TECHNICAL MANUAL

TECHNICAL MANUAL 


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Composite Production Systems shawcor.com i


Contents 

List of Tables ...................................................................................................... v 

List of Figures .................................................................................................... v 

1 Introduction ................................................................................................... 1 

2 Pipe ................................................................................................................ 1 

2.1 Product Lines ............................................................................................. 1 

2.2 Design ....................................................................................................... 2 

2.3 Materials .................................................................................................... 4 

2.4 Manufacturing ............................................................................................ 5 

2.4.1 Liner ..................................................................................................... 5 

2.4.2 Reinforcement ...................................................................................... 5 

2.4.3 Pipe ...................................................................................................... 6 

2.4.4 Quality Control ..................................................................................... 6 

3 Fittings ........................................................................................................... 7 

3.1 Fitting Configurations ................................................................................. 7 

3.2 Design ....................................................................................................... 8 

3.3 Materials .................................................................................................. 10 

3.4 Manufacturing .......................................................................................... 11 

3.5 Corrosion Protection ................................................................................ 11 

4 Qualification ................................................................................................ 12 

4.1 Introduction to Standards and Regulations .............................................. 12 

4.2 Standards ................................................................................................ 12 

4.2.1 American Petroleum Institute (API) .................................................... 12 

4.2.2 Canadian Standards Association (CSA) ............................................ 13 

4.3 Regulations.............................................................................................. 14 

4.3.1 Canadian Provincial Regulatory Bodies ............................................. 14 

4.3.2 United States Regulatory Bodies ....................................................... 14 

4.3.3 Australia Regulatory Bodies ............................................................... 15 

4.3.4 Latin America Regulatory Bodies ....................................................... 15 

4.4 Testing ..................................................................................................... 15 

5 Performance ................................................................................................ 16 

5.1 Applications & Chemical Compatibility .................................................... 16 

5.1.1 Application Evaluations ...................................................................... 16 

5.1.2 Gas .................................................................................................... 17 

5.1.3 Oil ....................................................................................................... 17 

5.1.4 Water ................................................................................................. 17 

5.1.5 H 2 S ..................................................................................................... 18 

5.1.6 CO 2 .................................................................................................... 18 

5.1.7 Aromatic and Cycloalkane Hydrocarbons .......................................... 18 

5.1.8 Chemical Injection .............................................................................. 19 

5.1.9 Methanol and Ethanol ........................................................................ 19 

5.2 Pressure and Temperature Ratings ......................................................... 19 

5.2.1 Maximum and Minimum Allowable Operating Temperature ............... 19 

5.2.2 Maximum Allowable Operating Pressures.......................................... 20 

5.2.3 Calculations for Determining Maximum Allowable Operating Pressure21 

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5.3 Cyclic Pressure ........................................................................................ 23 

5.3.1 FPLP Cyclic Capabilities .................................................................... 24 

5.3.2 FPLP HT Cyclic Capabilities .............................................................. 24 

5.3.3 FCLP Cyclic Capabilities .................................................................... 24 

5.3.4 Pump Jacks ........................................................................................ 25 

5.4 Flow Characteristics ................................................................................ 26 

5.4.1 Pipe Flow ........................................................................................... 26 

5.4.2 Fittings ............................................................................................... 28 

5.5 Durability ................................................................................................. 28 

5.6 Corrosion ................................................................................................. 29 

5.7 Erosion .................................................................................................... 29 

5.8 Ultra-Violet Protection .............................................................................. 29 

5.9 Bend Radius ............................................................................................ 29 

5.10 Permeation .............................................................................................. 30 

5.11 Expansion/Contraction and Axial Growth ................................................ 31 

5.12 External Load and Internal Vacuum Capability ........................................ 32 

5.13 Thermal Conductivity ............................................................................... 33 

6 Installation ................................................................................................... 33 

6.1 Field Services Support ............................................................................ 33 

6.2 Transportation ......................................................................................... 34 

6.3 Trenching ................................................................................................ 34 

6.4 Plowing .................................................................................................... 35 

6.5 Insertion as a Freestanding Liner ............................................................ 35 

6.6 Surface Installation .................................................................................. 36 

6.7 Support Spacing ...................................................................................... 38 

6.8 Buoyancy and Pipe Weights .................................................................... 38 

6.9 Crossings ................................................................................................ 40 

6.10 Risers ...................................................................................................... 40 

6.11 Tracer Wire .............................................................................................. 41 

6.12 Cold Temperature Installation.................................................................. 41 

6.13 Heat Tracing ............................................................................................ 41 

6.14 Fitting Installation ..................................................................................... 42 

6.15 Cathodic Protection ................................................................................. 42 

6.16 Tying into Steel – Welding ....................................................................... 43 

6.17 Tying into Plastic ..................................................................................... 43 

6.18 Field Pressure Testing of New Pipelines ................................................. 43 

7 Accessories ................................................................................................. 45 

7.1 A-frames .................................................................................................. 45 

7.2 Turn Table and Lifting device for Coiled pipe .......................................... 45 

7.3 Riser Support Trays ................................................................................. 45 

7.4 Pull Tools ................................................................................................. 45 

7.5 Sacrificial Anodes .................................................................................... 45 

8 Operations ................................................................................................... 46 

8.1 Startup ..................................................................................................... 46 

8.2 Pigging .................................................................................................... 46 

8.3 Hot Oiling ................................................................................................. 47 

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8.4 Static Electricity ....................................................................................... 47 

8.5 Secondary Excavations ........................................................................... 47 

8.6 Field Pressure Testing of Existing Pipelines ............................................ 48 

8.7 Shutdown Procedures ............................................................................. 48 

9 Reliability ..................................................................................................... 49 

9.1 History ..................................................................................................... 49 

9.2 Leak Testing ............................................................................................ 49 

9.3 Cut-outs ................................................................................................... 49 

9.4 Reliability Management ........................................................................... 50 

9.5 Integrity Verification ................................................................................. 51 

10 Appendix ..................................................................................................... 53 

Product Data Sheets ....................................................................................... 53 

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List of Tables 

Table 1: Product Lines .................................................................................................... 2 

Table 2: Standard Fittings ............................................................................................... 7 

Table 3: Custom Fittings ................................................................................................. 8 

Table 4: Shawcor Fitting Material List ........................................................................... 10 

Table 5: Links for Specific CSA Z662 Requirements .................................................... 14 

Table 6: Pipe and Fitting Tests and Applicable Standards ............................................ 16 

Table 7: Allowable Aromatic and Cycloalkane Hydrocarbon Content ........................... 19 

Table 8: Maximum and Minimum Allowable Operating Temperatures .......................... 20 

Table 9: Maximum Allowable Operating Pressure ........................................................ 21 

Table 10: Flow Coefficients for Shawcor Spoolable Products ....................................... 28 

Table 11: K Factor for Shawcor Spoolable Products Coupling Fittings ......................... 28 

Table 12: Minimum Bend Radius for Operation, Transport and Handling ..................... 29 

Table 13: Permeability Coefficients for HDPE ............................................................... 30 

Table 14: Representative Permeation Rates for Shawcor Spoolable Products ............. 31 

Table 15: FPLP and FPLP HT Thermal Conductivity and Resistivity ............................ 33 

Table 16: Conduit Compatibility for Shawcor Spoolable Products Insertion .................. 36 

Table 17: Maximum Allowable Pull Forces for Shawcor Spoolable Products ................ 36 

Table 18: Recommended Pipe Support Spacing for Shawcor Spoolable Products ...... 38 

Table 19: Recommended Sand Bag Weight for Weighting Shawcor Spoolable Products 

...................................................................................................................................... 39 

Table 20: New Pipeline Hydrostatic Test Pressures and Durations .............................. 43 

Table 21: Custom Polyurethane Disk Pigs .................................................................... 46 

Table 22: Shawcor Pig Dimensions for Shawcor Spoolable Products .......................... 47 

List of Figures 

Figure 1: FPLP and FPLP HT Three-layer Design .......................................................... 3 

Figure 2: FCLP Design .................................................................................................... 4 

Figure 3: Cutaway View of Shawcor Fitting ..................................................................... 9 

Figure 4: Procedure for Determining MPR and MAOP .................................................. 22 

Figure 5: Representative Pressure Drop Comparison: Water at Various Flow Rates ... 27 

Figure 6: Representative Pressure Drop Comparison: Methane at Various Flow Rates27 

Figure 7: Sandwich Type Insulated Barrier Configuration ............................................. 42 

Figure 8: Cut-out Burst Test Results ............................................................................. 50 

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In an effort to provide useful product information, Shawcor makes 

available a three part document: 

Part 1 – Technical Manual 

This part is mainly addressed to engineers, supervisors and procurement 

personnel. It is intended to present a general description of Shawcor 

products’ materials, construction, qualification, performance, installation, 

operation and reliability. 

Part 2 – Installation Guide 

This part is mainly addressed to field personnel and is intended to provide 

general guidance on Shawcor products’ handling, joining, installing and 

testing. 

Part 3 – Operators Guide 

This part is mainly addressed to pipeline operations and is intended to 

provide general guidance on the compatibility of Shawcor products. 

Each of the three parts emphasizes particular aspects of the Shawcor 

product application. Familiarity with the three parts is recommended for a 

broader perspective. 

This document is intended solely as a reference for use by persons of 

technical competence. It is the responsibility of the pipeline operator to 

ensure the suitability of Shawcor products for any specific pipeline 

application. While the information contained in this document is believed 

to be correct as of the date of issue, under no circumstances will Shawcor, 

or any of its subsidiaries, be liable in any way for any loss, damage or 

injury of any kind (whether direct, consequential, punitive or otherwise) 

incurred as a result of any omissions in this document or as a result of 

reliance on any information contained in this document. This document 

does not contain any warranty, express or implied. 

All rights reserved. Any reproduction of this document in part or as a 

whole without the written permission of Shawcor is prohibited. 

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Composite Production Systems shawcor.com vi


1 Introduction 

Shawcor has designed, tested, and manufactured high pressure, corrosion-resistant, 

coiled, continuous pipeline systems utilizing new and exciting engineering technologies 

intended primarily for the Oil and Gas and Utility industries. Typical applications include 

oil and gas gathering, oilfield water transferring, disposal and injection, gas distribution 

and transmission lines. 

Shawcor has also developed an innovative crimp fitting technology that allows efficient 

joining directly to steel lines, standard flanged connections, or other Shawcor Spoolable 

products pipelines. Shawcor holds patents for its unique pipe and fitting designs 1 . 

2 Pipe 

2.1 Product Lines 

Shawcor currently offers three product lines: 

 

 

 

FlexPipe Linepipe (FPLP) 

FlexPipe Linepipe High Temperature (FPLP HT) 

FlexCord Linepipe (FCLP) 

FPLP and FPLP HT are intended for static or mild cyclic applications with service 

temperatures up to 60°C and 82°C, respectively. FCLP is suited for severe cyclic 

applications with service temperatures up to 60°C. 

The product range for each product line is as shown in Table 1: 

1 Fiber reinforced pipe: US patent number 6,889,716 (May 10, 2005); Canadian patent number 2,513,506 (August 

3, 2010); International patents pending. 

Compression-style fitting: US patent number 6,902,205 (June 7, 2005); Canadian patent number 2,513,468 

(February 1, 2011); International patents pending. 

Crimp-style fitting: US patent numbers 7,946,629 B2 (May 24, 2011) and 8,042,252 B2 (October 25, 2011); 

Canadian patent number 2,562,823 (May 22, 2012). 

High temperature pipe: US patent number 12/712,060 (pending); Canadian patent number 2,753,024 (pending); 

International patents pending. 

Steel cord pipe: US patent number 12/763,506 (pending); Canadian patent number 2,755,289 (pending); 

International patents pending. 

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Table 1: Product Lines 

Pressure Rating 

2,068 kPa 

(300 psi) 

5,171 kPa 

(750 psi) 

10,342 kPa 

(1,500 psi) 

13,790 kPa 

(2,000 psi) 

Shawcor Grade 150 301 601 801 

Product Line 

FlexPipe Linepipe 

(FPLP) 


High Temperature 

(FPLP HT) 

FlexCord Linepipe 

(FCLP) 

Nominal Size (inches) 

3”, 4” 2”, 3”, 4” 2”, 3”, 4” 

2”, 3”, 4” 2”, 3”, 4” 

3”, 4” 

FPLP and FCLP are available in a standard white jacket, and FPLP HT is available in a 

standard grey jacket. All product lines provide a minimum of 20 years protection against 

exposure to ultraviolet (UV) light. 

All three product lines will hereafter be collectively referred to as Shawcor Spoolable 

Products. 

The product data sheets in the appendix list the Shawcor Spoolable Products 

dimensions and parameters. 

2.2 Design 

Shawcor Spoolable Products are manufactured at the state-of-the-art Shawcor facility in 

Calgary, Alberta, Canada. Shawcor Spoolable Products are patented three-layer 

designs constructed from a thermoplastic liner (liner), helically wrapped continuous high 

strength reinforcement and an external thermoplastic jacket (jacket). FPLP and FPLP 

HT product lines are reinforced with high strength glass fibers, while the FCLP product 

line is reinforced with high strength galvanized steel cords. 

The liner acts as a bladder, the reinforcement provides strength, and the jacket protects 

the load-bearing layer. This construction is unique and has the following advantages: 

The reinforcement is not encased in a thermosetting matrix and is therefore flexible, 

avoiding potential micro-cracking or over-straining of the matrix material. Shawcor 

Spoolable Products are very rugged, durable and easy to handle. 

The simplicity of construction reduces the manufacturing costs. 

The high strength reinforcement enables design for high-pressure applications. 

The liner ensures that the pipeline system is immune to corrosion and eliminates the 

need for inspections. 

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The continuous, long-length spools facilitate fast and easy installation with fewer 

connections and less disturbance to impacted parties. 

Environmental impact and soil disturbance can be reduced since Shawcor Spoolable 

Products can be trenched with a narrower trench and right of way than steel line 

pipe, or plowed in without trenching. 

The low weight minimizes handling equipment requirements leading to lower 

installation costs when compared to stick and other spoolable products. 

Figure 1: FPLP and FPLP HT Three-layer Design 

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Figure 2: FCLP Design 

Shawcor Spoolable Products have been designed using a sophisticated mathematical 

model that was developed specifically for the unique construction of these products. 

The mathematical model was used to design the reinforcement configuration and 

optimize pressure capacity and strain. The strength of Shawcor Spoolable Products 

depend on the thickness and configuration of the reinforcement layer, thus traditional 

pipe design models based on wall thickness are not applicable. The validity of the 

mathematical model and the material properties used by this model has been verified 

through extensive physical testing. 

The design and manufacturing of Shawcor Spoolable Products are in accordance with 

standards and guidelines regarding qualification, quality control and testing of 

composite pipe and accessories. Please refer to Section 4 in this document for 

additional information on these standards, and Section 5.2 for a summary of the design 

methods and calculations. 

