Installation Manual FPI
Installation Manual FPI
Installation Manual FPI
YELLOW BOX
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General Installation Manual
This guide is specifically for Future Pipe Industries (FPIs) medium and high pressure line pipe with threaded end connections.
As this pipe may contain corrosive fluids and/or operate at a high pressure level, the instructions in this manual must be followed
to avoid serious personal injury or property damage.
Improper installation can cause injury or damage. Installation contractors should read and follow all cautions and warnings to
avoid personal injury. They should also: observe the general safety practices with all the tools to avoid personal injury, wear
protective clothing when necessary and pay particular attention to section # 7 in this guide on testing.
We highly recommend that all installation contractors be trained by FPI before installing our fiberglass line pipe. For current
information on field training, installation training seminars or FPIs Field Service, please contact us.
It is the policy of FPI to improve its products continually. In accordance with this policy, FPI reserves the right to make changes in
specifications, descriptions, and illustrative material contained in this manual as the conditions warrant. The information contained
herein is general in nature and does not intend to express any warranty of any type whatsoever nor shall any be implied.
This is a dynamic, live and in-process document which can be revised at any time by FPI based on the recommendations of stress
analysis of a given pipe system, changes in products or improvements in installation techniques.
This document contains confidential and proprietary information. Reproduction or disclosure of any part of this document is only
allowed with written authorization from Future Pipe Industries.
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Note that the services provided do not include earthwork, excavation, construction, design or any activities not specifically related
to the assembly and makeup of the fiberglass products provided by FPI. Typical services provided by FPI for line pipe installations
are given below. Due to logistical constraints not all of these services are available in all locations.
FPI field personnel have extensive experience in the installation of fiberglass products in numerous applications. Typically they can
be of assistance in many aspects of a fiberglass project, only some of which are listed above. Their responsibilities, however, do
not include the success or failure of a given project. Their authority on a customers work site is restricted to advice and recommen-
dations provided to the customer and its employees. Field installation services are not available for products not manufactured
by FPI.
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TABLE OF CONTENTS
1 PACKING, STORAGE & HANDLING 3 5 THREAD MAKEUP & INSTALLATION
1.1 Packing 3 PROCEDURE 20
1.2 Inspection 3 5.1 Scope 20
1.3 Transportation, Storage & Handling 3 5.2 Crew Size 20
1.3.1 Pipe 3 5.3 General Precautions 20
1.3.2 Fittings 4 5.4 Visual Inspection: Pipe & Fittings 20
1.3.3 Teflon Thread Compound 4 5.5 Visual Inspection: Threads 21
1.3.4 Thread Sealant 4 5.6 Inspection: Thread Compound / Thread
Sealant 21
2 SITE STORAGE & PIPE LOWERING/STRINGING 5.7 Thread Makeup: Integral Joint / Threaded &
PROCEDURE 7 Coupled Joint 21
2.1 Pipe Distribution Along the Trench 7 5.8 Thread Makeup: Elbow and Other Fittings 23
2.2 Pipe Lowering Procedure (For Buried 5.9 Flanged Connections 23
Installation) 7
2.3 Ultraviolet Effects 7 6 FLANGE TIGHTENING PROCEDURE 27
6.1 General Guidelines 27
3 TRENCH SPECIFICATIONS & BACKFILLING 6.2 Precautions 27
PROCEDURE 9 6.3 Gasket 27
3.1 General 9 6.4 Installation Procedure 27
3.2 Common Trenching Guidelines 9 6.5 Determination of the Bolt Lengths 28
3.3 Minimum Recommended Trench Width 9
3.4 Trench Depth 9 7 FIELD HYDRO-TESTING RECOMMENDATIONS 31
3.5 High Water Table Conditions 9 7.1 Scope 31
3.6 Pipe Bedding and Foundation 9 7.2 Precautions 31
3.7 Pipe Embedment Zone 10 7.3 Test Frequency 31
3.8 Backfilling Materials (Pipe Foundation & 7.4 Visual Inspection 31
Pipe Embedment Zone) 10 7.5 Backfilling Checks Before Field
3.9 Cement Stabilized Sand Backfill for Poor Hydro-Testing 32
Soil Conditions 11 7.6 Field Hydro-Test Preparation 32
3.10 Installation at Road Crossings 11 7.7 Water Filling 32
3.11 Backfilling Checks Before Hydro-Testing 12 7.8 System Pressurization 33
7.9 System Depressurization 33
4 BASIC TOOLS & EQUIPMENT 15
4.1 General Guidelines 15 8 REPAIR PROCEDURES 34
4.2 Wrenches 15 8.1 Available Repair Options 34
4.2.1 Strap Wrench 15 8.2 Spare Joint with Flanges & Coupling 34
4.2.2 Friction Wrench 15 8.3 Factory Repair Joint 39
4.2.3 Chain Tong 15 8.4 Repair Coupling (Adhesively Bonded /
4.2.4 Power Tong 16 TB-TS Joint) 39
4.3 Brushes 16 8.5 Laminate Joint 40
4.4 Pipe Stands 16 8.6 Leaking Elbow Replacement 41
4.5 Thread Compound or Sealant 16
4.5.1 Teflon Thread Compound 16 9 HYDRAULIC PROPERTIES & HEAD LOSS
4.5.2 Thread Sealant 16 CHARTS 42
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1.1 Packing
Pipe is shipped in 30 ft. standard lengths complete with thread protectors. Length is determined by measuring the full,
overall length of the joint including the threads. For determining the joint length, the length of thread must be deducted from
the overall length.
