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PROJECT:
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CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
PAGE NO
3
3
3
3
4
5
6
7
8
9
10
PURPOSE
SCOPE
SAFETY
REFERENCES
HDPE LINER WALL THICKNESS CALCULATION
HDPE PIPE PROPERTIES
HDPE LINER & STUB END DATA SHEET
DRAWING OF HDPE STUB END
DRAWING OF RETAINER RING FOR FLANGE INTERFACE
DETAILED DRAWING OF STEEL FLANGE FACING
HDPE PACKING, TRANSPORTATION, HANDLING, RECEIVING
INSPECTION & REPAIR OF DEFECTS
HDPE BUTT FUSION WELDING PROCEDURE
11
HDPE LINER INSERTION PROCEDURE
18
HDPE STUB END INSTALLATION PROCEDURE
23
FLANGE BOLT UP PROCEDURE
27
POST INSTALLATION HDPE LINER AIR TEST PROCEDURE
30
LIST OF TOOLS AND MACHINERY
38
ATTACHMENTS
18.1 SAEP 387
39
18.2 JOB SAFETY ANALYSIS (JSA)
40
18.3 LINER INSTALLATION ITP & CHECKLIST
47
18.4 BUTT FUSION PARAMETERS
48
18.5 BELL HOLE DRAWING
51
18.6 SAUDI ARAMCO TYPICAL INSPECTION PLAN (SATIP-HDPE-001) 53
18.7 SAUDI ARAMCO INSPECTION CHECKLIST
54
SAIC-HDPE-001, SAIC-HDPE-002, SAIC-HDPE-003, SAIC-HDPE-004
WPS
55
REPAIR PROCEDURE (Scratches)
61
REPAIR PROCEDURE (COLD CUTS)
67
FORMS
72
HDPE INTERNAL LINING PROCEDURE
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PURPOSE
•
This document provides a comprehensive overview and the guideline for HDPE internal lining
activities required to carry out at the project associated with SAUDI ARAMCO.
• The purpose of this procedure is to ensure that lining activities are correctly planned, executed
and controlled in accordance with SAUDI ARAMCO requirements specified in the contract as
per the following references.
2. SCOPE
• This procedure provides the guidelines, precautionary measures to be taken for HDPE lining of
pipelines.
• This procedure is applicable to all types of HDPE lining.
• HDPE lining procedure shall be reviewed and approved by Saudi Aramco concerned
department through SAPMT
3. SAFETY
•
•
4.
All necessary health, safety, security and environmental procedures shall always be followed to
protect personnel and the surrounding environment during the job execution. Daily tool box
talks and review of the job safety analysis shall be carried out daily with all PE-100 liner
installation supervisors and crew members.
All relevant safety requirements of the client/contractor/vendor’s HSE policy shall be
conformed to for all works performed within the site-specific work areas. This will be verified
by carefully identifying all the possible hazards related to each work process involved in the
HDPE liner installation activities at site. In addition, JSA shall be the reference document for Site
Safety.
REFERENCES
4.1
RELEVANT SAUDI ARAMCO ENGINEERING STANDARDS AND PROCEDURES
SAEP‐387
: THERMOPLASTIC LINERS FOR NEW AND EXISTING PIPELINES
01-SAMSS-051: MATERIALS SYSTEM SPECIFICATION |HIGH DENSITY POLYETHYLENE
(HDPE)PIPES & FITTINGS
4.2
JOB SAFETY ANALYSIS.
ATTACHED
:
18.2 JOB SAFETY ANALYSIS
HDPE INTERNAL LINING PROCEDURE
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5. HDPE LINER WALL THICKNESS CALCULATION
Description
UNIT
HDPE LINER SIZE
24
12
STEP 1
OD (steel)
mm
610.00
323.90
Steel W.T.
mm
22.23
12.70
ID (steel)
mm
565.55
298.50
MPA
25
25
MAXIMUM ALLOWABLE STRESS DURING PULLING
%
50%
50%
MAXIMUM ALLOWABLE STRESS DURING PULLING
= HDPE tensile strength x max allowable %
MPA
12.5
12.5
Maximum Pull Force
KG F
N
m²
25,000
245,170
0.0196
8,000
78,454
0.0063
mm
543.02
284.80
mm
11.26
6.85
mm
13.50
8.10
R = 0.5 x (ID steel - h): installed liner inside
mm
276.0
145.2
Cross sectional area of HDPE
m²
STEP 2 Calculate Minimum Wall Thickness
HDPE Tensile Strength
Required Minimum Cross-Sectional Area
= (Required Pull Force N) / (Maximum Allowable Stress
During Pull x 10⁵)
Required HDPE ID = √ (ID steel² x 10⁵ - (cross sectional
area x 4 / π )
Minimum Calculated Wall Thickness
= (Steel Pipe ID - Required HDPE ID)/2
Standard Wall Thickness per Raymond International
MAXIMUM ALOWABLE LOAD DURING PULLING
= (cross sectional area of HDPE pipe x maximum
allowable stress during pulling x 105)
LINER PIPE WALL THICKNESS - Greater of Minimum Wall
Thickness Calculation or Standard Wall Thickness per
Raymond International
HDPE INTERNAL LINING PROCEDURE
0.02341327 0.00738978
N
KG F
292,670
29,840
92,370
9,420
mm
13.50
8.10
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HDPE PIPE PROPERTIES
DIMENSIONS
SIZE
TOLERANCE
OD
(MM)
THICKNESS (MM)
OD
TOLERANCE
± MM
THICKNESS
TOLERANCE
+ ONLY (MM)
24”
572.00
13.50
± 1.5
1.5
12”
303.50
8.10
± 1.0
1.5
OVALITY TOLERANCE ≤ 5% OF NOMINAL OD OF LINER PIPE
Liner Manufacturer: UNION PIPES INDUSTRY (Plant ID # 30008646)
9COM: 6000000039
VENDOR ID 10061799
HDPE INTERNAL LINING PROCEDURE
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HDPE Liner & Stub End data sheet
HDPE INTERNAL LINING PROCEDURE
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PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
DRAWING OF HDPE STUB ENDS
Manufacturer: ITS Technodue India Limited (Plant ID # 30012065)
9COM: 6000000039
8.1: STUB END FOR NPS 24” x 0.875”
HDPE INTERNAL LINING PROCEDURE
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8.2: STUB END FOR NPS 12” x 0.5”
HDPE INTERNAL LINING PROCEDURE
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PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
9. DRAWING OF CARBON STEEL RETAINER RINGS FOR FLANGE INTERFACE
9.1: CS RETAINER RINGS FOR 24” x 0.875” FLANGE INTERFACE
HDPE INTERNAL LINING PROCEDURE
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9.2: CS RETAINER RINGS FOR 12” x 0.500” FLANGE INTERFACE
HDPE INTERNAL LINING PROCEDURE
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10. DETAILED DRAWING OF ASME B 16.5 RFWN FLANGE FACING
10.1: 24” CL 1500
HDPE INTERNAL LINING PROCEDURE
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10.2: 12” CL 1500
HDPE INTERNAL LINING PROCEDURE
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11. HDPE SURE LINER™ PACKING, TRANSPORTATION, HANDLING, RECEIVING INSPECTION &
REPAIR OF DEFECTS
11.1 PACKING
• Upon completion of HDPE liner production, the HDPE liner pipe will be cut to the required
length, a dimensional check will be performed, and if all OK, plastic wrap will be fixed at both
ends of the liner to protect against dust before it is moved to the packing area.
•
11.2
•
11.3
•
HDPE pipes / wood will be used in conjunction with polyester / nylon straps to bundle the
liner pipes. This support will be provided approximately every interval of pipe length. Each
bundle will be marked as per agreement. HDPE pipes / wood and polyester / nylon straps
are used to avoid damage or scratches on the liner surface.
TRANSPORTATION
Before loading, the liners should be packed according to the contract. Care shall be taken to
avoid any mishandling while loading, unloading and transportation. Flatbed trucks are used
to transport the liner pipes
HANDLING
Care shall be taken while handling, shifting the finished products at shop floor or at site.
Power lifting equipment (forklift, crane) are usually utilized to move, load and unload the
liner pipes. Operators of power lifting equipment should be trained and competent in the
operation of their equipment to assure the safety of worker and prevent any damage to the
liner pipe. Metal slings, hooks and chains are not allowed in direct contact with liner pipes.
Only Nylon slings shall be used to avoid any damage. Storage requirements shall be as per
SAEP-387
11.4 RECEIVING INSPECTION
• Thorough visual inspection of the HDPE Liner shall be carried out before installation
activities begin. Site Foreman are to verify that all liners are without damage due to poor
handling or manufacturer defects. Liners shall be accepted/rejected as per below criteria:
• Scratches in Pipe: Surface scratches and nicks in the HDPE pipes may not exceed a depth of
10% of the HDPE wall thickness.
• Dents: The maximum depth shall not be greater than 10% of the liner OD
11.5 REPAIR OF DEFECTS
• Repair of defects observed in the HDPE SureLiner™ pipe, in any form, is prohibited. Pipe
sections with defects exceeding the requirements shall be cut out, as required, to remove
defective portions.
HDPE INTERNAL LINING PROCEDURE
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12. HDPE BUTT FUSION WELDING PROCEDURE & TECHNICIAN QUALIFICATION
12.1 RESPONSIBILITIES
OF THE QA/QC INSPECTOR, OR SUPERINTENDENT:
✓ To verify the use and compliance of this procedure.
✓ To recover the QA/QC documentation generated during the work, check it for accuracy, and
file it accordingly.
OF THE LINER INSTALLATION FOREMAN:
✓ To comply with this procedure.
✓ To complete a Job Safety Analysis (JSA) and daily Tool Box Talk.
✓ To uphold Health, Safety and Environmental requirements.
OF THE FUSION TECHNICIAN(S):
✓ To confirm completion of Job Safety Analysis, Daily Toolbox Talk & issuance of work permit.
✓ To take all the necessary safety precautions and comply with the HDPE Sure Liner™ Butt
Fusion steps as established under this procedure.
✓ To properly prepare and QC the HDPE Sure Liner™ pipes prior to beginning the butt fusion
process.
✓ To adequately record the activities in the corresponding report.
12.2 BEND BACK TESTING OF THE FUSION PROCEDURE QUALIFICATION AND FUSION TECHNICIAN
QUALIFICATION WELDS.
• 180° reverse bend back testing will be completed per ASTM F2620.
• HDPE Sure Liner™ pipes of the smallest and largest diameters to be used will be tested.
• Four (4) test strap specimens shall be cut from different quadrants of the fusion test pipe
sample (3 o’clock, 6 o’clock, 9 o’clock, and 12 o’clock positions).
• Minimum length of the test strap shall be 15x the wall thickness (WT) from each side of the
fusion weld and the minimum width of the test strap shall be 1.5x the WT.
• The procedure (or technician) shall be qualified for fusion of mainline HDPE pipe and stub ends
of the range of sizes encompassed by the test. (Ex. test was completed and passed on 6in & 30in
pipe, the fusion technician is then qualified to fuse all pipes in that range – 6in - 30in).
• All butt fusion welding technicians who successfully complete a welding procedures
certification shall be considered qualified for butt fusion welds of the same type, material grade,
and diameter range as represented by the procedure. DOC-F-APT-02-B (Clause 12.7)
HDPE INTERNAL LINING PROCEDURE
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12.3 PROCEDURE: HDPE BUTT FUSION WELDING
• Clean the inside and outside of the liner pipe to be joined by wiping the ends with a clean, lintfree cloth. Remove all foreign matter.
• Clamp the two pipes in the machine. Check alignment of the pipe ends and adjust as needed.
• Face the pipe ends to establish clean, parallel mating surfaces. Facing is continued until the
jaws of the machine and the facer are squarely between the jaw bushings. This operation
provides for a square face, perpendicular to the pipe centreline on each pipe end and with no
detectable gap.
• The pipe profiles must be rounded and aligned with each other to minimize mismatch (highlow) of the pipe walls. This can be accomplished by adjusting clamping jaws until the outside
diameters of the pipe ends match. The jaws must not be loosened, or the pipe may slip during
the fusion process. Re-face the pipe ends and with a clean, untreated, lint-free cloth, remove
any chips or foreign matter from the re-facing operation. Isopropyl alcohol (if available) can be
used for cleaning if required.
• Check the heater plate for temperature. The surface temperature must be within the range of
400-450°f (204-232°c). In addition to the temperature gauge on the heater plate, a pyrometer
or other surface temperature-measuring device should be used to insure proper temperature
of the heater plate surface (both sides).
• The heater plate faces that come into contact with the pipe should be clean and oil-free. Heating
of the pipe ends can now be initiated. Insert the heater plate into the butt fusion machine and
bring the pipe ends into full contact with the heater plate. Ensure that full and proper contact is
made between the pipe ends and the heater plate before proceeding.
• The initial contact should be under moderate pressure and may be maintained until a slight
melt is observed around the circumference of both pipe ends before releasing pressure. Assure
that contact is maintained between the pipe ends and heater plate surface. Continue to hold the
components in contact with each other, without force, while a bead develops between the
heater plate and the pipe ends. When the proper bead size is formed against the heater surfaces
and the specified time on the fusion parameter data sheet has elapsed, prepare to remove the
heater plate. Melt bead size is dependent on pipe size and shall be observed as a QC check
before removing the heater plate. After the heater plate is removed, quickly inspect the molten
pipe ends before joining the pipe ends together under the prescribed pressure settings.
Note: If a concave melt surface is observed, unacceptable pressure during heating has occurred. Do
not continue. Allow the pipe ends to cool completely and restart from the beginning of this
procedure. Except for a very brief time to seat the pipe ends fully against the heater plate, do
not apply pressure during heating.
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PROJECT:
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Immediately bring the molten pipe ends together with sufficient fusion force to form a double
rollback bead against the pipe wall.
Fusion force is determined by multiplying the interfacial pressure, (60-90 psi) by the pipe area.
For hydraulically operated fusion machines, the fusion force can be divided by the total effective
piston area (tepa) of the carriage cylinders to give a hydraulic gauge reading in psi. The gauge
reading is theoretical. Internal and external drags are added to this figure to obtain the actual
fusion pressure required by the machine.
Note: The hydraulic gauge reading and interfacial pressure are not the same value. Refer to the
fusion parameters data sheet for specified timings and pressures.
Hold the molten joint immobile under interfacial fusion pressure until cooled to adequately
develop strength of the fusion weld and complete the HDPE butt fusion process. Allowing for
proper time under pressure for cooling prior to removal of the pipe from the clamps of the
machine is important in achieving the required butt fusion weld joint integrity.
