FIBERSPAR LinePipe Engineering Guide

Transcription

1 FIBERSPAR LinePipe Engineering Guide Fiberspar Corporation Northwoods Industrial Park West FM 529 Houston, TX Tel: Fax: Fiberspar Corporation, Canada Headquarters th Avenue S.W., Suite 300 Calgary, Alberta T2P 3B6 Canada Tel: Fax: February 1, 2004

2 Table of Contents Page 1. Introduction FIBERSPAR LinePipe... 1 A. Design Overview...1 B. Connectors Fiberspar Quality System... 3 A. Overview... 3 B. Certificate of Conformance Applicable Industry Standards...3 A. API 15 HR - Specification for High Pressure Fiberglass Line Pipe"... 3 B. CSA Z Section "Fibreglass Pipelines"... 4 C. ASTM D "Standard Specification for Filament-Wound Glass Fiber Reinforced Thermosetting Resin Pipe"... 4 D. FIBERSPAR LinePipe Supplemental Qualification Tests Long Term Hydrostatic Strength... 5 A. ASTM D2992 Testing... 5 B. Calculations for FS LP Product Line Per API 15 HR Operational and Installation Considerations... 7 A. Chemical Compatibility and Pressure Barrier Selection... 7 B. Pressure Drop Calculations and Abrasive Flow... 7 C. Pigging and Hot Oiling... 8 D. Asphaltines, Paraffins and Hydrates... 8 E. UV Resistance and Protection... 8 F. Static Discharge... 9 G. Land Installations... 9 H. Pull -Through Remediation... 9 I. Marine Installations and Weighting... 9 J. Thermal Movement K. Growth and Shrinkage from Pressure Fluctuation L. Fiberspar Installation Manual M. FIBERSPAR Connector Installation N. Fire Resistance Application Summary and Customer Reference List - North America Engineering Guide i

3 APPENDIXES Page Appendix 1. Fiberspar Quality System Documentation Appendix 2. Typical Product Data Sheet - FS LP 3 ½ 1,500(E) Appendix 3. API 15 HR Design Calculation for FS LP 3 ½ 1,500(E) - Imperial Units Appendix 4. API 15 HR Design Calculation for FS LP 3 ½ 1,500 (E) Metric Units Appendix 5 Maximum Pressure Rating Calculations per CSA Z Specification Appendix 6. Chemical Resistance Data for HDPE & PEX Pressure Barriers Appendix 7. Thermal Expansion Data for FS LP 3 ½ 1,500 (E) Appendix 8. Pressure Versus Axial Load for FS LP 3 ½ 1,500 (E) Appendix 9. FIBERSPAR LinePipe Compression Slip Connector Fittings Engineering Guide ii

4 1. Introduction Fiberspar's spoolable fiber-reinforced pipe has been developed to provide the oil and gas industry with a family of products to address the market requirements for a reliable, corrosion-resistant, cost-effective solution for tubulars used during the production and transportation of oil and gas. FIBERSPAR LinePipe (FS LP) is a continuously manufactured fiber-reinforced pipe that is designed for production gathering and injection applications. Advantages of FIBERSPAR LinePipe compared to alternative pipeline systems include: rapid and low cost installation, improved corrosion resistance, long lengths without joints or connections (up to 8 km), improved flow characteristics, tolerance to impact damage, and light weight for improved safety during field installation operations. FIBERSPAR LinePipe is designed and manufactured in accordance with the following specifications: API 15HR - Specification for High Pressure Fiberglass Line Pipe, CSA Z Section 13.1, Fibreglass Pipelines, and ASTM D2996 Standard Specification for Filament-Wound Glass-Fiber-Reinforced Thermosetting-Resin Pipe. The following report provides an overview of Fiberspar s LinePipe design and qualification program. 2. FIBERSPAR LinePipe A. Design Overview The LinePipe consists of an inner thermoplastic pressure barrier layer that is reinforced by high-strength glass embedded in an epoxy matrix. LinePipe Product Geometry OD Thermoplastic Pressure Barrier Reinforced Wall Glass Fiber Reinforced Epoxy Laminate Liner Thickness Engineering Guide 1