YELLOW BOX products up to 6 are shipped from the plant packaged in crates with wooden supports and reinforced with steel
bands. The pipe is encircled with 2 x 4 wooden boards in four places for support and protection (Figure 1). Standard crates
are 48 wide, 21 tall and about 32 long. Individual crates weigh from 1,600 to 2,250 kg. An estimate on the number of joints
per crate is given in Table 1. Typically, eight crates can be loaded on a standard flatbed trailer.
Pipe larger than 6 size is loaded directly on a trailer or inside a container. Joints are separated and secured by means of wooden
spacers, stoppers and straps (Figure 2).
1.2 Inspection
Upon arrival of a shipment, each pipe must be inspected. Check to see if the load has shifted, or shows signs of unusual or rough
handling. Unless rough handling is evident, usually only a normal visual inspection is sufficient. A shifted load or other signs of
rough treatment are cause for careful inspection of each joint. Look for light, discolored spots on the outside of the pipe resulting
from impact or mechanical damage. Check pipe ends for damage, especially when the material is transported on a common
carrier.
Damaged or missing items should be marked on the delivery receipt. Notify the carriers agent immediately and leave the
material as received for their inspection. Replacements for shortages and damaged materials are not automatically reshipped.
Replacement materials must be ordered in the normal manner. Also check the bill of lading to assure accountability of all items.
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11. A forklift can lift several joints at a time, depending on the forklift capacity and the pipe size.
12. Side posts of trailers must be wrapped with rubber sheets to avoid contact of RTR with steel. To provide adequate protection,
side posts shall always be higher than the load.
13. While loading and offloading by crane, single joints must be lifted using a spreader bar with pliable nylon straps or nylon
ropes. Lift with two support points placed at equal distance from the pipe ends so the pipe is balanced.
14. Ensure the storage surface is clear, levelled, firm and free from rocks or any other sharp objects.
15. Pipe should be stored separately according to pressure class and diameter.
16. During storage, pipe shall be uniformly supported throughout the pipe length at all times by flat, cross boards placed under
each pipe layer with spacing not greater than 2 meters. The wooden supports shall cover the length of the entire pipe until
a maximum of 1 meter from the ends (Picture 2). Wooden wedges are used to prevent the stored pipe from sliding. Wedges
should be placed on both sides of the stack on the cross timbers, as shown in Picture 2.
17. If RTR products will be stored for long periods (6 12 months) or subjected to high temperatures, they must be covered with
tarpaulins or white polyethylene sheeting.
18. Small diameter pipe can be stacked in the same crate as shipped (Figure 1).
19. It is important to note that YELLOW BOX threads (both male and female) shall not be subjected to direct Ultraviolet (UV)
rays. Exposure to UV rays from the sun for an extended period of time causes thread disintegration. Hence it is vital to cover
them using the FPI-supplied thread protectors. In case no thread protectors are available at site, cover the threads temporarily
using dark tarpaulin sheet, and arrange for replacements. The pipe surface is resistant to UV rays see section # 2.3.
1.3.2 Fittings
1. Fittings are normally disspatched pre-packed in wooden boxes (Figure 3). All fittings in the box are separated by corrugated
sheet to prevent damage. It is recommended to store fittings in the same box until they are required to be installed.
2. During shipping, strap the wooden boxes to the vehicle using pliable straps or nylon ropes.
3. When fittings are shipped individually, handle them manually (for small sized fittings) or on wooden pallets.
4. When loading and unloading, any mechanical handling equipment (such as metal slings, hooks and chains) must not come
into direct contact with RTR pipe nor fittings.
5. Unprotected flange faces should never be placed directly on the ground or on concrete floors.
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Table 1: Estimated joints & length per crate (for high pressure classes, the number of joints / crate may be lower: refer to
section 10 for details).
Pipe Diameter Joints/ Crate Meters/ Crate Feet/ Crate Crates/ Truck Total Joints/ Truck
2 102 930 3,060 10 1020
2 1/2 69 630 2,070 10 690
3 53 480 1,590 10 530
4 30 270 900 10 300
5 20 180 600 10 200
6 12 110 360 10 120
6L or 150 mm 12 110 360 10 120
Figure 1: Stacking method of pipe up to a size of 6 inside a crate frame; the crate in which this stack is enclosed is not shown
in the figure below.
