V3-07-06

INTRODUCTION : PAGE 3

DESCRIPTION : PAGE 4 TO 5

DATA SHEETS : PAGE 6 TO 9

BENEFITS : PAGE 10

OFFSHORE : PAGE 11

FITTINGS : PAGE 12 TO 13

APPROVALS AND REFERENCES : PAGE 14 TO 15

CONNECTION SYSTEM GUIDELINE: PAGE 16 TO 23

2
 PIPELIFE INTERNATIONAL

S
oluforce is a high pressure plastic pipe
system designed and manufactured by
Pipelife Nederland B.V., which is part of
the Pipelife International group of companies.

Pipelife International G.m.b.H. is a global

player in the manufacture of plastic pipe
systems with offices and production
facilities in over 25 countries.

3
 SOLUFORCE

Soluforce RTP (reinforced thermoplastic pipe) is a high pressure

plastic pipe system for use in oil flow lines, water injection and
gas transport, and can also be used in other pressure
applications such as potable or effluent water lines and
irrigation.

Soluforce can be used in on shore and off shore

projects.

Soluforce is made of a polyethylene (PE 100) inner

core, a reinforcement tape, and a special
external coating of white, UV resistant,
PE 100.

The reinforcement tape, which gives

the pipe its strength, is composed
of different tape designs. The tapes
give the pipe different performance
characteristics for a wide variety of
applications and operational parameters.

Soluforce RTP pipes are manufactured in two dimensions:

4” ID, and 5” ID. However the flow capacity of the
5” Soluforce pipe is comparable to the flow capacity of a
6” steel pipeline.

Soluforce supplies the RTP pipes on disposable wooden reels in

lengths of 400 meters. The wooden reels can be economically
transported worldwide.

4
P R O D U C T R A N G E

Soluforce Light:
A synthetic fibre tape reinforcement for
lower pressure applications.

Soluforce Classic :
An synthetic fibre tape reinforcement
for medium pressure applications.

Soluforce Heavy :
A flexible steel tape reinforcement
for high pressure applications.

5
 SOLUFORCE LIGHT
Soluforce Light has been designed for low pressure applications such as
gas transmission networks up to 25 bars (360 psi).

Soluforce light can be used with new installation methods such as

cable ploughing or deep trenching.

Soluforce Light is ideal for beam pump oil flowlines operating up

to 26 bar (377 psi) for the 4” pipe, and 21 bar (305 psi) for the 5”
pipe.

Soluforce Light can be used for potable/effluent water applications up

to 36 bar (522 psi) for the 4” pipe, and 29 bar (421 psi) for the 5”
pipe.

Synthetic fibre tape

PE 100

PE U.V. resistant

6
 D A T A S H E E T

Soluforce Light
Soluforce Type L450 L540
Dimensions
Inside diameter 100 mm / 4” 125 mm / 5”
Outside diameter 125 mm / 5” 150 mm / 6”
Weight in air 4.5 Kg/m / 3.0 lb/ft 5.8 Kg/m / 3.9 lb/ft
Coil length 400 m / 1312 ft 400 m / 1312 ft
Technical details
Liner material HDPE, black, type PE100
Cover material HDPE, white, UV stabilized, type PE100
Reinforcement Aramid fibre

Gas distribution & transport (buried) according to ISO TS 18226

Ratings according to ISO TS 18226 / DVGW VP 642
Design lifetime 50 years 50 years
Service temperature ambient ambient
Maximum service pressure 25 bar / 363 psi 25 bar / 363 psi
Hydrotest pressure 40 bar / 580 psi 40 bar / 580 psi
Gas Capacity 3300 Sm3/hr / 2.8 MMScf/day 6000 Sm3/hr / 5.1 MMScf/day

Oilfield and waterservice applications according to API RP 15S

Ratings according to API RP15S
Design lifetime 20 years 20 years
Maximum service temperature 65 °C / 150 °F 65 °C / 150 °F
Maximum service pressure, hydrocarbons 26 bar / 377 psi 21 bar / 305 psi
Maximum service pressure, water 36 bar / 522 psi 29 bar / 421 psi
Maximum Hydrotest pressure 49 bar / 711 psi 40 bar / 580 psi
Liquid Capacity (Approx.) 57 m3/hr / 8600 bbl/day 88 m3/hr / 13000 bbl/day

The flow capacity, or pressure drop can be calculated by any common pipe design procedure. Thanks to the low
friction of the HDPE liner, the flow capacity of Soluforce is higher than steel pipe of the same internal diameter. The
flow capacity of 125 mm (5”) Soluforce is comparable to 6” steel pipe. Therefore 5” Soluforce is meant to replace
6” steel pipe.

