Materials System Specification

01-SAMSS-050 15 December 2012

Thermoplastic Tight Fit Grooved or
Perforated Liners for New and Existing Pipelines
Document Responsibility: Non-metallic Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 2
2 Conflicts and Deviations................................. 2
3 References..................................................... 2
4 Abbreviation and Definitions........................... 6
5 Materials......................................................... 8
6 Manufacture of Thermoplastic Liner............. 20
7 Quality Program........................................... 21
8 Documentation............................................. 22

Previous Issue: New Next Planned Update: 15 December 2017

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Primary contact: Mehdi, Mauyed Sahib on 966-3-8809547

Copyright©Saudi Aramco 2012. All rights reserved.

Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
Issue Date: 15 December 2012 Thermoplastic Tight Fit Grooved or
Next Planned Update: 15 December 2017 Perforated Liners for New and Existing Pipelines

1 Scope

This document refers to the minimum technical requirements for thermoplastic material
specification and manufacture of vented grooved or perforated tight fitting, non-bonded,
liners in carbon steel pipelines. In addition to water injection, other aggressive fluids
such as sour gas, three phase system, and sour crude oil shall also be included. The use
of these liners is for rehabilitating existing carbon steel pipelines and flowlines as well
as new pipelines and flowlines. Lining with thermoplastic liner is applicable to
aboveground, buried and sub-sea pipelines.

This specification covers grooved, perforated and smooth liners. Grooved liner
provides a path for any gases that may permeate the liner to be vented to avoid liner
collapse due to process depressurization. In the case of perforated liners, metallic or
plastic frit devices are installed through the perforated locations to provide a venting
means that allows gas to flow from the micro-annulus into the center of the pipeline
assembly but not in the opposing direction.

2 Conflicts and Deviations

2.1 Any conflicts between this specification and other applicable Saudi Aramco
Materials System Specifications (SAMSSs), Engineering Standards (SAESs),
Standard Drawings (SASDs), or industry standards, codes, and forms shall be
resolved in writing by the Company or Buyer Representative through the
Manager, Consulting Services Department of Saudi Aramco, Dhahran.

2.2 Direct all requests to deviate from this specification in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, Consulting Services Department of
Saudi Aramco, Dhahran.

3 References

The following references in force on the date of the Purchase Order form a
supplementary part of this specification, as applicable:

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedure

SAEP-302 Instructions for Obtaining a Waiver of a Mandatory
Saudi Aramco Engineering Requirements

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Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
Issue Date: 15 December 2012 Thermoplastic Tight Fit Grooved or
Next Planned Update: 15 December 2017 Perforated Liners for New and Existing Pipelines

3.2 Industry Codes and Standards

American Petroleum Institute

API Spec 17J Specification for Unbounded Flexible Pipe
API 15 LE Specification for Polyethylene Line Pipe (PE)
API RP 5L1 Recommended Practice for Railroad Transportation
of Line Pipe
API RP 5LW Recommended Practice for Transportation of Line
Pipe on Barges and Marine Vessels

American Society for Testing and Materials

ASTM A106 Standard Specification for Seamless Carbon Steel
Pipe for High-Temperature Service
ASTM A193 Standard Specification for Alloy-Steel and Stainless
Steel Bolting Materials for High-Temperature
Service
ASTM A194 Standard Specification for Carbon and Alloy Steel
Nuts for Bolts for High-Pressure or High-
Temperature Service, or Both
ASTM D256 Standard Test Methods for Determining the IZOD
Pendulum Impact Resistance of Plastics
ASTM D618 Standard Practice for Conditioning Plastics for
Testing
ASTM D638 Standard Test Method for Tensile Properties of
Plastics
ASTM D648 Standard Test Method for Deflection Temperature
of Plastics under Flexural Load
ASTM D746 Standard Test Method for Brittleness Temperature
of Plastics and Elastomers by Impact
ASTM D792 Standard Test Methods for Density and Specific
Gravity (Relative Density) of Plastics by
Displacement
ASTM D1044 Standard Test Method for Resistance of Transparent
Plastics to Surface Abrasion
ASTM D1238 Standard Test Method for Flow Rates of
Thermoplastics by Extrusion Plastometer

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Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
Issue Date: 15 December 2012 Thermoplastic Tight Fit Grooved or
Next Planned Update: 15 December 2017 Perforated Liners for New and Existing Pipelines

