Since 1982, pipeline insulation has been Flowline’s primary line of work. During our tenure we have insulated over 3,000 miles of pipe, most of which was installed in the oil fields of Prudhoe Bay. In addition to straight run pipe, Flowline insulates pipe fittings, induction bends, welded joints and fabricated spool pieces.
Current production capabilities allow for pipe and induction bend insulation processes to run concurrently with each other. Production capacities include the ability to insulate upwards of 8,000 LF per day of straight run pipe as well as 700 induction bends per month when running single 8-hour shifts in our plant. The facility was designed to insulate pipe up to 80’ in length with a maximum diameter of 60 inches.
We routinely insulate high yield/low temp carbon steel, stainless steel and duplex stainless steel pipe. In addition to the materials previously listed we have the capability to insulate galvanized steel, ductile iron, HDPE, PVC, ABS, and copper piping.
The polyurethane insulation used is a plural component system which is purchased in railcar quantities and stored on site in one of six 17,500 gallon heated bulk tanks. Insulation densities ranging from 2.25 to 4.5 pounds per cubic foot can be achieved using our specially designed urethane system.
Our plural component system is applied as a foam-in-place process to each pipe after the jacketing has been formed to the required dimensions. The jacketing systems utilized for the insulated pipe are typically one of the following: 24 gauge corrugated galvanized steel, 16 gauge corrugated aluminum, polyethylene coated 24 gauge corrugated galvanized steel, or high density polyethylene (HDPE). Flowline manufactures the metal jacketing on a custom roll forming machine during the insulation process. Electrical heat trace channels in galvanized steel, stainless steel, or ABS plastic can be installed on the pipe surface prior to insulation. Additionally, larger glycol or hot water heat trace channel can be installed. Multiple channel installations are also available. Insulation cutbacks (the exposed end length of non-insulated pipe) can be customized to accommodate job specific field welding or weld coating processes. Exposed end faces of insulation have waterstop sealant applied to ensure additional protection against infiltration of water during storage, transport, installation and system operation.
Induction bends are insulated by using a pre-manufactured “slip-on” jacket that is applied to each bend in gored segments. Each segment is secured and jacket tangents are customized to meet the job specific insulation cutback dimensions. Jacket construction is typically 24 gauge non-corrugated galvanized steel. The annulus is filled with Flowline’s pour-in-place urethane insulation system. Exposed end faces of insulation can have waterstop sealant applied to ensure additional protection against infiltration of water during transport and installation.
SPOOLS / WELD PACKS
Flowline can provide “turn-key” spools for field installation. This service includes insulating spools from end to end after fabrication. Use of pre-insulated straight run pipe during fabrication, as well as a pour-in-place polyurethane insulation system or pre-formed half shells allow insulation of fittings and weld joints prior to shipment. This ultimately creates a final product that provides for a more cost effective field installation and expedited field installation scheduling. This service can be applied to both “on-pad” and “cross-country” pipeline spools. Jacketing in these systems may be galvanized steel wraps, aluminum couplings bands, or heat shrink sleeves.
Flowline has developed a proprietary traceability program that is used to collect in-process data for our clients’ final reporting requirements. The program allows entry and tracking of heat numbers and production numbers against each pipe processed in our facilities. This is done by collecting data at each critical station in our production facility while processing double joint welds, FBE coating, insulation application, and final shipping. This system allows for final traceability documentation to be delivered via electronic means to the client and their installation contractors.