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Picture 1: RTR pipe loading / off-loading method by forklift. Picture 2: RTR pipe storage method in stockyard.
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The correct direction of fluid flow is from the pin end into the integral box end. So the pipe installation for the integral joint should
always start from the downstream side. In case of the line containing only coupling installation (and no integral joints), then the
direction of installation is not important due to the couplings symmetry.
If for some reason the trench is not yet open, determine which side the excavated earth will be placed and string the pipe on the
opposite side, allowing ample room for the trenching machine.
For the pipe surface (non-threaded area), ultraviolet effects are only limited to surface discoloration. Fiber bloom or fazing may
occur if the pipe is exposed to sunlight for a long period of time (3 5 years). As this effect is only limited to the outer 0.1 to
0.25 mm of the pipe surface, the mechanical integrity of the pipe system is not affected in any way. Pipe will operate at 100% of
its rating with no effect on its physical properties.
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Pipe stringing inside the trench Pipe stringing above the trench
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3.1 General
This section contains specifications for the trench and procedures for backfilling the RTR line.
FPI recommends that all high pressure pipes be buried. For other applications and/or when pipelines will not be buried, contact
FPI for recommendations.
If it is necessary to install the fiberglass line under another pipe line crossing, connect three to four pipe joints together, install
them under the existing line and then tie this section back into the previously installed or joined fiberglass pipe section. It may be
necessary to dig a bell hole at the tie-in point to allow enough room for wrenches and personnel.
If the field makeup is intended to be performed inside the trench, it is required for the trench to be wide enough so as to
accommodate a power tong, or the rotation of a manual wrench.
To ensure firm support for the pipe, proper bedding must be provided under the pipe. During trench excavation, a pipe bedding
thickness of 150 mm or one pipe diameter (whichever is greater) must be provided. In the case of very poor native soils (silt, clay
or mud), an additional 150 mm thick foundation layer must be provided below the bedding. Selected backfill material should be
placed at the foundation and bedding levels. Wetting of the bedding in case of poor soil conditions is recommended.
The bedding material should provide firm, uniform and continuous support over the entire length of the pipe. High spots in the
trench bottom will cause uneven bearing on the pipe, damage due to stress during backfill and unnecessary wear at these points.
This is particularly significant if pulsation is present in the pipe system. Avoid sharp bends and abrupt changes in elevation in
the line. Check the minimum bending radius in the product data sheets for guidance. If these conditions are unavoidable, then
elbows, vacuum breakers, and/or check valves may be necessary. It is important to remove all sharp rocks, or objects and other
abrasive material from the trench.
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The Contractor should note that the compaction of clean and mixed sand is best achieved when the material is at its optimum
moisture content. While the wetting of sand is recommended prior to compaction, trench flooding should be avoided to prevent
the pipe from floating.
Following the first two layers where the backfill has been correctly placed, compaction should proceed from the sides of the trench
towards the pipe. Clean backfill must be used with vibrator equipment as this type of equipment can drive stones or foreign
material into the pipe wall.
The pipe embedment zone backfill should proceed in 150 to 300 mm lifts depending on backfill type. The pipe embedment zone
backfilling and compaction should continue until the backfill reaches at least 150 mm above the pipe crown. Sand layers of more
than 300 mm cannot be compacted properly and may result in loss or reduced support for the pipe.
After completion of backfilling in the pipe embedment zone, native material excavated from the trench may be used to complete
the native backfill (Figure 4) to final grade. No compaction is required in these final backfilling layers except where specified by
the engineer or if traffic or other high wheel-loads over the pipe is expected.
Multiple lines in the same trench must be separated by clean backfill or sand by a distance of 150 mm or one pipe diameter,
whichever is higher.
Maximum particle size for all installations of YB is 13 mm. As a general guideline, the material used for backfill must be free of
sharp rocks, heavy boulders, large clods of dirt, frozen lumps of mud in cold weather and any foreign material. If the native soil
meets the above specifications, the same soil may be used in the pipe embedment zone.
Frozen earth will eventually thaw leaving the pipe with insufficient support and voids around the pipe. Foreign material or trash
will eventually rot or break down which can also cause voids. Voids under or around the pipe must be avoided at all times.
In areas where the backfill material contains large amounts of sharp rocks, heavy boulders, large clods of dirt or frozen lumps,
a padding (sifting) machine is recommended. Padding machines sift the backfill material for rocks and foreign material. Padding
machines are often more economical than hauling sand or clean backfill to the job site. In environmentally sensitive areas, a
padding machine may be required by local authorities.
SPD is standard Proctor density as determined by ASTM Test Method D698 (AASHTO T-99).
