689 Attachment-01 SP-2380 Design & Const of PE Lined Carbon Steel Lines

Petroleum Development Oman L.L.C.
Design and construction of PE lined Carbon steel lines
Document ID SP-2380
Document Type Specification
Security Restricted
Discipline Pipeline Engineering
Owner UEMP – Pipelines Corporate Functional Discipline Head
Issue Date December 2020
Version 1.0
Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any
part of this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted
in any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written
consent of the owner.
Printed 16/12/2020 SP-2380: Design and construction of PE lined Carbon steel lines Page 1
Printed copies are UNCONTROLLED.

Revision: 1.0
Petroleum Development Oman LLC Effective: Dec-20
This page was intentionally left blank

Revision: 1.0
i Document Authorisation
Authorised for Issue
Document Authorisation
Document Owner Document Custodian Document Author

(CFDH)
Habsi, Badar UEMP Suliman, Omar UEMP3 Mawali, Zaid PDEMP19
Date : Date : Date :

Revision: 1.0
ii Revision History
The following is a brief summary of the most recent revisions to this document. Details of all revisions
prior to these are held on file by the issuing department.
Version Date Author Scope / Remarks

No.
1.0 Dec-20 UEMP / UEMP3 / PDEMP19 Design and construction of PE
lined Carbon steel lines
iii Related Business Processes

Code Business Process (EPBM 4.0)
iv Related Corporate Management System (CMS) Documents

The related CMS Documents referenced in section 1.8 can be retrieved from the Corporate
Management Portal (CMS).

Revision: 1.0
TABLE OF CONTENTS
i Document Authorisation............................................................................................................... 3
ii Revision History ........................................................................................................................... 4
iii Related Business Processes ....................................................................................................... 4
iv Related Corporate Management System (CMS) Documents...................................................... 4
1 Introduction .................................................................................................................................. 6
1.1 Purpose .................................................................................................................................. 6
1.2 Distribution, Intended use and regulatory considerations ...................................................... 6
1.3 Definitions .............................................................................................................................. 6
1.4 Abbreviations ......................................................................................................................... 7
1.5 Comments on this SP ............................................................................................................ 7
1.6 Conflicting Requirements ....................................................................................................... 7
1.7 Exceptions .............................................................................................................................. 7
1.8 References ............................................................................................................................. 8
2 Design .......................................................................................................................................... 9
2.1 Introduction ............................................................................................................................ 9
2.2 PE liner design basis.............................................................................................................. 9
2.3 Wall thickness calculation .................................................................................................... 10
2.4 Selection of Outside Diameter ............................................................................................. 11
2.5 Pulling force calculations...................................................................................................... 11
2.6 Stub end design ................................................................................................................... 13
2.7 Retainer ring design ............................................................................................................. 13
2.8 Vent Design .......................................................................................................................... 14
3 Construction ............................................................................................................................... 15
3.1 Introduction .......................................................................................................................... 15
3.1.1 Tight fit liner .......................................................................................................................... 15
3.1.2 Loose fit liner ........................................................................................................................ 15
3.2 Inspection of liner materials ................................................................................................. 16
3.3 Storage ................................................................................................................................. 16
3.4 Handling ............................................................................................................................... 16
3.5 Transportation ...................................................................................................................... 16
3.6 Pre-insertion of PE liner. ...................................................................................................... 17
3.7 Liner Installation ................................................................................................................... 19
3.8 Hydrostatic testing................................................................................................................ 20
3.9 Testing after commissioning ................................................................................................ 21
3.10 Shop Lining: ......................................................................................................................... 21
APPENDIX 1 – SOP for (PE) liner pulling force calculations ............................................................ 23
APPENDIX 2 – SOP for PE Liner wall thickness, Stub end and Retainer ring design ..................... 24
APPENDIX 3 – Standard Drawing for Vent design ........................................................................... 25
APPENDIX 4 – USER COMMENT FORM ........................................................................................ 31

Revision: 1.0
1 Introduction
1.1 Purpose
This specification is intended for design, construction and commissioning of polyethylene lined CS
flowlines, pipelines and piping systems. Applications are for both buried and above ground, for oil,
water and multiphase (GLR ≤ 300) service.
1.2 Distribution, Intended use and regulatory considerations

Unless otherwise authorised by the Company, the distribution of this SP is confined to Contractors,
Design Consultants and Manufacturers/Suppliers approved by the Company.
This SP is intended for use in facilities related to pipelines and flowlines in oil and gas production,
No liability shall be incurred by PDO for any cause arising from the authorised or unauthorised use
of this SP.
1.3 Definitions
1.3.1 General Definitions
Company Petroleum Development OMAN. LLC

Contractor The party that carries out all or part construction, commissioning
assistance
Design Consultant The party who enter into a contract i.e. agreement with the
Company or contractor and is responsible for providing the
engineering services.
Manufacturer / The organization that manufacture / fabricate and supplies the
Supplier / Vendor material and associated accessories
Shall The word 'shall' used throughout this document indicates a
mandatory requirement.
Should The word 'should' used throughout this document indicates a
recommendation.
1.3.2 Special Definitions
Tight fit lining It’s a construction methodology where the HDPE Pipe liner has a
larger outside diameter than the inside diameter of the steel pipe. The
liner pipe is compressed radially as it passes through the roller
reduction box.
Loose fit lining It’s a construction methodology where the HDPE Pipe liner has a
smaller outside diameter than the inside diameter of the steel pipe.
The liner pipe is pulled out through the pipeline, then expands during
hydrotest.
Annulus gap Space between the PE liner outer diameter (prior to expansion) and
the carbon steel inner diameter. This gap will be closed after the
hydrotest.

Revision: 1.0
1.4 Abbreviations
ANSI American National Standards Institute

API American Petroleum Institute
ASTM American Society for Testing and Materials
CFDH Corporate Functional Discipline Head
CS Carbon steel
ISO International Organization for Standardization
ITP Inspection test plan
MOT Maximum Operating Temperature
OD Outside Diameter
PE Polyethylene
PE-RT Polyethylene of Raised Temperature
PSG Pipeline Service Group
SOP Standard Operating Procedure
1.5 Comments on this SP

This specification shall not be changed without approval from the Custodian, Pipeline CFDH, who
owns this specification. If you have any feedback, write your comments on a copy of the User
Comment Form in Appendix 4. Send the copy with your comments and personal details to Pipeline
CFDH.
1.6 Conflicting Requirements
All conflicts between the requirements of this specification, referred specifications, standards, codes,
requisition data sheets shall be referred to Purchaser for clarification before proceeding with the
manufacturing.
The Order of precedence of documents shall be as below:
 Local Laws, Decrees and Statutory Requirements
 Material Requisition / Purchase Requisition
 Project Specific Specifications, Procedures, Instruction etc.
 Codes of Practice (COP)
 Engineering Specification (SP)
 Procedures (PR)
 Guidelines (GU)
 Exploration and Production (EP)
 International Standard.
In case of conflict among documents or sections, the more stringent requirements shall apply, unless
otherwise agreed with the Purchaser in writing.
1.7 Exceptions
Vendor shall make a formal request with full supporting information and justification when a deviation
from standard is requested. Vendor is required to notify any inaccuracy or ambiguity encountered in
this document.
Any proposed exceptions or changes to this specification shall be submitted to the Pipeline CFDH
for approval. Any work completed with unauthorised modifications shall be rejected by the Company.
All deviations shall be handled as per PR-2066.