For water service, we suggest to use the simple Hazen Williams calculation model. A free-to-use Hazen Williams
calculator can be found on the internet: http://www.lmnoeng.com/hazenwilliams.htm

For other fluids and gases more advanced methods should be used, such as the Darcy Weisbach method (http://
www.lmnoeng.com/darcy.htm ).

Darcy Weisbach requires the calculation of the “Moody Friction Factor” (f) from the kinematic viscosity of the fluid
(v) and the surface roughness of the pipe: (http://www.lmnoeng.com/moody.htm ).

For calculation purposes:

Hazen Williams Flow Factor: C = 150 (C = 100 for utilised steel pipe)
Darcy Weisbach surface roughness: e = 0.0015 mm
7
 SOLUFORCE CLASSIC
Soluforce Classic is designed for medium pressure applications such as
oil flowlines, water flowlines and water injection lines.

Operating pressures can go up to 90 bar (1305 psi) for water

applications in the 4” pipe dimension, and 72 bar (1044 psi) for the 5”
pipe.

Soluforce Classic can also be used for dry gas up to 42 bars (609 psi).

Synthetic fibre tape

PE 100

PE U.V. resistant

8
 D A T A S H E E T

Soluforce Classic
Soluforce Type M480 M570
Dimensions
Inside diameter 100 mm / 4” 125 mm / 5”
Outside diameter 125 mm / 5” 150 mm / 6”
Weight in air 4.6 Kg/m / 3.1 lb/ft 5.9 Kg/m / 4.0 lb/ft
Coil length 400 m / 1312 ft 400 m / 1312 ft
Technical details
Liner material HDPE, black, type PE100
Cover material HDPE, white, UV stabilized, type PE100
Reinforcement Aramid fibre

Gas distribution & transport (buried) according to ISO TS 18226

Ratings according to ISO TS 18226 / DVGW VP 642
Design lifetime 50 years 50 years
Service temperature ambient ambient
Maximum service pressure 42 bar / 609 psi 42 bar / 609 psi
Hydrotest pressure 84 bar / 1218 psi 84 bar / 1218 psi
Gas Capacity 5660 Sm3/hr / 4.8 MMScf/day 10260 Sm3/hr / 8.7 MMScf/day

Oilfield and waterservice applications according to API RP 15S

Ratings according to API RP15S
Design lifetime 20 years 20 years
Maximum service temperature 65 °C / 150 °F 65 °C / 150 °F
Maximum service pressure, hydrocarbons 65 bar / 943 psi 52 bar / 754psi
Maximum service pressure, water 90 bar / 1305 psi 72 bar / 1044 psi
Maximum Hydrotest pressure 123 bar / 1784 psi 100 bar / 1450 psi
Liquid Capacity (Approx.) 57 m3/hr / 8600 bbl/day 88 m3/hr / 13000 bbl/day

The flow capacity, or pressure drop can be calculated by any common pipe design procedure. Thanks to the low
friction of the HDPE liner, the flow capacity of Soluforce is higher than steel pipe of the same internal diameter. The
flow capacity of 125 mm (5”) Soluforce is comparable to 6” steel pipe. Therefore 5” Soluforce is meant to replace
6” steel pipe.

For water service, we suggest to use the simple Hazen Williams calculation model. A free-to-use Hazen Williams
calculator can be found on the internet: http://www.lmnoeng.com/hazenwilliams.htm

For other fluids and gases more advanced methods should be used, such as the Darcy Weisbach method (http://
www.lmnoeng.com/darcy.htm ).