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In case the traffic loads are frequent, or if the load intensity is higher than specified in Table 3, or if the minimum burial depth
cannot be maintained, then the RTR pipe is run through a steel casing or a conduit. A typical example of a road crossings detailed
drawing is presented in Figure 6.
Prior to the insertion of RTR pipe into the casing pipe, spacers/centralizers shall be installed to the required distances. It is
recommended to have at least 4 centralizers per pipe length. The assembled pipe section shall be a minimum of one pipe
length longer than the casing pipe on both sides. The end-sealing rubber sleeve or concentric-boot shall be fixed to the casing
pipe (Picture 6).
While inserting the RTR pipe into the steel casing, adequate end protection shall be provided on the RTR pipe end to avoid
accumulation of debris and/or sand inside the RTR pipe. Care should be taken to ensure that the fiberglass pipe is properly
bedded at the points of entry to - and exit from the steel conduit to prevent excessive wear on the pipe.
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Min. Trench Width while making up Min. Trench Width while making up
Pipe Size
the joints inside the trench the joints above the trench
10 X Pipe DN, 3.5 X Pipe DN,
All Sizes
with a maximum width of 1.85 meters with a minimum width of meter
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Centralizer
Steel sleeve
Rubber end sleeve
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4.2 Wrenches
All joints supplied are designed with an extra thickness at the ends called pipe upset. While using to makeup a pipe, all wrenches
shall be applied only on the upset area.
Warning: Do not use steel pipe wrenches to make up fiberglass pipe. Steel pipe wrenches will cause point loading or wall
deformation. This can give a false sense of tightness and can damage the product and void the warranty.
See Table 4 for the type and number of wrenches recommended for make-up of YELLOW BOX products.
When using a strap wrench, ensure not to point-load the tubing. Point loading can collapse or damage the pipe wall when the
wrench is pointed perpendicular into the pipe.
1. A Ridgid No. 5 strap wrench (Picture 7) is normally used for makeup of 3 diameters and smaller. The handle of this wrench
is approximately 18 long.
2. The 24 cast aluminium strap wrench (Picture 8) is normally used with 4 and larger diameter pipe during makeup, or as a
backup wrench on smaller diameters. The handle of this wrench is about 24 long. This strap wrench could also be used in
hand-tightening for larger diameter pipe.
Note: Check the ID and adjustability of the friction wrench versus the OD of the pipe being installed.
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4.3 Brushes
2 types of brushes are commonly used:
Teflon tape should be 25 mm wide and 0.1 mm thick and shall contain 100% Teflon.
See Table 5 on page # 24 for the amount of thread compound and Teflon tape recommended per diameter.
Minimum properties of Teflon thread compound for use on YELLOW BOX threads:
1. 15% minimum Teflon content.
2. 60 to 120 mesh Teflon particle size (powder is unacceptable).
3. The lubricant must be of API standard oilfield thread lube composition.
4. The lubricant should not be thickened with abrasives, clay, etc.
Thread sealant should also be used on all large-diameter YELLOW BOX with 6 round threaded connections, and on all pressure
classes above 172.5 bar (2,500 psig). See Table 5 on page # 24 for recommended amounts.
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Key:
A Ridgid No. 5 or 24 Cast aluminium strap wrench
B Friction wrench or chain tong
C Power tong
1, 2, 3 or 4 Indicates the quantity of required wrenches
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Picture 16: Fixed pipe-stands made of steel. Picture 17: Fixed pipe-stands made of light-weight material
(hard plastic or hard rubber).
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5.1 Scope
The procedures in this section are general in nature. More specific, additional details may be provided during the actual
installation in the form of project specific work instructions. It must be ensured that all levels of staff are aware of these procedures
in order to ensure the quality of the connection. It is important that only qualified personnel perform the thread makeup procedure.
The objective is to ensure that the installed pipeline will meet the specified performance requirements.
Although these procedures are as complete as possible, it is impossible to describe every circumstance that may be encountered
in the field. Because of this, FPIs experienced site supervisor may vary the described procedure in order to achieve an optimum
solution using the latest installation techniques.
In case the joining is performed without the supervision of FPI, the responsibility of proper makeup (torque application) lies with
the end-user, or their contractor.
See Table 4 on page # 17 for guidance on required number of installation tools. FPI can provide recommendations for specific
circumstances.
In case of sand/dust storm, snow, hail or rain, use an appropriate shelter such that the joint to be made up is protected from
adverse weather conditions. In case of sunny, cold, humid or foggy weather, joint installation can continue as normal provided
the sealing compound is stored at the correct conditions described in sections # 1.3.3 and 1.3.4.
