FlexSteel Installation and Operations Manual - Metatron · Title: FlexSteel Installation and Operations Manual Author: Brian Anderson Keywords: Document control, style, format, Microsoft

FLEXSTEEL INSTALLATION AND OPERATIONS MANUAL

4 February 2015

Printed copies are “UNCONTROLLED” “See controlled electronic copy for up to date information”

Responsibility: Brian Anderson Supersedes: FLD-H-9925 Rev 0 FLD-H-9925 Rev 1 │ © FlexSteel Pipeline Technologies, Inc. │ Classification A

FlexSteel Installation and Operations Manual FLD-H-9925 Rev 1 Date: 4 February 2015 REVISIONS ARE HIGHLIGHTED

Copyright © 2011-2014 by FlexSteel Pipeline Technologies, Inc. All rights reserved.

This publication contains proprietary information and is considered to be the intellectual property of FlexSteel Pipeline Technologies, Inc. Neither this document nor any “other” information in connection with the disclosure of this document shall be reproduced in any form, for any purpose, without the expressed written consent from FlexSteel Pipeline Technologies, Inc. This publication is provided in the English language by FlexSteel Pipeline Technologies, Inc. Any translated versions that are not provided by FlexSteel Pipeline Technologies, Inc. are not guaranteed to be accurate or up to date. FlexSteel Pipeline Technologies, Inc. therefore does not accept liability for any errors or omission in the contents of the manual which arise as a result of any unauthorized translation.

FlexSteel Pipeline Technologies, Inc.

500 Dallas Street

Suite 500

Houston, TX 77002

USA

832.531.8555 Office

832-531-8542 Fax


Responsibility: Brian Anderson Supersedes: FLD-H-9925 Rev 0 © FlexSteel Pipeline Technologies, Inc. │ Classification A │ Page 2 of 113


Table of Contents

1 INTRODUCTION ................................................................................................................................................... 6

2 SAFETY ................................................................................................................................................................ 7 2.1 Safety Hazards ...................................................................................................... 7 2.2 Personal Protective Equipment (PPE) ................................................................... 8 2.3 Communications .................................................................................................... 9 2.4 Stop Work Authority ............................................................................................... 9

3 FLEXSTEEL PRODUCT DESCRIPTION ............................................................................................................. 9 3.1 About FlexSteel Pipe ............................................................................................. 9 3.2 Pipe Construction .................................................................................................. 9

3.2.1 Inner Liner .......................................................................................... 10 3.2.2 Steel Reinforcement ........................................................................... 10 3.2.3 Outer Shield........................................................................................ 10

3.3 Fitting Configuration and Materials ...................................................................... 11 3.3.1 Fitting Configuration ........................................................................... 11 3.3.2 Fitting Material .................................................................................... 12

3.4 Standard FlexSteel Designs ................................................................................ 12

4 PACKAGING ...................................................................................................................................................... 13 4.1 Reels.................................................................................................................... 13

4.1.1 Pipe Tie-downs ................................................................................... 13 4.1.2 Clam Shells ........................................................................................ 15

4.2 Fittings ................................................................................................................. 15

5 TRANSPORTATION ........................................................................................................................................... 16 5.1 Reels.................................................................................................................... 16

5.1.1 Reel Safety ......................................................................................... 16 5.1.2 Loading and Unloading Reels ............................................................ 17 5.1.3 Vertical Reel Lifts................................................................................ 23 5.1.4 Horizontal Reel Lifts ........................................................................... 26 5.1.5 Up-righting and Overturning ............................................................... 27 5.1.6 Reel Storage....................................................................................... 27 5.1.7 Pipe Storage ....................................................................................... 28 5.1.8 Fitting Storage .................................................................................... 28

5.2 Installation Equipment Handling .......................................................................... 28 5.3 Miscellaneous Equipment .................................................................................... 28 5.4 International Transportation ................................................................................. 29




6 INSTALLATION AND HANDLING ..................................................................................................................... 31 6.1 Installation Equipment ......................................................................................... 31

6.1.1 Reel Support Structures ..................................................................... 31 6.1.2 Installation Aids .................................................................................. 37 6.1.3 Swage Machines and Hydraulic Power Unit....................................... 43 6.1.4 Miscellaneous ..................................................................................... 50

6.2 Installation Considerations .................................................................................. 51 6.2.1 Communication and Personnel .......................................................... 51 6.2.2 Inspection of Pipe ............................................................................... 51 6.2.3 Positioning the Reels .......................................................................... 53 6.2.4 Positioning from Deployment Trailer .................................................. 53 6.2.5 Positioning from Stationary Reel Support Structure ........................... 54 6.2.6 Installation Stability ............................................................................. 55 6.2.7 Installation Tension............................................................................. 59 6.2.8 Cold Weather Installation ................................................................... 61 6.2.9 Expansion/Contraction ....................................................................... 65 6.2.10 Excavation Requirements................................................................... 65 6.2.11 Buried Pipe at Crossings .................................................................... 66 6.2.12 Rough Terrain..................................................................................... 67 6.2.13 Steep Terrain ...................................................................................... 68 6.2.14 Desert ................................................................................................. 72 6.2.15 Padding and Backfilling ...................................................................... 72 6.2.16 8-inch Pipe Considerations................................................................. 72 6.2.17 Fitting Compatibility ............................................................................ 73

6.3 Installation Methods ............................................................................................. 74 6.3.1 Surface Lines...................................................................................... 74 6.3.2 Trenching............................................................................................ 75 6.3.3 Plowing ............................................................................................... 76 6.3.4 Pipeline Rehabilitation ........................................................................ 77 6.3.5 Horizontal Directional Drilling ............................................................. 78 6.3.6 Shallow Water .................................................................................... 80

6.4 Fitting Installation ................................................................................................. 81 6.4.1 Overview of the Process..................................................................... 81 6.4.2 Fitting Preparation .............................................................................. 81 6.4.3 Pipe Preparation ................................................................................. 81 6.4.4 Swage Machine Setup and Tooling .................................................... 82 6.4.5 Documentation Requirements ............................................................ 82 6.4.6 Venting System .................................................................................. 82 6.4.7 Annulus Test....................................................................................... 86 6.4.8 Fitting Wrapping Recommendations .................................................. 86

7 COMMISSIONING .............................................................................................................................................. 87 7.1 End Termination Venting Considerations ............................................................ 87 7.2 Conditioning and Stabilization ............................................................................. 87




7.3 Field Hydro Test .................................................................................................. 88 7.3.1 Pressure Guidelines ........................................................................... 88 7.3.2 Pressurization/Depressurization Rates .............................................. 90

7.4 Pigging ................................................................................................................. 90

8 FLEXSTEEL PIPE OPERATION ........................................................................................................................ 91 8.1 Pipe Capabilities .................................................................................................. 91 8.2 Minimum Bend Radius......................................................................................... 91 8.3 Chemical Compatability ....................................................................................... 92

8.3.1 Conveyed Product Compatibility with PE ........................................... 92 8.3.2 Conveyed Product Compatibility with Steel ........................................ 93

8.4 Cathodic Protection ............................................................................................. 94 8.5 Change in Service ............................................................................................... 94

9 INSPECTION AND MAINTENANCE .................................................................................................................. 95 9.1 Visual Inspection ................................................................................................. 95 9.2 Pipe Maintenance ................................................................................................ 97

9.2.1 Liner.................................................................................................... 97 9.2.2 Shield.................................................................................................. 99 9.2.3 Fittings .............................................................................................. 100 9.2.4 Maintenance of Pipe after Recovery ................................................ 101

10 TROUBLESHOOTING AND REPAIRS ............................................................................................................ 102 10.1 Leak Detection ................................................................................................... 102

10.1.1 Before You Start ............................................................................... 103 10.1.2 Leak Detection Method 1: Re-swage Fittings ................................... 103 10.1.3 Leak Detection Method 2: Drill into Midline and Pressurize Pipe ..... 103

10.2 Recognizing Damage ........................................................................................ 104 10.2.1 Damage to Flowline or Outer Shield................................................. 105 10.2.2 Damage to End Fittings .................................................................... 108

10.3 Repairing Offshore and Submerged Pipe .......................................................... 108 10.4 Repairing New Line ........................................................................................... 108 10.5 Repairing Line in Service ................................................................................... 108 10.6 Hydro Excavation............................................................................................... 109

11 DECOMMISSIONING ....................................................................................................................................... 110 11.1 Typical FlexSteel Retrieval ................................................................................ 110 11.2 Respooling ......................................................................................................... 110

12 TRAINING ......................................................................................................................................................... 111 12.1 Training Program ............................................................................................... 111 12.2 Course Curriculum ............................................................................................. 111 12.3 Flexibility ............................................................................................................ 112 12.4 Maintaining Certification .................................................................................... 112




1 INTRODUCTION This manual provides basic information on the use and service of FlexSteel™ pipe over its lifecycle, from delivery to final placement at the in-service location. Included is information on personnel training requirements, transportation and storage methods, installation, commissioning, operational capabilities, inspections and maintenance, troubleshooting and repairs, decommissioning and recovery for disposal or reuse of FlexSteel pipe.

FlexSteel pipe has been optimized for cost competitiveness, ease of installation, long life, high reliability, and corrosion resistance. It is suitable for a variety of applications including tundra, desert, swamp, shallow water, and it can be laid directly in rough terrain. FlexSteel pipes can be deployed on the surface or installed below grade through trenching or plowing installations. The pipe is also suitable for pull-in applications such as directional drilling and pipeline rehabilitation.

Further, this manual provides a description of the design and range of pipe sizes and pressure ratings within FlexSteel’s product line. For specific data for each design or additional information, contact FlexSteel Pipeline Technologies, Inc. (“FlexSteel”) or consult our website at www.flexsteelpipe.com for the most current Pipe Specification Sheet, case studies and multi-media presentations.

The handling and use of the pipe must be limited to the design conditions and considerations specified in this manual to avoid possible damage to the inner lining and outer shield, the stainless steel reinforcements, and the fittings. The instructions and recommendations contained herein are to be used as a general guide to aid the operator in developing detailed written procedures for conducting normal, abnormal, and emergency operations and maintenance activities. Nothing written or implied in this manual is intended to supersede the contractual requirements or the use of sound engineering judgment or good operational practice. Warranty provisions as specified in the contract will apply as appropriate. Questions pertaining to product operational limitations should be directed to FlexSteel Pipeline Technologies, Inc.

This manual is intended specifically as a reference during the handling and installation of FlexSteel pipe. It is the responsibility of the pipeline operator to ensure the suitability of FlexSteel’s products for any specific pipeline application. While the information contained in this document is believed to be correct as of the date of issue, under no circumstances will FlexSteel Pipeline Technologies, Inc. be liable in any way for any loss, damage or injury of any kind incurred as a result of any omissions in this document or as a result of reliance on any information contained in this document.




2 SAFETY Safety is everyone’s responsibility. Knowing the guidelines covered in this manual will help to provide for the safe installation of FlexSteel pipe. All personnel should become familiar with the following standard safety hazards, personal protective equipment, and communication guidelines.

2.1 SAFETY HAZARDS

Table 1 - Common Deployment Safety Hazards

AREA HAZARD SAFEGUARD SUSPENDED LOADS AND HOISTING

Equipment could fall or swing while being hoisted or lifted and can crush people or body parts, causing serious injury or death. Pipe could fall or swing, striking or crushing personnel in the work area.

Keep all personnel clear of suspended loads; personnel in the area should be aware of the location of suspended loads at all times. NEVER stand or allow body parts underneath a suspended load. Ensure that feet and hands are not underneath a suspended load. Avoid placing yourself or others between objects that may swing in the proximity of other objects or equipment. Identify clear paths for egress in case of emergency. Use approved rigging when lifting. Inspect equipment and rigging (including straps) before use. Use tag lines to help control the motion of the suspended load when the use of a tag line does not present an additional hazard. Use a spotter when visibility is limited. Do not leave suspended loads unattended.

HEAVY EQUIPMENT

Equipment, accessories, and tools are heavy and could crush feet or hands.

NEVER stand or allow body parts underneath a suspended load. Ensure that feet and hands are not underneath a suspended load.

PINCH POINTS

Hands can be pinched or caught in the equipment. Failure to adhere to pinch point warnings can result in serious injury or death.

Keep personnel and equipment (including tooling and high pressure hoses) clear of pinch points. ALWAYS verify that hands and fingers are away from pinch points before engaging or operating equipment.

HYDRAULIC PRESSURE

Hydraulic system parts and connection lines can contain high pressures that, if released suddenly or unexpectedly, can cause serious injury or death.

Always inspect hydraulic equipment and hoses for damage or excessive wear before use. Do not exceed recommended working pressure. Avoid striking or puncturing of any of the components or connections. When working in the area, slowly bleed pressure and disconnect prior to any work on the system.




AREA HAZARD SAFEGUARD

FLAMMABLE / COMBUSTIBLE FUELS

Gasoline (petrol) used for some hydraulic power units is highly flammable. Diesel fuel is combustible.

Ensure flammable fuels are properly stored in approved containers. Allow equipment to cool before refueling. Use appropriate PPE as recommended on the Safety Data Sheet (SDS).

LUBRICATION AND FILTRATION

Failure to adequately maintain lubrication and/or filtration systems can result in various types of equipment failures.

Institute a complete lubrication program at regular intervals and thoroughly inspect all systems before each operation.

LINES UNDER TENSION

Winches or ropes under tension can fail, suddenly releasing loads and rigging, creating a hazardous line of fire.

Always stay away from loaded lines, especially when directly in front of tensioned line. Personnel in the area should remain aware of loads under tension at all times. Select proper gripping equipment based on size and load limit. When releasing tension from a line, keep the load secured enough to remain under control.

HEAVY LIFTING AND MANUAL HANDLING

Improper lifting measures can cause injuries.

Use team lift for objects that weigh between 50 and 100 lbs. Use a mechanical assistance for any object over 100 lbs. When possible, shorten the distance the material must be moved manually. Inspect path of travel for tripping hazards, slippery areas, small doors, sharp corners, and blind spots. When lifting, keep spine as neutral as possible, keep load as close to the body as possible, and lift with your legs. Do not twist during lift.

2.2 PERSONAL PROTECTIVE EQUIPMENT (PPE)

Table 2 - Common Deployment Safety Hazards

Wear protective eyewear and/or face shield meeting

ANSI Z87+

Wear hard hat meeting ANSI Z89

Wear protective safety-toed footwear with non-slip soles

and metatarsal guards meeting ASTM F2413

Wear hearing protection when exposed to high noise

level equipment and activities

Wear hand protection suitable for the task

Wear protective clothing suitable for the task Wear high resolution vest




2.3 COMMUNICATIONS

All parties involved in the same activity will maintain voice communication at all times. The communication can be via UHF/VHF radios and/or intercom systems. In the event of a radio failure, previously agreed upon hand signals are used. When working with vessel or dock cranes, a designated crane signalman is identified to direct the crane. FlexSteel recommends the prohibition of cellular phones while personnel are in the area or operating powered mobile equipment.

2.4 STOP WORK AUTHORITY

FlexSteel considers no job or task urgency to be so important that the company’s Health, Safety, and Environmental expectations and standards are compromised. Each individual employed by FlexSteel has the right and responsibility to ensure tasks undertaken pose no undue risk to themselves or their fellow employees; therefore, the Stop Work Authority Policy takes precedence over all other priorities and process. Under this policy, every FlexSteel employee, including any subcontractors, has the authority and responsibility to stop work for conditions that pose an imminent danger.

3 FLEXSTEEL PRODUCT DESCRIPTION This section documents the development of the FlexSteel pipe, its construction, the range of available pipes, pipe properties and related definitions, and end fitting designs.

3.1 ABOUT FLEXSTEEL PIPE

FlexSteel couples the best features of flexible pipe with the durability of steel. FlexSteel pipe is a steel-reinforced, unbonded structure that makes it a reliable and economically viable spoolable choice for both onshore and offshore applications. FlexSteel pipe is an off-the-shelf line pipe solution developed by engineers with more than 25 years of experience with custom built deep water flexible riser and flowline systems operating in some of the most extreme pipeline environments.

3.2 PIPE CONSTRUCTION

FlexSteel pipes are composed of three layers:

• An extruded polymer inner liner (internal fluid barrier or internal pressure sheath) • Continuous helically wrapped steel strip reinforcement (structural layer or tensile armor) • An extruded polymer outer shield (environmental protection or outer sheath)

This section provides an overview of the functional characteristics and structures for each of the pipe layers and materials.




Figure 3-1 FlexSteel Standard Pipe Structure

3.2.1 Inner Liner

The innermost layer is a liner designed to provide a continuous barrier to properly contain the bore fluids. The liner is made of API 17J-qualified High Density Polyethylene (HDPE). The HDPE pipe used for the liner is extremely tough, abrasion resistant and has excellent Environmental Stress Crack Resistance (ESCR). This polymer typically retains a high degree of toughness (high strain at break values) even when aged by chemicals over the design life. Considerations regarding the compatibility of the service application with the inner liner are documented in section 8 FlexSteel Pipe Operation of this manual and in the FlexSteel Technical Manual (Document #TR 004).

3.2.2 Steel Reinforcement

The hoop and tensile structural strength of FlexSteel pipe is provided by steel reinforcement. This reinforcement consists of unbonded layers of contra-wound continuous helical steel strips wrapped around the liner. These steel layers are often referred to as armor, tensile layers or tensile armor in accordance with API 17J. The steel reinforcement is not exposed to the conveyed chemicals but rather the considerably milder annulus environment. Considerations regarding compatibility of the service application with the steel are documented in section 8 FlexSteel Pipe Operation of this manual and in the FlexSteel Technical Manual (Document #TR 004).

3.2.3 Outer Shield

The outer shield (or outer sheath) is an extruded HDPE barrier designed to protect the steel reinforcements from physical and environmental damage. This HDPE is the same formulation as that used for the liner and is generally not affected by water, salts, or low concentrations of hydrocarbons that may be in the annulus.

Ultraviolet (UV) light can break the polymer chains in polyethylene (PE), rendering the material brittle and easily damaged. The standard outer shield material is a PE formulated with carbon black to absorb UV and protect the underlying PE indefinitely. However, the black pipes absorb incident light (radiant heat), which heats the pipe during daylight hours. The heat then radiates from the pipe at night, causing the shield to cool.

The optional white PE outer shield is specifically designed for surface applications with long-term, high-intensity exposure. It is formulated with a high concentration of titanium dioxide (TiO2) pigment as well as antioxidants and stabilizers. The TiO2 reflects most incident light, minimizing temperature gain during the day as well as temperature

Steel Reinforcement

Shield

Liner




loss at night. The high concentrations of stabilizers and antioxidants extend the service life of the pipe, and, although untested in the field, FlexSteel’s expectation is that this service life could potentially extend to 20 years even in exposed desert applications.

3.3 FITTING CONFIGURATION AND MATERIALS

Fittings are a key element to successful pipeline operations. They maintain the integrity of the pipe structure, seal to the inner and outer extruded layers, and provide a fixture to transmit tension and pressure loads to the pipe structure.

3.3.1 Fitting Configuration

There are three main types of FlexSteel fittings:

• The Midline coupling connects two lengths of FlexSteel pipe together without having an intermediate flanged or welded joint.

• The Flanged end fitting is most often used to connect with other standard pipeline components, such as valves and other upstream/downstream connections. These fittings are typically provided with a standard ANSI Lapped Flange in 300, 600, 900, and 1500 classes. Alternate types of flanges are available upon request.

• The Weldneck end fitting are generally used when welded connections are preferred in lieu of bolted connections. The fitting body is a steel tube that fits inside the pipe bore. The jacket is a concentric steel tube that fits outside the pipe. The body and jacket are welded together and the end connector is attached prior to assembly on the pipe. The fitting ID is typically 0.59 to 0.79 inch (15 to 20 mm) smaller than the ID of the pipe.

Figure 3-2 Connection Types, from left to right: Midline Coupling, Lapped Flange End Fitting, and Weldneck End Fitting

Weldneck fittings terminate the end of the pipe with standard 60-degree bevel weld prep suitable for installation of any client-specified connector or connection to a stub end.

Specialty fittings, such as crosses, 90-degree turns, reducers, and tees, may be ordered upon request.




