FlexPipe Systems’ products, systems and processes have been stringently developed to minimise field failures and produce quality line pipe solutions for varied applications including flow lines, gathering lines for transfer of oil emulsion, sour gas, sweet gas, water, and gases or liquids with carbon dioxide, salt water disposal, water injection and other enhanced oil recovery injection.
Industry standards
FlexPipe Linepipe products have been accepted as AS2885-compliant and designed in accordance with the Canadian Standard CSA Z662, the Recommended Practice RP 15S and the applicable requirements of API 17J.
Flexpipe Systems’ rigorous internal qualification testing is conducted above and beyond these standards to ensure customer installation and application requirements are met.
Testing programs
At Flexpipe Systems’ state-of-the-art testing laboratory in Calgary, Canada, products are subjected to a wide variety of in-house tests to ensure high reliability and durability. Pipe performance is tested under high and cycling pressure and temperature; high aromatic hydrocarbon exposure; high impact, pull force and external loads; decompression; and, repeat reverse bending to simulate re-coiling and re-use.
Additional testing is executed to determine product long term pressure rating, minimum bend radius, thermal and pressure expansion and rates of gas permeation and venting.
Reliability assurance
Flexpipe Systems ensures the reliability of its products through a strict assurance process.
- A robust application review process
- Continual product range expansion: FlexPipe Systems launched FlexPipe Linepipe High Temperature for higher temperature applications up 82°C; FlexCord Linepipe for severe cyclic applications; and has new products including large diameter FlexFlow Linepipe and FlexCord Anti-Buoyant Linepipe for shallow water applications under development
- Pipeline installation support: an industry-leading installation guide for use by pipeline end users and third-party installation contractors and a requirement for training and certification of contractors prior to installation
- Clear guidelines to operate and maintain its pipeline systems and working with customers to ensure best practices are adopted.
In-service pipe sample testing
Flexpipe Systems performs numerous evaluations of operating pipelines in a variety of applications by conducting in-field and in-house testing. Some of the tests conducted by Flexpipe Systems include:
Cut-outs
A program was conducted with the Alberta Energy Resources Conservation Board to validate the condition of pipe that has been in service in a variety of applications for at least one year (typically in excess of two years).
30 cut-out samples from the field were subjected to destructive burst testing and detailed dissection. In all cases, destructive burst testing results exceeded the minimum acceptable levels and none of the samples showed any indications of degradation. This demonstrates that there is no significant degradation of pipe performance even after a few years of service.
Durability
Flexpipe Systems conducted a test to compare the impact resistance of FlexPipe Linepipe to thermoset resin-reinforced composite pipe.
A nine kilogram weight was dropped from a 2.7 m height at -20°C onto unused test samples of 50 mm pipe with 1,500 psi maximum allowable operating pressure. The samples were then subjected to destructive burst testing.
FlexPipe Linepipe showed almost no reduction in burst pressure after impact, while the thermoset resin-reinforced pipe showed an approximate 15 per cent reduction in burst pressure. This test confirms FlexPipe Linepipe is more durable and has considerably better impact resistance than thermoset resin reinforced pipe.
Post-installation tests and inspection
Flexpipe Systems provides a number of options to measure the integrity of the installed pipeline systems, including:
- Visual inspection of jacket: for surface lines, where pipe is exposed, the jacket can be inspected for any damage or signs of degradation.
- Gas detection testing: buried and surface fittings can be checked for leaks during operation using gas detection equipment.
- Cut-out testing: a 3-5 m sample of pipe can be removed, assessed and analysed for integrity.
Flexpipe Systems’ excellent track record is a testament to the reliability and durability of its products. The application review process, manufacturing processes and robust product test programs ensure high quality and reliability of its product offerings.
Flexpipe Systems continues to expand its application envelope by understanding customer needs and developing products to meet these needs.
FlexPipe Linepipe is available in Australia, New Zealand and South East Asia exclusively through Energy Process Services: www.energyprocess.com.au
Energy Process Services offers a comprehensive service to engineering groups and operators to ensure the correct application and design of pipelines using FlexPipe products in order to deliver maximum cost and schedule benefits.