SP-2094 Version 03

Version: 03
Petroleum Development Oman LLC Effective: NOV-21
Petroleum Development Oman L.L.C.
Document Title: Specification for Polyethylene liners

in carbon steel flow lines, pipelines and piping
Document ID SP-2094
Document Type Specification
Security Restricted
Discipline Materials & Corrosion
Owner UEC
Issue Date November 2021
Version 3
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 02/01/2022 SP-2094 Polyethylene liners in carbon steel flow lines pipelines & piping Page 1
Printed copies are UNCONTROLLED.
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This page was intentionally left blank
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i Document Authorisation
Authorised for Issue
Document Authorisation
Document Owner Document Custodian Document Author
(CFDH)
Behlani, Nasser UEC NABHANI,TALAL UEC1 Kharusi, Imran UEC1E
Date : 02-01-2022 7:36 AM Date : 01-01-2022 9:19 PM Date : 27-12-2021 7:24 AM
Version: 03
ii Revision History
The following is a summary of the 4 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.
UEC125 Initial issue (ERD-43-15 revised to
0 08.09.2010
Rama Ramanhalli SP2094)
Revised based on the feed backs, trials
1 30.06.2018 UEC13 & UEC1X
& experience in PE lined CS lines
Revised based on the feed backs, trials
2 29.07.2019 UEC13 & UEC1E
& experience in PE lined CS lines
Installation & design aspects moved to
SP-2380 and Material aspects revised
3 14.11.2021 UEC1E & UEC13
based on international standards & new
qualifications
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iii Related Business Processes

Code Business Process (EPBM 4.0)
iv Related Corporate Management Framework (CMF) Documents