Revision: 1.0
1.8 References
In this SP, reference is made to the following publications:
PDO Standards
GU -969 Pipeline Stress Analysis
PR-2066 Managing Variance from Technical Standards

Specification For Quality Management System Requirements for
SP-1171
Product & Service
SP-1208 Pipeline Construction Specification
SP-1210 Specification for Pipeline Integrity Management
SP-1211 Onshore Pipeline Engineering
SP-1212 Hydrostatic pressure testing of new pipelines
SP-1236 Isolation systems for cathodically protected pipelines

Specification for pressure testing & Sensitive leak testing of piping
SP-2051
system (ASME B31.3)
SP-2094 Specification for manufacturing and joining of HDPE liner pipes
SP-2347 Procurement specification for CS line pipe
International Standards (Latest Edition unless otherwise specified)
API RP 15LE Recommended practice for Polyethylene line pipe and fittings
API RP 5L1 Recommended practice for railroad transportation of line pipe

Recommended for transportation of line pipe on barges and marine
API RP 5LW
vessels
ASME B16.5 Pipe flanges and flanged fittings
ASME B31.4 Pipeline transportation systems for liquids and slurries
ASME B31.8 Gas transmission and distribution piping systems
ISO 4427 Polyethylene (PE) pipes for water supply – specifications
ISO 13479 Environmental stress crack resistance
ISO 9969 Thermoplastic pipes- determination of ring stiffness
Bolt torque for polyethylene flanged joints - Technical note#38 - plastics

TN-38-PPI pipe institute
NOTE: Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments, supplements, revisions thereto.

Revision: 1.0
2 Design
2.1 Introduction
This section covers the design of PE liners for flowlines, pipelines and piping systems.
The PE liner design shall be carried out by approved engineering consultant as per AVME PSG-101
and confirmed by the approved installation contractor under AVME PSG 105 and 106.
Installation technique (tight fit / loose fit) shall be specified by Company Pipeline TA2 based on cost
analysis (Material, installation cost, contractor capability,… etc.)
For sour service applications, CS line pipes shall be supplied as per SP-2347.
Design of PE liner system including pulling forces calculations and wall thickness shall be prepared
as per the SOPs detailed in (Appendix-1 and 2) and submitted for Company Pipeline TA2 review and
approval.
2.2 PE liner design basis

The wall thickness of the liner shall comply with the following requirements:
a. Minimum wall thickness of the liner shall not be less than 6 mm.
b. It is the responsibility of the design consultant to design the PE liner, calculate the pulling
force and finalizing the sections length after consultation with installation contractor and
obtain the necessary approval from Company pipeline TA2.
2.2.1 Water Service

Water service is defined as the total hydrocarbon fraction less than 1 vol. percentage of total fluids
flowing in the pipeline.
a. The maximum operating temperature shall be as follow in line with SP-2094: -
• For HDPE Liners is 70°C.

• For PE-RT Liner is 85°C.
b. PE Liner shall be designed with minimum 1.5 bar collapse pressure for loose and tight fit
liners.
2.2.2 Hydrocarbon / Multiphase Service

Hydrocarbon service is defined as the total hydrocarbon fraction exceeding 1 vol.% of total fluids
flowing in the pipeline, the following points shall be considered in line with SP-2094:
a. The maximum operating temperature for PE lined shall not exceed 65°C including PE-RT
b. PE Liner shall be designed with 3 bar collapse pressure for loose and tight fit liners.

Revision: 1.0
2.3 Wall thickness calculation

HDPE shall be manufactured from PE100 grade only. The wall thickness calculations shall be
performed by using the below equation with below PE material properties and as detailed in
Appendix-2
Where,
(swell) = Liner linear swell (%)
h = Liner wall thickness (mm)
R = Average radius of the liner (mm) = 0.5 * (ID steel – h)
E = Modulus (in MPa)
PE MATERIAL PROPERTIES
Below properties values as per SP-2094 shall not be interpolated, values of higher temperature shall
be considered.
• PE 100 MATERIAL properties as per Table 1
Service PE Liner max. Linear E Modulus Poisson’s Coefficient of thermal

operating swell 5% secant Ratio expansion.
temp. value (MPa) -6
(%) (m/mK * 10 )
(ºC)
NEN-EN-9969
Air/water 20 0 310 0.35 120
60 0 150 0.40
70 0 100 -
Crude 20 2 170
60 5 110
70 7 80
Table 1
• PE-RT MATERIAL properties as per Table 2
Service PE Liner max. Linear E Modulus Poisson’s Coefficient of thermal

operating swell 5% secant Ratio expansion.
temp. value (MPa) -6
(%) (m/mK * 10 )
(ºC)
NEN-EN-9969
Air/water 20 0 310 160
60 0 150
85 0 80
Table 2

Revision: 1.0
2.4 Selection of Outside Diameter
2.4.1 For loose fit liners

The OD of liner shall be selected so that, minimum annulus gap maintained when the liner is
installed. The following conditions shall be applied in determining the OD of HDPE liner pipe
in loose liner design:
• OD of PE liner ≥ CS pipe ID - 4mm for 2” to 4” NPS.
• OD of PE liner ≥ CS pipe ID - 6mm for 6” to 10” NPS.
• OD of PE liner ≥ 97.5% of CS pipe ID for 12” to 24” NPS.
• OD of PE liner ≥ CS pipe ID-15mm for 26” NPS & above.
The OD of liner shall be calculated based on the minimum nominal CS pipe wall thickness.
Selected OD of liner shall be verified to be less than the minimum ID of CS pipes (e.g. road
crossing, wadi crossings, …etc) to ensure the ability to pull liner through.
Purchase order placement of PE liner shall not be taken place unless the CS pipe wall
thickness is confirmed by pipe manufacturer. This is to avoid any mismatch between the
calculated annulus and the OD of PE liner with the ID of manufactured CS pipe.
2.4.2 For tight fit liners

The OD of liner shall be more than the ID of CS pipe based on the main pipeline wall thickness.
Installation contractor shall be consulted before selecting the OD of PE liner.
2.5 Pulling force calculations

Preliminary pulling force calculation shall be performed by design consultant at various
installation temperature and shall be sent to Contractor to ensure the availability of pulling
machine capacity.
The max. allowable pulling stress are not exceeding 50% of the PE pipe yield stress listed in
the Table-3 at various surface temperatures measured on the surface of the HDPE liner pipe
section before start of pulling.
Sl # Temperature Yield stress

(°C) (MPa)
1 ≤23 21
2 24 to 30 19
3 31 to 40 16
4 41 to 50 14
5 51 to 60 12
6 61 to 70 8
Table 3 – Yield stress

Revision: 1.0
• The max. pulling length (Fpull) can be calculated as per the below formula.
Fpull = L Liner x W x f x Σ (e(Σnfθ) ) + Freduce

Where;
L Liner : Liner length Straight section
f : Friction factor. (can be assumed 0.4)
W : Weight of PE liner per unit length
n : Nmber of bends of each combination of angle & radius
θ : Angle of bend
F reduce : The load applied to the liner from installation technique

• Zero for using loose and tight fit – roll down method
• 5 MPa for tight fit - other technologies.
• Stretching force calculation (F stretch)
PE liner shall be designed to sustain the thermal expansion due to the temperature
difference between the max. operating temperature and the installation temperature
as per below formula. Stretching is applicable only for loose liners.
F stretch = E x A x L stretch / L Linear
Where;
L stretch : Max. stretch length = α (T MOT – T ambient)
α : Differential thermal expansion between PE liner and CS pipe
E : Modulus of elasticity of PE liner
A : Cross section area of PE liner
• Pulling force calculations shall be revalidated at site based on the actual installation
temperature.
• The maximum pulling length should not exceed 700m as detailed in Appendix-1.

