OIL & GAS

&

STAR™ Threaded
Line Pipe
Pipe Installation Handbook

8rd (ACT, PGT)

O-Ring (SS, SSSHP, CEN, SP, SPH)

nov.com/fgs
 Introduction
1. This installation handbook is offered to assist you in the
proper installation procedures of Fiber Glass Systems STAR
high pressure line pipe.
2. If you have any questions regarding procedures in this
installation handbook, please contact a Fiber Glass Systems
Representative for assistance.
3. Fiber Glass Systems Field Service Representatives will
not substitute for a crew member, nor be responsible for
supervising the crew, nor does their presence warrant that
the installation practices have been correctly performed.
4. It is the Customer’s, Contractor’s, and End-User’s
responsibility to read and understand all engineering and
installation related handbooks, guides, and other relevant
documents for the product to be installed and understand
the Field Service Policy as it relates to onsite training and/or
certification.
5. Fiber Glass Systems does not warrant the installation of
the goods nor shall it be responsible for the performance
of workmanship of any person or entity engaged in the
installation or installation supervision.
6. It is strongly recommended that all installers be properly
trained prior to the installation. Fiber Glass Systems offers
several types of certification training classes and/or
installation job startups.
7. Fiber Glass Systems recommends a pre-installation startup
meeting with the Distributor, Sales Manager, and Field
Service to discuss specifics of the installation to include but
not limited to:
• Review handling and storage
• Review installation procedures
• Tools and materials required for a proper installation
• Job startup and/or certification training by a certified
Fiber Glass Systems Representative
• Review installation schedule

2 3
 8. Fiber Glass Systems strongly recommends early hydrostatic • Type of lubricant
testing to ensure the reliability of the field workmanship. • Type and size of O-ring for Super Seal threads
Testing is recommended at the following intervals of the
• Required fittings, flanges, and flange accessories
installation:
• Acquire proper tools such as makeup wrenches, select
• STAR high pressure line pipe – first 5,000-ft maximum thread lubricant or sealant, and accessories
• Fitting intensive piping projects – first 50 joints maximum • Check the effect of makeup thread length loss on the
quantity of pipe ordered (Reference Table 5)
SAFETY
Responsibility of the Fiber Glass Systems Field Service
The safety alert symbol indicates an important safety
Representative
message. When you see this symbol, be alert to the
possibility of personal injury. • Train and advise the supervisor and crew members in the
recommended practices in this handbook.
CAUTION
• Provide testing after training to qualified personnel who
As this pipe may carry hazardous material and/or operate at a
handle pipe Any new or substitute crew member and
hazardous pressure level, you must follow instructions in this
supervisor must be trained prior to taking over activities. At
manual to avoid serious personal injury or property damage. In
minimum, two experienced and qualified crew members
any event, improper installation can cause injury or damage.
and a supervisor must be on location. Their qualifications
In addition, installers should read and follow all cautions and
must be in accordance with the procedures in this manual.
warnings on adhesive kits, heat packs, propane torches, etc. to
avoid personal injury. Also, observe general safety practices Procedure / Personnel Qualification
with all saws, tools, etc. to avoid personal injury. Wear protective • It is recommended that each person responsible for working
clothing when necessary. Make sure work surfaces are clean and on the connections be qualified and tested in accordance
stable and that work areas are properly ventilated. with recognized standards such as:

Fabrication and Installation Assistance - API 15TL4, Appendix B

- ISO 14692, Section 4
Prior to starting an installation, several parameters must be
defined: - ASME B31.3
• Type of service - Basic Fiber Glass Systems training
• Service conditions such as natural gas require an additional
safety factor of 0.67
• Buried or above ground installation
• Type of thread
- API 5B 10rd or 8rd
- Super Seal – CEN
- Super Seal – SP
- Super Seal – SPH
- Super Seal – SS
- Super Seal – SS-HP

4 5
 Table of Contents
Introduction��������������������������������������������������������������������������������������������� 3
Fabrication & Installation Assistance����������������������������������������������������� 4

Section 1
STAR Line Pipe Products 10
Line Pipe��������������������������������������������������������������������������������������� 11

Table of
Resin Systems������������������������������������������������������������������������������� 11
Threaded Connections������������������������������������������������������������������ 12

Section 2
Installation Tools and Equipment13

Contents
Section 3
Receipt, Handling and Inspection 18
Transportation���������������������������������������������������������������������������������������19
Load Inspection��������������������������������������������������������������������������������������19
Unloading������������������������������������������������������������������������������������������������20
Storage����������������������������������������������������������������������������������������������������20
Ultraviolet Effects����������������������������������������������������������������������������������21
Reshipping and Stringing Line Pipe������������������������������������������������������22

Section 4
Line Pipe Installation23
Burial Guidelines������������������������������������������������������������������������������������24
Ditch Preparation�����������������������������������������������������������������������������������24
Backfill Guidelines���������������������������������������������������������������������������������27
Buried Installation���������������������������������������������������������������������������������29
Above Ground Installation���������������������������������������������������������������������47

Section 5
Section 1 — Pipe Products
Section 2 — Site Considerations STAR 10rd and 8rd Joint Assembly49
Section 3 — General Installation Instructions
Introduction�������������������������������������������������������������������������������������������50
Section 4 — Fabrication of Red Thread HP, Green Thread HP and Silver Streak
Pipe and Fittings Makeup Tools������������������������������������������������������������������������������������������50
Section 5 — Installation Considerations / Hydrotesting
Section 6 — Helpful Information / Conversions 7
Precautions���������������������������������������������������������������������������������������������50 Tables
Cleaning and Inspection������������������������������������������������������������������������52 Table 1 - Threaded Connections/Resin Systems����������������������������������12
Lubricant�������������������������������������������������������������������������������������������������52 Table 2 - Ultraviolet Effects on GRE Pipe�����������������������������������������������21
Joining Procedures��������������������������������������������������������������������������������53 Table 3 - Recommended Bedding Materials�����������������������������������������28
Lowering Pipe in Trench (Roping)���������������������������������������������������������55 Table 4 - Maximum Deflections (per joint)��������������������������������������������33
Table 5 - Recommended Tools, Lubricants, Crew Size / Installation Rates�51
Section 6
Table 6 - STAR Super Seal Connections�������������������������������������������������57
STAR Super Seal Joint Assembly56
Table 7 - STAR Super Seal Makeup Tool Recommendations����������������59
Introduction�������������������������������������������������������������������������������������������57 Table 8 - O-ring Size Chart����������������������������������������������������������������������60
Makeup Tools������������������������������������������������������������������������������������������57 Table 9 - General Guidelines for O-ring Compatibility�������������������������61
Precautions���������������������������������������������������������������������������������������������58 Table 10 - STAR API 8rd Thread Table����������������������������������������������������71
Lubricant�������������������������������������������������������������������������������������������������60 Table 11 - STAR API 8rd Thread Removal�����������������������������������������������71
Cleaning and Inspection������������������������������������������������������������������������60 Table 12 - Bolt Torque vs Bolt Size���������������������������������������������������������� 74
Joining Procedure����������������������������������������������������������������������������������62 Table 13 - Typical Thread Dimensions���������������������������������������������������75
Table 14 - Thread Size - Maximum Pressure Ratings����������������������������84
Section 7 Table 15 - Bonded Saddle Repair�����������������������������������������������������������89
Field Hydrostatic Testing66 Table 16 - Bonded Bell x Male Thread Adapter Codes���������������������������90
Frequency�����������������������������������������������������������������������������������������������67 Table 17 - O-ring Bell x Male Thread Adapter Codes�����������������������������93
Preparation���������������������������������������������������������������������������������������������67 Table 18 - Cure Methods�������������������������������������������������������������������������93
Testing�����������������������������������������������������������������������������������������������������67 Figures
Locating a Leak���������������������������������������������������������������������������������������68
Figure 1 & 2 - Stable Soil����������������������������������������������������������������� 25 & 26
Figure 3 - Unstable Soil���������������������������������������������������������������������������26
Section 8
Fiberglass to Steel Connections69 Figure 4 & 5 - Road Crossing�������������������������������������������������������������������30
Figure 5 & 6 - Thrust Block����������������������������������������������������������������������31
STAR Threaded Connections�����������������������������������������������������������������70 Figure 8 - Line Crossing Burial Depth����������������������������������������������������46
STAR Flanges�������������������������������������������������������������������������������������������72 Figure 9 - Natural Roping of Line to Flange�������������������������������������������47
Figure 10 - Recommended Riser Configuration, 45° Elbow�����������������47
Section 9
Figure 11 - Recommended Riser Configuration, 90° Elbow�����������������47
Field Fabrication82
Figure 12 - Proper Aligning for Joining��������������������������������������������������54
API 8rd Threaded Nipples����������������������������������������������������������������������83 Figure 13 - Flange Connection, Fiberglass to Fiberglass��������������������73
Super Seal Threaded Nipples����������������������������������������������������������������83 Figure 14 - Flange Connection, Flat Face to Flat Face��������������������������73
Repair Methods���������������������������������������������������������������������������������������85 Figure 15 - Flange Connection, Flat Face to Raised Face���������������������� 74
Bell x Male Threaded Adapters��������������������������������������������������������������90 Figure 16 - Flange Bolt Torque Sequence����������������������������������������������81
Application of STAR 8rd Field Threads��������������������������������������������������94 Figure 17 & 18 - Repair Method #1����������������������������������������������������������86
Figure 19 - Repair Method #2������������������������������������������������������������������88
Figure 20- Repair Method #3������������������������������������������������������������������88
8 9
 STAR Line Pipe Products
Line Pipe
The performance characteristics of a fiberglass piping system
depend on several important elements including, but not limited
to the resin system, curing agent, and manufacturing process.
STAR Line Pipe is manufactured by using the epoxy resin
system along with one of three distinct curing agents: Anhydride,

Section 1
Aliphatic Amine or Aromatic Amine. All are heat cured for
optimum chemical resistance and physical properties.
Each resin system has certain characteristics, such as
mechanical properties, chemical resistance, temperature
capability, and cost which may make one system more suitable
than the other for a particular application.
Match your temperature, pressure, and chemical resistance

STAR Line Pipe

requirements to the fiberglass piping system
Resin Systems

Products
STAR Anhydride Line Pipe – Ideally suited for the majority of
common oilfield applications. Fluids such as sweet and sour
crude, fresh water, salt water, multiphase service, natural gas,
and nitrogen can be transported at continuous service
temperatures of up to 150 °F (65 °C).
STAR Aliphatic Amine Line Pipe – Ideally suited for the majority
of common oilfield applications. STAR Aliphatic Amine Line Pipe
can handle all the fluids mentioned above for Anhydride and can
handle continuous service temperatures of up to 200 °F (93 °C).
STAR Aromatic Amine – Ideally suited for the majority of oilfield
applications that require high temperature service. STAR
Aromatic Amine Line Pipe can handle all the fluids listed above
and can handle continuous service temperatures of up to 212 °F
(100 °C).

Line Pipe
REsin Systems 11
Threaded Connections
Threaded Connections
STAR Line Pipe offers the industry standard API 5B 10rd and 8rd
connections, and also offers 5 proprietary connections known
as Super Seal – CEN, SP, SPH, SS, SS-HP.
Table 1 shows the threaded connections that are available for
each resin system.

Table 1

Section 2
STAR Line Pipe

Resin Systems Connection Type Pipe Size

API 5B 10rd/8rd 1 1/2"-8"

CEN 2"-3"
STAR Anhydride SP 2"-4"
SPH 4"-6"
SS-HP 6"-12"

Tools and
API 5B 10rd/8rd 1 1/2"-8"
STAR Aliphatic Amine
SS 8"-12"

Equipment
API 5B 10rd/8rd 1 1/2"-8"
CEN 2"-3"
STAR Aromatic Amine SP 2"-4"
SPH 4"-6"
SS-HP 6"-12"

Metal Friction Wrench

Strap Wrench Pin Mold
Unique Tapering Tool Woven Roving
Unique Grinding Tool Heat Collar
STARtec Pipe Roller/Cradle
12 Hi13
Pro Plus Centrilizers
Epoxy Kit Standard Pull on End Seals
Metal Friction Wrenches Tool Model 010 series is factory assembled with 2” expandable
Designed to give 360 degrees collets, Ridgid 11-R ratchet, ¾” end wrench, 1” nipple bar and
of uniform compression on detailed instructions in a plastic box.
the male pipe upset, STAR Unique Grinding Tool - Model 10-612 (2”-12”)
metal friction wrenches are The Unique Grinding Taper
used for make-up and break Tool - Model 10-612 is designed
out of GRE pipe 8rd threaded to accurately cut tapers on
connections. The wrenches Photo 1 GRE pipe in nominal pipe sizes
are equipped with replaceable
Metal Friction Wrench 2” through 12”. The motor
operates on 120V or 230V and
dies which firmly grip the pipe without slipping. The dies may
comes with a flex cable 7 ft. in
require replacement if they become dull from heavy usage. length and the switch box is on Photo 4
These wrenches are hand operated tools; handle extensions an 8 ft. cable for safe operation. Grinding Tool - Model 10-612
which reduce the required force can be used successfully and
are recommended for larger pipe sizes. STARtec™ Threaded
Connection Lubricant/Sealant
Strap Wrenches STARtec is a Teflon based
The STAR recommended lubricant that is used for the
strap wrenches are designed assembly of STAR API 10rd
to be used by hand on GRE and 8rd Patented Advanced
pipe. These wrenches should Composite Thread (ACT) and
always be used on the pipe Precision Ground Thread
end connection upsets, never (PGT) Connections. STARtec
Photo 2
on the pipe body. Handle Strap Wrench assures power tight makeup
extensions can be used successfully on wrench sizes No. 11 and at low torque and allows easy
larger. These wrenches require the use of abrasive powder to breakout without seizing,
assist the grip of the strap on the pipe. Never use the point of the stripping or galling. It also Photo 5
STARtec
wrench against the strap onto the pipe; always use the heel which provides a permanent seal and
provides uniform compression 360° around the pipe. maintains joint efficiency under vibration, pressure, surge, and
temperature fluctuations. Use of any other lubricant can void the
Unique Tapering Tool - product warranty and requires special approval from Fiber Glass
Model 010 (2"-6") Systems. Startec is available in 1-gallon containers. Do not use
The Unique Tapering Tool STARtec lubricant on Super Seal Connections.
Model 010 series is designed to
Hi Pro Plus Kit
accurately cut tapers on GRE
pipe in nominal pipe sizes 2” Hi Pro Plus is a two-part, manganese dioxide cured polysulfide
through 6”. It can be operated based PTFE (polytetrafluoroethylene) filled sealant that is solvent
manually by a ratchet or by an free. Hi Pro Plus is used as pipe thread sealing compound for
electric power drive. (Ridgid® joining and coupling threaded oilfield pipe. The mixed compound
#700). The Unique Tapering Photo 3 has a paste consistency and can be readily applied with a spatula
Tapering Tool - Model 010 or brush to the threaded surfaces. It will cure to a fuel-resistant