3.3.2 Fitting Material

The fitting material is selected by the end user based on fluid compatibility and corrosion resistance.

• 316L stainless steel (SS) is the standard material for fittings and is highly recommended for the best performance in most common corrosive environments.

• Carbon steel (CS) is generally used where corrosion is not an issue, such as for test and installation fittings, or for dry gas production. Additional corrosion preventive measures for carbon steel fittings such as an appropriate coating or heat shrinkable wrap is recommended to protect the fitting from environmental degradation.

• Fittings of other materials suitable for various extreme chemical environments can be provided on special request for specific applications where the standard materials may not be compatible.

3.4 STANDARD FLEXSTEEL DESIGNS

FlexSteel Pipeline Technologies, Inc. manufactures various pipe sizes and pressure ratings. The available sizes are 2, 3, 4, 6 and 8 inch, with available pressure ratings from 750 to 3000 psi, depending on the pipe size. In addition to the standard pipe, FlexSteel also offers a Marine Grade pipe, which includes a thicker shield for additional protection (white PE outer shield optional for improved subsea visibility), thicker steel strip for improved on-bottom stability, and a thicker liner to provide a higher level of collapse resistance.

Figure 3-3 FlexSteel Marine Grade Pipe

Detailed information for each pipe is described in the Pipe Specification Sheet. This document includes general pipe information and specifications such as dimensions, weights, tension and bending limits, pressures, flow properties, thermal properties, and mechanical properties.

Thicker steel strip reinforcements provide negative buoyancy and improved on-bottomstability

Thicker corrosion-resistant shield offers added protection

Thicker corrosion-resistant liner offers increased collapse resistance




4 PACKAGING FlexSteel pipe is packaged on 12 or 13.5 foot diameter steel reels. Packaging items such as reels and cradles can be purchased or rented from FlexSteel.

4.1 REELS

FlexSteel pipe is normally shipped on steel reels that are generally 12 ft (3.7m) in diameter x 8.5 ft (2.6m) wide or 13.5 ft (4.1m) in diameter x 8.5 ft (2.6m) wide. Several similar styles of reels used by FlexSteel have some variations in reel dimensions and drum sizes. An empty reel weighs approximately 3,000 to 4,000 lb. (1,300 to 1800 kg.). The reels are sized to fit on trucks for road transport, and approximate lengths of pipe per reel are shown in the most current Pipe Specification Sheet. Additionally, the 13.5 ft reels are designed with sections on the flanges that detach to meet width restrictions when transported empty by truck in the horizontal position.

For more information on handling reels, see section 5.1 Reels.

Reels can be rented or purchased from FlexSteel Pipeline Technologies, Inc. If the reels are not purchased or rented, they must be returned within a reasonable period after delivery to avoid rental fees (pre-rental period is noted in the FlexSteel proposal or the negotiated contract).

Figure 4-1 FlexSteel Pipe Reels

4.1.1 Pipe Tie-downs

The term tie-down refers to the rope, cable, and tape that attach the pipe to the flange of the reel. There are two sets of tie-downs:

• Outboard tie-downs attach to the exterior end of the pipe to the reel flange and are detached in order to start deploying pipe.

• Inboard tie-downs attach the interior end of the pipe to the reel flange and are detached after the reel has been unspooled.




Figure 4-2 Outboard Tie-downs on 8-inch Pipe (Tape removed from end of pipe for illustrative purposes only)

To remove outboard tie-downs, lower the pipe into position by loosening or cutting the side of the tie-down that is connected to the reel, maintaining control of the pipe at all times. When the pipe is in a safe location and the end connection or pipe is supported, remove the tie-down from the pipe. When a pipe is secured using both cable and rope, remove the cable first before detaching the rope. During unspooling operations, the inboard tie-down might loosen. The installation contractor will inspect the tie-down before the deployment and then regularly (every 100m of flexible pipe deployment) to ensure that it remains tight in order to prevent product damage. However, if loose tie-downs are evident at any point, then the installation contractor should stop and re-tighten as necessary.

When getting close to the end of the reel, slow down deployment to make sure the pipe is not pulling the reel with the tie down. Doing so could damage the product or reel, or cause the tie down to fail resulting in uncontrolled movement of the free pipe end.

To remove the inboard tie-down, the pipe must first be fully unspooled and safely secured so that the pipe remains controlled after the tie-down is removed. The installation contractor must ensure a safe working environment prior to removal of the inboard tie-down. Do not subject the tie-down to installation loads.

Observe the following safety precautions when working with tie-downs:

• Always use caution when cutting the tie-downs; maintain control of the pipe end at all times.

• Personnel should avoid any line-of-fire hazard when the tie-downs are removed.

• Place one person with a handheld radio (or equivalent) to watch the deployment of the pipe at the reel which will allow contact between the reel location and operator pulling the pipe.




4.1.2 Clam Shells

In order to prevent violating the Minimum Bend Radius (MBR) of the 8-inch pipe and some of our higher pressure-rated 6-inch pipe some reels are fitted with wooden “clam shells” to increase the drum diameter. These clam shells require no special care or handling. To remove the clam shells, the reel should be placed in a horizontal orientation and the segments unbolted. Refer to section 5.1.5 Up-righting and Overturning for more information.

Figure 4-3 Clam Shell on Reel

4.2 FITTINGS

All fittings are shipped with caps on both ends of the fitting to keep dust and dirt out of the fittings and to prevent the vent assurance rings (VARs) from getting lost in shipment. Fittings are shipped in closed crates.

To help prevent corrosion during storage and shipment, carbon steel fittings are packed with a desiccant bag placed in the open portion of the fitting (ID), capped on both ends, and then enclosed in a clear polymer bag with the ends either heat-sealed or taped shut. Carbon steel fittings should be stored in this configuration or repackaged to this configuration, kept in the sealed crate and placed in a location that prevents moisture accumulation by weather or other means. For best results, it is recommended carbon steel fittings are kept indoors in a dry controlled environment until they are installed. If there is any corrosion on the internal serrations of the fitting, the fitting should be discarded as the seal integrity of the fitting has been compromised. If a fitting is placed on the ground or floor, use neoprene or similar material to protect it from abrasion or damage.




Figure 4-4 Packaged Carbon Steel Fitting

5 TRANSPORTATION FlexSteel pipe and equipment can be shipped by truck, by rail, or overseas on properly equipped vessels.

Before transporting reels, make sure the transportation is properly coordinated with consideration for the physical dimensions of the reels (weight, height, width), and the route is cleared for the loads being transported. When transporting empty 13.5 ft reels by truck in the horizontal position, be sure to remove the detachable flange sections. Preparations of the receiving site are important to assure deliveries are timely and the appropriate resources are available. Any site specific requirements (e.g. off-road trucks, etc.) need to be clarified early in the process.

5.1 REELS

Reduced time required to install FlexSteel pipe compared to steel pipe is one of the major advantages of FlexSteel’s products, made possible by the flexible nature of the pipe and the long, continuous lengths of pipe that are stored and transported on each reel.

5.1.1 Reel Safety

When handling reels, observe the following safety guidelines:

• Visually inspect the reels for cracks, defects, or other anomalies before handling. • Make sure that the lifting machinery is appropriate for the task:

Machinery shall be maintained following the manufacturer’s recommendations. Machinery shall be operated by certified operators. Machinery must be sufficiently rated to handle the full weight of the loaded reel. Forklifts for lifting reels must have a capacity of at least 20,000 lb at 52-inch load center; the rated

capacity of the forklift is listed on the data plate provided by the manufacturer. When an attachment is added to a forklift, the data plate must be replaced with an updated version

provided by the manufacturer.




Shackles and other lifting devices should be made according to the strictest manufacturing guidelines. These devices must be certified and in good condition. Visually inspect these devices to make sure they are certified and in good condition. When lifting reels offshore, ensure that the load rating of the rigging is appropriate for the dynamic lifting conditions.

• During a lift, use basic safety precautions for a suspended load, as described in section 2.1 Safety Hazards.

• Do not lift loaded reels by the flange. • Do not lift reels by the bolted section of the flanges. • Pay attention to environmental conditions such as mud, ice, ridges, bumps that can affect the movement of

the forklift while holding the reel. • After moving a reel, use cradles or chocks to prevent it from rolling. In areas of high wind, place empty

reels horizontally (lying on the flange). • Do not climb on reels. Use a step ladder when necessary. Follow site Fall Protection requirements. • Maintain eye contact and clear communication with the operator of any machinery, including trucks. • The minimum standard personal protective equipment (PPE) required includes:

Gloves Safety glasses Hard hat Hard-toed shoes (with metatarsal protection recommended) Reflective vest Any other site specific PPE

5.1.2 Loading and Unloading Reels

During transport by truck or rail, reels are to be stored on cradles at all times. For loading and unloading, a suitable lifting mechanism or spreader beam must be used. Other means of moving the reels should be reviewed with FlexSteel Pipeline Technologies, Inc. Field Services or Engineering prior to attempting to load or unload reels to minimize the potential for damage to personnel, the reel, the pipe, or other equipment.

When loading:

• Inspect all equipment before use, including chains, slings, and spreader bars. Use equipment that is certified for the application and in good operating condition.

• Make sure cradles are in the correct orientation. • Reel spokes should be pointing toward the ends of the cradles. No spoke should be pointing straight down. • Check Load Paperwork and compare with what is being shipped. • Loader will place three chains, one chain on each side of the inner drum, and one chain inside the middle

of the drum. The transporter is responsible for properly securing reels on vessels with approved rigging such as D-rings, chains, shackles, and turn-buckles.




Figure 5-1 Loaded Reel for Transport

When unloading:

• Follow the lifting recommendations in sections 5.1.3 Vertical Reel Lifts and 5.1.4 Horizontal Reel Lifts.

• Compare Load Paperwork to items in the shipment. • When staging reels on the job site, with the exception of 6-inch and 8-inch lower pressure pipe, situate the

reel with the outboard pipe end facing up so that the pipe can be pulled from the bottom. With the 6-inch and 8-inch lower pressure pipe product, situate the reels so that pipe can be pulled from the top.




Figure 5-2 Outboard Pipe End Facing Upwards

When handling reels:

• Follow the safety precautions outlined in section 5.1.1 Reel Safety.

• During the lifting process, personnel need to keep clear of the reel.

• If a forklift or equivalent is used, ensure the reel is not raised or lowered while equipment is in motion.

• During transport from one location to another while using a forklift, the reel must be tilted slightly back with the flange against the mast. The flange next to the mast should be as low to the ground as reasonably possible without causing ground collision during travel.

• Spotters are highly recommended during reel movements, especially where movements are tightly constrained.

• Maintain eye contact and clear communication between all personnel, including the truck driver.

• Before and during use, inspect all rigging equipment for damages and defects. Damaged and defective rigging equipment should be immediately removed from service.




5.1.2.1 Truck Transportation

Typical truck transportation equipment is double drop deck trailers, as shown:

Figure 5-3 Reels Loaded on Truck

Each reel loaded with pipe should be set on cradles and secured with chains running through the drum in the following manner:

Figure 5-4 Transport Tie-downs for Transport on Truck

Empty reels may be transported overturned or rotated sideways. The flanges of overturned reels may overlap. These methods may require a pilot car. Always check state and local traffic laws. Reels loaded with pipe must not be transported on their side and should always be maintained in the vertical configuration.




Figure 5-5 Empty Reels Ready for Truck Transport

5.1.2.2 Rail Transportation

Reels are loaded onto rail cars as shown:

Figure 5-6 Reels Loaded on Rail Car

Reels should rest on cradles and appropriately chocked.

Attach load rated chain at a maximum angle of 60-degrees and hook around the reel spindle on both sides. Anchor the chain with hook and lok-a-loy connecting link. Safety lock wire is to be securely tied to all chain hooks, turnbuckle ratchets and spreader bars after all rigging has been tightened with turnbuckle ratchets.

Spreader bars are to be used on the end reels. When loaded, 12-foot reels must be at least 32 inches from the end of the car; 13.5-foot reels must be at least 45 inches from the end of the car.




Figure 5-7 Transport Tie-downs for Rail Transport

Figure 5-8 Transport Tie-downs for Rail Transport

Chain tie-downs are used to secure the reels and braces are used to reinforce the reels and cradles.




Figure 5-9 Braces for Rail Transport

5.1.3 Vertical Reel Lifts

Reels spooled with FlexSteel pipe require proper handling to insure safety and avoid damage to the pipe or reels. These vertical reels are usually loaded and unloaded using overhead hooks.

Figure 5-10 Spreader Bar to Lift Vertical Reel




When lifting reels with an overhead hook, observe the following precautions:

• Use basic safety precautions for a suspended load, as described in section 2.1 Safety Hazards. • Lift a vertical reel by the spindle, not by the flange. • Verify headroom on the crane using the planned load and rigging before conducting a lifting operation. • Use a spreader beam or spreader bar when lifting the reels, as the flanges are not designed for side loads

resulting from a direct hook lift. When using a spreader beam or bar, lifting straps should remain on the exterior of the flange to prevent damage to the pipe.

Figure 5-11: Proper Position (straps outside flanges)

Figure 5-12 Improper Placement (straps are not to be placed inside, against the pipe)

The reels also can be lifted by a sufficiently large forklift with a capacity of at least 20,000 lb at 52-inch load center by inserting the forks in the top corner sides of the reel drum. For determining the size of the forklift needed, both the Center of Gravity (CG) and the weight of the loaded reel must be considered.




Figure 5-13 Lifting a Vertical Reel with a Forklift

When handling reels, follow the safety precautions outlined in section 5.1.1 Reel Safety.




5.1.4 Horizontal Reel Lifts

Only empty reels are transported horizontally (lying on their flanges). These reels are to be secured tight with straps and chains on the bottom during transport. If the reels in the drop deck are vertical, they can be secured with straps over the drums as shown in Figure 5-4.

Reels may be lifted by forklift with sufficient lifting capacity (i.e., a capacity of at least 20,000 lb at 52-inch load center) as illustrated in Figure 5-14:

Reels may also be lifted with a forklift with a triple-or quad-leg sling. Use shackles to connect the lifting slings or chains to the reel at appropriate lift points.

Figure 5-14 Lifting an Empty Reel in Horizontal Orientation with a Forklift

When handling horizontal reels:

• Follow the safety precautions outlined in section 5.1.1 Reel Safety.

• Do not stack horizontal reels.




5.1.5 Up-righting and Overturning

Reels are up-righted and overturned only when they are not loaded with pipe and with the use of a forklift, crane or other piece of heavy equipment. To prevent damage to the reels during the process, make sure the flanges do not have a significant side load applied near the rim.

When handling reels, follow the safety precautions outlined in section 5.1.1 Reel Safety.

5.1.6 Reel Storage

Round reels that are stored vertically are placed on cradles or chocked to prevent rolling. Reels should not roll on the ground for structural and safety reasons. Empty reels can be stored horizontally but should not be stacked on top of each other.

Figure 5-15 Correct Reel Storage Positions

The ground where the reels are unloaded or stored should be firm enough to support the weight of the full reel. Placing a reel on soft ground can cause the reel to sink up to the pipe, increasing the risk of damaging the pipe. If a reel does sinks into soft ground or mud, the deployment trailer could have problems lifting the reel. Where soft ground is an issue, two railroad cross ties can be placed perpendicular to the cradles.

• For long-term storage, place the reels under cover to protect the carbon steel from extensive weathering. • For short-term storage, the reels can be left outside without protection. • Where space is limited, orient the reels so the outboard end is positioned to deploy off the bottom and rear

of the deployment trailer. This orientation avoids having to lift and rotate the reel before loading into a deployment trailer. Note: This orientation does not apply to 6-inch and 8-inch lower pressure pipe which must be deployed from the top rear of the deployment trailer.

• Place empty reels in areas protected from high wind speeds, as they can be blown over even when they are set on cradles. Use tie-downs to secure the reels.




5.1.7 Pipe Storage

Environmental conditions should be considered when storing FlexSteel pipe:

• The storage temperature must remain within the acceptable design limits. • Small amounts of residual water from factory testing can be exposed to unlimited freeze/thaw cycles

without problems. The pipe should not be frozen when full of water and capped on the ends. • The pipe inner liner generally has adequate chemical resistance and does not require preservation fluid

inside the pipe. • Sealing the open ends of the bore of the pipe is recommended, but not required. • Cover and seal the cut ends of the pipe to protect the steel layer from environmental conditions.

Inspect the ends periodically to ensure they are fully covered.

5.1.8 Fitting Storage

• All fittings should be stored in a safe and secure location. • Protect fittings to prevent damage to the seal area (both flange face and grooves where pipe is inserted)

and threads. If any deformation or damage to fittings is identified, the end user should check with a FlexSteel representative prior to use.

• Carbon steel end fittings require standard protective measures for carbon steel. For best results, it is recommended carbon steel fittings be kept indoors in a dry controlled environment until ready to install. At minimum, carbon steel fittings should remain in their original packaging in a sealed crate located in an area that prevents moisture accumulation by weather or other means until the time of installation.

5.2 INSTALLATION EQUIPMENT HANDLING

Installation equipment, including deployment trailers, A-frames, Respoolers, and swage machines, are secured by tie-downs, chains, or bars.

Follow standard safety procedures and reference the applicable equipment O&M manual when loading and unloading. Always:

• Use properly rated machinery to move equipment. • Inspect lifting eyes prior to use. • Use spreader bars when needed. • Make sure fuel supply is terminated on HPU motors. • Observe center of gravity (CG) labels.

5.3 MISCELLANEOUS EQUIPMENT

Miscellaneous equipment that is shipped includes tooling, crates, and specialized equipment such as the Deckhand®.




Figure 5-16 The Deckhand in its Specialized Shipping Container (with lid removed and with lid in place)

5.4 INTERNATIONAL TRANSPORTATION

Reels and equipment can be shipped internationally using skids, vessels, and cargo containers.

Skids are used to ship a single reel internationally:

Figure 5-17 Single Reel on Skid




Vessels are used to ship multiple reels internationally.

Figure 5-18 Reels in Hull of Vessel

Cargo containers are used to ship equipment.

Figure 5-19 Cargo Container used to Ship Equipment

The shipping process must be coordinated properly with the transport agent to comply with all logistic and international regulations and best practices.




6 INSTALLATION AND HANDLING Installation methods for FlexSteel pipe vary greatly, depending on the application and the environmental conditions. FlexSteel can be installed as part of new construction, field revitalization, or even rehabilitation of existing pipelines. FlexSteel is suitable for both onshore and shallow water applications. Onshore applications can be buried or the pipe may remain on the surface as the product is designed for direct sunlight/UV exposure. The durability and flexibility of FlexSteel pipe makes it ideal for temporary lines that can be recovered and reused as necessary to optimize operational objectives.

The keys to a successful installation are good communication and careful planning before arrival of the pipe, equipment, and personnel. A site evaluation should be performed prior to delivery to stage the pipe and equipment for efficient deployment in the field. For example, if a crane is being used to unload the reels at the installation site, determination of the location and orientation of the reels allows the pipe to be deployed and distributed without requiring additional crane moves, thereby reducing the equipment and time required.

Deployment trailers, A-Frames, or Respoolers are commonly used during deployment of FlexSteel pipe. The reel can be either static, as in a pull-in operation, or can be driven along the route as the pipe is laid from a deployment trailer or flatbed/A-frame configuration. Some of the least invasive methods of installation include pipeline rehabilitation, horizontal directional drilling, and plowing.

The equipment and personnel necessary to support the installation is dependent on the specific project. In a typical pull-in scenario with the FlexSteel Installation Technician and equipment on-site, the following is needed (the mechanical equipment chosen depends greatly on the type of terrain):

• Tractor, dozer, or grader (with qualified operator) with a pintle hitch rated for 5 tons • Excavator, loader, or side-boom to pull the pipe and place it into position • General laborer(s) to help with the manipulation of the installation aids and monitoring of the pipe route to

minimize the potential for installation related damage • Many installation scenarios only require a FlexSteel Installation Technician, an Operator (Excavator if

ditching), and one or two laborers

6.1 INSTALLATION EQUIPMENT

FlexSteel pipe can be installed using methods similar to any rigid or spoolable pipeline product. A wide range of equipment and installation aids are used in the different types of installation. The installation scenario and proper equipment selection should be discussed during the planning process for a specific project. FlexSteel can provide experienced personnel to support this planning process and help assure the end-user client realizes the maximum benefit of utilizing flexible steel pipe technology.

