UNITED PIPELINE SYSTEMS

ENGINEERING AND
CONSTRUCTION GUIDE
 ENGINEERING AND CONSTRUCTION GUIDE

1.0 Introduction and Overviews

The Tite Liner and Safetyliner systems begin with a
thermoplastic liner pipe with an outside diameter larger
than the inside diameter of the host pipe it will protect.
The pipeline will be accessed in intervals that allow for the
insertion of the liner pipe. Under normal conditions, average
insertion lengths are 1,500 to 3,000 feet (600 to 800 meters).
Longer insertion lengths greater than 3,000 feet (1 kilometer)
can be achieved depending on the diameter, bends, terrain
and condition of the steel. To date, our longest continuous pull
is 7,920 feet.

A winch cable is sent through a section of pipeline and

attached to the liner pipe. The winch pulls the liner pipe
through the roller reduction box, which is positioned at
the insertion end of the pipeline section. The liner pipe is
compressed radially as it passes through the roller reduction
box. This temporary reduction provides sufficient clearance
between the host pipe and the liner pipe to allow insertion.
Until the pulling is complete, the liner is under tension,
causing it to remain at a reduced diameter. When the tension
is released, the liner pipe expands, creating a tight fit against
the inner wall of the steel pipe.
Following relaxation of the liner pipe, the thermoplastic end-
fittings are installed, the system is tested and the pipeline is
ready for service.
2.0 Tite Liner and Safetyliner Systems Materials
Uniteds Tite Liner and Safetyliner pipe is manufactured
according to our strict specifications and qualified procedures.
Our requirements often exceed internationally recognized
standards, assuring that each Tite Liner and Safetyliner
installation is with the finest liner pipe available. United
maintains a global footprint and liner pipes are manufactured
at several qualified locations throughout the world.
United usually installs a customized thin wall liner to provide
protection from corrosion and minimize installation costs.
A thicker liner can be provided for more aggressive abrasive
applications or to provide additional structural capabilities.
3.0 Liner Connection Systems
United offers the widest range of welded and bolted connections
in the industry. Selection of a particular termination should take
into account a number of factors including:
Medium
Environmental considerations
Pipeline location
Pipeline section length
Applicable codes
The most common type of termination is a bolted flange
connection but United also offers welded connections to serve
the broadest customer base. When flanges are required,
United uses weld neck flanges.
3.1 Flange Connections
All sections of the host pipe lined with Tite Liner and
Safetyliner are joined using flange connections. These
connections are capable of the ANSI pressure rating of the
steel flanges. United uses two types of flanged connections
for the Tite Liner and Safetyliner systems:
Tite Liner Flange Connection
Slurry Flange Connection
The seal for both of these connections is achieved by
compression of the thermoplastic flange-fitting between the
faces of the steel flanges. All components of the connection
should be specified and supplied as a unit. Specific
information needed for this includes:

Steel flange rating

Steel pipe outside diameter
Steel pipe wall thickness
Steel pipe and flange material specifications

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3.1.1 Tite Liner Flange Connection
The standard Tite Liner flange connection is generally
used in corrosive applications, fittings, valves, lined or
unlined sections, and is shown in Figure 1. Each steel
flange is machined to match the inside diameter of
the steel pipe and inspected to verify that the raised
face dimension is correct. A radius that matches the
thermoplastic flange-fitting is machined on the inside of
the raised face bore. A retaining ring is placed between
each of the steel flanges to allow the correct amount of
compression of the thermoplastic flange-fitting. No gasket
is required as the compressed thermoplastic flange-fitting
provides a pressure seal. The retaining ring provides long
term stability to the connection. United manufactures
the key components used in the connection to ensure the
steel flange, the thermoplastic flange-fitting and the steel
retaining ring can be assembled as a unit. Quality control
must be maintained in these items so that the:
Radius of the steel flange internal bore matches the
thermoplastic flange-fitting
Raised face is square and of the correct diameter and
tolerance to mate to the retaining ring
Retaining ring is manufactured to the correct width
and diameter
The same connection is used to connect a lined section to
an internally lined fitting or unlined connection. A special
retaining ring is used in this situation to provide the correct
compression.
Raised Face
Weld Neck
Flange
Riser Pipe
Thread-o-let
Tite Liner
Thermoplastic
Flange Fitting
Steel
Compression Ring
Figure 1. Tite Liner Flange
3.1.2 Slurry Flange Connection
For abrasive applications, United recommends the patented
Slurry Flange connection shown in Figure 2. Both the steel
flange and the thermoplastic flange-fitting are machined
with specially designed interlocking features. When the
two flanges are bolted together, a uniform surface is
maintained across the interface, eliminating excessive wear
from turbulence. The sealing method is the same proven
compressed thermoplastic technology that we use in our
standard flange connection. An optional gasket may be
available to provide a secondary seal. The Slurry Flange
connection incorporates standard bolting geometry to mate
with standard flanges.
The Slurry Flange connection was designed and tested
to meet ASME B31.11 of the Slurry Transportation Piping
System Code.
Modified Weld
Neck Flange
Riser Pipe
Thread-o-let
Tite Liner
Secondary
Seal
Figure 2. Slurry Flange Connection
3.2 Welded Connections
In some cases the use of a flanged connection is not
preferred due to high environmental sensitivity, offshore
installation techniques or lack of code compatibility. In these
cases a welded connection can be used and United offers
two options:
WeldTite EF (electrofusion) welded connection
WeldTite CRA (corrosion resistant alloy) welded connection
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 ENGINEERING AND CONSTRUCTION GUIDE