Remove the pipe from the fusion machine and visually inspect the weld for proper appearance.
Sequentially number and record each fusion joint on the pipe and on the PE-100 butt fusion
weld report.
After completion of the butt fusion weld, the external beads shall be removed. If required by the
client specification, the internal bead may also be removed at this time.
Internal and external beads shall be removed by a specialty tool designed for this process.
Removal of internal weld bead may not be required for all applications.
12.4 PROCESS CONTROLS
• Bend back testing of the fusion procedure qualification and fusion technician qualification
welds shall be completed and verified prior to initiating production welding.
• Bend back testing will be completed per ASTM F2620.
• The adequate control of parallel and clean mating surfaces shall be observed and verified.
• The adequate control of fusion parameters - temperature, heat soak time, fusion pressure, and
sufficient cooling time shall be reviewed and verified.
12.5 ACCEPTANCE CRITERIA
• Fusion welds that have been carried out under compliance of this procedure and that do not
present any abnormal features or appearances shall be deemed as acceptable. Visual
parameters of acceptance include:
• Appearance - proper alignment of pipe ends, absence of concave surfaces after heat cycle,
and continuous/uniform bead size and shape with the bead rolled to pipe surface
throughout the weld perimeter.
• Record of correct temperatures, times, and pressures.
• Heater plate condition in terms of roughness and cleanliness.
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Welded dimensions, high-low misalignment tolerance is max. 10% of wall thickness.
The removal of the fusion beads shall not produce excessive gouging or other damage, and
the surface shall have a smooth appearance.
Fusion weld back bend test will be completed once per day and acceptance criteria is no
cracking of the fusion weld.
12.6 ILLUSTRATION
BUTT FUSION BENT STRAP TEST SPECIMEN
12.7 CERTIFICATION
•
Training & Certification requirements as per SAEP 407 of Fusion technicians, foreman
supervisors and contractor QC shall be provided by Raymond International as Raymond
International is the manufacturer (Saudi Aramco approved Technology provider &
Installer) for the HDPE lining activities.
HDPE INTERNAL LINING PROCEDURE
HDPE INTERNAL LINING PROCEDURE
SIGN
QC INSPECTOR
DATE
NAME
SIGN
BIN QURAYA REPRESENTATIVE
DATE
NAME
SIGN
SIGN
COMMENTS
ARAMCO REPRESENTATIVE
BEND
GAUGE COOLING VISUAL
HEAT
HEATER
FUSION PRESSURE
CHECK BACK TEST
PRESSURE TIME
TEMP. SOAK TIME
INSTALLATION FOREMAN
DATE
NAME
TEST #
PROCEDURE
DATE
NAME
DATE
BI #
11-22000-2437
FUSION MACHINE
EFFECTIVE PISTON AREA FOR FUSION MACHINE
DOC F- APT - 01 - A
PROJECT #
Contract #
6600051205
NAME
LINER PIPE OD:
WALL THICKNESS
HDPE BUTT FUSION TEST LOG
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PROJECT:
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12.8 ATTACHMENTS
• DOCUMENT NO. F-APT-01-A
BUTT FUSION TEST LOG:
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DOCUMENT NO F-APT-02-A
FUSION LOG
HDPE INTERNAL LINING PROCEDURE
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DOCUMENT NO. F-APT-02-B
HDPE BUTT FUSION WELD PROCEDURE AND TECHNICAIN QUALIFICATION REPORT
PROJECT: HDPE LINER SERVICES FOR
SAFANIYA SFNY 24” HDPE HDR T/L PROJECT
HDPE BUTT FUSION WELD PROCEDURE AND
TECHNICIAN QUALIFICATION REPORT
DOC F- APT - 02 - B
DETAILS
TECHNICIAN NAME:
DATE:
LOCATION:
HDPE FUSION MACHINE:
MODEL:
SERIAL # :
AMBIENT TEMPERATURE:
HDPE PIPE OD:
HDPE PIPE WT:
TECHNICIAN PHOTO
(PASTE HERE)
FUSION WELD PARAMETER CHECK
HEATER PLATE CONDITION:
HEATER PLATE TEMPERATURE:
COOLING TIME:
VISUAL CHECK:
EXTERNAL BEAD VISUAL CHECK:
COMMENTS:
FUSION PRESSURE:
DRAG PRESSURE:
GAUGE PRESSURE WITH DRAG:
GAUGE PRESSURE WITHOUT DRAG:
BEND BACK TEST
WIDTH OF SAMPLE:
LENGTH OF SAMPLE:
TEST PASSED (YES / NO)
COMMENTS:
RAYMOND INTERNATIONAL
BIN QURAYA REPRESENTATIVE
SIGN:
NAME:
DATE:
HDPE INTERNAL LINING PROCEDURE
ARAMCO REPRESENTATIVE
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13. HDPE LINER INSTALLATION
13.1RESPONSIBILITIES
OF THE QA/QC INSPECTOR OR SUPERINTENDENT:
✓ To verify the use and compliance of this procedure.
✓ To recover the QA/QC documentation generated during the work, check it for accuracy, and
file it accordingly.
OF THE LINER INSTALLATION FOREMAN:
✓ To comply with this procedure.
✓ To complete a Job Safety Analysis (JSA) and daily Tool Box Talk.
✓ To uphold Health, Safety and Environmental requirements.
OF THE PULLING TECHNICIAN(S):
✓ To confirm completion of Job Safety Analysis, Daily Toolbox Talk & issuance of work permit.
✓ To take all the necessary safety precautions and comply with the HDPE SureLiner™
Insertion (Pulling) steps as established under this procedure.
✓ To properly measure, prepare, and QC the HDPE liner prior to installation.
✓ To adequately record the activities in the corresponding report.
13.2 CABLE BLOW-DOWN AND STEEL PIPE GAUGING
• The winch cable blow-down and gauging operation shall commence once the construction of
the steel pipeline section has been hydrotested, completed, cleaned, and the thread-o-lets have
been welded onto both ends of the pull section by the Contractor. At this stage, the pipeline
section shall be officially turned over to the installation supervisor and foreman.
• Contractor should make sure that the weld bead penetration is as per API 1104 (max 1.5 mm)
• Cordon off both ends of the pipeline section and keep all personnel and traffic clear of the winch
cable and exit end of the host pipe.
• Put together the pig assembly with the polyurethane pig cups and gauging plate.
• The gauging plate shall be made of Carbon steel with OD to be 95% of steel pipe ID.
• Insert the pig assembly into steel pipeline. This may require substantial force as the pig cups
will be oversize to provide an adequate seal.
• Pass the winch cable through the pack-off and blow-down flange plate.
• Attach the winch cable to the eyelet of the pig assembly.
• Securely bolt the blow-down flange plate onto pipeline flange.
• Connect a compressed air source to the air coupling on the blown-down flange plate.
• Slowly initiate constant air supply and allow for the pressure to build up, while holding tension
on the winch cable.
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Payout the winch cable under controlled load and speed. The feed rate should be synchronous
with the capacity of the air compressor to maintain stable pipeline (back) pressure and thus
constant pig travel.
Observe and record the position of any abrupt stoppages that could indicate possible
obstructions or damage in the pipeline.
Continue providing adequate air supply and pay out cable until the pig traverses the complete
pipeline section and emerges from the exit flange.
Attach the pig assembly to a suitable piece of equipment capable of pulling additional cable
from the flange to the pull head of the prepared HDPE Sure Liner™ pipe string.
The winch cable shall be detached from the pig, threaded through the roller box, and pulled up
to the pull head of the HDPE Sure Liner™ pipe string.
Thoroughly inspect the pig cups and gauging plate for damage.
Any severe indentations or bending of the gauging plate edges can indicate steel pipeline
damage or obstructions. Report any anomalies to the installation supervisor and foreman for
inspection and verification prior to continuing with the HDPE Sure Liner™ installation
procedure.
Fill out corresponding report.
13.3 HDPE LINER INSERTION
• Unbolt the blow-down flange and off-set the host pipe into the pulling position.
• The maximum pulling forces (MPF) shall be calculated using the HDPE Sure Liner™ dimensions
and the tensile yield (design) strength. During the pulling operation, tensions are not to exceed
90% of the calculated MPF of the HDPE liner pipe. This shall be verified by calculating the
corresponding theoretical MPF and monitoring the wireline tension during the pulling
operation.
• All thread-o-lets shall be previously welded, inspected, and a 1/8in (3mm) diameter vent hole
drilled through the steel host pipe prior to the liner insertion. Check and remove any burrs on
the inside of the steel pipe that can damage the HDPE liner.
• The roller box shall then be positioned in line with the entry flange.
• The winch cable shall be connected to the pull head that has been prepared and attached to the
fused liner pipe string.
• Once communication between operators at both ends of the pull section has been confirmed,
the pull sequence can be initiated.
• Coordination for the commencement of pulling shall be agreed upon and initiated by the site
foremen or equipment operators positioned at each pipe end.
• Take up residual slack in winch cable until the cable becomes tensioned with the HDPE liner
string.
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
•
•
•
•
•
•
•
•
•
•
RI-BQ-HDPE-001
Page 23 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
Slowly pull the pull head of the liner pipe section into the roller box. Once the pull head has
completely passed through the roller box, pulling speed may be gradually increased.
The cable tensions and pipe geometry should be checked. The HDPE Sure Liner™ pipe shall be
thoroughly inspected and measured with a diameter tape after exiting the roller reduction box.
Observations shall be communicated to the winch operator.
If tensions are within the acceptable limits and the liner pipe has passed the roller box without
signs of damage/failure, the pulling speed may be increased while continuously checking the
pulling tensions and assuring that the maximum pull force (MPF), as established by the
engineering calculations, is not exceeded.
The maximum allowable pull force is indicated on the attached table “HDPE maximum pulling
force data sheet – allowable tensile load.” this table shall be prepared in advance by the
installation supervisor and foreman.
Note: the combined forces during insertion of loading the pipe in tension (pulling) and
from radial compression (reduction of OD from the roller box) serves as an additional test
for the integrity of the HDPE butt fusion welds. In the instance of a “bad weld” the fusion
could fail in the roller box. At this point the insertion process would be stopped.
During the overall pulling operation, it is very important that continuous communications be
maintained between the roller box operator and winch unit operator to coordinate and control
pull speed and pull tensions.
The pipe shall also be checked continuously to assure that all major surface debris is removed
prior to entering the roller box. Visual inspection of the liner pipe as it exits the roller box and
enters the steel pipeline shall be maintained during the entire pulling operation to visually
check for any potential anomalies.
Once the liner pipe exits the flange at the winch unit end, a determined length shall be pulled
beyond the flange to allow for contraction and relaxation of the liner pipe. The winch and roller
box operators shall mark the HDPE liner pipe at intervals (no less than 2’ increments) from the
flange face to allow for precise monitoring of the liner relaxation/expansion.
Once the pipe has been marked on both sides, the winch unit tension may slowly be decreased
until the cable is fully relaxed. Once the cable tension is fully relaxed, the cable may be detached
from the pull head.
The leading edge (winch side) of the HDPE string shall be inspected for damage caused by the
steel host pipe during insertion. Should excessive damage/gouging be witnessed, notify the
installation supervisor immediately. Any observed damage shall be measured and documented
on the cable blow down, gauging, and liner insertion form.
Depth of the scratches shall be measured with a Calibrated Vernier Calliper and documented in
the cable blowdown, gauging & liner insertion form.
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 24 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
•
The lined pull section shall be allowed to fully relax and expand within the host pipe for a
period of time to eliminate any residual tensions within the liner pipe prior to the installation of
the HDPE stub ends.
Note: HDPE stub end installation may not begin until the liner section has been inspected and
approved by the installation Supervisor.
13.4
•
•
•
•
•
PROCESS CONTROLS
Observation and recording of the condition of the pig cups and gauging plate.
Observation, recording, and adequate control of pulling tensions (MPF).
Appropriate radial compression of the HDPE Sure Liner™ pipe (power roller reduction).
Visual inspection of the pipe as it exits the roller box and prior to entry into the host pipe.
Inspection of the leading edge of the HDPE Sure Liner™ exiting the flange on the winch side of
the host pipe section after insertion.
13.5 ACCEPTANCE CRITERIA
• Cable blow down & gauging plate condition
- If the sizing plate gets stuck or obstructed and is unable to traverse the pipeline section, the
host pipe shall be repaired accordingly.
- If the sizing plate shows signs of excessive damage, the condition of the host pipe shall be
assed to determine the extent and nature of the damage prior to liner insertion.
• Liner insertion (pulling)
- If the liner pipe and all its fusion welds pass through the roller box without collapsing or
other indication of failure, it is considered to be suitable and the pull sequence shall be
continued.
• Winch unit tension (MPF)
- The load or tension shall not exceed the calculated MPF. (Clause 5)
• Leading edge of liner after insertion
- Damage to the liner pipe from the steel pipe shall not be above the specified amount i.e.
10% of actual HDPE liner wall thickness.
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
RI-BQ-HDPE-001
Page 25 of 71
Contract #
6600051205
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
BI #
11-22000-2437
Revision
0
13.6 ATTACHMENTS
CABLE BLOW DOWN, GAUGING, AND LINER INSERTION FORM - DOC NO. F-APT-03-A
CABLE BLOWDOWN, GAUGING & LINER
INSERTION LOG
PULL #:
STEEL PIPE OD & WT:
HDPE PIPE OD & WT:
GAUGING PLATE DIAMETER:
ARE THREAD-O-LET'S DRILLED:
DOC F- APT - 03 - A
PROJECT #
PULL LENGTH:
LINEAR LENGTH:
MAX LOAD (LBS):
START (FT.):
END (FT.):
DESCRIPTION OF PULL:
BLOWDOWN & GAUGING
OBSTRUCTIONS / STOPPAGES:
DATE:
LOCATION DEPTH
START TIME:
END TIME:
CORRECTIVE ACTIONS TAKEN / COMMENTS:
(YES / NO)
FINAL RESULTS / COMMENTS:
LINER INSERTION
DATE:
MAXIMUM TENSION DURING PULL
CONDITION OF LEADING EDGE OF LINER
START TIME:
LOCATION DEPTH
END TIME:
FINAL RESULTS / COMMENTS:
QC INSPECTOR
DATE
NAME
SIGN
INSTALLATION
FOREMAN
DATE
NAME
SIGN
BIN QURAYA
REPRESENTATIVE
DATE
NAME
SIGN
HDPE INTERNAL LINING PROCEDURE
ARAMCO
REPRESENTATIVE
DATE
NAME
SIGN
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 26 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
14. HDPE STUB END INSTALLATION
14.1 RESPONSIBILITIES
OF THE QA/QC INSPECTOR OR SUPERINTENDENT:
✓ To verify the use and compliance of this procedure.