The related CMF Documents can be retrieved from the Corporate Business Control Documentation
Register CMF.
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Table of contents
i Document Authorisation ................................................................................................. 3
ii Revision History .............................................................................................................. 4
iii Related Business Processes ............................................................................................. 5
iv Related Corporate Management Framework (CMF) Documents ....................................... 5
1. INTRODUCTION ........................................................................................................... 8
1.1 SCOPE ................................................................................................................................. 8
1.2 APPLICABILITY ..................................................................................................................... 8
1.3 STANDARD DEFINITIONS ..................................................................................................... 8
1.4 SPECIAL DEFINITIONS .......................................................................................................... 8
1.5 ACRONYMS ........................................................................................................................ 10
2. PE LINER PIPE PURCHASING REQUIREMENTS .............................................................. 11
2.1 GENERAL............................................................................................................................ 11
2.2 RAW MATERIAL QUALIFICATION ........................................................................................ 11
2.3 UV PROTECTION................................................................................................................. 11
2.4 CONNECTIONS ................................................................................................................... 11
2.5 NON-METALLIC RETAINER RING .......................................................................................... 11
3. MANUFACTURE ......................................................................................................... 12
3.1 PIPE MATERIAL .................................................................................................................. 12
3.2 FLANGE MATERIAL ............................................................................................................. 13
3.3 ROTOLINED SPOOLS ........................................................................................................... 13
3.4 FINISH AND WORKMANSHIP .............................................................................................. 13
3.5 DIMENSIONS, WEIGHTS AND TOLERANCES ......................................................................... 13
4. QUALITY PROGRAM ................................................................................................... 15
4.1 QUALITY MANUAL ............................................................................................................. 15
4.2 PROCESS AND QUALITY CONTROL REQUIREMENTS ............................................................. 15
4.3 QUALITY CONTROL EQUIPMENT ......................................................................................... 15
4.4 QUALITY CONTROL TESTS ................................................................................................... 15
4.5 INSPECTION AND REJECTION .............................................................................................. 16
4.6 QUALITY CONTROL RECORDS REQUIREMENTS .................................................................... 17
5. MARKING ON THE HDPE LINER PIPE ........................................................................... 18
6. HANDLING AND STORAGE .......................................................................................... 19
6.1 STORAGE ........................................................................................................................... 19
6.2 HANDLING ......................................................................................................................... 19
6.3 TRANSPORTATION ............................................................................................................. 19
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7. REFERENCES .............................................................................................................. 20
7.1 COMPANY STANDARDS ......................................................................................................20
7.2 NATIONAL STANDARDS ......................................................................................................20
7.3 INTERNATIONAL STANDARDS .............................................................................................20
Cathodic protection of pipeline systems Part 1: On-land pipelines .................................................20
APPENDIX A - BUTT FUSION AND EXTRUSION WELDING QUALIFICATION .......................................21
APPENDIX B - PE MATERIAL PROPERTIES.......................................................................................25
APPENDIX C – RETAINER RING MATERIAL PROPERTIES ..................................................................27
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1. INTRODUCTION
1.1 SCOPE
This Specification specifies requirements for the selection, manufacture and jointing requirements of
polyethylene liners in carbon steel pipelines, flow lines and piping for water, oil and multiphase (GLR≤300)
applications.
1.2 APPLICABILITY
This specification is intended for procurement, manufacturing and joining process of polyethylene liners.
Applications include flow lines, pipelines and piping for both buried and above ground applications.
Design and construction of HDPE lined CS shall follow SP-2380.
If there is any change to the specification requirements, it shall be approved by CFDH materials and
corrosion (the owner of the document).
1.3 STANDARD DEFINITIONS
The following terms are applicable to this specification:
 Company: Petroleum Development Oman LLC.
 Contractor: The party that carries out all or part of the design, engineering, procurement,
construction, commissioning or management of a project or operation of a facility. The Principal
may undertake all or part of the duties of the Contractor.
 Vendor: The person or organisation that supplies the company with materials and/or equipment.
 The word shall indicate a requirement.
 The word should indicate a recommendation.
 The word may indicate a permitted option.
1.4 SPECIAL DEFINITIONS
The list that follows tells you the special meaning of some words in this specification.
1.4.1 Acceptance criteria
Defined limits placed on characteristics of materials, products, or services.
1.4.2 Annulus
Space between the PE liner outer diameter and the carbon steel inner diameter
1.4.3 Bell hole
Excavated area allowing access to a buried carbon steel pipeline for insertion of PE liner.
1.4.4 Butt fusion welding
A process of fusing of polyethylene materials that entails squaring and aligning the pipe materials, heating
the pipe ends, pressuring the two aligned ends together and cooling for a predetermined time, all as
specified by the qualified procedure which results in a joining of two pipe materials. The joint will exhibit a
hydrostatic strength equal to the parent pipe.
1.4.5 Extrusion Welding
The principal of extrusion welding is that, a machine that heats a plastic filler material in the form of a rod
or pellets and at the same time heats the base material surface with hot air or halogen lamps. The molten
filler material is extruded through a die on the molten surface of the base material (with some pressure
applied) and allowed to cool.
1.4.6 Flanges
Steel raised face flanges with bolt circle per ANSI B 16.5. Incorporates use of PE flange and metallic backup
ring.
1.4.7 Lot (number)
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For PE pipe a ‘lot’ is defined as being all pipes continuously produced from the same base polymer batch
with the same diameter and wall thickness, up to a maximum number of 200 pipe lengths or 2000 m of
coiled pipe.
For moulded or machined PE flanges a ‘lot’ is defined as being all flanges continuously produced from the
same base polymer batch with the same dimensions, up to a maximum number of 200.
For rotational moulded PE spools, a lot is defined as 20 spools produced continuously with same base
polymer batch. A lot number is a unique code to maintain traceability.
1.4.9 Ovality
This is a measurement of the deflected set in a cross section of pipe and is expressed as a percentage. It
is measured by taking the maximum measured diameter minus the minimum measured diameter (the out
of roundness value) and dividing that sum by the average measured diameter and multiplying that resultant
by 100.
1.4.10 PE liner
Internal PE pipe for corrosion protection of carbon steel pipelines or flow lines. A PE liner consists of several
PE pipe lengths, which are fused together and inserted into sections of new or existing carbon steel
pipelines and flow lines. The Carbon Steel pipe provides the pressure containment and the PE liner provide
corrosion protection. At the ends of the sections, the liners are terminated by PE flanges.
1.4.11 Permeation
Diffusion of liquid and gas through the PE liner under the influence of pressure and temperature.
1.4.12 Point of fusion
The end of pipe available for trimming, heating, and pressing together during the heat fusion process.
1.4.13 Records
Retrievable information.
1.4.14 Standard Dimension Ratio (SDR)
A specific ratio of the average specified outside diameter to the minimum specified wall thickness (OD /h)
for outside diameter-controlled plastic pipe.
1.4.15 Vent point
Hole in the carbon steel outer pipe to allow the release of gas accumulated in the annulus.
1.4.16 Venting
The release of gas accumulated in the annulus.
1.4.17 Visual examination
Examination of parts and equipment for visible defects in material and workmanship.
1.4.18 Raw Material Manufacturer
Company that provides the raw PE material (granular) to the PE pipe supplier.
1.4.19 PE Pipe Supplier
Company that extrudes the PE liner pipe. Company approved suppliers listed in AVME shall be used to
supply the HDPE pipes.
1.4.20 Rotational moulding (Rotolining)
Production technique in which a PE lined spool is produced by heating and rotating a carbon steel spool
with PE powder inside. The PE powder melts and forms a liner on the surface of the carbon steel pipe.
1.4.21 Crude oil service
Fluids with crude oil fraction of more than or equal to 1% by volume.
1.4.22 Water service
Fluids in which the volume fraction of crude oil is less than 1%.
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1.4.23 5% Secant Modulus