6.1.1 Reel Support Structures

Reel support structures must be stable enough for deployment and strong enough to safely support the 10-ton weight of a fully loaded reel. These structures can include mechanisms for lifting the reels, braking during deployment, and respooling FlexSteel pipe.

For every system used, precautions must be taken to assure the support structure remains stable and that some means of braking is available to help prevent free-spooling of the reel which can lead to excess slack in the pipe and possible cross-over looping that can result in damage to the pipe when pulled. Using the proper back tension is also critical to prevent kinking or torque build-up that can result in adverse installation conditions such as extreme cold weather or constrained installations. Braking/tensioning mechanisms can be built into the support structure or can be an independent device.




The most common types of reel support structures include:

• Deployment trailers • A-frames • Respoolers

6.1.1.1 Deployment Trailers

Deployment trailers are the preferred method for installation; they minimize set up time and provide the safest means of handling the reels and deploying FlexSteel pipe. The trailers can be easily relocated to various sites and allow for easy repositioning of the reels on the job site. They also allow the option of laying the pipe as the trailer is pulled, or pulling the pipe off the reel while the trailer remains stationary.

Figure 6-1 Deployment Trailers

A wide variety of trailers have been developed by FlexSteel Pipeline Technologies, Inc. All trailers incorporate a means of lifting the reels into place and a braking system for providing back-tension. Some models are collapsible




for easy storage and transport. All of these trailers can be rented or purchased from FlexSteel Pipeline Technologies, Inc.

The following are required in order to pull these trailers safely:

• A custom made Deployment Trailer Hitch. This hitch has adjustable vertical and horizontal portions. • A pintle hitch with a tongue weight of 5 tons.

Figure 6-2 Pintle Hitch

A pintle hitch can be attached to a truck, trackhoe or dozer. However, for heavy equipment, operational considerations (i.e., sharp turns) are required to prevent damage to the hitch.

When using deployment trailers, observe the following safety precautions:

• Adhere to all safety precautions relevant to hydraulic pressure, pinch points, and heavy equipment, as described in section 2.1 Safety Hazards.

• Inspect the trailer prior to use. • Inspect the Deployment Trailer Hitch for deformation and/or

cracks. • Make sure the trailer pins are secured with d-rings or cotter pins

that are in good condition. • Use safety chains during transport. • Use caution on rough terrain to prevent damage to the lift

supports. • Do not use deployment trailers for road transportation of reels;




6.1.1.2 A-Frames

The A-frame structure is another piece of equipment that can be used when installing FlexSteel pipe. A-frames must be both stable and strong enough to support the weight of a fully loaded reel of pipe. A-frames loaded with pipe can be mounted onto trucks, skids, or barges and then taken onsite to where the pipe is being deployed. Empty A-frames can be moved to where reels are located so that they can be loaded with pipe for installation at the job site.

To eliminate the need for cranes to load the A-Frames, FlexSteel provide A-Frames with hydraulic lift mechanisms and swing gates that can be pushed under the reel so it can be lifted and deployed. FlexSteel A-Frames incorporate an axle-based brake system to provide back-tension during installation. The common configurations of A-frame reel support structures provided by FlexSteel are:

• Simple A-frame – Constructed from rectangular steel tubing, the basic A-frame supports and elevates the reel into position. Pipe can be unspooled from the reel in one of two ways: The A-frame remains stationary while the pipe is pulled off the reel. The end of the pipe is held stationary, while the A-frame is moved on a flatbed and the reel unspools

the pipe.

Figure 6-3 Simple A-Frame Configuration

• Advanced A-frame – This model offers the same sturdy structure as the Basic A-frame, plus the following features: The capacity to incorporate modifications that convert it to a respooling machine; Four padeyes attached to the frame for balanced overhead lifting (e.g., by crane or helicopter);

these trailers are for off-road use only. • FlexSteel pipe must be decommissioned and dewatered before

lifting with the Deployment Trailer. • Do not lift a Deployment Trailer loaded with a reel. Proper lifting

and operation of the deployment trailer is detailed in the applicable trailer O&M manual.




Two anchor rods to stabilize and secure the frame.

Figure 6-4 Advanced A-Frame Configuration

Most A-frame structures include two 10-ton hydraulic cylinders for lifting the reels into place. These cylinders can be raised by hand pumps or by a built-in HPU, a combined engine, and pumping assembly. The reel supports of an A-frame may also be powered by a hand-operated pump.

A simple braking/tensioning system is also included to help prevent free-spooling during deployment. If more back tension is required, the reel can be lowered so the rims of the reel rest on the ground.

6.1.1.3 Respoolers

The Respooler is designed to provide a stationary deployment and re-spooling platform for FlexSteel pipe. In the deployment role, the Respooler works in the same manner as a standard A-Frame reel stand: pipe can be drawn

When using A-frames, observe the following safety precautions:

• For A-frames that are to remain stationary during deployment, the ground should be firm enough to support the weight of the full reel so that the A-frame does not sink. Use anchors or stakes to hold the A-frame in place and prevent it from sliding during pipe deployment, as it can be susceptible to slipping and skidding on slick terrain or due to weather conditions.

• Visually inspect the A-frame before use. • FlexSteel pipe must be decommissioned and dewatered before

lifting with the A-Frame. • Do not lift an A-Frame loaded with a reel. • Use basic safety precautions for hydraulic pressure, pinch points,

and heavy equipment, as described in section 2.1 Safety Hazards.




from the reel or the reel can deploy pipe as it is towed or carried on a flatbed. In the recovery role, the Respooler uses a hydraulically-powered chain drive to re-spool pipe onto the reel.

Figure 6-5 Respooler

The Respooler features a sturdy steel structure with braking/tensioning mechanism, a hydraulic lifting mechanism, and a motorized device that spools the pipe onto an empty reel mounted on the A-frame structure.

Be aware of the following safety issues when working with Respoolers:

• Recognize the potential for load shifting. • Before using, visually inspect the Respooler and all mechanical

parts including hoses. • The ground should be firm enough to support the weight of the

full reel so that the Respooler does not sink. • Use anchors or stakes (supplied with unit) to hold the Respooler

in place and prevent it from sliding during pipe deployment, as it can be susceptible to slipping and skidding on slick terrain or due to weather conditions.

• Use basic safety precautions for hydraulic pressure, pinch points, and heavy equipment, as described in section 2.1 Safety Hazards.




Figure 6-6 Respoolers

FlexSteel Pipeline Technologies, Inc. offers and recommends proper training before using a Respooler.

6.1.2 Installation Aids

Installation aids are used during deployment to direct the pipe around corners and obstacles and for placing the pipe in specific areas. Types of installation aids include:

• Pull heads • Synthetic lifting straps (slings) • Roller slings/Pipe cradles • Line conditioners • Deckhand®

FlexSteel pipe is rated with a minimum bend radius (MBR) and a maximum installation tension (reference Pipe Specification Sheet) which should not be exceeded (i.e., do not bend below the MBR value) as damage to the pipe could result. In general, there should be a support for every 30 degrees to assure the pipe does not bend below the MBR value. The higher the tension load, the more supports are needed. If the pipe begins to flatten or ovalize, the bending or local load on the support is too high. Any “necking down” of the pipe is indicative of excessive tension. Necking down refers to a localized reduction in an area of a specimen when a ductile metal is stressed beyond its yield point in tension. Furthermore, the installation tension rating of the pipe should never be exceeded. Use of an appropriate tension monitoring device such as a dynamometer is mandatory for any configuration that may approach these maximum tension values.




Figure 6-7 Installation Aids

6.1.2.1 Pull Heads

Various pull heads can be used to aid pulling FlexSteel pipe into position. These are mainly used in situations where a choke strap is not feasible or where the situation requires straight line pulling and/or torsional freedom of the pipe. Installations such as horizontal directional drilling, pushovers, or a pull through rehabilitation of an existing carrier pipe are some examples when pull heads are required. Two types of pull heads are available:

• The internal pull head is primarily used in rehabilitation installations. It fits inside of the pipe and is secured with a bolt that is inserted through pre-drilled holes in the pipe.

Figure 6-8 Internal Pull Heads

• The external pull head is used for all other types of installations such as horizontal directional drilling. It is attached externally and has bolts to secure the head onto the pipe.




Figure 6-9 External Pull Head

If there is a long bore and concerns about possible fluids getting into the pipe while boring, expanding foam may be used to minimize ingress into the pipe. For situations where no fluid is permitted, or if conditions require the strongest application for pulling the pipe, use of a weldneck fitting with a cap and pad eye welded to it is recommended. Only pull heads designed to accommodate the pipe load capacity are used for FlexSteel pipe installation.

Figure 6-10 Weldneck Fitting with Cap and Pad Eye

Never use internal pressure plugs to pull FlexSteel pipe.

When pulling any product, device, or implement, be aware of line-of-fire hazards in the event any part of the pulling system fails.




6.1.2.2 Synthetic Lifting Straps (Slings)

Synthetic lifting straps can also be used to pull FlexSteel pipe into position. When using this configuration, the load cannot be lifted as high as when using a pull head due to the potential for overloading and damaging the pipe. FlexSteel recommends a minimum of a 2-inch wide strap and three or more wraps to help distribute the load. These straps can be utilized in two locations:

• Directly to the pipe – Using a proper choke configuration, these straps might need the addition of duct tape or equivalent to help grab the pipe, since the polyethylene shield has a low friction coefficient.

Figure 6-11 Synthetic Strap on Pipe

• Immediately behind the end fitting – When using this method, make sure that the load does not result in a bend where the pipe and end fitting are joined to avoid creating a kink in the pipe.

Figure 6-12 Strap behind Fitting




To prevent damage to the pipe:

• Monitor the straps to make sure the pipe is not deforming or bending in the area of the strap point load. Do not use chains or cables.

Observe the following safety precautions when using lifting straps:

• Inspect the straps before use. Do not use straps that do not meet all of the manufacturer’s requirements for operating condition.

• Do not exceed the working load ratings for the straps. • Do not use a strap that has been shock loaded. • Watch for sharp or jagged objects that can compromise or

damage the straps. • Use basic safety precautions for suspended loads and lines

under tension, as described in section 2.1 Safety Hazards.

6.1.2.3 Roller Slings/Pipe Cradles

Roller slings and pipe cradles are low friction directional aids used to maneuver the pipe. When pulling the pipe around sharp bends, use multiple supports to make sure the pipe does not exceed the minimum bend radius (i.e., do not bend below the MBR value). A roller sling should be used for every 30 degrees in a bend.

When using roller slings or pipe cradles, observe the following precautions:

• Make sure the roller slings are properly rated for the type of pipe and load.

• Visually inspect the equipment before use to make sure they are in good condition.

• When using, be aware of pinch points, suspended loads, and lines under tension, as described in section 2.1 Safety Hazards.

Figure 6-13 Roller Slings




6.1.2.4 Line Conditioner

When the pipe is restrained on a reel, it can lose its round shape and become more oval. The line conditioner straightens and re-rounds the pipe as it comes off the reel. The pipe is drawn through the machine which uses rollers under hydraulic pressure to reshape the pipe.

When using a line conditioner, observe the safety precautions for pinch points and hydraulic pressure, as described in section 2.1 Safety Hazards.

Figure 6-14 3 and 4-inch Line Conditioner

6.1.2.5 Deckhand®

The FlexSteel customized Deckhand is designed to provide a safe solution for handling pipe and swage machines for 6- and 8-inch pipe installations. It is a modular, hydraulically-driven excavator bucket replacement attachment that can safely grip and manipulate pipe and pipe fittings into place.

The initial installation of Deckhand equipment on an excavator is a specialized procedure that must performed by qualified technicians. Installation times will vary by manufacturer and model of excavator. Contact a FlexSteel representative for further information on the use of these devices.




Figure 6-15 Deckhand Customized for FlexSteel Pipe

When using the Deckhand, observe the safety precautions for pinch points, heavy equipment, and hydraulic pressure, as described in section 2.1 Safety Hazards.

6.1.3 Swage Machines and Hydraulic Power Unit

FlexSteel Pipeline Technologies, Inc. has two midline swage machines (MSM) specifically designed for the installation FlexSteel fittings:

• 8018-MSM is used with 2-inch to 6-inch connections • MSM-3000 is used with 6-inch and 8-inch connections

The following information is a brief description of the swage machines and hydraulic power unit (HPU). FlexSteel Installation Technicians and contractors must be certified by FlexSteel to perform the swaging process.

6.1.3.1 Unit Description and Specifications

The primary components of the 8018-MSM midline swage machine are:

• two hydraulic cylinders • one grab plate • one grab plate gate • one die plate • one die plate gate • various dies

This machine produces up to 160 tons of axial load, with a maximum operating pressure of 10,000 psi. The 8018-MSM is used in conjunction with a 10,000 psi HPU with control capability to ensure proper operation and a flow rate of approximately 100 cu in/min at 2,000 psi or greater.




Figure 6-16 8018-MSM Swage Machine

Figure 6-17 Components of the 8018-MSM Swage Machine

The primary components of the MSM-3000 midline swage machine are:

• three large hydraulic cylinders • three small hydraulic cylinders • three grab plates • three die plates • various dies




This machine produces up to 240 tons of axial load, with a maximum operating pressure of 10,000 psi. The MSM-3000 is used in conjunction with a 10,000 psi HPU with control capability to ensure proper operation and flow rate of approximately 200 cu in/min at 10,000 psi or greater. This machine is controlled by a pedestal-mounted valve control unit.

The MSM-3000 is often used in conjunction with the Deckhand®. The Deckhand® allows hands-free manipulation of the pipe as it is placed into the midline couplings before swaging.

Figure 6-18 MSM-3000

Figure 6-19 Components of the MSM-3000 Swage Machine




6.1.3.2 Swaging Dies

Dies are specific tooling used in the midline swage machines to compress the fittings onto the pipe. Dies are made of specially treated steel that is designed to withstand high pressures and friction. Selection of the appropriate dies is determined based on the pipe dimensions, such as the outer diameter (OD) and inner diameter (ID) of the pipe. Refer to the appropriate Installation Procedure and Fitting Installation Inspection Logs for proper fitting installation process and requirements, including die selection.

• The 8018 MSM is designed to hold two dies in the die plates. These dies come in various sizes to be used with end fitting components and midline connections ranging from 2 inch to 6 inch nominal ID.

• The MSM-3000 is for end fitting components and midline connections ranging from 6-inch to 8-inch nominal ID and is designed to use three dies of varying sizes. These dies are also inserted into the machine’s die plates.

Figure 6-20 Dies for Midline Swage Machines

6.1.3.3 Hydraulic Power Units

There are two types of hydraulic power units (HPU) that FlexSteel Pipeline Technologies, Inc. currently uses:

• Gas-powered (standard) • Diesel Powered (offshore)

Contractors may use other HPUs as long as they meet the flow and pressure requirements of the equipment they are operating.

Refer to the equipment manufacturer’s manual for detailed instructions in the operation and maintenance of the equipment.




Figure 6-21 HPU for 8018 Swage Machine

Figure 6-22 HPU for MSM 3000

6.1.3.4 Swaging Process

The fittings are installed in several sequential steps. First, the pipe is prepared, the swaging tooling is assembled, and the fitting and swaging equipment are positioned on the pipe end. Once positioned properly on the pipe and fitting, the swage machine uniformly compresses the outer jacket of the fitting resulting in a reliable, permanently attached pipe end connection. After the swaging operation has been completed, a dimensional check assesses if




the end fitting is applying the correct amount of compression to the pipe wall. The pipe is then connected with other pipe or facility terminals using traditional methods – flanges, welding, or specialty connectors.

FlexSteel Installation Technicians and external contractors must be certified by FlexSteel to perform swaging operations on FlexSteel pipe.

Figure 6-23 Swaging Process

For more information on fitting installations, refer to the following documents

• For 8018-MSM 8018-MSM Operation and Maintenance Manual (Document #TR038) 2 inch to 6 inch Midline/EF Fitting Installation Procedures (Document # FLD-P-9901)

• For MSM-3000 MSM-3000 Operation and Maintenance Manual (Document #TR043) 8 inch Midline/EF Fitting Installation Procedure (Document # FLD-P-9907)




When using the midline swage machines and the HPUs, observe the following precautions:

• Refer to section 2.1 Safety Hazards for safety requirements pertaining to suspended loads, heavy equipment, pinch points, heavy lifting and manual handling, and hydraulic pressure.

• While the HPU is in operation, hearing protection is recommended.

• Prior to any maintenance, slowly bleed pressure, disconnect, and tag-out.

• Hydraulic Valve Locking Mechanisms (HVLMs) are installed on the swage machine and HPU to prevent accidental activation. Inspect the HVLMs prior to use to verify they are in good working order.

• Make sure the hydraulic valve on the HPU and MSM are disengaged and that the valve is placed in neutral prior to handling the machine or fitting.

• During the swaging process, do not stop the machine until swage is complete unless absolutely required.

• Monitor HPU pressures. For 8018-MSM and the MSM-3000, pressures must not

exceed 10,000 psi. While the hydraulic systems are rated for 10,000 psi,

keeping pressure as low as possible to complete the work will extend the life of the HPU and hydraulic seals.

• Keep all personnel and equipment away from the swaging unit during operation.

• For the 8018-MSM, all personnel should observe safe zone requirements as shown in the following illustration:




(CONTINUATION)

• For the MSM 3000, all personnel should observe safe zone requirements as shown in the following illustration:

6.1.4 Miscellaneous

Additional items, such as ancillary equipment, pipe supports, weights, etc., might be required during installation.

6.1.4.1 Ancillary Equipment

Numerous types of ancillary equipment are used during the handling and installation of FlexSteel pipe.

• Slings and spreader bars used to lift reels are typically reusable. • Some equipment, such as pull heads, dynamometers, and pressure plugs are job specific and will be

supplied with the Installation Technician when appropriate. These items can also be rented or purchased directly from FlexSteel.

• In most circumstances, other items, such as gaskets and bolt up kits, will be supplied by the installation contractor or end user client.

6.1.4.2 Pipe Supports

FlexSteel products do not require pipe supports or trays that are commonly used with welded steel pipe. However, FlexSteel pipe can be laid along existing pipeline routes with these structures. The contact surface between FlexSteel pipe and the support should be designed to prevent over-bending and excessive movement that can cause wear to the thermoplastic shield. Spacing between supports for FlexSteel pipe is typically approximately 15 feet (~5 meters). Contact FlexSteel to determine the spacing between supports for a particular application.

6.1.4.3 Weights

Weights are added in some shallow water installations to assure the line remains in position when subjected to strong currents or wave action. FlexSteel Marine Grade products are designed to sink and provide some degree of on-bottom-stability although it is the responsibility of the end user client or the installation contractor to assure proper weight on bottom for the anticipated operating environment. FlexSteel on-shore products, especially the lower pressure classes (600 and below), will float unless flooded. The interface between the weight and the pipe should be configured to assure there is no damage to the outer shield during installation or service. Contact a FlexSteel representative to evaluate a specific weight configuration for a particular application.

6.1.4.4 Riser Protection

FlexSteel pipe can be connected below grade to a steel riser, or more commonly, simply brought up to the surface without any special riser support considerations. The surface connection is often horizontal, though a 45 degree elbow canted downward, which is helpful in routing the riser during installation. In Canadian applications, CSA Z662 requires mechanical protection for risers in composite systems. This requirement reflects the relatively brittle nature




of the fiberglass pipe for which Clause 13 of Z662 was originally written. FlexSteel is both durable and flexible and has better impact resistance than both composite and steel pipe. Thus, no mechanical protection for risers is required in typical applications.

6.2 INSTALLATION CONSIDERATIONS

FlexSteel products are highly advantageous for faster deployment compared to steel or fiber reinforced pipe, extreme environments, and long term durability. While the product is durable and easy to handle, it is different than most traditional pipeline materials and requires some planning to assure the benefits are fully realized. In the planning process for a specific application, some of the important factors to consider are the arrangement of facilities, equipment capabilities, allowable pipe configurations, and environmental conditions. FlexSteel Installation Technicians are certified in a wide range of applications and are available to provide guidance and consultation at all phases of the project to help assure the work is completed correctly in a safe and efficient manner.