Revision: 1.0
2.6 Stub end design

At the end of each PE lined section, the PE liner shall be terminated by stub ends with retainer rings.
Connection between PE lined pipes and metallic pipes shall be flanged. The design of PE lined
flanges shall be raised face with spacer/backing ring. The following steps shall be considered during
the design and to be further detailed in Appendix-2: -
a. PE flanges, Stub end and extrusion flange ring shall be moulded or machined from
extruded material and shall be from the same PE grade. The wall thickness of the HDPE
flanges shall be equal to the wall thickness of liner pipe.
b. For tight fit method, Consultant shall make a proposal for stub end and retainer ring design
in consultation with Construction Contractor and submit to Pipeline TA2 for approval.
c. Allowable compressive strain of Stub end is restricted to 7.5% as per TN-38 of PPI.
d. Diameter of bolt holes should be obtained from ASME B16.5 or ASME B16.47 Series A as applicable
e. The collar thickness (tc) should be 1.5 times the PE liner wall thickness.
Figure-1
2.7 Retainer ring design
Retainer ring is used to hold the stub ends in place (to avoid the plastic material from deformation).
Allowable hoop stress shall be 90% SMYS of the selected material for retainer ring.
Diameter of bolt holes should be obtained from ASME B16.5 or ASME B16.47 Series A as applicable.
Figure-2
Non-metallic phenolic type shall be used for isolation system as per SP-1236.
The retainer ring shall be analysed for bulking under the applied clamping force due to bolting torque.

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2.8 Vent Design

Every PE lined pipeline and flowline shall have vent points. Vent hole size shall be either single 5mm
or 2 number of 3mm diameter. The valves shall be opened only for venting purpose. Continuous
venting is not permitted. The purpose of venting is as follows.
• To vent the (ambient) gas from the pipe/annulus during installation.
• To vent the permeated fluids accumulated in the annulus to prevent collapse.
• To allow monitoring of the integrity of the PE liner during the service life.
Vent holes shall be designed such that no extrusion of the PE liner will occur. The following are
applicable for the vent design:
2.8.1 Water Service
• One vent with valve shall be provided for section length less than 150 m. For section
length greater than 150 m, two vents shall be provided.
• For flange rating of 300# and below, vents may be flanged with U shaped vent points
facing down and continuously kept open during operation.
• For flange rating of greater than 300#, vents shall be supplied with valves and U-shaped
vent points facing down and kept closed during normal operation. Refer Appendix 3 for
standard drawings.
2.8.2 Hydrocarbon Service

• Each section shall have a minimum of 2 vent points. For shop PE lined spool (Less than 20m)
number of vents can be one. For sour service where double block and bleed requirements are
applied, the PE lined section inside the station shall follow the same.
• The vent points shall be supplied with valve and U-shaped pipe facing down and only
opened for venting activity. Continuous venting is not permitted.

Revision: 1.0
3 Construction
3.1 Introduction
This section outlines general requirements for field installation of PE liners in carbon steel pipelines
and flowlines. Carbon steel construction shall be executed as per SP-1208.
In order to optimize the number of field joints, the length of PE liner can be supplied with random
length of 17-18m.
Installation of PE liners shall be undertaken only by Company approved Contractors under AVME
(PSG-105 and 106) working in accordance with written procedures and method statements approved
by the company. The procedures and ITP shall be detailed in the Quality Plan and shall cover as a
minimum the following areas:
 Materials handling and control.
 Site and pipe preparation and stringing.
 Liner prefabrication and fusion.
 Pulling through and stub end installation.
 Testing and inspection.
 Pre-commissioning.
No work shall be commenced until the relevant procedures have been approved.
Requirements for leak and hydro testing of the carbon steel line, the PE liner as well as the lined
carbon steel line are given in Section 3.8.
The following method of construction are approved by Company: -
3.1.1 Tight fit liner

 PE liner that has a larger outside diameter than the inside diameter of the CS pipe it
protects. A wire line cable is sent through a section of pipeline and is then attached to the
liner pipe. The wire line pulls the internal pipe lining system through the roller reduction
box which is positioned at the insertion end of the pipeline section. The liner pipe is
compressed radially as it passes through the roller reduction box. This temporary
reduction provides enough clearance between the steel pipe and the liner pipe to allow
insertion.
 Until the pulling is complete, the liner is under tension, causing it to remain at a reduced
diameter. When the tension is released, the liner pipe expands and creates a tight fit
against the internal wall of the steel pipe. Following relaxation of the inner pipe, the
polyethylene flange-fittings are attached, and the line is ready for bolt-up and
testing. Depending on diameter, bends, terrain and condition of the steel, the maximum
section length (pull length) can be calculated as detailed in Appendix-1.
3.1.2 Loose fit liner

 Technique merely involves the insertion of a PE liner into a CS host line pipe. Where the
outer diameter of the liner is smaller than the inner diameter of the host CS pipe.
 The annular space existing between the outer walls of the HDPE pipe and the inner walls
of the CS host pipe is called annulus. Its width can vary between as little as a few
millimetres to some centimetres according to the metallic pipe size.

Revision: 1.0
3.2 Inspection of liner materials

3.2.1 General
Material which shows injurious defects onsite inspection, or which proves to be defective when
properly applied in service may be marked and rejected.
In case of any section replacement: -
1- Reuse of CS pipes is permitted provided fully inspected and approved by Pipeline integrity
engineer.
2- The entire pull section of HDPE liner shall be replaced. Re-using of installed HDPE liner is
prohibited.
3.2.2 Defects
a. Scratches in pipe: surface scratches and nicks in PE pipes may not exceed a depth of 5%
of the nominal PE wall thickness.
b. Scratches in flanges: PE flange surfaces shall be free of scratches and nicks.
c. Dents: the acceptable limits shall be as stated in SP 2094.
d. Repair of defects in any form is prohibited.
3.2.3 Compliance
The Contractor is responsible for complying with all of the provisions of this specification.
The Company may make any investigation necessary to satisfy that there is compliance by the
Contractor and may reject any material that does not comply with this specification.
3.3 Storage
All liner pipes shall be packed and stored in accordance with a procedure agreed by the Company. For
periods longer than 3 months, polyethylene pipe shall be stored under cover with adequate protection
from direct sunlight to avoid UV degradation and/or deformation. If the pipe has to be stored in the
open air before, during or after shipment, it shall be suitably protected from environmental
contamination. The packing shall avoid ingress of moisture or dirt to the inside of the pipe.
Coils shall be stored stacked flat one on top of the other. Straight lengths shall be stored on horizontal
racks in such a way to prevent damage to the pipe. In either form, PE pipe shall not be allowed to
touch ground, hot water or steam pipes and shall be kept away from hot surfaces.
3.4 Handling
All pipes shall be cleaned, dried, packed, handled and transported to arrive at its destination without
distortion or damage. Dragging of HDPE Pipe or coils over rough ground shall not be permitted.
Storage & handling damages beyond acceptable limits shall be rejected.
3.5 Transportation
The minimum requirements for transportation shall be as specified API RP 5L1 and API RP 5LW2.
Pipe transported by sea shall not be shipped as deck cargo.