14 15
rubber at temperatures above 60 °F purpose of curing field threads or bonded connections. They are
with very low shrinkage. Hi Pro Plus available in a variety of sizes and ordered by the nominal pipe size.
exhibits excellent adhesion to a wide Specify either 110V or 220V-240V when ordering. Chemical heat
range of substrates including reinforced packs are also available.
fiberglass, stainless steel, carbon steel,
and galvanized pipe. Hi Pro Plus has Woven Roving
superior chemical resistance to oils and Woven roving glass mat is used for
fuels and should be considered on all 3000 increasing the outside diameter of
psi, 4” 2500 psi, 6” 1500-2000 psi, and 8” a pipe body to the correct size for a
1000-2000 psi 8rd threaded products. Photo 6 pin mold inside diameter when the
Hi Pro Plus
Do not use Hi Pro Plus on Super Seal pipe outside diameter is insufficient
Connections to apply a field thread. Application
of this material requires the use of an
Epoxy Kit Epoxy Kit and special training by a Photo 10
Epoxy kits are used for field Fiber Glass Systems representative. Woven Roving

fabrication of our patented 8rd

Pipe Roller / Cradle
molded threads or assembly of
bonded fittings. The kit comes The pipe roller/cradle is designed
in either small or medium sizes to help support and keep large
and includes pre-measured Photo 7 diameter pipe, typically 6” and
epoxy and amine hardener.
Epoxy Kits above, aligned during makeup.
Also, included in the kit are complete mixing instructions, a small Centralizers
piece of sand paper and a mixing stick. Plastic centralizers are used to
support and provide spacing for
Pin Molds
fiberglass pipe during insertions into
Fiber Glass Systems manufactures a secondary pipe for road crossing Photo 11
Pipe Roller/Cradle
threaded pin molds for field fabrication or river crossings. The centralizers
of STAR API 10rd and 8rd molded threads are made of lightweight high density
for use with the Epoxy Kits. The precision polyethylene and are easy to install.
molds are made from hardened alloy steel, Reference Pg. 21 for spacing.
which if properly maintained can be used Photo 8
repeatedly to mold numerous threads. Pin Molds Standard Pull On End Seals
Prior to attempting to use a mold, several End seals are used to seal off the
items must be addressed, such as the ends of the conductor pipe when a
pipe outside diameter and ensuring all the fiberglass pipe is inserted, such as
required accessories for applying threads at a road crossing or river crossing.
are available. Reference Pg. 70-74 for The end seals protect the inside of Photo 12
Centralizer
complete instructions and procedures on the conductor pipe and the outside
making field threads. of the fiberglass pipe by eliminating the possibility of foreign
material entering the annular space. Manufactured from 1/8” thick
Heat Collars synthetic rubber, the Model S end seals are extremely robust and
Photo 9
Electric heat collars are used for the Heat Collar resistant to wide variations in environmental conditions.

16 17
 Transportation
Domestic U.S.A. or Inland Shipments Require:
• Dedicated (GRE Only) 34 ft. to 40 ft. flat bed or drop deck
trailers (oil field hauler).
• Do not hang pipe off trailer.
• Transporting the pipe on racks above a small truck can
cause potential impact damage.
• Use nylon straps for tie downs, do not use chains.

Section 3
• Tie downs should be located near the dunnage, four
locations minimum.
International shipments require:
• Dedicated (GRE Only) 40 ft. either open top or high cube
containers.
• All containers are loaded at the factory.
• It is highly recommended that the containers are not

Receipt, unloaded at port of destination.

• Shipments where the containers cannot be transported

Handling and
inland require the pipe to be crated at the factory.
• Crates can be installed inside of containers for removal at
the port of destination and then transported inland.

Inspection • Seaworthy crates and insertion crates for containers are

available

Load Inspection
Shipment inspection upon arrival:
• Check quantities, report deviations.
• Check for load shifting, and for missing dunnage.
• Check for excessive bending caused by over-tightening of
straps.
• Check for missing thread protectors and thread damage.
Transportation Replacement protectors are availablend and can be
Load Inspection purchased. If thread protectors cannot be obtained, protect
Unloading threads from sunlight with rags, cardboard, etc.
Storage
Ultraviolet Effects 19
Reshipping/Stringing Line PIpe
 • Check for impact damage (blister caused by abrasion or Ultraviolet Effects
blow with a sharp object).
• Ultraviolet effects on the pipe are limited to surface
• Quarantine or mark joints which appear damaged. Do not
discoloration. Eventually, “fiber bloom” or fusing will occur if the
install damaged pipe. Contact your local distributor/agent
pipe is left exposed to the sun long enough. The degradation
or Fiber Glass Systems representative.
is limited to the outer 0.005”-0.010” (0.13-0.25 mm) of the pipe.
• Receiving party is responsible for noting shipping damage (Reference Table 2.)
and contacting carrier.
• Fiberglass pipe may be protected from the ultraviolet rays
Unloading by painting with a heavily pigmented industrial coating or by
coating with an ultraviolet absorbing agent.
Common practices:
• Forklifts are commonly used to off load bundled pipe. Use a • Since STAR Line Pipe has an added safety factor, the surface
spotter to avoid damaging other bundles. effect of ultraviolet is minimum and does not reduce the
long-term performance of these products significantly.
• Use padded forks when possible.
• Use a spreader bar and slings for off loading with a crane.
• Never allow pipe to roll off trailer to racks or ground.
Table 2
Ultraviolet Effects on GRE Pipe
• Breaking a bundle allows the pipe to move freely and can be
Time
off loaded individually. Exposure
Pipe Conditions

Storage 6 months
Pipe color changes from amber/green to tan. No effect on
physical properties
Protect the pipe
Pipe color becomes dull tan and shiny fibers become
1 year
• Set the pipe on a surface free of sharp rocks. visible. No effect on physical properties

• Pipe bundles must not be stored directly on the ground. 2 years

Approximately 50% of the pipe surface shows shiny fibers.
No effect on physical properties
• Leave the separator boards between the pipe layers.
Approximately 90% of the pipe surface shows shiny fibers.
3 years
• If pipe racks are used, strip them with lumber to protect the No effect on physical properties
pipe from sharp edges.
Pipe will be fuzzy with the entire outer layer of glass
• Use four racks equally spaced to avoid permanent bending 5 years exposed. No further damage to pipe will occur. Pipe will
particularly for long term storage. operate at 100% of rating.

• Storage of more than six months requires coverage with a

tarp.
• Thread protection must remain in place to avoid
degradation of thread tolerances.

20 21
Reshipping and Stringing Line Pipe
Necessary precautions include:
• Loose pipe must be loaded with the joints staggered.
• Separate each layer of pipe with wooden dunnage.

CAUTION: Never groove pipe and pyramid.

• Always use nylon straps to tie down pipe, never chains.

Section 4
• Do not drop pipe off the trucks.
• Place uprights on the trailer to keep the pipe from falling off
the trailer while stringing.
• Avoid sharp rocks
• Lay the pipe on the opposite side of the ditch from where the
dirt is piles.
• It is recommended not to string out more pipe than can be
installed in one day.
• If more than 1 day’s installation is strung out, it is Line Pipe
Installation
recommended to support the pipe with a minimum of 4
contact points to prevent bending or bowing of the pipe
which could make joining difficult.
• Do not remove thread protectors prior to installation and
joint assembly.

Burial Guidelines
Ditch Preparation
Backfill Guidelines
22 Buried
23 Installation
Above Ground Installation
Burial Guidelines • Always use dry, unfrozen bedding materials that does not
contain foreign objects or debris.
Below ground installations are preferred over above ground
installations. • Never use water flood for compaction.
Fluid Applications: • Slurries can be used that are intended for burial of flexible
piping systems. When using slurries, care must be taken to
• Minimum burial depth of 3 ft (900 mm) of stable cover is
prevent floating or deformation of the piping system.
recommended for high pressure pipe lines.
• Reference Figure 1.
• Compacted, sandy or fine grain soil installation conditions
are preferred.
• Fiberglass line pipe must be buried below the freeze depth or
insulated to protect against freezing.
• Rocky conditions require extra precaution of a minimum 6”
(150 mm) of sand pad or select backfill around the pipe.
• The ditch bottom must be level such that the pipe does not
bridge along the bottom.
Gas Applications:
• ALL gas applications - Line pipe requires a minimum of 5
feet (1.5 mt) of stable cover.
• Additional service factors should be considered for gas
applications.
Ditch Preparation
Figure 1- Stable soil installation
Stable soil bedding procedures:
• Fiberglass pipe can be damaged by point contact or wear Swampy, unstable soil procedures:
with the trench bottom and walls, improper bedding First, attempt to excavate deep enough to find a stable layer of
materials, or adjacent pipe. soil. If this is not possible, there are several options.
• Remove all debris from ditch including tree roots, thread A. Saddle bag style weights can be used to prevent pipe from
protectors, etc. floating in unstable soil.
• Use recommended bedding material a minimum of 6 inches B. Special anchors can be designed to prevent pipe from
thick at the bottom, sides, and top of the piping. floating or raising. These anchors are designed depending
• The pipe can be laid directly on the undisturbed trench on the conditions. Many are 360° saddles around the pipe
bottom if the native soil meets the requirements of a that are welded to work over rig type screw anchors (Figure
recommended bedding material. 2).
• Never lay fiberglass pipe directly against native rock, shale,
caliche, etc.

24 25
 Frozen Soil
Stabilization of the ditch in some regions, such as Canadian
muskeg, may only be possible in the winter when the ground is
frozen. The following are some techniques which have been used
successfully:
• Prior to installing the pipe gradual compaction of the ice can
be achieved by driving over the pipe route with light vehicles
over a period of time.
• The ditch is prepared by first pushing away the snow and
then excavating the surface ice. Lay the surface ice away
from the installation area so it does not become mixed with
the unfrozen material.
Figure 2 - Workover Rig Type Anchors • Excavate until you find a stable layer of soil. If this is not
possible, use Geotextile and sand bags.
C. Stabilization of the soil can be achieved with a filter cloth • Steel casing with end seals may become necessary in the
such as Geotex®. This material has proven useful to stabilize event that a stable bottom cannot be found or Geotextile
the ditch bottom in boggy, wet conditions. Geotextile can be will not work.
placed below the pipe to reduce sinking and above the pipe • Since frozen backfill cannot be put in the pipe zone, it is
to stabilize backfill (Figure 3). recommended that the pipe is installed as the ditch is
D. Steel casing with end seals may become necessary in the excavated.
event that a stable bottom cannot be found or Geotextile • Backfill which has been excavated and left overnight will
will not work. Centralizers are required if steel casing is used. freeze. This material cannot be used in the pipe zone.
• Never attempt to compact backfill by driving heavy vehicles
on the ditch line.
• Preparing the ditch before the line is laid will require
additional work to remove snow and fall-in off the sides of
the ditch.

Backfill Guidelines
• Loose backfill free of large rocks or debris must be used in
the pipe zone (6” (150 mm) around the pipe).
• Reference Table 3 for bedding material recommendations.
• Bedding material should be sifted into the ditch to ensure
proper pipe support beneath and on the sides of the pipe.
Figure 3 - Geotextile installation

26 27
 • Backfill leaving 2’ (600 mm) on each side of connections Buried Installation
exposed for inspection during hydro test.
Joining Connections Above Ground
• Do not backfill over connections until hydrotesting is
• Do not exceed the minimum bend radius or the maximum
complete.
deflection when lowering the pipe into the ditch.
• Use thrust blocks or support for pipe and fittings if
• Exercise caution not to over bend the pipe during the
necessary.
process of lowering it into the ditch. Reference Table 4.
• Cold weather backfilling with frozen material in the pipe
• Never allow the pipe to whip into the ditch on its own weight.
zone must be avoided since impact damage can occur.
• Never compress the backfill on top of the pipe by driving • Always use nylon straps or pipe rollers to lift the pipe. Never
heavy equipment on the ditch line as this can damage the use chains for lifting the pipe.
pipe. • Construction of a side boom support cradle has proven
• Do not backfill a ditch full of water. Pump the ditch out and successful for heavy pipe support and leveling
check the layout for voids beneath the pipe. Fill any voids • Use only straps for handling pipe, never chains.
that are found then backfill with dry soil.
Joining Connections in the Ditch (“Including” Cross Lines or
• Swampy areas with unstable soil require special attention. Repairs)
Anchors or steel casing may be required in some instances.
• Requires attention to wrench movement.
• The ditch width must accommodate full movement of
Table 3 the wrenches or it must be widened (bell holes) at the
Recommended Bedding Materials
connections.
Compaction Protor
Bedding Material
Density Road Crossings (Figure 4)

Crushed rock or pea gravel ¾” maximum size Not Required

• Road crossings require steel casing, centralizers and end
seals.
Coarse-grained sand or soil with little or no fines 75-85%
• Protect the pipe at the entry and exit of casing against
Coarse-grained sand or soil with more than 12% settling shear from sharp edges.
85-95%
fines
• Avoid over bending pipe to enter or exit road bore casings.
Sand or gravel with more than 30% coarse-grained
particles
85-95% • Either prepare the ditch for a gradual elevation change, or
use fittings.
Sand or gravel with less than 30% coarse-grained
Greater than 95%
particles • Stabilize soil beneath casing to minimize settling.
• Sand bags may provide sufficient thrust restraint or support,
if necessary.
• Centralizers should be used to support pipe within casing.

28 29
 • Make sure there are no sharp objects, rocks, etc. that the
pipe will be pulled over. This can cause damage to the pipe.
• The pipe should be monitored during the pull to ensure it
does not get caught or stuck.
Fittings Thrust Blocks
• It is the responsibility of the engineer to evaluate the need
and design for thrust blocks. A complete evaluation must
consider the combined effects of temperature changes,
Figure 4 - Road crossing internal pressure surges and pipeline geometry.
• Pipe, components and joints are intended to operate safely
• Line Crossings (Figure 5)
with maximum free end internal pressure thrust, axial loads
• Line crossings must be padded for abrasion. in excess of those produced by operating at maximum
internal pressure rating should be considered for external
• It is common practice to install the fiberglass under existing thrust restraint.
lines when possible.
• Thrust blocks should be considered at directional changes
• Good practice is to leave a minimum of 12” (300 mm)
where the pipeline may approach its axial stress limits.
between lines.
Higher pressure rated components cannot be used to
compensate for additional loading.

