FUTURE PIPE INDUSTRIES

Spoolable Reinforced Composite Line Pipe

Installation Guide
July 2005
Spoolable Reinforced Composites
(SRC) Line Pipe
INSTALLATION GUIDE
January 2005
Table of Contents
SECTION 1
1
SECTION 2
3
SECTION 3
8
SECTION 4
15
SECTION
5
16
SECTION
6
21
SECTION 7
22
Spoolable Reinforced Composite Line Pipe
INSTALLATION GUIDE
July 2005
Table of Contents
SECTION 1
Introduction
SECTION 2
Transport, Handling and Storage
SECTION 3
Installation Techniques
SECTION 4
End Connections
SECTION 5
Installing Lap Joint Flanges
SECTION 6
Field Testing
SECTION 7
Line Pipe Repairs
i
This symbol identifies instructions specific to SRC line pipe in cold weather.
CAUTION: This bullet-and-title identifies instructions relating to safety of personnel and equipment in the installation of SRC
line pipe.
NOTE: This bullet-and-title identifies instructions relating to speed and efficiency in the installation of SRC line pipe.
FPI reserves the right to incorporate improvements into our products continually, and make changes in specifications and de-
scriptions contained in this publication as conditions warrant. The information in this publication is general in nature, and does
not intend to be engineering advice. FPI products are provided subject to FPIs General Terms and Conditions, and nothing
herein modifies or expands said General Terms and Conditions.
ii
This guide provides recommended practices for the installa-
tion of Future Pipe Industries Spoolable Reinforced Compos-
ite (SRC) line pipe in upstream oil and gas applications.
Line pipe is a general industry term that refers to horizontal
pipe applications and includes flow lines, production lines,
gas-gathering systems, disposal lines and injection lines.
Following these guidelines is essential to a successful installa-
tion and to a long service life. The end user is encouraged to
read and understand these recommended procedures prior to
installing SRC.
NOTE: FPIs Trainers are available to train contractors con-
cerning the proper procedures for installing SRC. All installa-
tion contractors must be trained prior to installing SRC. Con-
tact FPI for scheduling.
GENERAL PRODUCT DESCRIPTION
SRC line pipe includes the following structural elements:
Extruded thermoplastic liner on the ID of the pipe
Composite laminate consisting of carbon and/or E-glass
fibers in an enhanced amine cured epoxy matrix
Optional damage tolerance layer of E-glass fibers in
an enhanced amine cured epoxy on the OD of the pipe
PRODUCT SPECIFICATIONS
Each SRC line pipe product has a specification detailing the
physical characteristics. FPIS SRC line pipe is an engineered
product, so special products can be produced to meet specific
applications.
STANDARD LINE PIPE PRODUCTS
Cobra is the product name used to describe line pipe with
an HDPE liner. Python is the product name used to describe
line pipe with a PEX liner. Boa is the product name used to
describe line pipe with a PA-11 liner (see Table 1-1).
1
SECTION 1: INTRODUCTION
Table 1-1: STANDARD FPI LINE PIPE PRODUCTS
Product
Thermoplastic
Liner
Maximum
Operating
Temperature F (C)
Typical Applications
Cobra
TM
High Density
Polyethylene (HDPE)
140 (60) Water lines, limited hydrocarbons
Python
TM

Crosslinked
Polyethylene (PEX)
180 (82) Same as HDPE, but for higher working temps
Boa
TM
Polyamide-11 (PA-11) 210 (99) Hydrocarbons, limited water*
*In applications with water, the maximum operating temperature is 165 F (74 C).
2
PRODUCT IDENTIFICATION
As shown in Figure 1-1, SRC line pipe is marked in epoxy
based ink with the following data:
Nominal Pipe Size (inches)
Maximum Operating Pressure (psig)
Product Name (liner material)
Footage Mark (feet and meters)
Serial Number (uniquely identifies the pipe)
NOTE: It is approximately 5 feet between the first vertical bar
of the F in FPI to the equivalent point on the next footage
mark.
CAUTION: Be sure to consult the appropriate Product Speci-
fication to verify mechanical properties before installation.
LINER MATERIALS
Thermoplastic liner materials for SRC line pipe should be se-
lected on the basis of chemical compatibility with flow media
and the required operating temperature. All liners are pres-
sure tested before being processed. Liners are not used in
design calculations of the finished product. Consult FPI for
product recommendations for your application.
STRUCTURAL LAMINATE
The structural composite laminate is constructed from carbon
and/or E-glass fibers in an enhanced amine cured epoxy ma-
trix. The laminate is designed with FPIs proprietary design
software. The enhanced amine cured epoxy formulation is
selected to provide the corrosion resistance and resistance
to hot/wet degradation necessary for oil and gas industry
applications.
Figure 1-1: Typical marks on SRC line pipe every five feet.
Nominal Pipe Size: 4 (100 mm)
Serial Number: 00369
Footage Marks: 4,855 ft (1,479.8 m)
Maximum Operating Pressure:
3,000 psig (200 bars)
Product Name:
Cobra (HDPE liner)
3
SRC line pipe is packaged on steel or wooden reels for trans-
port, storage and deployment. Smaller reels can usually be
shipped upright, but may require a drop-deck trailer to be
shipped without a permit. Larger reels (greater than 120 or
3,000 mm flange diameter) are usually shipped horizontally
on wooden strips (see Figure 2-1).
Generally, SRC line pipe is spooled so that there is a minimum
gap of 1-3 inches (25-75 mm) between the outer wrap of pipe
and the outer rim of the reel. For North American transporta-
tion, no protection for the outer layer is generally required.
For export shipments, a ring of wooden planks can be placed
on the outside of the reel to protect the pipe.
All SRC line pipe is 100% hydrotested at the factory to 1.5
times the maximum operating pressure. After hydrotesting at
the factory, test water is chased from the pipe with foam pig
and several gallons of alcohol antifreeze to reduce the chance
of water pockets, which could freeze and damage the pipe.
Both ends of the pipe are plugged before shipping.

CAUTION: While SRC line pipe is very flexible, it will still
retain a small amount of stored elastic energy when wound
on the reel. Care should be taken to insure that the free end
of the spooled pipe is restrained or under tension during all
operations to avoid injury to personnel or damage to pipe
and equipment.
CAUTION: Improper handling of reels can cause injury to
personnel as well as damage to the product. Insure that the
lifting equipment used, including straps, slings and spreader
bars, is adequate for the load and conditions. Insure that
equipment operators have received the proper training in
handling SRC.
NOTE: Handling equipment (e.g. forklift tines, lifting slings
and chains) must not be allowed to contact SRC line pipe
during handling.
NOTE: SRC line pipe is designed for reels with a specified
minimum bend radius, which is documented in the specifica-
tion sheet for each product. SRC line pipe MUST NOT BEND
BEYOND THE MINIMUM BENDING RADIUS AT ANY TIME!
Typical shipping reel sizes and capacities are shown in Figure
2-2, Table 2-1 and Table 2-2.
SECTION 2: TRANSPORT, HANDLING AND STORAGE
Figure 2-1: Shipment of reel in horizontal position.
Figure 2-2: Reel nomenclature.
Outer
Flange
Diameter
Overall
Width
Drive Holes
(inboard)
Lifting Holes
(outboard)
4
Table 2-1: FPI SHIPPING REEL INFORMATION (Imperial)
Nominal
Pipe Size
(ID)
Typical Reel Dimensions
Typical
Length of
Pipe on
Reel
Total Weight of Pipe and Reel
Reels per
Truck
Outer
Flange
Diameter
Overall
Width
Empty
Weight
750 psi
MOP
1500 psi
MOP
2250 psi
MOP
(in) (in) (in) (lb) (ft) (lb) (lb) (lb) (-)
1 138 80 2,100 10,000 5,400 5,400 6,500 4
1 1/2 138 80 2,100 10,000 6,600 7,900 7,900 4
2 138 80 2,100 9,000 8,300 10,200 11,900 4
2 1/2 166 96 6,100 8,000 14,400 15,900 17,400 3
3 166 96 6,100 6,500 14,400 15,800 17,200 3
3 1/2 202 102 7,100 6,000 16,600 18,100 19,700 2
4 202 102 7,100 4,500 16,400 17,900 19,400 2
4 1/2 210 102 7,800 3,200 16,900 18,500 21,500 2

