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This document provides guidance for cement-mortar lining of steel pipes and fittings for use with corrosive water. It specifies B International's requirements for surface preparation, lining methods, mortar mix, lining thickness, curing, repair, identification, and protection of cement-mortar lined steel pipes and fittings. The document contains details on pipe and fitting materials, joint types, lining application techniques, and quality control. Figures illustrate typical cement-mortar lined pipe configurations, joint designs, bending and cutting details.
Descrizione originale:
Gs106-1 - Cement-mortar Lined Steel Pipe and Fittings
Titolo originale
Gs106-1 - Cement-mortar Lined Steel Pipe and Fittings
This document provides guidance for cement-mortar lining of steel pipes and fittings for use with corrosive water. It specifies B International's requirements for surface preparation, lining methods, mortar mix, lining thickness, curing, repair, identification, and protection of cement-mortar lined steel pipes and fittings. The document contains details on pipe and fitting materials, joint types, lining application techniques, and quality control. Figures illustrate typical cement-mortar lined pipe configurations, joint designs, bending and cutting details.
This document provides guidance for cement-mortar lining of steel pipes and fittings for use with corrosive water. It specifies B International's requirements for surface preparation, lining methods, mortar mix, lining thickness, curing, repair, identification, and protection of cement-mortar lined steel pipes and fittings. The document contains details on pipe and fitting materials, joint types, lining application techniques, and quality control. Figures illustrate typical cement-mortar lined pipe configurations, joint designs, bending and cutting details.
AND FITTINGS October 1995 Copyri!t " T!e #riti$! Petro%e&' Co'p()y p*%*c* Copyri!t " T!e #riti$! Petro%e&' Co'p()y p*%*c* All rights reserved. The information contained in this document is subject to the terms and conditions of the agreement or contract under which the document was supplied to the recipient's organisation. None of the information contained in this document shall be disclosed outside the recipient's own organisation without the prior written permission of Manager, Standards, B !nternational "imited, unless the terms of such agreement or contract e#pressl$ allow. #P GRO+P RECOMMENDED PRACTICES AND SPECIFICATIONS FOR ENGINEERING !ssue %ate October 1995 %oc. No. GS 106-1 "atest Amendment %ate %ocument Title CEMENT-MORTAR LINED STEEL PIPE AND FITTINGS &'eplaces B (ngineering Std )*+, APPLICA#ILIT, 'egional Applicabilit$- I)ter)(tio)(% SCOPE AND P+RPOSE This .uidance for Specification specifies B/s re0uirements for the lining of steel pipe and fittings with sulphate1resisting cement1mortar for use with water which would otherwise corrode the bare pipe. AMENDMENTS Amd Date Page(s) Description ___________________________________________________________________ C+STODIAN &See 2uarterl$ Status "ist for 3ontact, Pipe%i)e$ - S&b$e( E)i)eeri). /FE I$$&e0 by1- (ngineering ractices .roup, B !nternational "imited, 'esearch 4 (ngineering 3entre 3hertse$ 'oad, Sunbur$1on1Thames, Middlese#, T5)+ 6"N, 7N!T(% 8!N.%9M Tel- :;; )<=> 6+ ;*+6 ?a#- :;; )<=> 6+ ;*66 Tele#- ><+*;) CONTENTS Section age FORE2ORD****************************************************************************************************************************** 1* INTROD+CTION****************************************************************************************************************** ).) Scope ........................................................................................................................ 3* PIPE AND FITTINGS*********************************************************************************************************** >.) ipe ........................................................................................................................ >.> ?ittings ........................................................................................................................ >.= @oints ........................................................................................................................ 4* CEMENT-MORTAR LINING********************************************************************************************** =.) Surface reparation.......................................................................................................... =.> Surface ?inish................................................................................................................... =.= "ining Methods................................................................................................................. =.; Mortar Mi#....................................................................................................................... =.A "ining ThicBness............................................................................................................... =.+ 3uring =.6 'epair of %amaged 3ement1Mortar "ining...................................................................... =.C 3utting 3ement1Mortar "ined ipe.................................................................................. 5* DAMAGE PROTECTION**************************************************************************************************** ;.) Dandling ;.> Transportation.................................................................................................................. ;.= ipe (nds and Branch 3onnections.................................................................................. ;.; !nstallation 5* IDENTIFICATION**************************************************************************************************************** FIG+RE 1*********************************************************************************************************************************** ?"AN.(% 39NN(3T!9NS 5!TD 3"ASS )A* ?"AN.(S.............................................. FIG+RE 3*********************************************************************************************************************************** <* B(N%S ........................................................................................................................ FIG+RE 4*********************************************************************************************************************************** B(N%S 9TD(' TDAN <*.................................................................................................. FIG+RE 5*********************************************************************************************************************************** (33(NT'!3 '(%73(' ASS(MB"!(S............................................................................. FIG+RE 5*********************************************************************************************************************************** T(( B'AN3D 39NNN(3T!9NS 5!TD 3"ASS )A* ?"AN.(S....................................