Thrust Block

12

Thrust Block
Elbow

Elbow
Thrust Block
Figure 5 - Line crossing burial depth

Multiple lines Tee

• Multiple lines laid in a single ditch require a minimum

spacing of 6 inches (150 mm) clearance between Elbow Figure 6 - Thrust block
connections. It is recommended that sufficient spacing is
allowed for flange sets to be installed. Reference Table 13 for
flange dimensions. Thrust Block

Figure 5 - Thrust blocks

Pulling Pipe
• If you need to pull pipe, make sure the short-term tensile
rating of the pipe is not exceeded.
• If possible, use a weight indicator to ensure the short-term
tensile rating of the pipe is not exceeded.

30 31
Maximum Deflection Table 4a
Maximum Deflections (per 30' joint) - Standard Design
• Avoid over bending pipe by avoiding sharp horizontal
Aliphaic
and vertical changes. Do not install pipe at less than Pipe Size ID Anhydride
Thread Type Amine
the minimum bending radius or exceed the maximum
deflection per 30 feet, see Maximum Deflections Table 4. in in in/30 ft in/30 ft
Series 500
NOTE: Below 32°F (0°C) reduce allowable maximum deflection
3" 3 1/2" 8rd 2.94 - 34
4" 4 1/2" 8rd 3.75 27 -
4 1/2" 8rd 3.85 - 26
4 1/2" 8rd 3.91 26 -
5" 5 1/2" 8rd 4.74 22 21
6" 6 5/8" 8rd 5.50 18 -
6 5/8" 8rd 5.85 17 -
Temperature °C 0 -20 -40 6 5/8" 8rd 5.94 - 17
Multiplier 0.9 0.8 0.7 6" SPH 6.10 17 -
8" 8 5/8" 8rd 7.50 13 -
8" SS 7.74 - 13
8 5/8" 8rd 7.74 - 13
10" 10" SS 9.84 - 10
12" 12" SS 11.81 - 8
Series 800
2" 2-3/8" 8rd 1.94 - 50
2-1/2" 2-7/8" 8rd 2.37 - 42
3" 3-1/2" 8rd 2.94 - 34
3-1/2" 8rd 3 33 -
3" SP 3 33 -
4" 4-1/2" 8rd 3.75 27 -
4-1/2" 8rd 3.85 - 26
4-1/2" 8rd 3.91 26 -
4" SP 3.91 26 -
5" 5-1/2" 8rd 4.74 21 21
6" 6-5/8" 8rd 5.50 18 18
6-5/8" 8rd 5.85 17 -
6-5/8" 8rd 5.94 - 17
6" SPH 6.1 16 -
8" 8-5/8" 8rd 7.5 13 -
8-5/8" 8rd 7.74 - 13
8" SS 7.74 - 13
10" 10" SS 9.84 - 10
12" 12" SS 11.81 - 8

32 33
Table 4a (continued) Table 4a (continued)
Maximum Deflections (per 30' joint) - Standard Design Maximum Deflections (per 30' joint) - Standard Design

Aliphaic Aliphaic
Pipe Size ID Anhydride Pipe Size ID Anhydride
Thread Type Amine Thread Type Amine
in in in/30 ft in/30 ft in in in/30 ft in/30 ft
Series 1000 Series 1250
2" 2 3/8" 8rd 1.94 - 50 4" 4 1/2" 8rd 3.75 26 -
2 1/2" 2 7/8" 8rd 2.37 - 42 4 1/2" 8rd 3.85 - 25
2 7/8" 8rd 2.375 42 - 4 1/2" 8rd 3.91 25 -
2 7/8" 8rd 2.43 41 - 4" SP 3.91 25 -
3" 3 1/2" 8rd 2.94 - 34 5" 5 1/2" 8rd 4.74 20 20
3 1/2" 8rd 3.00 33 - 6" 6 5/8" 8rd 5.50 18 17
3" SP 3.00 33 - 6 5/8" 8rd 5.85 16 -
4" 4 1/2" 8rd 3.75 26 - 7" 8rd 5.94 - 16
4 1/2" 8rd 3.85 - 26 6" SPH 6.10 16 -
4 1/2" 8rd 3.91 25 - 8" 8 5/8" 8rd 7.44 - 13
4" SP 3.91 25 - 8 5/8" 8rd 7.74 - 12
5" 5 1/2" 8rd 4.74 21 21 8" SS 7.74 - 12
6" 6 5/8" 8rd 5.85 17 - 8" HP SSS 7.485 13 -
6 5/8" 8rd 5.50 18 18 8 5/8" 8rd 7.50 13 -
6 5/8" 8rd 5.94 - 16 10" 10" SS 9.84 - 10
6" SPH 6.10 17 - 10" HP SSS 9.84 10 -
8" 8" HP SSS 7.485 13 - 12" 12" SS 11.81 - 8
8 5/8" 8rd 7.50 13 - 12" HP SSS 11.81 8 -
8 5/8" 8rd 7.74 - 13 Series 1500
8" SS 7.74 - 13 1 1/2" 1.90 10rd 1.44 - 66
10" 10" SS 9.84 - 10 1.90 10rd 1.50 64
10" HP SSS 9.84 10 - 2" 2 3/8" 8rd 1.94 -
12" SS 11.81 - 8 2" SP 1.95 49
12"
12" HP SSS 11.81 8 - 2 3/8" 8rd 2.00 47
2 1/2" 2 7/8" 8rd 2.37 -
Series 1250
2 7/8" 8rd 2.375 41
2" 2 3/8" 8rd 1.94 - 50
2 7/8" 8rd 2.43 39
2" SP 1.95 50 -
3" 3 1/2" 8rd 2.94 -
2 3/8" 8rd 2.00 49 -
3 1/2" 8rd 3.00 32
2 1/2" 2 7/8" 8rd 2.37 - 41 3" SP 3.00 32
2 7/8" 8rd 2.375 41 - 4" 4 1/2" 8rd 3.75 25
2 7/8" 8rd 2.43 40 - 4 1/2" 8rd 3.85 -
3" 3 1/2" 8rd 2.94 - 33 4 1/2" 8rd 3.91 24
3 1/2" 8rd 3.00 32 - 4" SP 3.91 24
3" SP 3.00 32 -

34 35
Table 4a (continued) Table 4a (continued)
Maximum Deflections (per 30' joint) - Standard Design Maximum Deflections (per 30' joint) - Standard Design

Aliphaic Aliphaic
Pipe Size ID Anhydride Pipe Size ID Anhydride
Thread Type Amine Thread Type Amine
in in in/30 ft in/30 ft in in in/30 ft in/30 ft
Series 1500 Series 1750
5" 5 1/2" 8rd 4.74 20 8" 8 5/8" 8rd 7.44 - 12
6" 6 5/8" 8rd 5.50 17 8" HP SSS 7.485 12 -
6 5/8" 8rd 5.85 16 8 5/8" 8rd 7.50 12 -
7" 8rd 5.94 - 9 5/8" 8rd 7.74 - 12
6" SPH 6.10 16 10" 10" HP SSS 9.84 9 -
8" 8 5/8" 8rd 7.44 - 12" 12" HP SSS 11.81 8 -
8" HP SSS 7.485 13 Series 2000
8 5/8" 8rd 7.50 13 1 1/2" 1.90 10rd 1.44 - 63
9 5/8" 8rd 7.74 - 1.90 10rd 1.50 61 -
10" 10" HP SSS 9.84 9 2 3/8" 8rd 1.94 - 47
2"
12" 12" HP SSS 11.81 8 2" SP 1.95 47 -
Series 1750
2 3/8" 8rd 2.00 46 -
1 1/2" 1.90 10rd 1.44 - 65
2 1/2" 2 7/8" 8rd 2.37 - 39
1.90 10rd 1.50 62 -
2 7/8" 8rd 2.375 39 -
2" 2 3/8" 8rd 1.94 - 48
2 7/8" 8rd 2.43 38 -
2" SP 1.95 49 -
3" 3 1/2" 8rd 2.94 - 31
2 3/8" 8rd 2.00 47 -
3 1/2" 8rd 3.00 31 -
2 1/2" 2 7/8" 8rd 2.37 - 40
2 7/8" 8rd 2.375 40 - 3" SP 3.00 31 -

2 7/8" 8rd 2.43 38 - 4" 4 1/2" 8rd 3.75 25 -

3" 3 1/2" 8rd 2.94 - 32 4 1/2" 8rd 3.85 - 24
3 1/2" 8rd 3.00 31 - 4 1/2" 8rd 3.91 23 -
3" SP 3.00 32 - 4" SPH 3.91 23 -
4" 4 1/2" 8rd 3.75 25 - 5" 5 1/2" 8rd 4.74 19 19
4 1/2" 8rd 3.85 - 24 6" 6 5/8" 8rd 5.50 17 17
4 1/2" 8rd 3.91 24 - 6" HP SSS 5.85 16 -
4" SPH 3.91 24 - 7" 8rd 5.94 - 15
5" 5 1/2" 8rd 4.74 20 20 6" SPH 6.10 15 -
6" 6-5/8" 8rd 5.50 17 17
8" 8 5/8" 8rd 7.44 - 12
6" HP SSS 5.85 16 -
8" HP SSS 7.485 12 -
7" 8rd 5.94 - 16
9 5/8" 8rd 7.74 - 12
6" SPH 6.10 15 -
10" 10" HP SSS 9.84 9 -
12" 12" HP SSS 11.81 8 -

36 37
Table 4a (continued) Table 4a (continued)
Maximum Deflections (per 30' joint) - Standard Design Maximum Deflections (per 30' joint) - Standard Design

Aliphaic Aliphaic
Pipe Size ID Anhydride Pipe Size ID Anhydride
Thread Type Amine Thread Type Amine
in in in/30 ft in/30 ft in in in/30 ft in/30 ft
Series 2500 Series 3500
1 1/2" 1.90 10rd 1.44 - 62 6" 6" HP SSS 5.85 15 -
1.90 10rd 1.50 59 - 8" 8" HPSSS 7.44 - 12
2" 2 3/8" 8rd 1.94 - 45 Series 3500
2" SP 1.95 46 - 1 1/2" 1.90 10rd 1.44 - 57
2 3/8" 8rd 2.00 45 - 2" 2 3/8" 8rd 1.94 - 42
2 1/2" 2 7/8" 8rd 2.37 - 37 2 1/2" 2 7/8" 8rd 2.37 - 35
2 7/8" 8rd 2.375 38 - 4 1/2" 8rd 2.94 - 28
3"
2 7/8" 8rd 2.43 37 - 4 1/2" 8rd 3.33 - 25
4"
3" 3 1/2" 8rd 2.94 - 30
5 1/2" 8rd 3.85 - 21
3 1/2" 8rd 3.00 30 -
6" 6" HP SSS 5.85 14 -
3" SP 3.00 30 -
4" 4 1/2" 8rd 3.75 24 -
4 1/2" 8rd 3.85 - 23
4 1/2" 8rd 3.91 23 -
4" SPH 3.91 23 -
6" 6" HP SSS 5.85 15 -
8" 8" HPSSS 7.44 - 12
8" HP SSS 7.485 12 -
10" 10" HP SSS 9.84 9 -
Series 3000
1 1/2" 1.90 10rd 1.44 - 60
1.90 10rd 1.50 57 -
2" 2 3/8" 8rd 1.94 - 44
2 3/8" 8rd 2.00 44 -
2 1/2" 2 7/8" 8rd 2.37 - 36
2 7/8" 8rd 2.375 37 -
2 7/8" 8rd 2.43 36 -
3" 3 1/2" 8rd 2.94 - 29
3 1/2" 8rd 3.00 29 -
3" SP 3.00 29 -
4" 4 1/2" 8rd 3.33 - 26
4 1/2" 8rd 3.75 23 -
5 1/2" 8rd 3.85 - 22
4" SPH 3.91 22 -

38 39
Table 4b Table 4b (continued)
Maximum Deflections (per 30' joint) - API Design Maximum Deflections (per 30' joint) - API Design

Pipe Aliphaic Aromatic Pipe Aliphaic Aromatic

Thread ID Anhydride Thread ID Anhydride
Size Amine Amine Size Amine Amine
Type Type
in in in/30 ft in/30 ft in/30 ft in in in/30 ft in/30 ft in/30 ft
Series 500 Series 750
2" 2" CEN 2.23 44 - 45 8" 8-5/8" 8rd 7.50 13 13
3" 3 1/2" 8rd 2.94 - 34 - 8-5/8" 8rd 7.74 - 13 -
3 1/2" 8rd 3.00 33 - 34 8" SS 7.74 - 13 -
3" CEN 3.35 30 - 30 10" 10" SS 9.84 - 10 -
4" 4 1/2" 8rd 3.75 27 - - 12" 12" SS 11.81 - 9 -
4 1/2" 8rd 3.85 - 26 - Series 1000
4 1/2" 8rd 3.91 26 - 26 1 1/2" 1.90 10rd 1.50 64 - -
5" 5 1/2" 8rd 4.74 21 21 - 2" 2 3/8" 8rd 1.94 - 51 -
6" 6 5/8" 8rd 5.50 18 - 18 2 SP 1.95 50 49
6 5/8" 8rd 5.85 17 - 17 2 3/8" 8rd 2.00 49 48
6 5/8" 8rd 5.94 - 17 - 2 1/2" 2 7/8" 8rd 2.37 - 42 -
6" SPH 6.10 16 - 16 2 7/8" 8rd 2.38 41 41
8" 8 5/8" 8rd 7.50 13 - 13 2 7/8" 8rd 2.43 40 40
8" SS 7.74 - 13 - 3" 3 1/2" 8rd 2.94 - 34 -
8 5/8" 8rd 7.74 - 13 - 3 1/2" 8rd 3.00 32 32
10" 10" SS 9.84 - 10 - 3" SP 3.00 32 32
12" 12" SS 11.81 - 8 - 4" 4 1/2" 8rd 3.75 26 26
Series 750 4 1/2" 8rd 3.85 - 26 -
2" 2-3/8" 8rd 2.00 49 - - 4 1/2" 8rd 3.91 25 24
2-1/2" 2-7/8" 8rd 2.37 - 43 - 4" SP 3.91 25 24
2-7/8" 8rd 2.38 42 41 5" 5 1/2" 8rd 4.74 20 21 20
2-7/8" 8rd 2.43 41 40 6" 6 5/8" 8rd 5.50 18 18 17
3" 3-1/2" 8rd 2.94 - 34 - 6 5/8" 8rd 5.85 17 16
3-1/2" 8rd 3.00 33 32 6 5/8" 8rd 5.94 - 17 -
3" SP 3.00 33 - 6" SPH 6.10 16 16
4" 4-1/2" 8rd 3.75 27 26 8" 8" HP SSS 7.49 13 13
4-1/2" 8rd 3.85 - 26 - 8 5/8" 8rd 7.50 13 13
4-1/2" 8rd 3.91 25 25 8 5/8" 8rd 7.74 - 13 -
4" SP 3.91 25 25 8" SS 7.74 - 13 -
5" 5-1/2" 8rd 4.74 21 21 21 10" 10" SS 9.84 - 10 -
6" 6-5/8" 8rd 5.50 18 18 18 10" HP SSS 9.84 10 9
6-5/8" 8rd 5.85 17 17 12" 12" SS 11.81 - 8 -
6-5/8" 8rd 5.94 - 17 - 12" HP SSS 11.81 8 8
6" SPH 6.10 16 16