5 FIBERSPAR LinePipe is available in North America in sizes between 1 ¼" to 4 ½" with pressure ratings between 1,000 psi and 2,500 psi in continuous lengths of up to 27,000 feet depending on size and reel capacity. Additional sizes of 5" and 5 ½" are available for export. Other sizes and higher-pressure ratings are available by special order. The selection of thermoplastic pressure barrier liner is driven by chemical compatibility with the flow medium and operating temperatures. Materials most commonly used are High Density Polyethylene (HDPE), which has excellent corrosion resistance in general low vapor pressure (LVP) or gas gathering applications; and for higher temperature applications, Cross-Linked Polyethylene (PEX) is generally recommended although other liner materials such as PVDF are available for highly specialized applications. All of these pressure barrier materials are commonly used in the oil and gas industry with widely published data on performance. B. Connectors FIBERSPAR LinePipe connectors are a full-strength, field-applied connection system. Drawings of FIBERSPAR LinePipe compression slip connectors appear in Appendix 9. The service-end connection is used to join the FIBERSPAR LinePipe to risers, T's or other fittings as required. The connector can have threaded ends or bevel end for welding. Welded-on flanges are preferred in buried applications. Fiberspar s pipe-to-pipe connector is a full-strength connection used to join two lengths of LinePipe. The pipe-to-pipe design is similar to the service-end, except a double seal carrier and two individual slips are used. The tensile and burst properties of the FIBERSPAR connection exceed the strength of the pipe itself. All qualification and quality tests required by CSA Z Section 13.1, API 15 HR and ASTM D2996 are conducted using FIBERSPAR LinePipe connectors. Connectors can be fabricated from numerous alloys depending on application and customer requirements. Commonly used materials for the end connectors include 4140 or 1018 steel. Machining and welding is performed by licensed machine and welding companies with proper QA and QC procedures only. Wetted surfaces are coated depending on customer and application requirements. For example, SRM s Impreglon 222 or 610E coating is commonly used on wetted surfaces in general purpose low vapor pressure production gathering applications. All welding procedures meet or exceed NACE and CSA specifications and include x-ray inspection on welds for every component. The seal rings are chosen based on service requirements and the three most common materials selected are: nitrile, AFLAS, and hydrogenated nitrile buna-rubber (HNBR). Engineering Guide 2

6 All LinePipe connections are performed in the field by certified technicians who have undergone training and are certified in the proper methods and procedures for installing FIBERSPAR LinePipe connectors in accord with requirements of API 15 HR and CSA Z Section Fiberspar Quality System A. Overview Fiberspar has made an extensive commitment to ensure the highest level of quality is employed in the design and manufacture of every spool of LinePipe. Toward that end, a four-tier quality assurance system has been implemented to meet the needs of the oil and gas industry. The Fiberspar quality system meets or exceeds the requirements of API 15 HR, and CSA Z and is ISO 9001 compliant. An overview of Fiberspar Quality System is contained in Appendix 1. B. Certificate of Conformance A Certificate of Conformance (COC) is supplied to customers prior to shipment, which summarizes the results from all quality assurance tests required by Fiberspar s quality system. LinePipe quality control tests meet or exceed the requirements of API 15 HR, CSA Z Section 13.1 and ASTM D2996 specifications. 4. Applicable Qualification Standards A. API 15 HR Specification for High Pressure Fiberglass Line Pipe FIBERSPAR LinePipe is designed and manufactured in accord with API 15 HR. Quality control Short-Term Failure Pressure tests required by API 15 HR (required every 5,000 ft.) are not ordinarily performed unless otherwise required by customer. Fiberspar s standard LinePipe test interval is at the beginning and end of each continuous length of production, which results ordinarily in testing intervals approximately 10,000 ft. long. The regression curve attached to this report conducted per ASTM D2992 Procedure B at 140 F is the maximum rated operating temperature for the HDPE liner used in most LinePipe applications. Testing at 200 F to create a regression curve for FIBERSPAR LinePipe with cross-linked polyethylene (PEX) pressure barrier liner is ongoing. Engineering Guide 3

7 B. CSA Z Section 13.1 Fibreglass Pipelines FIBERSPAR LinePipe is designed and manufactured in compliance with CSA Z Section C. ASTM D2996 Standard Specification for Filament-Wound Glass Fiber Reinforced Thermosetting Resin Pipe FIBERSPAR LinePipe is designed and manufactured in compliance with ASTM D2996. D. FIBERSPAR LinePipe Supplemental Qualification Tests In addition to the qualification tests outlined in API 15 HR, Z Section 13.1, and ASTM D2996, Fiberspar also conducts supplemental qualification tests to ensure FIBERSPAR LinePipe is fit for purpose for the actual commercial applications. All qualification and quality tests are conducted on specimens, which have been preconditioned by ten fully reversed bend cycles to maximum spooling strain per Fiberspar Quality System Work Instruction WI10.006, Pre-Conditioning of Test Specimens. Fiberspar has also conducted long-term spooling tests, per Fiberspar WI , Long Term Spooling Test, as well as long-term brine exposure tests on both constituent materials and pipe samples per Fiberspar WI , Long Term Brine Exposure Test. Hydrotests are conducted at 1.5 times operating pressure on 100% of the FIBERSPAR LinePipe, which is produced, per Fiberspar WI , Hydrostatic Pressure Proof Test Procedure. Engineering Guide 4