ASTM D1505 Standard Test Method for Density of Plastics by the

Density - Gradient Technique
ASTM D1599 Standard Test Method for Short-Time, Hydraulic
Failure Pressure of Plastic Pipe, Tubing and
Fittings
ASTM D1603 Standard Test Method for Carbon Black in Olefin
Plastics
ASTM D1693 Standard Test Method for Environmental Stress-
Cracking of Ethylene Plastics
ASTM D2122 Standard Test Method for Determining Dimensions
of Thermoplastic Pipe and Fittings
ASTM D2240 Standard Test Method for Rubber Property –
Durometer Hardness
ASTM D2513 Standard Specification for Thermoplastic Gas
Pressure Pipe, Tubing and Fittings
ASTM D2657 Standard Practice for Heat Fusion Joining of
Polyolefin Pipe and Fittings
ASTM D2990 Standard Test Methods for Tensile, Compressive,
and Flexural Creep and Creep - Rupture of
Plastics
ASTM D3222 Standard Specification for Unmodified Poly
Vinylidene Fluoride (PVDF) Molding Extrusion
and Coating Materials
ASTM D3350 Standard Specification for Polyethylene Plastic Pipe
and Fitting Materials
ASTM D3895 Standard Test Method for Oxidative-Induction Time
of Polyolefins by Differential Scanning
Calorimetry
ASTM D4060 Standard Test Method for Abrasion Resistance of
Organic Coatings by the Taber Abraser
ASTM D4066 Standard Classification System for Nylon Injection
and Extrusion Materials (PA)
ASTM D4101 Standard Specification for Propylene Plastic
Injection and Extrusion Materials
ASTM E328 Standard Test Methods for Stress Relaxation Tests
for Materials and Structures

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Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
Issue Date: 15 December 2012 Thermoplastic Tight Fit Grooved or
Next Planned Update: 15 December 2017 Perforated Liners for New and Existing Pipelines

ASTM E831 Standard Test Method for Linear Thermal

Expansion of Solid Materials by
Thermomechanical Analysis
ASTM E1356 Standard Test Method for Assignment of the Glass
Transition Temperatures by Differential
Scanning Calorimetry or Differential Thermal
Analysis
ASTM F491 Standard Specification for Poly Vinylidene Fluoride
(PVDF) Plastic-Lined Ferrous Metal Pipe and
Fittings
ASTM F492 Standard Specification for Propylene and
Polypropylene (PP) Plastic-Lined Ferrous Metal
Pipe and Fittings
ASTM F714 Polyethylene Plastic Pipe Based on Outside
Diameter
ASTM F1733 Standard Specification for Butt Heat Fusion
Polyamide (PA) Plastic Fitting for Polyamide
(PA) Plastic Pipe and Tubing

American Society of Mechanical Engineers

ASME B16.5 Steel Pipe Flanges, Flanged Valves and Fittings
ASME D2513 Thermoplastic Gas Pressure Pipe

British Standard
BS 4515 Specification for Welding of Steel Pipelines on Land
and Offshore

Canadian Standards Association

CSA Z662-03 Oil & Gas Pipeline Systems

International Organization for Standardization

ISO 4427 Polyethylene (PE) Pipes for Water Supply
ISO 4437 Buried Polyethylene (PE) Pipes for the Supply of
Gaseous Fuels
ISO 10931 Plastic Piping Systems for Industrial Applications:
Poly Vinylidene Fluoride Part 2 Pipes
ISO 11414 Preparation of Polyethylene Pipe/Pipe or
Pipe/Fitting Test Pieces Assemblies by Butt
Fusion

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Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
Issue Date: 15 December 2012 Thermoplastic Tight Fit Grooved or
Next Planned Update: 15 December 2017 Perforated Liners for New and Existing Pipelines

ISO 11922 Thermoplastic Pipes for the Transport of Fluids-

Dimensions and Tolerances, Part 1: Field
Welding, Part 2: Shop Welding
ISO 13628 Specification for Unbonded Flexible Pipe
ISO 13953 Polyethylene Pipes and Fittings-Determination of
Tensile Strength of Test Specimens from a Butt
Fused Joint

Manufacturers Standardization Society

MSS SP-44 Steel Pipe Line Flanges

National Association of Corrosion Engineers

NACE RP0304 Design, Installation and Operation of Thermoplastic
Liners for Oilfield Pipelines
NACE 35101 Plastic Liners for Oilfield Pipelines

4 Abbreviation and Definitions

SDR: Standard Dimension Ratio; Nominal outside diameter of liner/Nominal wall

thickness

CRA: Corrosion Resistant Alloy

ESC: Environmental Stress Cracking

ID: Nominal internal diameter

OD: Nominal outside diameter

UV: Ultra violet light

Contractor: The party that conduct all or part of the project design, engineering,
procurement, construction, commissioning or management of a project.

Principal: The party, in this case; Saudi Aramco, which initiates the project and pays
for its design and construction. The Principal usually specify the technical requirements
directly to the contractor or through an agent or consultant working or acting on his
behalf.

Annulus: Space between thermoplastic liner and the host outside carbon steel pipe.