Notes:
Table 2-2: FPI SHIPPING REEL INFORMATION (Metric)
Nominal
Pipe Size
(ID)
Typical Reel Dimensions
Typical
Length of
Pipe on
Reel
Total Weight of Pipe and Reel
Reels per
Truck
Outer
Flange
Diameter
Overall
Width
Empty
Weight
50 bar
MOP
100 bar
MOP
150 bar
MOP
(mm) (mm) (mm) (kg) (m) (kg) (kg) (kg) (-)
25 3,505 2,030 950 3,000 2,400 2,400 3,000 4
38 3,505 2,030 950 3,000 3,000 3,500 3,500 4
50 3,505 2,030 950 2,700 3,700 4,600 5,300 4
63 4,216 2,440 2,770 2,400 6,500 7,200 7,800 3
75 4,216 2,440 2,770 2,000 6,600 7,200 7,900 3
88 5,130 2,590 3,220 1,800 7,500 8,100 8,800 2
100 5,130 2,590 3,220 1,400 7,500 8,200 8,900 2
155 5,335 2,590 3,540 1,000 7,650 8,400 9,750 2

Notes:
1. All values are estimates.
2. Specific lengths and/or custom reels can be supplied for special project needs.
1. All values are estimates.
2. Specific lengths and/or custom reels can be supplied for special project needs.
STANDARD STEEL REELS
Standard FPI reels are radial-spoke steel reels equipped with
heavy steel drive plates on the sides as shown in Figure 2-3.
There are seven to nine holes in the drive plate:
One center shaft hole is 4 (101mm) diameter
Four inboard drive holes are 3 (76mm) diameter on a
20 (508mm) diameter circle
Two or four outboard lifting holes are 3 (76mm)
diameter on a 41 (1,041mm) diameter circle
RECEIVING & INSPECTION
Check the Bill of Lading and Certificate of Conformance
for any discrepancies between the Purchase Order, re-
ceived pipe, end connections and equipment.
Visually inspect all exposed surfaces of the pipe and the
reel upon arrival.
Inspect the pipe for bruises, light spots or rough
resulting from impact, and damage to the reel indicate
damage during transportation.
Note any discrepancies or observed damage to the pipe
on the delivery receipts before accepting or signing for
products.
UNLOADING UPRIGHT REELS
Smaller reels of SRC line pipe may be received in the up-
right position and can be unloaded using one of the following
methods:
With an appropriately rated forklift with widely spaced
tines, slide the tines under the radius of one flange, chain
the top of the flange to the top of the forklift mast, and lift
the reel.
A steel bar or pipe of the appropriate size and strength
is passed through the central hole. A forklift is placed on
either side of the truck and the reel is lifted by both forklifts
simultaneously.
A steel bar or pipe is placed through the center hole of
the reel and a crane using slings attached to the bar lifts
the reel. A spreader bar is recommended to space out
the slings.
With any lifting method, the reel should be lifted only enough
to clear the truck bed, and then the truck is driven slowly from
under the reel.
UNLOADING HORIZONTAL REELS
Reels shipped horizontally are typically unloaded by one of
the following methods:
Two forklifts are placed on either side of the trailer to lift
the reel under the flanges.
A crane using a bar or pipe lifts the fixture in the center
hole.
A crane using slings attached to the reel structure lifts
the reel. A spreader bar is recommended to space out
the slings.
The trailer is driven slowly away from under the reel.
With any lifting method, the reel should be lifted only enough
to clear the truck bed.
UPRIGHTING REELS
Reels that are horizontal may be lifted upright using a suitably
sized crane or two suitably sized forklifts working together.
The following techniques have been found to be suitable:
A crane using slings attached to the flange rims (or to
the lifting holes in the drive flange), picks up the reel to
upright it. See Figure 2-4.
One forklift lifts the reel from one side and the second
fork lift is on the opposite side to catch the reel and
lower it to the ground.
The installer should consider local conditions and available
equipment to develop suitable alternative approaches.
5
Figure 2-3: Typical drive plate configuration.
6
NOTE: Reels in the upright position should always be chocked
to prevent rolling. Be sure to chock ONLY on the reel flange.
DO NOT CHOCK ON SRC LINE PIPE.
FIELD TRANSPORT
Transport should be on a trailer that is as close to the ground
as practical. The speed of the transport should be carefully
controlled, especially during turns.
CAUTION: Upright reels are top-heavy loads that are easily
overturned. The reel and frame should be mounted as close
to the ground as possible and the frame chained tight to the
trailer. During transport, speed should be reduced and turns
handled with care.
MOVING THE REELS
Reels may be moved short distances using one or two forklifts,
gin pole truck, steel track backhoe, or a crane and sling. The
method is the same as described for unloading.
CAUTION: MOVING REELS BY ROLLING IS NOT RECOM-
MENDED. Rolling reels may become unstable and roll out of
control. Upright reels are top heavy and may tip over when
rolling.
STORAGE
Reels of SRC line pipe should be stored on level stabilized
ground with no protruding objects that might contact and
damage the pipe on the outermost layer. Chock or anchor the
reel to be sure it can not roll. Do not chock on pipe.
ULTRAVIOLET STORAGE
If SRC line pipe is to be stored for an extended period of time,
it should be protected from ultraviolet (UV) exposure by being
covered with a tarpaulin.
THERMAL STORAGE
SRC utilizes a design philosophy that involves use of a ther-
moplastic liner that serves as a fluid containment element and
a composite laminate that serves as a structural element. The
thermoplastic liner has a large coefficient of thermal expan-
sion, relatively low strength and modulus, and large elonga-
tion at the break point. The composite structural element on
the other hand has a very small coefficient of thermal expan-
sion, relatively high strength and modulus and relatively low
elongation at the breakpoint.
As temperatures decrease, the modulus and strength of both
the composite and thermoplastic components increase while
the elongation at the break point decreases. Additionally, as
temperatures decrease, the thermoplastic liner contracts in
diameter and length, with respect to the composite, by the ef-
fects of thermal expansion/contraction. When the liner is well
bonded to the composite such that its expansion/contraction
is limited by the strength of the composite, an increased stress
on the thermoplastic liner will result.
When SRC stored on a reel at 3.5% spooling strain is ad-
ditionally subjected to extremely low temperatures, the in-
creased thermal stresses can result in circumferential breaks
in the liner (a loss of fluid containment). Forces resultant from
removal of SRC from the reel in extremely cold temperatures
can have the same effect. The thermoplastic liner material se-
lected limits storage temperatures as indicated in Table 2-3.
SRC, like steel pipe, is subject to bursting when a slug of
water is trapped in the pipe and the temperature drops to
freezing. Special precautions are taken at the factory to mini-
mize water entrapment following hydrotest. If excess water is
found to be in the SRC line pipe, from whatever source, efforts
should be made to remove it, protect the water from freezing
by adding anti-freeze, or to keep the spool of pipe above the
freezing temperature.
Figure 2-4: Righting and lifting a reel.
SRC line pipe should be protected from freezing
water damage by insuring that no water has en-
tered/can enter the pipe.
Table 2-3: Minimum storage temperatures
Product
Thermoplastic
Liner
Minimum
Storage Temperature
Cobra
TM
High Density
Polyethylene
(HDPE)
-29 F (-34 C)
Python
TM
Crosslinked
Polyethylene (PEX)
-29 F (-34 C)
Boa
TM