Darcy Weisbach requires the calculation of the “Moody Friction Factor” (f) from the kinematic viscosity of the fluid
(v) and the surface roughness of the pipe: (http://www.lmnoeng.com/moody.htm ).

For calculation purposes:

Hazen Williams Flow Factor: C = 150 (C = 100 for utilised steel pipe)
Darcy Weisbach surface roughness: e = 0.0015 mm
9
 SOLUFORCE HEAVY

Soluforce Heavy is designed for high pressure applications, especially

water injection lines.

Design pressures go up to 150 bars (2175 psi). Soluforce Heavy has

been designed with an innovative, high strength, flexible steel tape, for
ultra-high performance.

For applications in oil flow lines please consult Soluforce.

Flexi-steel reinforced tape

PE 100

PE U.V. resistant

10
 D A T A S H E E T

Soluforce Heavy
Soluforce Type H415 H515
Dimensions
Inside diameter 100 mm / 4” 125 mm / 5”
Outside diameter 125 mm / 5” 150 mm / 6”
Weight in air 7 Kg/m / 4,7 lb/ft 9 Kg/m / 6 lb/ft
Coil length 300 m / 984 ft 220 m / 722 ft
Technical details
Liner material HDPE, black, type PE100
Cover material HDPE, white, UV stabilized, type PE100
Reinforcement High tenacity steel wire

Waterservice applications according to API 17J

Ratings according to API 17J
Design lifetime 20 years 20 years
Maximum service temperature 65 °C / 150 °F 65 °C / 150 °F
Maximum service pressure 150 bar / 2176 psi 150 bar / 2176 psi
Burst pressure > 303 bar / > 4395 psi > 303 bar / > 4395 psi
Design pressure 150 bar / 2176 psi 150 bar / 2176 psi
Factory acceptance test 195 bar / 2828 psi 195 bar / 2828 psi

11
 BENEFITS
No Corrosion

Very fast Installation

Maintenance Free

Design life up to 50 years

No Scaling

Re-Usable

400 meters length per coil

12
 OFFSHORE

Soluforce pipes may be installed safely underwater. For installation

guidelines please contact Soluforce at [email protected] and ask for the
Offshore Installation Guideline.

When installed empty, the maximum external pressure on Soluforce is

0.3 MPa, which limits the water depth to 30 meters. However, when the
Soluforce RTP system is kept pressurized or water filled during
installation, there is no theoretical limit to the water depth.

For oil and water pipe, the maximum water depth is therefore much more
than 30 meters, and limited in practice by the maximum allowable tensile
load during installation. For gas pipe, the maximum water depth is 30
meters.

13
 FITTINGS
FOR PIPE TO PIPE CONNECTION

Plastic in-line coupling

Stainless steel pipe to pipe connection

FOR CONNECTION ON EXISTING PIPE

Stainless steel end flange

Stub weld

14
 VALVE
SAFETY VALVE SYSTEM

Pipelife Nederland b.v. has recognized in several oilfields the

large difference between the actual operational pressure
and the design specifications for flowlines. The high design
pressure in these cases is mainly a result of the high reser-
voir pressure, which will be present in the well and pipeline
when the valve is closed at the gathering station side.

In order to comply with these design requirements stron-

ger pipes are to be used. For the Soluforce RTP system this
means the use of the Classic or even Heavy type, increasing
the material price to a large extent.

Pipelife Nederland developed a Soluforce pipe system

including a safety valve. The safety valve has the required
design specification, while the Soluforce pipe is designed
for the operating pressure. The safety valve is a fully auton-
omous ball valve system, which closes when the pressure
in the Soluforce pipe rises above the pressure setting of the
safety valve.

The safety valve system consists of standard used parts and

is applied in many oil fields.

This option will save material costs and increase the safety
of operations.