Bell hole: Excavations made at a section joints of a pipeline for the purpose of
insertion of a section of thermoplastic liner.

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Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
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Next Planned Update: 15 December 2017 Perforated Liners for New and Existing Pipelines

Butt fusion welding: A method of joining plastic pipe, sheet, or other similar forms of
a thermoplastic resin wherein the two ends to be joined are heated to the molten state
and then bringing the two aligned pipe ends together under pressure and a
predetermined cooling time resulting in a fused joint having a hydrostatic strength equal
to the parent pipe.

End connector: A device used to provide a leak-tight structural connection between

two sections of lined pipe. The lining is terminated inside the end connector.

Flanges Face: ASME B16.5 code requires that the flange face (raised face and flat
face) has a specific roughness to ensure that this surface be compatible with the gasket
and provide a high quality seal.

Hot plate welding Technique: The process of hot plate welding uses a heated platen
to melt the joining surfaces of the two halves of a thermoplastic pipe. The part halves
are brought into contact with a precisely heated platen for a predetermined period.

In-line compression joint: System of terminating lined pipelines by compression of

the liner between an internal ring and a CRA material.

Inspector: Professional assigned by the principal to ensure a project's compliance with

its specifications and statutory requirements.

Modulus Elastic: The ratio of the stress applied on a body to the strain that results in
the body in response to it. The modulus of elasticity of a material is a measure of its
stiffness and for most materials remains constant over a range of stress.

Ovality: Ovality is the deviation from roundness as a result of extrusion, coiling,

handling, or installation. 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 result by 100.

Permeation: Diffusion of liquid and gas through a plastic layer under the influence of
pressure and temperature. Permeation is a physicochemical mass transfer phenomenon
involving diffusion of a solute through a porous medium. The driving force for mass
transfer is the presence of an activity (e.g., concentration) gradient with respect to the
solute.

Vent connection or point: Vent hole through the carbon steel outer pipe to allow the
release of gas accumulated in the annulus between the liner and the host carbon steel pipe.

Venting: The release of gas accumulated in the annulus between the thermoplastic
liner and the host carbon steel pipeline.

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Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
Issue Date: 15 December 2012 Thermoplastic Tight Fit Grooved or
Next Planned Update: 15 December 2017 Perforated Liners for New and Existing Pipelines

5 Materials

5.1 General

Typically, High Density Polyethylene (HDPE PE100) material is being used as

grooved, perforated or smooth liner. However, there are other materials that
have the potential to be used for highly aggressive fluids and these include;
cross-linked Polyethylene (PEX), Unplasticised Polyvinylidene-fluoride
(PVDF), Polypropylene (PP), and Polyamide (PA 11, PA 12 and PA6-12).

In this specification, emphasis will be made on HDPE (PE100), PEX and

unplasticised PVDF materials as a liner due to their successful performance in
many applications operated at their allowable service conditions in terms of
maximum operating temperature and chemical resistance. The other materials,
PP and PA, will also be considered in this specification.

The Lining contractor shall be responsible in selecting and supplying of all

materials required to meet the specified service design conditions and
installation requirements. The selection of materials shall be based on actual
test data or documented methods for predicting the liner material properties for
the specified service conditions. This document which includes test results and
records shall be submitted by the Contractor for review by the Principal.
For gas service and services containing gas, the Contractor shall demonstrates
by testing or documented evidence that the selected material will not fail during
service start-up and continuous operation or shut-down and when the process
undergoes rapid de-pressurization.

The mechanical, thermal, fluid compatibility and permeability properties of the

selected material shall be documented by the Contractor for future references.

5.2 Thermoplastic Liner Materials

Plastic liners have been used for many years in areas of steel pipe construction.
In most cases they are used for relining corroded steel pipes, but new pipes, such
as subsea pipes for water injection lines used in oil production, are also provided
with liners to prevent corrosion. Currently, there are many thermoplastic
materials that are used for liners and these may include; HDPE, Cross-linked
Polyethylene, Polypropylene (PP), Polyamide (PA) and Polyvinylidenefluoride
(PVDF).

This specification provides more emphasis on HDPE (PE100), PEX and PVDF
materials.

In general, the following guidelines shall be considered during the selection of

the liner material:

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Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
Issue Date: 15 December 2012 Thermoplastic Tight Fit Grooved or
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 Effect of service fluid(s) on the chemical and physical long term

performance of the liner material.
 Liner resistance to depressurization and collapse
 Effect of design and operating temperatures on the liner
 Suitability of the liner to pigging operations

The selected material shall only be utilized as the liner material after approval is
granted by the Principal to ensure that it meets the required installation and
service conditions.