Polyamide-11
(PA-11)
-55 F (-48 C)
7
FPIs SRC line pipe is designed to be stored, handled, de-
ployed and installed using a reel. The pipe can be deployed
using an A frame, winch truck, picker, crane and/or side
boom. The flexibility, long continuous lengths, and reduced
sensitivity to impact/wear dictate installation techniques that
differ substantially from methods used to install jointed steel
or fiberglass pipe.
This section discusses the installation techniques that have
been successfully used in the past. A brief discussion of some
of the essential tools required for installations are included in
this section. Specific installation techniques may require tools
not listed or discussed.
DEPLOYMENT
SRC utilizes a design philosophy that involves use of a ther-
moplastic liner that serves as a fluid containment element and
a composite laminate that serves as a structural element. The
thermoplastic liner has a large coefficient of thermal expan-
sion, relatively low strength and modulus, and large elonga-
tion at the break point. The composite structural element on
the other hand has a very small coefficient of thermal expan-
sion, relatively high strength and modulus and relatively low
elongation at the breakpoint.
As temperatures decrease, the modulus and strength of both
the composite and thermoplastic increase while the elonga-
tion at the break point decreases. At extremely low tempera-
tures, (temperatures below the minimum installation temper-
ature) both the composite and thermoplastic can buckle or
fracture when attempts are made to deploy the pipe from the
reel. Table 3-I provides suggestions for minimum installation
temperatures for the various liner materials.
Table 3-1: Minimum installation temperatures
Product
Thermoplastic
Liner
Minimum
Installation
Temperature
Cobra
TM
High Density
Polyethylene (HDPE)
-20 F (-29 C)
Python
TM
Crosslinked
Polyethylene (PEX)
-20 F (-29 C)
Boa
TM

Polyamide-11
(PA-11)
-30 F (-35 C)
NOTE: It is STRONGLY RECOMMENDED that contractors
and construction crews have a FPI Field Service Technician or
Certified Representative train their personnel before their first
installation of SRC line pipe. Please contact FPI for additional
information and scheduling.
NOTE: It is recommended that all contractor and construction
crews be briefed on the installation procedures to be followed
and the difference between SRC line pipe and other types of
products. Individuals that plan to install FPI end connections
on SRC line pipe MUST be trained and certified by FPI prior
to installation.
A person with training in composites piping should visually
examine the pipe as it is deployed from the reel to identify
anomalies in the product that may result from shipping, han-
dling or deployment. If damage is discovered, it should be
repaired or removed prior to field-testing or burial. Always
document and mark the location of the damaged area for
future reference.
As a general rule, SRC line pipe should not be un-
spooled or respooled if the pipe itself is at tempera-
tures below -20 F (-29 C). Certain high-perform-
ance polymer liners may have different minimum installation
temperature limits (see Table 3-1).
SECTION 3: INSTALLATION TECHNIQUES
8
DEPLOYMENT METHODS
Several different methods have been used to deploy and in-
stall SRC line pipe:
Spooling frame or A frame
Steel track backhoe with a spreader bar
Winch truck with a spreader bar
Cherry picker with a spreader bar
Crane with spreader bar
Side boom with spreader bar
Spooling trailer
SPOOLING FRAMES
A spooling frame suitable for supporting and controlling the
reel of pipe is recommended. Insure that the reel will physi-
cally fit into the spooling frame (including the shaft diameter
and spacing of the drive holes). The frame must hold the reel
such that it can rotate in a controlled fashion to deploy pipe
(see Figure 3-1).
Ideally, the frame should:
Support the reel off the ground allowing it to rotate in a
controlled fashion
Have an integral braking device that allows the operator
to maintain tension on the pipe as it is pulled off the reel
(adequately sized friction brakes have been used success-
fully)
Be positioned as close to the ground as possible to
minimize the overturning moment of the top-heavy reel
For respooling operations, a fairlead mechanism is
recommended to insure even spooling
NOTE: Hydraulically powered frames such as those used in
coiled tubing operations have been used successfully, when
properly employed
STEEL TRACK BACKHOE, WINCH TRUCK, CHERRY
PICKER, CRANE OR SIDE BOOM
Many types of equipment have been used to deploy SRC line
pipe. All equipment must have the load capabilities to safely
lift and handle the reel of pipe being installed. In most lifting
cases, the cable or wire rope attached to the reel must be
spread in order to prevent placing a collapse force at the top
of the reel. This can be prevented by using a spreader bar.
The spreader bar must be wider than the width of the reel to
prevent damage to the reel when lifting and placing tension
on the cable or wire rope.
SPOOLING TRAILER
A spooling trailer is a specifically built trailer for hauling, de-
ploying and respooling SRC line pipe.
UNSPOOLING FROM A STATIONARY POSITION
To install SRC line pipe from a stationary position, the reel is
secured at one position and the pipe is pulled off the reel. This
is the preferred method for installation of SRC in areas with
soil that is not excessively rocky or abrasive; that is, where
the pipe will not be damaged by being dragged over the
ground.
The equipment used to pull SRC line pipe must have sufficient
power. Experience has shown that estimating the force (in
pounds) for dragging SRC line pipe across dry level soil is:
0.5 X Line Pipe Weight (lb/ft) X Length (ft) X = Axial Pulling
Load (lb)
Experience has shown that SRC line pipe may be pulled by a
pickup truck, tractor, backhoe or similar piece of construction
equipment. See Figure 3-2.
The maximum pulling load must not exceed the maximum
allowable tensile of the pipe being deployed. See Product
Specification for tensile allowable.
Figure 3-1: Reel mounted into a spooling frame.
9
A load indicator should be fitted between SRC line pipe and
the pulling equipment so that the axial load on the pipe is
monitored. If the maximum pull load exceeds the products
tensile rating, multiple pulling devices spaced along the length
of the pipe should be used to insure that the maximum allow-
able pull load is not exceeded. However, these multiple units
must be operated at exactly the same speed to avoid buckling
of the pipe.
CAUTION: Tension should be maintained on the pipe at
the reel at all times (preferably with a brake on the spooling
frame, to prevent bird nesting of several layers of spooled
pipe). Bird nesting results when unrestrained pipe is free to
change spooling diameter and there is a rapid, uncontrolled
release of stored energy. Care must be exercised when re-
moving a bird nest of crossed pipe. Applying tension to pipes
that are crossed may result in pipe damage.
CAUTION: Do not cut the pipe until the ends are securely
restrained, due to the residual elastic energy in the spooled
pipe.
PULLING DEVICES
Pulling devices must be capable of pulling the predicted load
and have a rated working load approximately equal to the
maximum allowable tensile strength of the pipe being in-
stalled. A steel cable pulling sleeve (finger puzzle) which is at
least ten pipe diameters in length is recommended, as shown
in Figure 3-3.
It is recommended that the portion of the pipe at and near the
pulling device be cut off and discarded after use.
Another method of pulling SRC line pipe is with an internal
expandable mandrel type pulley. Contact FPI for details.
UNSPOOLING FROM A MOVING REEL
SRC line pipe can also be unspooled by anchoring one end
of the pipe at the starting point (using a pulling device as
described above) and hauling, lifting or pulling the reel away
from the starting point with an A-frame on a trailer or truck
bed, steel track backhoe, winch truck or cherry picker (see
Figure 3-4). This is the preferred method for installation in
areas with rocky or very abrasive soil, as this approach mini-
mizes the opportunity for abrasion damage to the pipe during
installation. This is also a preferred method for lines that are
not straight.
Figure 3-2: Unspooling of pipe from stationary spooling frame, using a
truck hitch to pull pipe alongside a trench.
10
Figure 3-3: Steel cable pulling sleeve (finger puzzle) on SRC.
Figure 3-4: Unspooling SRC line pipe from a trailer mounted spooling
frame.
11
CAUTION: All equipment must have sufficient load capabili-
ties to SAFELY handle the weight of the reel.
CAUTION: The reel of pipe represents a top-heavy load that
may be prone to overturning when crossing rough terrain. An
overturned load can result in injury to personnel and/or dam-
age to equipment and the pipe. Be sure to evaluate the center
of gravity of the equipment with the reel and insure that the
track of the vehicle is adequately smooth, wide, and level to
prevent overturning along the intended route.
BURIED INSTALLATIONS
SRC line pipe can be buried either by conventional trench &
backfill methods using conventional trenching equipment or
plowing-in with specialized trenching plows.
For buried installations, consideration must be given to the
method of attachment to surface equipment. This is particu-
larly critical in areas subject to soil movement or heave. The
transition from ditch to riser must be on a gentle slope with
mechanical support. Contact FPI for recommendations.