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Threads shall be free from visible tears, cuts, grinds, shoulders or any other imperfections which break the continuity of the
threads within the normal mating surface on the pin and the box at the final makeup position. Superficial scratches and surface
irregularities that do not affect the continuity of thread surfaces are occasionally encountered and may not necessarily be
detrimental. Use API 15HR as a reference for acceptable visual standards for threads. As a guide to acceptance, the most critical
consideration is to ensure that there are no detectable protrusions on the threads to score mating surfaces.
During installation, if thread damage is suspected, lay the joint aside and replace it. In case a wrong makeup is observed, break
out the connection and continue installation as normal after inspecting the retrieved threads.
If the thread has been previously used and is being reinstalled, remove sand, dirt or any foreign material which may cause
improper make up and sealing. Wash pin and box threads with a hydrocarbon (ex: petrol) or a solvent (ex: acetone, methylene
chloride) which will remove the old thread lubricant, tape or foreign material. Dry both threads completely. Any liquid left in the
base of the threads will prevent good thread lubrication.
In case the Teflon thread compound is used, ensure that it is between 10C and 50C for optimum brush-ability.
In case thread sealant is used, ensure that its temperature is between 40C and 55C to ensure correct application on the threads.
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5. Apply Teflon thread compound to both the pin and box threads with a dope brush. Before applying the thread compound, stir
thoroughly. Apply enough Teflon thread compound to have a thick film in the root of the threads (see Picture 21). In cold weather,
if the bristles of the dope brush are stiff, they can tear Teflon tape. When it is cold (below freezing), use a flat stir stick to apply the
thread compound and prevent tearing the tape. Always apply the thread compound in the same (clockwise) direction as the tape
to prevent the tape from unwinding. Refer to Table 5 for the estimated Teflon thread compound usage rate.
6. Thread Sealant will be used for all dry gas applications. This one-part sealant cures in 10-15 minutes once exposed to
moisture. Refer to Table 5 for the estimated thread sealant usage rate. If a thread sealant is used, the following additional
precautions shall be observed during thread makeup:
a. Apply the thread sealant using a comb which has the thread profile on it. The comb is typically a thin slice of a
threaded connection with truncated thread crests (approximately 30% less thread height compared to standard round
thread).
b. Using a caulking gun, apply the sealant onto the pin and box and then distribute it uniformly over the thread area with
the comb. The comb will fill the sealant in the root of the threads to about 50% of the total thread height.
c. Apply the sealant quickly so as to save as much time as possible for the makeup procedure before the cure starts to set.
d. Lightly spray the sealant with water.
e. Pay close attention to the joint alignment as there will normally be a maximum of three alignment attempts available
before curing proceeds to such an extent as to disable installers from concluding the make-up.
f. If the curing starts before the makeup is complete, back the connection out and thoroughly clean the now cured sealant
out of the threads with a wire brush. It may not be possible to completely clean the sealant out of the threads; but attempt
to remove the majority of it.
g. Once clean, re-apply the sealant again and re-make the connection.
7. Insert the pin thread into the box thread and manually rotate until the hand tight position is reached, while checking for
correct alignment. It is possible to use a strap wrench to obtain the hand tight position. Depending on the size and weight
of the pipe, pin alignment can either be achieved manually (using pipe jack, lazy boards, adjustable pipe stand, etc.) or
facilitated by means of powered lifting equipment such as pipe cradle, side boom / cargo-crane truck (Picture 22). If the pipe
is not engaged straight, any misalignment will cause a false sense of tightness. Make sure that the pipe is aligned properly
at all times during the makeup.
8. Use a tong fitted with a torque indicator for power tight makeup (Picture 23). Set the torque indicator to the required torque
level. Nominal torque range is shown in Table 5. When using a power tong, place the pipe jack near the end of the joint
being installed; make sure the joint of pipe is straight to allow proper make up of the connection; one person may be
needed in the center of the joint to prevent the pipe from wobbling or jumping. Appropriate wrench can be selected per
Table 4 on page # 17.
9. The last thread on the pin end shall just enter inside the box at final position of the thread makeup. This position is called the
power tight (final) standoff. Tolerance for power tight standoff is 1 thread. Note that at this stage, the torque shown by the
torque indicator (if used) will normally be within the nominal torque range as shown in Table 5. While obtaining the power
tight standoff, it is allowed to exceed the average nominal torque value by a maximum of 30%.
10. During the makeup process, a few scratch marks will occur on the pipe OD due to the action of the tong on the pipe surface.
This is quite normal and does not affect the performance of the system. The pipe ends are designed with extra thickness (pipe
upset) to handle this installation technique. Tolerance for the depth of these scratch marks is such that the minimum total
wall thickness of the pipe (TW as specified in the product drawings / catalogue), measured from the inside diameter, shall
remain intact.
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Installation of elbows or tees may require concrete thrust blocks. The size of the thrust block depends on the soil modulus, operating
pressure and pipe diameter. An engineering company should be used to size the thrust blocks based on recommendations from
system design. Contact FPI for assistance.