5.2.1 High Density Polyethylene (PE100)

HDPE (PE 100), is also termed high performance polyethylene (HPPE)

pipe material, and it differs from other grades of HDPE such as PE80
medium density polyethylene (MDPE) pipe material in that it
demonstrates exceptional resistance to rapid crack propagation
(60°C to -30°C) as well as long term stress crack resistance. The number
classification refers to the strength of the material with PE100 being
stronger than PE80. Pipe made from PE100 can withstand a greater
pressure than pipe with the same diameter and wall thickness made from
PE80 material.

HDPE grooved or perforated liner is formed from a number of HDPE

pipe lengths heat fused together into sections currently up to 1 km long.
After pressure testing, each section of the liner is inserted into a pre-
welded carbon steel pipeline or flowline section. At the ends of the
section the liner is terminated in an HDPE flange or other connection
system, to enable sections to be joined together.

A summary of typical material properties of PE 100 at ambient

conditions is presented in Table [Link]. This Table is for guidance only.
Manufacturers/Contractors shall submit the relevant (minimum) material
property specifications at the specific service conditions.

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Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
Issue Date: 15 December 2012 Thermoplastic Tight Fit Grooved or
Next Planned Update: 15 December 2017 Perforated Liners for New and Existing Pipelines

Table [Link] – Typical PE 100 Material Properties

Test Typical
Property Unit
Procedure Value
PE4710
Material Designation --- PPI-TR4
PE100
445574C
Cell Classification --- ASTM D3350
445576C
Pipe Properties
3
Density gms / cm ASTM D1505 0.961 (black)
Melt Index (HLMI) Condition 190 / 21.6 gms/10 min ASTM D1238 8.0
Hydrostatic Design Basis, 73°F (23°C) psi ASTM D2837 1,600
Hydrostatic Design Basis, 140°F (60°C) psi ASTM D2837 1,000
Minimum Required Strength Mpa (psi) ISO 9080 >10 (>145)
Rapid Crack Propagation Critical
Bar (psi) ISO 13477 >12 (>174)
Pressure(Pc), 0°C (32°F)(2)
Pipe Test Category --- ASTM D2513 CEE
Material Properties
Flexural Modulus at 2% strain psi ASTM D790 >150,000
Tensile Strength @ Yield (Type IV) psi ASTM D638 >3,500
Elongation at Break 2 in / min., Type IV Bar % ASTM D638 >800
Elastic Modulus @ Secant 2% strain
psi ASTM D638 >200,000
(2 in/min., type IV bar)
Hardness Shore D ASTM D2240 65
PENT hrs ASTM F1473 >5000
Thermal Properties
Vicat Softening Temperature °F (°C) ASTM D1525 255 (124)
-180
Brittleness Temperature °F ASTM D746
(-118)
Thermal Expansion in / in / °F ASTM D696 1.0 x 10-4

All PE pipe and fittings shall be stabilized against UV degradation in

accordance with ASTM D3350 using a minimum of 2% Carbon Black.

It is recommended to specify the material properties of PE listed in

(Table [Link]) rather than specifying a grade.

PE 100 liners shall not be operated above 65°C in water service and
50°C in hydrocarbon service or three phase system. In a liquid phase or
a dry gas phase, PE 100 may be used at slightly higher temperature than

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Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
Issue Date: 15 December 2012 Thermoplastic Tight Fit Grooved or
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50°C. However, the maximum operating temperature shall be specified

and agreed by the Principal before approval of the material for lining.
Utilization of PE100 in hydrocarbon service or three phase system is
limited to 50°C due to the presence of organic compounds that easily
diffuse into the PE100, causing swelling and softening of the material.
(Table [Link]) lists the recommended maximum operating temperature
as a function of fluid composition.

Table [Link] – Maximum Operating Temperature

for PE100 Liner as a Function of Fluid Composition

Fluid Composition Temperature (C)

Water injection service 65
Dry gas 65
Three phase system 50
Crude oil containing water 50
Gas and condensate 50

5.2.2 Cross-linked Polyethylene (PEX)

PEX is an engineering thermoplastic material manufactured by cross-

linking polyethylene with either peroxide or silane coupling agents.
PEX typical properties are displayed in Table [Link]. PEX has good
resistance to hydrocarbons and water at temperatures up to 85°C.
Table [Link] shows the recommended maximum operating temperature
as a function of fluid composition.