8 5. Long-Term Hydrostatic Strength A. ASTM D2992 Testing The Hydrostatic Design Basis (HDB) of the FIBERSPAR LinePipe is determined in accordance with ASTM D , Procedure B (static), at the maximum rated temperature of the FS LP. The maximum allowable design pressure for static pressure service for the LinePipe is determined by the formula stipulated in the applicable specification. API 15 HR specifies that the calculations are based on a 20-year design life and a minimum 0.67 service factor is applied to the extrapolated data to determine maximum operating hoop stress. Based on the actual regression curve for FIBERSPAR LinePipe it is expected that the FIBERSPAR products will have a minimum safety factor of two times maximum operating pressure and temperature after twenty years in service. The following is the regression curve for FIBERSPAR LinePipe per ASTM D , Procedure B. Regression Curve for Fiberspar Linepipe ASTM 2992 Procedure B per API-15HR 100,000 ASTM D-2992 Data LTHS of Test Data Hoop Stress (psi) 95% LCL of LTHS 20 yrs = 37,533 psi HDB = 95% LCL of 20 yrs = 35,407 psi HDS = 0.67 of HDB = 23,723 psi FS LP HDS - 1,500 PSI rating and greater = 18,000 psi FS LP HDS - 1,000 PSI rating = 13,300 psi 10,000 FS LP HDS - Less than 1,000 PSI rating = 12,000 psi ,000 10, ,000 1,000,000 Time (h) Engineering Guide 5

9 B. Calculations for FS LP Product Line Per API 15 HR and CSAZ Section 13.1 The regression curve for FIBERSPAR LinePipe per ASTM D , Procedure B results in a Long Term Hydrostatic Strength (LTHS) of 37,533 psi in accord with API 15 HR. The Hydrostatic Design Basis (HDB), which is the 95% Lower Confidence Limit of the LTHS, is 35,407 psi. The Hydrostatic Design Basis (HDS) is therefore 23,723 psi after applying the 0.67 service factor stipulated by API 15 HR. The formula used by API to calculate maximum operating hoop stress is less conservative than required by Canadian Standards Association, Z Section Consequently, the FIBERSPAR LinePipe is designed to comply with the more conservative CSA requirement, which increases the safety factor of Fiberspar design under API 15 HR. Fiberspar has taken the additional step of using a higher safety factor on the thinner walled, lower pressure LinePipe products. Although this is not required by API or CSA standards, we have chosen to incorporate additional structural material in the design of the lower pressure rated products to mitigate the potentially harmful effects of external abrasion, wear, and damage which can occur to pipe during handling, transport and installation operations. Any loss of strength based on external wear would disproportionately affect structural integrity of lower pressure, thin walled pipe when compared to thicker walled LinePipe products. For example, the 1,000 psi FIBERSPAR LinePipe is designed to have a maximum hoop stress of 13,300 psi, compared to 23,723 psi HDS allowable pursuant to API 15HR. This results in a service factor of 0.38 based on the actual regression curve, as opposed to 0.67 service factor required by API 15 HR. The higher-pressure rated FIBERSPAR LinePipe products are designed to have an HDS of 18,000 psi, or a service factor of 0.51 per API 15 HR, which is still considerably below the maximum allowable HDS per API 15HR. Fiberspar has utilized this conservative design approach to establish leadership for our products in reliability and robustness for production gathering and injection applications. Appendix 2 is a data sheet for a representative FIBERSPAR LinePipe product which is 3 ID, 3 ½ nominal diameter with recommended maximum operating pressure by Fiberspar of 1,500 psi. Appendix 3 has an example calculation of maximum operating pressure per API 15 HR in imperial units, and, and Appendix 4 has a sample calculation per API 15 HR in metric units. Appendix 5 is a summary of maximum pressure ratings allowable for various fluid services pursuant to CSA Z Section Engineering Guide 6