Ratio of stress to strain at the 5% strain point on curve in a stress-strain diagram.
1.4.24 XLPE
XLPE also indicated as XPE or PEX is a cross-linked high-density polyethylene grade.
1.5 ACRONYMS
ANSI American National Standards Institute
API American Petroleum Institute
ASTM American Society for Testing and Materials
H Minimum specified wall thickness
ID Inside Diameter
ISO International Standards Organisation
MAOP Maximum Allowable Operating Pressure
OD Outside Diameter
PE Polyethylene
SDR Standard Dimension Ratio
HDB Hydrostatic Design Basis
PE-RT Polyethylene Raised Temperature
SLT Standard Laboratory Temperature
SGC Slow Crack Growth
TA2 Technical authority – Level 2
RCP Rapid Crack Propagation
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2. PE LINER PIPE PURCHASING REQUIREMENTS

2.1 GENERAL
This section provides requirements for purchase of HDPE and PE-RT liner pipe. HDPE and PE-RT liner
pipe shall be purchased from only company approved vendors listed in approved vendors list.
2.2 RAW MATERIAL QUALIFICATION
The resin manufacturer SHALL [PS] determine the long-term hydrostatic design stress (LTHS) for the
compound to be qualified as per qualification method ISO 9080.
In addition to the regression tests, the raw materials shall be listed in PE100 association and shall be in
compliance with ISO4427/ISO4437.
PE-RT material shall be in compliance with ISO 22391-2 and shall be approved by PDO Non-metallic TA-
2.
Only Company approved raw materials shall be used to manufacture HDPE liner pipe. Pipe material shall
be HDPE grade PE100 or PE-RT type II material based on temperature requirements.
2.3 UV PROTECTION
All HDPE pipe and fittings supplied to this specification shall be stabilised against degradation by UV-light
by a minimum of 2% (by mass) of Carbon Black.
2.4 CONNECTIONS
HDPE and PE-RT liner pipe supplied to this specification shall be joined by butt fusion welding. Connections
between HDPE lined carbon steel pipes shall be flanged. Other joining methods shall not be used for site
lining.
Extrusion welding is only allowed for spool shop lining and shall be authorised by Non- Metallic Materials
TA2. All joining procedures and operators shall be qualified in accordance with Appendix A of this
specification prior to the commencement of production. All joining procedures shall be approved by PDO
quality Engineers, authorized by PDO non-metallic TA2.
2.5 NON-METALLIC RETAINER RING
Non-metallic retainer ring (Phenolic/Composite Ring) is required on the isolation flanged joint. The
properties of the phenolic retainer ring supplied by United are listed in Appendix C. Other material/suppliers
shall be assessed by the company. The Non-metallic retainer ring shall meet the electrical isolation
requirements as per ISO-15589-1.
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3. MANUFACTURE
3.1 PIPE MATERIAL
Polyethylene liner pipe shall be produced and classified in accordance with a recognised Industry Standard
(API 15LE or ISO 4427).
The Contractor shall be responsible for identifying any supplementary requirements, such as special
dimensional tolerances, necessary to meet the liner design criteria.
Liner pipe furnished to this specification shall be produced by extrusion process.
The inclusion of rework materials during pipe manufacture shall not be permitted. The form of supply,
whether as cut lengths or coils shall be as stated on the Purchase Order.
Minimum properties for the PE 100 & PE-RT Type II liner material are given in Table 1 &Table 2
respectively .
Table 1 Minimum Properties for PE100 Polyethylene Liner Pipe
Property Test Method Requirement
ISO1183-1
Density (g/cm3) ≥ 0.941
Method A
Melt index
ISO1133 0.2-0.3
(g/10min; 190 ⁰C, 5000-gram load)
Modulus (MPa) ≥750
ISO 527-2 /
Yield strength (MPa) ≥ 21
ASTMD638
% of Elongation ≥400
Environmental stress crack
ASTM D1693 Failure less than 20%
resistance (Condition C, 192 hours)
MRS value
ISO 9080 ≥10
(MPa at 20 ⁰C, 20 years)
Oxidation Induction Time
ASTM D3895 ≥ 20 minutes
(at 210 ⁰C)
Resistance to Slow Crack Growth
ISO 13749 ≥ 1000hours
(SCG) 9.2bar, 80°C
Carbon black content ISO6964 ≥2%
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Table 2 Minimum Properties for PE-RT Liner Pipe