Revision: 1.0
3.6 Pre-insertion of PE liner.
3.6.1 Carbon Steel Pipe checks.

Carbon steel construction shall be executed as per SP-1208. Prior to liner insertion, the following
checks and provisions are required on the steel line:
• For existing lines, the condition of the steel pipe shall be assessed to determine that sufficient
mechanical strength is retained to meet the design pressure rating for the proposed service,
based on hydro test and/or inspection survey data.
• The internal condition and dimensions of all lines shall be evaluated to ensure that the liner
can be pulled through each segment without any damage e.g. due to excessive local weld
penetration. These should be checked by gauging pigs/plates and/or by pulling a test sample
of liner through every flanged CS pipe section.
• Locations for cutting and flanging of the line and any requirement for separate spooled sections
need to be determined. The longest continuous length of liner which can be installed in straight
pipe depends on diameter and wall thickness but is generally reduced in practice by local
curvature of the line. Breaks are also required at road crossings, changes in ID and any bends
of radius. (In general, minimum bend radius shall not be less than:
• 25D for pipe NPS of less than 8”
• 30D for pipe NPS 8” to 16”

• 40D for pipe NPS of over 16”
3.6.2 Pulling qualification requirements: -
• For field pulling, maximum of one bend is permitted.
• For shop lining spools, two cold bends are permitted.

• Pulling up to 6 numbers of 15° bends and below is permitted.
• For more than one bend, Qualifications shall be carried out with the following conditions:
a. Trail liner pulling shall not indicate any scratch in the liner equal to more than 5% of the
liner wall thickness.
b. Pulling force recorded during pulling shall be within the limits specified in the approved
pulling force calculations.
c. There shall not be any indication of wall thickness loss in the CS bends due to wire rope
friction during pulling. UT measurement of thickness on the CS bends before and after
pulling the liner shall not show any decrease in wall thickness.
d. Pulling direction should be in such a way that it minimizes friction between the wire rope
& the carbon steel bends. This can be optimized by ensuring that pulling head is inserted
as close as possible to the bends location and exit at the straight section.
e. The above qualification shall be witnessed and approved by Company Pipeline TA2.
• Inner edges of CS flanges at the raised face side shall be rounded off to avoid sharp edges.

Revision: 1.0
• Pulling qualification range shall be as indicated in Table 4
Sr. Test pipe Qualification Angle of Qualification Bend Qualification Number Qualification
No. Size range bend range radius range of bends range
1 6" - 10" ≤ 10" X° ≤ X° RxD ≥RxD n ≤n
2 12" - 16" 12" to 18" X° ≤ X° RxD ≥RxD n ≤n
3 20" - 24" 20" to 28" X° ≤ X° RxD ≥RxD n ≤n
4 28" - 40" 30" to 42" X° ≤ X° RxD ≥RxD n ≤n
Table 4
Where;
X° : Bend angle in degree
R : Radius of curvature
D : CS outside diameter
n : Number of bends.
Example for clarity purpose, 1st row of table means that 6" line, 4 numbers of 25D bends - 45°
mock-up can qualify all sizes up to 10", up to 4 bends, equal or more than 25D bends and angles
up to 45°.
3.6.3 Vent point assemblies
Every PE lined pipeline and flowline shall have vent points. The minimum number of vent points &
arrangement shall be as stated in section 2.8 of this specification.
Vent holes shall be designed such that no extrusion of the PE liner will occur. Metallic chips resulting
from vent hole drilling shall be removed from the bore and sharp edges of the vent hole at the inner
surface of the carbon steel pipes shall be removed.
3.6.4 Lining of Buried Pipelines

For lining buried pipelines, bell holes are required at the ends of the line and at any other locations
where breaks in the liner need to be made. In addition to the normal safety considerations in
excavating, sizing and ensuring stability of the bell holes, the following factors should also be
considered:
• The working area within the bell hole is required to be of sufficient size to accommodate the pipe
fusion machine and operator.
• The entry slope shall be sufficiently shallow to enable the liner pipe to bend smoothly from
ground level to the pipeline depth without severe abrasion against the steel flange during pull-
through. (Provision may also be required for pulling from two directions within a single bell
hole)
• Provision of enough length and width to enable the pipe ends to be offset for flange welding
and pulling in of the liner.
3.6.5 Wireline and Pig Train

The wireline unit should be suitably instrumented with footage and weight indicators, an overload
control set to a maximum of 100% of the calculated maximum allowable pulling force and fitted with
a speed controllable reel with cable spooling and braking facility.
Contractor is required to provide suitable pigs and launching equipment to propel the wireline and pig
train through the pipeline.

Revision: 1.0
A typical pig train should include:
• Sizing pig,
• Cleaning pig
• Cup pig
• Segment of liner pipe (for loose liner)
Once the wireline has been passed through the pipeline section, the pig train is pulled through, the
pulling force being continuously monitored and recorded to determine the location of any
constrictions.
The disc plate diameter shall be of sufficient diameter to verify that internal weld beads do not protrude
excessively taking into account the dimensional tolerances of the steel pipe. Disc plate size shall not
be less than the OD of PE liner for loose liner. For tight fit, the OD of PE liner shall not be less than
97.5% of ID or max 15mm less than ID of carbon steel whichever is higher.
The liner test segment attached to the pig train should emerge without serious damage. Minimum
length of test liner segment shall not be less than the two complete 90° bend length plus 2 meters.
Scuffing of the liner surface is permissible but sharp longitudinal scars or other penetration damage
exceeding 0.5 mm or 5% of the wall thickness, whichever is larger, is unacceptable. Weld protrusion
shall not exceed 1.5mm and would require rectification by further pigging using a breaker pig or by
other means prior to continuing with liner installation. After rectification another liner test segment
shall be pulled through.
3.7 Liner Installation

3.7.1 Liner fabrication & butt fusion welding
Field joining of liner pipe shall be by butt fusion welding techniques. Qualification of procedures and
operators shall be in accordance with SP-2094. Full time inspector shall be dedicated by Contractor
for every welding machine. A check list shall be used during fusion welding and all relevant welding
parameters shall be measured and recorded (including the identification of the welder) for each fusion
weld.
To confirm that correct machine parameters are maintained, daily test samples (strips) shall be taken
of a butt welded joint and subjected to a 180º reverse bend test without failure. The test shall also be
conducted when machine settings are altered. The bend test shall be in accordance with ASTM
F3183/ASME IX. T
The following are applicable to the welding process and its control:
a. Welding procedures shall be in accordance with the recommendations of liner supplier.
b. Contractor shall be responsible for providing the fusion machine, ancillary equipment and any
necessary environmental protection.
c. Trimming with an approved tool of the external bead, and, if required by the Company, the
internal bead.
d. The following testing and inspection of field joints shall be carried out:
• Visual inspection of the welds and the full circumference of trimmed beads for evidence
of lack of fusion.
• Production testing to confirm the correct machine parameters are maintained. A test
sample (strip) of butt-welded pipe should be subjected to a 180º reverse bend test without
failure. The test should be conducted daily, for every flanged section, whichever is more
frequent, and additionally whenever machine settings are altered.
• Low pressure air test of completed liner prior to installation (maximum pressure
approximately 3 barg). All fusion joints should be checked for leakage with a soap solution,
witnessed by a Company representative.