Table [Link] – Typical PEX Material Properties

Physical Properties and
Test Method Units Values
Mechanical Properties
3
Density at 23°C ASTM D792 Kg/m 953
Melt flow index at 5 kg ISO 1133 g/10 min 1.3
Gel content EN 579 % > 65
Yield strength at 23°C ISO 527, Test Spec. ISO MPa 47
Elongation at Yield at 23°C 1B, 50 mm/min % 7
Yield strength at 100°C MPa 26
Elongation at Yield at 100°C 25 mm/min % 8
Elongation at Break at 23°C % 390
Elongation at Break at 100°C 1 mm/min % 170

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Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
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Physical Properties and

Test Method Units Values
Mechanical Properties
Tensile Modulus (Young) MPa
at 23°C 1250
at 100°C 130
ISO 178
Flexural Modulus MPa
at 23°C 1200
at 100°C 167
Charpy Impact Resistance ISO 179 / 1A kJ/m²
at 23°C partial break
at 100°C No break

VICAT Point (5 kg) ISO 306 / B 50 °C 88

This specification is provided as guidelines. The specifications for PEX

liners shall be agreed upon between the Contractor and the Principal.

HDPE is cross-linked through the use of HDPE, silane grafting agent and
catalyst and stabilizing masterbatch. This result of high mechanical and
thermal properties liner is achieved once crosslinking is complete.
The crosslinking is brought about by post-treatment of the installed liner
with hot water or steam.

It is important that Butt-welding of PEX is carried out by keeping the

liner at a maximum critical degree of gel content, around 30%, before
installation.

The maximum utilization temperatures of PEX in different services are

given in Table [Link] below.

Table [Link] – Shows PEX Maximum Operating Temperature

as a Function of Fluid Composition

Fluid Composition Temperature (C)

Oil/gas/water mixture (three phase system) 90
Oil/water mixture 90
Gas and condensate 85
Dry gas 85

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Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
Issue Date: 15 December 2012 Thermoplastic Tight Fit Grooved or
Next Planned Update: 15 December 2017 Perforated Liners for New and Existing Pipelines

5.2.3 Unplasticized Polyvinylidene Fluoride (PVDF)

Plasticized PVDF have been used in subsea flexible pipe as an internal

sheath. Unfortunately, plasticized PVDF has experienced premature
embrittlement due to leech out of the plasticizer during operation.

Unplasticized PVDF is accepted to be more stable material, since there is

no plasticizer. However, unplasticized PVDF homopolymer has higher
elastic modulus than plasticized PVDF, reducing the yield and ultimate
strain and increasing the yield stress.

For liner applications unplasticized PVDF copolymer shall be based on

vinylidene fluoride (VF2) and chlorotrifluoroethylene (CTFE).
Other grades of copolymer or unplasticized PVDF shall be assessed by
the Principal before acceptance. Table [Link] shows the properties of
one grades of unplasticized PVDF copolymer that may be considered for
use as thermoplastic liners in new and existing corroded pipelines and
flowlines in hydrocarbon services. Table [Link] – Shows the fluid
composition and the maximum allowable operating temperatures of
PVDF Liners.

Table [Link] – Typical PVDF Material Properties

Properties Standards Units Values

Physical Properties
Water absorption (24 h at 23°C) ISO 62 (method 1) % <0.04
3
Density ISO 1183 g/cm 1.77
ASTM 1238
230°C, 10 kg g/10 min 3
Melt Flow Index
230°C, 5 kg g/10 min 1
230°C, 2.16 kg g/10 min -
Mechanical Properties
Tensile ASTM D638
Tensile stress at yield 23°C, 50 mm/min MPa/psi 35-40/5075-5800
Tensile stress at break 23°C, 50 mm/min MPa/psi 35-40/5075-5800
Elongation at yield 23°C, 50 mm/min % 10-12
Elongation at break 23°C, 50 mm/min % 100-350
Modulus 23°C, 1 mm/min MPa/psi 1300/188500
Flexion ASTM D790
Maximum load 23°C MPa/psi -

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Properties Standards Units Values

Modulus 2 mm/min MPa/psi -
IZOD impact (notched V 10 mm – at
ASTM D256 J/m 1000
23°C – 4 mm thick)
Shore D Hardness (2 mm thick) ASTM D2240 - 70
Abrasion resistance TABER CS 10/1 kg mg/1000 rev 5-10
Friction coefficient (static) - 0.2-0.4
ASTM D1894
Friction coefficient (dynamic) - 0.2-0.3
Thermal Properties
Crystallinity by DSC ASTM D3418
Melting point °C/F 173/343
Heat of fusion (80° to end of melting) J/g 51
Crystallizing point °C/F 140/284
Crystallization heat J/g 41
VICAT point (4 mm thick) ISO 306 - 0.2-0.4
Load 1 kg °C/F 167/333
Deflection temperature (4 mm thick) ASTM D 648
Load 0.46 MPa After annealing °C/F 140/284
Load 1.82 MPa °C/F 64/147
Glass transition (Tg) DMTA °C/F -28/-18
Brittleness temperature
ASTM D746 A °C/F -31/-24
(on 2 mm pressed sheet)
Molding shrinkage % 2-3
TGA beginning and at
Thermal stability °C/F 320-340/608-644
1 % weight loss in air
Linear thermal expansion coefficient ASTM D699 10-6 K-1 130-180
Thermal conductance at 23°C ASTM 177 W/m.K 0.2
Specific heat 23°C & 100°C J/g.K 1.2-1.6
Electrical Properties
Surface resistivity (Voltage< 1 V, ASTM D257 /
Ohm/square ≥ 1.1014
after 2 min – 500 V at 23°C) DIN 53483
Volume resistivity (Intensity = ASTM D257 /
[Link] ≥ 1.1014
10 mA, after 2 min at 23°C) DIN 53483
UL-94 Flammability test UL-94 Class -
Limiting Oxygen Index
ASTM D2863 % -
(sheet 3 mm thick)