40 41
Table 4b (continued) Table 4b (continued)
Maximum Deflections (per 30' joint) - API Design Maximum Deflections (per 30' joint) - API Design

Pipe Aliphaic Aromatic Pipe Aliphaic Aromatic

Thread ID Anhydride Thread ID Anhydride
Size Amine Amine Size Amine Amine
Type Type
in in in/30 ft in/30 ft in/30 ft in in in/30 ft in/30 ft in/30 ft
Series 1250 Series 1500
1 1/2" 1.90 10rd 1.50 63 - - 3" 3 1/2" 8rd 2.94 - 32 -
2" 2 3/8" 8rd 1.94 - 50 - 3 1/2" 8rd 3.00 31 30
2" SP 1.95 49 48 3" SP 3.00 31 31
2 3/8" 8rd 2.00 47 47 4" 4 1/2" 8rd 3.75 25 24
2 1/2" 2 7/8" 8rd 2.37 - 41 - 4 1/2" 8rd 3.85 - 25 -
2 7/8" 8rd 2.38 41 40 4 1/2" 8rd 3.91 24 23
2 7/8" 8rd 2.43 39 39 4" SP 3.91 24 -
3" 3 1/2" 8rd 2.94 - 33 - 4" SPH 3.91 - 23
3 1/2" 8rd 3.00 32 31 5" 5 1/2" 8rd 4.74 20 19
3" SP 3.00 32 31 6" 6 5/8" 8rd 5.50 17 17 16
4" 4 1/2" 8rd 3.75 25 25 6" HP SSS 5.85 16 15
4 1/2" 8rd 3.85 - 25 - 7" 8rd 5.94 - 16 -
4 1/2" 8rd 3.91 24 24 6" SPH 6.10 15 15
4" SP 3.91 24 24 8" 8" HP SSS 7.49 12 12
5" 5 1/2" 8rd 4.74 20 20 8 5/8" 8rd 7.50 12 -
6" 6 5/8" 8rd 5.50 17 18 - 10" 10" HP SSS 9.84 9 9
6 5/8" 8rd 5.85 16 - 12" 12" HP SSS 11.81 8 -
7" 8rd 5.94 - 16 - Series 1750
6" SPH 6.10 15 15 1 1/2" 1.90 10rd 1.44 - 63 -
8" 8" HP SSS 7.49 13 12 1.90 10rd 1.50 60 59
8 5/8" 8rd 7.50 12 12 2" 2 3/8" 8rd 1.94 - 48 -
9 5/8" 8rd 7.74 - 13 - 2" SP 1.95 47 46
10" 10" HP SSS 9.84 9 9 2 3/8" 8rd 2.00 46 44
12" 12" HP SSS 11.81 8 8 2 1/2" 2 7/8" 8rd 2.37 - 39 -
Series 1500 2 7/8" 8rd 2.38 39 38
1 1/2" 1.90 10rd 1.44 - 65 - 2 7/8" 8rd 2.43 38 37
1.90 10rd 1.50 61 60 3" 3 1/2" 8rd 2.94 - 32 -
2" 2 3/8" 8rd 1.94 - 49 - 3 1/2" 8rd 3.00 30 30
2" SP 1.95 48 47 3 1/2" 8rd 3 - 30
2 3/8" 8rd 2.00 46 45 3" SP 3.75 24 24
2 1/2" 2 7/8" 8rd 2.37 - 40 - 4" 4 1/2" 8rd 3.85 - 24 -
2 7/8" 8rd 2.38 40 39 4 1/2" 8rd 3.91 23 23
2 7/8" 8rd 2.43 38 37 4 1/2" 8rd 4.74 19 -
5" 5 1/2" 8rd 5.50 17 17 -

42 43
Table 4b (continued) Table 4b (continued)
Maximum Deflections (per 30' joint) - API Design Maximum Deflections (per 30' joint) - API Design

Pipe Aliphaic Aromatic Pipe Aliphaic Aromatic

Thread ID Anhydride Thread ID Anhydride
Size Amine Amine Size Amine Amine
Type Type
in in in/30 ft in/30 ft in/30 ft in in in/30 ft in/30 ft in/30 ft
Series 1750 Series 2500
6" 6 5/8" 8rd 5.85 16 15 2 3/8" 8rd 1.94 - 45 -
2"
6" HP SSS 5.94 - 16 - 2" SP 1.95 44 -
7" 8rd 6.10 15 14 2 3/8" 8rd 2.00 44 42
6" SPH 7.49 12 12 2 1/2" 2 7/8" 8rd 2.23 - 38
8" 8" HP SSS 9.84 9 - 2 7/8" 8rd 2.37 - 37 -
10" 10" HP SSS 11.81 7 - 2 7/8" 8rd 2.38 37 -
12" 12" HP SSS 11.81 8 - 2 7/8" 8rd 2.43 36 -
Series 2000 3" 3 1/2" 8rd 2.72 - 31
1 1/2" 1.90 10rd 1.44 - 62 - 3 1/2" 8rd 2.94 - 30 -
1.90 10rd 1.50 59 57 3 1/2" 8rd 3.00 28 -
2" 2 3/8" 8rd 1.94 - 47 - 3" SP 3.00 29 -
2" SP 1.95 46 45 4" 4 1/2" 8rd 3.33 - 26 -
2 3/8" 8rd 2.00 45 43 4 1/2" 8rd 3.35 - 25
2 1/2" 2 7/8" 8rd 2.37 - 38 - 4 1/2" 8rd 3.85 - 23 -
2 7/8" 8rd 2.38 38 37 5 1/2" 8rd 3.75 23 23
2 7/8" 8rd 2.43 37 36 4" SPH 3.91 22 -
3" 3 1/2" 8rd 2.94 - 31 - 6" 6" HP SSS 5.85 15 14
3" SP 3.00 30 29 8" 8" HP SSS 7.49 11 -
3 1/2" 8rd 3.00 30 29 Series 3000
4" 4 1/2" 8rd 3.75 24 23 1 1/2" 1.90 10rd 1.44 - 57 -
4 1/2" 8rd 3.85 - 24 - 1.90 10rd 1.50 55 56
4 1/2" 8rd 3.91 23 - 2" 2 3/8" 8rd 1.88 44 45
4" SPH 3.91 23 - 2 3/8" 8rd 1.94 - 43 -
6" 6 5/8" 8rd 5.50 16 - 2 7/8" 8rd 2.23 37 37
2 1/2"
7" 8rd 5.50 - 17 - 3" 3 1/2" 8rd 2.72 30 30
6" HP SSS 5.85 15 15 4 1/2" 8rd 2.94 - 29 -
6" SPH 6.10 15 - 3" SP 3.00 28 28
8" 8" HP SSS 7.49 12 11 4" 4 1/2" 8rd 3.33 - 25 -
10" 10" HP SSS 9.84 9 - 5 1/2" 8rd 3.85 - 22 -
12" 12" HP SSS 11.81 7 - 6" 6" HP SSS 5.85 14 14
Series 2500
1 1/2" 1.90 10rd 1.44 - 60 -
1.90 10rd 1.50 56 56

44 45
Transition From Buried To Above Ground
GRE Nipple
Transition to above-ground piping can be accomplished in
several manners. Proper restraint of buried risers should be GRE Flange

analyzed by the engineer or installer. (See Thrust Blocks)

GRE Line Pipe

GRE 45° Elbow

Figure 9- Natural roping of line to flange
GRE Nipple

Above Ground Installation

GRE Nipple
GRE Flange

GRE Nipple Support and Guide Spacing

GRE 45° Elbow
• Contact Applications Engineering for support and guide
spacing.
• The fiberglass pipe should never support the weight of any
GRE 45° Elbow steel components.

GRE Nipple
GRE Nipple
Wear Saddles
GRE Flange

• Wear saddles 360° around the pipe must be used to protect

the pipe against pulsation abrasion or pipe movement due
GRE 45° Elbow to temperature fluctuation.

Figure 7 - Recommended riser configuration - 45° elbow

GRE Nipple

GRE 90° Elbow

GRE Line Pipe GRE Nipple

GRE Flange

GRE 90° Elbow

Figure 10 - Above ground value support

GRE Nipple

GRE Nipple

GRE 90° Elbow

GRE Nipple GRE Line Pipe

GRE Flange

GRE 90° Elbow

Figure 11 - Above ground thrust restraint

Figure 8 - Recommended riser configuration - 90° elbow

46 47
UV Effects
• Reference Section 3 Ultraviolet Effects.
Thrust Blocks
• Thrust blocks for above ground installation must be
constructed to support fittings listed in Figures 10 & 11.
• The design must simulate the same support as buried
concrete thrust blocks; abrasion padding is recommended.
• Thrust blocks may be required for above ground fittings.

Section 5
• The need for thrust restraint should be considered by the
system design engineer.

STAR 10rd
and 8rd Joint
Assembly

Introduction
Make-up Tools
Precautions
Cleaning and Inspection
Lubricant
48 Joining
49 Procedure
Lowering Pipe in the trench
Introduction Table 5
Recommended tools, lubricants, crew size and insallation rate
Threaded connections manufactured to API 5B long-form
specifications are provided as patented Advanced Composite

1000 to
2000 ft.

STAR industry standard API EUE 10rd, 8rd and OD 8rd threads are designed to advance to the “power tight”
9 5/8

4.75

Torque and thread standoff should be monitored for 1.90”, 2 3/8”, 2 7/8”, and 3 1/2” threads. Care must be taken to ensure excessive torque is not required
26
3

6
Thread (ACT) or precision ground (PGT) thread. Depending

No. 30
on the size and pressure rating, the connection utilizes either

position with 2 thread standoff; 1 to 3 thread standoff,are typical due to manufacturing tolerances
1000 to
2000 ft.
a Teflon®-based lubricant (STARtec) or a proprietary sealant

8 5/8

4.5

26
4

6
(Hi Pro Plus) to achieve the seal. All API threaded products can
be installed using Hi Pro Plus. Table 4 lists by size and pressure

1000 to
2000 ft.
the recommended lubricants and the estimated number of

4.5

34
7

6
connections, which can be made up per container with daily

No. 20
installation rates.

1000 to
2000 ft.
3.88
6 5/8

34
Make-Up Tools

6
Make-up tools are designed to provide uniform 360° compression

Metal Friction Wrench (MFW)

MFW or

2000 to
3000 ft.
No. 20

Reference thread standoff

Reference thread standoff
Reference thread standoff
4.38
5 1/2
on the pipe while applying the required make-up torque. The

34
10

6
STAR friction wrench, along with one of three different strap
wrenches, are required for proper make‑up. Friction wrenches

2000 to
3000 ft.
5 to 6
4 1/2

3.5
are designed to fit the cylindrical male end upset diameters.

50
12
Use on conical shaped integral joint upset ends can cause
point loading and damage to the pipe wall. Table 5 shows the

3000 to
4000 ft.
No. 11

5 to 6
3.88

50
12
combinations of recommended wrenches for each size pipe.

4
Precautions

3000 to
4000 ft.
5 to 6
3.13
3 1/2

225
300
• Never use typical oil field pipe wrenches on fiberglass pipe.

175
68
16
Chain tongs may be used on high pressure GRE fittings only.

5000 to
6000 ft.
• The strap wrench may be on male upsets and conical

4 to 5
2.86
2 7/8

250
150
185
100
20
shaped integral female joint ends.
• Metal Friction Wrench (MFW) may only be used on the

5000 to
7000 ft.
4 to 5
No. 5
2.56

Do not use Hi Pro Plus if it has started to setup.

2 3/8

225
125
150
100
25
cylindrical pin end upset diameters.

Crew size includes contractor supervisor.

• When using a torch to warm the pipe ends, be careful not to

5000 to
7000 ft.
4 to 5
1.90

burn, delaminate, or damage the pipe. Do not exceed 130°F.

2.06

125
100

100

175
33
• Strap and friction wrenches are designed to fit around upset
Make-Up Length Loss (in)

ends, not pipe bodies.

Hi Pro Plus (1) (jts/gal)

Max. Torque (ft•lb)

Opt. Torque (ft•lb)
Strap Wrench Size

Min. Torque (ft•lb)

Thread Standoff(3)
STARtec (jts/gal)

for proper standoff.

Installation
Thread Size

Crew Size(2)
Male Upset

(feet/day)

(2)

(3)
(1)
50 51
Cleaning and Inspection • The lubricant must be kept
warm 65°F (18.3°C) in order
• Thread protectors must be left in place until just before
to apply it evenly.
joining pipe.
• Never use solvent to thin
• Ice will make thread protectors impossible to remove. Heat
the lubricant, even in cold
the ends of the pipe with a propane torch to melt the ice.
weather.
• If an open flame is not permitted, methyl alcohol can be • Agitate or stir the lubricant
used to melt the ice or a heat blanket (electric or chemical) frequently to keep it from
may be used. balling.
• Clean threads with a soft bristle brush (solvents can be used, Hi-Pro Plus Thread Sealant
but the threads must be dried thoroughly).
• Hi-Pro Plus requires mixing
• Sand, dirt, ice or other debris must be removed from the
of ingredients prior to
threads prior to joining.
using.
Lubricant • Using the wooden stir
Two different lubricants are available for use with API threaded stick, scoop out all of the
connections. contents of hardener
Component B into jar of
The standard lubricant is a Teflon-based lubricant, STARtec, base Component A. Do not split the kit. The base is a light-
which offers excellent lubrication for ease of make up along with colored paste; the hardener is a dark paste.
optimum sealing characteristics.
• Thoroughly mix the two components together until a
A specialty two-part thread sealant, Hi Pro Plus, can be used on
uniform color is achieved and the particles in the bottom of
all API threaded connections. When cured, Hi Pro Plus becomes
the container are evenly dispersed.
a solid thread seal. The primary usage of Hi Pro Plus is for high
pressure applications or when field installation expertise is • Use the brush provided to spread a thin, even coat of sealant
limited. Installations where Hi Pro Plus should be considered on all exposed pin and box threads, removing any excess.
are on all 3000 psi, 4” 2500 psi, 6” 1500-2000 psi and 8” 1000- • If the sealant is difficult to spread, warm the joint enough for
2000 psi products. Hi Pro Plus works best on installations the sealant to spread easily. Do not overheat.
above 50°F (10°C). When ordering Hi Pro Plus, specification of
job site temperature is required. Curing of Hi Pro Plus at low • The cure of Hi Pro Plus below temperatures of 50°F (10°C)
temperatures can be accelerated by the use of electric heat requires the use of electric heat blankets.
blankets. • Hi Pro Plus must be fully cured prior to hydro testing.
NOTE: STARtec lubricant or Hi Pro Plus thread sealant must be Joining Procedure
used to maintain the warranty of Fiber Glass Systems products.
• Support pipe behind the female end to allow tool
STARtec Lubricant
movement and leveling.
• Apply lubricant evenly with a typical lube brush to both the • Alignment is very important for full thread engagement
male and female threads (the entire base of the thread must (particularly on large diameter pipe).
be coated).