✓ To recover the QA/QC documentation generated during the work, check it for accuracy, and
file it accordingly.
OF THE LINER INSTALLATION FOREMAN:
✓ To comply with this procedure.
✓ To complete a Job Safety Analysis (JSA) and daily Tool Box Talk.
✓ To uphold Health, Safety and Environmental requirements.
OF THE STUB END TECHNICIAN(S):
✓ To confirm completion of Job Safety Analysis, Daily Toolbox Talk & issuance of work permit.
✓ To take all the necessary safety precautions and comply with the Stub End Installation steps
as established under this procedure.
✓ To properly measure and prepare the HDPE liner for the precise installation of the HDPE
Stub End.
✓ To adequately record the activities in the corresponding report.
14.2 HDPE STUB END INSTALLATION
• The following sequence of activities are to be performed for the safe fusion and installation of
the HDPE stub end flange adapters:
• The stub end flange adapter installation can be initiated after allowing sufficient time for the
relaxation of the HDPE Sure Liner™ pipe after installation.
• Once the liner has sufficiently relaxed, the liner pipe shall be clearly and accurately marked with
an indelible marker at the position where it begins to protrude beyond the flange edge.
• The internal clamp shall be inserted into the liner pipe, positioned beyond the flange inside the
steel pipe to prepare for a subsequent phase of the procedure.
• The external clamp shall be bolted onto the liner pipe and butted against the push plate of the
stretcher box or securely connected to a piece of equipment (Telehandlers / excavator) for
pulling/stretching the installed HDPE Sure Liner™ pipe.
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
•
•
•
•
•
•
•
•
•
RI-BQ-HDPE-001
Page 27 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
If using a stretcher box, the hydraulic cylinders shall be actuated, and the liner pipe can be
stretched to the prescribed length to accurately allow enough pipe length for the stub end
installation. Precautions shall be taken to assure that the liner pipe is not over stressed during
the stretching operation. If necessary, the liner may be stretched and then allowed to relax
before reaching the full calculated stretch amount. This can aid in finding the correct point of
relaxation to ensure that the stub end retracts to the flange face and is not excessively tight.
An alternate option to the stretcher box is using a pull head or external clamp and stretching
the liner with equipment such as a winch, excavator, telehandler, etc.
Once the Sure Liner™ pipe has been stretched to the pre-determined length, the internal clamp,
already inside the pipe, shall be actuated to hold the stretched liner pipe in position and allow
for the removal of the external clamp or pull head.
After removing the external clamp, the stretched liner length shall be accurately measured and
cut (trimmed) to an exact length to allow for the precise installation of the HDPE stub end by
means of butt fusion welding.
The HDPE butt fusion machine shall be positioned onto the stretched liner pipe and the stub
end shall be welded onto the liner pipe using standard fusion process as established in the
corresponding HDPE butt fusion procedure.
The fusion weld shall be allowed to cool, and the external weld bead shall be removed utilizing
an external bead trimmer.
The internal bead may also need to be removed to allow for the internal clamp to be extracted
from the pipe after the stub end weld is completed.
The internal clamp shall then be released, and the liner pipe will retract until the stub end
flange adapter rests against the steel flange, thereby completing the stub end flange adapter
installation process.
The stub end installation record (form) shall be accurately completed.
14.3 PROCESS CONTROLS
•
•
•
•
•
Measurement control and accurate marking of the HDPE liner stretch to allow for the precise
stub end installation.
The completion of the fusion procedure qualification and fusion technician qualification prior to
stub end welding.
The adequate control of parallel and clean mating surfaces.
The adequate control of fusion parameters - temperature, heat soak time, fusion pressure, and
sufficient cooling time.
Proper alignment of the stub end to the installed HDPE Sure Liner™.
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 28 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
14.4 ACCEPTANCE CRITERIA
•
•
•
•
•
•
•
•
A stub end installation that has been carried out under compliance of this procedure and does
not present any abnormal features or appearances shall be deemed as acceptable. parameters
of acceptance include:
Reference marking on the Sure Liner™ pipe must indicate that the liner has completely relaxed
inside the steel prior to stub end installation.
Proper liner stretch measurements.
Appearance - proper alignment of pipe ends, absence of concave surfaces after heat cycle,
continuous and uniform bead size & shape with the bead rolled to pipe surface throughout the
weld perimeter.
Record of correct temperatures, times, and pressures.
Heater plate condition in terms of roughness and cleanliness
The removal of the fusion beads shall not produce excessive gouging or other damage, and the
surface shall have a smooth appearance.
The HDPE stub end has retracted completely and evenly to the steel flange face.
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
RI-BQ-HDPE-001
Page 29 of 71
Contract #
6600051205
BI #
11-22000-2437
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
14.5 ATTACHMENTS
HDPE SURELINER™ STUB END INSTALLATION REPORT - DOCUMENT NO. F-APT-04
DOC F- APT - 04 - A
PROJECT #
STUB END INSTALLATION LOG
FUSION MACHINE:
FUSION PRESSURE:
NAME
QC INSPECTOR
TEPA:
GAUGE PRESSURE (W/O DRAG):
PULL NO.
DATE
TIME
HEAT SOAK TIME:
COOLING TIME:
WINCH / RETRACT OD HDPE LENGTH OPPOSITE
ROLLER LENGTH
(IN)
STUBEND SIDE LENGTH
EXTRA CUT
FOR TIGHT
HEATER PLATE TEMP
TOTAL
CUT
COMMENTS
DATE
NAME
INSTALLATION FOREMAN
DATE
NAME
BIN QURAYA REPRESENTATIVE
DATE
NAME
ARAMCO REPRESENTATIVE
DATE
NAME
SIGN
SIGN
SIGN
SIGN
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 30 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
15. BOLT UP PROCEDURE (To be followed by pipeline contractor)
15.1 PROCEDURE FOR BOLT UP
• Clean the surfaces of the flanges. Mating faces shall be free of rust, dirt, and gouges should not
be present.
• Situate the retainer ring over the raised face/stub end on one of the mating flanges before
aligning the mating flange faces. If the retainer ring will not stay in place during the alignment
of the flange faces, hydraulic flange spreaders may be used to place the retainer ring between
the flange faces after flange alignment.
• Align the flanges faces parallel to one another. Special care should be taken as not to damage the
carbon steel flange, HDPE stub end flange faces & retainer ring.
• Flange alignment pins can be used to facilitate accurate alignment during the bolt-up process.
Install pins in bolt holes straight across from one another, as close to the 3 and 9 o’clock
positions as possible.
• Assure that the retainer ring is properly installed and not bound up between the mating flange
faces before proceeding with the installation of the studs and nuts.
• Lubricate the studs, nuts, and flange area under the nuts with molykote, a widely used lubricant
on Aramco projects.
• Install studs and hand tighten to prevent movement of the flanges when the alignment pins are
removed.
• Remove the alignment pins and install the remaining studs and hand tighten the nuts.
• Number each stud according to its position in the flange as shown in figure below - stud
tightening sequence.
• Tighten studs on the first pass to 20%-30% of the calculated final torque, using the stud
tightening sequence.
• Tighten studs on the second pass to 50%-70% of the calculated final torque, using the stud
tightening sequence.
Note: it is important that the flange faces remain parallel throughout the tightening process. if the
flange faces make contact on one side too soon it may not be possible to get them to make
contact on the opposite side. In this case it may be necessary to loosen the nuts on one side in
order to realign the flange faces and tighten the nuts on the other side.
• Tighten studs on the third pass to 100% of the calculated final torque, using the stud tightening
sequence.
• Check the studs on the fourth pass at 100% in a circular pattern. If a lot of the studs are not at
the correct torque repeat the previous step.
• It is critical to the joint integrity that the studs remain at the proper stress value after the PE100 joint has fully relaxed. It is recommended that the torque be rechecked a minimum of 24
hours after the initial bolt up has been completed and the nuts tightened if the torque has
dropped below the final target torque.
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
15.2
•
•
•
RI-BQ-HDPE-001
Page 31 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
PROCESS CONTROLS
Flange face alignment.
Calculation and measurement of applied torque values.
Physical appearance of completed connection.
15.3 ACCEPTANCE CRITERIA
• The flange bolt up that has been carried out under compliance of this procedure and does not
present any abnormal features or appearances shall be deemed as acceptable.
• visual parameters of acceptance include - proper alignment of flange faces, absence of gaps
between mating surfaces
• All studs shall be tightened and checked (Manual Torquing)
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 32 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
15.4 ILLUSTRATIONS
• FIGURE 1 - STUD TIGHTENING SEQUENCE
HDPE INTERNAL LINING PROCEDURE
Revision
0
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 33 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
16. POST INSTALLATION HDPE LINER AIR TEST PROCEDURE
16.1 RESPONSIBILITIES
OF THE QA/QC INSPECTOR, OR SUPERINTENDENT:
✓ To verify the use and compliance of this procedure.
✓ To recover the QA/QC documentation generated during the work, check it for accuracy, and
file it accordingly.
OF THE LINER INSTALLATION FOREMAN:
✓ To comply with this procedure.
✓ To complete a Job Safety Analysis (JSA) and daily Tool Box Talk.
✓ To uphold Health, Safety and Environmental requirements.
OF THE AIR TEST TECHNICIAN(S):
✓ To confirm completion of Job Safety Analysis, Daily Toolbox Talk & issuance of work permit.
✓ To take all the necessary safety precautions and comply with the Air Test steps as
established under this procedure.
✓ To properly set up the air test parameters.
✓ To adequately record the activities in the corresponding report.
16.2 AIR TEST
• Air Test can be done either for individual lined sections, in bolted sub sections or for the
complete line
• Gauges limits and validity shall be verified before start of the test.
• Temporary blind flanges used during Air test shell be uniformly tightened by hand tools.
Hydraulic. Mechanical torqueing for this temporary activity shall be avoided in order to prevent
damage to the Stub ends.
• Installation supervisor, foreman and technicians are responsible for verifying that all
procedures prior to the air test have been followed and that the corresponding documentation
(reports) have been completed.
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 34 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
•
•
Revision
0
Thread-o-lets at each end of the lined pipeline section are open, unplugged, and free of debris.
The calibrated pressure gauges shall be installed at each end of the test section. These gauges
shall have a range of 0 - 200 psi.
• Connect the compressed air source and elevate the pressure to 30 psi.
• Resume with compressed air source and elevate the pressure to 60 psi.
• Resume with compressed air source and elevate the pressure to 100 psi. Close off the feed and
other test tree valves to hold the pipeline at this pressure.
• Check for any leaks at the blind flanges and test apparatus. If a leak is detected at any of these
positions, depressurize the pipeline, resolve the leak, and re-pressurize the pipeline section.
• Upon reaching the test pressure (100 psi) inspect thread-o-lets for signs of leaking. In certain
circumstances if may be necessary to apply a soapy water solution to the unplugged thread- olets at each end of the test section and inspect for signs of leak. Signs of a leak will be evidenced
by a bubbling effect and/or a hissing sound.
• Soapy water solution can also be applied around flange plate and valves or gauges to inspect for
signs of a leak.
Note: a small amount of air/moisture is expected to be vented through the thread-o-let. This is due
to PE-100 liner expanding and ridding the annulus space of voids. The amount should taper off.
• Calibration of pressure gauges should not be older than one (1) month.
• Capacity of relief valve shall be set at 5% above the test pressure.
• Calibration of relief valive should not be older than 14 days.
• If there are no signs of a leak, hold the air pressure for a period of no less than one hour,
inspecting the thread-o-lets at every twenty (20) minutes and recording the pressure and
ambient temperature values in the corresponding report.
• Hold pressure for a minimum of one hour. More time may be necessary to determine if there is
a leak is present.
• Report any signs of a leak to the installation supervisor & foreman immediately. If a leak occurs,
document the details in the test report.
• It is the responsibility of the installation supervisor and foreman or the superintendent to
determine if there is a leak in the PE-100 liner and to either approve/reject the test section(s).
• If no leaks are evident at the end of the test period, complete the test report and depressurize
the pipeline section by carefully opening the drain valve.
16.3 PROCESS CONTROLS
• The safe and proper installation of the test apparatus.
• Continuous monitoring for leaks during the complete duration of the test.
• Verification that the pressure gauges hold the test pressure for the duration of the test.
16.4 ACCEPTANCE CRITERIA
• The lined pipeline section shall be considered as accepted if signs of a leak are not evident or a
sudden/constant pressured loss is not observed.
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 35 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
16.5 24” & 12” Fabricated Blind flange for HDPE liner Air leak test (Temporary use)
Pressure
Pipe Bore
Yield Strength
Factor of safety
Poissons Ratio
Max bending
Thickness
100 psi
22.25 in
30 ksi
80.00%
0.3
2552.666 in lb/in
0.799 in
20.291 mm
𝜈
𝜎
The above Equations are used to calculate the required thickness
Equations are from Roark's Formulas for Stress and Strain 6th Ed. (page 398)
Where:
M = maximum bending moment
q = pressure on surface of circular plate
r = radius of disk
𝜈 = poissons ratio
𝜎 = maximum stress
T = thickness
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 36 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
HDPE INTERNAL LINING PROCEDURE
Revision
0
Contractor:
Document Ref. No.
PROCEDURE
RI-BQ-HDPE-001
Page 37 of 71
Contract #
6600051205
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
BI #
11-22000-2437
Revision
0
16.6 ATTACHMENTS
HDPE SURELINER™ AIR TEST REPORT: DOCUMENT NO. F-APT-06
AIR TEST LOG
DESCRIPTION
TEST # 1
TEST # 2
DOC F- APT - 06 - A
PROJECT #
TEST # 3
TEST # 4
TEST DATE
SECTION #
UPSTREAM LOCATION
DOWNSTREAM LOCATION
TEMPERATURE
TIME 1
PRESSURE READING 1
TIME 2
PRESSURE READING 2
TIME 3
PRESSURE READING 3
THREAD-O-LET CHECK
PASS / FAIL
FOREMAN SIGNATURE
COMMENTS
QC INSPECTOR
DATE
NAME
INSTALLATION FOREMAN
DATE
NAME
BIN QURAYA REPRESENTATIVE ARAMCO REPRESENTATIVE
DATE
DATE
NAME
NAME
SIGN
SIGN
SIGN
HDPE INTERNAL LINING PROCEDURE
SIGN
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 38 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
17.LIST OF TOOLS AND MACHINERY
- List of tools and machinery required for HDPE lining works listed but not limited to the
following:
- Additional support hand tools, power tools, machinery and equipment may be required
depending on the site conditions and work front.