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Table [Link] – Shows the Fluid Composition

and the Service Temperatures for PVDF Liners

Fluid Composition Temperature (C)

Oil/gas/water mixture (three phase system) 70
Oil/water mixture 70
Gas and condensate 75
Dry gas 80

5.2.4 Polypropylene (PP)

Random copolymer of polypropylene shall be used for liners due to its

high molecular weight and excellent physical, mechanical and chemical
properties. The grade selected for liner application shall be highly heat
stabilized and especially formulated for extraction resistance.

PP is not commonly used as a thermoplastic liner material despite the

fact that it has higher thermal properties than high density polyethylene.

Table [Link], lists the maximum recommended operating temperature as

a function of fluid composition.

Table [Link] – Maximum Operating Temperature

of PP as a Function of the Fluid Type

Fluid Composition Temperature (C)

Three phase system; Oil/gas/water mixture 75
Oil/water mixture 80
Gas and condensate 75
Dry gas 85

PP liners shall comply with the requirements of ASTM D2657,

ASTM D4101 and ASTM F492.

5.2.5 Polyamide (PA)

Polyamide such as PA11, PA12, and PA6-12 shall be used as a liner for
hydrocarbon services provided that the crude is free from water, or at
very low levels, and within its limited maximum operating temperatures.
Table [Link] provides guidelines for the use of Polyamide as a function
of fluid composition and operating temperatures.

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Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
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Manufacturers shall submit the relevant PA (minimum) material

specification at the specified operating conditions. This specification
shall comply with the requirements of ASTM D4066 and ASTM F1733.

Table [Link] – Shows the Polyamide Liner Use as a Function

of Fluid Composition and Maximum Operating Temperature

Fluid Composition Temperature (C)

Oil/gas/water mixture (three phase system) 70
Oil/water mixture 70
Gas and condensate 75
Dry gas 80

5.3 Guidelines to Selecting Thermoplastic Liners

Liner material selection for pipelines shall consider the fluid(s) being carried; its
chemical constituents and concentrations, abrasiveness, flow rates, the long term
effect of the fluid(s) on the liner, resistance to pressure change that may lead to
blistering and collapse of the liner, operating conditions (flow, temperature,
pressure), compatibility with pigging operations and swelling.

5.3.1 Quality Control and Qualification Testing

Thermoplastic liner material shall be manufactured and qualified

according to ISO 4427 or API SPEC 15 LE. These specifications
provide standards for polyethylene (PE) line pipe suitable for use in
conveying different types of fluid including; oil, gas and non-potable
water in underground and above ground applications.

A qualification and quality control testing program for the selected

thermoplastic liner shall be established. This program shall include the
following properties.

[Link] Physical/Mechanical and Thermal Properties

Thermoplastic liner is chosen for its good range of physical,

mechanical and thermal properties. In this application,
designers are looking for a wide range of properties that have
direct impact on the installation and performance of the liner.
These properties are tabulated in Table [Link] below.

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Table [Link] – Shows the Properties Required for Material Selection

Implementation QC
Physical/Mechanical Properties Standard
Requirements Tests
Melt flow rate ASTM D1238 B
Specific gravity ASTM D792 B
Tensile Strength/elongation at break ASTM D638 A B
Yield strength/elongation at yield ASTM D638 A B
Hardness ASTM D2240 B
Stress relaxation ASTM D2990 A
Modulus of elasticity ASTM D790 A
Flexural Creep and Creep-Rupture ASTM D2990 A
Thermal Properties
Heat distortion temperatures (HDT)
ASTM D648 A B
or Tg using DSC
Coefficient of thermal expansion ASTM E831 A B

A: Implementation requirements include properties required before, during and after insertion
of the liner.
B: QA/QC Properties are required to ensure that the measured properties are in line with
specified properties. These properties are required to be documented by the Contractor
and the Principal.