10 6. Operational and Installation Considerations A. Chemical Compatibility and Pressure Barrier Selection FIBERSPAR LinePipe is designed to contain a wide range of fluids. Pressure barrier liner selection is based on the specific anticipated service conditions. Appendix 6 contains a list of recommendations for the most commonly encountered fluids for the most popular FS LP pressure barriers, high-density polyethylene (HDPE) and cross-linked polyethylene (PEX). Chemical compatibility information on other pressure barrier materials such as PVDF is available from Fiberspar upon request. Due to the almost limitless number of combinations, concentrations, temperature and pressure conditions which are possible in the field, Fiberspar materials scientists can provide recommendations on a case-by-case basis for specific applications, and can also undertake compatibility testing upon request. Chemical compatibility of the exterior surface of FIBERSPAR LinePipe is generally not of concern since the epoxy resin and glass fiber outer surface typically is inert in the environments encountered in most buried applications. In some applications, an external thermoplastic jacket is recommended to provide further protection to the laminate from unusual external conditions, for example if immersed in an aggressive fluid, or to provide external collapse resistance from hydrostatic pressure in deep water. B. Pressure Drop Calculations and Abrasive Flow FIBERSPAR Line Pipe has a smooth internal thermoplastic pressure barrier that improves flow by reducing frictional losses when compared to steel pipe. The smooth interior surface generally does not deteriorate in service and improved flow properties are maintained over time. Fiberspar recommends that a C factor of 150 be used in the Hazen-Williams formula for friction pressure drop calculations. Friction flow factors for other commonly used formulas are contained in FIBERSPAR LinePipe product data sheets. Each of the thermoplastic pressure barrier materials used by Fiberspar have good flow abrasion properties, and will normally show less abrasive wear than steel pipe under the same abrasive flow conditions. Where highly abrasive flow is expected, tests are recommended to establish wear life. Engineering Guide 7

11 C. Pigging and Hot Oiling Pigs can be run through FIBERSPAR LinePipe to remove deposits and blockages. However, because the thermoplastic pressure barriers in the FIBERSPAR LinePipe are softer than steel, sharp-edged scraper-type pigs should be avoided, and soft pigs should be used. Intermittent hot oiling of the FIBERSPAR LinePipe up to a maximum hot oil temperature of no more than 15 C or 30 F above maximum-rated operating temperature of the FS LP can be employed. Because of the reduced thermal conductivity of the FS LP when compared to steel, lower hot oiling temperatures can be employed while maintaining the exit temperature from the line. Fiberspar engineers can provide information and advice on selection of pig types and sizes to avoid damage to FIBERSPAR LinePipe, as well as provide technical support regarding temperature profiles for hot oil treatments. D. Asphaltines, Paraffins and Hydrates Formation of asphaltine or paraffin in hydrocarbons is caused by fluid conditions. Build up of these precipitates inside the tubular leading to reduced flow or blockage occurs when the precipitated solids can adhere to the pipe wall. Precipitates can adhere to thermoplastics, and tendency depends on the specific thermoplastic. In all cases the smooth thermoplastic internal pressure barrier material generally aids removal. Fiberspar can provide application specific technical support based on customer request. Since hydrate crystals tend to originate in cracks and crevices in the inner pipe surface, the smooth thermoplastic inner surface of the FIBERSPAR LinePipe can have the effect of delaying the onset of hydrate formation, and can be very beneficial in completely preventing any build up. E. UV Resistance and Protection The outermost layers of FIBERSPAR LinePipe include a UV absorbing additive. However, slow degradation of the outer surface of the pipe will take place when exposed to strong sunlight over time due to the oxidizing effect of UV light on the resins. Testing on fiber-reinforced epoxy pipe conducted over long time periods has demonstrated the structural effects from UV exposure are minimal as the UV rays are absorbed by the outer layers of the pipe, and any damage is limited to the outer of thickness. Any effect on the FIBERSPAR LinePipe from UV rays would be cosmetic and the pipe can continue to be used to the full rating for the designed 20-year service life. Engineering Guide 8

12 F. Static Discharge Fiberspar LinePipe is an electrical insulator, and in applications that involve transport of non-polar liquids and gases, especially at high velocities, a static charge may be generated on pipe surfaces. If it is required to repair, purge the line, make a new connection, etc., grounding and static control procedures should be employed during the intervention. Static electric discharge can ignite a flammable gas or a combustible atmosphere. Where a flammable gas or combustible mixture may be encountered and static electric charges may be present, observe all Company (operator, contractor, etc.) procedures for static electricity safety and control, including procedures for discharging static electricity and personnel protection. G. Land Installations FIBERSPAR LinePipe can be installed using construction practices commonly employed for stick fiberglass pipe. However, given the flexibility, continuous lengths, and axial strength of FIBERSPAR LinePipe, specialized techniques can be employed which can reduce installation time and costs. Fiberspar s Installation Manual, available upon request, summarizes general good practices, as well as some of the specialized techniques that may be used to install FIBERSPAR LinePipe. H. Pull-Through Remediation FIBERSPAR LinePipe is ideally suited to repair leaking or failed steel lines by pulling the FIBERSPAR pipe in a continuous length inside of existing pipelines. This technique is possible because of the continuous, flexible, smooth OD, and high axial strength of the product. Fiberspar has developed installation processes that allow continuous lengths of up to 10,000 feet to be used to rehabilitate damaged or failing pipelines. This process provides a full-strength, corrosion-resistant repair, and because of the improved flow characteristics of the FIBERSPAR LinePipe when compared to steel, the reduction in flow area from the pull-through remediation is generally offset by the better flow properties of the FIBERSPAR LinePipe. Fiberspar can design LinePipe specifically to provide the optimum solution where flow rates are critical I. Marine Installations and Weighting FIBERSPAR LinePipe is buoyant when not completely full of water and should be weighted in most marine applications. In sub-sea pipeline remediation, it is not necessary to weight LinePipe as the steel pipe provides sufficient weighting. If LinePipe is pulled into position during the installation process care must be taken to avoid damaging or snagging the pipe on rocks, sharp surfaces or other objects on the seabed. Fiberspar should be consulted in applications involving weighting of LinePipe. Engineering Guide 9