If future recovery of the pipe is a potential issue, SRC line pipe
can be installed inside a conduit, such as corrugated HDPE or
steel pipe, to facilitate retrieval.
TRENCH & BACKFILL: EXCAVATION & BEDDING
Proper construction of trenches is important. Trenches should
be constructed according to the following guidelines:
Trenches must be wide and deep enough to accommo-
date the SRC line pipe and other lines.
The trench should be as straight as possible.
Avoid sharp bends and abrupt changes in elevation in
the line.
When changes in direction are required, trenches
should be made with gentle, gradual turns which have a
radius greater than the minimum operating radius of SRC
line pipe product being installed (see Product Specifica-
tions for minimum operating bend radius).
The bottom of the trench should be as UNIFORM as
possible and provide a smooth, firm bearing surface to
support the bottom quarter of the pipe circumference. This
is often accomplished by healing the bottom of the trench
with a hoe bucket. High spots in the trench bottom can
cause uneven bearing on the pipe, damage due to local-
ized stress during backfill, and unnecessary wear at these
points.
It is important to remove all sharp rocks and other
abrasive material from the trench bottom.
The pipe should be properly supported to prevent low
spots, traps or sumps.
If the trench is excavated through rock or shale ledges,
or through unstable soil, make the trench slightly deeper.
Use a minimum of six inches of river sand or other clean
backfill such as pea-gravel in the bottom of the trench and
over the pipe to protect the pipe from rocks.
If bedding is used it should be in place before the pipe
is placed into the trench.
If multiple lines are installed in the same trench, they
should be separated by a distance of at least four to six
inches (100 - 150 mm) or one pipe diameter, which ever
is greater. This is particularly important if any lines in the
trench will experience pulsation or movement.
At road crossings, SRC line pipe is typically laid through
a conduit. See recommendations under Relining Applica-
tions section for installing SRC line pipe inside a conduit.
If it is not possible to use a conduit, see Table 3-2 for rec-
ommended burial depths beneath typical unpavedgravel,
asphalt or concrete roads.
NOTE: The depth of the trench affects the installation method.
SRC line pipe should be deployed beside the trench and low-
ered into the trench manually.
CAUTION: Safe work practices must be followed when work-
ing inside an open trench, including but not limited to the use
of adequate shoring of the sides of the trench. Local regula-
tions regarding shoring requirements should be consulted.
12
TRENCH & BACKFILL: BACKFILLING
Before backfilling the trench, check to be sure that the pipe
is properly positioned and that any tools or positioning jigs
used during installation are removed from the trench. Flange
connections and splices should be left exposed for inspection
during testing.
NOTE: Prior to hydrotesting, the trench should be backfilled
every 30 feet (10 meters) to surface. The trench should be
backfilled as soon as possible after hydrostatic testing to elimi-
nate the chance of damage to the pipe, floating if the trench
floods, or shifting due to collapse of the sides of the trench.