Tools
Hand Tools:
Hammers, Mallets (Wood / Rubber), Bead Trimmers, Screw Drivers
- Allen Key Set (Metric & Inch), Spanner Sets (Metric & Inch)
- Shovels, Crow Bars
Power Tools:
- Wired & Battery operated drill machines
- Wired and Battery operated jack saw
- Wire & Battery operated Hammer drills
Machinery
Liner Fusion:
- McElroy & ITS Technodue Fusion Machines
- Diesel Generator
- Fusion Accessories (Pipe Racks, Stands etc)
Liner Insertion:
- Truck Mounted Hydraulically powered Roller Reduction Box
- Truck Mounted Hydraulically powered Wire Rope Winch
- Support machinery and equipment
- Air compressor
Stub End Installation:
- Fusion Machine
- Equipment for liner stretching
- Diesel Generator
- Internal & External Clamps
- Hydraulic Hand Pumps & accessories
Air Test:
- Air compressors 350 – 850 CFM
Equipment
- Telehandlers, Forklifts, Excavators, Cranes, Trucks, Half lorries
Accessories
- Wire ropes, Slings, Nylon Ropes, Roller slings, Belts etc.
/ Others
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 39 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
18.1
SAEP 387
HDPE INTERNAL LINING PROCEDURE
Engineering Procedure
02 June 2021
SAEP-387
Thermoplastic Liners for New and Existing Pipelines
Document Responsibility: Nonmetallic Standards Committee
Previous Revision: 22 January 2019
Contact: (ASIRAY0A)
© Saudi Arabian Oil Company, 2021
Saudi Aramco: Company General Use
Next Revision: 02 June 2026
Page 1 of 26
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
Saudi Aramco: Company General Use
Page 2 of 26
Document Responsibility: Nonmetallic Standards Committee
SAEP-387
Issue Date: 02 June 2021
Next Revision: 02 June 2026
Thermoplastic Liners for New and Existing Pipelines
Summary of Changes
Paragraph Number
Change Type
Previous Revision
(22 January 2019)
Current Revision
(02 June 2021)
(Addition, Modification, Deletion,
New)
Technical Change(s)
I
Addition
Added reference to 01SAMSS-025 for in-plant piping
systems with PTFE/fluorinated
polymer lining
IV.3.11
Addition
Qualification requirements for
PERT material
Section 4. 3.12
IV.3.13
Modification
NA
IV.4.5
Addition
Section 4. 5.5
IV.5.6
Modification
Section 4. 6.3
IV. 6.3
Modification
IV. 6.3
Addition
Section 4. 6.6
IV. 6.6
Modification
Section 4. 6.3
IV.7.7
Modification
NA
IV.6.6
Addition
1
© Saudi Arabian Oil Company, 2021
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Clarification between the
cases for smooth liner and
grooved liner utilization
The design of liner system
shall be carried out by the liner
installer for the approved
engineering contractor
Clarification on the
requirement of re-injection
system for systems in sour
service
Hydrostatic testing
requirements for steel pipes
before liner insertion
Steel pipe assessment
requirements for rehabilitation
projects as per SAEP-326
Clarification on the use of
raised face flanges for high
pressure lined pipelines (Class
900 and higher) as allowed
per SAES-L-109
− Marking requirements
moved to IV.7.7.
Surface markers is newly
required in addition to pipeline
marking.
− New conditions and
requirements for the use of
extrusion welding of stubend flanges
− New requirements for the
steel flanges internal
diameter and bend radius to
avoid sharp corners in
Page 3 of 26
Document Responsibility: Nonmetallic Standards Committee
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Issue Date: 02 June 2021
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Thermoplastic Liners for New and Existing Pipelines
contact with the
thermoplastic liner
Existing flange insulation kits
at the flange connections shall
not be disturbed by the
installation of the liner.
NA
IV.6.7
Modification
Hydrostatic testing
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.
NA
IV.7.6
Addition
− Requirement to replace the
vent/re-injection tubing, for all
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.”
Section 4.5.8
NA
Deletion
Deletion of the Commentary
Note
Section 4. 6.6
NA
Deletion
Deleted requirement for
washers between the nut and
the flange
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Page 4 of 26
Document Responsibility: Nonmetallic Standards Committee
SAEP-387
Issue Date: 02 June 2021
Next Revision: 02 June 2026
Thermoplastic Liners for New and Existing Pipelines
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
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Document Responsibility: Nonmetallic Standards Committee
SAEP-387
Issue Date: 02 June 2021
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Thermoplastic Liners for New and Existing Pipelines
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
III.2
High Density Polyethylene (HDPE) Pipe and Fittings.
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
Pipe and Fittings
Standard Practice for Heat Fusion Joining of Polyethylene
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
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Document Responsibility: Nonmetallic Standards Committee
SAEP-387
Issue Date: 02 June 2021
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Thermoplastic Liners for New and Existing Pipelines
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
IV
Design, Installation and Operation of Thermoplastic Liners
for Oilfield Pipelines
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
SP0304
2004 Edition
Section
Number
Title
Remarks
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
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Document Responsibility: Nonmetallic Standards Committee
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Thermoplastic Liners for New and Existing Pipelines
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
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Document Responsibility: Nonmetallic Standards Committee
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Issue Date: 02 June 2021
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Thermoplastic Liners for New and Existing Pipelines
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.
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Thermoplastic Liners for New and Existing Pipelines
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
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Thermoplastic Liners for New and Existing Pipelines
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.
3.12
[Addition] Liner material
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 Nonmetallic 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.
3.13
[Addition] Liner material
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
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Issue Date: 02 June 2021
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Thermoplastic Liners for New and Existing Pipelines
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)
Materials
Water injection and
Disposal service
Multiphase Crude Oil
Gas
Gas Condensate
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 PERT 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
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Thermoplastic Liners for New and Existing Pipelines
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
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Thermoplastic Liners for New and Existing Pipelines
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
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Thermoplastic Liners for New and Existing Pipelines
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.
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Thermoplastic Liners for New and Existing Pipelines
Lined pipelines in sour service, such as sour water disposal and multiphase 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.
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Thermoplastic Liners for New and Existing Pipelines
For other type of end connectors, such as flangeless connections and
others,
the liner installer shall submit the design for approval to the CSD Nonmetallic 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
© Saudi Arabian Oil Company, 2021
Saudi Aramco: Company General Use
Page 17 of 26
Document Responsibility: Nonmetallic Standards Committee
SAEP-387
Issue Date: 02 June 2021
Next Revision: 02 June 2026
Thermoplastic Liners for New and Existing Pipelines
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 stubend 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.
© Saudi Arabian Oil Company, 2021
Saudi Aramco: Company General Use
Page 18 of 26
Document Responsibility: Nonmetallic Standards Committee
SAEP-387
Issue Date: 02 June 2021
Next Revision: 02 June 2026
Thermoplastic Liners for New and Existing Pipelines
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.
© Saudi Arabian Oil Company, 2021
Saudi Aramco: Company General Use
Page 19 of 26
Document Responsibility: Nonmetallic Standards Committee
SAEP-387
Issue Date: 02 June 2021
Next Revision: 02 June 2026
Thermoplastic Liners for New and Existing Pipelines
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.
b)
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.
Lined pipe hydrostatic pressure testing
The completed lined pipeline system shall be pressure tested with
as per the following:
© Saudi Arabian Oil Company, 2021
Saudi Aramco: Company General Use
Page 20 of 26
Document Responsibility: Nonmetallic Standards Committee
SAEP-387
Issue Date: 02 June 2021
Next Revision: 02 June 2026
Thermoplastic Liners for New and Existing Pipelines
− 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
7.4
Liner operation
[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
© Saudi Arabian Oil Company, 2021
Saudi Aramco: Company General Use
Page 21 of 26
Document Responsibility: Nonmetallic Standards Committee
SAEP-387
Issue Date: 02 June 2021
Next Revision: 02 June 2026
Thermoplastic Liners for New and Existing Pipelines
•
•
•
•
•
7.5
Venting
Pigging
Start-up procedure
Routine operations
De-pressurizing
[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
© Saudi Arabian Oil Company, 2021
Saudi Aramco: Company General Use
Page 22 of 26
Document Responsibility: Nonmetallic Standards Committee
SAEP-387
Issue Date: 02 June 2021
Next Revision: 02 June 2026
Thermoplastic Liners for New and Existing Pipelines
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.
© Saudi Arabian Oil Company, 2021
Saudi Aramco: Company General Use
Page 23 of 26
Document Responsibility: Nonmetallic Standards Committee
SAEP-387
Issue Date: 02 June 2021
Next Revision: 02 June 2026
Thermoplastic Liners for New and Existing Pipelines
•
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.
© Saudi Arabian Oil Company, 2021
Saudi Aramco: Company General Use
Page 24 of 26
Document Responsibility: Nonmetallic Standards Committee
SAEP-387
Issue Date: 02 June 2021
Next Revision: 02 June 2026
Thermoplastic Liners for New and Existing Pipelines
VI.
•
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.
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.
© Saudi Arabian Oil Company, 2021
Saudi Aramco: Company General Use
Page 25 of 26
Document Responsibility: Nonmetallic Standards Committee
SAEP-387
Issue Date: 02 June 2021
Next Revision: 02 June 2026
Thermoplastic Liners for New and Existing Pipelines
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
22 January 2019
26 April 2018
Major revision.
Editorial revision.
Merger of 01-SAMSS-050 and SAEP-387 and overlaying with NACE RP0304.
© Saudi Arabian Oil Company, 2021
Saudi Aramco: Company General Use
Page 26 of 26
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 40 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
18.2
JOB SAFETY ANALYSIS (JSA)
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 41 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
JOB SAFETY ANALYSIS (JSA)
HDPE LINER SERVICES FOR
SAFANIYA SFNY 24” HDPE HDR T/L PROJECT
Job Safety Analysis Sheet
Job: HDPE Butt Fusion
welding & HDPE Liner
Installation inside
Pipeline
Facility:
SFNY 24” HDR T/L
JSA Ref. No. JSA: 001
Work Area/Equipment:
1st week
2nd week
3rd week
4th week
Permit
No.
Date:
Note: If JSA Revised, updated JSA shall be used
Personal protective equipment and tools:
Hard Hat, Safety Shoes, Safety Goggles / Face Shields, Hand Gloves, Coverall
SEQUENCE OF
BASIC JOB STEPS
Pre - work
POTENTIAL HAZARDS
Poor
Planning
PRECAUTIONS
Pre-Task •
•
•
•
Obtain required Permit to Work
Ensure all heavy equipment used have a valid
Clearance Certificate
All equipment/ tools i.e. Pulling shackles, wire
rope equipment and other pulling tools shall
be inspected and certified (TPI)as applicable
Ensure the equipment / tool to be used for
the installation of HDPE Liner are free from
defect and suitable for the pulling force of the
system
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 42 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
Training
•
•
•
•
•
Non Compliance of
HSEMS Procedures
•
•
Personnel injured due
to poor
communication or
having no knowledge
of ERP
•
•
•
•
HDPE butt fusion Hot surface
welding
Electrocution
Fire hazard
•
•
•
•
Ensure all personnel have undergone Project
HSE Induction and training
Ensure to comply with Saudi Aramco HSEMS
procedures as applicable
Ensure only competent/authorized personnel
are carrying out the task
Ensure all personnel have undergone HDPE
liner for pipeline operation safety awareness
training
prior
to
deployment
and
commencing of work
Conduct TBT and ensure that PPE is
appropriate for the work to be undertaken is
correctly identified & used
Ensure to comply with Saudi Aramco HSEMS
Permit to Work procedure, Mobile
Equipment, First Aid and Emergency
Response, PPE etc.
Ensure all firefighting equipment available is
approved by the company
Ensure that the Emergency Numbers are
posted at site, and personnel are informed in
the TBT once per week
First Aid kit and Eye Wash Equipment shall be
available at all times at the work area.
Ensure proper communication means
available
In case of any medical assistance supervisor /
safety personnel must call Bin Quraya
paramedic and Saudi Aramco emergency.
The area shall be cordoned off and only
personnel associated with HDPE fusion
welding operation shall be allowed in the
work area.
Electric power supply for all power tools
must be through ELCB
Ensure the power pack is properly grounded.
Fire extinguishers to be placed at site and
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 43 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
0
•
•
•
•
Pig/ gauging plate Equipment Failure/
insertion in pipe Damaged Tools
through the winch Unauthorized entry of
personnel at work
location
Over Pressure
Sudden release of
stored energy
Vibration
Noise
•
•
•
•
•
•
•
Set up of HDPE
liner
Pulling
Equipment
Roller reduction
Box installation
Revision
Personnel injury due
to Struck By/ crushing
Fall into trench due to
cave in / collapse of
soil
Slips & Trips
Pinch point injuries
Equipment Failure/
Damaged Tools
•
•
•
•
near electric pump.
Deploy only skilled workmen who have
formal training
Proper/ damage free insulated handle should
be ensure for the heated plate.
Heater plate to remain in the canvas
enclosure when not in use
Involved personnel should wear appropriate
PPE’s.
The area shall be cordoned off and only
personnel associated with HDPE operation
shall be allowed in the work area.
When using Air compressor for air pressure
testing of double fusion seams, to ensure the
area is cleared and only standard hose/
fittings are used and whip checks are
provided at each coupling joint location.
All pressure testing equipment shall have
valid calibration certificates.
Securely bolted the blow-down flange onto
pipeline flange.
If applicable safety pins must be in place on
all fittings or connections.
Precaution to ensure that body parts don’t
become trapped while clamping the pipes.
Ensure to follow the pig tracking instruction
manual if the pig/ gauging plate get stuck
inside the pipe.
Only suitably experienced and competent
personnel shall be used for the activity
No unauthorized personnel shall be
permitted at the location.
Ensure the Roller box installed is secured to
prevent movement during the installation of
HDPE liner.
Ensure the working area is clean, remove all
hazardous or toxic materials prior to start the
activity
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 44 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
•
•
•
•
•
•
Not following
methodology of work
Untrained personnel
Incompetent
supervision
HDPE
Liner
Installation inside
pipelines
•
•
•
•
Equipment Failure/
Damaged Tools
Personnel injury due
to Struck By/ crushing
Nips and Pinch
Injuries Entrapment/
entanglement with
moving parts
•
•
•
•
Ensure appropriate access / egress into
trench/ work area
Do not use damaged tools or equipment’s
Ensure ground is stable and properly
compacted as required for positioning of
pulling equipment and HDPE Roller box.