6.2.1 Communication and Personnel

The basic concept of spoolable pipe solutions is based on expeditious deployment of long lines with minimal connections. This translates operationally to a dispersed work crew focused on pipe position and pay off locations. Therefore, clear communication and Stop Work Authority are critical for the entire crew. In the case of deployment from a trailer, the lines are laid on the ground in a stable condition and the work crew is generally in close proximity to the deployment system. When pipe is dragged into place, whether previously laid out (repositioning) or from a stationary deployment system, there can be significant distances between the pulling equipment and deployment reel. In this situation, there are also long lengths of moving pipe on the ground. It is very important in this latter situation that there is enough personnel to verify the pipe is not being damaged and to be able to stop the pulling device as quickly as possible.

• All personnel monitoring the installation should have a reliable means of communication (e.g., radios or pre-determined hand signals) for clear communication during the deployment process.

• Only necessary personnel should be in the proximity of the deployment. Those personnel that remain in close proximity are to be aware of line of fire hazards as the pipe is deployed.

• All personnel shall be clear of load lines, pipe swing radius (both at pulling implement and deployment system), and the path of any moving pipe or equipment.

6.2.2 Inspection of Pipe

Fundamental to assuring long term performance of FlexSteel pipe is proper inspection before, during, and after installation.

FlexSteel utilizes stringent quality control measures throughout the manufacturing process to assure all materials and constructions meet the manufacturing requirements and external quality standards. Once manufactured, every segment of FlexSteel pipe is subjected to an 8 hour factory hydrotest to validate the structural integrity and documentation for a product that is prepared and tested according to design standards. Finally, visual inspections performed during final packaging assure that the product leaves the factory in good condition and ready to install.

When the product is received on site, the end user or its contractor should inspect the pipe for damage that may have occurred during shipment. The inspection includes observing that the wraps remained secure and tight on the reel and for any unusual deformation or gouges in the product or outer shield. In addition, the inspector should verify that the reels are in good condition without deformation or damage.




• This inspection should continue prior to and during deployment of the pipe. When dragging the pipe into position, the inspector should assure there are no sharp objects or obstructions that may result in damage to the outer shield or over-bending of the pipe. If the pipe appears to be damaged, depending on the severity of the damage, the area might be repaired using Canusa sleeve or other FlexSteel-approved wrap. For more information on types of damage and repair, see section 10




Troubleshooting and Repairs. In general, it is a good practice to have someone following the pipe to assure it is laying properly and that nothing is digging into the shield. Due to the high level of damage tolerance and general durability of the product, most instances of contact with sharp surfaces or abrasion from pulling pipe across rough surfaces create only superficial damage to the shield that does not require repair.

6.2.3 Positioning the Reels

When stringing out the pipe, position each reel so that the beginning of each pipe faces the end of the previous pipe, rather than facing away, creating an “S” bend. This will greatly aid the alignment of the midline fittings.

6.2.4 Positioning from Deployment Trailer

A common installation method is positioning the FlexSteel pipe directly from a deployment trailer. This method gives of the most control of the pipeline orientation during the installation, and lines are deployed quickly and efficiently.

The trailer should be loaded and operated in accordance with the applicable equipment O&M manual. In general, FlexSteel trailers are typically backed into the loaded reel, so that the pipe end is facing up and toward the back of the trailer and can be pulled from the bottom of the reel during deployment. It is sometimes advantageous to deploy from the top of the reel, especially with larger diameter, low pressure pipe. Most FlexSteel trailers incorporate hydraulic lifting arms to raise the reel onto the trailer to prepare the reel for deployment.

On the free end of the pipe, straps or slings are typically wrapped around the pipe (at least three wraps) and then attached to a suitable stationary object (vehicle or piece of equipment). The end of the pipe is held steady while the deployment trailer is pulled down the right-of-way by a tractor, dozer, or other suitable equipment. It is recommended that the piece of equipment used during the deployment process is heavier than the loaded trailer because the deployment trailers are typically not equipped with brakes, lights, or suspension. If a piece of equipment is used to move the loaded trailer on mountainous terrain and the loaded trailer outweighs the piece of equipment, it will push or pull the equipment down the hill. A smaller piece of equipment can be used to move the loaded trailer on flat ground.

The brake/tensioner system on the trailer is used during the deployment process. The brake is designed to provide back tension to keep the pipe tight and assist in straightening the pipe from the stored reel shape. This mechanism also keeps the remaining pipe on the reel from becoming loose. To prevent free-spooling, never position the pipe downgrade of the reel. The deployment trailer is not designed to deploy pipe down a steep grade, as the trailer brakes do not provide enough back tension to prevent free-spooling.

Use caution when pulling the deployment trailer around corners. When the pipe is unspooled from the trailer around a corner with back tension, it will continue to move into the corner until it is stopped by an object, such as a tree, post, or other barrier. Care must be taken to assure these barriers maintain the pipe minimum bend radius or installation tension limits. To control corners without barriers, use roller cables to control the bend radius and keep the pipe in position (See Section 6.1.2).




Figure 6-24 Deployment Trailer

6.2.5 Positioning from Stationary Reel Support Structure

Another common installation method is to deploy the FlexSteel pipe directly from a stationary reel support structure, such as an A-frame, or Respooler. This type of installation method is utilized when the job site is too unstable for deployment trailers to cross or the pipe is dragged to its final position.

Slings are attached to the pipe (at least three wraps) and then to a backhoe, dozer, excavator, or other available equipment. The reel support structure stays stationary while the heavy equipment pulls the pipe into position. When a backhoe or other equipment is used to drag pipe from a deployment trailer the installation contractor will tie another piece of equipment to the front of the trailer to anchor the trailer and reel while the pipe is unspooled.

Observe the following safety precautions:

• Refer to section 6.2.6 Installation Stability and the design specific Pipe Specification Sheet for maximum installation tensions.

• Make sure that the pipe is not pulled over any sharp rock or metals.

• Always inspect pipe for damage after placing into position. • Make sure a piece of equipment is tied to the pipe before cutting

the pipe loose. • Make sure a piece of equipment is tied to the reel support

structure. • Keep personnel away from the reel while the reel is turning.




6.2.6 Installation Stability

FlexSteel pipe is designed to be durable and resistant to the extreme installation handling requirements of a pipeline construction environment. However, as with any pipeline product, improper handling can cause the pipe to be damaged. One type of damage is a compromise of the pipe structure due to excessive bending or torsional loads. These are often referred to as kinks or twists. To determine whether FlexSteel pipe has been damaged by this type of deformation, examine the pipe for sharp creases, bulging, or wrinkling on the surface. If these conditions are present, then the Installation Technician or qualified FlexSteel representative will need to evaluate and determine if the segment of pipe must be cut out. Many times these can be recovered during the hydro test without any effect on the structural integrity of the product; however, in extreme cases where damage to the steel layers is suspected or unknown, it is recommended that these sections be cut out.

The stability of the FlexSteel structures, as with all thin walled tubes, is proportional to the wall thickness and stiffness. As such, as the diameter increases, or the pressure rating decreases, the propensity of the product to experience a stability issue increases. FlexSteel pipe sometimes requires special handling considerations to reduce the sensitivity of the structure to the bending and torsional loads introduced during deployment. To counteract these effects, the pipe can be pressurized during installation using FlexSteel designed end plugs. Consult a qualified FlexSteel Installation Technician for details on the use of these pressurization devices.

The 6-inch and 8-inch lower pressure pipe may require special handling.

• FlexSteel recommends pressurizing this pipe to 60-80 psi before deployment.

• If the pipe is pressurized or if no torqueing issues are encountered, deploy from the bottom of the reel as a standard installation. If pressurizing the pipe is not possible or torqueing issues are encountered, deploy the pipe from the top of the reel.

• Keep the pipe under tension during the deployment.

Observe the following safety precautions:

• Refer to section 6.2.6 Installation Stability and the design specific Pipe Specification Sheet for maximum installation tensions.

• Stationary deployments should be done from a location where the ground is reasonable flat and stable. Inclines should be avoided.

• Make sure that the pipe is not pulled over any sharp rock or metals.

• Always inspect pipe for damage after placing into position. • Tie a piece of equipment to the pipe before cutting the pipe

loose. • Tie a piece of equipment to the reel support structure. • Keep personnel away from the reel while the reel is turning.




6.2.6.1 Torque and Bending

The unbonded construction of flexible steel pipe results in behavior characteristics similar to those seen in cables or even common garden hose. Certain bending and torsion inducing loads can cause these types of structures to twist, flatten, or kink. In FlexSteel pipe, the structure is designed to minimize these issues for most installation scenarios. Torsion, bending, and local loading can lead to a flattening of the pipe structure which further increases the sensitivity to torque and bending.

FlexSteel pipe is torque-balanced through the counter-winding of the adjacent steel layers. This construction results in preferential bending and torque directions since these layers are independent. When the pipe is loaded such that the twist introduced is against the lay direction of the outer layer, the outer layer tends to try to open up while the inner layer tightens down on the liner. Twist in the opposite direction causes the outer layer to tighten down while the inner layer tries to open up. In extreme over-torque situations, the former can result in a “birdcage” type failure. This damage occurs when the outer steel layers expand beyond the capacity of the outer shield. In the latter condition, the interface pressure (and friction) between the layers increases which can reduce the ability of the structural layers to shift relative to each other leading up to an increase in pipe stiffness and ultimately a twist in the pipe structure.

Kinking is a result of simple over-bending of the pipe structure. This can occur due to point loading or load induced over bending. FlexSteel pipe is designed with an industry leading minimum bend radius capacity. To achieve this bend radius in practice, radial support of the product is required. Without this support, the pipe will kink before the minimum bend radius is achieved. As a general rule, a support is required every 30 degrees of bend. To bend all the way to the minimum bend radius, a drum or continuous support structure may be required. Another situation where over bending can occur is under suspended loads. Improper support of the product with a single strap and long spans on either side will cause over bending. Like making a bend, for supporting long lengths of suspended pipe, the bend radius at the support must be controlled to be sure the pipe does not bend below the product minimum bend radius or exceed bending load capacity. Finally, when paying off the top or bottom of the reel, the suspended length can exceed the bending capacity of the product causing a kink. To avoid this scenario, be sure to maintain the appropriate installation tension as defined on the Pipe Specification Sheet.

6.2.6.2 Manufacturing and Spooling Considerations

While FlexSteel pipe is manufactured using high quality materials and strictly controlled processes, during manufacturing, slight variations in process and properties can affect the friction between layers and ultimately the ability of the layers to move relative to each other. This is why most pipes behave in a very “neutral” manner, but some may have characteristics (appear stiffer) resulting from retained torque.

It is important to understand that torsion is introduced into an unbonded flexible steel pipe whenever the product is bent or twisted. Furthermore, the spooling operation itself results in a small amount of torsion spread over the length of each wrap. This torsion accumulates across each layer and then reverses when the direction of the layer shifts.




Figure 6-25 Torsion during Spooling

6.2.6.3 Installation Tips

In most cases, FlexSteel pipe can be deployed with little concern for any torque or bending issues. Many installations with complex, close proximity bends are completed without any pipe stability issues. However, if the application requires a large diameter pipe, low pressure rated product, or when the installation contractor experiences problems resulting from torque or bending, the following tips can help alleviate these issues:

• Bending induces torsion. To minimize the risk of damage, assure all bends are performed well away from constraints such as fixed fittings, other bends, and the deployment reel. Try to deploy pipe first and then pull around the bend or make a large sweep and tighten the bend once the pipe is off the reel. In general, unspooling 50 to 100 feet is sufficient to alleviate torque concerns completely although it varies with climate, cumulative torque resulting from other bends or constraints, and each specific pipe. In general, the more directional changes in a short distance, the higher the potential for issues with torque.




Figure 6-26 Bending/Torsion Relationship

• Avoid point loads. Use pipe rollers for all bends (concave or V-rollers preferred). An additional pipe roller should be used for each 30 degree increment of bend to help assure the MBR is not exceeded (i.e., do not bend below the MBR value).

• Bend only to the radius needed to meet the installation requirements. Remember, the tighter the bend, the more constraint and the more concentrated the twist.

• Observe the pipe behavior. If the pipe begins to tighten or twist into loops, reassess and determine if torsion can be reduced by deploying in a different manner. Note: Although the following method does not always work, only a FlexSteel-certified technician may strike the pipe with a rubber mallet or dead-blow in the region of the tightening to free up the steel bands to try to alleviate the localized torque build-up.

• Understand the torque state on the reel relative to your installation need. For minimization of suspended pipe spans coming off of the reel, FlexSteel recommends paying off the bottom of the reel. When paying off the bottom of the reel, the even number layers on the reel (from the inside) tend to have a more sensitive torque condition. This torque builds up as the pipe traverses across the reel and is the highest at the flange where the directional change occurs (wringing effect). The most common torque condition that results in twisting is making a left hand turn in close proximity to the reel when the pipe is adjacent to the left hand flange on the second layer (direction is relative to looking at the reel from the deployed pipe).




Figure 6-27 Left-Hand Turns for Mobile Deployment Equipment

If conditions require paying off the top of the reel, the issue is reversed. The highest torque occurs adjacent to the right hand flange on odd layers and the issues manifested when making right hand turns close to the reel.

• For ultimate stability of the pipe structure during deployment, a small amount of pressure in the pipe can make a big difference. Consult a FlexSteel representative for details on pressurization kits and procedures to ensure safe pressurization and handling of pressurized product during installation.

6.2.7 Installation Tension

In order to prevent damage to the pipe, the installation contractor will consider the installation tension during the pipe handling process. FlexSteel Pipeline Technologies, Inc. has performed extensive testing to determine the maximum tensile capacity and Minimum Bend Radius (MBR) of the FlexSteel line of products.

The maximum installation tension, spooling tension, and minimum bend radius are provided in the Pipe Specification Sheet. These recommended values are not to be exceeded during any part of the installation process.

When the pipe is subjected to tension loads, the steel layers squeeze down on the liner. While ultimate failure occurs when the steel strips break, permanent damage to the liner may occur before the pipe fails. Any visible “necking down” (i.e., a localized reduction in an area of a specimen when a ductile metal is stressed beyond its yield point in tension) of the pipe is a clear indication that the installation tension has been exceeded. If this condition exists, contact a FlexSteel representative for evaluation prior to putting the line into service.

Particular care must be taken when dragging full reels or multiple reels into position. Many factors will affect the drag friction load on the pipe (e.g., round condition, obstacles, turns, elevation changes, etc.). A dynamometer is recommended to accurately measure the tension on the pipe. Contact a FlexSteel representative if the pipe’s maximum installation tension as specified in the Pipe Specification Sheet has been exceeded.

When pulling FlexSteel pipe around guides, through the ditch, through cable rollers, etc. in addition to monitoring tension, it is important to monitor the ovalization of the product where it contacts the guides. If ovalization is noted (typically seen at guide closest to the pulling device), additional guides, or a continuous support through the turn, may be required to prevent over-tension, flattening or kinking of the product.

Deployment Trailer Stationary Deployment Equipment (e.g. Respooler)




Figure 6-28 Dynamometer

Some additional pipe handling considerations to avoid exceeding the tension of the pipe include:

• Personnel should inspect the pipe for damage periodically during the deployment process. • Use proper lifting and rigging techniques when using lifting straps or roller slings. For straps, secure at

least three wraps around the pipe. Refer to section 6.1.2 Installation Aids for more information.

• Use caution when lifting or maneuvering the pipe from a single point using a strap or roller sling. Use appropriate mechanisms to support pipe when lifting to avoid bending below the MBR value.

• Do not exceed tension values when handling the pipe from the installed fitting or pull head. • Pulling the pipe from more than one reel at a time is feasible within the allowable values of total tension

and depending on installation conditions. • Environmental conditions can increase tension due to friction factors. • Special considerations may be required for different types of installation, such as steep grades, rough

terrain, cold weather, shallow water, among other variables in conditions and location. • Dynamometers do not work while the pipe end is underground during horizontal directional drilling or inside

carrier pipe during pipeline rehabilitation. Use an appropriate monitoring device to provide the maximum tension at the FlexSteel pull head. See section 6.3.5 Horizontal Directional Drilling for information on other ways to monitor the tension.

• All curves in pipe require at least two points of contact with roller slings. Three points of contact are strongly recommended. In general, a support is needed for every 30 degrees to avoid bends below the MBR value.




6-29 Roller Sling Configuration

6.2.8 Cold Weather Installation

FlexSteel pipe requires special considerations for cold weather handling and installation.

6.2.8.1 Effects of Cold Temperature on the Pipe

While the polyethylene (PE) of the inner liner and outer shield layers of FlexSteel™ pipe retain their toughness at very cold temperatures, the pipe stiffness increases as the temperature decreases. When the pipe becomes too stiff (such as during cold weather conditions), it is more resistant to release its curvature when deployed from the reel where stored (i.e., retains stored memory). Preheating the pipe reduces this stiffness and helps prevent cold weather splits and kinks. If the shield splits, contact a FlexSteel representative for evaluation. Most cases of splitting can be repaired using a FlexSteel-approved wrap, depending on the severity of the split. Refer to section 100




Troubleshooting and Repairs for more information on repairing the outer shield.

The steel reinforcement layers of the pipe are insulated by the liner and shield and will remain colder than the outside temperature for a prolonged period of time. The coldest temperature during the 72-hour period prior to installation is the temperature of the pipe at the start of the installation.

An infrared pyrometer is used to determine the pipe’s core temperature from the inside wraps of the reel.

6.2.8.2 Preheating Pipe

At temperatures below -13°F (-25°C), FlexSteel Pipeline Technologies, Inc. highly recommends preheating both the outer and the inner layers of the pipe for safer and more efficient handling and installation. Occasionally, it may be required to preheat the pipe at temperatures above -13ºF (-25ºC), as in the case with lower pressure pipe.

Reels of pipe can be efficiently heated using following equipment:

• One regulated internal flame heater (such as Herman Nelson) with sufficient capacity to concurrently heat 1 1/2 to two reels of pipe. Infrared heaters are not recommended.

• One blower with sufficient capacity to supply heated air into a reel of pipe. • Generators with sufficient capacity to provide power to the heaters and blowers. • An insulated tarp (or two insulated tarps in extreme cold conditions) large enough to cover all of the reels. • Ductwork to direct air from the blower into the pipe.

Depending on the site requirements, a hot-work permit might be required.

Figure 6-30 Preheating a Single Reel of Pipe

To heat the reels:

1. Closely align two or three reels, one in front of the other. 2. Remove the tape from both ends of each reel of pipe staged in the heating configuration. 3. Feed the hose from the heater inside the tarp laid on the ground and into the center of the reel or in between

each reel.




4. Completely cover all reels with one very large insulated tarp. Two insulated tarps may be required in extreme cold weather conditions.

5. Start heaters and check if any air is escaping from the tarps. Do not exceed 140ºF (60ºC). 6. For best results, start heating the reels at the end of the day before deployment with the heater, heating the

reels overnight. Be sure the heater is regulated so as to not exceed 140ºF (60ºC).

Figure 6-31 Cold Weather Pre-heating Setup

To heat the inside of the pipe:

• First thing in the morning on the day of deployment, connect the ductwork from the blower to the outboard end of the pipe in the first reel, and turn on the blower. It is not recommended to use the blower overnight.

• As one reel is transported for deployment, place another cold reel to the heating configuration inside the insulated tarp.

• After the heating process, the reels should be deployed as soon as possible.




Figure 6-32 Heated Air Supply to End of the Pipe

6.2.8.3 Other Cold Weather Considerations

The following are additional tips for a successful cold weather installation:

• Make sure proper back tension (braking) and reduced deployment speeds are maintained throughout the deployment process.

• Inspect the pipe for shield damage throughout the entire deployment process. • In icy conditions, use tracked equipment, fitted with ice cleats, that significantly outweighs the reel/trailer. • Before installing a fitting, make sure that the pipe is absolutely clean and dry, inside and out. Make sure no

water is present that could form ice between the pipe and the fitting. The fitting must be in direct contact with the bare pipe.

