lined pipe.
Liner installer shall determine the length of the pipeline and the number
of vent tubing that can be connected using a jumper before connecting
with a passive re-injection system or to an exit to the atmosphere.
Grooved liner requires to incorporate steel screen mesh to prevent any
extrusion of the liner through the vent hole.
5.8 [Addition] Other design aspects
Routing of the pipeline shall be properly studied in the design phase to
incorporate long radius bends to allow for longer length pull. If flanged
system is used, routing optimization study will aid in reducing number
of flanges.
5.9 [Addition] Design of end connectors
In general, flanged connections are considered for termination at the
ends of pipeline sections. The thermoplastic stub-ends shall be made
from the same material as the liner and have the same internal
diameter as the liner.

For other type of end connectors, such as flangeless connections and

others,
the liner installer shall submit the design for approval to the CSD Non-
metallic Engineering Group. The liner installer shall demonstrate by
means of a qualification test that the end connection meets the same
operational requirements as the rest of the thermoplastic liner.
The design shall account for shrinkage, creep, aging of the
thermoplastic material and operational pressure fluctuations. The
specific system shall be limited up to the maximum size of the qualified
jointing system.
6 Liner installation
6.3 [Addition] Preparation
An accurate assessment of the condition of the host pipeline in the
rehabilitated project per SAEP-306 is critical to ensure a successful
lining operation. For rehabilitation of existing corroded pipelines,
preparation issues to consider include:
• Remaining steel wall thickness;
• Corrosion damage;
• Presence of leaks;
• Internal deposits;
• Diameter variations and mismatches (telescopic);
• Weld protrusions and misalignment;
• General lay-out with bends, road, pig traps, manifolds, etc.
The following measures shall be performed:

• Before installation of the liner in new projects, the bare steel pipes
shall be hydrotested as per SAEP-L-150.
• For rehabilitation projects, the condition of the existing steel pipe

shall be assessed to ensure that the steel pipelines have sufficient
mechanical strength to meet the design pressure rating for the
proposed service as per SAEP-326, either through Inline
Inspection, Pressure testing or Direct Examination.
• The internal condition and dimensions of all pipelines shall be
evaluated to ensure that the liner can be pulled through each
segment without damage due to excessive local weld penetration.
• A metallic gauging plate shall pass through the host pipe to break
any weldments or icicles and clean the pipe. Liner installer shall

provide the plate size and the gauge running procedure prior to
installation.
• In case a gauging plate cannot be passed through (e.g., cement
lined pipe), a short section of liner can be pulled through the host
steel/carrier pipe to assess the internal condition of the pipeline.
Damage extending deeper than 10% of the liner nominal wall
thickness shall not be allowed for lining activity.
• Locations for cutting and flanging of the line and any requirement for
separate spooled sections needs 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 bend where possible is 40D).
• Flanges welded to the steel pipeline requires to have a matching
bore and with a minimum internal radius which is required to
provide a smooth interface between CS flange and the HDPE stub-
end to avoid any sharp corners touching the HDPE. Roto-lined
reducers are recommended in case of lining telescopic carbon steel
lines.
Lining in offshore can be implemented either by towing, Reel-ay or

S-Lay method. Lining in offshore application is limited to water
injection and disposal application only with no/minimal dissolved gas
in the stream.
Particularly for offshore liner installation, special attention shall be paid
to ensuring that there are sufficient spaces, weight, and anchoring
provisions for all the equipment required for the installation and testing
of the liner.
Liner installation in the new and rehabilitated pipe shall be carried out
by pulling the liner through a host pipe utilizing a wireline equipment or
winching unit and the calibration certificate of the equipment shall be
submitted.
Liner material shall be compatible with chemical treatment utilization,
if still utilized to protect unlined portions of the pipeline.
6.4 [Addition] Bead cleaning
After completion of the fusion weld, external bead shall be removed by
trimming tool / bead remover. After removal of external bead, 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.
The requirement of internal bead removal, if any shall be decided
during initial stage of project. In case of internal bead removal is
required for the liner fusion joints, the liner installer shall obtain the
required tools as necessary during mobilization stage of the project.
6.5 [Addition] Joints testing
Field fusion joints shall be tested by bend back testing per ASTM
F2620 to ensure that proper fusion parameters, adequate performance
of fusion machine and technician proficiency are accomplished.
Frequency of the testing shall be at least 3 liner samples per 1 KM pull
length. Acceptance criteria shall be that no voids and visible cracks on
the joint surface.
6.6 [Addition] End flanges and in-line flanged joints
Connections between thermoplastic lined pipes and metallic piping
shall be flanged. The design of the thermoplastic lined flanges shall be
proposed by the liner installer. The design of the lined steel flanges is
typically raised face with retainer rings. The use of raised face flanges
for high pressure lined pipelines (Class 900 and higher) is allowed as
per SAES-L-109 paragraph 8.3 as specialty flange assemblies.
When the liner has been pulled in, flange adapters shall be fusion
welded to the liner pipe-end.
Extrusion welding of thermoplastic flange ring as per DVS 2207-4 or
equivalent, is allowed for short length spools, for which stretching of
liner may not be possible.
Steel flanges welded to the steel pipeline require to have a matching
bore and with a minimum internal to provide a smooth interface
between the steel flange and the thermoplastic stub-end to avoid any
sharp corners.
The steel retainer rings shall be designed in such a way that they fit
between the thermoplastic flange and inside the bolt circle of the steel
flanges.
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 liner installer. Bolts are typically required to be re-torqued after an
initial service period of 24 hours.
A typical flange configuration is exhibited in Figure 1.