2.3 Materials 

The materials used in Shawcor Spoolable Products have been widely used in the oil 

and gas industry for many years. The liner and jacket are manufactured using bimodal 

pressure-pipe-grade high density polyethylene (HDPE) thermoplastic resin. This 

material is designated PE4710 by PPI TR-3 2 , in accordance with ASTM D3350 3 . This 

leading-edge material meets rigorous standards for high strength and resistance to slow 

crack growth. It also provides excellent wear resistance and impact toughness, and a 

2 PPI TR-3 Policies and Procedures for Developing Hydrostatic Design Basis, Pressure Design Basis, Strength 

Design Basis, and Minimum Required Strength Ratings for Thermoplastic Piping Materials or Pipe 

3 ASTM D3350 Standard Specification for Polyethylene Plastics Pipe and Fittings Materials 

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low-friction internal surface for decreased pressure losses. Colorant and a ultra-violet 

(UV) stabilizer are blended with the thermoplastic pellets during the extrusion process, 

providing resistance to weathering. 

The glass fiber reinforcement utilized in FPLP and FPLP HT is constructed from a 

series of continuous glass fiber rovings which have been manufactured in accordance 

with ASTM D578 4 . The fiber chemistry and coatings are specifically selected to 

optimize long-term performance. 

The high-strength steel cords utilized in FCLP are constructed from a series of stranded 

wires and galvanized for optimum performance and corrosion resistance. 

Shawcor is committed to maintaining high standards of quality and reliability. Each 

individual supplier is qualified by Shawcor, in accordance with API RP 15S 5 and API 

17J 6 , to ensure that quality inspections, physical testing, and material traceability meet 

Shawcor’ quality standards. Each specific material is qualified by Shawcor through 

rigorous physical testing, prior to use in manufacturing and in finished products. 

2.4 Manufacturing 

Shawcor is equipped to manufacture all components of 

Shawcor Spoolable Products in-house. Each step of the 

manufacturing process is closely monitored, resulting in direct 

control over the quality of the products. 

2.4.1 Liner 

The liner is manufactured and inspected by highly experienced 

operators using state-of-the art equipment, in accordance with stringent dimensional 

requirements defined by ASTM D2513 7 . Each liner is 100% inspected for diameter, wall 

thickness, and concentricity by online ultrasonic measurement. 

2.4.2 Reinforcement 

Glass Fiber Reinforcement 

The fiber reinforcements for each product are constructed from 

a single type of input strand, purchased from qualified 

suppliers. Shawcor roving construction process combines 

these strands into custom packages for use in the construction 

of Shawcor Spoolable Products. Each package is specially configured for the individual 

finished product in which it will be used. Shawcor has developed extensive expertise in 

this area through critical evaluation and physical testing of various materials, coatings, 

4 ASTM D578 Standard Specification for Glass Fiber Strands 

5 API RP 15S Recommended Practice for the Qualification of Spoolable Reinforced Plastic Line Pipe 

6 API RP 17J Specification for Unbonded Flexible Pipe 

7 ASTM D2513 Standard Specification for Thermoplastic Gas Pressure Pipe, Tubing, and Fittings 

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and processing methods. State-of-the-art roving machines are used with tensioning 

systems designed in-house specifically for this process. 

Galvanized Steel Cord Reinforcement 

The galvanized steel cord reinforcements are applied directly as purchased from 

qualified suppliers. 

2.4.3 Pipe 

Each reel of pipe is manufactured in a single continuous production run that combines 

liner, reinforcement, and jacket into the finished product. The liner length is sufficient to 

complete an entire pipe production run without fusions. 

The first step in the process is cleaning and drying the incoming liner. A laser 

measurement system inspects the diameter and roundness of the liner. If needed, 

multi-directional rounding rollers are applied to correct the roundness. 

The reinforcement is applied by sequential custom-designed 

winding machines, which wrap the reinforcement from multiple 

bobbins around the liner in a tightly controlled process. An 

automated control system directly measures the line speed, 

and maintains the correct wrap angle by controlling the speed 

of each individual winding machine. Each bobbin of 

reinforcement is individually braked to maintain the correct 

tension. 

The jacket is applied over the fiber reinforcement with a customized cross-head 

extrusion die, and immediately cooled. Computerized laser and ultrasonic 

measurement systems are used to ensure that strict quality standards are maintained 

as the protective jacket is applied. The jacket is marked with identifying information by 

an inline printer. Finally, the finished product is coiled either onto a reel or a pallet for 

transportation. 

2.4.4 Quality Control 

Quality control (QC) is critical to the manufacturing process. Shawcor is an ISO 

9001:2008 certified manufacturing facility. From supplier evaluation and approval to the 

qualification of every finished product, quality control data is diligently reviewed and 

evaluated. Shawcor is committed to using suppliers that provide material-composition 

data and maintain certification and QC test results for all raw products. Material 

certification and traceability is critical to the Shawcor quality assurance program that 

cohesively links raw materials with production records and serial markings on pipe and 

fittings. Shawcor routinely verifies and audits the QC programs of its suppliers. 

The manufacturing process is designed with many levels of quality monitoring. 

Sophisticated instrumentation systems, lasers, ultra-sonics and production operators 

continually monitor the production line at specific intervals. Corrective action is 

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implemented according to the established non-conformance reporting (NCR) system if 

design parameters are not within the specified tolerance limits. 

Every finished product is tested in accordance with the Shawcor Production 

Qualification Testing (PQT) Standards, and in accordance with API RP 15S or the 

applicable requirements of API 17J. Samples are taken from the beginning and the end 

of every pipe reel. The samples are subjected to destructive burst testing. The results 

from these tests must meet or exceed stringent QC requirements. 

In addition, Shawcor tests raw materials to ensure compliance with material 

specifications. Shawcor testing equipment includes burst chambers, ovens, a cold 

chamber, a cyclic testing station, an Instron tensile testing machine, stress-rupture 

testing machines, density test equipment and numerous custom jigs and fixtures. 

3 Fittings 

The Shawcor fitting is a metallic device that mechanically fastens to the pipe. The fitting 

can terminate the pipe with a standard ASME B16.5 8 lap-joint flange or a weld neck 

transition. The weld neck fitting allows direct connection to steel pipe. The end of the 

Shawcor product from one coil can be attached to the beginning of the Shawcor product 

from a second coil with a pipe-to-pipe coupling, thus eliminating an underground flanged 

connection. 

3.1 Fitting Configurations 

The three types of fittings that are used with FPLP are shown in Table 2. Each of these 

fittings is available for each pipe size and grade. 

Shawcor fittings come in two lengths, a standard length for use with FPLP and an 

Extended Length (EL) for use with FPLP HT and FCLP. Refer to the installation manual 

document number 14-1096 for guidance on the installation of both types of fittings. 

Shawcor also offers pre-assembled flow joints in the configurations shown in Table 3. 

Table 2: Standard Fittings 

Flanged End Fitting 

Compatible with standard 

raised face flanges. Flange 

is free to spin until bolts are 

tightened, allowing easy 

connection without stressing 

existing flanges. 

Dimensional 

drawings available 

upon request. 

8 ASME B16.5 Pipe Flanges and Flanged Fittings 

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Coupling Fitting 

Used to connect two pieces 

of FPLP together. 

Weld Neck Fitting 

Used to connect FPLP to 

steel pipe, using standard 

field welding procedures. 

Table 3: Custom Fittings 

90 Degree Elbow Flow Joint 

Tee Flow Joint 

Dimensional 

drawings available 

upon request. 

True Y Flow Joint 

Y-Lateral Flow Joint 

3.2 Design 

The fitting consists of a mandrel that is inserted into the pipe, and a sleeve that is 

crimped around the pipe. The mandrel and sleeve are both equipped with unidirectional 

teeth that securely grip the liner and jacket of the pipe. Crimping the sleeve 

creates very high permanent clamping pressure, which holds the reinforcement securely 

in place. The fitting system does not require the application of heat or adhesives in 

order to bond components together. 

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Figure 3: Cutaway View of Shawcor Fitting 

The mandrel is sealed to the liner by the clamping pressure. For additional security, the 

mandrel is equipped with two o-rings that provide an additional seal. 

The vent hole in the sleeve allows the annulus of the pipe (the space between the liner 

and jacket which contains the reinforcement layer) to vent freely at each fitting. This 

allows any gases that may have permeated through the liner to escape, and prevents 

any pressure buildup in the annulus. 

Shawcor fittings are installed in a two-step process, using portable installation 

equipment. In the first step, the mandrel is inserted into the liner. In the second step, 

the sleeve is crimped to the pipe. The fitting is supplied with the sleeve already welded 

to the mandrel to hold it in the correct position. Shawcor fittings can be installed in the 

field in about 20 to 30 minutes. To view a simulation of the fitting installation process, 

visit the Shawcor website at www.shawcor.com. For more information on fitting 

installation, see Section 6.14. 

Shawcor fittings have been tested together with our products as a complete system in 

long-term, high pressure tests, and have undergone rigorous testing to verify their 

performance in field conditions. More information on qualification testing is presented in 

Section 4.4. 

The inside diameter of the mandrel in the fitting is smaller than the inner diameter of the 

pipeline. However, the restriction is minimal, and results in negligible pressure loss (see 

Section 5.4 for further information). Fittings are compatible with pigging programs as 

detailed in Section 8.2. 

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3.3 Materials 

Standard Shawcor fittings are manufactured from seamless steel that meets the 

requirements of NACE MR0175 9 for sour service. See Table 4 for a full list of materials 

used in Shawcor fittings. Material certificates are reviewed by Shawcor prior to 

manufacture of the fittings, and are retained as part of Shawcor QC System. 

Weld neck fittings are manufactured using the same alloy steel material as flange and 

coupling fittings, with a short carbon steel pup welded to the end of the mandrel. This 

pup makes the weld neck fitting suitable for field-welding to standard carbon steel pipe 

and fittings of various pipe schedules, with no special weld procedures required. 

The steel used in 4” Shawcor fitting mandrels and flanges meet the low-temperature 

notch-toughness requirements of Category II of CSA Z662-11 with a minimum design 

temperature of -45°C. Whenever required, custom made mandrels and flanges in 2”and 

3” sizes with proven low-temperature notch-toughness properties can also be supplied. 

In addition, custom made crimp fittings with a stainless steel mandrel can also be 

supplied whenever specifically requested. 

Table 4: Shawcor Fitting Material List 

Part Material type Material grade(s) 

Mandrel 

Alloy steel a 

or 

Stainless 

AISI 4130, 4140 or equivalent 

or 

Duplex 2205 

Steel a 

Sleeve Carbon steel a ASTM A106, A333, A519, or 

equivalent 

Flange (flanged fittings Carbon steel a ASTM A105 or ASTM A350 LF2 

only) 

Class 1 

Weld neck fitting welding Carbon steel a ASTM A106, A333 or equivalent 

end 

Flow joints Carbon steel a ASTM A234 WPB or ASTM A420 

O-rings 

FKM/FPM 

Fluorocarbon 

Elastomer b 

WPL6 

75 Durometer 

Coatings c 

Electroless Nickel or uncoated 

a Meets requirements of NACE MR0175 for sour service 

b 

Special o-rings are available for high-pressure CO2 service 

c 

Weld neck and Stainless Steel fittings are not coated 

9 ANSI / NACE MR0175 / ISO 15156 Petroleum and Natural Gas Industries—Materials for Use in H2S-Containing 

Environments in Oil and Gas Production 

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3.4 Manufacturing 

Shawcor fittings are manufactured, coated, assembled, and labeled according to 

Shawcor specifications by suppliers whose processes have been qualified by Shawcor. 

Shawcor routinely verifies and audits the QC programs of these suppliers. 

All welding required for the manufacture of Shawcor fittings is performed in shop 

conditions, by suppliers qualified to Shawcor weld procedures in accordance with CSA 

Z662. These procedures are specific to the materials used, and include appropriate 

heat treatments and inspections. 

3.5 Corrosion Protection 

Standard fittings are supplied with high-phosphorus electroless nickel plating with a 

fluoropolymer sealer on all wetted surfaces of the fitting. This plating protects the fitting 

from corrosion and erosion for many applications. Additional information about 

electroless nickel plating is available upon request. Weld neck fittings are not coated or 

plated, since the coating or plating would be destroyed by the heat input during welding. 

Prefabricated flow joints can be coated, since no welding is required during installation. 

All fittings are also available with no coating. 

Although the sleeves may be coated with electroless nickel plating, it is not intended for 

corrosion protection as the crimping process will damage the surface of the nickel 

plating. Flash surface rust may occasionally be present on the sleeves surface. 

External corrosion control of Shawcor fittings is achieved by the application of the 

Denso Petrolatum Tape Anti-Corrosion System. Denso paste is applied to the exposed 

reinforcement fibers at the end of the pipe prior to installing the fitting, to protect the 

fibers from moisture. The fitting is wrapped in Denso tape after installation. When 

applied according to the product data sheet supplied with the tape, the system meets 

AWWA C217 10 . A high temperature version of the Denso products is available for use 

with the FPLP HT product line. 

Polyken tape is used to protect the Denso tape on each fitting from being damaged or 

removed. White Polyken tape is also required to be applied over couplings in surface 

lines to prevent excessive heating due to solar radiation and to prevent external 

moisture from entering the fitting. 

Additional corrosion control via cathodic protection is available. Cathodic protection 

requirements for buried steel fittings are covered in Clause 13.1.5 of CSA Z662-11. 

Shawcor has developed a ribbon anode kit for buried steel fittings that provides external 

corrosion protection for a 50 year life in soil resistivities ranging between 1500 to 3000 

ohm/cm. This is based on a fitting external coating efficiency of 95%. Anode test posts 

and monitoring for buried steel couplings in composite pipelines are not required. 

10 AWWA C217 Cold-Applied Tape Coatings for the Exterior of Special Sections, Connections, and Fittings for 

Buried/Submerged Steel Water Pipelines 

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The anode kit consists of a magnesium ribbon anode connected to a copper lead wire, 

along with a roll of cloth tape to fix the anode to the Shawcor and a stainless steel hose 

clamp to secure the lead wire to the fitting. Shawcor anode kit can be readily installed 

in the field by attaching a clamp around the fitting and taping the ribbon along the pipe. 

Fittings with anodes attached are compatible with installation by trenching or plowing. 

Please refer to the Shawcor Installation Guide for more information. 

4 Qualification 

4.1 Introduction to Standards and Regulations 

According to industry terminology, Shawcor line pipe is classified as a reinforced 

thermoplastic pipe (RTP). Various standards deal with this type of product, and cover 

topics such as materials, testing, manufacture, and installation. Standards are 

guidelines that are generally accepted throughout an industry as appropriate, usually on 

the basis of industry-wide experience. They are often referenced by regulations, which 

may adopt some or all of the guidelines, or even introduce more stringent requirements. 

Regulations are requirements that must be followed by law. 

Standards that apply to Shawcor products are primarily performance-based. This 

means that they emphasize the demonstration of a product’s capabilities through 

repeated testing, rather than relying only on theoretical design calculations. A detailed 

theoretical design model serves as a starting point for Shawcor product designs. The 

designs are validated through extensive long term testing in accordance with accepted 

test standards. 