[Link] Chemical Resistance Aging Test

Aging test shall represent the liner operating conditions and be

conducted according to ISO 23936-1 to provide experimental
data about the changes of the liner mechanical properties with
time.

An initial pre-check test shall be performed if no previous

knowledge about the behavior of a liner material in a certain
fluid exists. The test duration shall be sufficient to reach
saturation of the fluid in the material at the test temperature.

The contractor shall, during accelerated testing for obtaining

results for extrapolation to service life, limit the test
temperature so that it can be ensured that the same chemical
and/or physical processes will occur as it does during service.

When extrapolating data from the present procedures,

appropriate statistical techniques shall be applied.

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Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
Issue Date: 15 December 2012 Thermoplastic Tight Fit Grooved or
Next Planned Update: 15 December 2017 Perforated Liners for New and Existing Pipelines

For example, if progressive degradation is dependent on a

single chemical aging process, a method based on Arrhenius
equation may be used, as described in ASTM D3032.

When analyzing the results for evidence of aging, the

Arrhenius principle is not always applicable. When such a
linear relationship is not appropriate, alternative curve-fitting
techniques will be investigated and the validity of the results
justified. All test results shall be evaluated by the Principal to
evaluate the long term performance of the liner. Rapid or
significant decay in critical mechanical/physical properties
shall not be accepted and the liner material should be either
modified to enhance performance or rejected and new liner
material shall be selected.

Table [Link] – Liner Acceptance Criteria after Chemical Aging Test

Length Mass TS at Elongation E-Modulus Thermostability*
(%) (%) Break (%) (MPa %) Δ°C
0–2 ±5 ± 20 ± 30 ± 20 0–5

*DSC test – ISO 11357-6

[Link] Swelling Test

Swelling is the increase in volume due to absorption of fluids.

The following conditions shall apply for the swell test procedure:
 Actual sample from the liner shall be cut for the test.
 Specimen weight shall be recorded to the nearest 0.001 g.

The cut samples shall be immersed in fluid(s) similar to those

used in the pipeline for 500 hours at the design pressure and
temperature in a sealed container.

After exposure, the dimensions and weights shall be measured

and recorded.

The percentage mass change as a result of exposure shall be

calculated for each sample from:

% mass change = (mass prior to exposure - mass after

exposure) x100/ mass prior to exposure

% volume change = (volume prior to exposure - volume after

exposure) x 100/volume prior to exposure

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Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
Issue Date: 15 December 2012 Thermoplastic Tight Fit Grooved or
Next Planned Update: 15 December 2017 Perforated Liners for New and Existing Pipelines

The mass and volume changes measured for each set of

specimens shall be reported in the test report together with the
average values used for qualification purposes.

[Link] Blistering Resistance Test

Thermoplastic liner swells when exposed to oil particularly at

high temperature and pressure. If the liner is exposed to sudden
variations in pressure, the liner may blister, tear or crack.

Blistering resistance test shall replicate the design requirements

of liner materials in fluid(s) containing gas under a given
environmental conditions of temperature, pressure and
operating at certain numbers of depressurization and
depressurization rate. For this test the following conditions
shall be followed.

 The test shall be only conducted on the gas component of

the fluid.
 The sample thickness shall be the same as that of the
selected liner.
 The design pressure of the liner shall be used during the test
 The sample conditioning time shall be sufficient to ensure
full saturation.
 The number of depressurizations (decompressions) shall be
a minimum of 20 cycles or the number expected during the
actual operating conditions.
 The depressurization rate (decompression rate) shall be the
expected rate or a minimum of 1000 psi/ minute.
 The actual service operating temperature shall be used
throughout the test.

Optical stereomicroscope shall be used at a magnification of

20 times to detect signs of blisters and cracks. The liner shall
only be acceptable when no blister or crack is seen.

[Link] Permeability Tests

Permeability is the penetration of permeates (such as liquid,

gas, or vapor) through thermoplastic materials such as PE100,
PEX, PP, etc. Permeability of the liner can be measured with
any gas or liquid provided that the test sample is cut from an

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Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
Issue Date: 15 December 2012 Thermoplastic Tight Fit Grooved or
Next Planned Update: 15 December 2017 Perforated Liners for New and Existing Pipelines

extruded liner having wall thickness and diameter

corresponding with the size of the testing machine. The test
conditions shall be per the operating temperature of the liner
and to as much as possible to the operating pressure.
A sufficient number of tests shall be performed to allow for
linear interpolation of the results as a function of temperature.

The test will provide an indication on the gas/liquid permeation

rate into the annulus between the host carbon steel pipe and the
liner. The result should help designer to account for correct
venting to eliminate potential collapse of the liner.

This test shall be conducted only if gas phase is present.

However, it may not be necessary to conduct the test if the
contractor provides tests results certified by a competent third
party testing laboratory.