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Table 5: Joint makeup torque / Teflon tape consumption / Thread compound consumption / Thread sealant consumption
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Picture 20: Application of Teflon tape. Picture 21: Thread compound application.
Picture 22: An example of the use of cradle and cargo-crane truck to achieve alignment.
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Manual chain tong fitted with a torque indicator Manual friction wrench fitted with a torque indicator
Picture 24: Making up the elbow directly on the pipeline. Picture 25: Making up the elbow with a pipe nipple.
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YELLOW BOX flanges are flat face flanges. All steel flanges should be of the same flat face configuration.
If a raised face steel flange is used with a flat faced RTR flange, a simple spacer ring should be used to take up the raised face
shoulder and present a flat surface to the RTR flange (Figure 7 and Picture 26). This is done to avoid excessive bending moment
on the outer circumference of the RTR flange. This spacer ring shall be made of a corrosion resistant material, such as SS316.
It is highly recommended to use steel backing plate / ring for each flange supplied (Picture 26). Flange backing
plates redistribute the bolt loads evenly over the circumference of the flange body and thereby protect flanges from over-torque
in the field.
Lubricated washers must be used to prevent the nuts and possible bolt heads from scrapping or damaging the RTR flanges.
6.2 Precautions
1. RTR flanges shall be assembled tension-free and with accurate alignment.
2. Never use flange bolts to pull two pipe sections together.
3. Only connect flanges belonging to the same nominal size & drilling class.
4. While connecting RTR flanges to steel flanges ensure that there is no load or movement transferred from the steel line to the
RTR line this is normally covered during system design recommendations by means of thrust blocks (Picture 27).
6.3 Gasket
The flange must be installed with spiral wound gasket to seal the connection (Picture 28). The recommended gaskets are Flexitallic
or Garlock brand ANSI B 16.5 standard, graphite filled with stainless steel ring(s).
Always double check the ID of the gasket to make sure it matches the flange face ID or is slightly larger.
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9. After completing one round of tightening, repeat the tightening sequence one more time. The bolts on one side tend to get
loose while tightening the bolts on the opposite side.
10. It is allowed to exceed the recommended bolt torque by 20% in case of any gasket leak or other special circumstances.
Exceeding the 20% limit may result in serious permanent cracks in the flange.
11. Note that spiral wound gaskets are normally for single use. Once the flange is disassembled, it is recommended to replace
the gasket.
Where:
T = thickness of the RTR flange
t = thickness of the steel flange
p = thickness of the gasket (typically 5 mm)
r = thickness of the washer
m = height of the nut
5 = allowance in addition to the tolerance of the flange thickness
ANSI 150 ANSI 300 ANSI 600 ANSI 900 ANSI 1500
Pipe Size
Bolt Size Bolt Size Bolt Size Bolt Size Bolt Size
(inches) Bolt Qty Bolt Qty Bolt Qty Bolt Qty Bolt Qty
(inches) (inches) (inches) (inches) (inches)
2 4 5/8 8 5/8 8 5/8 8 7/8 8 7/8
2 4 5/8 8 3/4 8 3/4 8 1 8 1
3 4 5/8 8 3/4 8 3/4 8 7/8 8 1-1/8
4 8 5/8 8 3/4 8 7/8 8 1-1/8 8 1-1/4
5 8 3/4 8 3/4 8 1 8 1-1/4 8 1-1/2
6 or 6-L 8 3/4 12 3/4 12 1 12 1-1/8 12 1-3/8
8 8 3/4 12 7/8 12 1-1/8 12 1-3/8 12 1-5/8
10 12 7/8 16 1 16 1-1/4 16 1-3/8 12 1-7/8
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Figure 7: Examples of raised face (RF) flange, flat faced (FF) flange and spacer for RF flange.
Picture 26: Example of a SS316 spacer for raised face steel flange and a steel backing plate / ring for YB flange.
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The procedures written are as complete as possible. It is not possible to describe all the different circumstances that may be
encountered in the field. For this reason, an experienced field engineer/supervisor from FPI may change these procedures in
order to achieve an optimum solution using the latest techniques and testing methods.
The pressurization steps given in this document are part of the standard FPI hydro-test method for YELLOW BOX. In case any
project specific hydro-testing requirements or specifications have been agreed to in written form, then the agreed project specific
steps will be ruling.
7.2 Precautions
The following safety precautions shall be taken while hydro-testing the system:
Any external damage of the RTR pipe that may have occurred during the installation and/or handling process shall be identified.
In case of any damage, the RTR pipe or fittings shall be repaired as per the repair procedure in section # 8.
Both open ends of the installed line shall be covered with thread caps or similar protection, when not in use. This is to avoid any
sand or dirt from entering the line.
Ensure that all the repair work is completed and the test equipment is properly connected to the line before starting the hydro-test;
the pipe should be cleaned (pigged) if required by the main contractor.