4.2 Standards 

4.2.1 American Petroleum Institute (API) 

The American Petroleum Institute (API) was the first North American standards body to 

develop a recommended practice specific to the spoolable composite pipe industry. API 

RP 15S, Recommended Practice for the Qualification of Spoolable Reinforced Plastic 

Line Pipe, includes guidelines for determining material properties, pressure ratings, 

safety factors and service factors, and minimum performance requirements. It also 

includes guidelines for manufacturing, quality control tests, and typical installation 

methods. This recommended practice applies to RTP and spoolable thermosetting 

composite pipe. 

API RP 15S is based on expert knowledge of the materials involved, extensive 

experience with related applications and related products used in other applications, 

and detailed research on related knowledge used in other countries. It uses proven 

ASTM testing methods, such as ASTM D2992 11 , for establishing long-term 

performance. 

11 ASTM D2992 Standard Practice For Obtaining Hydrostatic or Pressure Design Basis For “Fiberglass” (Glass- 

Fiber-Reinforced Thermosetting Resin) Pipe And Fittings 

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API 17J, “Specification for Unbonded Flexible Pipe”, is a standard created for the design 

of flexible pipe primarily for the offshore industry. The FCLP product line has been 

designed following the requirements of API 17J that are applicable to onshore 

applications. 

All Shawcor products meet or exceed the stringent qualification requirements 

established by API RP 15S or applicable requirements of API 17J. 

4.2.2 Canadian Standards Association (CSA) 

CSA provides standards to which manufacturers should comply. CSA Z662-11, Oil and 

Gas Pipeline Systems, “covers the design, construction, operation, and maintenance of 

oil and gas industry pipeline systems”. Shawcor Spoolable Products fall under Clause 

13.1 of this standard, which specifically addresses design, manufacturing and 

installation requirements for reinforced composite pipelines. 

Shawcor is fully compliant with CSA Z662-11 Clause 13. Some of the specific 

requirements are discussed below. Other requirements are discussed in more detail 

elsewhere in this document, as referenced in Table 5. 

According to Clause 13.1.1.3, reinforced composite pipelines may be used in low vapor 

pressure (LVP) 12 , gas gathering, and oilfield water pipelines. High vapor pressure 

(HVP) 13 pipelines are excluded by this clause. FPLP and FPLP HT also meet the 

requirements of Clause 12.4.6.3 for gas distribution systems 14 . 

Design pressure calculations for RTP are outlined in Clause 13.1.2.8. This clause 

refers to API RP 15S as the industry standard according to which FPLP and FPLP HT 

must be qualified. This clause also refers to API 17J as the industry standard according 

to which FCLP must be qualified. It uses the qualification methods given in the product 

standards and specifies the values to be used for derating factors used in these 

methods. These factors are a minimum requirement; in some cases, Shawcor has 

chosen service fluid factors (Ffluid) which are more conservative than required by CSA. 

These factors are already included in the Maximum Allowable Operating Pressures 

(MAOP) published for Shawcor Spoolable Products, as shown in the design pressure 

calculations in Section 5.2.3. 

Shawcor fittings are engineered for suitable low-temperature notch toughness. The 

material properties meet CSA Z662 Category II requirements with a minimum design 

temperature of -45°C. 

12 Includes oilfield water, multiphase fluids, or liquid hydrocarbon mixtures with vapor pressure of 110 kPa 

(absolute) or less at 38˚C. 

13 Hydrocarbons or hydrocarbon mixtures in the liquid or quasi-liquid state with a vapor pressure greater than 110 

kPa (absolute) at 38°C. 

14 Based on a design life of 50 years at a design temperature of 40ºC (104ºF). 

06-1876 R4.3 



Table 5: Links for Specific CSA Z662 Requirements 

Requirement CSA Z662 clause 

Reference in this 

manual 

Gas service design pressure limit 13.1.1.4 Section 5.1.2 

Sour gas limits 13.1.1.4 Section 5.1.5 

Cyclic service 13.1.2.9 Section 5.3 

Tracer wire 13.1.4.1 Section 6.11 

Cathodic protection 13.1.5 and 9.1 Section 6.15 

Crossings and casing 

13.1.4.2 

13.1.4.6 

Section 6.9 

13.1.4.7 

Freestanding liner insertion 13.1.4.8 Section 6.5 

Pressure testing – new installations 13.1.6 Section 6.18 

Pressure testing – 13.1.8.2 Section 8.6 

Static electricity 13.1.8.3 Section 8.4 

Maximum external pressure 13.1.2.12 Section 5.12 

4.3 Regulations 

4.3.1 Canadian Provincial Regulatory Bodies 

The Energy Resources Conservation Board (ERCB) is a regulatory body that oversees 

the development of Alberta’s energy resources, including oilfield pipelines. Any oilfield 

pipeline in Alberta must be approved by the ERCB before installation, in accordance 

with its regulations. Other provinces in Canada have regulatory bodies with a similar 

role. Cross provincial installations are licensed under the National Energy Board (NEB) 

in a similar manner. 

The ERCB allows Shawcor Spoolable Products applications to be processed as routine 

for fresh water, salt water, multiphase, crude oil/LVP, and natural gas service. Shawcor 

has developed a positive history with the ERCB through provision of data on design, 

manufacturing, testing, installation and in-service evaluations. More information on the 

results of these evaluations can be found in Section 9. Shawcor has also established 

relationships with the corresponding regulatory bodies in British Columbia, 

Saskatchewan, and Manitoba, and installations have been completed in each of these 

provinces. 

Full instructions for completing Directive 56 – Schedule 3 for ERCB applications are 

available from the Shawcor website. Examples are given for a new pipe line and as a 

freestanding liner. 

4.3.2 United States Regulatory Bodies 

Shawcor Spoolable Products are extensively used in unregulated areas in the United 

States. In regulated areas, the United States Department of Transportation (DOT) 

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considers the use of Shawcor Spoolable Products through special permit applications 

submitted to the Office of Pipeline Safety. Currently, Shawcor is working with the 

Department of Transportation to eventually include Reinforced Thermoplastic Pipes as 

an approved material in 49 CFR Part 192 “Transportation of Natural and Other Gas by 

Pipeline”. 

4.3.3 Australian Regulatory Bodies 

FPLP and FPLP HT have been accepted by regulatory bodies in South Australia and 

Queensland, in accordance with AS 2885.1 “Pipelines – Gas and liquid petroleum” for 

use as emulsion and oil pipe lines. 

4.3.4 Latin American Regulatory Bodies 

Shawcor Spoolable Products have been certified by ABS Group Services de Mexico. 

FPLP and FPLP HT comply with NRF-185-PEMEX-2008 “Tubería Plástica Reforzada 

Enrollable para recolección y Transporte de Hidrocarburos Líquidos y Gaseosos” 15 and 

FCLP complies with P.2.0730.01 “Tubería Plástica Reforzada Enrollable para 

recolección y Transporte de Hidrocarburos Líquidos y Gaseosos” third edition. 

Shawcor is currently in the final stages of qualifying its products with several oil and gas 

operators in the Latin American Region. 

4.4 Testing 

Shawcor is committed to ensuring that its products are rugged, reliable, and safe. 

Shawcor Spoolable Products are tested together with fittings as a complete system. 

This system has undergone extensive testing to demonstrate that it meets and exceeds 

the strict requirements of API 15S or the applicable requirements of API 17J. Shawcor’ 

test procedures have been audited and accepted by an independent laboratory 16 . 

Shawcor strongly believes that its products should perform as well under field conditions 

as in the laboratory. Therefore, Shawcor has gone beyond the strict requirements of 

the applicable standards, and has developed its own procedures to test field handling of 

Shawcor Spoolable Products and related equipment. 

Some of the specific tests in Shawcor’ testing program are listed in Table 6. These 

tests have resulted in a comprehensive base of knowledge about product performance 

under a wide variety of service conditions. 

15 Spoolable Reinforced Plastic Pipe to collect and transport liquid and gaseous hydrocarbons 

16 Jana Laboratories Inc. (Aurora, Ontario) 

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Table 6: Pipe and Fitting Tests and Applicable Standards 

Test description 

Applicable standard(s) 

Regression pressure testing 

ASTM D2992 Procedure B 

API RP 15S Section 5.1.2.3 

Elevated temperature pressure testing API RP 15S Section 5.2.1 

Low temperature pressure testing 

ASTM D1599 17 Procedure A 

Minimum bend radius pressure testing API RP 15S Section 5.3.2 

Installation pressure testing – samples retrieved 

after liner insertion 

ASTM D1599 Procedure A 

Installation pressure testing – samples retrieved 

after plowing 


Shawcor Test Procedure 10-0942 

Short term burst pressure testing 



Cyclic pressure testing 


Shawcor Test Procedure 10-0941 

Pressure testing - samples subjected to reverse 

bending 


Axial load testing API RP 15S Section 5.3.3 

Vent testing - gases venting from annulus API RP 15S Section 5.3.1 

Impact resistance testing API RP 15S Section 5.5.2 

Thermal expansion & pressure-expansion testing API RP 15S Sections 5.5.4 and 5.5.5 

Kink testing Shawcor Test Procedure 10-0940 

Fitting gas leak testing API RP 15S Section 5.3.1 

Thermal cycle testing 

Flexpipe Systems Test Procedure 10- 

0945 

External load testing ASTM D2412 18 

Corrosion Testing - for steel cords API 17J / ISO 13628‐2 

5 Performance 

5.1 Applications & Chemical Compatibility 

It is the responsibility of the pipeline operator to understand the suitability of Shawcor 

Spoolable Products for specific pipeline applications. The information in this section is 

intended to provide an understanding of the suitability of the products for a wide range 

of common applications. For these or other applications, Shawcor’ engineering team 

will be pleased to evaluate the application and advice regarding compatibility of 

Shawcor Spoolable Products. 

5.1.1 Application Evaluations 

Shawcor has established a systematic process to evaluate proposed applications in 

order to verify compliance with the normal operational limits given in the following 

sections. These limits are intended to provide a consistent and conservative basis to 

17 ASTM D1599 Standard Test Method for Resistance to Short-Time Hydraulic Pressure of Plastic Pipe, Tubing, 

and Fittings 

18 ASTM D2412 Standard Test Method for Determination of External Loading Characteristics of Plastic Pipe by 

Parallel-Plate Loading 

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potential applications. While Shawcor Spoolable Products may perform well in 

applications that exceed these limits, it may not be appropriate for certain combinations 

of factors when one or more of the limits are exceeded. 

Application evaluations are provided by Shawcor Engineering team as a service to 

clients. Each evaluation assesses the details of a proposed application to identify 

potential risks and determines specific measures that can be taken to eliminate or 

minimize them. Recommendations resulting from these evaluations have allowed many 

projects to successfully take advantage of the full capabilities of Shawcor Spoolable 

Products. Shawcor believes that this approach reflects its commitment to public safety 

and has contributed to its outstanding service record, while allowing it to meet the 

unique needs of its clients. 

5.1.2 Gas 

Shawcor has a strong historical record in gas gathering applications. There is no 

requirement to further de-rate the Shawcor MAOP in gas applications (see Section 5.2 

for determination of pressure ratings). Suitable environments include natural gas, 

solution gas, exhaust gas, and fuel gas. See Section 5.1.6 for information on CO2 

applications. 

For gas applications in which condensates can form, a suitable pigging program should 

be implemented to prevent condensate buildup at low points along the pipeline. 

Clause 13.1.1.4 of CSA Z662-11 limits the allowable design pressure for RTP gas 

pipelines to a maximum of 9930 kPa (1440 psi). 

Shawcor Spoolable Products can also be used in sour (H2S) applications, but limits 

apply. Please refer to Section 5.1.5 for more details. 

5.1.3 Oil 

Shawcor Spoolable Products are suitable for oil effluent or oil emulsion (two- or threephase) 

applications. The product lines are corrosion resistant, fully piggable, and are an 

excellent option for production with high water-cut. For applications with high wax 

content, suitable pigging programs should be in place. Please refer to Section 5.3 for 

more information on cyclic pressure applications. Please refer to Section 8.2 for more 

information on pigging. 

5.1.4 Water 

Shawcor Spoolable Products are corrosion resistant and an excellent option for oilfield 

water applications such as water transfer, disposal and injection lines. However, these 

applications often involve cyclic pressure variations, and should be evaluated for 

compatibility. Please refer to Section 5.3 for more information on cyclic pressure 

applications. 

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5.1.5 H2S 

H2S (hydrogen sulphide, also known as sour gas) is a toxic and potentially lethal 

substance commonly found in oilfield media. Accordingly, a greater risk exists in routine 

pipeline inspection or maintenance, or in the event of fluid release due to pipeline 

damage. 

Non-metallic pipelines such as Shawcor Spoolable Products may allow small amounts 

of the transported fluids to permeate through the pipeline materials (see Section 5.10), 

accumulate within the materials or fitting system, and/or be released through the outer 

surface of the pipeline (please refer to the Shawcor Sour Service Pipeline Bulletin, 

available from the Shawcor website, for more information). Similar to other components 

in sour gas service, due consideration should be given to the potential accumulation of 

H2S around the vent hole of the Shawcor fittings. 

Sour applications must comply with the regulatory requirements of specific regional 

authorities. 

FPLP and FPLP HT are compatible with H2S. Shawcor chooses to limit H2S content of 

up to 10% by mol in the gas phase of liquids (oil and/or water) or multiphase 19 . 

Applications above 10% are evaluated on a case by case basis. FCLP is suitable for 

the transport of liquids (oil and/or water), gas or multiphase with up to 3000 ppm of H2S. 

This limit has been established by extensive corrosion testing on the steel cord 

reinforcements of the FCLP product and has been approved by an independent third 

party engineering firm as well as the ERCB (Energy Resources Conservation Board) of 

Alberta. 

5.1.6 CO2 

Shawcor Spoolable Products can be used for gases or liquids containing up to 100% 

CO2 by volume. The suitability for CO2 service has been confirmed by a rapid 

decompression testing. The standard 75 Durometer Vition o-rings are suited for a wide 

range of CO2 applications. For applications having higher than 10% CO2 and operating 

at pressures above 750 psi, Shawcor recommends the use of special o-rings that 

provide superior performance for these conditions. Refer to Section 3.5 for further 

information on the fittings corrosion resistance and coating. 

5.1.7 Aromatic and Cycloalkane Hydrocarbons 

Shawcor Spoolable Products are compatible with aromatic and cycloalkane 

hydrocarbons (e.g. benzene, toluene, ethyl benzene, xylene, naphthalene and 

cyclohexane) in gas or liquids. Table 7 lists the allowable aromatic and cycloalkane 

concentrations for normal operating pressures, based on Shawcor test data. 

19 

CSA Z 662-11 Clause 13.1.1.4 limits the partial pressure of H 2 S in gas to 50 kPa (7.25 psi) for all composite pipe 

used in sour gas applications. 

The ERCB (Directive 71) requires calculation of H 2 S release volumes for multi-phase pipelines 

06-1876 R4.3 



Table 7: Allowable Aromatic and Cycloalkane Hydrocarbon Content 

Maximum allowable 

Product Line Operating temperature aromatic and cycloalkane 

content (by volume) 

FPLP and 60˚C (140˚F) or below 

FCLP 

25% 

FPLP HT 82˚C (180˚F) or below 25% 

See also: Section 5.1.8 Chemical Injection. 