Revision: 1.0
3.7.2 Liner insertion

For tight fit method, after inserting the PE lined into the reduction machine, the reduction shall not
exceed 50% of yield strength of the pipe in any case.
The liner is pulled through the pipe section at a controlled rate using an adequately designed and
calibrated pulling head. The following points shall be noted:
• Pulling shall be at a controlled rate consistent with safe working conditions.
• The preliminary pulling force and stretching calculations as explained in section 2.5. shall
be updated at sites based on the actual ambient temperature.
• Pulling force shall be monitored and automatically recorded to ensure that 50% of the PE
pipe yield stress listed in Table-1 at various surface temperatures measured on the
surface of the HDPE liner pipe section before start of pulling. The temperature shall be
measured at four locations (12, 3, 6 & 9 O’clock positions). Surface temperature shall be
average of the four readings measured at four locations (12, 3, 6 & 9 O clock positions).
• Pulling shall not be carried out at the average surface temperatures more than 60°C or
any single reading exceeding 65° C. Precautions shall be taken to ensure that no debris
is introduced into the line on the external or internal surface of the liner.
• If the use of a friction reducing agent is proposed by the Contractor, the type and
application method shall be approved by the Company.
3.7.3 Installation of stub ends and retainer rings
Connections between PE lined pipes and CS piping shall be flanged. No other joining methods shall
be permitted unless agreed with the Company. End flange dimensions, joining and liner stretching
details shall be clearly specified in the contractor procedures submitted for company approval.
After the PE liner has been pulled in, stub ends shall be fusion welded to each end. The method shall
be detailed by the Contractor but will generally involve the following steps:
• Welding a to the liner segment trailing end and pulling into the steel flange.
• Clamping and stretching the liner from the leading end, enough to trim to required length and
butt the second flange adapter. (Normally a minimum 100 m segment length is required for this
technique to accommodate the necessary elastic strain).
• Releasing the clamp to allow the liner to contract on to the steel flange face.
• Fitting metal retaining rings around the liner flanges. These are designed to a controlled
thickness to limit compression of the PE flanges to a pre-determined value when bolting
adjacent segments and to prevent spreading of the PE material under load.
3.8 Hydrostatic testing

All installed liners shall be subjected to hydrostatic test of the complete line. For loose installed liners
a separate expansion operation may be required. Detailed procedures shall be submitted by the
Contractor for Company approval.
The PE liner shall be air leak tested at 3 barg before insertion. The entire CS+PE lined pipeline shall
be hydro tested in accordance to SP-1212. Piping spools shall be hydrotested as per SP-2051.
Vents shall be kept open during the hydrotest and to be witnessed by Company.
For loose fit liners : During the final hydro test the pressure shall be increased first to 3 times the
PE pipe freestanding pressure rating with all vents open to allow annular fluids to escape. If all
fluids have escaped or after one hour, which ever takes longer, the pressure shall be increased to
the required hydro test pressure.

Revision: 1.0
For Tight fit liners: Rate of pressurization can be followed as per SP-1212. When the pressure
reaches the design pressure of flowline or pipeline hold at least 1 hour to inspect the vents for any leak.
3.9 Testing after commissioning

All vents should be opened for four weeks after commissioning to check the integrity of the liner and
closed again to allow fluids which may have permeated through the annulus to the vents to escape
as well as to check whether any liner defects have developed (e.g. through creep of the PE liner).
This vent inspection shall provide the basic indication of any liner breach of any in the line. Inspection
of PE liner during operation shall be as per SP-1210.
3.10 Shop Lining:

Shop lining is permitted to short spools of maximum length of 19 meters in length and size from 3”
to 48” diameter in Company approved workshops only. Spools length less than 3meter shall be
roto lined. Qualification of welding procedures and operators shall be in accordance with SP-2094.
For fusion welds, quality control parameters shall be defined including the full circumferential fusion
of the removed external roll-back weld bead at every joint (removed by a trimming tool). To confirm
that correct machine parameters are maintained, daily test samples (strips) shall be taken of a butt
welded joint and subjected to a 180º reverse bend test without failure. The test shall also be
conducted when machine settings are altered. The bend test shall be in general accordance with
ASME IX section QW-466.
For extrusion welds, quality control parameters shall be defined including the geometry of the weld
joint, Filler material and size of the filler materials, melt temperature, welding speed, cooling time and
the type of welding extruder used. To confirm that correct parameters are maintained, daily test
samples (strips) shall be taken of a butt welded joint and subjected to a 180º reverse bend test without
failure. The test shall also be conducted when machine settings are altered. The bend test shall be
in general accordance with ASTM F3183 or ASME IX as applicable.
Contractor shall be responsible to carry out any verify the followings points: -
• Before commencing any activity, the contractor representative shall inspect the flanged steel
pipe for its lining suitability. Carbon steel flanges inside edges shall be ground to a radius of
minimum 6mm and the internal welding bead should be flush ground.
• Flange weld shall be smooth or ground flush from weld penetration.

• Contractor inspector shall inspect the spool for any sign that may indicate the internal condition
is unacceptable. The pipe internal surfaces shall be ensured that, the internal surface shall be
free from burrs, sharp edges, and any other substance which may create obstruction to insert
the liner.
• HDPE liner fusion and extrusion procedure including the bed trimming and vent holes shall be
approved by Company non-metallic material engineer TA2. Technician shall be qualified prior
start-up of any activity in accordance with SP-2094.
• The liner shall be fully inserted into CS spool until the stub end is in full contact with CS flange.
Insertion of liner can be done either by pushing or pulling method for straight spools. Pulling
method shall be used for spools with bend(s). The excess length of the liner is marked at the
other end using pencil at 200 from the face of the CS flange.
• Pulling force calculation and stretching required for shop lining shall be calculated as specified
in section 2.5.
• Heating is not permitted as a mean of expansion.

• During HDPE liner stretching, CS spool at both ends and pulling machine shall be bolted
together with steel frame to arrest any longitudinal and transverse movement of the CS pipe.

Revision: 1.0
• Once the maximum expansion / stretch accomplished the liner pipe shall be arrested within
the CS spool by a restraining mechanism. The cutting location on the liner which shall include
the width of the slip-on flange to be extrusion welded to the liner shall be marked and the liner
cut to remove the excess length.
• After cutting, the joint preparation and fit-up shall be carried out before commencing extrusion
welding. The slip-on flange shall be clamped to the steel flange by a minimum of two
diametrically opposed clamps to prevent any movement. Only qualified welding procedure,
welder, welding rods and welding equipment shall be used for the extrusion welding operation.
The expansion length, temperature details shall be recorded in the approved format. All the
welding parameters shall be recorded in the extrusion welding joint record.
• The detailed clamping/holding arrangement for expanded this extrusion welding shall be
submitted for company quality or materials for approval.
• Contractor shall ensure that the arrangement shall not allow any movement of the liner pipe
and flange being welded until the welding operation is completed including the cooling of the
joint.
• The welded joint shall be allowed to cool to ambient temperature before removing any defects.
The joint shall be flush externally and suitable grinders shall be used to achieve a good finish.
• The spool shall be hydro-tested before and after the insertion of PE liner.
• The Contractor shall be responsible for maintaining, fusion welding, inspection, test and as-
built documentation during installation and compiling a package of hand-over documentation
on completion of the work.