Property Test Method Requirement
ISO1183-1
Density (g/cm3) ≥ 0.941
Method A
Melt index
ISO1133 ≤2
(g/10min; 190 ⁰C, 5000-gram load)
Modulus (MPa) ≥850
ISO 527-2 /
Yield strength (MPa) ≥ 22
ASTMD638
% of Elongation ≥350
MRS value
ISO 9080 ≥10
(MPa at 20 ⁰C, 20 years)
Oxidation Induction Time
ASTM D3895 ≥ 40 minutes
(at 210 ⁰C)
Carbon black content ISO6964 ≥2%
3.2 FLANGE MATERIAL
HDPE/PE-RT flanges or Stub end and extrusion flange ring shall be moulded or machined from extruded
pipe. Stub end material shall be made from the same grade as that of the pipe. Minimum wall thickness
shall be equal to the wall thickness of the pipe.
3.3 ROTOLINED SPOOLS
Rotolining of CS spools shall be carried out in accordance with approved procedures.
Initial procedures qualification shall be reviewed and approved by Non-metallic TA2. Project specific
rotolining procedures shall be reviewed by quality team in line with initial approved procedures. The ITP of
rotolining and procedures shall be approved by PDO quality or non-metallic material TA2.
Rotolining shall be carried out only in the company approved facility listed in AVME list using approved
material grade.
3.4 FINISH AND WORKMANSHIP
Cut pipe ends shall be plain and square. Cut edges shall be clean and without ledges, shaving tails, burrs,
or cracks. The interior of the pipe shall be blown or washed clean of cuttings and shavings.
The interior and exterior of the pipe shall be uniform with smooth finish. The pipe shall be free from voids,
cracks, crazing, foreign inclusions and waviness. Any defect causing reduction of wall thickness beyond
specified minimum wall thickness as per purchase order shall be rejected.
Non-destructive testing techniques shall be subject to approval by MCI TA2.

3.5 DIMENSIONS, WEIGHTS AND TOLERANCES
3.5.1 Size, tolerances
The purchaser shall specify nominal values of liner outside diameter and wall thickness in the HDPE liner
pipe wall thickness calculations. Liner pipe wall thickness calculation shall be approbeved by Pipeline
design prior to issue of purchase order or production. The tolerance on the liner wall thickness shall be -
0%/+10% of the specified value. Dimensions shall be measured once the product is cooled down to
ambient temperatures.
Tolerance on outer diameter of pipe shall be within the limits specified in ISO 4427-2.
3.5.2 Length of liner pipe joints
The length of individual joints of liner pipe shall be as per purchase order to minimise the number of field
welds; consistent with transportation, handling and any other project constraints.
The average, maximum and minimum liner joint lengths shall be agreed between the Contractor and the
Company.
3.5.3 Ovality and out-of-roundness

The ovality of the pipe shall be measured as per ASTM D-2513 and shall not exceed limits in ISO 4427-2.
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During production, both ovality and out-of-roundness shall be monitored and recorded at the frequency
specified in Table 3 in ISO 4427-2.
3.5.4 Toe in
The toe in of produced Polyethylene pipe shall be measured in accordance with ASTM F714 and shall not
exceed 1.5% OD.
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4. QUALITY PROGRAM
4.1 QUALITY MANUAL
The pipe supplier shall maintain a quality manual which describes the quality program. The quality
requirements shall meet SP-1171 requirements. All prior revisions shall be retained for a period of not less
than five years.
4.2 PROCESS AND QUALITY CONTROL REQUIREMENTS
The pipe supplier shall establish and maintain a documentation programme to assure, implementation of
quality management system throughout the organization. Manufacturing, quality control personnel & their
respective supervisory personnel shall be well trained to skill level to manufacture and supply the PE liner
pipe materials to meet the specification requirements. The following procedures shall be submitted to the
Company for review and approval:
a. Raw material acceptance.
b. Extrusion procedures.
c. Pipe manufacturing practices.
d. Process validation and in process inspection.
e. Welding procedures and qualifications.
f. Inspection and test procedures.
g. Acceptance criteria.
h. Control of non-confirming products.
4.3 QUALITY CONTROL EQUIPMENT
4.3.1 General
Equipment used to inspect, test or examine material or other equipment shall be identified, controlled,
calibrated and adjusted at specified intervals in accordance with documented pipe supplier instructions,
and consistent with referenced industry standards to maintain the accuracy required by this specification.
4.3.2 Dimensional measuring equipment
Dimensional measuring equipment shall be controlled and calibrated by the pipe supplier written
specification.
4.3.3 Pressure measuring devices
Test pressure measuring devices shall be either pressure gauges or pressure transducers. All pressure
measuring devices shall be calibrated to a certified standard annually.
4.4 QUALITY CONTROL TESTS
4.4.1 Conditioning
Quality control testing
Unless otherwise specified, all QC specimens shall be conditioned for a minimum of 4 hours prior to test
in SLT or 1 hour in water at 23  2 °C.
4.4.2 Test conditions
Tests shall be conducted at the Standard Laboratory temperature of 23  2 °C unless otherwise specified
in the test methods or in this specification.
4.4.3 Test requirements
Tests shall be carried out on pipe, moulded/machined flanges or rotational moulded spools once per lot to
determine the material properties (and following the procedures) listed in Table 1 except HDB, ESCR,
SCG, RCP tests which are done during qualification of materials and processes. The results of the tests
shall be within 5% of the material property data provided by the pipe supplier before start of production.
Alternatively, for short production runs or a small number of flanges or spools (less than as defined for a
lot), material data supplied by the raw material manufacturer may be accepted after agreement by the
Company.
In addition, inspection and tests listed in Table 3 below shall be carried out.
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Table 3 Requirements for production tests on PE liner pipe