Figure 1 - Typical flange configuration for pipe liner [Ref. CSA Z662]
6.7 [Addition] Testing

a) Liner pressure testing
Following the fusion jointing, the fused liner shall be subjected to
pneumatic pressure testing as follows:
(1) After the insertion of the liner in the host pipe, the
liner shall be tested at a pressure of 6.9 barg (100 psig) for
15 minutes with the vent tubing kept open for monitoring
any release of air.
Or
(2) The liner shall be tested at a pressure of 0.3 barg
(4.35 psig) for 4 hours while the fusion joints are inspected
with soap.
Acceptance criteria shall be no pressure drop in the test gauge
after stabilization and during test phase. Marginal release of air
from vents shall not be concluded as leak/fail because, in an air
test, it is impossible to get all the air squeezed out of the annulus
and so it can continue to come out slowly in very low volumes
over a long time. If considerable amount of air is coming out
consistently and a pressure drop in the gauge is witnessed, then
it would be indicative as liner leak.
b) Lined pipe hydrostatic pressure testing
The completed lined pipeline system shall be pressure tested with
as per the following:

− Lined piping systems shall be pressure tested as per ASME

B31.4 at 1.25 times MAOP (including de-rating factor for
rehabilitated systems, if applicable) for 4 hrs
− All flanged joints shall be left exposed for inspection.
− Same conditions shall apply for both aboveground and

underground systems.
− Hydrotest shall be done with water at ambient temperature.
− Same conditions shall apply for both aboveground and

underground systems.
− Acceptance criterion of the hydrotest shall be no weeping

at flanges and/or vent holes witnessed during the test.
− At the end of the hydrotest the vents shall all remain closed
After the hydrotest and until the lining being implemented, the
following shall be met:
− The pipeline shall be left cleaned, dried properly after
hydrotest and ensure flange ends protected from entering
to any sand, dust/ingress while preventing any microbial
corrosion situation.
− If the lining will not be conducted in short time after
hydrotesting, the pipeline shall always be kept dried
utilizing the liner installer recommended practice.
− Ensure that pipe ends are protected against the foreign
particles intrusion until the liner insertion.
Note:
It is prudent that the steel pipeline requires to be lined within short period of time after the
hydrotesting and the liner installer shall develop an implementation plan accordingly.
7 Liner operation
7.4 [Addition] Liner operation
An operational procedure shall be developed for all lined pipelines and
flowlines. This procedure shall as a minimum address the following
aspects:
• Operating envelope

• Venting
• Pigging
• Start-up procedure
• Routine operations
• De-pressurizing
7.5 [Addition] Maintenance

Vent tubing shall be kept clean and, if blocked, it is recommended to
be cleaned with low-pressure water or per the liner installer
recommended practice. High pressure water jetting or sharp tools shall
not be permitted for cleaning.
If toxic gases (e.g., H2S) are present in the vent tubing and cannot be
re-injected back to the bore, it shall be cleaned with supervision of the
liner installer while following the liner installer recommended practice
and adhering to the requirements stated in section 5.6.
After the start-up, the lined pipeline shall be monitored for any leakage
while the vent tubing shall be checked for any pressure build-up at a
regular interval. Monitoring frequency shall be adjusted based on the
built-up pressure in the annulus. Vent shall not be opened if the lined
pipeline annulus pressure exceeds the bore pressure. Vent tubing shall
be checked for blockage at a regular interval.
7.6 [Addition] Repair

If the lined pipeline suffers external corrosion, it shall be repaired with
composite wrap and no hot work shall be allowed which can deteriorate
the mechanical properties of the liner.
For lined water injection system, if the liner is breached, it shall be
pulled out of the host pipe and once the breached location is found, it
shall be cut and repaired with a new liner manufactured with the similar
liner material.
For lined hydrocarbon system, if the liner is breached, the breached
section shall be pulled out of the host pipe and replaced with a new
section.
For all breached lined pipe, the host steel pipe shall be inspected to
ensure integrity of the pipe. Furthermore, a root cause analysis shall

be conducted to identify the causes so it becomes clear whether to

repair and replace in kind or change the design (e.g., using another
liner material)
In case flange connection is dismantled for any reason, replacement of
appurtenances such as vent, jumper line, re-injection tubing is
required.
In case annulus fluid passes through a jumper from the breached
section to the adjacent lined section, an engineering assessment shall
be carried out to determine the effect of the annular fluid in the adjacent
pipe.
Repair work shall be done per the repair procedure submitted by the
liner installer. Repaired pipeline shall be pressure tested at 1.1 times
the design pressure for 24 hours and 4 hours for buried and
aboveground pipelines respectively.
Any damage to the internal/external coating of the steel flanges at the
termination sides shall be repaired per para 9.6 of SAES-H-001.
If the pipeline failed, beyond repair or when it reaches its end-life, the
nonmetallic liner shall be recycled or repurposed as appropriate.
7.7 [Addition] Marking