5.1.8 Chemical Injection 

Common injection chemicals used in the oil gathering industry, such as corrosion 

inhibitors, biocides, paraffin dispersants, surfactants, scale inhibitors, defoamers, and 

demulsifiers, are not considered problematic to the HDPE liner. Shawcor recommends 

that chemical injection programs use dilute concentrations or batch treatments, as per 

the standard practice for HDPE applications as set out by the chemical manufacturing 

company. 

Injection chemicals which are made up from aromatic and cycloalkane hydrocarbons 

are acceptable for use with the HDPE liner provided the concentration of the injection 

chemicals is controlled such that the aromatic and cycloalkane concentration stays 

within the limits listed in Table 7 as applicable for the pipe service temperature. Any 

higher concentration batch treatment process should be of limited duration as 

recommended by the injection chemical manufacturer for use in HDPE pipe. 

This section addresses only the more common injection chemicals used in the oil 

gathering industry. Due to the variety of injection chemicals available, however, 

Shawcor recommends that the oil field operating company develop an injection program 

in conjunction with the chemical manufacturing company to ensure there are no 

chemical compatibility concerns with HDPE. 

5.1.9 Methanol and Ethanol 

HDPE has good resistance to concentrated methanol and ethanol at temperatures up to 

60˚C (140˚F). Alcohols may be used in Shawcor Spoolable Products during hydrotests 

to prevent freezing. They may also be used in FPLP and FPLP HT in continuous and 

batch programs. Due to the possible introduction of oxygen with alcohols, continuous 

injection of alcohols in FCLP is not recommended. 

5.2 Pressure and Temperature Ratings 

5.2.1 Maximum and Minimum Allowable Operating Temperature 

The Maximum Allowable Operating Temperatures (MAOT) and minimum allowable 

operating temperatures for Shawcor Spoolable Products are indicated in Table 8. 

These temperatures have been proven by the successful completion of the required 

06-1876 R4.3 



qualification testing and the positive track record of field applications in the northern 

United States and Canada. 

Shawcor supplies tags for installation on risers to notify operators of the temperature 

limitations of the pipe. 

Table 8: Maximum and Minimum Allowable Operating Temperatures 

Product Line Maximum Allowable 

Operating Temperature 

Minimum Allowable 

Operating Temperature 

(°C) (°F) (°C) (°F) 

FPLP 60 140 -46 -50 

FPLP HT 82 180 -25 -13 

FCLP 60 140 0 32 

Shawcor Spoolable Products have excellent impact resistance properties and do not 

become brittle at low temperatures. Shawcor Spoolable Products can be installed at 

temperatures lower than 0˚C (32˚F). Refer to Section 6.12 for cold temperature 

installation limits, Section 3.3 for fittings materials selection and Section 8.1 for starting 

up pipelines at low temperatures. 

During hot oiling applications using FPLP HT, it is allowable for excursions to exceed 

the pipe maximum allowable operating temperature of 82°C (180°F) for a brief period. 

The hot oiling temperature is allowed to reach up to a maximum of 93°C (200°F) for a 

cumulative maximum duration of 500 hours over the lifetime of the pipeline. It is 

recommended to limit the amplitude of the temperature differential between the 

maximum and minimum operating temperatures to 87°C / 156°F or lower. Contact your 

Shawcor Account Manager to discuss applications with extreme temperature swings. 

Insulation or white Polyken tape is required for protecting aboveground portions of 

Shawcor Spoolable Products (for example at risers) from exceeding the maximum 

allowable operating temperature as a result of heating due to solar radiation. 

5.2.2 Maximum Allowable Operating Pressures 

The Maximum Allowable Operating Pressures (MAOP) is shown in Table 9. These 

pressures have been established by performing the qualification testing at the MAOT of 

each product line. 

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Table 9: Maximum Allowable Operating Pressure 

Maximum Allowable Operating Pressure* 

Produc 

t Line 

150 301 601 801 

(kPa) (psi) (kPa) (psi) (kPa) (psi) (kPa) (psi) 

FPLP 2,068 300 5,171 750 10,342 1500 

FPLP 

2,068 300 5,171 750 10,342 1500 

HT 

FCLP 13,790 2,000 

*Check your local regulations to verify the maximum allowable operating pressure 

does not exceed the maximum allowable design pressure. 

5.2.3 Calculations for Determining Maximum Allowable Operating Pressure 

The MAOPs listed in Table 9 have been determined by the following equation: 

MAOP MPR F fluid 

F cyclic 

Where 

MAOP = Maximum Allowable Operating Pressure 

MPR = Maximum Pressure Rating 

Ffluid = Service Fluid Factor 

Fcyclic = Cyclic Pressure Service Factor 

The Maximum Pressure Ratings (MPR) have been determined at the maximum design 

temperatures and minimum 20 years design life of the pipeline in accordance with API 

RP 15S 20 or API 17J 21 as applicable, and include the required Pressure Service Factor 

(PSF). 

The Service Fluid Factor (Ffluid) is a service factor that is intended to account for the 

effects of the transported fluid on the pipe materials, to ensure that the fluid does not 

reduce the pipeline’s capability of maintaining the MAOP over the design life. This 

factor is applied to the MPR to determine the MAOP at the qualification temperature. 

The procedure utilized to establish the MAOP of FPLP and FPLP HT is illustrated in 

Figure 4, where data from multiple long-term pressure tests are plotted on a log-log 

graph. The MPR is derived using statistical calculations, and includes a Pressure 

Service Factor (PSF) which is the service factor intended to account for small variations 

in materials, installation, or operating parameters, to ensure that these variations do not 

cause the pipe’s actual capabilities to be exceeded. The PSF is applied to the Lower 

20 API RP 15S Recommended Practice for the Qualification of Spoolable Reinforced Plastic Line Pipe 

21 API 17J Specification for Unbonded Flexible Pipe 

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Confidence Limit (LCL) at the Design Life to determine the MPR at the qualification 

temperature. Shawcor uses PSF=0.67, as recommended by API 15S. 

Figure 4: Procedure for Determining MPR and MAOP 22 

FPLP and FPLP HT have been designed using an Ffluid=0.67 for all types of fluids. This 

value allows a consistent MAOP for all types of fluids. It meets the CSA Z662-11 

requirements for gas, and is more conservative than CSA Z662-11 requirements for 

other services. Shawcor believes that this conservative approach has contributed to its 

outstanding track record. 

The FCLP Maximum Pressure Rating is determined in accordance with API 17J / ISO 

13628-2. Table 9, includes the use of the required design factors, and considers the 

effects of the transported medium on the material properties. Accordingly, and in line 

with CSA Z662-11 clause 13.1.2.8, FCLP’s MAOP has been determined using a Fluid 

Factor (Ffluid) of 1.0 for all service fluids shown in Table 13.1 of CSA Z662-11. 

Because Shawcor’ MAOP already includes the required design and fluid factors, 

Shawcor Spoolable Products can be operated in the field at pressures up to the MAOP 

published by Shawcor. 

The effect of pressure cycling (i.e. cyclic pressure service factor Fcyclic of CSA Z662-11 

section 13.1.2.8) is taken into account during the application evaluation conducted by 

Shawcor on a project by project basis. The amplitude of the pressure fluctuations that 

the system will see under typical operating conditions is compared to the cyclic test data 

generated by Shawcor during laboratory testing, and a safe cycling frequency is 

determined. A Cyclic Pressure Service Factor (Fcyclic) of 1.0 has been used to determine 

the MAOP values shown in Table 9. 

22 Based on Figure 1 of API RP 15S (2006). 

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5.3 Cyclic Pressure 

Water transfer, disposal or injection applications and oil gathering applications are 

typically quite corrosive and are a natural fit for Shawcor Spoolable Products corrosion 

resistance properties. However, to ensure the optimal performance and reliability of the 

products in these applications, consideration must be given to the cyclic pressure 

characteristics of the system design and the operating regime. 

As part of Shawcor’s commitment to quality and customer satisfaction, an application 

evaluation process is offered. The pipeline end user provides the operating parameters 

as per the Application Review Form for assessment. Shawcor applications engineers 

can provide project specific recommendations regarding selection of the best product, 

optimal system design, and operational considerations for the intended application. 

Shawcor requires that an application review be completed for all liquid applications to 

ensure optimal performance of the product and the overall system. The 

recommendations of an application review are based on a minimum 20 year service life. 

The key parameters that influence the selection of the pipe type for a cyclic service 

application are: 

Type of pump: The pump type plays a major role in determining the cyclic 

characteristics of a pipeline system. Pumps can be generally divided into 

pulsating and non-pulsating types. All pulsating pumps are of the reciprocating 

positive displacement type, such as Triplex, Quintuplex and Diaphragm pumps. 

These pumps generate a pulsating flow and pressure output as a result of their 

back and forth mechanical action. Non-pulsating pumps such as centrifugal, 

progressive cavity, screw, and gear, are characterized by their rotating 

mechanical action resulting in a smooth flow and pressure output. Pump Jacks 

are a unique type of positive displacement pumps and will be treated separately 

in Section 5.3.4. 

 

Pressure fluctuations: Pressure fluctuations may either be the result of: 

o Pump start/stop cycles where the pressure in the pipeline system cycles 

between the operating pressure and the shut off pressure, or 

o Modifications to the system operation or layout, such as operating an 

additional pump or injecting into a different well. 

Depending on their magnitude and frequency, pressure pulsations and fluctuations 

could be detrimental to the pipe performance. Contact your Shawcor representative for 

a project specific application evaluation. The Application Review process evaluates the 

feasibility of using Shawcor Spoolable Products on your project and provides guidance 

on how to safely operate the pipeline. 

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5.3.1 FPLP Cyclic Capabilities 

Applications with non-pulsating pumps can be operated at the full FPLP pressure rating, 

as this type of pump provides a steady pressure output free of high frequency pressure 

pulsations or excessive vibration. Additionally, FPLP can handle mild pressure 

fluctuations and these applications need to be evaluated on a case-by-case basis using 

Shawcor’ application review process. 

Applications with pulsating pumps can be detrimental to many pipeline materials. It is 

required to maintain the peak-to-peak amplitude of the high-frequency pressure 

pulsations below 15 psi for FP301 and below 25 psi for FP601. To protect FPLP from 

progressive damage, effective pulsation dampeners are required at the pump inlet and 

outlet, designed to limit peak to peak amplitude to 3%. As the industry practice 

estimates the peak-to-peak amplitude of high-frequency pulsations to be 10% of the 

mean pressure value, this translates into a maximum service pressure of 150 psi for 

FP301 and 250 psi for FP601. This does not affect the capability of the pipe to handle 

infrequent pressure excursions up to the pipe MAOP as shown in Table 9. In addition, a 

minimum of 100 feet of steel pipe between the pump and the FPLP is recommended to 

assist with vibration dissipation. 

For all application types and in order to eliminate large amplitude pressure fluctuations 

resulting from pump on/off cycles, Shawcor recommends using a variable frequency 

drive (VFD) to regulate the flow rate while maintaining continuous operation of the 

pump, and provide a soft start/stop whenever the pump shuts down. 

5.3.2 FPLP HT Cyclic Capabilities 

Applications with non-pulsating pumps can be operated at the full FPLP HT pressure 

rating, as this type of pump provides a steady pressure output free of high frequency 

pressure pulsations or excessive vibration. Additionally, FPLP HT can handle mild 

pressure fluctuations and these applications need to be evaluated on a case-by-case 

basis using Shawcor’ application review process. 

For all application types and in order to eliminate large amplitude pressure fluctuations 

resulting from pump on/off cycles, Shawcor recommends using a variable frequency 

drive (VFD) to regulate the flow rate while maintaining a continuous operation of the 

pump, and provide a soft start/stop whenever the pump shuts down. 

It is not recommended to utilize FPLP HT with pumps generating a pulsating pressure 

output, such as Duplex, Triplex, Quintuplex, Diaphragm, Hydra-Cell, etc. 

5.3.3 FCLP Cyclic Capabilities 

FCLP is suitable for service in systems subject to severe cyclic pressure conditions-with 

either pulsating (piston, diaphragm) or non-pulsating (centrifugal, gear, screw, 

progressive cavity) pumps. FCLP is adequate for use with pulsating pumps operating at 

pressures up to 13,790 kPa (2,000 psi) and peak-to-peak pressure pulsations of up to 

06-1876 R4.3 



1,380 kPa (200 psi). Pulsating pumps can generate large peak-to-peak pulsations well 

in excess of 200 psi. Properly designed, operated and maintained pulsation dampeners 

at the pump suction and discharge of pulsating pumps are required. A typical maximum 

peak-to-peak design value for pulsation dampeners is 3% of the operating pressure. 

FCLP is also suitable for applications with large amplitude pressure cycles of up to 10 

cycles per day of 0 – 10,342 kPa (0 - 1,500 psi) or 1 cycle per day of 0 – 13,790 kPa 

(2,000 psi) based on a minimum service life of 20 years. 

5.3.4 Pump Jacks 

Shawcor Spoolable Products corrosion resistant properties are a natural fit for corrosive 

oil emulsion production. However, to ensure the optimal performance and reliability in 

pump jack applications, consideration must be given to the cyclic pressure 

characteristics of the system design and the operating regime. 

In general, using sound system design and good industry operating practices will 

optimize the integrity and life of all production equipment. The pressure differential 

between the upstroke and down stroke pressures generated by the operation of the 

pump jack is of critical importance to the long term integrity of the FPLP. 

Some of the design and operational factors that can affect the magnitude of the 

pressure differential in the flow line include: 

 

 

 

 

 

 

 

Length and diameter of the flow line 

Production volumes 

Production fluid properties 

Down hole pump integrity 

Wax build-up 

Flow line check valve integrity 

Hot oiling and pigging practices 

For FPLP applications with an upstroke pressure above 150 psi, Shawcor recommends 

limiting the amplitude of the pressure differential between the routine upstroke and 

down stroke pressures to 50 psi for FP301 and 75 psi for FP601. For example, if the 

normal upstroke pressure in a FP301 flow line is 175 psig, the minimum pressure during 

the down stroke should be no less than 125 psig. Infrequent pressure excursions 

beyond these limits are generally acceptable. 

FPLP HT is a very good fit for applications with pump jacks. For pump jacks with an 

upstroke pressure above 150 psi, Shawcor recommends limiting the amplitude of the 

pressure differential between the routine upstroke and down stroke pressures to 30 psi 

for FP301 HT and 50 psi for FP601 HT. Infrequent pressure excursions beyond this limit 

are generally acceptable. 

06-1876 R4.3 



FCLP is suitable for use in pump jack applications with severe pressure cycling 

parameters, with consistent upstroke pressures of up to 3,450 kPa (500 psi). 

These recommendations are based on both qualification test results and field 

experience. They provide safe operating limits based on a minimum design life of 20 

years. In order to ensure the long term integrity of the piping system, Shawcor 

recommends: 

Installing and maintaining a pressure switch (such as a Presco switch) set at a 

maximum of 100 psi above the upstroke pressure to limit the possibility of 

subjecting the pipeline to excessive pressure swings for extended time durations. 