• When using slings, apply at least three wraps and apply polykin tape in front of the choke to prevent slipping.

• When boring the pipe in horizontal directional drilling, apply pipe tape around the pull head followed by a shrink sleeve and complete the seal with additional pipe tape. An improper seal can allow water to enter and cause ice plugs.

• When stringing out the pipe, position each reel so that the beginning of each pipe faces the end of the previous pipe, rather than facing away. The two pipes to be joined with a midline fitting will be configured into an “S” bend.

• FlexSteel pipe is much stiffer in cold weather and can retain considerable memory when unspooled. When cutting pipe in cold weather, use extreme caution and secure both sides of the cut location to prevent the pipe from jumping or springing upon completion of the cut.

• For trenching installations, FlexSteel recommends that fittings be installed on the surface at a minimum safe distance of 6 ft. (1.8 m) before laying the pipe in the trench.

• Keep all fittings and lubricants in warm area prior to installation, but do not store in the tarp where reels are pre-heated.

• Follow these precautions to protect hydraulic equipment: Consider using cold weather hydraulic fluid or an all season fluid.




Warm the hydraulic fluid by allowing the pump to run prior to use and use a magnetic block heater on the reservoir.

Prevent snow from accumulating on the open air vent of the pump’s fluid reservoir to keep water from seeping into the fluid. Cover the pump at night when not in use.

Extend and retract the cylinders of the swage machine several times to circulate the hydraulic fluid prior to fitting installation. For further operational guidance in cold weather, reference the 8018-MSM Operation and Maintenance Manual (Document #TR 038) or the MSM-3000 Operation and Maintenance Manual (Document # TR 043).

• Field hydro testing in cold weather conditions requires a methanol mixture to insure that water does not freeze inside the pipe during the test.

6.2.8.4 Heat Trace/Insulation

A heat trace system that is compatible with HDPE piping can be used with FlexSteel pipe to prevent freezing of fluids in pipes. This technique is important on water lines that are susceptible to freezing. When using heat trace, make sure that the voltage of the heat trace is within the proper limits to prevent melting the pipe.

Pipes that are coming up to the surface should be insulated. Use the next larger size of insulation for FlexSteel pipe. For example, if you are using 4-inch pipe, use an insulation kit for 5-inch pipe.

6.2.9 Expansion/Contraction

Contraction and expansion factors that are commonly seen with regular PE pipe are not commonly seen with FlexSteel pipe. Traditional steel pipe and conventional PE pipe have contraction and expansion factors that must be mitigated by expansion loops or flexible buffers. If these factors are not controlled, upheaval buckling can occur. The design of FlexSteel pipe, with its independent steel layers between the PE liner and shield, is considered an unbonded structure. This structure allows the layers to move independently from each other and allow elongation and small, internal movements to compensate for any changes in the pipe due to temperature. These movements are considered negligible and do not affect the integrity of the pipe.

6.2.10 Excavation Requirements

Excavations require extra safety precautions as they present hazards to all personnel involved. Among these hazards, cave-ins pose the greatest risk and can result in a fatality if safety precautions are neglected. Other potential hazards during trenching operations include:

• Slips, trips, falls – Keep the workspace and walkways clear of any potential trip hazards. Wear fall protection when working around a trench.

• Hazardous atmospheres due to poor ventilation – Use a gas monitor to detect any harmful gases in the trenches.

• Water accumulation – If water accumulates in a trench in the work area, create a slope in the bottom of the trench to allow the water to run off into an area where it can be pumped.

• Loose rock or soil – Be aware of soil conditions. All soil piles should be at least two feet away from the edge of the ditch. Watch for erosion at the base of the trench wall; this condition can cause trench walls to collapse rapidly, causing a potentially fatal accident.

• Mobile equipment – Use basic safety precautions such as using a spotter in areas of low visibility, standing clear from suspended loads, and remaining in constant communication with all equipment operators. A consistent set of hand signals should be established between operator and spotter.

One important safety precautions is the bell hole. A bell hole is a type of excavation where the walls of the trench are appropriately sloped or benched away from the centerline of the trench to prevent a cave-in and to make it easier to work around obstacles such as existing buried pipe. This bell hole gives the trench a cross section like an upside-down bell. The hole should be a minimum of 2 feet deep, 5 feet wide, and 10 feet in length. FlexSteel




Pipeline Technologies, Inc. recommends bell holes at all tie-in locations, with 20 feet on either side of the tie-in exposed.

Figure 6-33 Bell Hole

Preplanning that incorporates safety precautions is essential to assure safe operations of FlexSteel pipe installation. Trenching operations require training following OSHA requirements and regulations, such as, 29 CFR 1926, Subpart P (or others such as Alberta OHS Code Part 32 and BC OHS Regulation Part 20). For example:

• For trenches deeper than 4 feet, access and egress must be provided every 25 feet, using ladders, ramps, or stairs.

• A competent person must inspect excavations daily, at the start of shift, and as needed for changing conditions, such as rainstorms or other hazard-increasing events.

• Personnel are prohibited from working under raised or suspended loads and must stand away from equipment being loaded or unloaded.

• OSHA requires a benching, sloping, or shoring when the trench is deeper than 4 feet. Sloping and benching of the trench must meet the requirements for the soil classification.

• Trenches deeper than 6 feet and wider than 30 inches must have walkways or bridges for crossing. Walkways must be at least 20 inches (.51 m) wide, have handrails, and extend 24 inches (.61 m) past the surface edge of the trench on both sides. Never jump across a trench.

6.2.11 Buried Pipe at Crossings

Subsurface installation requires adequate planning that considers the interaction between the pipe and its surrounding soil and uses a safety impact factor for the particular application. The pipe responds to soil pressures, which are a combination of soil weight and surface loads.

FlexSteel pipe has been analyzed using worst case scenario factors, such as the weight for wet sand, the heaviest permitted wheel load at surface, and the wet collapse determined experimentally for several pipe sizes. Calculations for the combined load pressures were done using methods described in Chapter 6 of the PE Design Handbook published by the Plastic Pipe Institute.




FlexSteel recommends that the pipe is buried at least 3 feet under the surface at road crossings. Contact a FlexSteel representative for any questions regarding specific job applications.

6.2.12 Rough Terrain

Regions that are uneven and rocky are considered rough terrain and require special installation consideration. Pre-task planning is important when working in rough terrain. Personnel should remain aware of the condition of the ground, and observe proper installation techniques for rocky surfaces, unexpected protrusions and areas of loose soil. Additionally, when pipe is placed over steep grades, pipe should be properly secured at all times to prevent sliding. All personnel should have radio or equivalent communication during the installation. FlexSteel recommends having at least one FlexSteel Installation Technician present who is experienced in rough terrain applications.

Typically no bedding (i.e., specialty fill material below the pipe) is required with FlexSteel pipe, but in areas with jagged, sharp rocks, the pipe should be padded with soil, sandbags, or fine gravel prior to using rough fill. Always verify proper shading methods (i.e., the fill material above the pipe) are being used.

Equipment considerations for rough terrain:

• Tracked equipment is preferred because of its greater surface area of contact to the ground. • When driving across rough terrain, drive slowly and use caution to prevent damage to trailers, lifting arms,

reels, and other equipment. • Tires on the deployment trailer are susceptible to sidewall damage. Drive carefully to avoid exposure to

sharp or jagged edges. • Use equipment that is properly rated for adequate load capabilities. • Use tension monitoring equipment at all times. Never exceed the maximum tension limits on the pipe. • If using a winch:

Use adequately trained operators Use equipment with an appropriate safety factor

• The pipe can be unspooled and then moved into position using proper equipment. When moving the pipe, take precautions not to drag it across sharp rocks or pointed objects that can cause damage to the pipe.

Be aware of the following safety issues when working in rough terrain:

• All personnel should remain aware of the condition of the ground and observe proper installation techniques for contact with hard rocks, unexpected protrusions, and areas of loose soil.

• All personnel should have radio or equivalent communication during this procedure.

• Typically no bedding is required with FlexSteel pipe, but in areas with jagged, sharp rocks, the pipe should be padded with soil, sandbags, or fine gravel prior to using rough fill. Always verify proper shading methods are being used. Contact a FlexSteel representative with concerns regarding padding or shading.




Figure 6-34 Rough Terrain

6.2.13 Steep Terrain

Installations in areas with steep grades require special handling due to the potential hazards to personnel, pipe, and equipment. This section covers basic requirements for the installation of FlexSteel pipe on a grade greater than 15 degrees.

Be aware of the following safety issues when working with steep terrain:

• Conduct a Job Safety Analysis (JSA) prior to installation that covers safety consideration with rough terrain applications.

• All rigging must be properly weight-rated and inspected prior to use.

• All personnel must have radio or equivalent communication during this procedure.

• Use tension monitoring equipment at all times. Never exceed the maximum installation tension of the pipe.

• Personnel familiar with the job scope and steep terrain should be present at all times.

• Keep personnel from being downgrade of equipment and the pipe while it is being deployed.

• Keep pathways clear of any debris that can be hazardous to personnel or that might prohibit safe deployment of the pipe.

• To prevent free-spooling, never position the pipe downgrade of the reel. The deployment trailer is not designed to deploy pipe down a steep grade, as the trailer brakes will not prevent free-spooling.




Figure 6-35 Steep Terrain

6.2.13.1 Equipment requirements

All equipment used during installation should be adequately rated for the load being held, pulled, or lowered (i.e., shackles, straps, bolts, and tractors or piece of equipment used to maneuver the pipe or swaging unit). When estimating weights, consider the pipe weight, pull tension, grade, and ground resistance. When installing pipe through bores, consider the bore size and wall structure inside the bore.

Tracked equipment of adequate weight is the best option when lowering pipe down steep grades because of its contact to greater surface area on the ground. The equipment used to pull the loaded reel must be heavier than the combined weight of the trailer and fully loaded reel. The deployment trailer is not designed with wheel brakes, lights, or suspension. If loaded trailer outweighs the piece of equipment, it will drag the equipment downhill.

FlexSteel Pipeline Technologies, Inc. recommends the following equipment for steep grades installation, but contractors and operators should make their equipment decisions based on their experience with the landscape:.

• A D8 bulldozer or excavator with a cable winch and an experienced operator. The piece of equipment may vary depending on availability, environmental conditions, and installation method.

• Cables, rigged as backup safety in case of slack in cable, failure of the winch, or loss of traction by the bulldozer.

• A second piece of equipment to assist the pipe as it is being lowered down the steep grade or to direct the pipe around objects/turns.

• External pull heads. • Dynamometer to measure tension during steep grade installations.

Depending on the severity of the slope, the deployment equipment might need to be properly anchored.




If the equipment cannot access a grade because of loose soil, jagged rocks, or the incline is too steep, there are two options: pull-up or push-over.

6.2.13.2 Pull-Ups

Figure 6-36 Pull-up

With the pull-up method, the pipe is pulled up the grade from a reel that remains stationary at the base of the grade. An A-frame or deployment trailer is used to support the reel. The pipe can be pulled with equipment such as a bulldozer, excavator, or winch. The degree of the slope determines the proper pulling equipment.

• An external pull head or weldneck fitting is installed on the outboard end of the pipe. • Attach the pull head and a tension monitor to the pulling equipment using a weight-rated sling or cable. • Pull the pipe up the grade until the entire pipe is off the reel. Spotter and equipment operator should

maintain constant radio or equivalent communication. • The equipment operator will monitor the tension on the pipe. If the tension approaches the tension limit for

that pipe, a second piece of equipment is required to assist in order to prevent over-tensioning. • After the pull-up is completed, the pipe must be anchored at all times. For example, a good portion of the

pipe can be buried with backfill. Make sure pipe is securely anchored before releasing any tie-downs.

Make sure the equipment that is used to pull is heavier than the combined load that it is pulling




6.2.13.3 Push-Overs

Figure 6-37 Push-over

With the push-over method, the pipe is completely removed from the reel and then lowered down the grade.

• First deploy the pipe on a level surface with no pipe hanging over the top of the hill. • External pull heads are installed on both the downhill end and uphill end of the pipe before proceeding

down the grade. The downhill end of the pipe is the end of the pipe that is lowered down the grade. The uphill end of the pipe is the end that remains higher on the grade.

• Attach a winch line or equivalent equipment to the downhill-end pull head to guide pipe down the hill. • Prior to putting tension on the winch or pulling equipment, connect the uphill-end pull head to a tension

monitor and anchor it to a piece of equipment. This anchor provides back tension on the pipe to keep it from sliding down the hill.

• During operations, the winch operator will maintain radio or equivalent communication. As the winch operator starts to pull the pipe down the hill, the operator of the anchoring equipment moves forward with the pipe while maintaining tension on the pipe.

• If a connection has to be made, support the weight of the pipe with a separate piece of equipment or proper anchor while the technician removes the pull head and prepares pipe for connection.

• After the connection has been completed, install a pull head on the uphill side of the new section and anchor it to the equipment to prevent the pipe from sliding down the hill.

• After the push-over has been completed, the pipe must be anchored at all times. For example, a good portion of the pipe can be buried with backfill. Make sure pipe is securely anchored before releasing any tie-downs.




• To prevent free-spooling, never position the pipe downgrade of the reel.

• The deployment trailer is not designed to deploy pipe down a steep grade, as the trailer brakes will not prevent free-spooling.

• A second piece of equipment might be necessary to handle the initial push weight or to hold the weight after the break-over begins.

6.2.14 Desert

Special precautions must be taken when installing pipe in hot, dry, desert areas where temperatures rise during the day and drop substantially at night. Even though FlexSteel pipe is durable enough to be used in a surface installation, burying the pipe will help protect it from wide temperature ranges that could affect the fluid inside. If the pipe is to remain on the surface, the white pipe is recommended as it has a higher level of UV protection. At road crossings, the pipe should be at least 3 feet under the surface.

Tracked equipment is preferred because of its greater surface area of contact to the ground. If using equipment with tires, lessen the air pressure to soften the tire, creating a larger surface area with the tire. Do not deflate tires to an unsafe level.

Machinery and fittings require special care to protect them from sand and heat:

• Cap and plug hoses to prevent sand from entering. • Use lubricants and HPU fluids specially designed for hot weather. • Vent ports of fittings must either be plugged or have a venting system installed to keep sand out of pipe

annulus.

6.2.15 Padding and Backfilling

FlexSteel pipe has no special bedding requirements. Similar to PE pipes, the areas in contact with the pipe should be free of large, sharp rocks or protrusions. Crossings under roadways are typically pulled into a carrier pipe. The bottom of the trench should be prepared with a thin layer of soil or sand in rough or rocky conditions. Always assure proper shading methods are being used. Contact a FlexSteel representative with concerns regarding specific applications.

6.2.16 8-inch Pipe Considerations

The 8-inch pipe requires some special handling and mechanical assistance.

This pipe is secured to the reels with two sets of tie-downs (a cable and a rope). Remove the cable first before detaching the rope, and maintain control of the pipe end at all times by securing it with a strap to a piece of equipment. Remove the break pad off the driver’s side of the deployment trailer to keep it from getting damaged.

Follow basic safety precautions for desert conditions:

• Use appropriate sun protection and PPE. • Stay adequately hydrated. • Watch for signs of heat stroke and heat exhaustion.




Figure 6-38 FlexSteel 8-inch Pipe Reel, showing outboard tie-down and clamshell

The heavy weight of the pipe might cause the Respooler to require extra pulling assistance when respooling 8-inch pipe. The fittings for 8-inch pipe fittings weigh more than 100 lbs. (45.4 kg) and require mechanical assistance for handling.

Additionally, the 8-inch pipe is normally shipped on 13.5 ft reels that are equipped with detachable flange sections. FlexSteel’s standard 12 ft reels are not equipped to prevent the 8-inch pipe from exceeding the minimum bend radius (i.e., preventing the pipe from bending below the MBR value) (MBR). However, if the 12 ft reels must be used to load 8-inch pipe and higher pressure rated 6-inch pipe, these reels are fitted with wooden clam shells to expand the drum circumference as illustrated in Figure 6-38. Refer to section 4.1 Reels for more information on reel shipping.

The following equipment is used with 8-inch pipe:

• MSM-3000 Swage Machine performs the swage process on the 8-inch fittings. See section 6.1.3 Swage Machines and Hydraulic Power Unit.

• Deckhand® allows for hands-free manipulation of the pipe. See section 6.1.2.5 Deckhand®.

6.2.17 Fitting Compatibility

The proper selection of fittings for FlexSteel pipe installation is essential for maintaining the integrity of the pipe structure and sealing the inner and outer extruded layers. The fitting material is typically selected based on fluid compatibility and corrosion issues. Each type of fitting has a function and purpose depending on the type of application. Improper selection of fitting could lead to damage to fitting and potential leak. For best performance against corrosion, FlexSteel highly recommends the installation of stainless steel fittings.

Carbon steel fittings require cathodic protection if in contact with the ground in standalone installations. If FlexSteel pipe is tied into a steel pipeline, then cathodic protection may be provided by the cathodic protection system used for the existing steel line. If using exothermic welding (e.g. CADWeld) to weld anode lead wires to the fittings, refer to TN 162 Exothermic Welding of Anode Lead Wires to Fittings for proper welding location. Refer to section 3.3 Fitting Configuration and Materials for more information about the different types of fittings and materials used.

Some fittings are manufactured for welding applications. It is not recommended to weld stainless steel to carbon steel due to various issues; it is possible, although difficult, to get a proper weld that meets structural requirements.




For connecting a stainless steel flange to a carbon steel flange, an isolation kit is recommended to prevent galvanic corrosion.

• Welding of end fittings should be done by a welder certified for the appropriate carbon steel or stainless steel alloy and appropriate non-destructive tests should be conducted.

• The use of chill rings or similar method is important during each weld cycle to direct heat away from the sealing section of the fitting. Excessive heat during welding can allow the plastic to creep within the end fitting, and may compromise the compression developed during the swaging process.

6.3 INSTALLATION METHODS

6.3.1 Surface Lines

FlexSteel pipe is often used as an alternative for temporary or permanent surface pipelines. This method allows quick and easy installation, and the pipe can be respooled for reuse on a new project.

Several advantages from using FlexSteel pipe as solution for surface lines include the following:

• Efficient reel-to-ground installation cuts labor, equipment, and cost; • Environmentally friendly with reduced emission completions; • Ideal for temporary applications, such as well testing and frac water transport; • Impervious to the elements for use in permanent surface lines;

Figure 6-39 Surface Line

6.3.1.1 Surface Lines on Support System

Surface lines can be suspended above ground for the following reasons:

• To run the pipe above or below other pipes in a pipeline system;




• To minimize disturbance during a high-water event; • To protect wetlands, marsh, and other environments where buried pipe is not permitted; • To allow for easy inspection.

Installation Considerations:

• Proper support distance is determined by diameter and pressure rating. • For lines that experience vibration, protect the outer shield with a protective material, such as neoprene,

between the pipe and the support. • FlexSteel pipe may be secured to the supports with neoprene coated U-bolts. Do not use steel clamps in

contact with the pipe. Vibration or movement can damage the outer shield. • FlexSteel Pipe may be strapped to existing steel pipelines with plastic strapping or neoprene-coated steel

banding. Do not install bolts, strapping, or banding tight enough to damage the pipe. • Depending on the height and type of support, FlexSteel pipe is generally deployed alongside the supports

on the ground and then lifted into place. • After installation, inspect the supports periodically for corrosion or degradation.

Figure 6-40 Surface Lines on a Support System

6.3.2 Trenching

Trenching is an installation method in which the pipe is laid into a trench and buried. FlexSteel pipe is typically installed by deploying the pipe from the reel as the reel is moved along the pipe route. The pipe can be pulled directly into the trench from the reel or laid beside the trench and then lowered into position using appropriate equipment. Typically, no bedding is required with FlexSteel pipe unless in areas with jagged, sharp rocks. In such cases, the pipe should be padded with soil, sandbags, or fine gravel prior to using rough fill. Always verify that proper shading methods are being used.

FlexSteel features several advantages as solution for trenching:

• Deploys quickly and easily from a reel, greatly reducing manpower and equipment needs; • Installs directly in rough terrain with no special handling or bedding materials needed.

Refer to section 6.2.10 Excavation Requirements for safety precautions during trenching operations.