Thermoplastic lined pipe shall be properly marked as “PIPE LINED
WITH PLASTIC MATERIAL” to avoid cutting of the liner in the event of
any operational set back.
For buried lines, surface markers shall be placed above the line at the
beginning and end of the thermoplastic lined pipeline
V. Documentation [Addition]
➢ Information to be submitted to the liner installer
The following information needs to be supplied to the liner installer:

• Internal/external diameter of carbon steel pipeline.
• Length of pipeline.
• ROW 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.
• Maximum design temperature.
• Minimum/maximum operating pressure of the system.
• Maximum rate of de-pressurization of the system.
• Indication of likelihood of large pressure fluctuations (surge, water
hammer)
• 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.
➢ Information to be submitted by the liner installer
The liner installer 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 thermal expansion due to operating temperatures.
• Liner manufacturing procedure.
• Liner installation procedure.
• Anticipated insertion (pulling) forces for each liner section in relation to the
liner strength capabilities.
• Bend limitations for the steel pipe.

• Maximum allowable weld penetration of carbon steel pipeline girth welds.

• Vent connection details and spacing. Vent installation and spacing details.
• Butt fusion/extrusion welding procedure, personnel certification and field
testing.
VI. Quality program [Addition]
The manufacturer shall maintain a quality manual which describes the quality
program. All prior revisions shall be retained for a period of not less than five
years.
The quality manual shall address a documentation program to assure

communication of approved manufacturing and inspection procedures to qualified
receiving, manufacturing, and quality control personnel. The quality manual 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.
For HDPE material, the liner manufacturer shall comply with the Quality Control
(QC) test requirements specified in Section 5 of 01-SAMSS-051. For any other
materials, e.g., PE-RT, PA, PVDF, liner manufacturer shall submit a copy of their
quality assurance plan to the CSD Non-metallic Engineering Group for review.
Shop fabricated joints shall be part of this quality plan and any relevant
imperfections observed, e.g., weld defects, scratches, and notches in the welded
joints, shall result in rejection of the welded pipe.
The liner installer shall submit a quality test plan for fittings, stub-end, vent piping,
and steel mesh screen, if used, in compliance with this procedure requirement.
VII. Drawing [Addition]
Drawings that showing dimensions and tolerances, for stub-end, lined pipe
connection, passive re-injection system shall be submitted for approval to the
Buyer’s Representative. The drawing shall show the fittings pressure rating and
the parent pipes SDR value.

VIII. Storage and handling [Addition]
Straight lengths liner shall be stored on horizontal racks and given support to
prevent damage. Coils shall be stored stacked flat one on top of another.
Pipe shall be protected from environmental contamination and damage by third

party.
Covers shall be used to prevent ingress of moisture or dirt inside the grooves of
the liner.
Liner 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 liner is damaged it shall be rejected.
Document History
02 June 2021 Major revision.
22 January 2019 Editorial revision.
26 April 2018 Merger of 01-SAMSS-050 and SAEP-387 and overlaying with NACE RP0304.

Saep-387 2021

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Engineering Procedure 02 June 2021

Previous Revision: 22 January 2019 Next Revision: 02 June 2026

Saudi Aramco: Company General Use

II CONFLICTS AND DEVIATIONS ................................................................................................... 5

III REFERENCES ................................................................................................................................. 5

IV DETAILED MODIFICATIONS OF NACE SP0304 .................................................................. 7

V. DOCUMENTATION [ADDITION] ............................................................................................. 23

VI. QUALITY PROGRAM [ADDITION] ............................................................................................ 25

VII. DRAWING [ADDITION]................................................................................................................ 25

VIII. STORAGE AND HANDLING [ADDITION] ................................................................................ 26

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Added reference to 01-

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contact with the

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II Conflicts and Deviations

III.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAES-H-001 Coating Selection and Application Requirements for

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SAES-L-132 Materials Selection for Pipelines, Piping and Process

01-SAMSS-051 High Density Polyethylene (HDPE) Pipe and Fittings.

III.2 Industry Codes and Standards

American Society for Testing and Materials

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ISO 24033 Polyethylene of raised temperature resistance (PE-RT)

Summary of modifications of NACE SP0304 “Design, Installation, and

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Subs. 5.1.2 Liner design types....................………. Modification

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Vent connection or point: A vent in a lined pipeline system is a hole

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Non-metallic Engineering Group before approval of the material for

Table 1 – Recommended liner material as a function

PA Not Applicable 185ºF (82ºC) 185ºF (82ºC) Not Applicable

PVDF Overdesign 250ºF (120ºC) 250ºF (120ºC) Not Applicable

3.14 [Addition] Guidelines to selecting thermoplastic liners

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pigging operations, and swelling. Other general characteristics that

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6000000039 for HDPE material), liner shall be procured from the

3.18 [Addition] Ovality

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For other type of end connectors, such as flangeless connections and