ASTM
Property Acceptance criteria Frequency
Method
Once every hour, once every
Outside diameter D2122 coil, whichever is less
ISO 4427-2 Table 2
Wall thickness D2122 frequent
≥ values specified in
Burst Pressure D1599 Table 4 of ASTM Once per lot
D3035
Within the limits
D 2513 Once per lot (production-
Out of roundness specified in Table 1 in
run)
ISO 4427-2
4.4.4 Retest and rejection

When the pipe, flange or rotolined spool fails to meet the specification requirements of any test, the test
shall be repeated on two more samples from the same production lot. Test results on both the retested
samples shall pass.
4.4.5 Hydro-testing
The mill hydro test shall be carried out minimum one pipe per production run.
Liner pipe sections shall not show any sign of leakage (burst or weep) or ballooning when subjected to a
hydrostatic pressure test. The test pressure shall be 1.5 times the “rated” pressure for the stand-alone
thermoplastic pipe and shall be maintained for 3 minutes.
4.4.5.1 Ballooning
Any abnormal localised expansion of a pipe specimen while under internal hydraulic pressure.
4.4.5.2 Bursting
Failure by a break in the pipe with immediate loss of test liquid and continued loss at essentially no
pressure.
4.4.5.3 Weeping
Failure that occurs through microscopic breaks in the pipe wall, frequently only at or near the test pressure.
At lower pressures, the pipe may carry liquids without evidence of loss of the liquids.
4.5 INSPECTION AND REJECTION
4.5.1 Inspection by the Company
All Quality Control tests shall be witnessed by a Company appointed representative at the start of
production and monitored thereafter at the discretion of the Company.
4.5.2 Visual inspection
Visual inspection of the coiled pipe interior shall be done by cutting a small section to be inspected for the
presence of visual defects.
For large diameter (>12inch) full 100% of the circumference shall be visually inspected of the pipe sections.
4.5.2.1 Injurious defects

Injurious defects are those which adversely affect the service life of the pipe such as foreign inclusions,
kinks,dents and visible cracks. Contamination and any other defects reducing the wall thickness below
minimum tolerance listed in the dimensional Table 5 in API 15LE or Table 2 in ISO 4427-2. Pipe, flanges
and rotationally moulded spools with injurious defects shall be rejected.
The pipe shall be coiled such that localized deformation, e.g. buckling and kinking, is prevented.
The minimum internal diameter of the coil shall be not less than 18 x nominal diameter.
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4.5.3 Repair of defects

Repair of defects is not permitted
4.6 QUALITY CONTROL RECORDS REQUIREMENTS

4.6.1 Purpose
The quality control records required by this specification are necessary to substantiate that all pipe made
to meet this specification conform to the specified requirements.
4.6.2 Records control
 Quality control records required by this specification shall be legible, identifiable, retrievable, and
protected from damage, deterioration, or loss.
 Quality control records required by this specification shall be retained by the pipe supplier and
Contractor for a minimum of five years from the date of manufacture.
 All quality control records required by this specification shall be signed and dated by the pipe
supplier's designated authorised person.
4.6.3 Records to be maintained and supplied by pipe supplier
1. Quality manual in accordance section 4.
2. Quality control test results in accordance.with section 4.
3. Design and material qualification data.
4. All procedures utilised by the pipe supplier in the process of fulfilling the order.
6. Quality assurance records for all materials supplied by the pipe supplier.
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5. MARKING ON THE HDPE LINER PIPE

Liner pipe manufactured in conformance with this specification shall be marked by the pipe supplier as
specified.
The required markings shall be paint-stencilled or printed on the outside surface of each length or coil of
pipe at intervals of not more than 1.5 m.
The markings on each length or coil of pipe shall include in any sequence:
1. Pipe supplier's name or trademarks
2. Base specification shown on purchase order, (e.g. API 15LE, ISO 4427)
3. Pipe OD and wall thickness
4. Date of manufacture
5. SDR
6. Pipe supplier's lot number
7. Appropriate material code used by the pipe supplier to uniquely identify the material.
8. HDB records as per appliacable standards specified in this specification .
9. Additional markings, except pressure ratings, as agreed between pipe supplier and Company.
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6. HANDLING AND STORAGE

6.1 STORAGE
Raw material storage used for the extrusion of the PE liner / Rotational moulding process shall be stored
in accordance with TDS and established procedure.
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 must 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 come
into contact with hot water or steam pipes and shall be kept away from hot surfaces.
6.2 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.
6.3 TRANSPORTATION
The minimum requirements for transportation shall be as specified in the following Recommended
Practices:
 API RP 5L1 for railroad transportation
 API RP 5LW for marine transportation
 SP-2000 Road Safety Standard
Pipe transported by sea shall not be shipped as deck cargo.
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7. REFERENCES
In this SPECIFICATION, reference is made to the following publications:
NOTE: Unless specifically designated by date, the latest edition of each publication shall be used, together with any
amendments, supplements, revisions thereto.
7.1 COMPANY STANDARDS