Figure 6-41 Trenching

6.3.3 Plowing

Plowing is a method of installation that uses a plow to cut a furrow and lay FlexSteel pipe simultaneously. Compared to trenching, plowing reduces or eliminates heavy equipment and associated labor requirements for dirt work, and it minimizes land disruption.

This method is best suited to the following conditions:

• Flat terrain; • Open areas without pipe crossings; • Soft ground (deep soil or sand).


• Before use, always inspect the chute for obstructions that could kink or cut the pipe. • Always use roller guides to direct pipe over the equipment pulling the plow to prevent damage to the pipe. • Feed the pipe over the top into the plow chute. • Do not use a plow chute that would allow the pipe to bend below the minimum bend radius (MBR). • FlexSteel recommends laying down the full length of pipe before plowing to avoid torqueing issues. • Avoid sharp turns if possible, especially sharp right angles with the trailer attached. • Pipe should be installed with low-profile end fittings and midline connections, as wider fittings have

clearance issues with the plowing tool. • Pre-rip rough ground to avoid overworking the plow. • Some trenching operations may be necessary. Digging a full trench is common when the operation crosses

existing pipe lines and cables or the pipe terminates. • A deployment trailer is recommended to keep up with the plow. Multiple deployment trailers may be

necessary if the installation is far away from the staging location/laydown yard or if deploying multiple lines.




Figure 6-42 Plowing

6.3.4 Pipeline Rehabilitation

When the deterioration of an existing pipeline makes repair not feasible, FlexSteel offers a valuable solution to pipeline rehabilitation. FlexSteel pipe’s durability, broad range of applications and ease in pulling through carrier pipe makes it a cost effective option to extend the service life of existing pipelines.

Advantages include:

• Cost-effective solution to aging and corroding pipeline;

• No need to decommission or remove existing pipelines;

• Can prevent permanent shut-down and abandonment of failed pipelines located in environmentally sensitive areas;

• Fast, non-invasive method of restoring the pipeline;

• Inherent pressure-retaining capability does not depend on the structural integrity of the carrier pipe;

• Continues to perform to original specifications with no need for de-rating over time;

• Multiple FlexSteel lines can be pulled through large diameter pipelines.


• FlexSteel recommends having a pipeline map or survey available during the rehabilitation process for planning purposes.

• The installation contractor must consider the bends in the existing pipe (such as sags, over bends, and Points of Intersections (PIs)) when calculating friction and pulling tensions.

• Before installation, run a sizing pig through the pipe to be rehabilitated to make sure it is clear of any obstructions that could damage the FlexSteel pipe.

• After pigging the line, run an internal pull head or Weldneck fitting attached to a sample section of pipe to verify that the line has no restrictions.

• Make sure the fittings of the existing pipe will allow the pull head to pass through the pipe. For example, if a 3-inch pipe is being run through a 4-inch pipe and the existing pipe does not have 3R fittings (the bend radius is 3x




the diameter of the pipe), the fittings will need to be cut out in order to allow the pull head to pass through the pipe.

• Grind and smooth the edges of the face of the steel pipe from the inside out to prevent damage to the outer shield of the FlexSteel pipe.

• Insert the FlexSteel pipe into the steel pipe slowly and as straight as possible.

• During the pull process, use a lubricant such as canola oil or equivalent at the opening of the pipe to facilitate the process and decrease friction.

• Take extra precautions to monitor pipe tension, as dynamometers cannot give an accurate measurement while the end of the pipe is inside the carrier pipe.

• Monitor the power winch unit gauges to determine the pull pressure applied when pulling the pipe. Note that these gauges do not directly reflect the tension on the pipe, but it is a good indication of the conditions inside of the pipe being rehabilitated.

• Install a leak seal over the end of the carrier pipe to keep the pipe free of water and mud. Use worm gear clamps to anchor the leak seal to the carrier pipe and FlexSteel pipe.

• Install the end fitting.

Figure 6-43 Pipeline Rehabilitation (RTJ Flange is by Special Order)

6.3.5 Horizontal Directional Drilling

Horizontal directional drilling is the method of installing pipe below ground where above ground installations are not viable, such as road and river crossings or installations in environmentally sensitive areas where absolutely no above-ground disturbance is tolerated. FlexSteel pipe offers exceptional strength that enables long pulls and a tough outer shield that resists damage.

6.3.5.1 Installation Operation

• Drill a pilot hole using a steerable drill head. • Retrieve the drill head from a receiving pit at the end of the run. • Replace the drill head with a reamer and attach the FlexSteel pipe with an external pull head.




• Pull the reamer back through the pilot hole to bore out the diameter of the hole and draw the pipe into position.

6.3.5.2 Installation Considerations

• Always verify that the reamer is in good condition and swivels easily before use. • Lubricant can be pumped through the drill pipe to the pull head. • Weldneck end fittings or pull heads are recommended for pulling pipe during directional drilling installations.

External pull heads are recommended for boring applications, while internal pull heads are recommended for pipeline rehabilitation.

Weldnecks are recommended for pulls over 1,000 ft (300 m) or pulls at temperatures below freezing. Use spray foam to seal the gaps between the pull head and the pipe.

• Extra precautions must be taken to monitor pipe tension during the boring phase of the operation: Dynamometers cannot give an accurate measurement while the end of the pipe is underground. When the pull head is visible, stop the rig and attach the dynamometer to get an accurate reading. Monitor the boring rig gauge to determine how hard the rig is working to pull the pipe. Note that this

gauge does not directly reflect pipe tension, but it is a good indication of what the hole is like. Calculations to determine the maximum expected tension must be performed before the boring

operation taking into account possible factors, such as environment, length of pull, and friction, among others.

• The suction in a bore hole can over-tension a pipe. A hydro test and annulus test can be performed on the section of pipe to determine if the bore is 100%. Pull the pipe with minimal stoppage to prevent possible collapse of the pipe or issues with suction in

the hole.

Figure 6-44 Directional Drilling




6.3.6 Shallow Water

FlexSteel pipe is suitable for lakes, marshes, coastal, and other shallow water applications. Its unique design resists corrosion and its high specific gravity simplifies submerged installations.

6.3.6.1 Installation Considerations

The following considerations must be addressed prior to deployment:

• Water Depth – Refer to the Pipe Specification Sheet for the maximum allowable depth of FlexSteel pipe. • Seabed Conditions and Profile – Be aware of the possibility of the pipe becoming stuck in muddy or

marsh environments. The pipe can become damaged if too much force is applied attempting to move it. • On-bottom Stability

FlexSteel’s Marine Grade product line is designed to be negatively buoyant. However, often the pipe requires on-bottom stabilization such as pipe burial or anchoring.

On-bottom stability analysis on submerged pipe in open waters must be conducted to determine that the pipe does not move under the applied environmental loads.

FlexSteel pipe is more tolerant of bending and spanning stresses than rigid pipe, so absolute stability is not necessarily required. For example, some criteria would be to require stability under one year storm conditions, while allowing some movement under 10-year or 100-year storm conditions.

FlexSteel pipe can also be restrained with concrete mattresses or buried to assure the pipe does not move.

If FlexSteel pipe is enclosed in a carrier pipe, floatation and on-bottom stability are not issues. • Contingency Plans for Abandonment and Retrieval provided by the installation contractor or the pipeline

operator.

6.3.6.2 Deployment

• Mobile equipment used to deploy FlexSteel pipe in shallow water installations includes airboats, installation vessels, floating roller systems, or winches to pull the pipe. Certified Installation Technicians ensure that all necessary equipment and tooling is available prior to leaving the dock.

• Use proper lifting equipment and techniques to avoid pulling pipe too high or lifting from a single point without support.

• Do not exceed the tension limit of the pipe or allow the pipe to bend below the Minimum Bend Radius (MBR).

• The use of guide or containment rollers is recommended. Ensure the pipe avoids contact with sharp edges. • Maintain a safe distance between the pipe and the vessel’s propellers.

• Securely tie the pipe to the vessel. • Maintain 3-point contact when ascending or descending. • Be aware of surroundings and traffic of boats and barges on the

water. • Assure the safety of personnel getting on and off the boat or

barge. • Use fall protection (with personal floatation device) within six feet

from of the edge. • Avoid walking along the unguarded edge of the barge.




For offshore applications, contact a FlexSteel representative for additional documentation.

Figure 6-45 Shallow Water Installation

6.4 FITTING INSTALLATION

After the pipe is in position, fittings are installed. This section outlines the major elements of the fitting installation procedure and recommendations that, when followed, ensures that the quality and integrity of the FlexSteel pipe is maintained.

6.4.1 Overview of the Process

A fitting is positioned on the pipe end and swaged to provide a tight connection between the fitting and the pipe wall. The FlexSteel Midline Swage Machines (MSM) are equipped with proper tooling and grab adapters, depending on pipe size. After the fitting has been swaged onto the pipe, the pipe is ready for connection to the other pipe or facility terminals by the end user’s installation contractor.

6.4.2 Fitting Preparation

Prior to installation, the fitting is cleaned of debris and inspected for damage that could compromise a proper seal (e.g., corrosion, damage to fitting jacket that cannot be re-rounded during the swaging process, etc.). Also, a magnet test is performed to verify the material of the fitting as either stainless steel (SS) or carbon steel (CS). The fitting is then checked to ensure that a Venting Assurance Ring (VAR) has been properly installed and secured into position.

6.4.3 Pipe Preparation

Prior to installing the fitting, the end of the pipe is laid out and visually inspected. For best results, position each reel so that the beginning of each pipe faces the end of the previous pipe, creating an “S” bend. Place the pipe in a straight approach to insert it into the swage machine while maintaining the roundness of the pipe end to properly accept the fitting. For more information, refer to the Deployment Method section of this manual.

After a fresh cut is made at the end of the pipe, the pipe is deburred, cleaned and continuity wires installed. For more information on preparing the pipe, refer to the Operating Procedures for the specific procedure:

• FLD-P-9901 – 2 Inch to 6 Inch Midline/EF Fitting Installation • FLD-P-9907 – 8 inch Midline/EF Fitting Installation




6.4.4 Swage Machine Setup and Tooling

The external sleeve (ferrule or jacket) of the fitting is swaged down to develop the clamping force and fluid seal that ensures performance over the life of the pipeline. Fittings are installed using the midline swage machine. For operation and maintenance of the equipment and tooling, reference the 8018-MSM Operation and Maintenance Manual (Document #TR038) or the MSM-3000 Operation and Maintenance Manual (Document #TR043).

6.4.5 Documentation Requirements

• Fitting Inspection Logs (one per fitting) that certifies that installation was performed in accordance with the procedure is completed and either emailed or faxed to FlexSteel Pipeline Technologies, Inc. within 48 hours following installation. This is a necessary step to maintain certification.

• FlexSteel Installation Technicians are also required to submit the following: Daily Field Ticket (DFT) and Daily Updates DOT Driver’s Daily Log

• Submission of documentation to FlexSteel is by email to [email protected] or by fax to (206) 350-3901.

6.4.6 Venting System

6.4.6.1 Purpose of a Venting System

In FlexSteel pipeline systems, the conveyed fluid is sealed within the pipe bore by the inner liner. The polyethylene liner is nearly hermetic, but a small amount of gases may permeate through. These permeated gases accumulate between the inner liner and the outer shield in the pipe annulus and must be vented. A venting system conveys the gasses through the annulus of the pipe to the end fitting and out of the pipe to prevent excessive pressure build-up.

Figure 6-46 Illustration of Permeated Gas Venting

6.4.6.2 Venting Considerations

End fittings require the installation of a venting system. In midline connections, a vent path is integrated inside the fitting itself and facilitated by the Vent Assurance Ring, which allows permeated gases to continue downstream, while end fittings contain an 1/8-inch NPT threaded hole for venting purposes. The configuration for the venting system depends on the type of end fitting arrangement and whether is it buried or on the surface.

Every fitting must be vented. To ensure proper venting and to avoid fluid entering the system:

• Install vent valves in every venting system. • Make sure all vent valves (one way flow valves) or vent hoses connected at the end of the vent line are

angled downwards toward the ground.

When connecting venting system components, it is highly recommended to avoid using metals other than carbon steel or stainless steel.




6.4.6.3 Venting System Configurations

• Onshore Surface Installation Vent valve can be connected directly into the fitting (preferable on high dry ground) Vent hose can be connected directly into the fitting and transition up a post then connected to a vent

valve • Onshore Buried Installation

Configurations vary in the length and number of hoses used when installing the vent line to the surface, where the end of the vent line can be wrapped around a riser or post. There are two main types of configurations for a single line, with a third configuration recommended for multiple lines installed side by side:

Connect the 90 degree adapter directly to the fitting, then connect the vent hose, followed by the vent hose adapter (JIC to NPT), and at the end connect the vent valve at the surface angled downward towards the ground.

Connect the vent valve directly to the fitting, then connect the vent hose adapter (JIC to NPT), followed by the vent hose at surface angled downward towards the ground.

If the application includes multiple lines installed side by side, it is recommended to connect a vent valve into each fitting, then connect the vent hose adapter (JIC to NPT), followed by the vent hose connected to tees between each fitting, and then connect to one hose that will be transitioned up to the surface angled downward towards the ground. Wrap the vent hoses with corrosion resistant pipeline tape to fitting to prevent grounding.

• Offshore Installation Generally, the vent valve is connected directly into the fitting. If risers are available, the vent hose can be connected directly to the fitting, transitioned up to the riser

and the vent valve is connected at the end of the line to allow better venting and limit risk of sand/ debris build up that can block the vent valve.

Figure 6-47 Onshore Vent Valve (left) and Offshore Vent Valve (right)




6.4.6.4 Venting System and Adapters

The following connections and adapters are installed in FlexSteel fittings as part of the venting system.

Table 3 – Venting Connections and Adapters

NAME SPECIFICS

Stainless Steel Vent Plug (NPT)

• Installed directly to the end fitting • For 2-, 3-, and 4-inch end fittings, if vent port is

located on the jacket of the fitting, the plugs must be installed prior to swaging

• Used for plugging the fitting and preventing thread damage during swaging process

90 Degree Adapter (JIC to NPT)

• The 1/8-inch NPT thread can be connected directly to the end fitting and the 1/4-inch male JIC thread can be connected to the standard length hose

• Used for positioning the hose at a better angle

Hose Adapter (JIC to NPT)

• Connected to hose and vent valves • Used for connecting from JIC thread to NPT

thread

JIC to JIC Adapter

• Connected to the standard length hoses • Used for connecting two sections of hoses




Venting Hose (JIC) or Tubing (NPT)

• Can be connected to different adapters to run venting lines up to the surface

• Venting hose Made of braided stainless steel with poly liner Has 1/4-inch JIC female thread on both ends Used in the standard lengths of 30 in and 48 in

• Venting tubing Made of stainless steel Has 1/8-inch NPT male thread on one end and

1/8-inch NPT female thread on the other end that connects to the vent valve

Stainless Steel Vent Tee (JIC)

• Connected to venting hose/tubing • Used for connecting hoses to integrate several

end fittings

Relief Valve for Offshore Applications (NPT)

• Made of stainless steel, inside and outside • Has screen to protect it from the environment • Can be connected directly to the stainless steel

or carbon steel end fitting • Used in subsea/marshy conditions • Used for controlling one-way flow of fluids • When installing, the arrow of the valve must

always point outward to make sure the flow follows the direction of the arrow

• Has 1/8-inch NPT male thread on one end • Cracking Pressure (Opening Pressure) is 30

psig

Check Valve for Onshore Applications (NPT)

• Stainless steel on the outside only • Can be installed directly to above ground

stainless steel or carbon steel end fittings, or underground if connecting more than one end fitting to be vented

• If required, a line can be connected from the fitting up the riser to the surface and then the vent valve will be installed on the end of the hose

• Used for controlling one-way flow of fluids • When installing, the arrow of the valve must

always point away from the fitting to make sure the flow follows the direction of the arrow

• Has 1/8-inch NPT male thread on both ends • Cracking Pressure (Opening Pressure) is 1 to 3

psig




6.4.7 Annulus Test

Annulus testing verifies that the vent paths are free of blockages and that the outer shield is in good condition.

A suitably qualified person can perform annulus testing, but it is highly recommended that a FlexSteel Installation Technician perform these tests.

A successful test is indicated by no pressure loss in the annulus for the duration of the test. Pressure dropping steadily to 0 psig indicates failure of the test.

The following is a summary of the steps to verify that the annulus of FlexSteel pipe is air-tight.

• Connect a compressed gas supply and pressure gauge to the vent port at one end of the pipe. Plug all other vent ports, if any, on the end fitting.

• Connect a shut-off valve and pressure gauge to the other end of the pipe. Plug any other vent ports, if any, on the end fitting.

• Introduce compressed gas at 20-30 psig and hold. Do not allow pressure to exceed 50 psig during this test. The use of a non-flammable, inert gas such as nitrogen is highly recommended. Do not introduce

compressed air unless using an air dryer to remove moisture. • Close the valve at the other end fitting when the compressed gas reaches its recommended pressure. • Close the regulator valve when 15-10 psig is registered at the other end. • Wait 15 to 30 minutes to allow the pressure to stabilize at both ends of the pipe. • Measure the drop in pressure, if any, after 15 to 30 minutes. • Record shut-in pressure and rate of pressure drop.

6.4.8 Fitting Wrapping Recommendations

Although FlexSteel manufactures fittings in stainless steel and carbon steel, the majority of the Lapped Flanges have a carbon steel swivel which is subject to corrosion over time. FlexSteel recommends that all carbon steel fittings be wrapped with a corrosion resistant pipeline tape application. However, for subterraneous applications, FlexSteel recommends that all fittings, whether carbon steel or stainless steel, are wrapped with a corrosion resistant pipeline tape application.

Figure 6-48 Wrapped Fittings




7 COMMISSIONING FlexSteel pipes are typically commissioned after installation by conditioning the pipes, performing a field hydrostatic test (hydro test), and then pigging to remove residual water. The purpose of the hydro test is to verify the integrity of field installed fittings and assure there is no damage to the pipe introduced during the installation process.

During hydro testing, FlexSteel pipe behaves differently than rigid steel pipes. Upon initial pressurization, the unbonded layers in FlexSteel pipe undergo a stabilization process called conditioning. After conditioning, the pipe is held at the test pressure for a period of time. A rapid drop in pressure indicates that the pipe may have a structural defect. The test is considered successful if the pressure does not drop below the minimum allowable value over the hold period. Upon successful completion of the test, the pipe is depressurized and ready to be put into service.

Every reel of FlexSteel pipe is hydro tested by a factory strength test at 1.3 times design pressure for an 8-hour period to verify the structural integrity of the pipe prior to leaving the facility. After installation, the pipe is again hydro tested during commissioning the pipeline.

7.1 END TERMINATION VENTING CONSIDERATIONS

For onshore applications, all vent valves are removed for conditioning and testing; Removing these vent valves assures that there is nothing in the vent port during the hydro test. After the pipe has passed the hydro test, the venting system is installed. For shallow water and offshore applications, all offshore vent valves are installed in the vents ports of the fittings before conditioning and hydro testing.

7.2 CONDITIONING AND STABILIZATION

When FlexSteel pipe is initially pressurized, the internal volume slightly increases as the inner lining expands. This effect, referred to as conditioning, does not occur at a constant rate. Instead, the volume initially increases relatively quickly and then gradually slows down with time until the pipe reaches its final, conditioned volume. As the volume increases during conditioning, the internal pressure drops.

Conditioning is necessary to ensure that the results of the hydro test are not misinterpreted. FlexSteel recommends conditioning the pipe overnight and conducting the hydro tests the following morning.

At no time during conditioning should the pipe pressure be allowed to exceed maximum hydro test pressure. Pressurize FlexSteel pipe up to or slightly below the nominal hydro test pressure or below the maximum allowed pressurization rate.

To condition the pipe:

1. Close the valves and pressurize the pipe. Monitor the pressure drop at least every 15 minutes for at least one hour. Refer to section 7.3.2 Pressurization/Depressurization Rates.