13 Fiberspar LinePipe is not recommended in new construction in marine environments where there is significant risk to damage Fiberspar LinePipe from high construction or fishing activity. FIBERSPAR LinePipe can be used in water depths up to 50 meters. If water depth exceeds 50 meters, an external thermoplastic jacket can be provided as a special order to ensure collapse resistance from hydrostatic pressure when the pipe is not internally pressurized. J. Thermal Movement As summarized in Section 2, FIBERSPAR LinePipe is manufactured from thermoplastic pressure barriers, and glass fiber-reinforced epoxy resin. The axial thermal expansion coefficient for FIBERSPAR LinePipe is approximately 12.5 x 10-6 in/in- F (2.26 x 10-5 mm/mm- C) and the hoop wise thermal expansion coefficient is approximately 7.14 x 10-6 in/in- F (1.28 x 10-5 mm/mm- C). Because the FIBERSPAR LinePipe has low axial stiffness compared to steel, forces exerted on end fittings from temperature changes will in almost all cases be negligible. None-the-less, it is good pipeline design practice to calculate these loads and make sure that sufficient margins are provided to accommodate this loading. The following formulas can be used to calculate the change in length of FIBERSPAR LinePipe due to temperature fluctuations, or axial force exerted over a given length. Given a length of flowline, L, the pipe will extend or grow due to a temperature change of T: L = L x α 1 x T Where :- = coefficient of thermal expansion in the axial direction α 1 The non-mechanical loads, P non-mecahnical, that arise from thermal expansion of FIBERSPAR LinePipe in the case of fully restrained ends (or segments) can be written as: P non-mecahnical = ε 1 non-mechanical x E 1 x A = α 1 x T x E 1 x A Engineering Guide 10

14 Where, E 1 is the axial modulus of elasticity of FIBERSPAR LinePipe and A is the crosssectional area of the LinePipe. Thermal expansion curves for any specific FIBERSPAR product are available upon request, or Fiberspar engineers can supply calculations for specific cases. Appendix 7 contains a typical thermal expansion curve for FIBERSPAR 3 1/2 nominal, 1,500 psi operating pressure LinePipe. K. Growth and Shrinkage from Pressure Fluctuation The mechanical behavior of FIBERSPAR LinePipe is well characterized. As in the case of thermal expansion, changes in pressure can result in changes in length or axial forces, but again these forces are generally negligible when compared to forces that can be exerted on end components from much higher stiffness steel pipeline materials. Axial force / displacement curves versus pressure for individual FIBERSPAR LinePipe products are available upon request, and an example of typical properties for 3 ½ nominal, 1,500 psi maximum operating pressure product is contained in Appendix 8. FIBERSPAR LinePipe is fabricated with a unique combination of materials and designed with glass fibers oriented such that the Poisson s ratio is greater than 0.5 so the axial hoop strain will induce, through the Poisson s effect, an axial contraction that is greater than the axial extension that results from the pressure induced axial load. Physically this means that FIBERSPAR LinePipe will often contract (or get shorter) when pressure is increased if the ends are not restrained, which is very different from what is generally observed in conventional stick fiberglass or steel line pipe. L. Fiberspar Installation Manual FIBERSPAR LinePipe should be installed in compliance with the Fiberspar Installation Manual. A copy of the Fiberspar Installation Manual is available upon request. M. FIBERSPAR Connector Installation FIBERSPAR connectors must be installed pursuant to API 15 and CSA standards by Fiberspar trained and authorized personnel pursuant to Fiberspar s Connector Installation Procedures, and Connector Installer Qualification Procedure. Fiberspar is able to train customer personnel or contractors in these procedures for safe installation. N. Fire Resistance The Flammability Classification of FIBERSPAR products is as follows: "Nonflammable under specified operating conditions. Material will not burn unless exposed to direct flame." Engineering Guide 11