SP-1171 Specification for Quality Assurance of design, construction and Engineering Works
SP-1208 Pipeline Construction Specification
SP-2380 Design and construction of PE lined Carbon steel lines
7.2 NATIONAL STANDARDS
ASME B 16.5 Pipe Flanges and Flanged Fittings
ASME Section IX Boiler pressure vessel code – welding & brazing qualification
ASTM: Title :
D638 Test method for tensile properties of plastics
D1238 Standard Test Method for Melt Flow Rates of Thermoplastics by Extrusion
Plastometer
D1505 Test Method for Density of Plastics by the Density-Gradient Technique
D1599 Standard Test Method for Short-Time, Hydraulic Failure Pressure of Plastic Pipe,
Tubing and Fittings
D1693 Standard Test Method for Environmental Stress Cracking of Ethylene Plastics
D2122 Determining Dimensions of Thermoplastics Pipe and Fittings
D2657 Heat Joining Polyolefin Pipe and Fittings
D2837 Obtaining Hydrostatic Design Basis for Thermoplastic Pipe Materials
D3035 Standard Specification for Polyethylene (PE) Plastic Pipe (DR-PR) Based on
Controlled Outside Diameter
D3350 PE Plastic Pipe and Fitting Material
D3895 Standard Test Method for Oxidative Induction Time of Polymeric Materials by
Differential Scanning Calorimetry
API 15LE Recommended Practice for Polyethylene Line pipe and Fittings
API RP 5L1 Recommended Practice for Railroad Transportation of Line pipe
RP 5LW Recommended for Transportation of Line pipe on Barges and Marine Vessels
7.3 INTERNATIONAL STANDARDS

ISO 1133-1 Plastics -- Determination of the Melt Mass-flow Rate (MFR) and
the Melt Volume-flow Rate (MVR) of Thermoplastics
ISO 1183-1 Plastics - Methods for determining the density of non-cellular
plastics - Part 1: Immersion method, liquid pyknometer method
and titration method
ISO 13479 Environmental stress crack resistance
ISO-15589-1 Cathodic protection of pipeline systems Part 1: On-land pipelines
ISO 21307 Plastic pipes and fittings- Butt fusion procedures for PE pipes and fittings
ISO 22391-2 Plastic piping Systems for Hot and cold water installation
ISO 4427-1 to 5 Polyethylene (PE) pipes for Water Supply – Specifications
ISO 4437- 1 to 5 Plastic piping systems for supply of gaseous fuels
ISO 527-2 Determination of tensile properties — Part 2: Test conditions for moulding and extrusion
plastics
ISO 6964 Polyolefin pipes and fittings — Determination of carbon black content by calcination and
pyrolysis — Test method
ISO 9969 Thermoplastic pipes- Determination of ring stiffness
ISO 9080 Plastics Piping and Ducting Systems - Determination of the Long- Term Hydrostatic
Strength of Thermoplastics Materials in Pipe Form by Extrapolation
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APPENDIX A - BUTT FUSION AND EXTRUSION WELDING QUALIFICATION
A.1 SCOPE
This appendix covers the minimum requirements for the qualification of butt fusion & extrusion welding
procedures and welding operators for both shop and field welding of PE liner pipe.
A.2 PROCEDURES
Welding of HDPE liner shall be carried out by the butt fusion process for the site installation joints. a
combination of butt and extrusion welding is only permitted for shorter (max 10meter spool length) shop
lined spools with flange joints at both ends
The Contractor shall prepare a detailed procedure for each type and size of joint to be welded. The
procedures shall be qualified as required in Section A.3. Extrsion welding procedure shall be prepared by
the contractor and shall obtain non-Metallic TA2 approval prior shoplining application.
Butt fusion welding procedure shall be prepared in accordance with ISO21307. The procedure shall detail
parameters mentioned in Table 4. In addition, the fusion procedure shall include the following:
 The joining surfaces preparation requirements.
 The alignment procedures and acceptable limits.
 The elapsed time required before the joint can be subjected to high stress.
 Visual assessment acceptance criteria.
Table 4 Fusion Variable and their classifications

Variable Description Essential Non-Essential
Joint Joint Type Change from X
butt fusion to
extrusion
welding
Material Material Grade i.e. change X
from PE100 to
PE-RT
Diameter (OD) X1
SDR (OD/thickness) X2
Equipment Fusion machine Change of X3

manufacturer and fusion
model machine
supplier/
model
Fusion Heater plate surface Change of X
parameters temperature fusion
parameter
Interfacial Pressure beyond X
Decrease in heating envelope of X
time ISO21307
Decrease in Cooling X
time under pressure
Initial heating X
pressure change.
Welding location Site or Shop floor X
Version: 03
Notes:
1. A change in the pipe diameter beyond the range qualified in Table 5 shall require
requalification.
2. Change in SDR beyond the range qualified as listed in the Table 6 shall require
requalification.
3. Butt fusion welding shall not be modified by the contractor.
Table 5 Pipe fusion diameter limits