Routinely monitoring the upstroke and down stroke pressure values using a 

calibrated pressure gauge mounted between the well head and the flow line. 

Implementing a suitable pigging program to ensure the upstroke pressure does 

not increase as a result of wax build up. 

5.4 Flow Characteristics 

5.4.1 Pipe Flow 

Relative to steel pipe, the smooth internal surface of Shawcor Spoolable Products 

polyethylene liner provides favorable flow rates and reduced pressure losses as a result 

of reduced friction. Figure 5 and Figure 6 show representative pressure drops at 

various flow rates for fresh water and methane, respectively. The results shown are 

based on calculation of the pressure drop for the given fluid in each size of the product 

using the Darcy-Weisbach method, repeated in each case for standard steel pipe of the 

same nominal size. As the charts show, the pressure drop for a given flow rate in the 

line will be significantly lower than for the corresponding steel pipe. Conversely, a 

higher flow rate can be attained for a given pressure drop using Shawcor Spoolable 

Products. 

For other flow scenarios, the pressure drop can be calculated using any of the flow 

coefficients listed in Table 10. 

06-1876 R4.3 



800 

700 

600 

Pressure Drop (PSI) 

500 

400 

300 

200 

100 

0 

2" Flexpipe 2" Sch 40 Steel 



0 5000 10000 15000 20000 25000 30000 35000 

Flow Rate (bbls/day) 

Figure 5: Representative Pressure Drop Comparison: Water at Various Flow Rates 

*Calculations based on 1 mile of pipe length, with fresh water at 30˚C (86˚F) 

500 

450 

400 

Pressure Drop (PSI) 

350 

300 

250 

200 

150 

100 

50 




0 

0 5000 10000 15000 20000 25000 30000 35000 40000 

Flow Rate (Mcf/day) 

Figure 6: Representative Pressure Drop Comparison: Methane at Various Flow Rates 

*Calculations based on 1 mile of pipe length, with methane at 20˚C (68˚F) compressed 

to 500 PSI 

06-1876 R4.3 



Table 10: Flow Coefficients for Shawcor Spoolable Products 

Hazen & Williams 150 

Darcy Weisbach 

0.0015 mm (0.000005 ft) 

Manning 0.009 

5.4.2 Fittings 

The inside diameter of the mandrel of the pipe fitting is smaller than the inner diameter 

of the pipeline (see Section 3.2). However, the restriction is minimal, and very few 

fittings are required even for very long lengths of pipe. The associated pressure loss is 

negligible compared to the pipe friction discussed above. 

The following equations and K factors for Shawcor coupling fittings can be used to 

calculate the loss in pressure or pressure head due to the flow constriction. 

V 

P fitting 

K 

Pressure loss: 2 

2 

V 

h fitting 

K 

Pressure head loss: 2g 

2 

Where: 

= fluid density 

V = fluid velocity 

g = acceleration due to gravity 

K = factor from Table 11 

Table 11: K Factor for Shawcor Spoolable Products Coupling Fittings 

Fitting size 

K factor 

2” 0.56 

3” 0.55 

4” 0.33 

5.5 Durability 

Shawcor Spoolable Products are a durable, rugged product. The high-strength, pipegrade 

thermoplastic used in the jacket protects the reinforcement from the environment. 

The jacket is highly resistant to cracking, and will not bruise, chip, or flake under normal 

handling. Shawcor Spoolable Products can be installed over rocks and rough terrain, or 

pulled into failed pipelines. 

Impact testing according to API RP 15S Section 5.5.2 at -25 ◦ C (-13 ◦ F) has 

demonstrated a high level of resistance to impact loading from normal handling and 

installation activities. 

06-1876 R4.3 



5.6 Corrosion 

Shawcor Spoolable Products liner and jacket will not corrode. External corrosion 

control of the fittings is achieved by the application of moisture resistant tape, and 

internal corrosion control by standard coatings on the fittings (see Section 3.5). 

Additional corrosion control via cathodic protection is an available option (see Section 

6.15) and may be required by local regulations (i.e.: Energy Resources Conservation 

Board – ERCB of Alberta). 

FCLP is intended for applications where lined steel is typically specified and is expected 

to perform corrosion free. 

5.7 Erosion 

Shawcor Spoolable Products will experience less erosion than steel in wet slurry 

applications (ie solid particles carried in a liquid) due to the elasticity and toughness of 

the liner material. However, a sufficient flow velocity should be maintained to prevent 

solid particles from settling out of the carrying liquid. Settled particles that slide along 

the bottom of the pipe may cause wear to the bottom surface. 

Dry slurry applications (ie solid particles carried by a gas) may cause excessive static 

electricity build-up and/or heating due to dry particles sliding on the surface. Shawcor 

Spoolable Products may not be suitable for dry slurry applications. Please contact your 

Shawcor representative to conduct an application evaluation for your project in this 

case. 

5.8 Ultra-Violet Protection 

Shawcor adds a UV stabilizer to the jacket material during the extrusion process. The 

outer jackets of all Shawcor Spoolable Products provide a minimum of 20 years 

protection against UV exposure. 

5.9 Bend Radius 

The minimum allowable bend radius of FPLP differs in operation (pressurized) and 

transport/handling (un-pressurized) conditions, as shown in Table 12. 

Table 12: Minimum Bend Radius for Operation, Transport and Handling 

Shawcor 

Spoolable 

Minimum bend radius 

OPERATION 

Minimum bend radius 

TRANSPORT & HANDLING 

Products (m) (ft) (m) (ft) 

2” 1.2 4.0 0.8 2.5 

3” 1.8 6.0 1.0 3.3 

4” 2.1 7.0 1.3 4.2 

Note: The minimum radius does not apply to fittings/couplings. These 

joints need to be kept straight to avoid point loading at the end of the 

fitting. Typically there should be no bends within 1.8 meters (6 feet) from a 

fitting. 

06-1876 R4.3 



5.10 Permeation 

Gas molecules are able to travel very slowly through pipe walls by moving through the 

spaces between the molecules of the pipe material. This is known as permeation of the 

gas. All piping materials allow gases to permeate to some extent, but composite 

materials allow more than steel pipes do. 

Shawcor Spoolable Products have a self-venting design which allows permeated gases 

to vent at the fittings. This prevents pressure from building up within the annulus (the 

space between the liner and jacket that contains the reinforcement layer), thereby 

avoiding the risk of liner collapse during line depressurization. Wherever it is desired to 

avoid venting permeated gas above grade, Shawcor offers a flange option where the 

vent hole has been plugged. In such installations, a coupling should be located within 

300 meters from the plugged flange to provide the pipeline with adequate venting 

capability. 

Field testing has shown that the actual rates of gas release from pipeline are generally 

insignificant (see Section 9.2). This is supported by calculations based on a 

conservative model, in which the gases in the pipe permeate through the liner and then 

permeate through the jacket or travel along the annulus to exit through the vent hole at 

the fitting. The calculations use the permeability coefficients given in Table 13, which 

are experimentally determined from testing conducted on unreinforced polyethylene. 

The following example provides a representative illustration of the extent of permeation 

in Shawcor Spoolable Products. 

Table 13: Permeability Coefficients for HDPE 

Permeability coefficient at 40°C 

Permeant 

(104°F) 

(cm 3 /cm-sec- (inch 3 /inch-secpsi) 

MPa) 

Methane 1 x 10 -7 1.07 x 10 -10 

H2S 1 x 10 -7 1.07 x 10 -10 

CO2 5.5 x 10 -7 5.88 x 10 -10 

Shawcor Spoolable Products liner has a similar SDR (Standard Dimension Ratio) in all 

sizes, which results in the same permeation rate for all sizes. Table 14 shows expected 

permeation rates for a gas mixture of 89% methane, 1% H2S, and 10% CO2. To obtain 

expected permeation rates at different temperatures, it can be approximated that a 5˚C 

(9˚F) increase in temperature results in a 30% increase in permeation rate. The values 

listed in Table 14 have been determined by the following equation: 

PA( p' 

p") 

q 

t 

Where: 

q = Volume of gas permeating per unit length per unit time 

P = Permeability coefficient from Table 13 

A = Surface area per unit length of pipe 

P’ = Internal partial pressure 

P” = External partial pressure 

06-1876 R4.3 



t = Wall thickness 

Table 14: Representative Permeation Rates for Shawcor Spoolable Products 

Permeation rate 

cm 3 /m of pipe/day (in 3 /ft of pipe/day) 

Pipe 689 kPa 5171 kPa 10,342 kPa 

Pipe at 10°C 

(50°F) 

Pipe at 40°C 

(104°F) 

Pipe at 60°C 

(140°F) 

Pipe at 82°C 

(180°F) 

pressure (100 psi) (750 psi) (1500 psi) 

89% methane 6 (0.1) 46 (0.9) 93 (2) 

1% H2S 0.1 (0.001) 0.5 (0.01) 1 (0.02) 

10% CO2 4 (0.07) 29 (0.5) 57 (1) 

Total mixture 10.2 (0.2) 76 (1.4) 151 (3) 

89% methane 30 (0.6) 224 (4) 447 (8) 

1% H2S 0.3 (0.006) 3 (0.05) 5 (0.09) 

10% CO2 18 (0.3) 138 (3) 276 (5) 

Total mixture 48 (0.9) 365 (7) 728 (13) 

89% methane 85 (2) 639 (12) 1277 (24) 

1% H2S 1 (0.02) 7 (0.13) 14 (0.3) 

10% CO2 53 (1) 395 (7) 789 (15) 

Total mixture 139 (3) 1041 (19) 2080 (39) 

89% methane 270 (5) 2025 (38) 4051 (75) 

1% H2S 3 (0.06) 23 (0.4) 46 (0.8) 

10% CO2 167 (3) 1252 (23) 2503 (47) 

Total mixture 440 (8) 3300 (61) 6599 (123) 

5.11 Expansion/Contraction and Axial Growth 

Shawcor Spoolable Products have been engineered to significantly minimize axial strain 

as a result of pressure or temperature changes in operation. When pressurized, 

expansion and contraction of the product is governed by the mechanics of the 

reinforcement layer, and axial expansion due to temperature or pressure changes is 

minimal. Radial expansion will occur, but will be far less than in unreinforced 

polyethylene. 

When unpressurized, the product will display approximately the same amount of growth 

or contraction with temperature changes as unreinforced polyethylene. However, the 

low modulus and viscoelastic properties of the pipe allow it to shift and relax, thereby 

minimizing any loads exerted at end connections. Therefore, expansion loops and 

special consideration for end loads at termination points are not required*. 

Sudden temperature and pressure changes should be avoided. Gradual or stepped 

flow increases should be used on very hot or very cold days to allow for gradual 

temperature and pressure changes in the system. 

*When Shawcor Spoolable Products are used as free standing liners (see Section 6.5), 

it is required to terminate the liner pull underground and provide 7 meters of uncased 

buried length before bringing the pipe to surface. This ensures any expansion or 

contraction concentrated inside the existing failed line is restrained by ground friction 

06-1876 R4.3 



before coming to surface. The entry and exit points of the Shawcor Spoolable Product 

should also be protected as per Section 6.9. 

5.12 External Load and Internal Vacuum Capability 

When the pressure outside the pipe may exceed the pressure inside the pipe, the pipe’s 

ability to withstand collapse should be considered. External pressure arises from 

factors such as ground water pressure and the weight of soil above the pipe. Additional 

loads (such as the weight of water or live loads due to moving vehicles) must be 

considered if the pipe runs through a bore below a creek, roadway, etc. Internal 

vacuums may result from gravity flow of liquid down a slope when the pipeline is 

unpressurized. 

The ability of the products to withstand collapse is based on the total difference in 

pressure between the outside and inside of the pipe. When the external pressure 

exceeds the internal pressure, the difference can be considered as a net external 

pressure (or equivalently, a net internal vacuum). The net external pressure can be 

calculated as follows: 

P . 

external 

P 

Where 

net, external 

Pexternal 

Pinternal 

P is a negative number for an internal vacuum, thus increasing 

internal 

Shawcor Spoolable Products external pressure resistance for buried applications has 

been measured according to ASTM D2412 23 , in accordance with Clause 13.1.2.12 of 

CSA Z662-11. The maximum net external load that the pipe can withstand at 23˚C 

(73˚F) is 214 kPa (31 psi), when installed in backfill embedment material with a soil 

modulus of 1000 psi or greater. This includes most soils, with the exception of very 

fine-grained or organic soils such as muck and clay 24 . If the total combination of dead 

loads, live loads, and internal vacuum will exceed this, the pipe should be protected by 

a steel casing (see Section 6.9). 

When on the surface, there is no support from surrounding soil. Under these 

conditions, the pipe can withstand a net vacuum pressure of 101 kPa (14.7 psi) at 23˚C 

(73˚F), the maximum vacuum pressure that will be created due to gravity flow down 

slopes. 

Higher temperatures or long term exposure to liquid hydrocarbons may reduce the net 

external load that the pipe can withstand. Shawcor Spoolable Products are not 

23 ASTM D2412 Standard Test Method for Determination of External Loading Characteristics of Plastic Pipe by 

Parallel-Plate Loading 

24 The soil modulus is typically 1000 psi or greater for backfill embedment materials consisting of manufactured 

angular granular materials, coarse grained soils with little or no fines with a Proctor density greater than 70%, or 

coarse grained soils with fines with a Proctor density greater than 85%; the soil modulus is not typically greater than 

1000 psi for fine-grained or organic soils (muck, clay, etc.). 

06-1876 R4.3 



intended for subsea applications. In case of shallow water applications (e.g. 30 meters 

water depth) an application review can be conducted to determine feasibility. 

5.13 Thermal Conductivity 

Shawcor Spoolable Products thermal conductivity properties result from the properties 

of the polyethylene and the reinforcement materials. Accordingly, Shawcor Spoolable 

Products is a good thermal insulator with higher resistivity than metallic pipes. Table 15 

lists the thermal conductivity and resistivity values of the FPLP and FPLP HT products. 

FCLP will have somewhat higher values than listed below. Contact Shawcor for 

guidance. 

Table 15: FPLP and FPLP HT Thermal Conductivity and Resistivity 

Item Units Values Units Values 

Pipe Size 

2" FP150 

Wall 

Thicknes 

s 

3" 

FP150 

4" FP150 2" FP150 3" FP150 4" FP150 

mm n/a 9.14 11.30 in n/a 0.36 0.45 

R'-value m*K/W n/a 0.15 0.14 hr*ft*F/Btu n/a 0.25 0.25 

K'-value W/m*K n/a 6.80 6.97 Btu/hr*ft*F n/a 3.93 4.03 


Pipe Size 

Wall 

Thicknes 

s 

2" 

FP301/HT 

3" 

FP301/HT 

4" 

FP301/HT 

2" 

FP301/HT 

3" 

FP301/HT 

4" 

FP301/HT 

mm 7.75 9.91 12.57 in 0.31 0.39 0.50 

R'-value m*K/W 0.28 0.25 0.25 hr*ft*F/Btu 0.49 0.43 0.43 

K'-value W/m*K 3.53 4.04 4.07 Btu/hr*ft*F 2.04 2.33 2.35 


Pipe Size 

Wall 

Thicknes 

s 

2" 

FP601/HT 

3" 

FP601/HT 

4" 

FP601/HT 

2" 

FP601/HT 

3" 

FP601/HT 

4" 

FP601/HT 

mm 9.40 11.94 15.37 in 0.37 0.47 0.61 

R'-value m*K/W 0.47 0.41 0.42 hr*ft*F/Btu 0.81 0.71 0.72 

K'-value W/m*K 2.14 2.45 2.40 Btu/hr*ft*F 1.24 1.41 1.38 

6 Installation 

This section provides a general overview of the installation of FPLP. Please refer to the 

Installation Guide for further information. 