Be sure to physically check the equipment/
tools before start of activity, and verify that
they have been inspected (colour marked) as
appropriate
Cordon off both ends of pipeline section and
keep all personnel and traffic clear of exit end.
All fittings & hoses must be correctly fitted,
checked prior to start up.
HDPE installation for pipeline shall be in
accordance
with
method
statements,
approved by Company.
Ensure only competent/authorized personnel
are carrying out the task Authorized
personnel to operate and work as minimal as
possible near or around the Pulling
equipment
Do not leave the HDPE liner insertion
operation unattended.
Ensure good communication between the
Pulling operator and the fusion welding
technician.
Ensure the winch pulling unit is capable of
controlling pull force as required
Ensure the winch / pulling unit is provided
with adequate protection for the operator
Ensure the winch should only be operated by
personnel trained and familiar with wire line
use and proper HDPE liner installation.
The maximum pulling forces (MPF) shall be
calculated and shall not exceed 90% of the
tensile yield (design) strength of the HDPE
liner pipe. This shall be verified by calculating
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 45 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
•
•
•
•
•
Unauthorized entry of
personnel at work
location
Line of Fire Injury
Presence of Toxic gas
•
•
•
•
•
•
•
the corresponding theoretical MPF, and by
monitoring during the pulling operation.
Ensure the roller reduction box should only
be use with correct rollers for the intended
pipe size and reduction as specified in the
approved CMS approved by Company
Ensure all electrical safe guards/ controls
including ELCB are in place to prevent any
electric shock to person/s
Ensure that all personnel hands are kept
away from the roller box
All guards are fitted and personnel are
wearing appropriate hand protection as
required.
Ensure that all safety guards installed on the
roller box are secure fixed in place
During the HDPE liner pulling operation the
area shall be cordoned off and only personnel
associated with pulling operation shall be
allowed in the work area.
Ensure are fully supported / secured to
prevent untoward movement during the
pressurization n of the system.
Ensure the pipeline has successfully
completed the hydro tested / pigging and
drying completed prior to commence HDPE
liner installation.
Ensure all personnel are wearing appropriate
PPE.
Gas testing to be carried out prior to start the
activity and kept records and frequency
monitored, if required, based upon work
location and degree of risk.
Remove all flammable and combustible
materials inside tank.
Personnel to be trained in line of fire injuries
prevention.
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 46 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
0
Struck by
Fall into trench due to
cave in / collapse of
soil
Poor access / egress
Slips & Trips
Pinch point
Poor illumination
•
•
•
•
•
•
Additional
hazards
Worksite
Supervisor
Name:
Company: RI
Designation:
Worksite
Supervisor
Signature:
Revision
Personnel injury due
to poor housekeeping
Unavailability of
transport in cases of
emergency evacuation
at work location
Injury / accidents due
to animal / reptile
bites
Exposure to extreme
weather
•
•
•
•
Ensure adequate and appropriate safety
signage’s posted at work location
Ensure adequate barricades (tapes) installed
around the winch /pulling equipment area.
Ensure the work place is maintained clear of
debris, waste, other rubbish & make the place
clean and tidy
Ensure appropriate protection on excavation
i.e. benching /sloping, if applicable.
Ensure appropriate access / egress at work
location in accordance with the Aramco
HSEMS procedure as applicable.
For extended hour work / night works,
ensure sufficient lighting arrangements are
available and in working condition and
appropriate PPE i.e. clear goggles are
provided to workforce.
Ensure the work place is maintained clear of
debris, waste, other rubbish & make the place
clean and tidy
Ensure the availability of standby transport to
evacuate personnel in cases of any emergency
situation at work location.
Provide adequate warning signage as
required for welfare facility / short breaks,
contractor temporary facility on work
location shall be used
Do not befriend any stray dogs or feed wild
animals
Permit Applicant
Permit Issuer
Name:
Company: Bin Quraya
Name:
Company: Bin Quraya
Designation: Permit Applicant
Designation: Permit Issuer
Signature:
Signature:
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 47 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
18.3
LINER INSTALLATION
ITP & CHECKLIST
HDPE INTERNAL LINING PROCEDURE
Project Name: HDPE (PE100) LINER SERVICES FOR
SFNY 24” Above Ground HDPE Lined Water Disposal Trunk Line
HDPE LINER INSTALLATION – INSPECTION & TEST PLAN (ITP)
Contractor
Sub Contractor
Inspection Location:
Purchase Order #:
Description:
Owner:
Contract No.:
BL No.:
Bin Quraya
Raymond International
Saudi Arabia
WX:
HDPE Liner Installation
Saudi Aramco
6600051205
11-22000-2437
S:
R:
H:
P:
Item
Activity Description
Stage/
Frequency
A
Approval of HDPE data
sheet, fusion procedure,
insertion (pulling) procedure,
stub end installation
procedure, bolt-up procedure,
and air test procedure.
In compliance with Purchase Order, MR, Data Sheet, and Project Specifications
B
Material Receiving Inspection
Once
Purchase Order, Material
Spec., Packing Slips,
Delivery/Shipping
Documentation
C
Calibration of Heating Plate,
Temperature Gauges &
Pressure Gauges
Annually
Calibration Status of
Instrments/Equipment
D
Qualification of HDPE Butt
Fusion Welding Procedure
and Fusion Technician
Item
Activity Description
PQT
A:
Approval Required
Witness Inspection, X=% coverage (RFI required)
Where X=10 means 10% coverage. Activity can proceed if witnessing party is
not present after due notification
Reference
Document
HDPE PE-100 Internal
Lining Procedure:
Clause 12
Inspection & Test Plan – HDPE PE-100 Internal Lining
Characteristics to be
Verified
Visual Inspections
Surveillance or Monitoring (RFI shall be at the beginning of the inspection)
Review of Documentation
Hold Point (RFI required). Activity cannot proceed without inspection
Perform (Perform the activity either by Vendor / Subcontractor / Contractor)
Inspection Involvement
Verifying
Acceptance Criteria
Document
Sub Contractor
Contractor
The HDPE pipe liner
shall be free from
dents or any
scratches deeper
than 10% of the wall
thickness
P
Delivery
documents
from
supplier(s)
As per Calibration Certificate
Alignment, Heater
Plate Temperature,
Heat Time, Fusion
Pressure, Cool Down
Time, and Fusion Weld
Bead Size/Appearance
Conforms to HDPE
PE-100 Internal
Lining Procedure
Acceptance Criteria
F-APT-01-A
A
P
R
R
R
P
A
Inspection Involvement
Page 1 of 5
Project Name: HDPE (PE100) LINER SERVICES FOR
SFNY 24” Above Ground HDPE Lined Water Disposal Trunk Line
HDPE LINER INSTALLATION – INSPECTION & TEST PLAN (ITP)
Stage/
Frequency
Reference
Document
Characteristics to be
Verified
HDPE PE-100 Internal
Lining Procedure:
Clause 12
Test Strap Dimensions
PQT
HDPE Fusion Bend Back
Test Strap, Cut-out
E
HDPE Fusion Bend Back /
Reverse Bend Back Test
Verifying
Document
As per ASTM 2620
F-APT-01-A
Sub Contractor
Contractor
P
S/R
P
W/H
P
R
P
R
Fusion Conditions
Production Activities:
1
Production Testing:
Strap Cut-out
Fusion Bend Back Test
Fusion Reverse Bend Back
Test
At Start of
Eah Day &
1 of 15 per
Technician/
Machine/
Fusion
Type
(Manual or
Automatic)
HDPE PE-100 Internal
Lining Procedure:
Clause 12
Alignment, Heater
Plate Temperature,
Heat Time, Fusion
Pressure, Cool Down
Time, and Fusion Weld
Bead Size/Appearance
Conforms to HDPE
Butt
Fusion Weld
Procedure
F-APT-01-A
Conforms to ASTM
F2620
No cracking or
separation
2
HDPE Pipe Fusion Weld
Alignment
Each Joint
HDPE PE-100 Internal
Lining Procedure:
Clause 12
Alignment
Maximum Misalignment 10% of WT
3
HDPE Fusion Pre-Heating
Each Joint
HDPE PE-100 Internal
Lining Procedure:
Clause 12
Heater Plate
Temperature and Heat
Time
Conforms to HDPE
Butt Fusion Weld
Parameters
F-APT-02-A
F-APT-02-A
Inspection Involvement
Inspection & Test Plan – HDPE PE-100 Internal Lining
Page 2 of 5
Project Name: HDPE (PE100) LINER SERVICES FOR
SFNY 24” Above Ground HDPE Lined Water Disposal Trunk Line
HDPE LINER INSTALLATION – INSPECTION & TEST PLAN (ITP)
Item
Activity Description
Stage/
Frequency
Reference
Document
Characteristics to be
Verified
Acceptance Criteria
4
HDPE Fusion Cool Down
Time
Each Joint
HDPE PE-100 Internal
Lining Procedure:
Clause 12
Fusion Pressure
Hold/Cool-down Time
and Beads
Conforms to HDPE
Butt Fusion Weld
Parameters
HDPE PE-100 Internal
Lining Procedure:
Clause 12
Fusion Beads
Weld Beads are
smooth with no
wrinkles,
discontinuities, full
bead rollback, and no
appearance of
separation
No damage to face of
steel flanges, internal
weld bead of steel
flange ground flush,
Bell Hole to safe and
adequate, ROW
graded for working
area, and Thread-OLet welded
5
HDPE Fusion Visual
Inspection
Each Joint
Taking Over Host Pipe
Section After Completion of
Welding, NDE & Hydrotesting
Each
Section
N/A
Unbolted flange
connections, internal
weld bead on steel
flange, Bell Hole
Excavation & ROW
graded, Thread-O-Let
Welded
7
Drilling Vent Hole
Each
Section
HDPE PE-100 Internal
Lining Procedure:
Clause 13
3 mm vent hole drilled
at center of each WeldO-Let
No burrs inside of the
steel pipe that can
damage the HDPE
liner during install
8
Visual and Dimensional
Inspection of Liner Section
Before Installation / Each
Liner Section
Each
Section
HDPE PE-100 Internal
Lining Procedure:
Clause 13
Check Liner condition
and dimensions
No scratches or
dents that exceed the
maximum allowable
tolerance
Item
Activity Description
6
Inspection & Test Plan – HDPE PE-100 Internal Lining
Acceptance Criteria
Verifying
Document
F-APT-02-A
F-APT-02-A
N/A
F-APT-03-A
F-APT-03-A
Sub Contractor
Contractor
P
R
P
W
W
R
-
P
P
S/R
Inspection Involvement
Page 3 of 5
Project Name: HDPE (PE100) LINER SERVICES FOR
SFNY 24” Above Ground HDPE Lined Water Disposal Trunk Line
HDPE LINER INSTALLATION – INSPECTION & TEST PLAN (ITP)
Stage/
Frequency
Reference
Document
Characteristics to be
Verified
Pig and gauge plate
rate of travel, Gauge
plate condition
Gauging plate does
not show excessive
damage that could
harm liner during
installation
Pull Force
Value is less than the
Maximum Pull Force
(MPF) Calculation
9
HDPE Liner Insertion – Blow
Down, Pigging, and Gauging
Each
Section
HDPE PE-100 Internal
Lining Procedure:
Clause 13
10
HDPE Liner Insertion –
Pulling
Each
Section
HDPE PE-100 Internal
Lining Procedure:
Clause 13
MPF: Clause 5
Verifying
Document
F-APT-03-A
F-APT-03-A
Sub Contractor
Contractor
P
R
P
R
P
R
P
R
P
R
Pipe remains round,
Fusions do not fail.
11
12
HDPE Liner Installation Pulling
HDPE Stub End Installation
13
HDPE Stub End Installation
Item
Activity Description
Each
Section
Each
Section
Each
Section
HDPE PE-100 Internal
Lining Procedure:
13
Pipe Appearance and
Geometry
HDPE Leading Edge
Condition
Damage from host
pipe during
installation is
acceptable provided
gouge depth is less
than 10%
HDPE PE-100 Internal
Lining Procedure:
Clause 14
Length of
Stretch/Additional
Movement
Liner is sufficiently
relaxed, sufficient
length to install Stub
End, liner does not
slip after internal
clamp is activated
HDPE PE-100 Internal
Lining Procedure:
Clause 14
Alignment, Heater
Plate Temperature,
Heat Time, Fusion
Pressure, Cool Down
Time, and Fusion Weld
Bead Size/Appearance
Conforms to HDPE
PE-100 Internal
Lining Procedure
Inspection & Test Plan – HDPE PE-100 Internal Lining
Acceptance Criteria
F-APT-03-A
F-APT-04-A
F-APT-04-A
Inspection Involvement
Page 4 of 5
Project Name: HDPE (PE100) LINER SERVICES FOR
SFNY 24” Above Ground HDPE Lined Water Disposal Trunk Line
HDPE LINER INSTALLATION – INSPECTION & TEST PLAN (ITP)
Stage/
Frequency
14
Flange Bolt Up – Alignment
Every
Connection
Reference
Document
HDPE PE-100 Internal
Lining Procedure:
Clause 15
Characteristics to be
Verified
Verifying
Document
Sub Contractor
Contractor
Alignment
Retainer Ring (if
required), O-ring (if
required), and
Alignment
Pins/Flange Bolts
installed. Assurance
that the mating flange
faces are parallel to
one another
-
-
P
ASME PCC-12010
-
P
P
W
15
Flange Bolt-up Torque
Every
Connection
HDPE PE-100 Internal
Lining Procedure:
Clause 15
Torque
Correct torque setting
following the proper
bolt torque sequence,
Retainer Ring/O-ring
(if required) is
properly installed and
in place
16
HDPE Liner Air Leak Test
Each
Section
HDPE PE-100 Internal
Lining Procedure:
Clause 16
Pressure Containment
Holds pressure and
does not leak from
Thread-O-Lets
Inspection & Test Plan – HDPE PE-100 Internal Lining
F-APT-06-A
Page 5 of 5
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 48 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
18.4
BUTT FUSION PARAMETERS
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 49 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
18.6: BUTT FUSION PARAMETERS: 24” & 12”
HDPE INTERNAL LINING PROCEDURE
Revision
0
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 50 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
HDPE INTERNAL LINING PROCEDURE
Revision
0
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 51 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
18.5
BELL HOLE DRAWING
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 52 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
HDPE INTERNAL LINING PROCEDURE
Revision
0
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 53 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
18.6
SATIP-HDPE-001
HDPE INTERNAL LINING PROCEDURE
SAUDI ARAMCO ID/PID FORM REV 1 - 010109
Rev 7
SAUDI ARAMCO TYPICAL INSPECTION PLAN
INSTALLATION OF HDPE LINERS
1.0
APPROVED DATE
MECHANICAL
WBS/BI/JO/NO.