It is recommended that the material used as backfill for SRC
line pipe be free from rocks, boulders, large clods of dirt,
frozen dirt and other objects that could damage the pipe.
Caution should be taken to prevent voids (areas that do not
contain backfill) under or around the pipe. See Table 3-2 for
recommended backfill depths.
If frozen earth is used as backfill, it will eventually thaw and
contract, leaving the pipe with insufficient supports and voids
around the pipe. Remove frozen lumps from all backfill ma-
terials before backfilling. Compaction of the material to at
least the same density as the surrounding undisturbed soil is
recommended.
For trenches excavated in roads or under structures, place
backfill in 6 inch (150 mm) layers to top of trench, and com-
pact each layer to at least 95% of maximum density. When
compacting, avoid causing damage to the pipe. Vibrating
tampers should not be used until there is at least one foot of
backfill over the pipe.
PLOW-IN
A variation of the moving reel installation involves the use
of a plow to trench, install and cover the trench in a single
pass operation (see Figure 3-5). The plow must have sufficient
capacity to bury SRC line pipe to the required depth and be
equipped with a shoe with a radius that is equal to or greater
than the minimum operating bend radius of SRC line pipe.
In a plow-in installation, consideration must be given to the
method of feeding the pipe into the shoe. The orientation and
location of the reel and equipment, and the feeding of the
pipe should minimize bending of the pipe. Reversal of the
direction of bending should be avoided.
Table 3-2: RECOMMENDED BACKFILL DEPTHS
(For soil modulus over 1,000 psi; see ASTM D 3839 or AWWA C 950)
Nominal
Line pipe
Size
Surface Condition
Minimum Burial Depth to
Top of Line pipe
Minimum Sand or Pea-Gravel
Above Top of Line pipe
2 (50mm)
Un-Paved 17 in. 432 mm 12 in. 305 mm
Asphalt Paving, Min. 4 (100mm) 12 in. 305 mm 8 in. 203 mm
Concrete Paving, Min. 4 (100mm) 9 in. 229 mm 5 in. 127 mm
3 (75mm)
Un-Paved 20 in. 508 mm 14 in. 356 mm
Asphalt Paving, Min. 4 (100mm) 13 in. 330 mm 9 in. 127 mm
Concrete Paving, Min. 4 (100mm) 11 in. 279 mm 7 in. 178 mm
Refer to ASTM D 3839 or AWWA C 950 for details. Soil modulus depends on soil type and compaction. For example, pea gravel typically has modulus of
1,000 psi with no compaction, while sand requires slight compaction for the same modulus.
13
SURFACE INSTALLATIONS
For surface installations, SRC line pipe is laid either on the sur-
face, directly at grade or on fabricated stands (usually steel)
above grade. For pipe laid at grade, the surface should be
free of rocks and other sharp objects that could damage the
pipe.
System design must evaluate the coefficient of thermal expan-
sion and anticipated temperature swings (including black-
body absorption of the line pipe). Adequate expansion loops,
expansion joints or changes in direction should be provided.
Contact FPI for assistance.
When desirable, the pipe may be placed on supports above
the ground. Spacing and construction requirements of above
ground supports will vary according to application. SRC line
pipe should not come in direct contact with steel. Consult FPI
for above ground support and spacing recommendations (see
Figure 3-6).
SRC line pipe, when installed on the surface, must be re-
strained horizontally with thrust blocks or anchored to exist-
ing structures whenever it changes direction, and periodically
anchored vertically to piles, foundations, or other supports.
Bends in the pipe should always be made with gentle, gradu-
al turns, which have a radius greater than the minimum oper-
ating bend radius of the SRC line pipe product being installed
(see Product Specifications).
CAUTION: SRC line pipe, which is installed on the surface,
must be properly restrained BEFORE HYDROTESTING.
RELINING APPLICATIONS
Relining or insertion is a technique used to replace failed lines
by pulling or inserting SRC pipe into an existing line.
NOTE: Relining steel with SRC line pipe does result in a re-
duction of ID cross-sectional area. Flow may be less affected
than expected, since the thermoplastic liner of the SRC line
pipe is much smoother than steel line pipe. The Hazen-Wil-
liams flow coefficient of SRC line pipe is 150. Contact FPI to
assist in single or multi-phase flow calculations.
In relining applications, there must be adequate clearance be-
tween the outside diameter of SRC line pipe and the inside di-
ameter of the existing steel line. There must be no obstructions
in the steel pipeline. Obstructions in the line include any sharp
turns, dents or kinks in the pipe, and internal weld-splatter. All
of these can reduce the effective ID of the steel line and dam-
age the pipe being installed. A pig with sizing plates should
be run through the old steel a few times to insure a successful
installation of SRC.
Figure 3-6: SRC installed aboveground on fabricated steel stands.
Figure 3-5: Plow installation of SRC line pipe inside an HDPE tile conduit up a grade at approximately 1 km per hour.
It is recommended that the drift or ID of the steel pipe be
checked by pulling a 30 foot (10 meter) length of SRC line
pipe through the line using a pulling line with swivel joints
attached to both ends. If this test segment of pipe successfully
passes through the entire steel line, the rest of the pipe can be
attached to the pull line and pulled into place. If the test pipe
becomes stuck, the trailing pull line can be used to retrieve
the drift segment. Then, the steel pipe can be prepared as
required for the application.
NOTE: If laid wire rope is used as the pull line, a swivel must
be installed between the pull line and SRC line pipe to prevent
the laid wire rope from applying torque to SRC line pipe as it
is pulled during installation.
It is recommended that both ends of the pipe be capped dur-
ing pulling or insertion to prevent a build up of foreign mate-
rial in the line.
Whenever the pipe passes through a conduit, be sure that the
pipe is properly bedded at the points of entry to and exit from
the conduit to prevent stress, wear or damage to the pipe.
If there is any possibility that the pipe will touch the edges
of the conduit, pad the pipe and conduit to prevent rubbing
against the conduit. Concentric rubber boots, which are prop-
erly sized, are recommended at entries and exits after SRC
is in place.
Pull lines should be sized for the maximum weight of the length
of pipe being pulled into the existing line as a minimum. Ac-
tual pulling force shall be limited to the products maximum
allowable tensile rating. A powered winch with controlled
take up speeds is recommended for pulling SRC line pipe.
Pull speeds should be limited to a maximum of 60 feet/minute
(18 meter/minute).
A load indicator system which provides real-time axial
weight/tension during installation is REQUIRED. The system
should also provide a record of the axial force applied. For
hydraulic winch systems, the hydraulic fluid pressure at the
winch is proportional to the axial pull of the winch with the
wire on a particular wrap.
RELINING BY INSERTION
An alternative means to reline existing lines is to insert SRC
line pipe using a conventional coiled tubing (CT) injector
head, as shown in Figure 3-7. This method can be effective, if
the existing line is known to be free of obstructions.
This insertion method is rarely employed due to the cost as-
sociated with mobilizing a CT injector, but it can be an ap-
propriate technique for particular jobs.
Because SRC has low stiffness, FPI should be consulted before
a relining job by insertion is planned, due to the risk of buck-
ling the line pipe under a compressive axial load.