52 53
 • Some instances may require a handle extension on the
wrench which will reduce the required force to reach full
makeup.
• The use of an abrasive powder may be needed to prevent
slippage of strap wrench on final torque.
• Power tongs can be effectively used on sizes 4” (2500-3500
psi), 6” (1500-2500 psi), and 8” (1000-2000 psi).
Lowering pipe in trench (Roping)
Figure 12
• Exercise caution not to over bend the pipe during the
process of lowering it into the ditch. (See Table 3, for
• Weather near or below freezing requires heating of the male
Maximum Deflection).
and female ends with a propane torch or electric heating
collar. The ends shall feel warm by touch to the back of your • Never allow the pipe to whip into the ditch on its own weight.
hand.
• Always use straps on the pipe, Never use chains for lifting.
• Apply lubricant.
• Construction of a side boom support cradle has proven
• Stab the joint gently until full engagement is felt. successful for heavy pipe support and leveling.
• Avoid cross threading by careful alignment.
• Rotate the pipe by hand.
• Rotation of the pipe can be
assisted by using a strap
wrench or a spinning tong.
(see Figure 12)
• Cross-threaded
connections must be
backed out, cleaned and
inspected for damage.
If the threads pass the
inspection, restart the
joining procedure.
• Final torque is applied using a friction wrench on the male
upset only and a strap wrench on the female connection
with wrenches close to connection. A strap wrench maybe
used on the male end also.
• STAR API threaded connection are designed to allow torque
control monitoring the joint make-up position. (Refer to
Table 5 for thread standoff)

54 55
 STAR Super Seal
Introduction
STAR Super Seal Line Pipe offers 5 proprietary thread types: CEN,
SP, SPH, SS, and SS-HP.
The STAR Super Seal threads are very coarse when compared to
typical industry threads, such as, NPT and API 8rd threads. The
coarse threads provide a fast and reliable installation, and are
difficult to cross-thread which is extremely beneficial, especially,
for large diameter products. The seal is achieved by compressing

Section 6
an O-ring between two mating surfaces.

Table 6
STAR Super Seal Connections

Thread Thread
Resin System Thread Pipe Size Count Length
(TPI) (in)

CEN 2"-3" 4 4.9

STAR Super Seal

SP 2"-4" 4 4.5
STAR Anhydride
SPH 4" 4 4.5

Joint Assembly
SPH 6" 4 6.0
SS-HP 6"-12" 2 9.0
SS 8" 2 5.0
STAR Aliphatic Amine SS 10" 2 6.2
SS 12" 2 6.9
CEN 2"-3" 4 4.9
SP 2"-4" 4 4.5
STAR Aromatic Amine SPH 4" 4 4.5
SPH 6" 4 6.0
SS-HP 6"-12" 2 9.0

Makeup Tools
• Strap wrenches are designed to provide a uniform 360°
Introduction compression on the pipe while applying the required makeup
Make-up Tools
torque.
Standare O-ring Sizes and Types
Precautions • Strap wrenches are required for proper makeup (Reference Table 7).
Lubricants
Cleaning and Inspection
Joining
56 Procedure 57
Final Make-Up
 Strap wrenches allow the installer to “feel” the O-ring seal Table 7
engagement. Power tool makeup provides no “feel” or Super Seal Makeup Tools
feedback to operator and are not recommended.

SS-HP
• Pipe Roller / Cradle can assist with support, alignment, and

8.8

1500 to
2000 ft.
rotation especially for large diameter pipe, typically 6” and

5 to 6
12
above.

6.1
SS
Standard O-ring Sizes and Types

SS-HP
• Buna N Nitrile 70 durometer is the standard O-ring material.

8.8

1500 to
2500 ft.
5 to 6
10
• Alternative elastomers are available and may be better
suited for your specific application. i.e. Explosives

5.4
SS

No. 11
decompression, gas service, CO2, etc. Reference Table 9 for
general O-ring material guidelines.

SS-HP

8.8

No. 11

1800 to
2800 ft.
5 to 6
NOTE: There are hundreds of varieties of each compound

8
available and are not all equivalent.

4.8
SS
• It is recommended that extra O-rings are ordered and kept
on the installation site for replacement of any that are found

SS-HP

0.25"
8.8
damaged or missing (Reference Table 8).

2000 to
3000 ft.
5 to 6
6
• O-rings are shipped separate from the pipe.

SPH

6.0
• During cold weather installations, keep the O-rings and

SPH
lubricants warm.

4.5

2600 to
3900 ft.
4 to 5
Precautions
4

4.5
SP
• Never use typical oilfield pipe wrenches on fiberglass pipe. Chain
tongs may be used on high pressure fiberglass fittings only.

4.5
SP

3900 to
5200 ft.
4 to 5
No. 5
• When using a torch to warm the pipe ends, be careful not to
3

CEN

burn, delaminate, or damage the pipe. Do not exceed 130°F. 4.9

No. 5

Crew size includes contractor supervisor.

• The strap wrenches should only be used on the pin upset and
4.5
SP

box buildup ends.

6500 to
9100 ft.
3 to 4
2

CAUTION: Do not overtighten the connection, the O-ring will

CEN

4.9

make the seal.

Make-Up Length
Pipe Size (in)

Installation
Thread Type

Crew Size(1)
Male Upset

(feet/day)
IJ Female

Standoff
Loss (in)

(1)

58 59
Lubricant Table 9
General Guildlines for O-ring Compatibility
• Do not use thread compounds of any kind.
• Lubricants must be protected from contamination by dirt,
sand, and debris.

Excellent(2)

Excellent
Excellent
Excellent
Excellent

Good
Good
Good
Aflas
• Clean, white lithium grease (non-aerosolized) is recommended
for joint makeup.
• Clean hydraulic fluid, light-weight motor oil, or silicone based
lubes can also be used for joint makeup.

Viton Fluorocarbon

Excellent

Excellent
Excellent
Table 8

Good(1)

Good
Good
Good
Poor
O-ring Size Chart

Super Seal
Pipe Size (in) Dash Number
Thread
2" 141
CEN

Propylene
Ethylene

Excellent
Excellent
Excellent

Excellent

Excellent
3" 152

Good(1)
Poor

Poor
2" 226
SP 3" 236
4" 244
4" 346
SPH

Nitrile Buna-N
6" 438

Excellent
Excellent

Excellent
Excellent
Good(1)

Poor(3)

Poor
Poor
8" 369
SS 10" 449
12" 453
6" 439
8" 445
SS-HP

Excellent
Excellent
Excellent
Excellent
Excellent
Excellent
Excellent
10" 450
HNBR

Good

12" 454

Cleaning and Inspection

• Each joint must be checked visually for shipping and/
or handling damage. Shallow scratches and abrasions
are generally insignificant, but if the pipe has cuts in the
Saltmater
H2S (15%)
Kerosene
Crude Oil

Methane

laminate, bruises, or fractures, it should be set aside for

Amines

Steam
Media

replacement. If unsure whether the pipe is damaged,

CO2

contact a Fiber Glass Systems Representative.

60 61
 • Thread protectors must be left in place until just before • The nylon straps or pipe rollers / cradles are typically
joining pipe. placed around the middle of the pipe during the alignment,
insertion, and rotating operations.
• Ice will make thread protectors impossible to remove. Heat
the ends of the pipe with a propane torch to melt the ice. • Do not use chains for lifting the pipe.
• If an open flame is not permitted, methyl alcohol, electric • If the pipe is light enough to lift by hand then a plastic pipe
heat blanket, or a chemical heat pack can be used to melt cone or pipe jack can be used for support and assistance
the ice. with alignment.

• After removal of thread protectors, inspect the box, pin, and • Proper alignment of the two joints is critical.
sealing surfaces for damage. Remove any contamination Final Makeup for CEN, SP, and SPH
from the box, pin, and sealing surfaces.
• You should be able to rotate the pipe by hand if proper
• Installer should ensure that no contamination can enter the alignment is achieved. For large diameter pipe, a No. 5 strap
joint prior to makeup. wrench may be needed to assist in pipe rotation.
• Any foreign material at the O-ring seal can cause leakage. • The makeup will gently slow as the O-ring compresses.
This includes grass, sand, lubricant, brush bristles, etc. • At this time, you may need to switch from the No. 5 strap
• Inspect O-ring making sure it is clean with no nicks, cuts, or wrench to a No. 11 strap wrench. Reference Table 7 for strap
gouges. wrench recommendations.
• Final makeup is achieved when standoff from pin shoulder
• If the surfaces are contaminated, clean with the use of a to the face of the box is at a 1/4”. The CEN pin will have a
soft bristle brush and water. Do not use metal brushes or white mark on the thread which will be entirely covered
compounds containing solvents for cleaning. when final makeup is achieved.
• Sand, dirt, ice, or other debris must be removed from the • Do not shoulder out the connection.
threads prior to joining.
• Once final makeup is achieved, you may back-out a 1/4
• Contamination inside the pipe, not in the joint and seal area, rotation for fitting alignment. If more than 1/4 rotation is
can fall into the joint during alignment. Keep pipe stored off required, revert to next nearest joint.
the ground with protectors in place until ready to join. • If standoff distance exceeds .25", then the joint should be
Joining Procedure disassembled and inspected for damage or debris and the
O-ring inspected for damage. If no damage is observed,
Lubrication and O-ring Procedure repeat the makeup procedure, and if the problem persists,
• Lightly lubricate the female threads, male threads, O-ring set the joint aside for disposition.
seating area, and O-ring sealing area. NOTE: CEN jointed pipe (≤ 500-psi) is designed for tapered and
• Lubricate the O-ring and place the O-ring into the seating bonded fittings. Reference Section 9 and INS1000 (Installation
area. Handbook for Matched Tapered Bell x Spigot Joints) for bonding
procedures.
Alignment
Final Makeup for SS
• If the pipe is too heavy to hold and makeup by hand then
side-boom with nylon straps and/or pipe rollers / cradles • Sub-freezing temperatures require the warming of the male
should be used to support and lift the pipe. and female ends of the pipe.

62 63
 • Check alignment to prevent O-ring and/or connection • Continue to make the connection with a strap wrench until
damage. Pipe rollers / cradles are recommended for lifting, the O-ring is compressed in the seal bore.
alignment, and pipe rotation.
• The connection should be made-up until the thread
• The 8”, 10”, and 12” Super Seal connections are match standoff distance falls between 15/16” to 1-7/16” with a
marked for thread engagement. Align the starter thread maximum allowable thread standoff distance of 1-1/2”.
marks on the male and female prior to engagement.
• 800 to 1000 ft·lb torque will be required to fully seat the
• Turn the connection slowly to the right by hand until the tapered pin into the tapered box.
threads engage.
• Once final makeup is achieved, you may back-out 1/4
• The makeup will gently slow as the O-ring compresses. rotation for fitting alignment. If more than 1/4 rotation is
required, revert to next nearest joint.
• Use of the strap wrenches will become necessary as rotation
becomes difficult. Reference Table 7 for strap wrench • If a longer standoff distance is observed, then the joint
recommendations. should be disassembled and inspected for damage or
debris and the O-ring inspected for damage. If no damage is
• The makeup will stop abruptly.
observed, repeat the makeup procedure, and if the problem
• Once final makeup is achieved, you may back-out 1/4 persists, set the joint aside for disposition.
rotation for fitting alignment. If more than 1/4 rotation is
required, revert to next nearest joint.
• Installation rates and crew sizes are listed in Table 7.
Improved rates can be achieved depending on crew and
conditions.
Final Makeup SS-HP
• Check alignment to prevent O-ring and/or connection
damage. Pipe rollers / cradles are recommended for lifting,
alignment and pipe rotation.
• Insert the pin threads into the box. Because the threads are
tapered, the pin may be inserted deep into the box before
thread engagement occurs.
• Turn the pipe slowly to the right by hand until the
threads engage. Ensure that the joint is aligned and not
crossthreaded.
• Continue to make the connection by hand until the joint will
not turn anymore. Rotation should be very smooth if proper
alignment is maintained.
• Listen for rubbing or grinding noises and, if present, recheck
alignment before additional rotation.

64 65
 Frequency
• Field hydrostatic pressure testing is recommended on all
lines to ensure line integrity and field workmanship.
• Testing is recommended at the following intervals of the
installation:
- STAR high pressure line pipe – first 5,000-ft maximum.
- Fitting intensive piping projects – first 50 joints
maximum.

Section 7
Preparation
• Backfill must be sufficient to minimize pipe movement with
2-ft on either side of the connection left exposed for joint
inspection.
• Soft pigs must be provided to fit the inside diameter of the
pipe and fittings. Pigs are used to displace the air when filling
the pipe with water.

Field Hydrostatic
• Test equipment should be capable of monitoring pressure
and temperature as a function of time.
CAUTION: Test with fresh water. Gas and air are not

Testing recommended for proof testing. Produced water is not

reliable as it is often contaminated and foamy.
• Testing at freezing or sub-freezing temperatures may
require the mixing of up to 50% methyl alcohol with the fresh
water used for hydrostatic testing. Other additives must be
approved by FGS. Test equipment lines must also be filled
with 50% methyl alcohol to prevent freezing.
Testing
• Place two soft pigs in the line at the lower end of the line one
behind the other. Pump the pig through the line by pushing it
with fresh water.
• A 50% methyl alcohol may be mixed with water for
subfreezing temperatures.
• Bleed the air at the highest elevation of the line since
trapped air will become compressed during testing and will
give erroneous results.
Frequency
Preparation
Testing
66 67
Locating a Leak
 • If water appears before the pig, air may be trapped in the
line.
• Beware of water temperatures versus the line temperature.
• Always let the line temperature stabilize before testing.
• Once the air is removed, begin slowly elevating the pressure
in increments up to 200-psi per minute.
• Stop and hold the pressure at each increment for 5 minutes.
• Maximum test pressure is equal to the pipe rating label.

Section 8
CAUTION: Do not exceed the maximum rated pressure of
the lowest rated component of the system.
• Do not test at higher than rated pressure of the pipe
(pipe label) without written permission from a Fiber
Glass Systems Representative.
• Typical test durations of 2 to 4 hours are typical.
• Inspect the line during the test by walking the line and
visually inspecting for leakage, over bending, or evidence of
damage. Fiberglass
to Steel
• Variations in ambient temperatures will cause fluctuations
in pressure over an extended test.
• Contact Fiber Glass Systems prior to any pneumatic testing.
CAUTION: Do not allow uncovered or uninsulated test lines filled
with water to freeze since the expansion of the ice in the
Connections
lines can damage the pipe.
Locating a Leak
Locating a leak in a line may become difficult. Techniques that
can be used to find leaks include:
• Walking the line and visually inspecting for leakage.
• Adding dye or odorant to the water.
• Add geophones, dye, or odor agents (use mercaptan) to the
water.
• Reference Section 9 for repair methods.