2. Re-pressurize to near nominal and shut-in the pipe in again. 3. Monitor the pressure drop for one hour and compare the findings to the readings of the previous hour. If the

pressure drop is less than that of the previous hour, the pipe is expanding rather than leaking. 4. If the rate of pressure drop does not taper off:

• Test for two additional cycles to verify that the pressure drop is not an isolated incident. • If the rate of pressure drop remains constant or increases, check the fittings for leaks. • If no leaks are found in the fittings, check the pipe’s outer shield for leaks. A leak in the pipe is rare but

could result from a faulty fitting or fitting installation. Check the vent ports located in the fittings for water. Small amounts of water might come from existing condensation in the pipe.




A steady flow of water indicates a leak. Check any other vented areas for water before depressurizing the pipeline to help determine the most likely direction of the leak. See section 10.1 Leak Detection for more information.

5. Repeat the previous steps 1-4 to cycle the pipe several times to near nominal pressure. Each cycle should last for one hour.

6. When the results have shown diminishing pressure drops for each cycle, the hydro test can begin.

7.3 FIELD HYDRO TEST

A field hydrostatic test is also called a hydro test or field acceptance test. It demonstrates that the pipe is leak tight and verifies the strength of the pipe by subjecting it to loads more severe than any it will encounter in service.

The hydro test is best performed with as much of the pipe system exposed, but at a minimum, the fittings should be accessible. For example, if a pipe is hydro tested before it is buried, the pipe and fittings can still be examined to locate any leakage. However, if testing cannot be performed prior to below ground installation, the pipe can still be hydro tested below ground.

Pipeline systems are filled with water to conduct a hydro test during the commissioning process. During the pipeline system design phase, methods to fill and dewater the system are normally provided by the pipeline operator or an independent contractor not involved in the pipeline installation. The following are examples of methods that might be used:

• The pipe can be filled directly before tie-in to the system, especially in pulled in applications. • Fill heads can be installed to provide a direct interface to fill hoses and pumps. Fill heads are fabricated by

drilling and tapping a fill hole in a blind flange, or in a steel plate if the fill head is not required to withstand hydro test pressures. This method is favorable when the flowrates needed to efficiently fill the pipe are much larger than can be reasonably accommodated by the very small ports in most pressure heads.

• A pig can be run through the pipe in front of the liquid to remove air along the line.

The pipeline operator or end user shall consult applicable design codes to determine the test period. This period is often 8-24 hours.

7.3.1 Pressure Guidelines

The hydro test is conducted in three parts.

• Leak Test – the pipe is tested to 1.1 times the design pressure. • Structural Maintenance Test – the pipe is tested to 1.25 times the design pressure. • Maximum Hydrostatic Pressure Test – the pipe is tested to 1.5 times the design pressure.




The following table displays the different pipes manufactured by FlexSteel with their corresponding hydrostatic test values.

Table 4 – Hydro Test Pressure Values

PIPE SIZE (INCH)

DESIGN PRESSURE (PSI)

LEAK TEST (1.1 X DESIGN PRESSURE)

STRUCTURAL MAINTENANCE TEST (1.25 X DESIGN PRESSURE)

MAXIMUM HYDROSTATIC PRESSURE (1.5 X DESIGN PRESSURE)

2

1500 1650 1875 2250

2250 2475 2813 3375

3

1000 1100 1250 1500

1500 1650 1875 2250

2250 2475 2813 3375

3000 3300 3750 4500

4

750 825 938 1125

1000 1100 1250 1500

1500 1650 1875 2250

2250 2475 2813 3375

3000 3300 3750 4500

6

750 825 938 1125

1500 1650 1875 2250

8 1000 1100 1250 1500

1500 1650 1875 2250

• Due to the high pressures created during the hydro test, it is recommended that personnel be at least 100 feet away from the pipe and test equipment during any pressure test.

• Other equipment might be the limiting factor for hydro test pressures. It is recommended that the personnel performing the test verify all other maximum equipment pressures and perform hydro test to the limiting pressure capacity.

• A field test should never exceed 1.5 times the design pressure.




The following table describes the internal volumes per foot of FlexSteel Pipe.

Table 5 – Internal Volume per Foot of Pipe

PIPE SIZE NOMINAL ID GALLONS PER FOOT OF PIPE

LITERS PER METER OF PIPE

2-inch Pipe 1.94 in. (49.25 mm)

0.153 gal./ft. 1.905 L/m

3-inch Pipe 2.82 in. (71.65 mm)

0.325 gal./ft. 4.032 L/m

4-inch Pipe 3.67 in. (93.19 mm)

0.549 gal./ft. 6.821 L/m

6-inch Pipe 5.60 in. (142.34 mm)

1.281 gal./ft. 15.913 L/m

8-inch Pipe 7.63 in. (193.68 mm)

2.372 gal./ft. 29.460 L/m

7.3.2 Pressurization/Depressurization Rates

API 17B 11.5.3.3 and 11.5.3.6 recommend the following typical pressurization and depressurization rates for the hydro test:

• Maximum pressurization rate of 45 psi/min (3 bar/min) • Maximum depressurization rate of 260 psi/min (18 bar/min)

FlexSteel pipe is rated at up to 145 psi/min (10 bar/min) for pressurization and 290 psi/min (20 bar/min) for depressurization, based on extensive in-house hydro test experience. For temperatures above ambient, especially in environments that include CO2, depressurizations under operating conditions are best limited as noted in the FlexSteel Technical Manual (Document #TR 004).

FlexSteel recommends filling the pipe in 250 pound increments and waiting 5 minutes between each increment until the test pressure is reached.

7.4 PIGGING

Pigging is used in several applications, including pipeline rehabilitations, field hydrostatic tests (hydro tests), leak detections and when decommissioning FlexSteel pipe. Pigging is performed to clear obstructions that could damage FlexSteel pipe, to dewater or clean a line or to prevent air pockets from forming when filling a line with water. There are several types of pigs, but the ones most commonly used with FlexSteel pipe are foam pigs and solid cast pigs. Pigs made of metal, sizing pigs, gauging pigs, or squeegee can damage the polyethylene liner of FlexSteel pipe and must not be used. For more information on pigging, refer to section 9.2.1.2 Pigging.




8 FLEXSTEEL PIPE OPERATION Flexsteel Pipeline Technologies, Inc. offers a wide array of pipe options with varying diameters and pressure ratings. In order for a pipeline to deliver many years of efficient, maintenance-free service, the end user will select the pipe while considering many factors of the project, including the environment and the product being conveyed in the pipe. The following section outlines different capabilities, compatibilities, and considerations for FlexSteel pipe selection.

8.1 PIPE CAPABILITIES

The following ratings are listed on the Pipe Specification Sheet. Refer to the FlexSteel Technical Manual (Document #TR 004) for more information. If the operating design parameters are exceeded, contact a FlexSteel representative as soon as possible. Any failure to report the operating parameters to FlexSteel may affect the terms of the pipe warranty.

• Temperature rating Contact a FlexSteel representative to verify the need for any temperature rating adjustments for the

pipe. Avoid external heat sources (e.g., open flame, welding, etc.) directly to the pipe. When welding fittings, use chill rings to direct heat away from the sealing section of the fitting. Do not place the pipe in contact with elevated temperature piping, heaters, exhausts, etc. Do not exceed the maximum operating temperatures during normal service. Cool down rates for FlexSteel pipe must be limited to a rate and distribution pattern that keeps thermal

stresses within the design limits. When FlexSteel pipe is flushed with seawater or other liquids that have a substantial temperature

differential from the transported product, allow the transported product to cool naturally in a static or reduced flow condition to a maximum of 40-degreesC before introducing a cooler flushing medium into the flexible system.

Pressure and temperature cycles can vary an unlimited amount of times as long as they are within the design range.

• Pressure rating Assure that the maximum steady state operating pressure and static head pressure with the line in

static condition do not exceed the internal design pressure. Assure that the level of pressure rise due to surges and other variations from normal operation does

not exceed the internal design pressure. The pipeline operator or end user is responsible for assuring the system is equipped with pressure

regulating devices of adequate capacity and design to meet the pressure, load, and other service conditions under which the system will operate or to which it may be subjected.

8.2 MINIMUM BEND RADIUS

The minimum bend radius (MBR) listed on the Pipe Specification Sheet and on the pipe shield should never be exceeded (i.e., do not bend below the MBR value). The MBR is sometimes referred to as the Storage Bend Radius (SBR).

The steel reinforcements are free to move in the unbonded pipe but are fixed in the fittings, making the pipe stiffer near the fitting and subjecting the steel strips to great stress if the pipe bends too close to the fittings. At each fitting




juncture, deploy the pipe in a straight line for at least the length of 5 times the pipe outside diameter (OD) before bending.

8.3 CHEMICAL COMPATABILITY

All materials used in FlexSteel pipe construction are reviewed to determine that:

• They are compatible with permeated gases and liquids at design temperatures. • Decomposition of these materials does not create by-products harmful to thermoplastic layers of the pipe. • All lubricants and corrosion protection coatings used in the manufacture of the pipe are compatible with the

thermoplastic pressure-sealing materials in the pipe.

This section provides an overview of the compatibility of various chemicals with the PE and steel used in the construction of FlexSteel pipe.

8.3.1 Conveyed Product Compatibility with PE

The resistance of the inner lining to the effects of the conveyed fluid over the design life is a primary concern in determining if FlexSteel pipe is suitable for a specific application.

Fluid compatibility details including compatibility charts are described in the FlexSteel Technical Manual (Document #TR 004). Consult a FlexSteel representative for assistance regarding fluid compatibility.

8.3.1.1 Hydrocarbons

For flexible steel pipes, the major issues with fluid compatibility are:

• Swelling is caused by chemical similarity between the solvent and the PE. • Blistering is caused by the plasticization effects of the solvents and the reduction in modulus caused by

increased temperature coupled with the action of dissolved gases in the matrix during rapid depressurization cycles.

The PE temperature capability is reduced by:

• High fractions of gas condensates and light crude, specifically concentrations of hexane, cyclohexane, heptane, and the benzene, toluene, ethyl benzene, and xylene aromatics. These components couple high solubility in PE with molecule sizes small enough to diffuse easily into the polymer and large enough to affect the properties. Thus, they plasticize the PE, reducing the resistance to blistering.

• High partial pressure of CO2 in the bore, and large numbers of rapid decompression cycles.

8.3.1.2 Fluids Other Than Hydrocarbons

Other fluids have the following considerations:

• Polar molecules, such as those with OH radicals including water, alcohols, and bases, typically have little or no effect on the liner.

• Most biocides, dyes, corrosion inhibitors, and oxygen scavengers in concentrations typical of hydrocarbon, water, and gas injection service have little or no effect on the liner.

• Very strong acids can attack the liner, and the damage is more severe at higher temperatures. The low concentrations and durations of acid exposure typical of oil production are not detrimental to PE, but avoid long-term exposure to highly concentrated acids.

• Carbon dioxide (CO2) does not chemically affect the liner; however, the molecules are relatively mobile and readily migrate throughout the liner. Blistering can occur when the bore rapidly depressurizes in repeated cycles. For more information, refer to the FlexSteel Technical Manual (Document #TR 004).




8.3.2 Conveyed Product Compatibility with Steel

The steel strip reinforcement in the pipe annulus is protected from the bore fluids by the inner liner. Small quantities of certain molecules can migrate through the PE inner liner into the pipe annulus. The light hydrocarbons do not adversely affect the steel in the pipe annulus, but H2O, H2S, and CO2 permeants can cause issues with typical carbon steels. Refer to the FlexSteel Technical Manual (Document #TR 004) for more information.

This section discusses four corrosion factors: water, pitting, CO2 service, and sour service.

8.3.2.1 Water

Water in the annulus by itself does not cause a corrosion problem. Many years of offshore experience with flexible steel pipe indicates that water in the annulus, even in the presence of ionics, does not result in serious corrosion. Dry gas, or dead crude which has been processed through a separator/dryer facility, will not result in permeated water in the annulus. Produced fluids are considered to contain water, as even small amounts of water in the conveyed fluid will permeate into the annulus.

8.3.2.2 Pitting Corrosion

Pitting is a loss of cross-sectional area and weight of the steel reinforcements, and is generally considered to be the most common type of steel corrosion. Pitting typically occurs as iron or steel form rust (Fe2O3) in the presence of oxygen. This iron oxide has poor physical integrity, and does not effectively protect the underlying base material. As a result, pitting continues as long as oxygen is present and uncorroded iron or steel remains. FlexSteel pipe is designed so that essentially no oxygen is available in the annulus; therefore, the pipe is extremely resistant to pitting corrosion.

8.3.2.3 CO2 Service

Carbon dioxide (CO2) is a common constituent of natural gases and is present in most types of formation fluids. CO2 is relatively mobile in PE and readily migrates into the annulus where the steel strip reinforcements are located. In the presence of water, carbon dioxide dissolves and forms carbonic acid (H2CO3). Carbonic acid reacts to form a thin oxidant film on the surface of the steel. This film partially protects the underlying metal, slowing the rate of corrosion. When the steel is in contact with flowing fluid, such as in a typical steel pipe, this film is continuously removed, exposing fresh metal to attack. Since the annulus environment is relatively protective, this film remains intact. In addition, the carbon dioxide ultimately causes scale production as the carbonic acid reacts with iron in the steel to form a white/gray corrosion product, FeCO3. This iron carbonate scale acts to protect the steel from further corrosion. Between the film and the scale, the corrosion of the steel layers in the annulus resulting from CO2 is minimal.

8.3.2.4 Sour Service

Hydrogen sulfide (H2S) is a toxic and corrosive gas that occurs naturally in some produced fluids. It is formed primarily by the decomposition of organic matter that contained sulfur. In sufficient concentrations, hydrogen sulfide can have a significant corrosive effect on steel. Per NACE International Specification MR0175, sour service is defined as “fluids containing water and hydrogen sulphide (H2S) that is at a total pressure of 0.4MPa (65psia) or greater, and if the partial pressure of hydrogen sulphide in the gas is greater than 0.0003MPa (0.05psia)." Nominally, the fluid is considered sour when there is a concentration of H2S of 50 ppm or more.

MR0175 considers steels with the following criteria to be suitable for sour service:

• A hardness of less than 22 HRC; • A permanent outer fiber deformation from cold working of less than 5%.

Steels that do not meet these criteria are not assured to be resistant to sour service, and must be tested to verify suitability. H2S service is an issue for flexible steel pipes because of its potential negative effect on the steel reinforcements. H2S in the pipe bore diffuses into the annulus.




8.4 CATHODIC PROTECTION

The FlexSteel pipe’s high-density polyethylene (HDPE) outer shield makes the pipe more resistance to corrosion than steel pipe. HDPE is a nearly ideal material for such a protective layer because of its combination of excellent electrical, mechanical and chemical properties.

Cathodic protection is the method of protecting iron or steel from electromagnetic corrosion. For typical onshore applications, cathodic protection of FlexSteel pipe is normally not required. However, cathodic protection (CP) is applied to many flexible steel pipes in subsea service. This prevents corrosion on the low alloy steel fittings in contact with the seawater and any internal structural elements exposed by damage to the external polymer shield.

FlexSteel pipes typically have electrical continuity between the steel strip reinforcements and the fittings provided by continuity wires applied during fitting installation as illustrated in Figure 8-1. The continuous electrical path allows the flow of a signal to facilitate pipe-locating as well as rectifier and anode voltage for CP current through the pipe. These wires can be omitted to provide electrical isolation.

Figure 8-1 Illustration of Continuity Wire Installed

8.5 CHANGE IN SERVICE

From time to time, the material conveyed in the FlexSteel pipe may change in type or composition given production demands or usage by the end user. For example, concentrations of substances like H2S, acids or bases could differ which can affect whether a pipe is suitable for continued use. If the service in which a FlexSteel pipe is used differs from originally specifications, contact a FlexSteel representative with details of the service condition for engineering review and to verify that the change in service will be covered by original warranty.




9 INSPECTION AND MAINTENANCE All pipe and fittings must receive efficient inspection and constant monitoring due to environmental influences, pressure and/or corrosiveness of the material in the pipe, and damage caused by human error. FlexSteel has developed a set of best practices for pipeline integrity to help ensure performance and safety.

9.1 VISUAL INSPECTION

FlexSteel pipe and fittings on surface applications should be inspected on a regular schedule and when any of the following events occur:

• A malfunction or operating error that causes the pressure of the pipe to rise above the specified maximum operating pressure;

• Unintended movement or abnormal loading by environmental causes; • Reported third-party encroachment on the pipeline corridor; • Any abnormal or emergency operating condition which might have subject FlexSteel products to conditions

beyond design limits; • Pipe recovery and installation in an alternate location; • Change in service (refer to section 8.5 Change in Service); • During respooling operations (refer to section 11.2 Respooling).

The pipe system should be inspected for the following:

• Damage to the shield, fittings, and attachments • Fluid coming out of the vent ports • Bulge in the outer shield • Distortion of pipe shape or axial alignment • Distortion of the end fitting shape (e.g., bent neck) • External corrosion of end fittings and connectors • Twisting of the riser or support • Leakage of conveyed fluid • Damage to any pipe attachment (e.g., anodes, bend restrictors, end fittings, engineered or manufactured

bracing) • Changes in environmental loading conditions (e.g., free spanning, increased localized over-burden

conditions) • Loose studs/nuts on easily accessible end connections • Damaged or blocked offshore vent valve screens • Loosely threaded, blocked, or damaged vent tubing (damage can include pinholes)

If anodes are in service as part of a cathodic protection system, the condition of the anodes, continuity cables, and their connections should be inspected at least once a year.

Underwater inspections may be performed by divers or Remotely Operated Vehicles (ROVs).

Any changes from the as-installed conditions should be documented. Documentation should include a full description of the condition such as type, size and location of defects or abnormal conditions as noted, and use of color video or still photography is recommended.




FlexSteel pipe is resistant to impact damage; however, in the event of a severe impact, contact a FlexSteel representative to conduct a pipeline damage analysis and determine possible repairs or if replacement is necessary. Other damage to pipe or fittings should also be referred to FlexSteel for disposition. Normally, the damaged area or fitting is cut out and new fitting(s) installed. See section 10




Troubleshooting and Repairs for more details.

If a shield breach is suspected, it is recommended to perform an annulus test. See section 6.4.7 Annulus Test.

9.2 PIPE MAINTENANCE

9.2.1 Liner

Maintenance of the liner is not normally required. For conveyed fluids with solid particles or paraffinic compounds, the liner can be cleaned occasionally using the following treatments:

• Methanol inhibition • Pigging • Hot oiling

9.2.1.1 Methanol inhibition

Methanol inhibition is the practice of injecting methanol into the pipe system to break down paraffins. It can be done as part of routine maintenance to prevent paraffin build-up as it is compatible with the liner and the stainless steel fittings.

9.2.1.2 Pigging

Pigging is an operation that involves the propulsion of a device known as a “pig” along the internal diameter (ID) of a pipeline to remove deposits, particulate matter and/or air pockets. Pigging is used with FlexSteel™ pipe in several applications. Selecting the appropriate pig for the application where FlexSteel pipe is used is important to ensure pipeline integrity and reduce the potential for damage to the inner liner of FlexSteel pipe

Types of Pigs

There are many types of pigs available, depending on application and type of pipe in which the pigging process is performed. The types of pigs most commonly used with FlexSteel pipe and the advantages and disadvantages of each are provided below. Consult a FlexSteel representative for recommendations in selecting the appropriate pig given use and application

• Foam Pigs (also known as “polly pigs”) are usually made of open-cell polyurethane foam and come in soft, medium and high density options. The outer body may be coated with polyurethane in a solid or crisscross pattern to make the pig stiffer. Foam pigs are typically used for drying the line but can also be used for cleaning, swabbing, liquid removal / de-watering and product separation in pipelines. These are usually the lowest cost pig alternatives but have a tendency of tearing in some application and may not form a tight seal. FlexSteel recommends medium density foam pigs. High density foam pigs can damage FlexSteel pipe. Additionally, if they are manufactured with bristles, only plastic bristles can be used with FlexSteel pipe. Contact a FlexSteel representative before using a pig with bristles.




.

9-1 Foam Pigs

A variation of the foam pig is a bi-directional pig constructed of foam disks between molded elastomer reinforcements. These require specific design considerations based on the ID of the pipe to ensure proper fit. FlexSteel highly recommends the use of these types of pigs in FlexSteel pipe.