Size of Test coupon Size qualified in mm
(mm) Minimum maximum
≤162 none Up to the size tested
163 to 315 163 Size tested
316 to 458 316 Size tested
Above 458 459 Size tested
Table 6 Pipe SDR limits

Size of Test coupon SDR qualified in mm
(SDR) Minimum maximum
≤11 Tested SDR 14
15 to 21 Tested SDR 21
≥22 Tested SDR
Essential variables are specified in Table 4. Any change in the essential variable shall require to new WPS
qualification.
Pipes Surface misalignment at the joint shall not be more than 10% of the wall thickness of the thinner
member to be fused.
Fusion joining procedure and procedure qualification report:

1. The fusion joining procedure shall be developed by the Installer using the fusion joining parameters
for the supplied pipe using the ISO21307-2011.
2. The fusion joining procedure and corresponding performance qualification report shall be subject to
approval by PDO nonmetallic materials team authorized personnel.
3. The fusion joining procedure SHALL [PS] be qualified and the performance qualification tests
reported for each type of joint.
4. Fusion joining shall be performed using fusion welding machines designed specifically for that
purpose and in accordance with ISO 12176 or ASTM F2620.
5. The fusion joining procedure shall include the following parameters:
a. Equipment and tooling required.
b. Joining surfaces preparation requirements.
c. Heating tool temperature required for fusion.
d. Heating soak time for each size and wall thickness of pipe.
e. Alignment procedures and acceptable limits.
f. Joining interfacial pressure and hold time requirements
g. Clamped cooling time requirements.
h. Cooling handling time requirements.
i. Elapsed time required before the joint can be subjected to high stress.
j. Precautions for inclement weather such as wind or rain.
k. Documentation and traceability of fusions and fusion joiner’s unique
l. Identification marking.
m. Visual assessment acceptance criteria.
n. Fusion joint destructive test method.
6. The specified fusion parameters in the fusion joining procedure shall be documented for each joint.
7. Fusion welding machines should be equipped with automated data logging devices.
Version: 03
8. Welding procedure qualification and testing shall be conducted in the presence of approved company
TPI.
9. The fusion joining performance qualification tests shall reference the fusion joining procedure and
include the following:
a. Visual inspection.
b. Tensile strength tests of fusion weld and pipe for all wall thicknesses in accordance with ISO 13953
Type A or Type B specimens or ASTM F2634. The fusion welds shall indicate a ductile failure
mode with a minimum tensile strength equal to 90 % of the actual parent pipe strength.
c. Bend testing in accordance with ASTM F3183 / DVS 2203 and shall not show any cracking marks.
d. Hydro test at SLT at 0.75 times the STHP pressure followed by burst test in accordance with ASTM
D1599.The acceptance criteria shall be the minimum specified burst pressure. The type of failure
shall be elastic failure. Brittle failures of weld resulting in joint separation is not acceptable.
Version: 03
A.3 BUTT FUSION/EXTRUSION WELDING PROCEDURE & WELDING OPERATOR

QUALIFICATION
All butt fusion welding operators shall be qualified by the contractor/installer in accordance with the below
requirements.
- Welding procedure shall be established and qualified in accordance with Appendix A.2.
- Each welding operator shall be qualified prior to engaging in construction activities.
- Fusion jointer qualification testing shall involve:
a) Visual examination in accordance with ASME Section XI QF-141.
b) Reverse bend test in accordance with DVS 2203 for thickness up to 25.4 mm (1 inch)
c) Guided side bend test in accordance ASTM F3183 for thickness >25.4mm (1inch).
d) Tensile strength tests of fusion weld and pipe for all wall thicknesses in accordance with ISO
13953 Type A or Type B specimens or ASTM F2634.
- Essential variables for operator qualification shall be as per Table 7.
For extrusion welding operator qualification shall be qualified through hydrotesting welded spool at SLT at
0.75 times the STHP pressure followed by burst test in accordance with ASTM D1599. Burst pressure shall
be higher than that specified in ASTMD 3035. The type of failure shall be elastic failure. Brittle failures of
weld resulting in joint separation is not acceptable.
Table 7 Fusion operator qualification Variable classifications

Variable Essential Non-Essential
Joint Joint Type X1
Material Material Grade (i.e. X2
PE100)
Diameter (OD) X3
Joining position ±20 deg beyond X
qualified position
Thickness ≥ 30mm X4
Notes:
1- Change of joint type require requalification.
2- Change of material grade i.e. from PE100 to PE-RT require requalification.
3- Change of diameter beyond qualified range specified in Table 8 shall require requalification.
4- Operator shall be qualified using project material.
Table 8 Pipe fusion operator qualification diameter limits