PROJECT
PHASE &
Activity Code
TASK / ACTIVITY
DISCIPLINE:
SATIP-HDPE-001
PROJECT TITLE:
ITEM
NO.
COS 03/31/2013
SATIP No.
QUALITY
PROCEDURE
QUALITY
RECORD
CONTRACTOR/SUBCONTRACTOR
INSPECTION RESPONSIBILITY
ASSIGNMENTS
CONTRACTOR
SAUDI ARAMCO
REMARKS
DOCUMENT REVIEW
1.1
Procedure for Installation of HDPE Liner
In Carbon Steel PipeLines
SAIC-HDPE-003
SAIC-HDPE-003
RH
RH
As per SAEP-387 / Shell DEP 31.40.30.34 Gen and
NACE RP0304
1.2
Butt Fusion Welding Procedure
Specification
SAIC-HDPE-002
SAIC-HDPE-002
RH
RH
Ensure fusion parameters as per liner size and type
of fusion machine
1.3
Procedure and Personnel Qualification
for Butt Fusion Welding
SAIC-HDPE-002
SAIC-HDPE-002
RH
RH
Reverse Bend Test : No voids, visible cracks and
mis-alignment on joint surfaces
SAIC-HDPE-001
SAIC-HDPE-001
H
W
Materials as per P.O & Design, 01-SAMSS-050 and
01-SAMSS-051
2.0
2.1
3.0
MATERIAL RECEIVING
HDPE Liner Materials - Pipes & Fittings
HDPE LINER INSTALLATION
3.1
Daily Calibration for welding machines
and welders Qulaifiction
SAIC-HDPE-003
SAIC-HDPE-003
H
W
3.2
Gauging of Pipeline section using sizing
plate as per HDPE Liner wherever is
required. Sub-contractor requirement)
SAIC-HDPE-003
SAIC-HDPE-003
H
W
Sizing Plate shall pass through the pipeline section
and as per SAES-L-450
3.3
Release of steel pipes for HDPE lining
SAIC-HDPE-003
SAIC-HDPE-003
H
H
Verification of Test Records for Host Pipe
Hydrotest ,Cleaning, etc
Saudi Aramco: Company General Use
SAUDI ARAMCO ID/PID FORM REV 1 - 010109
Rev 7
SAUDI ARAMCO TYPICAL INSPECTION PLAN
INSTALLATION OF HDPE LINERS
PROJECT
PHASE &
Activity Code
APPROVED DATE
DISCIPLINE:
SATIP-HDPE-001
PROJECT TITLE:
ITEM
NO.
3.4
COS 03/31/2013
SATIP No.
MECHANICAL
WBS/BI/JO/NO.
CONTRACTOR/SUBCONTRACTOR
INSPECTION RESPONSIBILITY
ASSIGNMENTS
H
W
TASK / ACTIVITY
Butt Fusion Welding
QUALITY
PROCEDURE
SAIC-HDPE-002
QUALITY
RECORD
SAIC-HDPE-002
3.5
HDPE Liner Pulling
SAIC-HDPE-003
SAIC-HDPE-003
H
W
Pulling force shall not exceed to Max. allowable as
perapproved vendor procedure and SAEP-387
3.6
Welding of HDPE flange Stub Ends
SAIC-HDPE-003
SAIC-HDPE-003
H
W
Ensure fusion parameters as per liner size and type
of fusion machine and approved vendor procedure
3.7
Extrusion Welding of HDPE Flange Ring
for Short Length CS Spools
SAIC-HDPE-003
SAIC-HDPE-003
H
W
Ensure Extrusion parameters as per Liner PQR,
Extrusion Welding Procedure and approved vendor
procedure
No sign of Air leakage at O'Iets
4.0
LEAK TEST OF HDPE LINER AFTER INSTALLATION
4.1
Air Test of HDPE Lined CS Spools
SAIC-HDPE-003
SAIC-HDPE-003
H
H
4.2
Final hydro test for the whole lined line
SAIC-HDPE-003
SAIC-HDPE-003
H
H
SAIC-HDPE-003
SAIC-HDPE-003
RH
R
5.0
5.1
REMARKS
As per FPS (Constrn.)
FINAL DOCUMENTATION
Quality Documentation for Installed Liner
Lining Installation Records
GENERAL NOTES
1
The first three incidents of each Inspection or testing activity listed require 100 % participation by Saudi Aramco Site Inspection Personnel. After this period, Saudi Aramco Inspection may adjust the levels
of Saudi Aramco participation based upon the Contractor’s performance.
2
Surveillance: QA/QC organization to monitor work in progress without notice from Construction Organization.
3
Witness: QA/QC organization shall be notified of the timing of Inspection or test in advance. However, the inspection or test shall be performed as scheduled if the QA/QC organization representative is not
present.
4
Hold: QA/QC organization shall be notified of the timing of inspection or test in advance. Inspection or test shall not be carried out without the QA/QC organization representative in attendance.
5
If the Main Contractor delegates the assigned responsibility to the Subcontractor, then the Main Contractor will have the same degree of responsibility as assigned to Saudi Aramco.
6
For Test Package Preparation & review on large projects, each new system designed for testing is thoroughly reviewed & approved. All subsequent packages within a given system shall be built following the
"Copy & Paste" theme for Test Package efficiency and then R1 (Contractor) & R2 (Company Sample Review of documents) Inspection may be performed.
Saudi Aramco: Company General Use
SAUDI ARAMCO ID/PID FORM REV 1 - 010109
Rev 7
COS 03/31/2013
SATIP No.
SAUDI ARAMCO TYPICAL INSPECTION PLAN
INSTALLATION OF HDPE LINERS
S
Surveillance
DISCIPLINE:
SATIP-HDPE-001
PROJECT TITLE:
PROJECT
ITEM
PHASE
&
TASK
ACTIVITY
H
100%
Hold Point
for QC Inspection
or/ Test.
NO.
Activity Code
W Witness Inspection/Test
APPROVED DATE
WBS/BI/JO/NO.
QUALITY
PROCEDURE
MECHANICAL
CONTRACTOR/SUBCONTRACTOR
INSPECTION RESPONSIBILITY
ASSIGNMENTS
Review of Documents
LEGEND
QUALITY
R
RECORD
RH
I
Review and Approval of Documents
100% Contractor Inspection
Saudi Aramco: Company General Use
REMARKS
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 54 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
18.7
SAIC-HDPE-001, 002, 003,
004
HDPE INTERNAL LINING PROCEDURE
SAIC NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
HDPE TIGHT LINER INSTALLATION
DATE APPROVED
QR NUMBER
SAIC-HDPE-001
PROJECT TITLE
WBS / BI / JO NUMBER
EQUIPMENT ID NUMBER(S)
EQUIPMENT DESCRIPTION
LAYOUT DRAWING NUMBER
REV. NO.
SCHEDULED INSPECTION DATE & TIME
ACTUAL INSPECTION DATE & TIME
MECHCONTRACTOR / SUBCONTRACTOR
EQPT CODE
SYSTEM ID.
PURCHASE ORDER NUMBER
PLANT NO.
EC / PMCC / MCC NO.
QUANTITY INSP.
MH's SPENT
TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER
SAUDI ARAMCO ACTIVITY NUMBER
SAUDI ARAMCO INSPECTION LEVEL
CONTRACTOR INSPECTION LEVEL
ITEM
No.
ACCEPTANCE CRITERIA
WORK PERMIT REQUIRED?
REFERENCE
PASS
A
HDPE Liner Pipes Receiving Inspection
A1
HDPE liner to be procedure from approved vendor
A2
Miscellaneous material (CS retainer ring, stub ends…etc ) shall be
01-SAMSS-050 and 01supplied by construction contractor and these material shall be approved
SAMSS-051
by CSD
A3
HDPE material Manufacturing & Testing IAP Documentation has been
submitted and conforms approved and available with contractor.
A4
FAIL
N/A
RE-INSP DATE
01-SAMSS-050 and 01SAMSS-051
Pipe shall have the material specification and grade stamped, stenciled,
or otherwise clearly marked with permanent marking method.
Sch Q, Att. III, Para.
3.22
ISO 4427
A5
Pipes are delivered with Min. 2% carbon black to protect from UV
deterioration for outside storagre conditions.
01-SAMSS-050 and 01SAMSS-051
A6
Received liner pipe size is inline with design requirements
SAEP-387 / As per
Approved Liner Design
A7
Wall thickness is greater than or equal to the corresponding minimum
specified wall thickness.
API 15LE
A8
Any visible cracks, holes, creases, foreign materials, or other injurious
defects that would be an indication of poor workmanship.
01-SAMSS-050 and 01SAMSS-051
A9
HDPE Fittings manufactured similar to Pipe material / Grade.
01-SAMSS-050 and 01SAMSS-051
B
Storage, Handling and Preservation of HDPE materials.
B1
Any visible cracks, sctracthes, gouges if any, having more than 10% of
wall thickness of pipe?
B2
Are the ends of the pipe cut squarely & protected / covered with film
B3
Storage height of pipe should be in accordance with the
manufacturer/contractor approved procedure
NACE RP0304 /
AWWA C906
01-SAMSS-050 and 01SAMSS-051
Per Approved Vendor
Procedure
REFERENCE DOCUMENTS:
1. Approved vendor procedure
2. SAES-L-350, 01-SAMSS-050 and 01-SAMSS-051
3. SAEP-387 and API 15LE
Contractor / Third-Party
Saudi Aramco
Sub Con Contruction & QC Representative*
Work is Complete and Ready for Inspection:
Name, Initials and Date:
PMT Representative
Construction Representative*
Work is Complete and Ready for Inspection:
Name, Initials and Date:
QC Inspector
QC Record Reviewed
Work Verified
T&I Witnessed
QC Record Reviewed
Work Verified
T&I Witnessed
QC Record Reviewed
Work Verified
PID Representative
Performed Inspection
Work / Rework May Proceed
Name, Initials and Date:
Name, Initials and Date:
QC Supervisor
Proponent and Others
Quality Record Approved:
Name, Sign and Date:
T&I Witnessed
Name, Initials and Date:
Name, Organization,
Initials and Date:
Saudi Aramco: Company General Use
SAIC NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
HDPE TIGHT LINER INSTALLATION
DATE APPROVED
QR NUMBER
SAIC-HDPE-002
PROJECT TITLE
MECH-
WBS / BI / JO NUMBER
EQUIPMENT ID NUMBER(S)
EQUIPMENT DESCRIPTION
LAYOUT DRAWING NUMBER
REV. NO.
SCHEDULED INSPECTION DATE & TIME
ACTUAL INSPECTION DATE & TIME
CONTRACTOR / SUBCONTRACTOR
EQPT CODE
SYSTEM ID.
PURCHASE ORDER NUMBER
PLANT NO.
EC / PMCC / MCC NO.
QUANTITY INSP.
MH's SPENT
TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER
SAUDI ARAMCO ACTIVITY NUMBER
SAUDI ARAMCO INSPECTION LEVEL
CONTRACTOR INSPECTION LEVEL
ITEM
No.
ACCEPTANCE CRITERIA
A
Butt Fusion & Extrusion Welding Procedure & Operator Qualification
WORK PERMIT REQUIRED?
REFERENCE
PASS
A1
Proposed Welding documents approved by CSD.
SAEP-387 and
ISO
21307 /
ASTM F 2620
A2
Proposed Welding documents approved by SAPMT and PID
SAEP-387 and
ISO
21307 /
ASTM F 2620
A3
The welding equipment pressure gauge / Temerature controller / coupler
are calibrated.
SAEP-387 and
ISO
21307 /
ASTM F 2620
A4
Fusion contact areas are free of any defects or surface disruption.
SAEP-387 and
ISO
21307 /
ASTM F 2620
A5
Temporary fusion shed available over fusion equipment and the fusion
operator.
A6
Fusion areas are correclty aligned and misalignment not more than 10%
of wall thickness for fusion contact areas.
B
FAIL
N/A
RE-INSP DATE
General
NACE RP0304 /
AWWA C906
PQR Qualification - Hydrotest and reverse bend test
B1
Reverse bend test done as per approved procedure and are free from
visible cracks and seperations in the joints.
ASTM F 2620 / Equiv.
Std.,
B2
Hydro test pressure gaugues, safety relief valves are cerfitied for use of
required test pressure.
B3
The test pressure calculated 1.5 x design pressure of thermoplastic Pipe.
SAEP-387 and API
15LE
B4
The test pressure de-rating with test temperature when conducted
hydrotest is above 27 Deg.C
SAEP-387 and API
15LE
B5
During test phase, additional water to be added to sustain required
pressure due to expansion of pipe material.
SAES-A-004
B6
Any leakage from weld joints / failure during test pressure holding time i.e
2 hrs
SAES-A-004
SAES-A-004 and
approved vendor
procedure
REFERENCE DOCUMENTS:
1. ISO 21307 / ASTM F 2620
2. SAES-A-004
3. SAEP-387
Contractor / Third-Party
Saudi Aramco
Sub Con Contruction & QC Representative*
Work is Complete and Ready for Inspection:
Name, Initials and Date:
PMT Representative
Construction Representative*
Work is Complete and Ready for Inspection:
Name, Initials and Date:
Name, Initials and Date:
QC Inspector
Name, Initials and Date:
QC Record Reviewed
Work Verified
T&I Witnessed
QC Record Reviewed
Work Verified
T&I Witnessed
QC Record Reviewed
Work Verified
PID Representative
Performed Inspection
Work / Rework May Proceed
QC Supervisor
Name, Initials and Date:
Proponent and Others
Quality Record Approved:
Name, Sign and Date:
T&I Witnessed
Name, Organization,
Initials and Date:
Saudi Aramco: Company General Use
SAIC NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
HDPE TIGHT LINER INSTALLATION
DATE APPROVED
MECH-
SAIC-HDPE-003
PROJECT TITLE
WBS / BI / JO NUMBER
EQUIPMENT ID NUMBER(S)
EQUIPMENT DESCRIPTION
LAYOUT DRAWING NUMBER
REV. NO.
SCHEDULED INSPECTION DATE & TIME
ACTUAL INSPECTION DATE & TIME
QR NUMBER
CONTRACTOR / SUBCONTRACTOR
EQPT CODE
SYSTEM ID.