68 STAR
69 Threaded Connections
STAR Flanges
STAR Threaded Connections 3. Dry fit the fiberglass to steel connection.
Changing over to steel pipe from STAR threaded connections can 4. If the connection seizes up premature to full engagement,
be accomplished in a variety of ways. Each changeover method then the steel is probably short-form. Reference Table 11 for
has distinct advantages depending on the pressure requirement. thread removal from front of the fiberglass male.
Options: Table 10
STAR API 8rd Threads vs. Steel
• Fiberglass flat faced female threaded flanges are
recommended for transitioning to steel or other materials. Thread
Thread Size API Thread Thread Make-Up
Length
• Fiberglass API 8rd change-over nipples or couplings. (in) Specification Length Loss
Diff.(3)
Reference Section API 8rd Change-Overs.
1.90 EUE 10rd (1) 2.36 2.06 0.50
• Steel API 8rd change-over nipples or couplings are available 2 3/8 2.94 2.56 0.63
from various supply stores. Reference Section API 8rd 2 7/8 3.25 2.88 0.63
Change-Overs. EUE 8rd (1)
3 1/2 3.50 3.13 0.75
• Super Seal x Male NPT crossover (< 500-psi). 4 1/2 3.88 3.50 0.88

• Super Seal x Male API 8rd (< 500-psi). 5 1/2 4.75 4.38 0.63
6 5/8 4.25 3.88 0.75
• Super Seal x Groove (< 500-psi). 7 OD 8rd(2) 4.88 4.50 0.88
CAUTION: Do not test above the pressure rating of the 8 5/8 4.88 4.50 1.125
fitting. 9 5/8 5.13 4.75 1.375

API 8rd Change-Overs (1) API Specification Standard 5B, 16th Ed., Table 8 (L4 min).
(2) API Specification Standard 5B, 16th Ed., Table 4 (L4 min).
• Expansion: Due to the higher expansion rate of fiberglass (3) Fiberglass threads are longer by this length.
versus steel, the preferred threaded change-over is a
fiberglass male to steel coupling. Table 11
STAR API 8rd Thread Removal
• Thread Compatibility: Fiberglass API 8rd threads are long-
form type and vary with typical steel short-form 8rd threads. Thread Size No. of Threads Thread
Reference Table 10. (in) to Cut Off Length
API 8rd Thread Removal 1.90 6

Some fiberglass 8rd long-form threads require removal 2 3/8 5

2 7/8 6 Dry fit prior to cutting off threads.
(using hacksaw) for proper sealing with steel 8rd short-form
connections. Most steel equipment and steel change-overs are 3 1/2 6
To take full advantage of the
prepared with short-form 8rd threads. The steps prior to thread 4 1/2 7
performance of the fiberglass thread,
removal are as follows: 5 1/2 5
it is good practice to have the steel
6 5/8 6
1. Chase the steel connection with a steel nipple. threaded connection ordered to match
7 7 the fiberglass long-form thread.
2. Make sure the steel threads are smooth with no burrs or 8 5/8 9
sharp edges. 9 5/8 11

70 71
STAR Flanges
GRE GRE
Fiberglass Flat Faced Flanges STEEL BACKING PLATE
(AS REQUIRED)
STEEL BACKING PLATE
• STAR API 8rd and Super Seal flat faced female threaded (AS REQUIRED)
SPIRAL
flanges are available in a variety of pressure ratings. WOUND
GASKET
• Proper gaskets, spacer rings, backing plates, bolt lengths,
nuts, and washers must be addressed for installation.
• Fiberglass flanges are thicker than steel flanges, therefore,
the required bolt length is longer. Reference Table 13.
Washers GRE Pipe GRE Pipe

• All fiberglass flanges require washers, unless a steel backing

plate is used. GRE GRE
FLANGE FLANGE
Flange Gaskets (FF) (FF)

Figure 13 - Fiberglass to Fiberglass

• Spiral wound gaskets are recommended for all fiberglass
flanges.
• For CEN, SP, and SPH flanges, Graph-Lock gaskets (TC3125)
GRE STEEL
can be used up through ANSI 600.
• Gaskets are purchased separately from flanges. SPIRAL
WOUND
GASKET
Steel Backing Plates
• Required for higher pressure flanges. Reference Table 13 for
steel backing plate requirements.
• Failure to use specified backing plates will void product
warranty.
GRE Pipe Steel Pipe
• Requires longer bolts to accommodate extra thickness, add
1/2” per steel backing plate to bolt length.
GRE Steel
Connecting to Raised Face Steel Flange FLANGE FLANGE
(FF) (FF)
• Requires a special spacer ring or machining off raised face Figure 14 - Fiberglass to Steel Flat Face
to avoid shearing or cracking the flange when bolts are
tightened.
• Specify thickness of flange raise when ordering.
• Raised face spacer rings are required for makeup of flanges
ANSI 600 and higher to steel raised face flanges.

72 73
74
1
7/8
3/4
5/8

1 1/4

1 7/8
1 1/8

1 1/2
1 5/8
1 3/8
Bolt
GRE Pipe

Table 12

Size (in)
(FF)
GRE

Bolt Torque vs Bolt Size

GRE

FLANGE

96
54

324

595
795
845
155

460
230

1. Multiply by 0.9 for plating.

ft•lb

1565
SPACER RING

Torque Requirements

Grade 2
Figure 15 - Fiberglass to Steel Raised Face
STEEL

73

311
210

439
130

806
623
(FF)

N•m

1145
1077

2121
Steel
FLANGE
SPIRAL

GASKET
WOUND

Torque
Steel Pipe

3. Reference Fig. 16 for bolt torque sequence recommendation

89

2. Regardless of bolting material, do not exceed Grade 5 torque.

776
160

386
258

544
ft•lb

1100
1347
1006

2000
Grade 5

216

737
120

523
349
N•m

1491
2711
1826
1052
1363
Pressure Rating Bolt Length

75
Pipe Thread Flange Flange Bolt Bolt Bolt
Size Size Thread 100°F 200°F O.D. Width Circle No. of Hole Size FG to Wt.
Table 13

in in Type psi psi in in in Bolts in in FG to FG Steel lbs

ANSI 150
2 2 3/8 8rd 285 260 6.0 3.06 4.75 4 0.750 .625 10 5.63 4.6
2 1/2 2 7/8 8rd 285 260 7.0 3.38 5.50 4 0.750 .625 12 6.06 7.0
3 3 1/2 8rd 285 260 7.5 3.63 6.00 4 0.750 .625 10 6.38 8.1
4 4 1/2 8rd 285 260 9.0 4.00 7.50 8 0.750 .625 14 7.25 12.0
6 6 5/8 8rd 285 260 11.0 4.38 9.50 8 0.875 .75 14 7.44 17.5
6 7 8rd 285 260 11.0 5.00 9.50 8 0.875 .75 14 8.06 18.4
ANSI 150 Typical Flange Dimensions (in)

8 8 5/8 8rd 285 260 13.5 5.00 11.75 8 0.875 .75 14 8.44 28.5
8 9 5/8 8rd 285 260 13.5 5.25 11.75 8 0.875 .75 14 8.44 24.8

2 2 SP 285 260 6.0 4.50 4.75 4 0.750 .625 14 10.50 7.0

3 3 SP 285 260 7.5 4.50 6.00 4 0.750 .625 14 10.69 11.0
4 4 SP 285 260 9.0 4.50 7.50 8 0.750 .625 14 10.69 14.0
4 4 SPH 285 260 9.0 4.50 7.50 8 0.750 .625 14 10.69 14.0
6 6 SPH 285 260 11.0 6.00 9.50 8 0.875 .75 16 10.50 23.0
8 8 SS 285 260 13.5 5.00 11.8 8 0.875 .75 14 8.44 28.2
10 10 SS 285 260 16.0 5.80 14.3 12 1.0 .875 16 11.44 37.2
12 12 SS 285 260 19.0 6.40 17.0 12 1.0 .875 18 12.8 61.1
NOTE: When ordering valves, check the ANSI bolt pattern versus the thread size and ANSI Rating. Some high-pressure line pipe sizes require jump-size threads.
 Pressure Rating Bolt Length

76
Pipe Thread Flange Flange Bolt Bolt Bolt
Size Size Thread 100°F 200°F O.D. Width Circle No. of Hole Size FG to Wt.
Table 13

in in Type psi psi in in in Bolts in in FG to FG Steel lbs

ANSI 300
4 4 1/2 8rd 740 675 10.0 4.00 7.88 8 0.875 .75 14 8.00 18.5
5 5 1/2 8rd 740 675 11.0 4.88 9.25 8 0.875 .75 14 10.5 26.6
6 6 5/8 8rd 740 675 12.5 4.38 10.63 12 0.875 .75 14 8.13 25.2
6 7 8rd 740 675 12.5 5.00 10.63 12 0.875 .75 14 9.19 27.2
8 8 5/8 8rd 740 675 15.0 5.00 13.00 12 1.000 .875 14 9.19 38.7
8 9 5/8 8rd 740 675 15.0 5.25 13.00 12 1.000 .875 14 9.19 35.4
ANSI 300 Typical Flange Dimensions (in)

2 2 SP 740 675 6.5 4.50 5.0 8 .75 .625 14 10.63 8.0

3 3 SP 740 675 8.2 4.50 6.62 8 .875 .75 14 10.87 12.0
4 4 SP 740 675 10.0 4.50 7.88 8 .875 .75 14 11.00 19.0
4 4 SPH 740 675 10.0 4.50 7.88 8 .875 .75 14 11.00 19.0
6 6 SPH 740 675 12.5 6.00 10.62 12 .875 .75 16 10.94 34.0
8 8 SS 740 675 15.0 5.00 13.0 12 1.0 .875 14 8.44 38.3
10 10 SS 740 675 17.5 5.80 15.3 16 1.125 1.00 16 12.13 50.4
12 12 SS 740 675 20.5 6.40 17.8 16 1.25 1.125 18 13.57 77.4
NOTE: When ordering valves, check the ANSI bolt pattern versus the thread size and ANSI Rating. Some high-pressure line pipe sizes require jump-size threads.

Pressure Rating Bolt Length(2)

77
Pipe Thread Flange Flange Bolt Bolt Bolt
Size Size Thread 100°F 200°F O.D. Width Circle No. of Hole Size FG to Wt.
Table 13

in in Type psi psi in in in Bolts in in FG to FG Steel lbs

ANSI 300/600 (2)
1 1/2 1.90 8rd 1480 1350 6.1 2.56 4.50 4 0.875 .75 10.0 5.69 4.3
2 2 3/8 8rd 1480 1350 6.5 3.06 5.00 8 0.750 .625 10.0 6.06 5.3
2 1/2 2 7/8 8rd 1480 1350 7.5 3.38 5.88 8 0.875 .75 12.0 6.75 7.6
3 3 1/2 8rd 1480 1350 8.3 3.63 6.63 8 0.875 .75 12.0 9.62 9.7
NOTE: When ordering valves, check the ANSI bolt pattern versus the thread size and ANSI Rating. Some high-pressure line pipe sizes require jump-size threads.

(1)
Spiral wound gaskets (Flexitalic®) are required in all flange joints.
(2)
Spacer rings are required for make-up of ANSI 600-1500 when mated to steel raised face flanges.
ANSI 300/600 Typical Flange Dimensions (in)

(3)
Steel backing plates are required.
 Pressure Rating Bolt Length

78
Pipe Thread Flange Flange Bolt Bolt Bolt
Size Size Thread 100°F 200°F O.D. Width Circle No. of Hole Size FG to FG to Wt.
Table 13

in in Type psi psi in in in Bolts in in FG Steel lbs

ANSI 600 (2)
4 4 1/2 8rd 1480 1350 10.8 4.00 8.50 8 1.000 .875 14.0 8.50 18.8
5 5 1/2 8rd 1480 1350 13.0 4.88 10.50 8 1.125 1.00 14.0 9.00 34.9
6 6 5/8 8rd 1480 1350 14.0 4.38 11.50 12 1.125 1.00 14.0 9.00 33.3
6 7 8rd 1480 1350 14.0 5.00 11.50 12 1.125 1.00 14.0 9.63 36.5
8 8 5/8 8rd 1480 1350 16.5 5.00 13.75 12 1.250 1.125 14.0 10.69 49.8
8 9 5/8 8rd 1480 1350 16.5 5.25 13.75 12 1.250 1.375 16.0 12.94 47.1
ANSI 600 Typical Flange Dimensions (in)

2 2 SP 1480 1350 6.5 4.5 5.0 8 .75 .625 14 10.75 8.0

3 3 SP 1480 1350 8.2 4.5 6.62 8 .875 .75 14 11.00 12.0
4 4 SP 1480 1350 10.75 4.5 8.5 8 .875 .875 14 11.25 23.0
4 4 SPH 1480 1350 10.75 4.5 8.5 8 1.0 .875 14 11.25 22.0
6 6 SPH 1480 1350 14.0 6.0 11.5 12 1.125 1.0 16 11.88 46.0
6 6 SS HP 1480 1350 14.0 9.2 11.5 12 1.125 1.0 24 16.93 69.0
8 8 SS 1480 1350 16.5 5.0 13.8 12 1.25 1.125 14 10.87 49.4
8 8 SS HP 1480 1350 16.5 9.2 13.8 12 1.25 1.125 24 17.24 88.0
10 10 SS 1480 1350 20.0 5.8 17.0 16 1.375 1.25 16 12.75 76.9
10 10 SS HP 1480 1350 20.0 9.2 17.0 16 1.375 1.25 24 17.55 123.5
12 12 SS 1480 1350 22.0 6.4 19.3 20 1.375 1.25 18 12.75 95.4
12 12 SS HP 1480 1350 22.0 9.2 19.3 20 1.375 1.25 24 17.67 138.7
NOTE: When ordering valves, check the ANSI bolt pattern versus the thread size and ANSI Rating. Some high-pressure line pipe sizes require jump-size threads.