3.2.1 WeldTite EF Welded Connection

CRA girth weld ties lined
sections together
United Pipeline's WeldTite EF welded connection allows
Special machined
for the connection of two thermoplastic lined sections of carbon steel pup with
CRA cladding
pipe without the use of flanges. The connection creates an
end seal on the thermoplastic liner which has been tested Carbon steel
girth weld
to over 9,000 psi and restrains thermoplastic liner ends
Carbon steel
from pull-out. All wetted materials are thermoplastic and Thermoplastic liner host pipe
the continuously smooth inside diameter of the connection
makes it suitable for a variety of applications. Radially compressed
thermoplastic seals
and prevents liner
US and international patents pending pull-out

Installation and operation complies with ASME pipeline CRA fillet seal weld
codes and standards
CRA compression ring

Carbon steel external Figure 4. WeldTite CRA Welded Connection

weld sleeve

Carbon steel 4.0 Lined Fittings

fillet weld
Special machined
Thermoplastic
liner
carbon steel hub United can furnish special
Thermoplastic
Carbon steel fittings internally lined with
girth weld
fusion weld
Carbon steel thermoplastic to match the
Thermoplastic host pipe
stubends
exact dimensions of the pipe
sections. Standard fittings such
Thermoplastic
electrofusion coupler as tees, short radius elbows and
Thermoplastic special configurations can be protected with factory-lined
filler bushing
thermoplastic or other suitable internal coatings.

5.0 Steel Pipeline Requirements

Figure 3. WeldTite EF Welded Connection
3.2.2 WeldTite CRA Welded Connection
United Pipeline's WeldTite CRA welded connection allows
for the connection of two thermoplastic lined sections of
steel pipe without the use of flanges. The connection creates
an end seal on the thermoplastic liner which is tested to
over 9,000 psi and restrains thermoplastic liner ends from
pull-out. All wetted materials are either thermoplastic or
corrosion resistant alloy (CRA).
US and international patents
Installation and operation complies with ASME pipeline
codes and standards
The Tite Liner and Safetyliner systems are applicable
to new or existing pipelines. Attention is required to the
following areas:
Welding and weld penetration
Bends and fittings
Pigging and cleaning
Proper welding techniques should ensure there is no excessive
penetration to impede the insertion or damage the liner
pipe. All internal weld bead penetrations should be kept to a
maximum of 1/16-inch (1.6 millimeter) as shown in Figure 5.

1/16-inch (1.6mm)
Max

Figure 5

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5.1 Welding and Weld Penetration
The Tite Liner and Safetyliner installation process requires
the root pass of the steel welds not to exceed 1/16 of
penetration into the pipeline which is typically achievable
with standard pipeline welding procedures.
5.2 Bends and Fittings
The ideal bend radius is approximately 50 pipe diameters (50D,
degree per foot requirement). A 20D or less bend radius can
be utilized, although the length of the installation segment
including the bend may be reduced.
Fittings and tight bends that prohibit the installation of the
liner pipe must be removed and replaced with internally-lined
flanged fittings or suitable replacement bends welded in place.
5.3 Pigging
The unobstructed bore of the steel pipe is established by passing
a sizing pig through the steel pipeline. The sizing pig is made of
steel and can break through rough weld tips or icicles. If it reaches
a point that it cannot pass, the obstruction must be removed.
5.4 Pipe Section Lengths
When a line is buried, excavations are made at each section
end-point as described in Section 5.1.2. The steel line is cut at
each excavation and the end connections are welded in place.
Installation segments are normally determined jointly by the
owner/engineer and United. This is determined primarily by
bends, fittings and other factors such as terrain, accessibility
and pipe cleanliness, with care taken not to exceed achievable
installation lengths.
6.0 Tite Liner and Safetyliner Systems Installation
Installation lengths from 1,500 feet (600 meters) to 3,000 feet
(800 meters) are achievable depending on diameter. Pull
lengths can be longer or shorter depending on many factors,
as discussed herein. Pull lengths in excess of 1.5 miles
(2.4 kilometers) have been achieved.
6.1 Site Preparation