15 The cured epoxy resin utilized in FIBERSPAR products is not by nature fire resistant. Unprotected, it would provide less resistance to fire than would carbon steel. It is not recommended that FIBERSPAR products be utilized under such conditions that the pipe could be directly exposed to flame for any duration. Given the implications of the above statements, it is highly recommended that the FIBERSPAR products be completely encapsulated in any situation where exposure to flame is a concern to prohibit such exposure. 7. Application Summary and Customer Reference List North America FIBERSPAR LinePipe has proven to be a cost-effective solution for production gathering and injection applications particularly in corrosive applications. More than 2.5 million feet have been installed for more than 75 operators since the company began commercial operations approximately 4 years ago. Repeat orders from numerous operators has demonstrated that the product has proven to be an attractive alternative to steel, coated/lined steel and stick fiberglass, due to the reduction in joints and couplings, faster installation, and competitive costs. A reference list of applications and customers for FIBERSPAR LinePipe installations in North America is available from Fiberspar upon request. Engineering Guide 12

16 Appendix 1 Fiberspar Quality System Documentation QUALITY ASSURANCE MANUAL QUALITY POLICY STATEMENT Fiberspar strives to be a leader in the design and manufacture of spoolable fiber reinforced pipe for the oil and gas industry by meeting and exceeding the expectations of our customers (internal and external). We will attain this goal by dedicating ourselves to: Our Customers Our People Our Technology Total Quality of Product and Services On-Time Delivery Continuous Improvement All FIBERSPAR personnel will adhere to the spirit of this Quality Policy, Quality Assurance Manual and supporting documentation. QUALITY SYSTEM PROCEDURE MANUAL WORK INSTRUCTIONS MATERIAL SPECIFICATIONS FORMS EXTERNAL SPECIFICATIONS Engineering Guide 13

17 Appendix 2 FS LP 3 1/2" 1,500 (E) 3 1/2 Inch Nominal, 1,500 Series Fiberspar LinePipe w/hdpe Pressure Barrier Product Data Sheet (Imperial Units) ASTM 2996 Designation: RTRP-11HZ Physical Properties: Fiberspar s/n: LEEN Geometry Tensile Modulus Outside Diameter (in) 3.65 Axial (psi) 8.59E+05 Inside Diameter (in) 3.05 Hoop (psi) 1.11E+06 Inside Flow Area (in 2 ) 7.28 Poisson's Ratio Total Wall Thickness (in) 0.30 Major 0.49 C/S Area (in 2 ) 3.17 Minor 0.63 Linear Weight Thermal Exp. Coeff. Linear Weight - Air (lb/ft) 2.06 Axial (in/in - F) 1.27E-05 Linear Weight - Water (lb/ft) 0.68 Hoop (in/in - F) 7.39E-06 Net Density (lb/in 3 ) Thermal Conductivity Flow Coefficients (BTU/hour/ft 2 - in/ F) 1.92 Hazen - William s 150 Resin T g Darcy-Wiesbach ( C ) 125 Manning ( F) 257 Mechanical Performance: Maximum Operating Temperature 140 F Minimum Operating Temperature -29 F 78 F 140 F Max. Operating Pressure (psi) 1,500* 1,500* Nominal Ultimate Burst Pressure (psi) 5,700 4,300 Maximum Recommended Tensile Load (lbs) 9,960 8,400 Nominal Ultimate Tensile Load (lbs) 24,900 20,900 Nominal Ultimate Compressive Load (lbs) -28,000-22,900 Nominal Ultimate Collapse Pressure (psi) Minimum Operating Bend Radius (in) Minimum Spooling Diameter (in) *Maximum Operating Pressures are based upon general oilfield water, low-vapor pressure hydrocarbon and multiphase service conditions. Specific maximum pressure ratings are made based upon your application's service condition in Thermoplastic Pressure Barrier in in Glass Fiber Reinforced Epoxy Laminate Engineering Guide 14

18 Appendix 3 API 15HR Design Calculation of FS LP 3 ½ 1,500 (E) Imperial Units Per Equation 1, API 15HR (Second Edition, April 1, 1995) The published Specification 15HR Standard Pressure Rating shall be calculated by the following equation and rounded down to the nearest integer multiple of 250 psi: Pr = S s X S f X (R 0 2 -R i 2 )/(R 0 2 +R i 2 ) (1) Where: P r = FIBERSPAR LinePipe Pressure Rating, psi S s = 95% Lower Confidence Limit (LCL) of the Long-Term Hydrostatic Strength 20 years per ASTM D 2992 Procedure B in psi. S f = 0.67 service (design) factor. R o = radius of the pipe at the outside of the minimum reinforced wall thickness, inches. R i = radius of the pipe at the inside of the minimum reinforced wall thickness, inches. For this example: FS LP 3 ½ 1,500 (E) Pr = 1,500 psi R o = inches R i = inches + Liner Thickness = inches inches = inches S s = 35,407 psi (HDB from LTHS Testing, ASTM 2992 Procedure B) From (1) above, solve for the service (design) factor: S f = Pr /(S s X (R 0 2 -R i 2 )/(R 0 2 +R i 2 )) (2) S f = 1,500/(35,407 x ( )/( )) = 0.51 Note: API 15HR requires a maximum service factor of 0.67 for determination of the API 15HR Standard Pressure Rating. FIBERSPAR LinePipe increases long-term reliability by using a service factor 25% less than the maximum allowable service factor. Engineering Guide 15