6.1 Field Services Support 

The Shawcor Field Services Department provides support services for the installation of 

Shawcor Spoolable Products, including training courses, project coordination services, 

06-1876 R4.3 



equipment rentals, onsite inspectors, and installation supervisors. Experienced 

managers and project coordinators are on call 24 hours per day, 7 days per week. 

Shawcor strives to ensure successful installation of its products on every project. 

Fitting installation equipment is available from Shawcor for sale or rental. Information 

on this equipment can be found in the Shawcor Installation Guide. In addition, Shawcor 

offers a variety of specialized installation accessories, including A-frames for carrying 

pipe reels, riser support trays, pull tools, custom cleaning pigs, moisture resistant Denso 

products, Polyken tape and sacrificial anode kits for cathodic protection. For more 

information on these accessories, see the Shawcor Installation Guide. 

6.2 Transportation 

Shawcor Spoolable Products are spooled onto 3.66-meter (12 ft)-diameter, custom 

engineered transport reels that have either 1.22-meter (4 ft) or 2.44-meter (8 ft) widths. 

Multiple reels can be transported on a standard flat-deck 

trailer, or a single reel can be transported on a special reel 

trailer. The reel capacities and weights are provided on the 

Product Data Sheets in the Appendix. 

Some reels can be disassembled in the field and stacked to 

reduce space requirements, which allows up to five times as 

many empty reels to fit on a truck deck. Please contact your 

Shawcor representative for more information and for Shawcor recommended 

disassembly procedure. 

Shawcor also offers a reel-less/coiled version of its products. 

The pipe is coiled in different lengths and is placed on to a 

wooden pallet for transportation. The coil is handled by using a 

Shawcor custom designed lifting device and is deployed using 

a Shawcor custom designed turn table. Please see the 

Shawcor Installation Manual and Technical Bulletin 06-4013 

for detailed information about the installation of reel-less/coiled 

pipe. 

6.3 Trenching 

Shawcor Spoolable Products can 

easily be un-spooled and placed into 

a trench or ditch. The pipe is 

handled and installed much like 

coiled HDPE pipe. The bending 

stiffness of the two is very similar, 

06-1876 R4.3 



but Shawcor Spoolable Products have less “memory” than HDPE pipe and will lay flat 

more readily. Soil condition and padding requirements for the pipe are typically similar 

to those for steel pipelines 

The flexibility of Shawcor Spoolable Products allows it to be easily threaded underneath 

existing lines for easy line crossings. This eliminates the need to cut the pipe and install 

extra fittings at line crossings. 

6.4 Plowing 

In a single-pass operation, a pipeline plow can trench, install the pipe and couplings, 

and cover the trench. This method is most beneficial when long continuous lengths of 

pipe are to be installed, and minimizes disturbance to the environment. Plowing also 

reduces the safety hazards associated with lifting and open trench installations. 

Recommended plow chute dimensions are available in the Shawcor Installation Manual. 

6.5 Insertion as a Freestanding Liner 

In situations where an existing pipeline has failed, Shawcor Spoolable Products can be 

pulled inside the failed pipeline as a remedial line. The pipe is a freestanding liner, and 

does not depend on the existing pipeline for any structural support. 

In pipeline remediation applications there must be adequate clearance between the 

outer diameter of the product and the inner diameter of the existing conduit. 

Table 16 shows the general compatibility of various conduits for insertion. The existing 

conduit must be free of obstructions that could damage the pipe (fittings, wax, scale, 

etc.). Excavating and removing any fittings is often a simple way to make a line 

compatible for insertion of Shawcor Spoolable Products, provided that enough pipe is 

removed to avoid bending the pipe tighter than the minimum radius for operation given 

in Table 12. Pipe must be suitably restrained at conduit exits. Refer to Section 5.11 for 

guidance. 

Shawcor fittings can be pulled along with the Shawcor Spoolable Products. A 

centralizing collar or sleeve may be used before each fitting to prevent the fitting from 

catching on weld beads or other discontinuities inside the conduit. The maximum 

allowable pull forces for Shawcor lines are shown in Table 17, and should not be 

exceeded with any type of pull tool. 

06-1876 R4.3 



Please see the Shawcor Installation Guide for information on pull tools available from 

Shawcor. 

Table 16: Conduit Compatibility for Shawcor Spoolable Products Insertion 

Conduit 3" Steel 4" Steel 6" Steel 

FPLP 

0.188 

" wall 

0.120 

" wall 

Sch 

. 40 

0.188" 

wall 

0.125 

" wall 

Sch. 

80 

Sch 

. 40 

0.188" 

wall 

0.156 

" wall 

0.125 

" wall 

2" 

FP301/HT 

P P PF PF PF PF PF PF PF PF 

2" 

FP601/HT 

N P PF PF PF PF PF PF PF PF 

3" FP150 N N P P P PF PF PF PF PF 

3" 

FP301/HT 

N N N P P PF PF PF PF PF 

3" 

FP601/HT 

N N N N P PF PF PF PF PF 

3” FC801 N N N N P PF PF PF PF PF 

4" FP150 N N N N N P P PF PF PF 

4" 

N N N N N P P PF PF PF 

FP301/HT 

4" 

FP601/HT 

N N N N N P P PF PF PF 

4” FC801 N N N N N P P PF PF PF 

N = Not compatible P = Compatible for pipe without fittings PF = Compatible for pipe with 

coupling fittings 

Note: The above table is based on 0.15” clearance on diameter between Shawcor Spoolable Products 

and the steel pipe weld bead, and a steel pipe weld bead allowance of 0.125”on diameter. 

Table 17: Maximum Allowable Pull Forces for Shawcor Spoolable Products 

Pipe Size 

(nominal) 

Maximum pull force 

(in) (kgf) (lbf) 

2 1000 2200 

3 2040 4500 

4 2720 6000 

6.6 Surface Installation 

Where permitted by the appropriate regulatory body, Shawcor Spoolable Products can 

be used above ground for permanent and temporary surface flowlines. Appropriate 

hazard control measures should be implemented in consideration of the elevated risk of 

injury or property damage inherent in surface installations. 

Non-metallic pipelines may be more susceptible to external damage than metallic 

pipelines. External forces, both during installation and during future disturbance or 

construction in the area, are additional potential causes of external damage to pipelines. 

06-1876 R4.3 



By their nature, surface pipelines 

are exposed to an uncontrolled 

environment and are exposed to 

greater risk of damage than buried 

pipelines. Examples of surface 

damage risks include sharp rocks, 

existing and growing foliage, fire, 

earth slides, flooding, vehicular 

traffic, weapon discharge, vandalism, and lightning strikes. 

Damage to or misuse of Shawcor products may result in uncontrolled release of the 

product being transported, which may result in serious injury or death. The energy 

stored in a pressurized compressible gas is significant, and may result in a highly 

explosive failure mode with the potential to cause significant property damage, serious 

injury, or death. 

Surface pipelines are subject to heating by solar radiation. Shawcor Spoolable 

Products with black jacket readily absorbs solar radiation and can reach excessively 

high temperatures very quickly when exposed to direct sunlight. This may be damaging 

and detrimental to the pipe. Shawcor Spoolable Products with white or grey jacket 

reduces solar heating and is required for surface lines. The operating temperature of 

the pipe, including the effect of solar heating, must be prevented from exceeding 60˚C 

(140˚F) for FPLP and FCLP and 82˚C (180˚F) for FPLP HT 

When used as a temporary surface line, Shawcor Spoolable Products can be unwound 

onto the surface and rewound back onto the reel. It is very important to adequately 

control the spooling and unspooling process to avoid damaging the pipe, such as by 

kinking, cutting, scraping, and abrading. Unspooling and re-using a damaged pipeline 

can result in pipeline failure. It is recommended to limit the re-spooling and re-using of 

Shawcor Spoolable Products up to a maximum of 5 deployment cycles (unspooling and 

re-spooling sets) per pipeline. 

Shawcor Spoolable Products are designed to vent gases that permeate from the 

transported fluid through the liner. Permeated gases travel via the annulus containing 

the reinforcement layers and are released at the fittings through a vent hole in each 

fitting. A fraction of the permeated gases may also be released across the outer jacket 

along the length of the pipeline. 

Operational experience has shown that unrestrained Shawcor Spoolable Products 

installed in surface line applications may experience undesirable pipe movement during 

operation. Excessive pipe movement may increase the risk of damage and/or reduced 

integrity. 

In order to reduce the risk of undesirable pipe movement, Shawcor recommends 

implementation of some measures during the pipeline installation. These measures 

06-1876 R4.3 



include hydro testing the line with a loose end, and securing the line at all corners or 

bends by trenching or sand bagging. Please refer to the Shawcor Installation Guide for 

further recommendations on the installation of surface lines. 

6.7 Support Spacing 

For elevated support of Shawcor Spoolable Products, a continuous tray which is wide 

enough to allow for the expected thermal expansion and snaking is recommended. 

Shawcor Spoolable Products may also be supported using individual (non-continuous) 

pipe supports or hangers, as long as the expected thermal expansion can be 

accommodated. The pipe should be allowed to rest in a rounded cradle, with a length 

approximately equal to or greater than the nominal diameter of the pipe being 

supported. Supports should have rounded edges that will not cut into the pipe. 

In order to prevent excessive sag between supports, Shawcor recommends spacing the 

supports no farther than the distances given in Table 18. 

Table 18: Recommended Pipe Support Spacing for Shawcor Spoolable Products 

Recommended maximum support spacing 

Liquid service 

Gas service 

(m) (ft) (m) (ft) 

2” 1.1 3.5 1.2 4 

3” 1.2 4 1.5 5 

4” 1.5 5 1.7 5.5 

6.8 Buoyancy and Pipe Weights 

Shawcor Spoolable Products will float in water or muskeg if not weighted or buried in a 

clay base. If conditions are suitable, the pipeline may be plowed into muskeg without 

weighting. The suitability of the conditions may be evaluated based on existing 

pipelines in the area and consultation with Shawcor or plow installation contractors. 

If there is a concern that the pipe may float, the pipe can be weighted during installation. 

The weights should not have sharp edges that could point-load or cut the protective 

jacket of the product. Sand-filled saddlebag weights are recommended. 

When weights are used, it is extremely important that the pipe is handled and lowered 

into the ditch by lifting on the weights directly. Lifting on the pipe may cause the pipe to 

kink or be damaged by the weights. 

The following formulas can be used to calculate the pipe buoyancy per unit length (note 

that some unit conversions may be required). To keep the pipe submerged, the sand 

bag weight per unit length must be slightly more than the buoyancy force per unit 

length. Note that there will also be a buoyancy force on the sand bags themselves, 

which is compensated for in the formulas below. 

06-1876 R4.3 



Pipe cross - sectional area OD 

2 

 

4 

Weight of fluid displaced per unit length of pipe Pipe cross - sectional area Fluid density 

Net buoyancy per unit length of pipe 

Weight of fluid displaced per unit length - Pipe weight per unit length 

Note that the pipe will sink if the net buoyancy is less than 0. 

Submergedsand bag weight requiredper unit length of 

pipe 

Net buoyancy per unit length of 

pipe1.1 

Shawcor recommends multiplying by 1.1 to ensure the pipeline is adequately weighted 

to remain submerged. 

Weight of fluid displacedby sand bag Volumeof fluid displacedby sand bag 

Fluid density 

Submergedweight of sand bag Weight of sand bag in air - Weight of fluid displacedby sand bag 

Submerged weight of sand bag 

Sand bag spacing 

Submerged sand bag weight required per unit length of pipe 

Note: The sand bag spacing should be small enough to prevent the unrestrained pipe between 

sand bags from rising too far. 

The recommended dry sand bag weight is shown in Table 19 for each type of Shawcor 

Spoolable Products. These results are based on muskeg with a fluid density of 1121 

kg/m 3 (70 lb/ft 3 ). 

Table 19: Recommended Sand Bag Weight for Weighting Shawcor Spoolable Products 

Pipe weight 

per length 

Pipe OD 

Recommended 

Weights a 

Recommended 

Maximum 

Spacing 

(kg/m) (lbs/ft) (mm) (in) (kg) (lb) (m) (ft) 

FP15 3” 2.5 1.7 95 3.75 100 220 8.9 29.2 

0 4” 4.0 2.7 122 4.80 100 220 5.3 17.4 

2” 1.7 1.1 69 2.73 27 60 5.2 17.1 

FP30 

3” 3.0 2.0 97 3.80 100 220 9.1 29.9 

1/HT 

4” 4.9 3.3 124 4.89 100 220 5.6 18.4 

2” 2.5 1.7 73 2.86 27 60 5.9 19.4 

FP60 

3” 4.3 2.9 101 3.96 100 220 10.3 33.8 

1/HT 

4” 6.9 4.6 130 5.11 200 440 12.1 39.7 

FC80 3” 4.3 2.9 101 3.96 100 220 10.3 33.8 

1 4” 6.9 4.6 130 5.11 200 440 12.1 39.7 

a 

Dry sandbag weight. These weights already include the recommended safety factor of 1.1 to 

ensure the pipe remains submerged. 

06-1876 R4.3 



6.9 Crossings 

Shawcor Spoolable Products are well-suited to a variety of 

crossings. Design of road, railway, and highway crossings 

must be in accordance with the regulations of the governing 

body, local authority, railway company, or highway 

department. Where applicable, depth of cover shall not be less 

than the applicable requirements listed in Table 4.9 of CSA 

Z662 Clause 4.11. 

Shawcor recommends casings for: 

Crossings of all public roads, highways and railways. 

Crossings of lease roads and general areas where only light weight traffic is 

expected (cars and pickup trucks) wherever the minimum burial depth is 

shallower than 1.2 meters (4 ft). 

Crossings of lease roads and general areas where heavy weight traffic is 

expected (heavy trucks, cranes) wherever the minimum burial depth is shallower 

than 2 meters (6.6 ft). 

Each bore is unique and therefore it is the responsibility of the installation contractor to 

assess the soil conditions and the need for casing (see Section 5.12). Steel casings 

may be required by regulations. 

Please see the Installation Guide for information on installations involving crossings. 

Centering spacers are not required for isolating Shawcor Spoolable Products from the 

metal casing. Allowing the pipe to snake inside the casing can accommodate minor 

thermal length changes of the pipeline in the casing. Pipe must be suitably restrained at 

conduit exits. Refer to Section 5.11 for guidance. 