15
 STANDARDS, TESTING
AND QUALIFICATION

Standards Soluforce has a proven track record in the oil and gas
industry, and has been used since 2000 for different
Soluforce complies with the following standards: applications, including oil and gas linepipe, water injec-
tion pipe, water transportation, and gas distribution and
Oilfield service: transport.
Soluforce maintains the highest quality levels with regard
API RP 15S “Qualification of Spoolable Reinforced to the design, manufacturing and testing of their pro-
Plastic Linepipe” ducts, according to, or exceeding the requirements in
(Soluforce Light, and Soluforce Classic international standards.
pipe system)
API 17J “ Specification for Unbonded Flexible
Pipe” (Soluforce Heavy, pipe body) Qualification and Certification

Gas distribution and transport: The design, testing and qualification of Soluforce is veri-
fied according to the applicable standards by ISO accredi-
ISO TS 18226 “Reinforced Thermoplastic Piping Systems ted independent institutes.
for Gaseous Fuels” For oilfield applications: “Det Norske Veritas” (DNV)
(Soluforce Light and Soluforce Classic, gas For gas distribution and transport: RWTÜV.
transport & distribution)
DVGW VP 642 “ Faserverstärkte PE-Rohre (RTP) und
zugehörige Verbinder für
Gasleitungen mit Betreibsdrücken über 16
Bar”
(German Standard for gas distribution
and transport, Soluforce Light
and Soluforce Classic)
QA/QC System

Soluforce is developed, manufactured and marketed

under ISO9001 QA/QC system, approved by KIWA.

Dynamic mechanical testing of Soluforce on Pipelife's

Flexi-Rig equipment

16
 CONNECTION
SYSTEM
GUIDELINE

1 SOLUFORCE® CONNECTION SYSTEM 16

1.1 Introduction 16
1.2 Soluforce pipe to pipe connection concept 16
1.3 Soluforce® pipe to pipe connection in 8 steps 17
1.4 Soluforce® end-fitting concept (flange) 19
1.5 Soluforce® end-fitting in 5 steps 20
®
1.6 Soluforce end-fitting (Weld stub) 21

2 SOLUFORCE® WELDING EQUIPMENT KIT 22

3 UNCOILING OF SOLUFORCE® PIPE 22

4 RENTAL OF INSTALLATION EQUIPMENT 23

 I N T R O D U C T I O N
1.1 Introduction

To connect Soluforce® pipes and hook-up the Soluforce® pipeline to existing

pipe work, PipeLife manufactures two special patented couplers: end-fitting
and In-liner coupler. Both couplers are based on the electrofusion principle.

Pipelife provides just one type of coupler and end-fitting for each nominal
pipe diameter. The couplers are stronger than the highest available pipe rat-
ing, and therefore do not need any special engineering attention.

Photo 1: Soluforce® in-line coupler

1.2 Soluforce pipe to pipe connection concept

To connect two Soluforce® pipes the Soluforce in-line coupler is used. The in-
line connection technique is a 2 step process consisting of: a) butt-weld of the
liner pipe for a 100% leak free connection; b) electrofusion of the centrally
placed in-line coupler for strengthening the connection.
After welding the pipe-ends form a fully integrated plastic connection.

The Soluforce® electrofusion in-line coupler basically consists of a GRE-rein-

forced plastic sleeve, with an integrated copper heating-coil (photo 1). Photo
2 shows the pipe to pipe connection after welding.

Photo 2: Soluforce® pipe to pipe connection

18
 P I P ES C
U O
M NM NA ER CYT I O N
1.3 Soluforce® pipe to pipe connection in 8 steps

The complete process is computer controlled with no possible human error.

1 Reading the coupler data

Running the “light pen” over the barcode of the in-line

coupler will identify the coupling and initiate the welding pro-
cedure (photo 3). After the in-line coupler condition is tested
by the CNC-unit the preparations can start.

Photo 3: Reading the barcode with the “light pen”

2 Scraping the pipe surface

The pipe-end cover layers are scraped to get a fresh PE-surface

to weld the in-line coupler electrofusion sleeve (photo 4)

Photo 4: Scraping the pipe cover layer

3 Loading pipe into the welding frame

The in-line electrofusion sleeve is cleaned and slid over one

pipe-end. The pipe-end with the in-line coupler and the sec-
ond pipe-end are loaded into the welding frame (photo 5).