19 Appendix 4 API 15HR Design Calculation for FS LP 3 ½ 1,500 (E) Metric Units Per Equation 1, API 15HR (Second Edition, April 1, 1995) The published Specification 15HR Standard Pressure Rating shall be calculated by the following equation and rounded down to the nearest integer multiple of 250 psi: Pr = S s X S f X (R 0 2 -R i 2 )/(R 0 2 +R i 2 ) (1) Where: P r = FIBERSPAR LinePipe Pressure Rating, KPa S s = 95% Lower Confidence Limit (LCL) of the Long-Term Hydrostatic Strength 20 years per ASTM D 2992 Procedure B in MPa S f = 0.67 service (design) factor. R o = radius of the pipe at the outside of the minimum reinforced wall thickness, mm. R i = radius of the pipe at the inside of the minimum reinforced wall thickness, mm. For this example: FS LP 3 ½ 1,500 (E) Pr = 10,342 kpa R o = 46.3 mm R i = 38.7 mm + Liner Thickness = 38.7 mm mm = 42.6 mm S s = MPa (HDB from LTHS Testing, ASTM 2992 Procedure B) From (1) above, solve for the service (design) factor: S f = Pr /(S s X (R 0 2 -R i 2 )/(R 0 2 +R i 2 )) (2) S f = 10,342/(244.1 x 1,000 x ( )/( )) = 0.51 Note: API 15HR requires a maximum service factor of 0.67 for determination of the API 15HR Standard Pressure Rating. FIBERSPAR LinePipe increases long-term reliability by using a service factor 25% less than the maximum allowable service factor. Engineering Guide 16

20 Appendix 5 Maximum Pressure Ratings Per Canadian Standards Association CSA Z Pipeline Regulations Fibespar Max Recommended Design Pressure (PSI) Maximum Design Pressures Per CSA Z Regulations CSA Z for Oilfield Water CSA Z for LVP Hydrocarbons CSA Z for Multiphase CSA Z for Gas Gathering Design ID Product ID LEDN FS LP 2 1/2" 1,000 (E) 1,000 1,794 1,435 1,435 1,202 LEDN FS LP 3" 1,000 (E) 1,000 1,786 1,429 1,429 1,197 LEDN FS LP 3 1/2" 1,000 (E) 1,000 1,805 1,444 1,444 1,209 LEDN FS LP 4" 1,000 (E) 1,000 1,789 1,431 1,431 1,198 LEDN FS LP 4 1/2" 1,000 (E) 1,000 1,789 1,431 1,431 1,199 LEDN FS LP 5" 1,000 (E) 1,000 1,790 1,432 1,432 1,199 LEDN FS LP 5 1/2" 1,000 (E) 1,000 1,785 1,428 1,428 1,196 LEEN FS LP 2 1/2" 1,500 (E) 1,500 1,994 1,596 1,596 1,336 LEEN FS LP 3" 1,500 (E) 1,500 1,979 1,583 1,583 1,326 LEEN FS LP 3 1/2" 1,500 (E) 1,500 1,994 1,595 1,595 1,336 LEEN FS LP 4" 1,500 (E) 1,500 1,984 1,587 1,587 1,329 LEEN FS LP 4 1/2" 1,500 (E) 1,500 1,981 1,585 1,585 1,327 LEEN FS LP 5" 1,500 (E) 1,500 1,981 1,585 1,585 1,327 LEEN FS LP 5 1/2" 1,500 (E) 1,500 1,982 1,586 1,586 1,328 LEGN FS LP 1 1/4" 2,500 (E) 2,500 3,337 2,669 2,669 2,236 LEGN FS LP 1 3/4" 2,500 (E) 2,500 3,317 2,653 2,653 2,222 LEGN FS LP 2 1/2" 2,500 (E) 2,500 3,325 2,660 2,660 2,228 LEGN FS LP 3" 2,500 (E) 2,500 3,321 2,657 2,657 2,225 LEGN FS LP 3 1/2" 2,500 (E) 2,500 3,310 2,648 2,648 2,217 HDB = 95% LCL of 20 years (psi) = HDPE Lined Products: Max Operating Temperature = 140 Deg. F Engineering Guide 17