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Complete the backfilling as soon as possible after successfully testing the system as a safety precaution and to eliminate the
chance for any damage to the pipe. Possible examples of damage are floatation due to flooding, shifting of the line or impact
damage due to cave-ins.
The recommended gaskets are spiral wound (Flexitallic or Garlock brands) graphite filled, with stainless steel inner & outer
rings for both hydro test and permanent connections. Gaskets can only be re-used if there is no visible damage or excessively
permanent compression after the hydro-test. In case of doubt, use a new gasket.
Connect all necessary valves and equipment prior to filling the pipeline with water. Any permanent valves in the system shall be
kept fully open and the check valves shall be removed from the system. Arrange for the necessary equipment i.e. filling pump with
break tank, pressure pump, etc. The blind flanges with required connections for air venting (such as ball valve) shall be available
to close the system.
If the total line length to be hydro-tested is more than 1 KM or if the pipeline has a major difference in elevation over its length,
a pig is launched into the system to remove all air. The pig shall be launched from one side of the pipeline (preferably the lowest
point). A blind flange with a ball valve shall be connected to the other side. Introduce a substantial slug of water into the pipe,
and insert the foam pig behind it and flange up. Pump more air-free water through the line behind the pig; provide a constant
pressurized flow behind the pig and do not stop until the pig reaches the end of the line. The pig should push the air ahead of it,
both uphill and downhill. When the pig arrives at the end of the line, close the valve. If the bore of the end valve is big enough,
it is possible to pump out the pig through the same valve; for instance, a soft foam pig inserted inside a 6 line can be extruded
through a 2 end valve. Due to any reason, if it is not possible to pump out the pig, it is acceptable to pressure test with the pig
inside the line.
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If changes in elevation are present in the pipe system, the difference in pressure head must be taken into consideration. Take
account of the pressure head difference between the lowest point of the system and the connection point of the pressure gauge.
The excess pressure head occurring due to elevation must be subtracted from the test pressure to reach the correct test pressure
on the lowest parts of the pipe system. All gauges and recorders shall be calibrated prior to be used in the system. All relevant
calibration certificates shall be available on site.
The rate of pressurization at all stages shall not exceed 5 bar / minute. Start pressurizing the system gradually in a steady
and controlled manner to 0.8 times of the design pressure. Maintain this pressure for at least 20 minutes to allow the system to
stabilize.
Once stabilized, continue pressurizing the system gradually in a steady and controlled manner to the required field hydro-test
pressure, and maintain this pressure for 4 hours (or as agreed) as an integrity test.
During the hydro-test, the entire pipeline shall be carefully inspected for any leaks from joints or pipe body.
If a leak is observed from the flange connections, it is not permitted to over-torque the flange when the line is under pressure. Take
the pressure off the line and then open the leaking flanges. The cause of the leak should be determined. If the flange or gasket is
found to be damaged, it must be replaced.
In case of any leaks in the pipe body or joints, the test shall be terminated and the leaks repaired.
If no leaks are observed during the inspection, the hydro-test is successful and the system is ready for use after depressurization
and backfilling (if applicable).
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8 REPAIR PROCEDURES
8.1 Available Repair Options
Depending on site conditions, there are primarily five methods for repairing a leaking RTR line:
Prior to initiation of this repair procedure, ensure that enough backfill is excavated so as to enable movement of pipeline during
repair and flange alignment. Expose at least 25 meters of pipeline on either side of the damaged portion. If site conditions do not
allow such excavation, then two sets of flanges (double-flanged connection containing a total of 4 flanges) can be used instead
of one set to minimise excavation length.
Replacement of the leaking line with each of these scenarios is outlined in Figure 9, Figure 10, Figure 11 and
Figure 12 respectively.
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Although designed for repairing high pressure products, the repair coupling can also be used on low-medium pressure line pipe.
This repair method can be used on all brands of RTR line pipe as long as the mating dimensions match. Various styles of repair
couplings are available depending on the product and pressure rating. Be sure to use the proper repair coupling for the pipe
being replaced. Contact FPI for the correct repair coupling configuration.
1. Uncover the line at least 15 meters for pipe sizes 4 & below, and at least 25 meters for pipe sizes 5 & larger to allow
insertion into one end of the repair coupling.
2. Cut out the damaged section of pipe and machine one end in the form of a tapered spigot.
3. Place the repair coupling on the tapered end, making sure you have a tight, dry fit. Once adhesive is applied, the repair
coupling may makeup an additional to .
4. While the repair coupling is on the first tapered end, lay it next to the other section of pipe to measure for the second
taper. Measurements should allow for the second taper to insert into the repair coupling. Always dry fit the repair coupling
before applying adhesive to make sure measurements and taper are correct. Allow extra length to compensate for wet fit
versus dry fit.