NOTE: When SRC line pipe is passed through a steel conduit
or casing, as in a road crossing, the pipe must be supported
on padding material to prevent vibration induced wear. Con-
centric rubber boots, which are properly sized, are recom-
mended. Care must be taken to insure that there are no bends
in the pipe within 6 feet (2 meters) of the conduit opening.
Figure 3-7: SRC line pipe is conveying pipeline survey tools (note horizon-
tal injector head).
14
The standard end connection for SRC line pipe is FPIs ANSI
Lap Joint Flange (LJK) with a raised face (RF) seal, as shown in
Figure 4-1 (US Patent #6,361,080). The LJK has the following
advantages:
Installs in the field in about one hour with common GRP
pipe tools plus one hour for cure/cooling prior to test-
ing.
Mates to standard ANSI RF flanges.
The Lap Joint Flange rotates to facilitate make-up.
Provides 100% pigging, with full-bore connection.
No flow wetted metal parts.
Uses the swaged thermoplastic liner as the primary
sealing gasket, eliminating seals between the end connec-
tion and the liner.
The internal/external advanced composite connection
provides a high safety factor and fatigue-resistance.
Available in ANSI 300 through ANSI 900 pressure
classes.
Installation Kits include all materials required for field
installation.
Installation Kits are available with or without the ANSI
flange.
NOTE: End connections installed but not approved by FPI in
writing are not the responsibility of FPI.
NOTE: SRC line pipe must not be used to support heavy
equipment such as flanges, valves, or steel risers. Both the
steel equipment and SRC must be supported independently,
and in such a way as to reduce relative motion between the
two.
When bolting FPIs ANSI Lap Joint Flanges to one another or
to standard ANSI raised face (RF) flanges, the swaged liner
is sufficient gasket material. The sequence for tightening the
bolts shall be in accordance with published standards. Please
see Figure 4-2. Care should be taken to avoid over-torquing
the bolts, as this will tend to excessively extrude the plastic
liner.
LINE PIPE TO LINE PIPE SPLICES
FPI supplies a Splice Kit for splicing Cobra line pipe up to
750 psig (50 bars) working pressure only. Splicing SRC line
pipe requires the following:
Standard HDPE pipe fusion equipment
Qualified HDPE pipe fitter
FPIs line pipe Splice Kit
FPI Tool Kit for installing ANSI Lap Joint Flanges
CAUTION: Pipe-to-pipe splices result in a slight increase in
OD (i.e. an external upset) and an increase in pipe bending
stiffness at the splice.
CAUTION: Pipe-to-pipe splices must be made on two straight-
ened sections of pipe, which have been arranged coaxially
and with no angular misalignment.
CAUTION: Pipe-to-pipe splices MUST NOT be respooled be-
cause of the increased stiffness at the splice.
Figure 4-2: Flange bolt tightening sequence.
15
Figure 4-1: Field installed ANSI Lap Joint Flange (note swaged HDPE liner
serves as sealing surface).
SECTION 4: END CONNECTIONS
A LJ Flange Kit or LJ Kit is required for each installation. All materi-
als included in the LJ Kit shall be provided by FPI. No substitution
of materials is permitted without prior written approval from FPI.
The typical components of a LJ Kit are depicted in Figure 5-1 and
listed in Table 5-1. The LJ Flange Kit is identical to the LJ Kit except
it also includes a modified ANSI B16.5 Lapped Flange
NOTE: If flanges are to be supplied by the end user, the end user
MUST consult FPI for assistance in proper flange selection.
NOTE: LJ Kits should be stored in a clean, dry location at a tem-
perature of 75 25 F (24 14 C). When LJ Kits are stored in
these conditions, a shelf life of 1 year can be expected.
Table 5-1: COMPONENTS OF A LJ KIT
A Protective gloves
B Coated stub end
C Glass and/or carbon braided sleeves
D Plastic mixing beaker
E FPI SP Field Resin Part A
F FPI SP Field Resin Part B
G Tow of glass fiber
H 2-part quickset epoxy
I Roll of shrink tape
J Resin stopping gasket
K Wooden mixing sticks
n.s. Isopropyl alcohol wipers (not shown)
n.s. Modified lapped flange (not shown)
NOTE: All end connections installed on FPI products must be
installed by crew members who have been trained and certified
by FPI.
Table 5-2: TOOLS FOR INSTALLATION OF LJ KIT
A Hacksaw
B Tapering tool
C Tapering tool mandrel (size specific)
D Tapering tool collet (size specific)
E* Tapering blade
F* Pre-swage (size specific)
G* Swage reaction tool (size specific)
H Hot plate
I High temperature dry silicone lubricant
J Pipe cutter (size specific)
K* Final-swage (size specific)
L High temperature tape
M Coarse sand paper
N Manual drive
O Tapering tool adapter to square head
P Square head adapter, Ridgid

700 or equivalent
Q Power drive, Ridgid

700 or equivalent
R Spray bottle
S Heat gun
n.s. Soft jaw pipe vise (not shown)
n.s.
Temperature indicating crayons
or thermometer (not shown)
n.s.* Heating blanket (size specific, not shown)
* Indicates items only available through FPI
SECTION 5: INSTALLING LAP JOINT (LJ) FLANGES
16
Figure 5-1: Components of a LJ kit.
Figure 5-2: Tools for installation of LJ Kit.
PIPE END PREPARATION
Assemble the necessary materials, tools and equipment at the
point of installation. When environmental conditions include
wind in excess of 5 mph (8 km/h), blowing sand, rain, snow or
temperatures less than 50 F (10 C) a shelter should be erected
around the pipe end.
Select a pre-swage and a final-swage (shown in Figure 5-3) that
correspond to the nominal pipe size and begin heating them. This
heating process is usually completed on a hot plate.
Clamp the pipe end in a soft jaw pipe vise with approximately
6 (150 mm) of pipe extending beyond the vise. Always protect
the clamped area of the pipe with two 180 pieces of plastic or
gasket material.
Use a pipe or tubing cutter to cut the end of the pipe square and
smooth.

NOTE: A hacksaw may be used to finish the cut if necessary. If a
hacksaw is substituted for a pipe cutter, extra care must be taken
to get a smooth square cut.

PIPE TAPERING
NOTE: Do not begin this operation unless preparation has been
made to complete the flange installation. Once tapered, the in-
stallation must be completed within two hours of the process must
start over.
The pipe must be carefully tapered to provide the proper bond-
ing surface. Select the proper size tapering machine collet for the
SRC product to be tapered and install the collet on the tapering
machine.
Insert the collet into the SRC liner (ID of the pipe) and position the
cutter such that it overhangs the pipe by approximately 0.25
(5 mm). Tighten the tapering collet screw until the collet is snug
within the pipe.
Rotate the taper depth screw clockwise until the tapering blade
contacts the composite pipe surface. Mount the Ridgid