Revision: 1.0
APPENDIX 1 – SOP for (PE) liner pulling force calculations

SOP for Polyethylene (PE) liner pulling force calculations
Pipeline Function team
Number of People Involved - 3 .  Total Cycle Time 32 days
Special Procedure Overview Instructions and Explanations Key Point Images

Requirements
Access to ASSAI for 1 Gather all reference 1.1 Check if all data is frozen in terms of  Reference docs:
reference documents to collect line size, design parameters, route,  Project alignment sheets OR
documentation all the required input before proceeding with calculations Routing plan
data and ensure they  Station approach dwgs
are latest by checking 1.2 Check the deliverable register, to  Process Engg Flow scheme
revisions in deliverable confirm latest revisions of reference (PEFS)
Via - Livelink / PDO
register. documents.  CS WT calcs report
LAN  PE WT calcs report
1.3 Make a note of all revision numbers of
the documents used in the  Abbreviations:
Process Performer: Cycle Time: 1 days
calculations; If new revisions are  CS – Carbon steel
Pipeline Engineer issued verify the changes in the input  ID – Inside diameter
data (if any), and revise calculations to
 OD – Outside diameter
reflect the changes.
 PE – Polyethylene
 PEFS - Process Engg
Flow scheme
 WT – Wall thickness
Data gathering 2 Collect all information 2.1 Ensure use of PE100 grade properties  Reference Standards
required for pulling like -Young’s Modulus, density, tensile SP-2094 : Specification for PE
force calculations strength, coefficient of thermal liners in CS flowlines & pipelines
Via – Livelink / PDO expansion, CS line ID, PE liner OD &
LAN WT….etc
SP-2094 CMS link
2.2 Allocate section numbers in alignment
sheets
Cycle Time: 3 days
2.3 For each section note the following:
 Section length
 Number of bends
 Radius of bend
 Type of bend
Process Performer:
Pipeline Engineer
Access to approved / 3 Use approved / 3.1 Enter all inputs in spreadsheet
See
validated PE liner calcs validated spreadsheet
pulling force attached
spreadsheet. calcs.xlsm Excel file
Cycle Time: 1 day
Via - email
Process Performer:
Pipeline Engineer
Document Owner Version (Revision) Effective Date Approval Document Location Page
UEMP UEMP/SOP1/ 20-May-19 UEMP / Badar Al Habsi 1 of 5
Ver1.0
PE pulling force 4 Perform PE pulling 4.1 Calculate the pulling force based on
calculations force calculations below:
DLo = PE liner OD
DLi = DLo – 2 x tL DLi = PE liner ID
tL = PE liner thk
Via approved
spreadsheet - Steps AL= π x (DLo^2 - DLi^2)/4 AL = Area of PE Liner
4.1
W = ρ x AL W = weight of PE liner per unit length
ρ = Density of PE liner
For Straight sections (without bends): Lliner = Liner length Straight section
Cycle Time: 2 days
Fpull = Lliner x W x f + Freduce (if
f = 0.4 (friction factor)
applicable)
Process Performer: Fpull = pull in force.
Pipeline Engineer
n = number of bends of each

For sections with bends:
combination of angle & radius
Σ θ = angle of bend
Fpull = Lliner x W x f x Σ (e( nfθ)) + (Bend radius as per SP-1211, 4.3.8)
Freduce (if applicable)
Freduce = Preduce x AL
Preduce = 0 MPa (slip lining Or
loose lining Or Tight
liner – roll down method)
Preduce = 5 MPa (Tight lining -
others)
For some PE installations, additional

force is required in terms of Freduce,
to reduce the diameter of liner and pull
into the main pipe.
Lmax – Max pull length (ignoring

Freduce)
Currently Lmax is limited to 700m
Maximum pulling straight length Lmax

= Puller Capacity / (W x f)
Maximum pulling length Lmax (with bends)

= Puller Capacity / (W x f x (e(Σnfθ)))
T = Tensile yield strength of PE liner at
Maximum allowed pulling Force PE surface temperature
= 0.5 x T x AL
Ver1.0
Optimisation of section 5 Optimise the section 5.1 Optimisation of pulling length as

pulling lengths length based on puller follows:
capacity  Select the right puller capacity
Via approved machine to pull liner
spreadsheet  Ensure that the calculated
Cycle Time: 1 day
pulling force is less than maximum
Process Performer: allowed pulling Force (Fmax)
Pipeline Engineer  Ensure that the section length
is less than calculated pulling length
(Lmax)
 Optimise the section length as
per flowchart below.
5.2 Prepare final report for PE liner pulling

force calculations after all sections are
GREEN in spreadsheet
Ver1.0
Input all data in

Increase Section
yellow cells
length
All light blue cells have

calculated values
Yes Yes Is Total Fpull

Is L < 0.9 x
< 0.9 x Fmax?
Lmax?
No
No
Yes
Is Total Fpull
> Fmax?
Yes
Is L > Lmax?
No
No
Section Length not
Section length is acceptable
acceptable
Calculation document 6 Review and approval 6.1 Client TA2 Pipeline Reviews and
approval of calculation report provides comments on the document
6.2 Pipeline Engineer incorporates
Via – ASSAI Cycle Time: 4 days comments (if any)
6.3 Client TA2 Pipeline approves
Process Performer: document
Client TA2 Pipeline &
Pipeline Engineer
Construction reporting 7 Use of standard

Via Email wireline report 7.1 Issued for information See
sample Wireline attached
template Report.xls
Excel file
Process Performer:
Construction Pipeline Cycle Time: 20 days
Engineer
Ver1.0
 Pre-Checks Key Point Images

Things to Do Before Starting the Process
☐ Design data – size, pressure, temperature
☐ PE properties
☐ Fluid / Design Temperature
☐ Section lengths with bend info
 Tools and Materials Step Key Point Images
Things You Need Before Starting the Process
☐ Routing plans / Alignment sheets for section 1
☐ SP-2094 2
☐ Approved PE calcs spreadsheet 3
☐ Wireline report template 7
People Key Point Images
Who Is Required to Be Notified
☐ PDO Pipeline engineers / FO / Design Consultants
☐ Construction Contractor
 Key Learnings; Performance Points  Key Point Images

What Have We Learned That We Should Share
 Correct methodology for calculation of Pulling forces
Ver1.0
Revision: 1.0
APPENDIX 2 – SOP for PE Liner wall thickness, Stub end and

Retainer ring design

SOP for HDPE Liner wall thickness and Stub End design
Number of People Involved - 3 .  Total Cycle Time 11 days
Special Requirements Procedure Overview Instructions and Explanations Key Point Images
STEP 1.0 : Data Collection
Access to ASSAI / SPO 1 Gather all 1.1 Check if all data is frozen in terms of line  Reference
for reference reference size, design envelop before proceeding - Pipeline design data summary
documentation documents to with calculations. sheet
collect all the - SP-2380
required input 1.2 Check the deliverable register (DDM), to
data and ensure confirm latest revisions of reference  Symbols
Via - Livelink / PDO
they are latest by documents which identified in the D = CS Outside diameter (mm)
LAN checking revisions incoming steps. E = Modulus (@ 5% Sec Value)
in deliverable t = CS wall thickness (mm)
register. 1.3 Make a note of all revision numbers of the ID = CS Inner diameter (mm)
Process Performer:
documents used in the calculations; If ε (swell) = Linear swell (%)
Pipeline Engineer new revisions are issued verify the Pc = Min Collapse pressure (bar)
changes in the input data (if any), and R = Average radius of the Liner (mm)
Cycle Time: 1 day
revise calculations to reflect the changes. h = PE Liner Wall thickness (mm)
hmin = Minimum Wall Thickness of the
PE Liner (mm)
 Abbreviations
CS – Carbon Steel
WT – Wall Thickness
PE – Poly Ethylene
DP – Design Pressure
SMYS – Specified Minimum Yield
Strength
TN – Technical Note
PPI – Plastic Pipe Institute
STEP 2.0 : Input data