Although cleaning is not usually required in a new line, an

existing line may require cleaning once it is taken out of service
prior to the addition of end connections and the lining process.
Any significant hydrocarbon and/or corrosion scale products
that would impede the insertion of the liner must be removed.
Both the amount and type of hydrocarbon, corrosion or scale
deposits must be considered. If cleaning is required, it can
often be accomplished by the use of pigs and/or chemicals.
6.1.1 Right-of-Way
Once end-points have been excavated, steel flanges installed
and all known restrictions removed, the size of the line is When the Tite Liner and Safetyliner systems are installed in
verified to ensure no unknown restrictions exist. new pipelines, the right-of-way is already cleared. However, in
rehabilitation of an existing buried line, provisions must be
The following table shows sizing pig dimensions through
made to locate and access the line.
16 inches.

6.1.2 Excavation of Buried Line

Sizing Pig O.D.
Nominal O.D. of
Amount Less Nominal At each end or mid-point, the line must be excavated to allow
Steel Pipe
Steel I.D. entry of the wireline cable and liner pipe. The length and width
inches (mm)
inches (mm) of the excavation required depends on numerous factors,
including the line size and the depth of cover. United can
2 inches to 6 inches 0.20 inches provide project-specific excavation details and requirements
(50mm to 150mm) (5.08) once pertinent site information is obtained.
8 inches to 12 inches 0.25 inches
(200mm to 300mm) (6.35) 7.0 Monitoring and Maintenance
14 inches to 16 inches 0.30 inches
Monitoring and maintenance programs are available from United.
(350mm to 400mm) (7.62)
Contact your United representative for more details.

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 ENGINEERING AND CONSTRUCTION GUIDE

TITE LINER AND SAFETYLINER SYSTEMS

INSTALLATION OVERVIEW

1
Tite Liner and Safetyliner pipe is
manufactured and delivered to the site in joint
lengths of up to 65 feet (20 meters). Diameters
of 4 inches (100 millimeters) and smaller can
be provided on longer length reels.
1
The liner pipe is joined together by thermal

2 fusionthe liner pipe ends are heated to the

melting temperature, then joined together
under pressure and allowed to cool. The
completed joint retains the qualities of the
liner pipe. A shelter protects the liner pipe and
operator during inclement weather and allows
positive control over the fusion environment. 2

3
After the fusion joint is inspected, the external
bead is removed. The internal fusion bead may
be removed for abrasive applications or for
future pigging.

4 The end fitting is welded to the steel pipe.

A pulling head, which is designed to provide

5 an even pull on the liner pipe, is fusion joined

or bolted to the pulling end of the liner pipe.

6 A winch cable is inserted through the pipe

using compressed air and a blow-down pig.

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7
Uniteds roller reduction box is positioned on
the end of the line where the liner pipe enters
the steel pipe.

8 The Tite Liner and Safetyliner pipe is

pulled through the hydraulic rollers on the
roller reduction box. The tension maintained
between the roller reduction box and the
winch keeps the outside diameter of the liner
pipe reduced until it is completely pulled
through the line. 8

9
After the liner pipe is pulled into the host
pipe, the tension is released and the memory
of the liner material allows the liner to
expand and form a compression fit against
the host pipe wall.
9

10
The liner pipe is pulled and clamped in
position for fusion joining of the
thermoplastic end-fittings.

10

11 The liner pipe end is trimmed, faced and

fused to the thermoplastic end-fitting.

11

12 The clamp is removed and the thermoplastic

end-fitting retracts into the steel pipe.

12

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 INFRASTRUCTURE SOLUTIONS CORROSION PROTECTION ENERGY SERVICES

Rehabilitation and Corrosion protection and Engineering, procurement,

strengthening for pipelines, pipeline rehabilitation fabrication, construction,
buildings and bridges maintenance, turnarounds
and safety services

OD and ID robotic coating

Trenchless pipeline Engineering, procurement,
solutions for field joints
rehabilitation fabrication, construction,
maintenance and turnarounds

Pipe coatings, linings

Pipeline and structure and insulation Safety services
fiber reinforcement

Cathodic protection Fabrication, construction,

systems maintenance and
turnarounds
Structural reinforcement

Thermoplastic lining

High-quality product and

equipment sales

Fusible PVC technology

United Pipeline Systems, Inc.

135 Turner Drive
Durango, CO 81303
970.259.0354
ups@unitedpipeline.com
www.unitedpipeline.com

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are trademarks of Aegion Corporation and its affiliates in the USA and other countries.
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