Clause 13.1.4.7 of CSA Z662 requires protection to be provided for the pipe at entry 

and exit points of the casing to prevent unacceptable shear and bending loads that 

could develop from settlement and embedment consolidation. A well-compacted trench 

bottom and bedding, exit and entry sand bagging, or other suitable protection should be 

provided. Cathodic Protection (CP) of the steel casing is not required unless requested 

by the local authority, railway company or highway department. If it is required, CP can 

be provided by installing sacrificial anodes on the casing. 

6.10 Risers 

Shawcor Spoolable Products may be terminated underground with either a flange or 

weld neck fitting. Alternatively, it can be brought to surface and supported by a metal 

support tray (riser support) mounted onto pilings. The purpose of the riser support is to 

prevent unnecessary shear or tensile loads on the pipe that could be caused by settling 

of backfill and earth movement. Sand bagging or other suitable protection should be 

06-1876 R4.3 



provided at the horizontal transition of the pipe to the riser support. For further 

information regarding risers see the Installation Guide. 

The aboveground portion of the riser must be covered with insulation or white Polyken 

tape. Shawcor Spoolable Products 

should be protected from mechanical 

damage similar to other piping 

materials above ground, depending 

on expected hazards in the area. 

Shawcor Spoolable Products is a 

ductile material and can withstand 

reasonable impact even at low 

temperatures. 

6.11 Tracer Wire 

Shawcor Spoolable Products are non-metallic. Therefore, tracer wire is required for 

buried installations to allow for future location of the pipe. The tracer wire should be 

installed simultaneously with the pipe and checked for electrical continuity immediately 

after installation. The wire termination points should be secured and clearly marked at 

readily accessible locations above ground. 

6.12 Cold Temperature Installation 

Shawcor Spoolable Products can be installed in cold, winter 

conditions, provided that precautions are taken. The 

precautions are based on the temperature of the pipe; therefore, 

wind-chill conditions do not apply. Consideration must also be 

given to the difference between the ambient temperature and 

the actual pipe temperature. Shawcor Spoolable Products have 

very low thermal conductivity, which means that it cools down or heats up very slowly. 

As a result, if pipe is stored outside overnight, the pipe may be much cooler than the 

ambient temperature the next day. 

When necessary, the entire reel of pipe must be pre-heated to a temperature above - 

25˚C (-13˚F) prior to deploying (unspooling) or plowing. Please refer to the Shawcor 

Installation Guide for recommended precautions for installing pipe at temperatures 

below freezing. 

6.13 Heat Tracing 

Shawcor Spoolable Products may be heated by means of a heat tracer wire to prevent 

freezing. However, the heat tracer must be separated from the pipe by an insulation 

barrier to prevent concentrated hot spots or over-heating of the jacket. 

Shawcor recommends a sandwich type insulated barrier with an insulation/heattrace/insulation 

configuration, as shown in Figure 7. Because the pipe jacket material is 

06-1876 R4.3 


The linked image cannot be displayed. The file may have been moved, renamed, or deleted. Verify that the link points to the correct file and location. 


a very poor thermal conductor, concentrated hot spots will appear directly below the 

heat tracing wire if an insulated barrier is not used. 

The maximum operating temperature of FPLP and FCLP is 60 ° C (140 ° F). Therefore, it is 

very important to select the insulation thickness and the amount of heat tracing per unit 

length of pipe accordingly. 

Figure 7: Sandwich Type Insulated Barrier Configuration 

6.14 Fitting Installation 

Shawcor proprietary fittings can be 

installed in the field in 20 to 30 

minutes by an experienced 

technician, and must be installed by 

certified technicians with specialized 

tools and equipment. Shawcor 

works with contractors and 

customers to provide certification training so that certified third-party contractors can 

provide the fitting installation service. Alternatively, Shawcor can provide certified fitting 

installation technicians. Fitting installation equipment is engineered and designed 

specifically for Shawcor Spoolable Products, and is available from Shawcor on a rental 

basis. 

6.15 Cathodic Protection 

Shawcor Spoolable Products are corrosion resistant and do not require cathodic 

protection. Wherever regulations require cathodic protection for buried metallic fittings, 

Shawcor can make available ribbon anode kits tailored for Shawcor fittings. Further 

information is available in Section 3.5. 

06-1876 R4.3 



6.16 Tying into Steel – Welding 

Shawcor has designed a weld neck fitting to accommodate tying into existing steel lines, 

or steel risers. This fitting eliminates the need for a buried flanged connection. See 

Section 3.3 for more details on the materials used in weld neck fittings. 

6.17 Tying into Plastic 

Transitions from Shawcor Spoolable Products to poly or other pipeline materials can be 

achieved by using transition fittings designed for the other pipeline material. These 

fittings can be connected to Shawcor fittings by means of welding or standard flanged 

connections as appropriate. For example, a poly-to-steel transition fitting can be welded 

to a Shawcor weld neck fitting to form a poly-to-Shawcor Spoolable Product transition 

fitting. 

6.18 Field Pressure Testing of New Pipelines 

Shawcor Spoolable Products are designed to accommodate the pressure-testing 

requirements specified by regulatory standards and codes. Due to the safety factors 

built into the pipeline design, there is no need to upgrade to a higher pressure-rated 

pipe if testing is required above the stated MAOP. Field pressure testing requirements 

and recommendations for Shawcor Spoolable Products depend on whether the pipeline 

is a new installation or a tie-in or repair job. 

Shawcor recommends that new pipelines that have not been placed in operation be 

subjected to a hydrostatic hold test at 1.25 x MAOP as shown in Table 20. Refer to 

Section 8.6 for hydrostatic testing of pipelines that have already been placed in 

operation. 

Table 20: New Pipeline Hydrostatic Test Pressures and Durations 

Pressure Rating 

Flexpipe Systems 

Grade 

Product Line 


(FPLP) 

FlexPipe Linepipe High 

Temperature (FPLP 

HT) 

FlexCord Linepipe 

(FCLP) 

2,068 kPa 

(300 psi) 

5,171 kPa 

(750 psi) 

10,342 kPa 

(1,500 psi) 

13,790 kPa 

(2,000 psi) 

150 301 601 801 

2,586 kPa (375 

psi) / 24 hrs. 

Hydrostatic test pressure and duration 

6,467 kPa (938 


6,467 kPa (938 


12,928 kPa 

(1,875 psi) / 24 

hrs. 

12,928 kPa 

(1,875 psi) / 24 

hrs. 

17,237 kPa 

(2,500 psi) / 8 

hrs. 

Check with local regulations to ensure required hydrostatic test pressures are met. 

Shawcor requires monitoring the system carefully to ensure that the pipeline 

06-1876 R4.3 



does not exceed 1.5 x MAOP at any point along the pipeline including low points 

at any time during the hydrostatic test. 

Suggested procedures for pressure testing new pipelines are given in the Shawcor 

Installation Guide. 

Pressure test failures involving compressible media such as air result in the 

sudden uncontrolled release of a great deal of energy, with the potential for 

property damage, personal injury, or death. For safety reasons, pressure testing with 

a gas medium is acceptable for test pressures up to 2900 kPa (420 psi), provided that 

the below conditions are considered. Pressure testing with air or gas above 2900 kPa 

(420 psi) is at the discretion of the engineering resources of the pipeline operating 

company, but must also consider the conditions listed below: 

It is not prohibited by local regulations or standards; 

Appropriate precautions are taken to protect the pipeline from damage and 

minimize the risks associated with a pressure test failure. 

Under no circumstances will Shawcor be liable in any way for any loss, damage or 

injury of any kind (whether direct, consequential, punitive or otherwise) incurred as a 

result of the use of a gas medium for pressure testing. 

To minimize the potential risk of injury or property damage in the unlikely event of a 

pressure test failure, a relatively incompressible liquid such as water is recommended 

as the pressurizing medium. Methanol is compatible with Shawcor Spoolable Products 

and is commonly used as an additive to prevent water from freezing at low 

temperatures. 

Where new Shawcor pipelines have been hydrotested in sections or require repair after 

a successful hydrotest prior to operation, retesting of the entire pipeline system is not 

required after tying in provided: 

 

Pipe sections used for tie-ins, repairs, or replacement are pre-tested as per Table 

20 where required by local regulations or standards. 

Joints of the tie-ins, repairs, or replacements are left exposed as the pipeline is 

brought into service and visually monitored for leaks for at least four hours, at the 

highest available operating pressure. 

Note: Pressure testing pipelines to a pressure greater than MAOP is generally only 

appropriate after original construction and prior to a pipeline being put in operation. 

06-1876 R4.3 



7 Accessories 

The following sections cover some of the tools and equipment that are commonly used 

for the installation of Shawcor Spoolable Products. For more detailed information on 

tools and accessories, please refer to the Shawcor Installation Guide. 

7.1 A-frames 

A-frames are steel structures used to hold the reel while the pipe is being deployed and 

are available on a rental basis. Please contact your Shawcor representative for more 

information. 

The following reference drawings are available from Shawcor upon request: 

8FT A-Frame Drawing 

4FT A-Frame Drawing 

7.2 Turn Table and Lifting device for Coiled pipe 

Turn tables and lifting devices are steel structures required to handle and deploy coiled 

Shawcor Spoolable Products and are available either on a rental basis or drawings can 

be provided upon request. Please contact your Shawcor representative for more 

information. 

7.3 Riser Support Trays 

Riser trays support the pipe as it comes out of the ground to connect to surface pipe 

(see Section 6.10). Shawcor offers 45°, 90° and S-bend riser support trays for each 

pipe size, as well as hardware for securing the pipe to the tray. 

The following reference drawings are available from Shawcor upon request: 

45° Riser Drawing 

90° Riser Drawing 

S-bend Riser Drawing 

7.4 Pull Tools 

Shawcor offers several types of pull tools for the installation of Shawcor Spoolable 

Products. Please refer to the Installation Guide for further information on the available 

pull tools. 

7.5 Sacrificial Anodes 

Shawcor anode kits consist of a magnesium ribbon anode connected to a copper lead 

wire, along with a roll of cloth tape to fix the anode to the pipe and a stainless steel hose 

clamp to secure the lead wire to the fitting. Please refer to Section 3.5 for more 

information on performance and installation. 

06-1876 R4.3 



8 Operations 

8.1 Startup 

In the case of large temperature differences between the pipeline and the conveyed 

fluid, startup procedures for Shawcor Spoolable Products should include a gradual or 

stepped flow increase to allow for gradual temperature and pressure changes in the 

system. 

8.2 Pigging 

Shawcor Spoolable Products are suitable for pigging. However, Shawcor Spoolable 

Product fittings have an ID that is smaller than the ID of the pipe. To ensure proper 

pigging, the use of a medium-density foam bullet pig, or a Shawcor disc (cleaning) pig is 

required. Use of a pig not approved by Shawcor could result in the pig becoming stuck 

in a fitting. Shawcor supplies tags for installation on risers to warn operators of the 

temperature limitations of the pipe and pigging restrictions of the fittings. 

Shawcor recommends medium-density (5 lb) foam bullet pigs for dewatering and 

Shawcor polyurethane disk pigs for removing wax build-up. The foam bullet pigs are 

also available with a polyurethane coated tip, which provides protection against damage 

during pigging operations. Ball pigs and brush pigs must not be used. 

Shawcor polyurethane disk pigs are designed specifically for 

Shawcor Spoolable Products, and offer more aggressive 

cleaning. However, a greater pressure differential is required 

to move them through fittings, and they require the presence 

of some liquid in the pipeline to provide lubrication. 

Polyurethane pigs are available from Shawcor in a variety of 

durometers to suit different pigging requirements (see Table 21). 

Table 21: Custom Polyurethane Disk Pigs 

Size Durometer Color 

2” 

80 Yellow 

70 Green 

80 Yellow 

3” 

70 Green 

60 Purple 

4” 

70 Green 

60 Purple 

Shawcor polyurethane pigs cannot be used for threaded fittings, and are not 

recommended for any T fittings or welded thin-wall elbows. They may be used with 

schedule 40 or 80 welded elbows (45° or 90°). If a pigging program is required on a 

Shawcor line joining another line, Shawcor recommends a y-lateral joint (see Section 

3.1), oriented to allow the pig to enter the joint from one of the arms and exit from the 

06-1876 R4.3 



bottom of the Y. Pig launchers must be sized to accommodate the Shawcor pig 

dimensions as indicated in Table 22. 

Table 22: Shawcor Pig Dimensions for Shawcor Spoolable Products 

Shawcor 

Shawcor 

Pipe Size 

polyurethane pig polyurethane pig 

(nominal) 

diameter 

length 

Required pressure 

differential a 

(in) (mm) (in) (mm) (in) (kPa) (psi) 

2” 57.2 2.25 101.6 4.0 138 20 

3” 82.6 3.25 139.7 5.5 207 30 

4” 104.9 4.13 165.1 6.5 276 40 

a 

Required pressure differential is approximate and assumes the line is lubricated. 

8.3 Hot Oiling 

Shawcor Spoolable Products can be hot oiled. The maximum allowable operating 

pressure and temperature of Shawcor Spoolable Products listed in Section 5.2.1 must 

not be exceeded at any time during the hot oiling procedure. Contact Shawcor to 

discuss the details of your hot oiling program. 

8.4 Static Electricity 

Standard operating and maintenance procedures for handling non-conductive pipe and 

dissipation of static electricity apply when working with Shawcor Spoolable Products. 

Static charge on a plastic pipe can be generated by friction during the physical handling 

of the pipe in storage, shipping, installation, and repairing operations. Also, flowing gas 

in an operational plastic pipe containing particulate matter in the form of scale, rust, or 

dirt can generate static electricity. Other causes of static charge include gas flow 

disrupters such as pipe elbows, valves, neck-downs, and leaks. 

Discharge of static electricity in the presence of a flammable gas-air mixture may cause 

an explosion or fire and result in property damage and/or personal injury. When 

conditions exist such that a flammable gas-air mixture may be encountered and static 

charges may be present, all company (pipeline operator, utility, contractor, etc.) 

procedures for static electricity safety and control should be followed, including 

procedures for discharging static electricity and personal protection. Information on 

handling static electricity in plastic pipelines is available in Occupational Safety and 

Health Administration Hazard Information Bulletin dated September 30, 1988. 

8.5 Secondary Excavations 

Excavation near installed pipe is the most common risk to the integrity of operational 

Shawcor Spoolable Products due to the potential for external damage. The preferred 

method for excavating buried pipe is hydro-excavation (hydrovac). 

The following practices are recommended to minimize the risk of external damage to 

the pipe: 

06-1876 R4.3 



Identify the location of the Shawcor Spoolable Product using the tracer wire installed 

with the pipe. 

Follow hydro-excavation procedures that comply with industry best practices for 

excavation of thermoplastic piping, including: 

o Use of protective tips (eg rubber, neoprene, etc) on spray nozzles and suction 

hoses. 

o Use of multi-jet nozzles with diverging spray patterns; not oscillating, rotating, or 

converging pattern nozzles. 

o Continuous movement of the spray wand while excavating. 

o A distance of at least 12” between the spray nozzle and the pipe. 

o Spray pressures as low as practical and not above 1500 psi. 

o Water temperatures below 40˚C (104˚F). 