Photo 5: Pipe-ends loaded in fusion frame

4 Trimming the pipe ends

By means of one of the trimming tools both pipe-end faces

are trimmed resulting in a small length of free liner pipe neces-
sary for butt-welding (photo 6).

Photo 6: Trimming the pipe-ends

19
 P I P E C O N N E C T I O N
Time Required: 45 min. approximately

5 Butt-welding the liners

After removing the burrs a heating-plate is inserted for around

60 seconds to heat both pipe-ends (photo 7).

Photo 7: Heating the liner-pipe ends by means of the heating-plate

6 Butt-weld cooling

The heating-plate is automatically removed and the pipe-ends

pressed together (photo 8). The butt-weld procedure is fully
controlled by the
CNC-unit.

Photo 8: butt-welding of the pipe-ends.

7 Welding of the electrofusion sleeve

After a cooling time of approx. 8 minutes the in-line coupler

electrofusion sleeve is slid back centrally on the butt-weld
and fused to the pipe connection by energizing the copper
heating-coil for about 4 minutes (photo 9). When the
Photo 9: In-line coupler electrofusion sleeve centrally placed over the electrofusion is finished the coupler must be cooled for about
pipe-ends and connected
30 minutes.

8 Cooling of the connection

After expiry of the cooling time, the welding parameters are

checked by the CNC-unit.

If the welding parameters are within the specifications, the

connection is approved (“Parameters OK” is displayed).

Photo 10: After cooling the in-line connection is ready

Now the pipe to pipe connection can be removed from the
welding frame and the pipe put in place.

20
 E NS DU -MF M
I TAT RI YN G
1.4 Soluforce® end-fitting concept (flange)

In order to hook-up the Soluforce® pipeline to existing pipe work the

Soluforce® end-fitting is used. The end-fitting is a combination of an
electrofusion end-fitting sleeve and several steel parts (photo 11)
The Soluforce® electrofusion end-fitting sleeve basically consists of a GRE-
reinforced plastic sleeve, with an integrated copper heating-coil (figure 10).
To make the connection the plastic sleeve is electrofused on the pipe-end.
After electrofusion the end-fitting and the pipe-end are fully integrated. To
connect the pipe-end to the existing pipe work the steel parts are put in
place. The steel parts mechanically interlock on the plastic sleeve and can be
bolted to the existing pipe works by means of a standard flange (See photo Photo 11: Soluforce® flanged end-fitting
11).
For all pipe sizes the Soluforce standard end-fitting product has a SS316L 6”
600 pounds ANSI RF flange, which easily can be bolted to the existing pipe
works (photo 11 and 12).

Photo 12: Soluforce® electrofusion end-fitting sleeve

Photo 12: Installed Soluforce® end-fitting

21
 E N D - F I T T I N G
1.5 Soluforce® end-fitting in 5 steps Time Required: 25 min. approximately
The complete process is computer controlled with no possible human
error.

1 Reading the coupler data

The CNC-unit will lead the operator through the welding procedure. By
running the “light pen” over the barcode the end-fitting is identified and the
end-fitting welding procedure started (photo 13).

Photo 13: Reading the barcode with the “light pen”

2 Scraping the pipe surface

By using the pipe-end scraping tool the top-layer of the pipe-cover is removed
over the entire pipe surface and length of the end-fitting (photo 14).

Photo 14: Scraping of the pipe outer surface

3 Trimming the pipe end

After loading the pipe-end into the welding frame the trimming tool is put in
place to trim the pipe-end (photo 15)

Photo 15: End-fitting trimming in progress

22
 E NS DU -MF M
I TAT RI YN G
4 Welding of the electrofusion sleeve

The cleaned end-fitting sleeve is pushed over the cleaned pipe-end and fixed
between the clamps. The fusion leads are connected to the end-fitting ter-
minals and the electrofusion started (photo 16). The CNC-unit will check the
connection and when the connection is approved electrofusion is started by
energizing the copper heating-coil for about 4 minutes.

When the electrofusion is finished the fitting must be cooled for about 30
minutes. After expiry of the cooling time, the welding parameters are checked
by the CNC-unit. If the welding parameters are within the specifications, the
connection is approved (“Parameters OK” is displayed).