PURCHASE ORDER NUMBER
PLANT NO.
EC / PMCC / MCC NO.
QUANTITY INSP.
MH's SPENT
TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER
SAUDI ARAMCO ACTIVITY NUMBER
SAUDI ARAMCO INSPECTION LEVEL
CONTRACTOR INSPECTION LEVEL
ITEM
No.
A
ACCEPTANCE CRITERIA
REFERENCE
HDPE Liner Pre-Installation Checks
SAEP-387 and
approved vendor
procedure
A1
Installation procedure to be reviewed and approved by CSD
A2
Host pipe to be gauged by gauging plate prior to HDPE installation
SAES-L-450
A3
Host pipe Hydro test, Cleaning & Drying completed before hand-over
pipeline for HDPE liner installation.
SAES-L-350
A4
Vent assembly available for flange ends as required
SAEP-387 and API
15LE
A5
Tubing shall have the same raating of the host pipe
General
A6
Flange radius to be selected as per SAEP-387 and approved vendor
procedure
SAEP-387 and
approved vendor
procedure
A7
Internal gauging done by contractor for pipeline / piping as required.
SAES-L-450
A8
CS flange internal welds are smooth and free from excess weld
protrusion.
A9
CS Flange raised face(RF) values are standard RF and inline with
retainer ring design.
SAES-L-109
A10
Are there any other type of coating like Clad or FBE for CS Flange RF? If
yes, the coatings are above the RF or within the RF?
SAES-L-109
A11
Is there any coating for CS flange faces for retainer ring seating area? If
yes, what is the max. coating thickness is less than 300 micorns?
SAES-L-109
B
IFC drawing and
SAEW-W-012
HDPE Liner Installation
B1
Daily Calibration for welding machines and welders Qulaifiction
B2
Bend back test performed once / day before starting of field fusions.
B3
Field fusions are prepared as per approved WPS (constrn).
B4
HDPE fused section pipe ends are covered with film / any other source of
end protection.
B5
Host pipe internal condition is suitable for liner installation.
Approved Vendor
procedure
ASTM F2620 / Equi.
Std.,
SAEP-387 and
ISO
21307 /
ASTM F 2620
SAEP-387
SAES-L-450
Saudi Aramco: Company General Use
WORK PERMIT REQUIRED?
PASS
FAIL
N/A
RE-INSP DATE
B6
Any deep scratches or gauges found more than 10% of liner wall
thickess for the pulled liner surface.
B7
Stubend fusion jointing done as per apporved WPS (constrn)
B8
Stubends seated properly on CS rasied face after lining?
NACE RP0304 /
AWWA C906
SAEP-387 and
ISO
21307 /
ASTM F 2620
Approved Vendor
procedure
REFERENCE DOCUMENTS:
1. APPROVED VENDOR PROCEDURE
2. SAEP-387
Contractor / Third-Party
Saudi Aramco
Sub Con Contruction & QC Representative*
Work is Complete and Ready for Inspection:
Name, Initials and Date:
PMT Representative
Construction Representative*
Work is Complete and Ready for Inspection:
Name, Initials and Date:
QC Inspector
QC Record Reviewed
Work Verified
T&I Witnessed
QC Record Reviewed
Work Verified
T&I Witnessed
QC Record Reviewed
Work Verified
PID Representative
Performed Inspection
Work / Rework May Proceed
Name, Initials and Date:
Name, Initials and Date:
QC Supervisor
Proponent and Others
Quality Record Approved:
Name, Sign and Date:
T&I Witnessed
Name, Initials and Date:
Name, Organization,
Initials and Date:
Saudi Aramco: Company General Use
SAIC NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
HDPE TIGHT LINER INSTALLATION
DATE APPROVED
QR NUMBER
MECH-
SAIC-HDPE-004
PROJECT TITLE
WBS / BI / JO NUMBER
EQUIPMENT ID NUMBER(S)
EQUIPMENT DESCRIPTION
LAYOUT DRAWING NUMBER
REV. NO.
SCHEDULED INSPECTION DATE & TIME
ACTUAL INSPECTION DATE & TIME
CONTRACTOR / SUBCONTRACTOR
EQPT CODE
SYSTEM ID.
PURCHASE ORDER NUMBER
PLANT NO.
EC / PMCC / MCC NO.
QUANTITY INSP.
MH's SPENT
TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER
SAUDI ARAMCO ACTIVITY NUMBER
SAUDI ARAMCO INSPECTION LEVEL
CONTRACTOR INSPECTION LEVEL
ITEM
No.
A
ACCEPTANCE CRITERIA
WORK PERMIT REQUIRED?
REFERENCE
PASS
FAIL
N/A
RE-INSP DATE
Pnematic Test for HDPE Lined Sections
SAES-A-004
Para 5.2 / NACE
RP0304
A1
Pneumatic Tests approved procedure is avalable at site for inspection
and verification.Also it shall be approved by CSD
A2
Bolt-up of HDPE lined sections done properly with suitable retainer ring.
Ensure position of retainer ring, torque vlaues and Bolt-up sequence
shall be done properly.
Approved vendor
procedure
A3
Retainer ring seated properly between flange faces & touches to CS
flange faces.
Approved vendor
procedure
A4
Pneumatic test all flanges, Equipment and gauges are suitable for
conducting pnemumatic test at Max. 100 psi.
A5
Leakage observed from vents / pressure drop for the test section during
test phase.
NACE RP0304
Approved vendor
procedure
REFERENCE DOCUMENTS:
1. SAES-A-004
2. Approved vendor procedure
3. SAEP-387
Contractor / Third-Party
Saudi Aramco
Sub Con Contruction & QC Representative*
Work is Complete and Ready for Inspection:
Name, Initials and Date:
PMT Representative
Construction Representative*
Work is Complete and Ready for Inspection:
Name, Initials and Date:
QC Inspector
QC Record Reviewed
Work Verified
T&I Witnessed
QC Record Reviewed
Work Verified
T&I Witnessed
QC Record Reviewed
Work Verified
PID Representative
Performed Inspection
Work / Rework May Proceed
Name, Initials and Date:
Name, Initials and Date:
QC Supervisor
Proponent and Others
Quality Record Approved:
Name, Sign and Date:
T&I Witnessed
Name, Initials and Date:
Name, Organization,
Initials and Date:
Saudi Aramco: Company General Use
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 55 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
19.0
WPS (12” & 24”)
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 56 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
12” McElroy 618
BUTT-FUSING PROCEDURE SPECIFICATIONS (FPS)
COMPANY NAME
RAYMOND INTERNATIONAL CO LTD
FUSION PROCEDURE SPECIFICATION NO.
CODE:
ASTM F2620
BY
NP-APT-BT-002
REV. NO.
0
DATE:
KISHORE
31-Aug-23
X
JOINTS ( QF-402 )
JOINT TYPE :
SQUARE BUTT JOINT
8.10
PIPE END PREPARATION : SQUARE
SQUARE FACE-MECHANICAL TRIMMING
MISALIGNMENT : 10 % OF WALL THICKNESS
MATERIAL (QF-403 )
SPECIFICATION TYPE AND CLASSIFICATION PE-RT (PE 100 HE3477RT)
TO SPECIFICATION TYPE AND CLASSIFICATION
Pipe Size (Diameter)
:
Pipe Wall Thickness
:
8.10 mm
Cross-Section Area
:
--
PE100
303.50 mm
POSITION (QF-404)
Position of Pipe
: Horizontal
Others
: -
THERMAL CONDITION (QF-405)
Heater Surface Temperature
400 ° F TO 450 ° F
Fusing Interfacial Pressure 75 PSI
Drag Pressure
30 - 40 PSI
Butt-Fusing Pressure
136 PSI
Melt Bead Size
2 MM
Heater Plate Removal Time
08 SECS
Cool-Down Time at Butt-Fusion Pressure 176 PSI AT 4 MINS
EQUIPMENT (QF-406)
Fusing Machine Manufacturer :McElroy
Data Acquisition System Manufacturer : Rolling 618
Hydraulic Extension Hose Length :N/A
EQUIPMENT (QF-407)
LOCATION :
SHOP AND FIELD
TECHNICAL APPROVAL
RAYMOND INTERNATIONAL CO LTD
Bin Quraya
SAUDI ARAMCO
NAME
:
NAME
:
NAME
SIGNATURE
:
SIGNATURE
:
SIGNATURE
DEPARTMENT :
DEPARTMENT :
DEPARTMENT
DATE
DATE
DATE
:
:
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 57 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
24” McElroy 824
BUTT-FUSING PROCEDURE SPECIFICATIONS (FPS)
COMPANY NAME
RAYMOND INTERNATIONAL CO LTD
FUSION PROCEDURE SPECIFICATION NO.
CODE:
ASTM F2620
BY
NP-APT-BT-004
REV. NO.
0
DATE:
KISHORE
31-Aug-23
X
JOINTS ( QF-402 )
JOINT TYPE :
SQUARE BUTT JOINT
PIPE END PREPARATION : SQUARE
SQUARE FACE-MECHANICAL TRIMMING
MISALIGNMENT : 10 % OF WALL THICKNESS
MATERIAL (QF-403 )
SPECIFICATION TYPE AND CLASSIFICATION PE-RT (PE 100 HE3477RT)
TO SPECIFICATION TYPE AND CLASSIFICATION
Pipe Size (Diameter)
:
572 mm
Pipe Wall Thickness
:
13.50 mm
Cross-Section Area
:
--
PE100
POSITION (QF-404)
Position of Pipe
: Horizontal
Others
: -
THERMAL CONDITION (QF-405)
Heater Surface Temperature
400 ° F TO 450 ° F
Fusing Interfacial Pressure 75 PSI
Drag Pressure
30 - 40 PSI
Butt-Fusing Pressure
94 PSI
Melt Bead Size
3 MM
Heater Plate Removal Time
08 SECS
Cool-Down Time at Butt-Fusion Pressure 124 PSI AT 6 MINS
EQUIPMENT (QF-406)
Fusing Machine Manufacturer :McElroy
Data Acquisition System Manufacturer : Rolling 824
Hydraulic Extension Hose Length :N/A
EQUIPMENT (QF-407)
LOCATION :
SHOP AND FIELD
TECHNICAL APPROVAL
RAYMOND INTERNATIONAL CO LTD
Bin Quraya
SAUDI ARAMCO
NAME
:
NAME
:
NAME
SIGNATURE
:
SIGNATURE
:
SIGNATURE
DEPARTMENT :
DEPARTMENT :
DEPARTMENT
DATE
DATE
DATE
:
:
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 58 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
24” McElroy 1236
BUTT-FUSING PROCEDURE SPECIFICATIONS (FPS)
COMPANY NAME
RAYMOND INTERNATIONAL CO LTD
FUSION PROCEDURE SPECIFICATION NO.
CODE:
ASTM F2620
BY
NP-APT-BT-003
REV. NO.
0
DATE:
KISHORE
31-Aug-23
X
JOINTS ( QF-402 )
JOINT TYPE :
SQUARE BUTT JOINT
PIPE END PREPARATION : SQUARE
SQUARE FACE-MECHANICAL TRIMMING
MISALIGNMENT : 10 % OF WALL THICKNESS
MATERIAL (QF-403 )
SPECIFICATION TYPE AND CLASSIFICATION PE-RT (PE 100 HE3477RT)
TO SPECIFICATION TYPE AND CLASSIFICATION
Pipe Size (Diameter)
:
Pipe Wall Thickness
:
13.50 mm
Cross-Section Area
:
--
PE100
572 mm
POSITION (QF-404)
Position of Pipe
: Horizontal
Others
: -
THERMAL CONDITION (QF-405)
Heater Surface Temperature
400 ° F TO 450 ° F
Fusing Interfacial Pressure 75 PSI
Drag Pressure
30 - 40 PSI
Butt-Fusing Pressure
94 PSI
Melt Bead Size
3 MM
Heater Plate Removal Time
08 SECS
Cool-Down Time at Butt-Fusion Pressure 124 PSI AT 6 MINS
EQUIPMENT (QF-406)
Fusing Machine Manufacturer :McElroy
Data Acquisition System Manufacturer : Rolling 1236
Hydraulic Extension Hose Length :N/A
EQUIPMENT (QF-407)
LOCATION :
SHOP AND FIELD
TECHNICAL APPROVAL
RAYMOND INTERNATIONAL CO LTD
Bin Quraya
SAUDI ARAMCO
NAME
:
NAME
:
NAME
SIGNATURE
:
SIGNATURE
:
SIGNATURE
DEPARTMENT :
DEPARTMENT :
DEPARTMENT
DATE
DATE
DATE
:
:
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 59 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
24” ITS Technodue
BUTT-FUSING PROCEDURE SPECIFICATIONS (FPS)
COMPANY NAME
RAYMOND INTERNATIONAL CO LTD
FUSION PROCEDURE SPECIFICATION NO.
CODE:
ASME IX
2019 Edition
BY
NP-APT-BT-005
REV. NO.
0
DATE:
KISHORE
31-Aug-23
X
JOINTS ( QF-402 )
JOINT TYPE :
SQUARE BUTT JOINT
PIPE END PREPARATION : SQUARE
SQUARE FACE-MECHANICAL TRIMMING
MISALIGNMENT : 10 % OF WALL THICKNESS
MATERIAL (QF-403 )
SPECIFICATION TYPE AND CLASSIFICATION PE-RT (PE 100 HE3477RT)
TO SPECIFICATION TYPE AND CLASSIFICATION
Pipe Size (Diameter)
:
Pipe Wall Thickness
:
13.50 mm
Cross-Section Area
:
--
PE100
572 mm
POSITION (QF-404)
Position of Pipe
: Horizontal
Others
: -
THERMAL CONDITION (QF-405)
Heater Surface Temperature
400 ° F TO 450 ° F
Fusing Interfacial Pressure 75 PSI
Drag Pressure
30 - 40 PSI
Butt-Fusing Pressure
20.3 Bar
Melt Bead Size
3 MM
Heater Plate Removal Time
08 SECS
Cool-Down Time at Butt-Fusion Pressure 17.5 m in @ 20.3 Bar
EQUIPMENT (QF-406)
ITS Technodue
Fusing Machine Manufacturer :McElroy
Data Acquisition System Manufacturer : WA630
Hydraulic Extension Hose Length :N/A
EQUIPMENT (QF-407)
LOCATION :
SHOP AND FIELD
TECHNICAL APPROVAL
RAYMOND INTERNATIONAL CO LTD
Bin Quraya
SAUDI ARAMCO
NAME
:
NAME
:
NAME
SIGNATURE
:
SIGNATURE
:
SIGNATURE
DEPARTMENT :
DEPARTMENT :
DEPARTMENT
DATE
DATE
DATE
:
:
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 60 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
20.0
Repair Procedure
Cracks, Fractures, voids
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 61 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
20.1. SCOPE
This procedure is for the repair of the HDPE lining or rotolined coating of lined carbon steel pipe
fittings. It is intended for the repair of cracks, fractures, voids, or other lining material cavities by the
method of extrusion weld fill material.