Data gathering 2 Collect all 2.1 For calculations, the following is to be  References:
information noted: - Pipeline design data summary
required to sheet
 Design Pressure
Via – reference docs calculate the wall - SP-2380
thickness  Class Rating
from step 1  CS line size and Outside diameter
 CS Wall thickness
 PE Liner Material (HDPE or PERT)
 Loose or Tight Fit Liner
Process Performer:
Pipeline Engineer  Service (Water or Crude)
Cycle Time: 1 day
 PE Liner Maximum Operating
Temperature
 Minimum Collapse Pressure (Water=1.5
bar or Crude=3 bar)
PDEMP19 (Zaid Al-Mawali) UEMP/SOP4 16-Dec-2020 UEMP (Badar Al Habsi) 1 of 7
Version 2.0
STEP 3.0 : Methodology for performing PE Liner wall thickness calculations
Start Simplify the Collapse Equation (Step 5.1)
Calculate the required wall thickness (Step 5.2)
Yes
h = hmin h < hmin
No
h to be considered
Select the value of PE Liner OD (Step 5.3)
Calculate the Stub End Length (Step 5.4)
Calculate the Retainer Ring Thickness (Step 5.5)
Optimize between No ODRR < ADRR

increasing/decreasing
& Sh ≤ SA
ODRR
Yes
Calculate the Retainer Ring Width (Step 5.6)
Retainer Ring Bulking Analysis (Step 5.7)
No SPE+PE, SPE+CS,
Increase “ h “ SPE+ROTO ≤ SA
Yes
End
Print results from
spreadsheet
Version 2.0
STEP 4.0 : Use of approved validated spreadsheet

Access to approved / 4 Use approved 4.1 Enter all inputs in spreadsheet
validated wall and validated
thickness calculation spreadsheet
spreadsheet.
Cycle Time: 1 day
Via: Email
Process Performer:
Pipeline Engineer
STEP 5.0 : Calculate the wall thickness

PE Liner wall thickness 5 Perform the wall 5.1 Simplify the Collapse Equation ε (swell) refer SP-2380,
calculations thickness Table 1 and Table 2.
calculations Pc = E * ( h / R )2 * ( 2.334 - [ 0.0385 * ε (swell) * ( R / h ) ] )
Via: Spreadsheet If the design temperature
(Step.4) Substitute X = h / R in above equation. is between 60 ºC to 70 ºC,
then swell and E value for
70 ºC to be considered for
Solve Quadratic Equation for ( X ):
HDPE. If the design
Process Performer: temperature is between 60
Pipeline Engineer Cycle Time: 1 day
X2+ ( -0.0165 * ε (swell) * X ) + ( - Pc / (2.334 * E ) = 0 ºC to 85 ºC, then swell and
E value for 85 ºC to be
X1 = (- B + SQRT ( ( B )2 – [ 4 * A * C ] ) ) / ( 2 * A ) considered for PERT.
A - Coefficient of squared
X2 = (- B - SQRT ( ( B )2 – [ 4 * A * C ] ) ) / ( 2 * A ) term in the quadratic
equation.
Where:
B - Coefficient of single
A=1 powered term in the
quadratic equation.
B = - 0.0165 * ε (swell)
C - Constant in quadratic
C = - Pc / ( 2.334 * E ) equation.
5.2 Calculate PE Liner Wall Thickness
R = 0.5 * (ID - h ) SP-2380, Clause 2.3
Taking positive value of X, and substitute ( X = h / R ) in

above equation, we get (h) PE liner wall thickness (mm)
h = (0.5 * ID) / [ (1/X) + 0.5 ]

Yes
h = hmin h < hmin
No
Note: The minimum wall thickness of the HDPE liner pipe

(hmin) shall be 6mm, as stated in SP-2380 clause 2.2.
Version 2.0
5.3 Select the value of PE Liner OD
For Loose Liner, select ODPE based on:

SP-2380 clause 2.4.1
a. ODPE ≥ ID - 4mm , “ 2” to 4” NPS “
b. ODPE ≥ ID - 6mm , “ 6” to 10” NPS “ Symbols:
c. ODPE ≥ 97.5% of ID , “ 12” to 24” NPS “
d. ODPE ≥ ID - 15mm , “ 26” NPS & above “ ODPE = PE Liner OD
(mm).
For Tight Fit Liner, the design of ODPE, Stub End and
Retainer Ring shall be proposed by Consultant after
alignment with Contractor and sent for PDO approval.
5.4 Calculate the Stub End Length Symbols:
ØD = IDPE ØD = Stub End internal dia

(mm)
IDPE = ODPE – ( 2 * h )
IDPE = PE liner internal dia
ØD1 = ODPE (mm)
ØD2 = ID - (2 * clearance) ØD1 = Stub end outside

dia at the PE Liner side
Clearance can be considered 0.5 mm (mm); applicable for loose
liner type only.
ØD3 = refer to symbols
ØD2 = Stub end outside
dia at the CS Flange side
tC = 1.5 * h (if h > 10 ) (mm); applicable for loose
liner type only.
Or
ØD3 = Outside Diameter
tC = 2 * h (if h ≤ 10 mm) Raised face (mm), refer to
ASME B16.5, table 4
L = L1 + L2 + tC
tC = Collar Thickness (mm)
Where:
Y = Welding Neck Length
L1 = (Y + RF) – 50 (mm), refer to ASME
B16.5, tables for
L2 = 100 mm Dimensions of Class#
flanged fittings
RF = Raised face height

(mm), refer to ASME
B16.5, clause 6.4.1.
L = Stub End Length (mm)
L1 = Length of the stub

end’s thick portion (mm)
L2 = length of the stub end

after the stub end’s thick
portion (mm)
Symbols:
Version 2.0
5.5 Calculate the Retainer Ring Thickness IDRR = Retainer Ring ID

(mm)
IDRR = ØD3 + (2 * Clearance)
BCD = Bolt Circle
ADRR = BCD – DBH – (2 * Clearance) Diameter (mm), refer to
ASME B16.5, Tables as
Note: Clearance can be considered 0.5 mm applicable flange rating
The value of ODRR need to be selected by using “Trial and DBH = Diameter of Bolt
Holes (mm), refer to
Error Method”:
ASME B16.5, Tables as
per applicable flange
- if ODRR < ADRR & Sh ≤ SA , then acceptable rating
- if ODRR ≥ ADRR or Sh > SA , then not acceptable
ADRR = Retainer Ring
tRR = ( ODRR – IDRR ) / 2 (Note-1) Allowable Diameter (mm)
SA = 0.9 * SMYS of the selected material for Retainer Ring ODRR = Retainer Ring OD
(mm)
PHT = 1.25 * DP
tRR = Retainer Ring
Sh = ( PHT * ODRR ) / ( 2 * tRR ) thickness (mm)
SA = Allowable Hoop
Stress (Mpa)
PHT = Pipeline Hydrotest