Model
700 Power Drive and Square Drive Adapter to the tapering ma-
chine and begin to rotate the tool clockwise. As the taper tool is
rotated, adjust the taper depth screw approximately 1/8th of a
turn clockwise for each revolution.
Continue tapering until approximately 1.25 (30 mm) of liner is
exposed beyond the composite overwrap at the end of the pipe.
When the proper amount of liner is exposed, rotate the taper
tool 6 to 10 additional revolutions without adjusting the taper
depth screw to cleanup the taper area. Remove the drive, back
off the tapering collet screw and remove the tapering tool from
the pipe.
Use a powered brush, grinding wheel or coarse sandpaper to
cleanup the liner/composite interface and the exposed liner as
necessary. Then, degloss and roughen the outside surface of the
SRC pipe for a length of 6 (150 mm) more than the longest
braided sleeve beyond the end of the tapered area. The surface
should be free of the gloss associated with an epoxy-rich surface.
Wipe the surfaces with a clean dry cloth to remove all dust and
debris. Visually inspect the surface for uniformity.
Always use isopropyl alcohol to clean all tapered and prepared
(deglossed and roughened) surfaces. In each LJ Kit, FPI provides
wipers that are presaturated with isopropyl alcohol for this pur-
pose. Diluted isopropyl alcohol may be used if the only diluent
is distilled water. If diluted isopropyl alcohol is used, care should
be taken to ensure that all of the water has evaporated before
proceeding with stub end bonding.
CAUTION: Tapering and sanding SRC can create dust that may
be irritating to the skin, eyes and respiratory system. Good venti-
lation is recommended to prevent this irritation. A dust breathing
mask is strongly recommended when working in poorly ventilated
areas. Long sleeve shirts and eye protection are strongly recom-
mended for all installers.
STUB END BONDING
Begin this process immediately after isopropyl alcohol cleaning
to avoid contamination of the tapered and roughened surfaces.
Avoid touching any bonding surface since natural oils from hu-
man skin can inhibit bonding. Protect the bonding surfaces from
moisture and other contaminants.
17
Figure 5-3: Pre-swage and final-swage.
CAUTION: Prior to handling epoxy, the installer must become fa-
miliar with the proper procedures for safe handling and disposal
of epoxies. Appropriate personal protective equipment should be
worn during all operations (gloves, safety glasses, etc.).
Check the fit of the stub end over the tapered area of the pipe.
A proper fit is identified as 1.0 to 1.25 (25-30 mm) of liner ex-
tending beyond the stub end, and the back of the stub end within
1/8 (3 mm) of the crest.
If the fit is too tight (less than 1 of liner exposed beyond the stub
end) additional tapering is required. If the fit is too loose, cut the
piece of glass fiber (provided in LJ Kit) into three equal lengths to
make positioning bundles. The bundles should be positioned and
taped to the OD and face of the stub end so that they are uni-
formly spaced around the circumference as shown in Figure 5-4.
Position the braided sleeves, resin-stopping gasket and flange on
the pipe end. The initial configuration is shown in Figure 5-5.
Certified installers should contact FPI with questions regarding the
proper order of these components.
Squeeze the contents of the two-part epoxy tube onto a clean
dry surface and stir thoroughly using the supplied wooden mix-
ing stick. The epoxy will have a thick consistency and a uniform
creamy white color when it is properly mixed.
Using the mixing stick, apply the mixed epoxy to the middle of
the tapered area in a circumferential direction. Spread the epoxy
from the middle of the area out to the root and crest of the taper
with the mixing stick. The whole tapered surface should have a
layer of at least 0.125 (3 mm) of epoxy. Be careful not to apply
the epoxy on the plastic liner.
Slowly slide the stub end onto the pipe and rotate it as it slides
into position. The small end of the stub end must be within 0.125
(3 mm) of the crest of the taper.
Using another mixing stick and/or dry, clean rags, remove ex-
cess epoxy from each end of the stub end. No excess epoxy is
permitted on either side of the flange surface.
The epoxy will harden quickly (within 10 minutes) when mixed
properly and applied at 60 - 80 F (15 -25 C). If the temperature
is lower, a heat gun may be used to speed the hardening of the
two-part epoxy. Do not allow the pipe surfaces to exceed 200 F
(90 C) during this heating process.
SWAGE THE LINER
Swaging the liner is the process of forming the liner into a gas-
ket using a combination of heat and pressure. When swaging a
Cobra (HDPE) liner into the flange gasket, heat the swages to
200 - 250 F (90 120 C). For a Python (PEX) liner, heat the
swages to 225 - 275 F (110 135 C). For other liners, please
contact FPI. Confirm that both swages have reached the proper
temperature with a thermometer or temperature indicating cray-
ons. Using a high temperature dry silicone lubricant, spray the
contact faces of each swage. Do not spray the stub end.
Insert the swaging collet into the liner to a depth of approximately
5 (125 mm) from the stub end flange and tighten the collet nut
with the swaging wrench. The threaded collet shaft will extend
beyond the end of the liner.
NOTE: The collet shaft should be lubricated with an anti-seize
lubricant prior to use.
Start the pre-swage on the collet shaft with the brass washer and
swaging nut. Tighten the swaging nut until the swage contacts the
liner. Slowly tighten the swaging nut until the swage bottoms out.
The rate of tightening should be approximately 2 rpm.
When the swage bottoms out as shown in Figure 5-6, allow it to
cool without further movement of the swage. Cooling may be ex-
pedited by spraying the swaged liner and swage face with a wa-
ter mist. When the mist stops steaming on contact and the swage
is cool to the touch, it is safe to proceed with the next step.
18
Figure 5-4: Glass fibers used to position stub end.
Figure 5-5: Initial configuration of braided sleeves, resin-stopping gasket,
flange and stub end.
Remove the pre-swage from the pipe. Confirm that the final-swage
is heated to the proper temperature and repeat the swaging proc-
ess with the final-swage. The final-swage should bottom out as
shown in Figure 5-7.
Remove the swage from the pipe end after it cools. The diameter
of the swaged liner should match the diameter of the stub end
face as shown in Figure 5-8. Axially, the liner gasket should relax
no more than 0.375 (9 mm) from the stub end face. The swaged
liner face should be smooth with no cracks.
REINFORCE THE CONNECTION
The stub end shall be reinforced with braided sleeves of E-glass
and/or carbon fiber to ensure that the connection is as strong as
the pipe body.
Slide the properly rated flange over the stub end until it bottoms
against the stub end flange. Position the resin stopping gasket
against the pipe side face of the flange. Clean the roughened
pipe and stub end with isopropyl alcohol. Avoid touching any
bonding surface since natural oils from human skin can inhibit
bonding. Protect the bonding surface from moisture and other
contaminants.
Begin mixing the two parts of the FPI Spoolable Pipe Field Resin
immediately after the isopropyl alcohol cleaning to avoid contam-
ination of the tapered and roughened surfaces. To mix the epoxy,
empty each bottle of into the mixing container supplied. Mix thor-
oughly with the provided wooden mixing stick. When properly
mixed, the epoxy should be of uniform color and consistency.
CAUTION: Prior to handling epoxy, the installer must become
familiar with the proper procedures for safe handling and dispos-
al of epoxies. Appropriate personal protective equipment should
be worn during all operations (gloves, safety glasses, etc.).
NOTE: FPI Field Resin is a prone to crystallization at tempera-
tures below 122 F (50 C). If the appearance of the resin is
hazy or the consistency is thicker than syrup, crystallization has
occurred. To return the resin to its original state, gently warm the
container and its contents above 122 F (50 C). The recom-
mended procedure is to hold the resin at 140 F (60 C) for one
hour. The resin should be cooled to 100 F (38 C) before using
in a LJ Flange installation. Upon cooling, the resin regains all of
its original physical properties.
After putting on a clean pair of latex gloves, pour enough resin on
the stub end to fully coat the stub end and tapered surfaces with
a layer of resin. Gently pull the longest braided sleeve over the
stub end up to the resin-stopping gasket. Impregnate the sleeve
with resin by pouring resin directly onto the sleeve and manually
kneading it into the fibers as shown in Figure 5-9. Take care not
to twist the sleeve around the pipe. Ensure that the sleeve is fully
wet with resin including the bottom of the pipe.
19
Figure 5-6: Using the pre-swage to form the liner into a gasket.
Figure 5-7: Final-swage inserted fully into the end of the pipe.
Figure 5-8: Acceptable liner gasket formed by swaging process.
Pull the next braided sleeve over the wetted sleeve and up to