Size of Test coupon Size qualified in mm
(mm) Minimum maximum
≤162 none Up to the size tested
163 to 200 none 200
201 to 500 201 500
≥501 501 Unlimited
Version: 03
APPENDIX B - PE MATERIAL PROPERTIES

PE100 and PE-RT properties as mentioned in Table 9 and Table 10 shall be used for the design of PE
liner as per SP-2380. Intrapolation is not Allowe and higher temperature properties shall be considered.
Table 9 PE 100 Material properties as a function of temperature

Service PE Liner design Linear E Modulus 5% Poisson’s Coefficient of
temperature (ºC)* swell secant value Ratio thermal expansion.
(%) (MPa) (m/mK * 10-6)
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
65 7 80
Table 10 PE-RT Material properties as a function of temperature

Service PE Liner design Linear E Modulus 5% Poisson’s Coefficient of
temperature (ºC)* swell secant value Ratio thermal expansion.
(%) (MPa) (m/mK * 10-6)
NEN-EN-9969
Air/water 75 0 120 160
80 0 95
85 0 80
Crude 70 5.3 110
75 5.9 93
80 6.5 77
85 7.1 60
*Note: PE & PERT liners are designed based on Maximoum operating temperature of the system.
Pulling force shall be monitored to ensure that 50% of the PE pipe yield stress listed in Table 11 below 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.
Table 11 Yield stress of PE100 and PE-RT as function of temperature

Average
surface PE-100 Yield PERT Yield
#
Temperature stress in MPa stress in MPa
in °C
1 ≤23 21 23
2 24 to 30 19 19
3 31 to 40 16 17
4 41 to 50 14 15
5 51 to 60 12 13
6 61 to 70 8 11
The stretch required for site liner pull to accommodate the thermal expansion coefficient shall be calculated
using the following formula (stretching is applicable only for loose liners, tight liners this stretching is not
applicable as the liner sits as interference fit):
Version: 03
0.2 mm/ m/∆ °C where

m-represents the total length of the spool
∆T is the difference between ambient and design temperatures.
Version: 03
APPENDIX C – RETAINER RING MATERIAL PROPERTIES
The following are the properties of the qualified phenolic non-metallic material retainer ring
Material Type LINEN PHENOLIC – LE

Ring Dimensions As per Attached Inspection Report
Specific Gravity (g/cc) 1.34
Tensile Strength (psi) 13,000
Comp. Strength (psi) 36,000
Flexural Strength (psi) 18,000
Hardness, M Scale 100
Bond Strength (psi) 1900
Shear Strength 13,500
CFTE, in/in/oC x 10-5 1.8
Water Absorption (% - 24 hrs) 1.9
Electric Strength (V/MIL Cond A) 625

SP-2094 Version 03

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Version: 03

Petroleum Development Oman LLC Effective: NOV-21

Petroleum Development Oman L.L.C.

Document Title: Specification for Polyethylene liners

Document Type Specification

Discipline Materials & Corrosion

Issue Date November 2021

This page was intentionally left blank

Version Date Author Scope / Remarks

iii Related Business Processes

iv Related Corporate Management Framework (CMF) Documents

1.4.23 5% Secant Modulus

2. PE LINER PIPE PURCHASING REQUIREMENTS

Liner pipe furnished to this specification shall be produced by extrusion process.

Table 2 Minimum Properties for PE-RT Liner Pipe

Non-destructive testing techniques shall be subject to approval by MCI TA2.

3.5.3 Ovality and out-of-roundness

Table 3 Requirements for production tests on PE liner pipe

4.4.4 Retest and rejection

4.5.2 Visual inspection

4.5.2.1 Injurious defects

4.5.3 Repair of defects

4.6 QUALITY CONTROL RECORDS REQUIREMENTS

5. MARKING ON THE HDPE LINER PIPE

6. HANDLING AND STORAGE

Pipe transported by sea shall not be shipped as deck cargo.

7.1 COMPANY STANDARDS

7.3 INTERNATIONAL STANDARDS

APPENDIX A - BUTT FUSION AND EXTRUSION WELDING QUALIFICATION

Table 4 Fusion Variable and their classifications

Equipment Fusion machine Change of X3

Table 5 Pipe fusion diameter limits

Table 6 Pipe SDR limits

Fusion joining procedure and procedure qualification report:

A.3 BUTT FUSION/EXTRUSION WELDING PROCEDURE & WELDING OPERATOR

Table 7 Fusion operator qualification Variable classifications

Table 8 Pipe fusion operator qualification diameter limits

APPENDIX B - PE MATERIAL PROPERTIES

Table 9 PE 100 Material properties as a function of temperature

Table 10 PE-RT Material properties as a function of temperature

Table 11 Yield stress of PE100 and PE-RT as function of temperature

0.2 mm/ m/∆ °C where

APPENDIX C – RETAINER RING MATERIAL PROPERTIES

Material Type LINEN PHENOLIC – LE

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