20.2. TOOLS, EQUIPMENT, MATERIAL AND SAFETY GEAR:
The equipment and tools used in this repair process are the following:
Tools:
• Random Orbital Sander: use Bosch model GEX125-150 AVE (230 Volt, 400W, 150 mm Disc diameter,
5.000-12.000 pm, weight 2,4kg); or equivalent model.
• Sanding disc sandpaper 60 grit.
• Hand Welding Extruder:
• Hand held scraper tool.
Equipment:
• Infrared Thermometer:.
• Standard industrial Compressor: for use of clean compressed air.
Materials:
• Repair Raw Material: PE100 HDPE rod, for handheld extruder
• Multipurpose cleaner
• Cleaning cloth (must not leave cloth residue or lint)
Personal and general Safety Gear:
Main:
1. Safety gloves: leather or equivalent with moderate heat resistance
2. Safety glasses for eye protection.
General:
1. Safety shoes
2. Safety Hard hat
3. Hearing protection
4. Mask
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 62 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
20.3. SEQUENCE OF ACTIVITIES FOR REPAIRING HDPE LINING / ROTOLINING COATING USING A
HANDHELD EXTRUDER
Important: prior to all work process’, you must perform a thorough check of possible
operational risks involved, verifying any existence of dangerous conditions which could harm
people or the surroundings.
a. Identify the area to repair:
For the HDPE lining or Rotolining coating, a repair should be performed if the lining is damaged or
cracked in a specific area of the lining. The damage of the coating will be seen by visual inspection and
can occur due to mechanical stress caused by an excessive squeeze on the coating, an impact by a solid
object, an area exposed to excessive heat or a scratch with a sharp object. If the coating is exposed to a
chemical substance that causes damage, a further analysis must be performed to understand the cause
of it. In this last case a spot repair process may not solve the problem. Thermoplastic welding or filling
of the damaged lining with HDPE filler material may be performed to repair a damaged zone of the
lining. The repair zone can be filled-in with HDPE material applied by a handheld extruder.
b. Sequence to Repair the damaged spot (for example a crack or other anomaly):
1. Clean the area around the crack or void. Use the Random Orbital Sander to sand the affected zone,
aiming to clean any loose particles in the affected zone. After few passes of the orbital sander / grinder,
stop the sander and blow air (supplied by the compressor) to the affected area to eliminate loose
particles and be able to clearly visualize the crack.
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 63 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
2. Using the handheld scraper, scrape the crack or void until it disappears forming a 45º to 60º bevel at
the entire edge of the crack or void: a V-seam or bevel with approximately 45º to 60° (for cracks) and a
“welding gap” of at least 3mm (for voids) must be prepared.
3. Once the crack or void has been prepared, blow the surface once more to remove all loose material,
particles and debris. Then clean the surface that has been sanded and scraped with the cloth and
alcohol.
4. Wait 5 minutes until all the alcohol has evaporated and the surface is dry. Avoid passing fingers or
other cloths on the repair area. Any grease or dirt particles are detrimental to achieving an effective
bonding of the HDPE filler for the next steps.
5. Set the Handheld Extruder to temperatures 250º for the material and 270-280 º for the air blower.
Apply heated air to the repair zone (crack or void), passing it a few times at about 2 -3 cm from the
surface, until the lining starts showing signs of surface melting. You will notice the temperature is being
reached because the surface of the coating will start show a black shine. Once the temperature of the
coating has reached 135 - 160 ºC, you may start extruding material. Do not heat the surface of the
coating above 195 ºC (measure the temperature with the IR Thermometer).
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 64 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
6. Start depositing a root weld in the V-seam in one continuous process, using the handheld extruder. If
more thickness of the weld is needed, subsequent weld passes may be performed to complete a full
weld fill or cover. For larger voids, start the extrusion fill process at one edge of the beveled void and
continue to fillet fill the entire void with consecutive and overlapping weld fillets until the complete
void has been filled. Additional layers of HDPE fillet welds may be necessary to completely fill the void.
7. Once the final cover weld has been completed, wait for 5 to 10 minutes letting it cool down to warm
temperature (about the same temperature as the rest of the coating).
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 65 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
8. Using the scraper and/or orbital sander, sand down and level the weld thickness to the rest of the
coating thickness.
9. Once the surface is leveled, use the orbital sander to polish the surface finishing off the repair area.
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 66 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
10. After repairs, following tests shall be carried out a. Dimensional confirmation after repair shall be
carried out to ensure uniformity with the existing lining.
20.4. ACCEPTANCE CRITERIA
a. Dimensional confirmation after repair shall be carried out to ensure uniformity with the
existing lining.
b. Free from Discontinuity by Holiday detection test
c. Acceptable level of flange surface finish to be verified by visual inspection
Notes (1):
1. There is no limitation on the length of repairs for superficial defects (cracks / scratches) within
the polyethylene lining.
2. Pictures shown are for reference purposes only and might defer to the actual scratches offered
for repair.
Notes (2):
Pictures of commercial handheld extruder and scraper.
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 67 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
21.0
Repair Procedure
Cold Cuts on HDPE Lined
Steel Pipes
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 68 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
21.1. SCOPE
This procedure is for the repair of the HDPE lining of lined carbon steel pipes where the HDPE lined
steel pipe is cold cut to perform future modifications.
21.2. TOOLS, EQUIPMENT, MATERIAL AND SAFETY GEAR:
The equipment and tools used in this repair process are the following:
Tools:
• Power Jack saw
• Hand tools
• Hand held scraper tool.
• Measuring Tape
• Wire slings
• Pipe Puller or Pull head
Equipment:
• Infrared Thermometer:
• Standard industrial Compressor: for use of clean compressed air.
• Internal Clamps
• Hydraulic Pump
• Butt Fusion Machine
• 20KVa Diesel Generator
Materials:
• HDPE Liner & Stub Ends
• Multipurpose cleaner
• Cleaning cloth (must not leave cloth residue or lint)
Personal and general Safety Gear:
Main:
1. Safety gloves: leather or equivalent with moderate heat resistance
2. Safety glasses for eye protection.
General:
1. Safety shoes ,Safety Hard hat
3. Hearing protection
4. Mask
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 69 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
21.3. SEQUENCE OF ACTIVITIES FOR COLD CUTTING AND MODIFICATION / REPAIR OF EXISTING
HDPE LINED PIPE
Important: prior to all work process’, you must perform a thorough check of possible
operational risks involved, verifying any existence of dangerous conditions which could harm
people or the surroundings.
a. Identify the area to repair:
-
Once the area for repair / modification is identified, perform cold cut at the nearest flange
end.
It is necessary to perform the first cold cut few meters away from the actual cold cut
position so that in case the liner is in tensile stress, it will tend to relax and retract within
the steel pipe.
Upon cold cutting the steel pipe the HDPE liner might tend to retract.
The steel pipe shall be allowed to rest for minimum 24 hours after cold cutting to permit
complete relaxation / retraction of the HDPE liner.
Once the HDPE liner is completely relaxed, perform cold cut at the desired location.
b. Pre-Preparation
- Option 1)
• Stretch the HDPE liner for a few inches and butt fuse a pull head.
• Affix the pull head with a wire through a D-shackle for installation of Stub end after
steel flange welding.
• Release the pull head to retract a few inches inside the steel pipe
-
Option 2)
• Install internal hydraulic clamps in the steel pipe to prevent any additional
retraction or movement of the HDPE liner.
c. Welding of Steel Pipe Flange
- Welding shall be done by the contractor as per approved procedures.
- While welding of the steel flange to the pipe additional cooling methods such as ice bags or
cold water circulation to be provided to avoid heat transfer and damage to the HDPE liner
inside the steel pipe.
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 70 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
d. Installation of HDPE Stub end
- For Option 1, stretch the liner by hooking the pull head with any equipment such as a
telehandler to the desired length and follow stub end installation as per clause 14.
- For Option 2, Install the internal puller and gradually stretch the liner by hooking the puller
with any equipment or telehandler to the desired length and follow stub end installation as
per clause 14.
HDPE INTERNAL LINING PROCEDURE
Contractor:
Document Ref. No.
PROCEDURE
Contract #
6600051205
BI #
11-22000-2437
RI-BQ-HDPE-001
Page 71 of 71
PROJECT:
CONSTRUCTION OF SFNY-24” HDPE TRUNK LINE
Revision
0
22.0
FORMS
HDPE INTERNAL LINING PROCEDURE
DOC F- APT - 01 - A
PROJECT #
HDPE BUTT FUSION TEST LOG
LINER PIPE OD:
WALL THICKNESS
NAME
QC INSPECTOR
FUSION MACHINE
EFFECTIVE PISTON AREA FOR FUSION MACHINE
DATE
TEST #
HEATER
TEMP.
HEAT SOAK
TIME
FUSION PRESSURE
GAUGE COOLING
PRESSURE
TIME
VISUAL
CHECK
BEND BACK
TEST
DATE
NAME
INSTALLATION FOREMAN
DATE
NAME
BIN QURAYA REPRESENTATIVE
DATE
NAME
DATE
NAME
SIGN
SIGN
SIGN
SIGN
COMMENTS
ARAMCO REPRESENTATIVE
HDPE BUTT FUSION LOG
DATE
PULL SECTION
LENGTH (FT)
LINER OD
W.T.
WELD #
DOC F- APT - 02 - A
PROJECT #
# OF FUSIONS
HEAT PLATE TEMP.
FUSION PRESSURE
HEAT SOAK TIME
COOLING TIME
VISUAL
CHECK
COMMENTS
WELD #
VISUAL
CHECK
COMMENTS
DATE
NAME
INSTALLATION
FOREMAN
DATE
NAME
DATE
NAME
ARAMCO
REPRESENTATIVE
DATE
NAME
SIGN
SIGN
SIGN
SIGN
QC INSPECTOR
BIN QURAYA REPRESENTATIVE
PROJECT: HDPE LINER SERVICES FOR
SAFANIYA SFNY 24” HDPE HDR T/L PROJECT
HDPE BUTT FUSION WELD PROCEDURE AND
TECHNICIAN QUALIFICATION REPORT
DOC F- APT - 02 - B
DETAILS
TECHNICIAN NAME:
DATE:
LOCATION:
HDPE FUSION MACHINE:
MODEL:
SERIAL # :
AMBIENT TEMPERATURE:
HDPE PIPE OD:
HDPE PIPE WT:
TECHNICIAN PHOTO
(PASTE HERE)
FUSION WELD PARAMETER CHECK
HEATER PLATE CONDITION:
HEATER PLATE TEMPERATURE:
COOLING TIME:
VISUAL CHECK:
EXTERNAL BEAD VISUAL CHECK:
COMMENTS:
FUSION PRESSURE:
DRAG PRESSURE:
GAUGE PRESSURE WITH DRAG:
GAUGE PRESSURE WITHOUT DRAG:
BEND BACK TEST
WIDTH OF SAMPLE:
LENGTH OF SAMPLE:
TEST PASSED (YES / NO)
COMMENTS:
RAYMOND INTERNATIONAL
SIGN:
NAME:
DATE:
BIN QURAYA REPRESENTATIVE
ARAMCO REPRESENTATIVE
CABLE BLOWDOWN, GAUGING & LINER
INSERTION LOG
PULL #:
STEEL PIPE OD & WT:
HDPE PIPE OD & WT:
GAUGING PLATE DIAMETER:
ARE THREAD-O-LET'S DRILLED:
DOC F- APT - 03 - A
PROJECT #
PULL LENGTH:
LINEAR LENGTH:
MAX LOAD (LBS):
START (FT.):
END (FT.):
DESCRIPTION OF PULL:
BLOWDOWN & GAUGING
OBSTRUCTIONS / STOPPAGES:
DATE:
LOCATION DEPTH
START TIME:
END TIME:
CORRECTIVE ACTIONS TAKEN / COMMENTS:
(YES / NO)
FINAL RESULTS / COMMENTS:
LINER INSERTION
DATE:
MAXIMUM TENSION DURING PULL
CONDITION OF LEADING EDGE OF LINER
START TIME:
LOCATION DEPTH
END TIME:
FINAL RESULTS / COMMENTS:
QC INSPECTOR
DATE
NAME
SIGN
INSTALLATION
FOREMAN
DATE
NAME
SIGN
BIN QURAYA
REPRESENTATIVE
DATE
NAME
SIGN
ARAMCO
REPRESENTATIVE
DATE
NAME
SIGN
DOC F- APT - 04 - A
PROJECT #
STUB END INSTALLATION LOG
FUSION MACHINE:
FUSION PRESSURE:
NAME
QC INSPECTOR
TEPA:
GAUGE PRESSURE (W/O DRAG):
PULL NO.
DATE
TIME
WINCH /
ROLLER
HEAT SOAK TIME:
COOLING TIME:
OPPOSITE
RETRACT OD HDPE LENGTH
LENGTH
(IN)
STUBEND SIDE LENGTH
EXTRA CUT
FOR TIGHT
HEATER PLATE TEMP
TOTAL
CUT
COMMENTS
DATE
NAME
INSTALLATION FOREMAN
DATE
NAME
BIN QURAYA REPRESENTATIVE
DATE
NAME
DATE
NAME
ARAMCO REPRESENTATIVE
SIGN
SIGN
SIGN
SIGN
AIR TEST LOG
DESCRIPTION
TEST # 1
TEST # 2
DOC F- APT - 06 - A
PROJECT #
TEST # 3
TEST # 4
TEST DATE
SECTION #
UPSTREAM LOCATION
DOWNSTREAM LOCATION
TEMPERATURE
TIME 1
PRESSURE READING 1
TIME 2
PRESSURE READING 2
TIME 3
PRESSURE READING 3
THREAD-O-LET CHECK
PASS / FAIL
FOREMAN SIGNATURE
COMMENTS
QC INSPECTOR
DATE
NAME
INSTALLATION FOREMAN
DATE
NAME
BIN QURAYA REPRESENTATIVE
ARAMCO REPRESENTATIVE
DATE
DATE
NAME
NAME
SIGN
SIGN
SIGN
SIGN