9-2 Foam Pig with Elastomer Reinforcements

• Solid Cast pigs are typically made of polyurethane but can also be manufactured with neoprene, nitrile, and other rubber elastomers. They come in a range of sizes and configurations and usually include a series of discs and/or cups. They are highly effective in removing wet gasses, pipeline residue and other fluids due to multiple points of contact with the inner liner of the pipe and generally form a tighter seal versus foam pigs. Soft or medium density solid cast pigs are compatible with FlexSteel pipes but require specific design considerations to ensure proper fit with the ID of the pipe. Additionally, solid cast pigs are not typically bi-directional and may become more easily lodged in the pipe during the pigging process compared to foam pigs. Contact a FlexSteel representative prior to using a solid cast pig.

9-3 Solid Cast Pig




Pigging Considerations

• Pigs made of metal, sizing pigs, gauging pigs, or squeegee pigs should not be used on FlexSteel pipe. • Fittings installed on FlexSteel pipe may reduce the ID for a short section of the pipe where the fitting

interfaces with the pipe. Pigs that are to pass through a section of pipe where a fitting is located should be appropriately sized so as to not become lodged.

• Soft pigs accommodate variations in pipe IDs of the same nominal size. • Custom pigs may be required for specific projects. Consult a FlexSteel representative to assist in pig

selection.

9.2.1.3 Hot oiling

Hot oiling is an annual pipe maintenance technique used to remove wax. It can be accomplished by flowing heated fluid through the pipe at temperatures up to 200°F for up to 4 hours. When hot oiling the pipe, provide special attention to ensure that the pipe pressure limitations are not exceeded.

9.2.2 Shield

Cleaning of the shield is normally not required, but if undertaken, the end user should select cleaning devices that avoid damage to the outer sheath. Do not use wire brushes or other mechanical cleaning devices without prior testing to ensure that the cleaning method does not damage the shield. The shield is highly resistant to most chemicals, but certain highly concentrated fluids can remove markings or cause potential damage to the fittings, seals, or outer shield. Refer to the FlexSteel Technical Manual (Document #TR 004) for PE fluid compatibility information.

Shallow damage to the shield can be covered with appropriate adhesive tape or shrink-wrap material. See section 10





9.2.3 Fittings

Damage to the fitting or fitting connection area should be referred to a FlexSteel representative for disposition. Normally, the damaged area or fitting is cut out and new end fitting(s) installed. See section 100





In cold environments, fittings are often wrapped in insulating tape during installation. Riser portions of the pipe might be covered from the ground to the flange, by tape or insulating half shells.

9.2.4 Maintenance of Pipe after Recovery

FlexSteel Pipeline Technologies, Inc. offers post-recovery inspections on a 60 day call-out basis. Contact a FlexSteel representative for details and terms.

Store FlexSteel pipe on a reel with a drum radius equal to or greater than the minimum bend radius of the pipe specified on the Pipe Specification Sheet.

Store packaged reels in a location where damage to the pipe and reel can be avoided. See section 5.1.6 Reel Storage for more information on storing reels.




10 TROUBLESHOOTING AND REPAIRS FlexSteel pipe is highly durable, corrosion resistant and easy to install with minimum handling. These are advantages over steel pipe and many other spoolable products. However, problems can occur as a result of installation handling, service conditions, or environmental factors.

An indication that there is a problem may be reflected by pressure loss, residue on a fitting, a visible spill, or a bulge in the pipe. The following section provides instructions on determining the cause of the problem, solution to the problem and how to retrieve and prepare samples for analysis, if required. Contact a FlexSteel representative when any of the following situations occur.

The troubleshooting table below summarizes common problem scenarios and recommended next steps.

Table 6 – Troubleshooting

FLEXSTEEL PIPELINE TROUBLESHOOTING

PROBLEM CAUSE RECOMMENDATION

Pressure Loss

Pervasive Leak: If no fluid is coming out of the vent ports, a pipe rupture might be causing loss of fluid.

Verify that the cause of pressure loss is not caused by a non-pipe issue, such as a change in suction in the well, a leaking valve, or operator error. Shut down the line. Contact FlexSteel Pipe Technologies, Inc.

Consistent Leak: If liquid or gas is coming out of the vent ports, a fitting might be leaking.

Residue on Fitting

If liquid is coming out of vent ports in a steady stream, a fitting may be leaking fluid into the annulus.

Depending on the amount of fluid coming out of the vent ports, the pipe may be operating as designed. Contact FlexSteel Pipe Technologies, Inc.

Carbon steel fitting has pitting on any surface.

Identify cause of corrosion before replacing the fitting. Address the original cause of the pitting; for example, re-evaluate the type of metal used for the fitting, coat the new fitting with mastic and wrap it in pipe tape, or add cathodic protection.

A gasket between two flanges has failed.

Replace gasket. If the face of the flange is damaged, replace the fitting.

Visible Spill Above Ground

Ruptured pipe is causing loss of fluid. Shut down the line. Contact FlexSteel Pipe Technologies, Inc.

A gasket between two flanges has failed.

Replace gasket. If the face of the flange is damaged, replace the fitting.

Bulge In pipe Product has accumulated in annulus due to lack of venting.

Shut down the line.

Contact FlexSteel Pipe Technologies, Inc.

10.1 LEAK DETECTION




FlexSteel pipe is highly durable, corrosion resistant and easy to install with minimum handling. However, pipe performance can be compromised as a result of improper fitting installation or damage during deployment. In the event that FlexSteel pipe fails to hold pressure or if a steady stream of water flows from the pipe annulus or vent ports, a leak is present. FlexSteel recommends the following leak detection methods for FlexSteel products.

10.1.1 Before You Start

• Contact a FlexSteel representative if the hydro test fails or if there is a concern about a leak. • Gases that may permeate through the HDPE liner travel within the annulus of the pipe to be vented

through vent valves at the upstream and downstream end fittings. A conservative vent rate is approximately 1 cubic foot per mile per day. This should not be interpreted as a leak in the pipe. FlexSteel can estimate permeation rates if the composition and operating parameters are provided.

• Review the fitting installation forms for abnormalities, such as the following: A spring back value greater than 3 millimeters. Incorrect ID or OD sizes. Based on the ID and OD measurements of the pipe, the die used does not match the die size specified

in the appropriate Die Selector Table. • To locate the source of the leak, start with the area adjacent to the leak. • Before handling any pipe, make sure it has been depressurized. • If the pipeline has a flanged connection, unbolt the flanges and pressure test each section of the pipe to

determine which section has the leak. Then proceed with one of the following methods.

10.1.2 Leak Detection Method 1: Re-swage Fittings

FlexSteel highly recommends that a FlexSteel Field Operations Supervisor is present for this method.

If the line contains less than five midlines:

• Expose the fittings and re-swage each midline, typically another 1 to 2 mm below the recommended final die.

• Perform another field hydro test on the line to make sure the leak has been repaired.

If the line contains five or more midlines:

• Use a pig to clean and de-water the line. • At the center of the line, at a point midway between two fittings, cut the line and install an end fitting at

each end of the pipe that was cut. • Test each individual side of the pipe.

If the leaking section of the line contains less than five midlines, then re-swage each midline and perform another field hydro test.

If the leaking section of the line contains five or more midlines, divide that section into two parts again. Keep isolating and testing sections until the leak is found. Re-swage the leaking fitting or repair/replace the leaking section of pipe. Perform another field hydro test on the line to make sure the leak has been repaired.

10.1.3 Leak Detection Method 2: Drill into Midline and Pressurize Pipe

FlexSteel highly recommends that a FlexSteel Field Operations Supervisor is present for this method.

• Expose the fittings, mark the hole to be drilled at the bottom of the fitting with a punch, and drill into the midline where illustrated in Figure 10-1 with a 7/32-inch drill bit. Be careful not to drill through the inner body of the fitting; only penetrate the outer jacket.




Figure 10-1 Location to Drill Hole

Figure 10-2 Cross Section of a Fitting

• Allow the fluid to drain completely from the fitting. If the fluid does not drain from the hole and plastic is clearly blocking the hole, drill through the plastic until you hit the stainless steel of the fitting. Be careful not to drill through the inner jacket of the fitting.

• Pressurize the line to 500 psi. • Water will flow from the drilled holes. A fitting with a leak will have a significant amount of water flowing

from it and will make the sound of pressurized air mixed with water. Check all the fittings as more than one fitting may have issues.

• Mark the leaking fittings and depressurize the line. • Re-swage the leaking fittings and perform another field hydro test on the line to make sure the leak has

been repaired. • Thread the drilled out holes and install vent plugs. If plastic a vent port is blocked, use two 90º adapters

with a vent hose to connect it to the other vent port on the opposite side of the midline.

10.2 RECOGNIZING DAMAGE

Location where a hole can be drilled




Damage can occur to the pipe or fitting during the installation process or during shipping. Given the type and extent of the damage, the affected pipe section or fitting may need to be cut out or repaired. If in doubt, cut the damaged area out and reconnect with two fittings or a midline connection. Contact a FlexSteel representative for further recommendations.

10.2.1 Damage to Flowline or Outer Shield

• Ovalized Pipe: Mildly ovalized pipe without creases in the steel reinforcement layers may still retain structural integrity and return to its original form during the field hydro test. In some cases, the pipe can be rounded with an 8- to 12-inch C-clamp. If the structural integrity of the pipe is compromised by creases, ridges, or points in the steel, cut out the damaged area and connect the severed ends with a midline fitting or two end fittings.

Figure 10-3 Ovalized Pipe with Noticeable Ridge

• Flat Spots, Kinks, and Twists: Examine the pipe for sharp creases, bulging, and/or wrinkling. If the structural integrity is compromised, cut the damaged area out and reconnect with two end fittings or a midline connection.

A pipe with a kink cannot be reshaped with a C-clamp




Figure 10-4 Kink and Flat Spot Damage

• Above Ground and Buried Shield Damage – No Steel Exposed: If the shield has been scraped, cut, or gouged deeply but no steel reinforcements are visible, then pipe wrap or tape can be used to fix the damaged area.

Figure 10-5 Above Ground and Buried Shield Damage - No Steel Exposed

• Above Ground and Buried Shield Damage – Steel Exposed: If the shield has been compromised and the steel layers are visible with no damage to the steel, then pipe wrap or a shrink sleeve or equivalent product can be used to fix the damaged area, but the integrity of the pipe cannot be assured. FlexSteel recommends cutting out the damaged section and installing a midline connection.




Figure 10-6 Above Ground and Buried Shield Damage - Steel Exposed

• Above Ground and Buried Shield Damage – Steel Damaged: If there is damage to the steel layers, cut out the damaged area and reconnect with two new end fittings or a midline connection.

An annulus test can be used to determine if the shield layer has been breached. Water that has flooded the annulus can be purged by flowing an inert gas such as nitrogen from the end fitting, making sure the annulus is still operational. See section 6.4.7 Annulus Test for more information.

Figure 10-7 Shrink Sleeve




10.2.2 Damage to End Fittings

Damage to the sealing face of the end connections must be addressed and repaired in accordance with the flange manufacturer’s recommendations.

10.3 REPAIRING OFFSHORE AND SUBMERGED PIPE

For any repairs to pipe offshore or submerged in wet conditions, contact a FlexSteel representative that specializes in offshore applications.

10.4 REPAIRING NEW LINE

If the pipe becomes damaged during installation, it may need to be repaired. The repair method depends on the type and severity of the damage and the environment where the pipe is being installed. Wet, marshy areas where the pipe will be subjected to constant moisture require higher levels of containment, whereas buried pipe in dry climates might only need moderate shield repairs.

A general rule for determining how to repair a pipe is that if there is a question about whether or not to cut out a section, it is recommended to cut it out and repair with a fitting.

Refer to section 10.2 Recognizing Damage for more information on the types of damage and possible repair methods.

10.5 REPAIRING LINE IN SERVICE

When damage occurs to a line in service, a number of extra precautions are observed. Note that the end-user companies often have their own set of safety procedures which are applicable to the project site and are to be followed.

If a leak is present:

• Prohibit personnel and equipment from entering the area until all hazards are evaluated. • Eliminate ignition sources, including those downwind. • Evaluate level of explosive or hazardous gasses in the area with a gas monitor. • Contact the operating company to notify them of a leak and have the line shut in.

Before starting the repair job:

• Perform a Job Safety Analysis (JSA), including information such as Reports, permits, and regulations and any other documentation that might be required; Contents of the line and MSDS to determine appropriate safety precautions and PPE; Excavation requirements; Other required precautions, such as confined space requirements.

• Perform the “Call before you dig” notification to any other underground utilities in the area. In the United States, call the Common Ground Alliance at 811.

• FlexSteel recommends the use of hydro excavation before mechanical or hydraulic excavation to verify accurate location, depth, and line size. See section 10.6 Hydro Excavation for more information.

When installing the new fittings, clean the outside and inside of the pipe completely of any chemical residue so that the fitting will be in direct contact with the bare pipe. This step is necessary to assure that the fitting creates a proper seal with the pipe during the swage procedure.




After the repair, monitor the pipe for leaks when it is put back in service.

• Make sure equipment, including communications, is certified and in good working order;

• Use proper Lock Out Tag Out (LOTO) procedures on the line as well as for electricity to the pumps; grounds, or other operatives that could impact the repair;

• Perform excavation under watch of competent person; • Dispose or decontaminate affected soil per regulations; • Decontaminate equipment and personnel if necessary; • Inside trench or excavation, take care to maintain proper footing

and use basic safety precautions; • The steel layers of the annulus have sharp edges. Wear proper

gloves.

10.6 HYDRO EXCAVATION

The end user or installation contractor may utilize a hydro excavation (also known as hydrovac) which is considered a non-destructive method which uses pressurized water and a vacuum system to quickly and safely expose underground piping or utilities. The hydrovac process consists of injecting pressurized water into the ground through a handheld wand. As the soil cover is liquefied, the resulting slurry is simultaneously extracted by an industrial-strength vacuum and stored into an onboard debris tank.

This process allows for a safe and precise excavation that requires less backfill and restoration, less labor, and less environmental impact than traditional excavating methods. This type of system can excavate effectively in all soil types, including clay. Some hydrovacs are available with onboard heaters to provide a safe means of digging in frozen ground.

• The contractor will follow the operating guidelines for the hydrovac equipment.

• Note that the standard safety procedures for excavation are followed.

• Perform the "Call before you dig" notifications to any other underground utilities in the area before starting excavation. In the United States, call the Common Ground Alliance at 811.

• To prevent electric shock, consider all power cables to be energized during excavation and backfill.

• Take precautions to prevent water from pooling at the bottom of the excavation.




11 DECOMMISSIONING When a pipeline is decommissioned, it is taken out of service and left in place, discarded in a landfill, or repurposed for a different location. Decommissioning FlexSteel pipe typically involves the pigging, flushing, filling and plugging of lines, followed by removal or abandonment, and may involve respooling the pipe.

11.1 TYPICAL FLEXSTEEL RETRIEVAL

To avoid damage when retrieving the pipe, take the following precautions:

• When retrieving FlexSteel pipe, do not bend the pipe below the minimum bend radius (MBR) value specified in the Pipe Specification Sheet at any time.

• To avoid additional repairs, do not damage the outer shield of the pipe when excavating buried pipe. • After the pipe has been respooled, wrap the end fittings in a protective wrap (1/8 inch neoprene or

equivalent). • Do not exceed the spooling tension shown on the Pipe Specification Sheet. • Inspect the pipe for physical damage as it is retrieved.

11.2 RESPOOLING

Respooling recovers the FlexSteel pipe so that it can be re-used, recycled, or completely decommissioned by spooling the pipe onto an empty reel. FlexSteel offers onsite training which is recommended for those who have no prior experience in respooling.

To respool the pipe, choose a suitable location for the Respooler and secure it in place to prevent it from sliding, as detailed in section 6.1.1.3 Respoolers. Inspect the equipment and verify that all retaining pins and safety guards are in place. Refer to the Respooler Operation and Maintenance Manual for safety recommendations and operation instructions and FLD-P-9921 Respooling Procedure.

FlexSteel pipe must be spooled from the side of the Respooler with the constraint bar to allow removal or replacement of the Respooler. Feed the end of the pipe over the constraint bar and under the reel. Attach the end of the pipe with an inboard tie-down to the left-side flange of the reel (the side closest to the chain drive). Spool the pipe onto the reel and watch to make sure the pipe is wrapping correctly around the reel. With heavier pipes, the Respooler might require pulling assistance to spool the pipes onto the reel. When the pipe is entirely spooled onto the reel, secure the end of the pipe to the reel flange with an outboard tie-down adequate for the weight of the pipe. Additional equipment might be required to handle the full reel after the spooling operation is complete. Refer to section 5.1 Reels for information on how to move and store the spooled pipe.

Special Considerations:

• The 6-inch and 8-inch lower pressure pipe must be pressurized with air prior to spooling to protect against damage. To pressurize the pipe, plug both ends of the pipe and fill it with compressed air to 40 psi. To pressurize the pipe, plug both ends of the pipe and fill it with compressed air up to 60 psi. Pressurizing pipe is not recommended for any other size or grade of pipe.




12 TRAINING FlexSteel Pipeline Technologies, Inc. is committed to providing our customers with pipeline solutions that integrate well with current onshore and offshore oilfield construction practices. To safely deliver cost-effective, high-quality FlexSteel pipeline solutions, it is critical that customers and contractors have a solid understanding of the products, equipment, and procedures associated with these implementations. To achieve this, FlexSteel offers a comprehensive Installation Training Program that encompasses product knowledge, installation processes, operating considerations, and pipeline maintenance. FlexSteel’s Installation Technician Certification assures customers that the technician has the appropriate qualifications to install FlexSteel products.

12.1 TRAINING PROGRAM

FlexSteel requires all installation technicians to be trained and certified through the FlexSteel Installation Technician Training Program.

The program encompasses classroom and supervised field training. The 5-day classroom training segment includes product and installation information followed by hands-on experience with equipment, pipe, and fittings. After the classroom, each trainee is required to complete a minimum of 60 days of supervised field work to become certified as a FlexSteel installer. The field training verifies that the trainee has retained the information from the classroom setting and their performance in the field meets FlexSteel’s stringent standards.

Subsequent to the training, each certified technician will receive product and process updates to keep current on FlexSteel technology. They will also receive Safety Briefs, Field Notes, Procedures, and other relevant information as it is developed. Finally, the certified technicians will be included in the FlexSteel Learning Management System to allow the company to provide continuing education and validate that critical information is properly understood and maintained.

12.2 COURSE CURRICULUM

The 5-day training course covers general installation and handling guidelines as well as the installation of the fittings with an emphasis on safety and proper documentation. The topics covered include:

• Safety




• Overview of the FlexSteel products and operations

• Installation equipment

• Fitting installation

• Deployment best practices

• Commissioning

• Maintenance

• Damage and repair

12.3 FLEXIBILITY

The specific topics covered in the course can be tailored to meet customer needs. In general, the training course is designed to accommodate class sizes of 4-10 people. Training can be performed at a FlexSteel service center or an adequate facility more convenient to the trainees. Additionally, the training course can be offered in the United States or internationally. Duration and scope of training may vary depending on available equipment and trainee performance. At least three weeks lead time is requested to allow sufficient arrangements to be made for a qualified trainer to deliver the course at alternative locations; international venues require additional scheduling considerations. Contact a FlexSteel representative for more information.

12.4 MAINTAINING CERTIFICATION

Certification is renewed annually to remain active as a FlexSteel installer. To maintain certification, each certified technician must remain in good standings regarding quality and safety, perform pre-established annual installation requirements (i.e. fitting quotas and documentation conditions) and successfully complete an annual on-site audit to re-certify the use of the latest methods and proper installation techniques. The technician may also be selected for random audits to verify work practices due to a high volume of installations or to address nonconformance issues.

Please contact a FlexSteel representative for more details on this program.




REVISION HISTORY

REVISION NO. DATE DESCRIPTION

0 10 September 2014 Initial Release

1 04 February 2015 Change of Responsibility from Michael Perdue to Brian Anderson



Documents

FlexSteel Installation and Operations Manual - Metatron · Title: FlexSteel Installation and Operations Manual Author: Brian Anderson Keywords: Document control, style, format, Microsoft