the resin stopping gasket. Repeat the impregnation process.
If additional sleeves remain, pull them into place and impreg-
nate them one at a time. Use most or all of the resin provided.
Excess resin will be squeezed out by the shrink tape.
Wrap the whole sleeve area with the shrink tape provided
starting at the flange end and working toward the pipe end.
The shrink tape should be placed on the reinforcement with
the exposed side of the tape adjacent to the reinforcement.
Placement should be such that each wrap overlaps approxi-
mately 50% of the preceding wrap of tape. Use high tempera-
ture tape to secure the loose end of the shrink tape.
The resin shall be cured by one of the methods listed below.
Heat gun
1) Move the heat gun slowly over all of the wet resin areas
until all surfaces reach 250 F (121 C).
2) Maintain this temperature on all wet resin surfaces for
atleast 30 minutes.
3) Allow the pipe to cool for at least one hour before
hydro testing the line.
Heating blanket
1) Wrap and secure the blanket over the wet resin area.
2) Allow the blanket to reach the preset temperature of
250 F (121 C).
3) Maintain this temperature for at least 30 minutes.
4) Allow the pipe to cool for at least one hour before
hydro testing the line.
NOTE: Cure temperatures above 300 F (150 C) will impair
the pipes performance. Precaution should be taken (especial-
ly with the heat gun) to not exceed this maximum allowable
cure temperature.
After completion of the curing procedure, the flange should
rotate freely. A completed LJ Flange end connection is shown
in Figure 5-10. It is recommended to allow at least one hour
to elapse between the end of the curing procedure and the
beginning of the hydrotest.
NOTE: If after installing a LJ Kit, the end will not be placed in
service or bolted to a companion flange in a short period of
time, FPI recommends bolting a cover on the LJ Flange. Stand-
ard blind flanges, light gauge steel plates or flat plywood
can be used to assure the gasket remains flat and the piping
system remains closed.
QUALITY REQUIREMENTS
Upon completion of the LJ Flange installation, the certified
installer shall permanently label the flange with his/her initials
and the date of installation. The labeling shall be completed
with a low stress steel stamp or a paint marker.
If possible, the installer should take photographs of the com-
pleted LJ Flange end connection. Records of each LJ Flanges
installation date, installers name, and location in the piping
system should be maintained with the pipeline data.
20
Figure 5-9: Impregnation of braided sleeve with epoxy.
Figure 5-10: Completed LJ Flange end connection.
21
All FPIs SRC line pipe is pressure tested two ways before
delivery:
Short-time failure pressure test
Two samples from each batch
Method per ASTM D 1599
Hydrostatic test on a reel
150% of products Maximum Operating Pressure (MOP)
Charts ship with the pipe
After installation of SRC line pipe, FPI STRONGLY RECOM-
MENDS a hydrotest before placing the line into service. All
testing should be performed in accordance with local, state
and federal laws.
CAUTION: Testing with fluids under pressure can be hazard-
ous. Personnel injury and/or equipment damage is possible.
Follow safety precautions.
CAUTION: Testing with compressible fluids such as air or gas
is NOT RECOMMENDED, as the potential energy developed
during such a test can be dangerous if a failure occurs.
In cold climates, hydrotest fluid must be protected
against freezing.
FILLING THE PIPE FOR FIELD TESTING
The recommended test fluid is water with antifreeze added
as necessary.
Fill the system by pumping a soft foam pig through the line in
front of the test fluid to help force the air out of the system. Test
fluid should enter the system at the lowest available point and
air should be vented from the highest point or points.
Allow the test fluid to flow through the vents until there is no
evidence of air (sputtering) coming from the system. When all
air is removed, seal the vents and prepare for testing. Blind
flanges may be used for to isolate the line.
CAUTION: Trapped air is a compressible gas. Use care to
ensure that all of the air is removed.
RECOMMENDED TESTING PROCEDURE
It is recommended that testing be conducted on each run of
pipe as it is completed. Complex piping systems should be
broken into smaller runs for testing.
At a minimum, lines shall be covered with dirt to the top of
the trench every 30 feet (10 meters) prior to hydrotesting.
Aboveground lines shall also be secured against movement
with dirt or sandbags.
The recommended hydrotest procedure is:
Apply pressure slowly up to 50% of the test pressure.
Hold pressure for 5 minutes for each 1,000 (15 minutes
for each 1,000 m) being tested.
During hold, walk the line and inspect for leaks,
particularly at end connections.
After initial pressure stabilizes, increase no faster than
20% of MOP/minute to the final test pressure.
Walk the line and inspect for leaks, particularly at end
connections
After final pressure stabilizes, hold pressure for desired
test period.
If there is an indication of a leak, stop the test, bleed-off
pressure and make repairs. After repairing the leak, refill
the pipe with hydrotest fluid and restart the testing proce-
dure.
Test pressure should be held for a minimum of thirty minutes
while the line is checked for leaks. The customer and/or ap-
plicable regulations may require longer testing periods.
NOTE: Maximum hydrostatic test pressure should not exceed
150% of the products MOP.
CAUTION: Notify all site personnel before pressure testing.
Maintain a safe distance from the pressurized piping system.
DO NOT STRADDLE THE PIPE or CLIMB INTO THE TRENCH
while the pipe is pressurized.
NOTE: Pressure may not remain constant during a long pe-
riod (such as 24 hours) due to changes in temperatures, expo-
sure to sunlight, changes in wind, etc. Temperature changes
will cause the test fluid to expand or contract leading to fluc-
tuations in pressure.
SECTION 6: FIELD TESTING
22
This section describes the recommended and approved meth-
ods for repair of SRC line pipe and end connections.
NOTE: External sleeves, patches and bolted couplings are
NOT RECOMMENDED for repairs to SRC line pipe. In gener-
al, these products are not sized properly to fit SRC line pipe.
LJ FLANGES
Leaks across flange faces are often caused by uneven torque
applied to the flange studs and nuts. To correct this type of
leak, apply even torque to the nuts following the sequence
shown in Figure 4-2. Care should be taken to avoid over-
torquing the bolts, as this will tend to excessively extrude the
plastic liner.
If a swaged liner gasket is pinched, cracked and/or dam-
aged, the entire connection must be replaced. Cut the pipe
behind the braided sleeves and have a FPI certified installer
construct a new LJ flange following the procedure in Section 5.
PIPE BODY DAMAGE
If a pipe body leak occurs, the piping system should be evalu-
ated to determine the type of failure involved and probable
cause of the failure. The two most common SRC line pipe
failure modes are burst and weeping.
Burst failures are localized pressure failures that breach the
pipe body wall. Burst failures are typically the result of local-
ized mechanical damage from impact, crushing or abrasion
of the pipe. A burst failure will typically be confined to a short
area (usually less than 12 inches or 300 mm long) and will
exhibit an obvious, axially oriented breach through the entire
thickness of the pipe wall. The area adjacent to the burst must
be examined for damage and evidence of the cause of the
burst, such as impact or abrasion from a foreign object. Ex-
amine the area near the burst for evidence of bruises or light
colored areas that could indicate mechanical damage.
Since burst failures are normally associated with mechanical
damage, the burst pipe typically needs to be cut back a short
distance, at least 5 feet (1.5 meters) on each side of the area
of the damage.
Weeping failures are characterized slow seepage of fluid
through the laminate wall. The weeping usually appears as a
multitude of tiny high pressure streams around the circumfer-
ence of the pipe which resembles a sprinkler hose. There usu-
ally is not a distinct, visually detectable breach in the compos-
ite laminate. Examine the area of the weeping for evidence
of bruises or light colored areas that could indicate damage.
Weeping can only occur if the liner is damaged or cracked
and the composite laminate is still intact.
In weeping failures, the location of the leak may be a consid-
erable distance from the actual liner damage point. It is rec-
ommended that at least 50 feet (15 meters) of pipe on each
side of the weeping area be cut back.
The recommended repair method for either type of failure is
to remove the recommended length of pipe and replace with
a length of SRC line pipe with LJ Flanges on each end. If
possible, hydrotest the replacement piece before installation.
Connect the replacement piece by installing new LJ Flanges
on the existing line. After repairs, repeat the hydrotest proce-
dure outlined in Section 6.
SECTION 7: LINE PIPE REPAIRS