Photo 16: The actual welding of an end-fitting

5 Assembly of the steel parts

Now the end-fitting connection can be taken out off the welding frame. After
installation of the steel parts (photo 17) the pipe can be connected to the
existing steel pipeline.

Photo 17: Installing the steel parts

1.6 Soluforce® end-fitting (Weld stub)

For the gas transport and distribution pipe systems flanged connections
are not allowed. For the connection of Soluforce pipes to the existing gas
steel works modified end-fitting steel parts can be delivered having a weld
stub. The end-fitting welding procedure is the same as for the flange type
connection, only the flange steel part is redesigned into a weld stub. The weld
stub can be steel welded on the existing pipe works.
On ordering the material type must be specified (photo 18).

Photo 18: Soluforce® end-fitting with weld stub

23
 W E L D SI N
U GM E
MQAU RI PY M E N T
2 SOLUFORCE® WELDING EQUIPMENT
KIT
The Soluforce® welding kit contains all the necessary tools to weld the
Soluforce® fitting system. The kit is packed in a 20 ft container.

The main part is the Soluforce® welding tool, which is based on standard
available equipment modified for the welding of the Soluforce® fitting system.
The equipment is fully automatic and CNC controlled. The welding system
consists of (photo 19):

a) CNC unit to make computer controlled welds, data acquisition of the

welding parameters and driving the hydraulic system ;
b) Welding generator for delivery of the electrical power for electrofusion ;
c) Heating plate for heating up the pipe-ends necessary for making the liner
butt-weld ;
Photo 20: Pipe-end trimmer for butt- weld preparations d) Welding frame for fixing the pipes and a weld controlled welding process ;
e) Pipe trimmers to prepare the pipe-end face before welding ;

Photo 19: Soluforce® welding kit.

3 UNCOILING OF SOLUFORCE® PIPE

The Soluforce® pipes are delivered on coils of 400 meter packed in a wooden
disposable reel. The wooden reel can be loaded directly into the Soluforce
installation trailer preferably by means of a crane or by reverse driving the
trailer. When the trailer is driven to the installation spot the pipe end is
loosened and fixed to a fixed point. By driving the trailer along the pipe track
the reel rotates and lays down the pipe on the ground. The Soluforce® trailer
can be pulled by a 4WD land cruiser or a mechanical shovel depending on the
local soil condition (see photo 21).

Photo 21: Soluforce® Coil loaded in the trailer and

ready for uncoiling.

24
W E L D I N G E Q U I P M E N T

4 RENTAL OF INSTALLATION
EQUIPMENT
Pipelife Nederland BV can offer the following installation related services:

1. Rental of the installation equipment ;

2. Supervision by qualified welder ;
3. Training in Soluforce® welding and installation ;

For more information please contact the Soluforce Installation Manager

+
Tel: 31 228 355555
+
Fax: 31 228 355520
Email: [email protected]
Web: http://www.soluforce.com

Soluforce®
Pipelife Nederland BV
Flevolaan 7
1601 MA Enkhuizen
The Netherlands

DATE: July, 2006

Copyright: Pipelife Nederland bv

Disclaimer:
All products purchased from or supplied by Pipelife are subjected to terms and
conditions set out in the contract, order acknowledgement and/or bill of lading. Pipelife
warrants only that its product will meet those specifications designated in such
contracts, order acknowledgements, and/or bills of loading. All other information
including that herein, supplied by Pipelife, is considered accurate but is furnished upon
the express conditions that the customer shall make his own assessment to determine
the product’s suitability for a particular purpose.
Pipelife makes no other warranty either express or implied, regarding such other
information, the data upon which the same is based, or the results to be obtained from
the use thereof; that any products shall be merchantable or fit for any particular
purpose; or that the use of such other information or product will not infringe any
patent.

25
www.soluforce.com
SOLUFORCE®
Pipelife Nederland B.V.
Flevolaan 7
1601 MA Netherlands
Tel.: +31(0) 228 355 555
Fax: +31(0) 228 355 520
[email protected]

www.pipelife.com