Pressure Rating Bolt Length

79
Pipe Thread Flange Flange Bolt Bolt Bolt
Size Size Thread 100°F 200°F O.D. Width Circle No. of Hole Size FG to Wt.
Table 13

in in Type psi psi in in in Bolts in in FG to FG Steel lbs

ANSI 900 (2)
3 3 1/2 8rd 2200 2025 9.5 3.63 7.50 8 1.000 .875 12.0 9.87 13.7
4 4 1/2 8rd 2200 2025 11.5 4.00 9.25 8 1.250 1.125 14.0 9.25 21.5
5 5 1/2(3) 8rd 2200 2025 13.8 4.88 11.00 8 1.375 1.25 16.0 12.62 38.9
6 6 5/8 (3) 8rd 2200 2025 15.0 4.38 12.50 12 1.250 1.25 14.0 10.87 39.4
6 7(3) 8rd 2200 2025 15.0 5.00 12.50 12 1.250 1.25 16.0 12.69 43.5
8 8 5/8 (3) 8rd 2200 2025 18.5 5.00 15.50 12 1.500 1.375 16.0 13.00 75.0
ANSI 900 Typical Flange Dimensions (in)

8 9 5/8 (3) 8rd 2200 2025 18.5 5.25 15.50 12 1.500 1.375 16.0 12.75 64.9

2 2 SP 2220 2025 8.5 4.5 6.5 8 1.0 .875 14 11.25 15.0

3 3 SP 2220 2025 9.5 4.5 7.5 8 1.0 .875 14 11.25 18.0
4 4 SP 2220 2025 11.5 4.5 9.25 8 1.25 1.125 14 11.50 25.0
4 4 SPH 2220 2025 11.5 4.5 9.25 8 1.25 1.125 14 11.50 25.0
6 6 SPH 2220 2025 15.0 6.0 12.5 12 1.25 1.125 16 12.69 54.0
6 6 SS HP 2200 2025 15.0 9.2 12.5 12 1.25 1.125 24 17.24 82.0
8 8 SS HP 2200 2025 18.5 9.2 15.5 12 1.5 1.375 24 17.55 119.3
10 10 SS HP 2200 2025 21.5 9.2 18.5 16 1.5 1.375 24 17.80 152.1
12 12 SS HP 2200 2025 24.0 9.2 21.0 20 1.5 1.375 24 18.17 181.7
NOTE: When ordering valves, check the ANSI bolt pattern versus the thread size and ANSI Rating. Some high-pressure line pipe sizes require jump-size threads.
 Pressure Rating Flange Bolt Length

80
Pipe Thread Flange Bolt Bolt Bolt
Size Size Thread 100°F 200°F O.D. Width Circle No. of Hole Size FG to Wt.
Type Bolts FG to FG Steel
Table 13

in in psi psi in in in in in lbs

ANSI 900/1500 (2)
1 1/2 1.90 8rd 3705 3375 7.0 2.56 4.88 4 1.125 1.125 10 6.56 5.6
2 2 3/8 8rd 3705 3375 8.5 3.06 6.50 8 1.000 1.125 10 7.06 9.7
2 1/2 2 7/8 8rd 3705 3375 9.6 3.38 7.50 8 1.125 1.375 12 7.75 13.6
ANSI 1500 (2)
3 3 1/2 8rd 3705 3375 10.5 3.63 8.00 8 1.250 1.125 12 8.75 16.8
3 4 1/2 8rd 3705 3375 10.5 4.00 8.00 8 1.250 1.125 12 10.38 18.8
4 4 1/2(3) 8rd 3705 3375 12.3 4.00 9.50 8 1.375 1.25 14 10.88 24.9
4 5 1/2(3) 8rd 3705 3375 12.3 4.88 9.50 8 1.375 1.25 16 13.50 28.5
5 5 1/2(3) 8rd 3705 3375 14.8 4.88 11.50 8 1.625 1.5 16 13.50 44.9
6 6 5/8 (3) 8rd 3705 3375 15.5 4.38 12.50 12 1.500 1.375 14 12.25 41.1
6 7(3) 8rd 3705 3375 15.5 5.00 12.50 12 1.500 1.375 16 13.75 45.4
8 9 5/8 (3) 8rd 3705 3375 19.0 5.25 15.50 12 1.750 1.625 18 15.87 72.0
ANSI 900/1500 and 1500 Typical Flange Dimensions (in)

2 2 SP 3705 3375 8.5 4.5 6.5 8 1.0 .875 14 11.25 15.0

3 3 SP 3705 3375 10.5 4.5 8.0 8 1.25 1.125 14 11.63 22.0
4 4 SP 3705 3375 12.25 4.5 9.5 8 1.375 1.25 14 11.62 29.0
4 4 SPH 3705 3375 12.3 4.5 9.5 8 1.375 1.25 14 11.87 29.0
6 6 SS HP 3705 3375 15.5 9.2 12.5 12 1.5 1.375 24 18.30 86.0
6 6 SPH 3705 3375 15.5 6.0 12.5 12 1.5 1.375 18 15.25 57.0
8 8 SS HP 3705 3375 19.0 9.2 15.5 12 1.75 1.625 26 19.89 123.9
10 10 SS HP 3705 3375 23.0 9.2 19.0 12 2.0 1.875 26 20.52 179.2
12 12 SS HP 3705 3375 26.5 9.2 22.5 12 2.12 2.0 24 19.93 239.0
NOTE: When ordering valves, check the ANSI bolt pattern versus the thread size and ANSI Rating. Some high-pressure line pipe sizes require jump-size threads.

(3)
(2)
(1)

81
flanges.
Figure 16 - Bolt Torque Sequence

Steel backing plates are required.

Spiral wound gaskets (Flexitalic®) are required in all flange joints.
Spacer rings are required for make-up of ANSI 600-1500 when mated to steel raised face
 Field Fabrication
Special length nipples are often required to locate a fitting or
flange in a certain location or to make a repair.
API 8rd Threaded Nipples
There are six methods for fabricating a nipple or spacing out of a
fitting for API 8rd threaded products. Methods #1 and #2 go on the
body of the pipe, not requiring upset. Methods #3 – #6 take into
consideration the fact that the API 8rd thread requires an upset
on the pipe body or factory nipple stock.

Section 9
1. Bell x male 8rd threaded adapters applied on the pipe body.
(Reference Table 14 and Table 16)
2. Field molded threads with a hand buildup on the pipe body.
(Reference Table 14.)
3. Field molded threads on nipple stock. (Maintains full
pressure rating of the nipple stock.)
4. Pre-fabricated factory nipples with molded threads from

Field Fabrication nipple stock.

5. Pre-fabricated factory nipples with precision ground
threads from nipple stock.
6. Threads can be molded in the field on existing pipe by using
the upset behind the pin thread. The upset must be long
enough for new threads and width of wrench without using
transition. Maintains full pressure rating of pipe.
Super Seal Threaded Nipples
There are two methods for fabricating a nipple or spacing out of
a fitting. Method #1 goes on the body of the pipe, not requiring
upset. Method #2 requires a special length nipple from the
factory.
1. Bell x male Super Seal threaded adapters applied on the
pipe body. (Reference Table 16.)
2. Pre-fabricated factory nipples with Super Seal threads.

API 8rd Threaded Nipples

Super Seal Threaded Nipples
REpair Methods
Bell
82x Male Adapters 83
Application of STAR 8rd Field Threads
Table 14 Repair Methods
API 8rd Field Threaded Options
The repair of Star Line Pipe primarily involves the installation
of a flange set. The following are the repair methods and the

2000
9 5/8

limitations of each method.

NR
NR
-

-
NOTE: The Fiber Glass Systems Field Service Representative
should never make any cut in the line during the repair. Customer
2000
1000

500-
8 5/8

800
800

3
is responsible for lock-out tag-out.
Method 1
2500(2)

1250-
1500
1500
1250

2000

Purchase a pre-fabricated repair joint designed to replace a full

7

2
Thread Size (in) / Maximum Pressure Ratings (psi)

joint of pipe and allows room for a flange set. This method works
for API 10rd and 8rd connections and for Super Seal connections.
2000(1)
1250

1000
6 5/8

800
800

This is the recommended repair method.

2

• Determine the length of the joint to be replaced by

measuring the total length of the exposed pipe.
1500

1250
1250
2000
5 1/2

• Purchase a pre-fabricated repair joint designed to replace

the full joint of pipe and allows room for a flange set.
1500-
2500

2000
2000

2000
4 1/2

• Cut the damaged joint using a hacksaw.

2

• Remove both remaining ends using two strap wrenches.

1500-
2500
2500

3000

2500
3 1/2

• Replace the damaged joint with the special length repair

2

joint.
• Install the flange set.
2000-
2500
2500

2500
3500
2 7/8

Lower rated products require many layers of reinforcement.

• Reference Figure 17 and 18.

Reference Table 16 for Super Seal bell x male adapters.

Star Aliphatic Amine Line Pipe (Figure 17)

2000-
4000
2500

2500

2500
2 3/8

• 1 pin x pin repair joint or 2 pin x pin repair joints plus a

Note: 5.93” ID = 1000 psi. 5.50” ID = 2000 psi.
Note: 5.93” ID = 2000 psi. 5.50” ID = 2500.

coupling
2000-
4000
2500

2500

2500
1.90

• 1 flange set
Star Anhydride and Aromatic Amine Line Pipe (Figure 18)
Standard Nipple Stock

• 1 pin x box repair joint

Bell x Male Adapter (4)

Molded Threads on

Molded Threads on

Minimum Layers of

Product Range(3)
Recommended
Reinforcement

• 1 pin x pin repair joint

Hand Buildup
Thread Type

• 1 flange set
(2)

(3)

(4)
(1)

84 85
 Method 2
If extra pipe is available, replace the damaged joint with a new
joint which can be shortened in the field to make room for the
flange set and a minimum length nipple.
• Cut the damaged joint using a hacksaw.
• Remove both remaining ends using two strap wrenches.
• Replace with a new joint of pipe.
• Shorten the joint as required to fit the flange set and a
minimum length nipple.
• API 10rd/8rd
• Cut the pipe on the upset only. If this is not possible, either
use nipple stock or buildup the pipe body.
• Reference Field Fabrication of Star 10rd/8rd Threaded
Nipples.
• Field thread the pipe and install the flange set.
• Super Seal
• Use bell x male adapters on the pipe body.
• Install the flange set.
NOTE: Some field thread options may de-rate the pressure of the
line.
Method 3
Make use of the undamaged pipe by rethreading the ends in
the field allowing for the flange set. Reference Table 14 for field
threading options for Star 8rd connections. Reference Table
16 for reference to Super Seal bell x male adapters. Some field
thread options or bell x male adapters may de-rate the pressure
of the line.
• Consider the length of the damage. If the width of a set of
flanges will repair the area, a nipple (long enough to repair
the damaged area) and a coupling will be required along
with the flange set.

Figure 17 - Method 1 Repair Joint Figure 18 - Method 1 Repair Joint

86 87
 • Cut out the damaged area of the pipe using a hack saw
taking into consideration the total laying length of the parts
needed to make the repair.
• Depending on how long the damaged area is, an extra joint
of pipe may be required.
• Rethread both square cut ends using procedures in the Field
Fabrication of Pipe Upset section for field threads or bell x
male adapters.
• Install the flange set.
Option for Low Pressure Repair – CEN Connections
Bonded Flanges, Bell x Bell Sleeve Couplings, and Bell x Groove
Adapters.
• Bell x groove adapters usually de-rate the line to 125 psi.
• Requires Star approved tapering tool set at 1-3/4° taper
angle.
• Follow bonding procedures in the bonded threaded
adapters section and in INS1000 (Installation Guide for
Matched Tapered Bell x Spigot Joints).
• Limited pressure ratings which depend on the type of fitting
that is used to make the repair.
Bonded Saddle Patch
• Bonded saddle patches are not considered permanent
repairs and they cannot be applied over a wet surface.
• Table 15 shows the maximum pressure that a bonded
saddle should be attempted.

Table 15
Max Pressure for Bonded Saddle Patches

Pipe Size (in) 1 1/2 - 2 2 1/2 - 3

Maximum Pressure Rating (psi) 450 300

Figure 19 - Method 2 Repair Joint Figure 20 - Method 3 Repair Joint

88 89
 • Patch length – A length of good pipe is cut and split Table 16 (continued)
longitudinally for 180° of circumferential coverage and long 8rd Bell x Male Threaded Adapter Codes
enough to cover the damaged area plus 1 foot on each side.
Thread Pressure Aromatic
• Sand the area to be patched and the interior of the saddle Size Rating Anhydride Aliphatic Amine Amine
with 40 grit sand paper; remove all the gloss or shine.
in psi STD 15HR STD 15HR 15HR
• Sanded areas must be thoroughly cleaned of all foreign 2 3⁄8 750 N/A S N/A R N/A
material, oils, grease, and fingerprints. If cleaning solvent is 800 N/A N/A R N/A N/A
used, the surfaces must be thoroughly dried. 1000 N/A S R R S
• Use a heavy coat of epoxy adhesive on both surfaces. 1250 S S R R S
1500 S S R R S
• Snap the patch in place over the damaged area.
1750 S S R S Q
• During curing hold the patch in place with several hose 2000 S Q R Q P
clamps, spaced 6” (152 mm) along the patch.
2250 Q P R P N/A
• Do not pressurize until fully cured. Check the hardness with 2500 Q P S N/A Q
a knife blade. 2 7⁄8 750 N/A T N/A U T
• Leave the patch visible for inspection during pressure test. 800 N/A N/A U N/A N/A
1000 T T U U T
Bell x Male Threaded Adapters
1250 T T U U T
Selection of Bell x Male Adapters 1500 T T U T Q
• Select the proper bell x male adapter by thread size and 1750 T S U S Q
pressure rating as shown in Table 16. 2000 S Q U Q N/A

• To order bell x male adapters, use the codes in Table 16. 2250 Q Q T Q N/A
2500 Q N/A R Q Q
Table 16 3 1⁄2 500 N/A T U U T
8rd Bell x Male Threaded Adapter Codes
750 N/A T N/A U T
800 T N/A U N/A N/A
Thread Pressure Aromatic
1000 T T U U T
Size Rating Anhydride Aliphatic Amine Amine
1250 T T U U S
in psi STD 15HR STD 15HR 15HR
1500 T S U S S
1.90 1250 N/A R N/A N/A N/A
1750 T S U S Q
1500 R R R R R
2000 S R S R P
1750 R R R R Q
2250 S Q S R S
2000 R Q R R Q
2500 R P R Q S
2250 R Q R Q S
2500 Q S R P N/A

90 91
Table 16 (continued) Table 17
8rd Bell x Male Threaded Adapter Codes O-ring Bell x Male Threaded Adapter Codes