5. Apply adhesive to all clean bonding surfaces and insert the tapered pipe end into the bell end of the repair coupling. This
can be done by lifting the line or moving it to one side, and then re-engaging the mating parts. Make certain all tapers are
tightly locked.
6. For the first bond, use a hammer and a block of wood to drive the joint together. For the second bond, use ropes and a puller
to pull the joint together. This procedure will assure a tight fit.
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Figure 14: Replacement of a leaking joint with a repair coupling (adhesively bonded joint).
The preparation of this rigid joint requires craftsmanship and shall only be performed by Future Pipe Industries approved
installation personnel.
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Figure 16: Replacing a leaking elbow (the integral joint is shown here as a primary connection for demonstration).
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Pressure loss charts for some common fluids are presented in this section.
42
100 0
100.0
10.0
OSS ((BAR/KM)
RESSSUREE LO
10
1.0
PR
PRESSURE LOSS VS. FLOW RATE
YELLOW BOX PIPE
FRESH WATER
SPECIFIC GRAVITY = 1.00
VISCOSITY = 1.00 CPS
0.1
1.00 10.00 100.00 1000.00
FLOW RATE (LITERS/SECOND)
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43
44
100 0
100.0
10.0
0FT)
PSI//100
UREE LOSSS (P
10
1.0
PREESSU
PRESSURE LOSS VS. FLOW RATE
YELLOW BOX PIPE
FRESH WATER
SPECIFIC GRAVITY = 1.00
VISCOSITY = 1.00 CPS
0.1
10 100 1,000 10,000
FLOW RATE (GALLONS/MINUTE)
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100.0
10.0
R/KM))
10
1.0
0.1
1.0 10.0 100.0 1000.0
FLOW RATE (LITERS/SECOND)
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45
46
100.0
10.0
RE LOSSS (PSI/100FT))
RESSUR
1.0
PR
PRESSURE LOSS VS. FLOW RATE
YELLOW BOX PIPE
BRINE WATER AT 60F
SPECIFIC GRAVITY = 1.10
VISCOSITY = 1.50 CPS
0.1
1 000
1,000 10 000
10,000 100 000
100,000 1 000 000
1,000,000
FLOW RATE (BARRELS/DAY)
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100.0
10.0
R/KM))
10
1.0
0.1
1.0 10.0 100.0 1000.0
FLOW RATE (LITERS/SECOND)
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47
48
100.0
10.0
RE LOSSS (PSI/100FT))
RESSUR
1.0
PR
PRESSURE LOSS VS. FLOW RATE
YELLOW BOX PIPE
40 API CRUDE OIL AT 60F
SPECIFIC GRAVITY = 0.825
VISCOSITY = 1.50 CPS
0.1
1 000
1,000 10 000
10,000 100 000
100,000 1 000 000
1,000,000
FLOW RATE (BARRELS/DAY)
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YELLOW BOX API Line Pipe (Joints & Feet per Container)
Size 500 750 1,000 1,250 1,500 1,750 2,000 2,250 2,500 2,750 3,000 3,250 3,500
825 825 825 825 825 825 825 825 765 677 611 - -
2
24,750 24,750 24,750 24,750 24,750 24,750 24,750 24,750 22,950 20,310 18,330 - -
623 623 623 623 623 623 623 578 507 454 371 - -
2.5
18,690 18,690 18,690 18,690 18,690 18,690 18,690 17,340 15,210 13,620 11,130 - -
405 405 405 405 405 405 405 384 342 305 240 - -
3
12,150 12,150 12,150 12,150 12,150 12,150 12,150 11,520 10,260 9,150 7,200 - -
255 255 255 255 255 254 224 183 165 149 - - -
4
7,650 7,650 7,650 7,650 7,650 7,620 6,720 5,490 4,950 4,470 - - -
173 173 173 173 173 173 173 173 157 140 - - -
5
5,190 5,190 5,190 5,190 5,190 5,190 5,190 5,190 4,710 4,200 - - -
90 90 90 90 90 90 90 83 75 - - - -
6
2,707 2,707 2,707 2,707 2,707 2,707 2,707 2,481 2,256 - - - -
89 89 89 89 89 89 89 89 89 - - - -
6-L
2,670 2,670 2,670 2,670 2,670 2,670 2,670 2,670 2,670 - - - -
56 56 56 56 56 56 56 56 56 - - - -
8
1,680 1,680 1,680 1,680 1,680 1,680 1,680 1,680 1,680 - - - -
42 42 42 42 42 42 42 42 - - - - -
10
1,260 1,260 1,260 1,260 1,260 1,260 1,260 1,260 - - - - -
41 41 41 41 41 41 - - - - - - -
10-L
1,230 1,230 1,230 1,230 1,230 1,230 - - - - - - -
30 30 30 30 - - - - - - - - -
12
900 900 900 900 - - - - - - - - -
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