21 Appendix 6 Chemical Resistance Data for HDPE & PEX Pressure Barriers Chemical Class Examples HDPE PEX Acids Carbonic R at 140 F (60 C) R at 195 F (90 C) Acetic Acid <25% R at 140 F (60 C) R at 140 F (60 C) (1) Hydrochloric (<30%) R at 140 F (60 C) R at 195 F (90 C) Hydrochloric (>30%) R at 140 F (60 C) R at 140 F (60 C) (1) Sulfuric <70% R at 140 F (60 C) R at 140 F (60 C) (1) Sulfuric >70% C to N N Hydrogen Sulfide R at 140 F (60 C) R at 195 F (90 C) Nitric See Oxidizing Agents See Oxidizing Agents Bases Sodium Hydroxide R at 140 F (60 C) R at 140 F (60 C) (1) Calcium Carbonate R at 140 F (60 C) R at 195 F (90 C) Salts Calcium Chloride R at 140 F (60 C) R at 195 F (90 C) Seawater R at 140 F (60 C) R at 195 F (90 C) Ferrous Chloride R at 140 F (60 C) R at 140 F (60 C) (1) Hydrocarbons Aliphatic C1-C4, Methane-Butane R at 140 F (60 C) R at 195 F (90 C) C5-C12 R at 73 F (23 C) R at 73 F (23 C) C5-C12 C at 140 F (60 C) C at 140 F (60 C) Aromatic Benzene (100%) C at 120 F (49 C) C at 175 F (79 C) Mixed Crude Oil (100%) C at 120 F (49 C) C at 175 F (79 C) Alcohols Methanol R at 140 F (60 C) R at 195 F (90 C) Phenol R at 140 F (60 C) C at 195 F (90 C) Ethylene Glycol R at 140 F (60 C) R at 195 F (90 C) Oxidizing Agents Nitric Acid R at 140 F (60 C) R at 73 F (23 C) Hydrogen Peroxide <50% R at 140 F (60 C) R at 73 F (23 C) Hydrogen Peroxide (90%) R at 73 F (23 C) R at 73 F (23 C) Carboxylic Acids, Esters, Acetone, MEK, Acetaldehyde C at 140 F (60 C) C at 140 F (60 C) Aldehydes and Ketones FAP C at 120 F (49 C) C at 135 F (57 C) Ethers Diethyl Ether C at 140 F (60 C) C at 140 F (60 C) Amines Diethyl Amine C at 140 F (60 C) C at 140 F (60 C) Ratings: R Recommended for Use C Conditionally Recommended. Consult with Fiberspar Corp. N Not Recommended Based on data provided by the materials supplier and recommendations of the Plastics Pipe Institute "Engineering Properties of Polyethylene" and TR-19 "Thermoplastic Piping for the Transport of Chemicals", and ISO /TR10358:1993 (1) To be upgraded to 195 F (90 C) when specific antioxidant package used. Available by end of Engineering Guide 18

22 Appendix 7 Thermal Expansion Data for FS LP 3 ½ 1,500 (E) Thermally Induced Strain (IN/IN) Thermally Induced Strains as a Function of Temperature/Thermally Induced Axial load as a Function of Temperature (constrained ends) 9.00E E E E E E E E E-04 FS LP 3 1/2" 1,500 (E) Thermally Induced Axial Strain Thermally Induced Hoop Strain Thermal Axial Load (constrained ends) ,000-1,500-2,000 Axial Load (Lbs) 0.00E+00-2, Tubing Temperature ( F) Non-mechanical strains, ε 1 non-mechanical and ε 2 non-mechanical, as a function of temperature for a 3 ½ nominal, 1,500 psi FIBERSPAR LinePipe. Also, the compressive axial load induced for the same LinePipe with restrained ends as a function of a positive temperature change. Engineering Guide 19

23 Appendix 8 Pressure Versus Axial Load for FS LP 3 ½ 1,500 (E) 2,300 Axial Load as a Function of Pressure: Fully Constrained Ends FS LP 3 1/2" 1,500 (E) Axial Load of Fully Constrained End (Lb) 1,800 1, F 100 F 120 F 140 F % 25% 50% 75% 100% 125% 150% Percent of Rated Pressure Axial Deflection per 1,000' of length (in) Axial Deflection per 1,000' as a Function of Pressure: Unconstrained Ends FS LP 3 1/2" 1,500 (E) F 100 F F 140 F % 25% 50% 75% 100% 125% 150% Percent of Rated Pressure Engineering Guide 20

24 Appendix 9 FIBERSPAR LinePipe Compression Slip Connector Fittings Service End Connector Weld Prepped Service End O-ring Grooves Slip Slip Nut Pipe to Pipe Connector Slip Nut Slip Double Seal Carrier Engineering Guide 21