Thread Pressure Aromatic Pressure

Size Rating Anhy Aliph Amine Pipe Size Rating Aliphatic Amine
Thread
in psi STD 15HR STD 15HR 15HR in Type psi
4 1⁄2 500 T T U U T 8 SS 500 R
750 N/A T N/A U T 10 SS 500 R
800 T N/A U N/A N/A 12 SS 500 R
1000 T T U U S
1250 T S U T R
1500 S R T R Q
1750 S R S Q P
2000 R P R P Q
TC
5 1⁄2 500 R R R N/A N/A
750 N/A R N/A N/A R
800 R N/A R N/A N/A
1000 R R R N/A Q
1250 R Q R N/A P
1500 Q P T N/A N/A
6 5⁄8* 500 V V S S V
750* N/A V N/A U (1) S
750* N/A S (2)
800* V N/A U(1) N/A N/A
800* S (2)
1000* V S U(1) T(1) Q
1000* R(2) R(2)
1250 S Q T N/A V
8 5⁄8 500 U U S S U
750 N/A U N/A R T
800 U N/A S N/A N/A
1000 T S R N/A R
* Important Notice - It is important to know the ID before ordering 6 5⁄8“ Threaded
Adapters.
(1)
5.50 ID
(2)
5.93 ID

92 93
Application of Star 8rd Field Threads Taper Tool Model 010 / Model 10-612
Required Tools and Accessories • Collets – (be sure to select the correct collets)
• Hack saw or circular saw equipped with carbide blade. –– Other than 2” – mount collets on tool before sliding collets
• Conventional tapering tool capable of making a 1 3/4°taper into pipe.
(1” increase of OD in 16” of length or 1 to 16 ratio. –– Slide tool into pipe until pipe and the collets are flush,
- Unique Tapering Tool – Model 010 (2” – 6”) collets contracted.
- Unique Grinding Tool – Model 10-612 (2” – 12”) –– Expand collets in the pipe by turning torque knob
clockwise.
• Epoxy kit and rubber gloves.
–– Hand tight for thin wall pipe.
• Electric heat collar, propane torch or chemical heat pack.
–– Hand tight – plus 1/4 turn with wrench for thick wall pipe.
Preparation
NOTE: Reference the Tapering Tool’s product brochure for a
• Calculate the length of the nipple by subtracting the laying
complete overview of tapering instructions.
length (center to center) of the fittings to be assembled and
adding the insertion depths (see Fittings Data Sheet) of the CAUTION:
nipple. 1. For all cutting and tapering, the pipe must be held
• Add adhesive lubricating factor to the nipple of 1/8” to 1/4” securely.
for each taper to be bonded to the nipple length previously 2. End of the pipe must be as straight as possible to
calculated. ensure proper insertion length.
• Mark the pipe with a wrap around. Cutting the Taper Operation
• Cut the pipe with a saw. A. For cutting a taper, the tool must be turning clockwise –feed
• Apply a 1 3/4° taper with tapering tool. the head down slowly every few turns by turning hex head
bolt clockwise.
• Avoid over tapering the end of the nipple.
B. Continue turning the tool and lowering the head alternately
Example: until the taper length is reached.
Fittings Taper Adhesive Nipple C. Rotate the tapering tool until tool stops cutting to eliminate
Measured any cutting ridge formed by the cutting blade.
- Laying + Insertion + Lubricating = Length
Distance
Lengths Depths Factors To Cut D. Loosen hex head bolt by turning counter clockwise before
loosening torque knob to contract collets and removing the
tool from the pipe.
NOTE: Cut a test taper, checking fitting to taper. The fit should be
snug without clearance.

94 95
Bell x Male Adapter Bonding Procedure –– Warm the epoxy by heating the can if the temperature is
below 80°F (26.6°C).
• Environment
–– Pour the entire contents of the pre-measured amine
–– The pipe surface temperature during bonding should be
hardener vial into the epoxy can.
65°F to 100°F (18.3°C to 37.8°C). At higher temperatures,
shade connection from direct sunlight (make sure –– Do not attempt to split a kit.
adhesive is “cool” when applied).
–– Cut the amine hardener into the epoxy using a mixing
–– The bonding surface must be completely dry. stick.
–– Humidity during bonding must be addressed; bonding is –– Care must be taken so that the amine hardener is not
not recommended on wet surfaces. spilled (affecting the mixture).
–– Work areas must be protected against blowing sand or –– Scrape the inside of the can to ensure that all epoxy is
dust. mixed. Mixing should take at least 2 to 3 minutes.
• Surface Bonding Preparation –– The working time (pot life) for thoroughly mixed adhesive
varies from 30 minutes at 70°F (21.1°C) to 10 minutes at
–– The joining surfaces must be visually examined for
100°F to 120°F (37.8°C to 48.9°C).
cleanliness, damage, and UV degradation.
–– DO NOT USE THE MIXED ADHESIVE IF IT IS TOO HOT TO
–– UV degradation is detected by sanding and looking for
TOUCH.
color changes or loose fibers.
NOTE: CAB-O-SIL (WHITE POWDER) IS SUPPLIED WITH EACH
–– Refinishing by sanding or re-tapering is required if UV
ADHESIVE KIT. DO NOT USE CAB-O-SIL TO THICKEN THE
degradation is detected.
ADHESIVE FOR BONDED JOINTS. CAB-O-SIL IS ONLY USED FOR
–– Rewarming of the bonding surfaces if the temperature FIELD MOLDING 8RD THREADS.
falls below 65°F (18.3°C). • Joint Assembly
• Joint Cleaning –– The joints must be axially aligned.
–– Solvents can be used to remove grease, oil, mud or –– Bonding surfaces must be at the appropriate bonding
fingerprints; however, the surfaces must be completely temperature (65°F to 100°F, 18.8°C to 37.8°C).
dry before bonding can proceed after solvent has dried.
–– Bonding surfaces should never be touched by fingers or
–– All prepared surfaces must be lightly sanded prior to
tools after cleaning.
applying adhesive.
–– Apply a thin layer of mixed adhesive, normally with a clean
• Adhesive mixing
brush, onto the bell end of the adapter first, then the male
–– Always wear rubber gloves. end of pipe.
–– Stir the epoxy contents of the can with mixing stick to –– The adhesive coat should be 3 to 10 mils (excessive
ensure mixture of settled material. Particular attention to adhesive may interfere with obtaining a locked position
stirring is required for kits which have been stored more –– Slowly stab the tapered male end into the bell end of the
than 6 months. The adhesive should be smooth and free adapter.
of lumps.

96 97
 –– Push and turn the male connection to the right until full • Additional Tools and Accessories
engagement is felt.
–– Steel thread mold (STAR).
–– Wipe off excessive adhesive with disposable towels.
–– Mold release agent (Trewax®) and application brush.
–– Use of a block of wood and a hammer may be required to
–– Epoxy thread paste kit.
achieve full lock up.
• Heat-Assisted Curing –– Strap Wrench.

–– The adhesive bonded connection must be heat cured if • Environment

the temperature is below 70°F (21°C). –– Pipe surface temperature of 65°F (18.3°C) to 80°F (26.6°C).
–– The adhesive will set up in 24 hours at temperatures Warm the connection if below 65°F (18.3°C).
above 75°F (24°C) –– Thread surface shall be clean and completely dry.
–– Electric heat collars or chemical cure packs are available –– Protect surface from blowing sand and dust.
that generate 250°F (121°C) for a minimum of 30 minutes.
• Pipe Preparation
–– Heat assisted curing ensures that the connection has
reached its full chemical and physical properties. –– Square cut the pipe to the proper length using a
hacksaw or cut off saw with carbide blade, taking into
–– Use a propane torch to assist curing a bell x male adapter consideration the laying length of the fittings and the
if a steel coupling can be screwed onto the adapter. Only insertion depth of the thread.
apply the propane flame to the body of the steel coupling
to heat the joint. Direct application of the flame to the –– Taper the pipe using a conventional tapering tool with a
fiberglass adhesive will damage the material. 1-3/4° taper.

• Examination / Documentation –– The taper should cover the entire length of the mold and
1/8” of the pipe should stick through the mold.
–– Each joint must be visually inspected and documented.
–– Verify the mold fit to the taper; it should be snug with no
–– Number each connection made and add initials of person movement.
responsible.
–– Make sure all oil, grease, mud, fingerprints, and sand are
–– Keeping an inspection sheet per API 15TL4, Appendix C is removed with sand paper before bonding.
good practice.
–– Once cleaned, the bonding area should not be touched.
Field Molded Thread Procedure
• Mold Preparation
Prior to beginning the process of making a thread the pipe must
–– Clean and warm factory supplied and approved thread
be qualified to the diameter of the thread mold. If the pipe is not
molds to touch (100°F to 130°F (37.8°C to 54.4°C)).
large enough to accept the full thread, either nipple stock must be
purchased or a field upset must be fabricated to obtain product –– An even, smooth coat of release agent should be applied
pressure rating as listed in Table 14. Hand buildups may de-rate uniformly with a soft brush to the threads and both mold
the line. faces.
–– Excess releasing agent must be removed. There should be
no visual signs of release agent.

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 • Thread Paste Preparation –– Force the paste into the thread cavity by moving it along
the thread, in one direction, from the small end of the
–– Always wear rubber gloves.
mold to the large.
–– Stir the epoxy contents of the can with the mixing stick to –– Cover the full surface of the thread. Break or remove any
ensure mixture of settled material. Particular attention to air pockets present in the thread.
stirring is required for kits which have been stored more
than 6 months. Adhesive should be smooth and free of –– Cover the tapered end of the pipe with approximately 1/8”
lumps. of mixed epoxy paste.
–– Warm the epoxy by heating the can if the temperature is –– Roll the paste around the tapered area in a fashion which
below 65°F (18.3°C). assists breaking any air pockets that are present.
–– Pour the entire contents of the pre-measured amine –– Build a 1/4” thick bead of paste around the small end of
hardener vial into the epoxy can. the taper.
–– Do not attempt to split a kit. –– Using a stabbing motion, insert the large end of the
thread mold onto the tapered pipe. Push the mold on in a
–– Cut the amine hardener into the epoxy using the mixing straight, smooth fashion.
stick.
–– Once the surfaces touch, turn the mold clockwise until
–– Care must be taken so that the amine hardener is not the mold is locked onto the tapered surface.
spilled (affecting the mixture).
–– Thoroughly clean the excess epoxy paste from the front
–– Scrape the inside of the can to ensure that all epoxy is and rear of the mold. Excessive thread paste left on the
mixed (mixing should take at least 2 to 3 minutes). mold will cause difficult torque requirements for mold
–– The working time (pot life) for thoroughly mixed adhesive removal.
varies from 30 minutes at 70°F (21.1°C) to 10 minutes at • Heat Assisted Curing
100°F to 120°F (37.8°C to 48.9°C).
–– Complete cure requires 24 hours at 75°F (23.9°C).
–– DO NOT USE THE MIXED ADHESIVE IF IT IS TOO HOT TO
TOUCH. –– Faster cure time and optimum chemical and physical
performance requires the application of heat. See Table
–– Depending on the thread paste temperature, adjust 17.
the paste viscosity with CAB-O-SIL (white powdery
substance) provided with the epoxy kit. –– Thread cure can be checked at the back of the mold with
a knife blade.
–– The consistency of the paste should adhere to the mixing
stick. –– The thread must resist puncture.

–– Make sure the CAB-O-SIL is thoroughly mixed into the • Mold Removal
adhesive. –– Tap the mold lightly all the way around using a small
• Threading hammer.
–– Fill the thread mold with the mixed thread paste using the –– Unscrew the mold using a strap wrench; avoid using a
mixing stick. pipe wrench since this type wrench can damage the mold.

100 101
 –– Support the pipe during the mold removal such that it
does not become bent due to torque of mold removal.
–– Using a metal friction wrench or a 360° padded vise for
backup during mold removal is good practice.
• Thread Inspection
–– A fully cured thread should be shiny in appearance and
substantially free of voids. Clean excess paste from mold Tap mold lightly

–– Check the thread hardness using a center punch on the

back of the threads.
–– Full quality inspection requires reference to thread visual
inspection standards.

Unscrew mold Inspect thread

Table 18
Feild Thread Cure

Pre-heat thread mold Apply mold release agent

Cure Methods Required Steps

250°F (121.1°C) for 30 minutes.

Electric Heat Collars Do not overlap.
Insulate in cold weather.

Propane Torch Contact FGS.

Follow manufacturer’s instructions.

Caution: Wear respirators and avoid
Mix thread paste Apply paste to mold Chemical Heat Blanket
breathing fumes.
Insulate in cold weather.

Field Fabrication of Pipe Buildup

The first step is to check the fit of the pin mold on the pipe. This is
performed by sliding the pin mold onto the pipe. If the mold does
not slide completely on the pipe, a good fit does not exist. Pipe
surface must be sanded with an Emery cloth to prepare the
Apply paste to pipe Stab mold onto pipe

102 103
surface for the buildup of the pin. The pin buildup consists of a • Once the buildup is large enough, the normal field threading
special woven roving reinforcement and resin lay up on the pin to procedure can be followed over the wet uncured upset.
form the threads. A step-by-step procedure follows.
NOTE: This method has shown satisfactory results; however,
• Cut pipe square and to length. it requires an expert competence level obtained only by
special training and experience. Training by FGS Technical
• Check pin mold fit.
Service Representative is required.
–– Good fit if it slides on completely.
–– Poor fit if it does not completely slide onto the pipe.
1/8”
–– If poor fit exists, the pipe surface must be sanded to
allow the mold to completely slide onto the pipe. A slight Good fit
tapering of the pipe surface is preferred and will make
it easier to slide the mold into position and to squeeze
excess resin out of the mold.
• The surface must be smoothed for pin buildup by sanding Pipe is too large,
with an Emery cloth. The glossy layer on the pipe surface must be sanded.
must be completely removed to provide a good bonding
surface. Failure to remove all glossy material will result in
a poor thread performance. This bonding surface must be
clean and free of any contamination by oil or other foreign
material.
• The epoxy adhesive must be mixed per the instructions for
Adhesive Mixing found in the Bell x Male Adapter Bonding
Procedure. The supplied CAB-O-SIL filler must be used for
adhesive viscosity control.
• The viscosity must be high enough to prevent the resin from
running or leaking out of the mold during setup.
• The woven roving glass strips must be thoroughly saturated
with epoxy thread paste. This glass will be on a roll 2 to 4
inches wide depending on the pin diameter.
• The saturated glass must be carefully laid up by wrapping
around the prepared end of the pipe. Care should be taken
not to contaminate the saturated glass with foreign matter
during this process.
• The number of wraps of woven roving required is dependent
on the size difference in the pipe outside diameter and the
diameter of the required upset for the thread. Specific data
is provided in Table 14.

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Fiber Glass Systems
17115 San Pedro Avenue, Ste 200
San Antonio, Texas 78232 USA
Phone: 210 477 7500 | Fax: 210 477 7560

National Oilwell Varco has produced this brochure for general information
only, and it is not intended for design purposes. Although every effort has been
made to maintain the accuracy and reliability of its contents, National Oilwell
Varco in no way assumes responsibility for liability for any loss, damage or
injury resulting from the use of information and data herein nor is any warranty
expressed or implied. Always cross-reference the bulletin date with the most
current version listed at the web site noted in this literature.

© 2019 National Oilwell Varco All Rights Reserved

INS8000ENG September 2019

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