Pressure (Mpa)
Sh = Calculated Hoop
Stress (Mpa),
∆lPE = Change in stub end

collar thickness (mm)
∆lROTO = Change in
rotolining thickness (mm)
tROTO = Rotolining
Thickness (mm)
5.6 Calculate the Retainer Ring Width
wX+X = Width of Retainer
∆lPE = tC * 7.5% (Note-2) Ring (mm)
∆lROTO = tROTO * 7.5% (Note-2) Note:
1. In case this thickness
wPE+PE = (2 * tc) + (2 * RF) - (2 * ∆lPE) results in impractical
dimensions, the consultant
shall propose practical
wPE+CS = tc + (2 * RF) - ∆lPE
thickness for approval by
TA2.
wPE+ROTO = (tc + tROTO) + (2 * RF) – (∆lPE + ∆lROTO)
2. Allowable compressive
strain (%) is restricted to
7.5%, refer to TN-38 of PPI.
Symbols:
Version 2.0
5.7 Retainer Ring Buckling Analysis: F = Clamping Force for

Flange Point (N)
F = T / ( K * DBH )
K = Nut Factor, refer to
SP-2020, Appendix B
APE+PE = π * ( ODRR – IDRR ) * wPE+PE
T = Bolt Torque (Nm),
APE+CS = π * ( ODRR – IDRR ) * wPE+CS refer to SP-2020,
Appendix D
APE+ROTO = π * ( ODRR – IDRR ) * wPE+ROTO
AX+X = Resistance Area
(mm2)
SPE+PE = F / APE+PE
SX+X = Applied Stress
SPE+CS = F / APE+CS (Mpa)
SPE+ROTO = F / APE+ROTO SA = Allowable Hoop
Stress (Mpa)
- If SPE+PE, SPE+CS, SPE+ROTO ≤ SA , then acceptable.
For isolation flanged joint, phenolic retainer rings shall be

used. The dimensions of the phenolic retainer ring are to
be specified by the Vendor.
STEP 6.0 : Report generation

Access to report 6 Use approved 6.1 Prepare report for PE Liner wall thickness calculations
template report template using report template.
Via - Email
Cycle Time: 2 days
HDPE Liner Wall
Process Performer: Thickness and Stub
Pipeline Engineer
STEP 7.0 : Document approval

Calculation document 7 Review and 7.1 Client TA3 Pipeline Reviews and provides comments
approval approval of on the document
calculation report 7.2 Pipeline Engineer incorporates comments (if any)
Via – ASSAI / SPO 7.3 Client TA3 Pipeline approves document
Cycle Time: 5 days
Process Performer:
Client TA3 Pipeline &
Pipeline Engineer
Version 2.0
 Pre-Checks Key Point Images

Things to Do Before Starting the Process
☐ Design data – size, design pressure, and class rating
☐ PE Liner Material
☐ Fluid Service
☐ PE liner Maximum Operating Temperature
 Tools and Materials Step Key Point Images

Things You Need Before Starting the Process
☐ Pipeline design data summary sheet 1
☐ SP-2380 1
☐ Approved calculation spreadsheet 4
People Key Point Images

Who Is Required to Be Notified
☐ PDO Pipeline engineers / FO / Design Consultants
☐ Construction Contractor
 Key Learnings; Performance Points  Key Point Images
What Have We Learned That We Should Share
 Spreadsheets which are not validated shall NOT be
used for calculations.
Version 2.0
Revision: 1.0
APPENDIX 3 – Standard Drawing for Vent design

Revision: 1.0

Revision: 1.0

Revision: 1.0

Revision: 1.0

Revision: 1.0

Revision: 1.0
APPENDIX 4 – USER COMMENT FORM
SP-2380 – Specification for design and construction of PE liner in Carbon steel flowlines
and pipelines
User Feedback Page
Any user who identifies an inaccuracy, error or ambiguity is requested to notify the
custodian so that appropriate action can be taken. The user is requested to return
this page fully completed, indicating precisely the amendment (s) recommended.
Name:
Ref ID Date:
Page Ref: Brief Description of Change Required and Reasons
Pipeline CFDH (UEMP)
Custodian of Document Date:

689 Attachment-01 SP-2380 Design & Const of PE Lined Carbon Steel Lines

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689 Attachment-01 SP-2380 Design & Const of PE Lined Carbon Steel Lines

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Petroleum Development Oman L.L.C.

Design and construction of PE lined Carbon steel lines

Document Type Specification

Discipline Pipeline Engineering

Owner UEMP – Pipelines Corporate Functional Discipline Head

Issue Date December 2020

Printed copies are UNCONTROLLED.

This page was intentionally left blank

Printed copies are UNCONTROLLED.

Document Owner Document Custodian Document Author

Printed copies are UNCONTROLLED.

Version Date Author Scope / Remarks

iii Related Business Processes

iv Related Corporate Management System (CMS) Documents

Printed copies are UNCONTROLLED.

Printed copies are UNCONTROLLED.

1.2 Distribution, Intended use and regulatory considerations

Company Petroleum Development OMAN. LLC

1.3.2 Special Definitions

Printed copies are UNCONTROLLED.

ANSI American National Standards Institute

1.5 Comments on this SP

Printed copies are UNCONTROLLED.

PR-2066 Managing Variance from Technical Standards

SP-1210 Specification for Pipeline Integrity Management

SP-1211 Onshore Pipeline Engineering

SP-1212 Hydrostatic pressure testing of new pipelines

SP-1236 Isolation systems for cathodically protected pipelines

SP-2347 Procurement specification for CS line pipe

International Standards (Latest Edition unless otherwise specified)

API RP 5L1 Recommended practice for railroad transportation of line pipe

ASME B31.4 Pipeline transportation systems for liquids and slurries

ASME B31.8 Gas transmission and distribution piping systems

ISO 4427 Polyethylene (PE) pipes for water supply – specifications

ISO 13479 Environmental stress crack resistance

ISO 9969 Thermoplastic pipes- determination of ring stiffness

Bolt torque for polyethylene flanged joints - Technical note#38 - plastics

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2.2 PE liner design basis

2.2.1 Water Service

a. The maximum operating temperature shall be as follow in line with SP-2094: -

• For HDPE Liners is 70°C.

2.2.2 Hydrocarbon / Multiphase Service

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2.3 Wall thickness calculation

R = Average radius of the liner (mm) = 0.5 * (ID steel – h)

E = Modulus (in MPa)

• PE 100 MATERIAL properties as per Table 1

Service PE Liner max. Linear E Modulus Poisson’s Coefficient of thermal

• PE-RT MATERIAL properties as per Table 2

Service PE Liner max. Linear E Modulus Poisson’s Coefficient of thermal

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2.4 Selection of Outside Diameter

2.4.1 For loose fit liners

2.4.2 For tight fit liners

2.5 Pulling force calculations

Sl # Temperature Yield stress

Table 3 – Yield stress

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Fpull = L Liner x W x f x Σ (e(Σnfθ) ) + Freduce

F reduce : The load applied to the liner from installation technique

• Stretching force calculation (F stretch)

F stretch = E x A x L stretch / L Linear