Inspect the exposed pipe thoroughly after the excavation is complete. 

Support the weight of exposed pipe at intervals of not greater than 6m (20 feet). 

Take appropriate precautions to avoid impact or sustained pressure from sharp or 

heavy objects. 

Exercise care during any mechanical excavation near Shawcor Spoolable Products. 

Inspect all exposed Shawcor Spoolable Products for external damage prior to 

backfilling. 

Replace any sections of Shawcor Spoolable Products that are damaged during 

excavation. 

Use proper backfill procedures. 

8.6 Field Pressure Testing of Existing Pipelines 

When a cut out is replaced, a failure is repaired or a tie-in is connected to a previously 

operating pipeline, the integrity of the new pipe section and the connections used to join 

or repair the pipeline is ensured as follows: 

Pipe sections used for tie-ins, repairs, or replacement are pre-tested as per Table 

20 where required by local regulations or standards. 

Joints of the tie-ins, repairs, or replacements are left exposed as the pipeline is 

brought into service and visually monitored for leaks for at least four hours, at the 

highest available operating pressure. 

Note: Pressure testing pipelines to a pressure greater than MAOP is generally only 

appropriate after original construction and prior to a pipeline being put in operation. 

8.7 Shutdown Procedures 

Shawcor Products containing high pressure gas or CO2 (including multiphase or liquid 

content, water, oil, CO2 dense phase, etc) have the unique characteristic of having a 

high rate of gas permeation that is typical of a gas service. Accordingly, it is 

recommended to depressurize these lines slowly, at a rate similar to what is typical for 

gas pipelines. This is to allow enough time for the gas that has permeated through the 

06-1876 R4.3 



liner and into the annular space to vent out to the atmosphere via the vent hole provided 

on each fitting, thus reducing the external pressure that may result in a liner collapse. 

It is recommended to slowly depressurize the pipeline (i.e. no more than 100 psi per 

hour) to 50 psi and hold for 24 hours to allow the permeated gas to vent out. The same 

recommendation applies to gas pipelines rich in CO2. 

9 Reliability 

9.1 History 

As of 2013, over 16 million meters (53 million feet) of Shawcor Spoolable Products and 

70 thousand fittings have been installed throughout Western Canada, the United States, 

and internationally. Shawcor Spoolable Products are currently in service carrying a 

wide range of liquid and gas media, at various operational temperatures and pressures 

up to and including the published limits. A number of different installation methods have 

been employed over a wide range of climate, soil, and terrain conditions. 

Shawcor Spoolable Products continuously meet the extensive challenges of operation 

in demanding applications, and have earned an excellent record as high quality and 

dependable products in the field. This has been demonstrated through numerous 

evaluations of operating pipelines in a variety of applications. 

9.2 Leak Testing 

Approximately 53 km (174,000 feet) of in-service gas gathering pipelines, including over 

140 coupling and end fittings, have been tested for gas leaks by an independent 

emission detection company. No gas was detected along any of the pipelines and only 

trace amounts of gas were detected at the surface end fitting vent holes, as expected. 

9.3 Cut-outs 

In order to satisfy Canadian regulatory requirements, Shawcor has cut out and tested a 

number of pipe samples after two years of service to validate the long-term performance 

of Shawcor Spoolable Products. In all cases, destructive burst testing results of the 

cut-out samples exceeded the minimum acceptable levels. In addition, detailed 

dissections were carried out and none of the samples showed any indications of 

degradation. The results of the destructive burst testing are found in Figure 8. These 

results demonstrate that there is no degradation of pipe performance after two years of 

service. 

06-1876 R4.3 



5000 

4500 

Sample Burst Test Results 

Burst pressure at time of manufacture 

Burst pressure after service 

4000 

Burst Pressure (psi) 

3500 

3000 

2500 

2000 

1500 

1000 

Test Pressure 

(937 psi) 

500 

0 

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 

Sample Number 

Figure 8: Cut-out Burst Test Results 

MAOP 

9.4 Reliability Management 

The reliability of Shawcor Spoolable Products is dependent on the proper engineering, 

installation and operation of the pipeline system. The following steps are crucial in 

assuring the pipeline system will operate as intended: 

 

Material Selection: 

o Shawcor offers an application evaluation process for all pipeline systems. 

o Make certain the pipeline end user provides accurate operating 

parameters to Shawcor for assessment. 

o Ensure Shawcor provides project specific recommendations regarding 

selection of the best product, optimal system design, and operational 

considerations for the intended application. 

 

Pipeline Installation: 

06-1876 R4.3 



o Shawcor offers an Installation Guide for use by pipeline end users and 

third party installation contractors. 

o Make certain the installation crew is in compliance with Shawcor 

comprehensive installation program documented by a currently valid 

individual ticket number certification. 

o Ensure the installation of risers and other transition locations are properly 

supported per the Installation Guide and best engineering practice. 

 

Operational Considerations: The following considerations are important to 

maintaining the integrity of Shawcor Spoolable Products. 

o Ensuring the pipeline is being operated within the parameters provided 

during the application evaluation. Contact Shawcor to discuss any 

observed variances. 

o Ensuring liquids do not freeze inside of the pipe. 

o Avoiding fluid hammer due to rapid opening or closing of valves, or water 

surge due to abrupt pump starts and stops etc. 

o Following Shawcor recommendations regarding hot oiling and chemical 

treatment. 

o Ensuring an adequate pigging program is in place to avoid wax build up. 

o Utilizing appropriate hazard controls for prevention of external damage to 

surface pipelines. The most significant risk to the integrity of Shawcor 

Spoolable Products is external damage. The risk of external damage 

during operation most commonly arises due to excavation near installed 

Shawcor Spoolable Products. Recommended practices to minimize this 

risk are given in Section 8.5. 

9.5 Integrity Verification 

Many operators elect to limit their integrity verification activities to an initial pressure test 

after installation. Some operating companies may choose to exceed normal industry 

practice by incorporating one or more of the activities listed below into their integrity 

verification activities, in line with their risk management strategies. It would typically be 

appropriate for an operating company to make use of the options below. 

Integrity verification options for Shawcor Spoolable Products include: 

Visual inspection of jacket. Where pipe is exposed above surface the jacket can be 

inspected for discoloration that may indicate UV degradation. 

Visual inspection for corrosion of metallic fittings. The external condition of a fitting 

can be inspected by removing the denso tape. The condition of the interior coating 

of a flanged fitting can be inspected visually after unbolting the flanged 

connection. It is recommended that new gaskets and denso tape be used during 

reassembly. 

Gas detection testing. Fittings can be checked for leaks during operation using gas 

detection equipment. Shawcor has performed this type of inspection on numerous 

buried and surface fittings in Canada in accordance with requirements of the local 

regulatory authority (see Section 9.2). 

06-1876 R4.3 



Integrity Pressure Testing. To verify the integrity of the pipe after a period of 

operation a pressure test may be conducted over a duration of 4 hours at the lesser 

of either the maximum allowable operating pressure or 1.25 times the normal 

operating pressure. 

Cut-out testing. A method for confirming pipe integrity is to remove a sample of pipe 

approximately 10-15 feet in length and have it tested. Shawcor offers integrity 

assessment testing and analysis of such samples. Refer to Section 8.6. 

The extent and frequency of the integrity testing program is to be determined by the 

operating company on a case by case basis, as required by pipeline modifications 

implemented to the equipment, service type, and/or operating conditions. 

06-1876 R4.3 



10 Appendix 

Product Data Sheets 

06-1876 R4.3 


Composite Production Systems 

PRODUCT DATA BULLETIN 



FP150 

FP301 

FP601 

Maximum Operating Pressure @ 60°C or 140°F 

2,068 kPa / 300 psi 5,171 kPa / 750 psi 10,342 kPa / 1,500 psi 

Nominal Size 3" 4" 2" 3" 4" 2" 3" 4" 

Outside Diameter Metric (mm) 95 122 69 97 124 73 101 130 

Imperial (inches) 3.75 4.80 2.73 3.80 4.89 2.86 3.96 5.11 

Inside Diameter Metric (mm) 77 99 54 77 99 54 77 99 


Weight Metric (kg/m) 2.6 4.0 1.7 3.0 4.9 2.4 4.3 6.9 

Imperial (lbs/ft) 1.7 2.7 1.1 2 3.3 1.6 2.9 4.6 

Min. Bend Radius (operational) Metric (m) 1.8 2.1 1.2 1.8 2.1 1.2 1.8 2.1 

Imperial (ft) 6 7 4 6 7 4 6 7 

Length / Reel* Metric (m) 760 750 1100 760 735 1100 700 570 

Imperial (ft) 2495 2460 3610 2495 2410 3610 2300 1870 

Reel Diameter Metric (m) 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 

Imperial (ft) 12 12 12 12 12 12 12 12 

Reel Width Metric (m) 1.2 2.4 1.2 1.2 2.4 1.2 1.2 2.4 

Imperial (ft) 4 8 4 4 8 4 4 8 

Reel Weight – Full* Metric (kg) 2760 4283 2635 3100 5013 3450 3820 5493 

Imperial (lbs) 6100 9430 5800 6800 11030 7600 8400 12130 

Reel Weight – Empty Metric (kg) 680 1150 680 680 1150 680 680 1150 

Imperial (lbs) 1500 2530 1500 1500 2530 1500 1500 2530 

Fitting Outside Diameter** Metric (mm) 110.7 139.7 80.5 110.7 139.7 85.1 115.6 144.3 


Fitting Inside Diameter** Metric (mm) 63.5 85.9 44.5 63.5 85.9 44.5 63.5 85.9 


Flow Coefficients 


Darcy Weisbach e=0.000005 ft or 0.0015 mm 

Manning 0.009 

*Length and reel weights are approximate as they may vary depending on the manufacturing run. 

**Fitting dimensions do not include O.D. of flange provided for Flanged End Fittings. 

**Fitting O.D. and I.D. apply to Flanged End, Weld-neck and Pipe-to-Pipe Coupling fittings. 

Product data is subject to change without notice. Shawcor's products are patented by US Patents 6,889,716, 6,902,205, 7,946,629 B2 

and 8,042,252 B2 by Canada Patents 2,513,506, 2,513,468 and 2,562,823 and by European Patent 1592908. Additional patents are pending. 

©ShawCor Ltd., 2015. 

Rev #003: 11/17/2015



FlexPipe Linepipe High Temperature (FPLP HT) 

FlexPipe Linepipe High Temperature (FPLP H 

FP301 HT 

FP601 HT 


Nominal Size 2" 

5,171 kPa / 750 psi 

3" 4" 2" 

10,342 kPa / 1,500 psi 

3" 4" 

Outside Diameter Metric (mm) 69 97 124 73 101 130 

Imperial (inches) 2.73 3.80 4.89 2.86 3.96 5.11 

Inside Diameter Metric (mm) 54 77 99 54 77 99 


Weight Metric (kg/m) 1.7 3.0 4.9 2.4 4.3 6.9 

Imperial (lbs/ft) 1.1 2.0 3.3 1.6 2.9 4.6 

Min. Bend Radius (operational) Metric (m) 1.2 1.8 2.1 1.2 1.8 2.1 

Imperial (ft) 4 6 7 4 6 7 

Length / Reel* Metric (m) 1120 760 735 1120 700 570 

Imperial (ft) 3675 2495 2410 3675 2300 1870 

Reel Diameter Metric (m) 3.7 3.7 3.7 3.7 3.7 3.7 

Imperial (ft) 12 12 12 12 12 12 

Reel Width Metric (m) 1.2 1.2 2.4 1.2 1.2 2.4 

Imperial (ft) 4 4 8 4 4 8 

Reel Weight – Full* Metric (kg) 2635 3100 5013 3450 3820 5493 

Imperial (lbs) 5800 6800 11030 7600 8400 12130 

Reel Weight – Empty Metric (kg) 680 680 1150 680 680 1150 

Imperial (lbs) 1500 1500 2530 1500 1500 2530 

Fitting Outside Diameter** Metric (mm) 8105 110.7 139.7 85.1 115.6 144.3 


Fitting Inside Diameter** Metric (mm) 44.5 63.5 85.9 44.5 63.5 85.9 





Manning 0.009 







Rev #003: 11/17/2015



FlexCord Linepipe (FCLP) 

FlexCord Linepipe (FCLP) - 800 ANSI 

FC801 


13,790 kPa / 2,000 psi 

Nominal Size 3" 4" 

Outside Diameter Metric (mm) 99 128 

Imperial (inches) 3.91 5.03 

Inside Diameter Metric (mm) 77 99 


Weight Metric (kg/m) 5.1 8.6 

Imperial (lbs/ft) 3.5 5.8 

Min. Bend Radius (operational) Metric (m) 1.8 2.1 

Imperial (ft) 6 7 

Length / Reel* Metric (m) 575 485 


Reel Diameter Metric (m) 3.7 3.7 


Reel Width Metric (m) 1.2 2.4 


Reel Weight – Full* Metric (kg) 3817 7036 

Imperial (lbs) 8415 15479 

Reel Weight – Empty Metric (kg) 680 1150 

Imperial (lbs) 1500 2530 

Fitting Outside Diameter** Metric (mm) 115.6 144.3 


Fitting Inside Diameter** Metric (mm) 63.5 85.9 





Manning 0.009 







Rev #003: 11/17/2015


Head Office and Manufacturing Facility 

3501 - 54 th Avenue S.E. 

Calgary, Alberta 

Canada T2C 0A9 

Tel: 403-503-0548 

Fax: 403-503-0547 

Manufacturing Facility 

195, 1820 – 100 Ave. NE 

Calgary, Alberta 

Canada T3J 0P7 

Tel: 403-503-0548 

Fax: 403-567-5452 

U.S. Head Office 

1155 Dairy Ashford, Suite 450 

Houston, Texas 

United States 77079 

Tel: 281‐670‐2105 

Fax: 281‐670‐2164 

Canada Solution Centers 

Estevan, SK 

Tel: 306-402-7196 

Grand Prairie, AB 

Tel: 780-882-1213 

U.S. Deployment Centers 

Canadian, TX 

Tel: 432-685-0865 

Myton, UT 

Tel: 970-243-0067 

Bakersfield, CA 

Tel: 970-243-0067 

Big Wells, TX 

Tel: 281-670-2108 

Ennis, TX 

Tel: 281-670-2108 

Australia Solution Center 

1517 Lytton Road 

Hemmant, QLD 

Australia 4174 

Mobile: +61 439390081 

Asia Pacific 

101 Thomson Road, 

#17-01 and 02, 

United Square 

Singapore 307591 

DID: +65-6477-5331 

Mobile: +65-8522-8729 

U.S. Solution Centers 

Grand Junction, CO 

Tel: 970-243-0067 

Midland, TX 

Tel: 432-685-0865 

Big Wells, TX 

Tel: 956-857-4665 

Dickinson, ND 

Tel: 970-243-0067 

06-1876 R4.3

TECHNICAL MANUAL

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