5.4 End Connectors

The material of the thermoplastic flange shall be the same as the liner material to
avoid incompatibility and failure at the joint.

The retaining rings shall be per ASTM A106 or equivalent material while bolts
and nuts shall be per ASTM A193 B7 and ASTM A194 Grade 2-H respectively.

6 Manufacture of Thermoplastic Liner

6.1 Manufacturing of the Liner

The manufacturing of thermoplastic liner shall be similar to pipe manufacturing

using extrusion machines.

Only 100% prime virgin materials shall be used for the production of the liner,
with a maximum of 0.2% wt of additives. Conductive additives such as special
grade of conductive carbon black may be added if electrically conductive liners
are required.

The Contractor shall be responsible for the manufacturing of the liner.

6.2 Flange Material

The flanges material shall be the same materials used in the manufacture of the
thermoplastic liner. The wall thickness of the flanges shall be equal to the wall
thickness of the liner. Flared flanges are only permitted for limited lengths, which
cannot be fitted with fused flanges and only after approval of the Principal.

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Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
Issue Date: 15 December 2012 Thermoplastic Tight Fit Grooved or
Next Planned Update: 15 December 2017 Perforated Liners for New and Existing Pipelines

6.3 Rotationally Molded Spools

Rotationally molded spools are acceptable after agreement by the Principal.

The material used shall have minimum material properties provided by the
Contractor unless otherwise agreed with the Principal.

The wall thickness of the liner in the spools should be equal to the minimum
wall thickness.

6.4 Dimensions, Weights and Tolerances

6.4.1 Size, Tolerances

Liner, manufactured to this specification shall comply with the

dimensions and tolerances given in ISO 4427 Tables 3 – 6 or
API SPEC 15 LE Table 3.

The tolerance on the liner wall thickness shall be -0%/+5% of the

specified value.

6.4.2 Ovality

The ovality of the pipe shall not exceed 5% when measured in

accordance with ASTM D2513.

During liner manufacturing, ovality / out-of-roundness shall be

monitored and recorded.

7 Quality Program

7.1 Quality Manual

The Manufacturer shall maintain a Quality Manual which describes the quality
program. All prior revisions shall be retained for a period of not less than five
years.

The Quality Manual shall address a documentation program to assure

communication of approved manufacturing and inspection procedures to
qualified receiving, manufacturing and quality control personnel. The Quality
Manual shall be submitted to the Principal for review and approval, and shall
cover at least the following aspects:
 raw material acceptance;
 extrusion procedures;
 pipe manufacturing practices;

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Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
Issue Date: 15 December 2012 Thermoplastic Tight Fit Grooved or
Next Planned Update: 15 December 2017 Perforated Liners for New and Existing Pipelines

 welding procedures and qualifications;

 inspection and test procedures;
 acceptance criteria;
 repair procedures.

7.2 Hydro-testing

The hydrotest pressure shall be 1.5 times the “rated” pressure for the stand-alone
thermoplastic pipe. The hydrostatic test pressure shall be maintained for at least
3 minutes. Liner pipe sections undergoing hydrostatic pressure test shall not
show any sign of leakage, weepage or ballooning.

7.3 Storage and Handling

Straight lengths shall be stored on horizontal racks and given support to prevent
damage. Coils shall be stored stacked flat one on top of another.

Pipe shall be protected from environmental contamination and damage by third

party.

Covers shall be used to prevent ingress of moisture or dirt inside the grooves or
perforations of the liner.

Liner can be susceptible to damage by abrasion and by sharp objects.

Dragging pipe sections or coils over rough ground shall not be permitted. If, due
to unsatisfactory storage or handling, a liner is damaged it shall be rejected.

8 Documentation

 Information to be submitted by the Contractor

The Contractor shall submit information on the liner system to be used.

This information shall contain as a minimum:
 Liner system identification.
 Manufacturer's material data.
 Material pre-qualification information.
 Type and thickness of liner material.
 Expected short-term and long-term volumetric swelling or shrinkage for the
range of operating conditions.
 Expected thermal deformations due to operating temperatures.
 Liner manufacturing procedure.

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Document Responsibility: Non-metallic Standards Committee 01-SAMSS-050
Issue Date: 15 December 2012 Thermoplastic Tight Fit Grooved or
Next Planned Update: 15 December 2017 Perforated Liners for New and Existing Pipelines

 Liner installation procedure.

 Anticipated insertion forces for each liner section in relation to the liner strength
capabilities.
 Bend limitations for the steel pipe.
 Maximum allowable weld penetration of carbon steel pipeline girth welds.
 Vent connection details and spacing.

Revision Summary
15 December 2012 New Saudi Aramco Materials System Specification.

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