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( = FORE2ORD I)tro0&ctio) to #P Gro&p Reco''e)0e0 Pr(ctice$ ()0 Speci8ic(tio)$ 8or E)i)eeri) The !ntroductor$ Eolume contains a series of documents that provide an introduction to the B .roup 'ecommended ractices and Specifications for (ngineering &'S(s,. !n particular, the '.eneral ?oreword' sets out the philosoph$ of the 'S(s. 9ther documents in the !ntroductor$ Eolume provide general guidance on using the 'S(s and bacBground information to (ngineering Standards in B. There are also recommendations for specific definitions and re0uirements. 9(%&e o8 t!i$ G&i0()ce 8or Speci8ic(tio) This .uidance for Specification provides users with a proven method of protecting steel pipes from internal corrosion b$ saline or fresh water. The specification has been updated based on feedbacB from both installers and operators of cement1mortar lined pipe s$stems App%ic(tio) This .uidance for Specification is intended to guide the purchaser in the use or creation of a fit1for1purpose specification for en0uir$ or purchasing activit$. Te#t in italics is 3ommentar$. 3ommentar$ provides bacBground information which supports the re0uirements of the Specification, and ma$ discuss alternative options. !t also gives guidance on the implementation of an$ 'Specification' or 'Approval' actionsI specific actions are indicated b$ an asterisB &J, preceding a paragraph number. This document ma$ refer to certain local, national or international regulations but the responsibilit$ to ensure compliance with legislation and an$ other statutor$ re0uirements lies with the user. The user should adapt or supplement this document to ensure compliance for the specific application. Speci8ic(tio) Re(0y 8or App%ic(tio) A Specification &B Spec )*+1), is available which ma$ be suitable for en0uir$ or purchasing without modification. !t is derived from this B .roup .uidance for Specification b$ retaining the technical bod$ unaltered but omitting all commentar$, omitting the data page and inserting a modified ?oreword. Pri)cip(% C!()e$ 8ro' Pre:io&$ E0itio) ). This document has been re1written in the new .S format &original document was B Standard )*+,. >. The cement1mortar curing time has been reduced from >C to 6 da$s. =. The original Standard )*+ specified the application of cement1mortar to lengths of revolving pipe. This specification now allows for other methods of application whereb$ the pipe lengths are stationar$. ;. This specification describes additional methods of joining lengths of cement1mortar lined pipe which allows for installation b$ pulling. Fee0b(c; ()0 F&rt!er I)8or'(tio) 7sers are invited to feed bacB an$ comments and to detail e#periences in the application of B 'S('s, to assist in the process of their continuous improvement. ?or feedbacB and further information, please contact Standards .roup, B !nternational or the 3ustodian. See 2uarterl$ Status "ist for contacts. 1* INTROD+CTION 1*1 Scope This document specifies B/s re0uirements for the lining of steel pipe and fittings with sulphate1resisting cement1mortar for use with saline and fresh water, where anal$sis shows that the water would otherwise corrode the bare pipe. !n some applications, e.g. tanBer ballast or produced water, the pipe ma$ also contain h$drocarbons. !ts use is limited to the following pressure and temperature ranges- &a, ressures within class )A* flange rating as defined b$ ANS! B)+.A. &b, Temperatures between * and <*3. ).> The specification does not limit the ma#imum pipe siKe which ma$ be lined and is e0uall$ applicable to onshore plant and offshore platform piping as well as onshore and offshore pipelines. 3* PIPE AND FITTINGS 3*1 Pipe >.).) ipe shall be either- &a, A! Spec A" .rade A or B, seamless. or &b, Automatic electric fusion welded, to A! A" .rade B, longitudinal seam submerged arc welded. All siKes of pipe shall be ordered with s0uare1cut ends unless it is to be butt welded. J The choice of seamless or welded pipe shall depend on availabilit$ and cost. The use of an alternative, eg. electric welded or spirall$1welded pipe, shall be subject to approval b$ B. >.).> The design and specification of pipe material and wall thicBness shall taBe account of the effect on the lining of deflections due to handling, transportation and installation. 'efer also to 3lause >.).; and Section ;, %amage rotection. >.).= "ined sections of pipe shall be joined b$ either sleeve t$pe or 'e$nolds t$pe joints, e#cept where a flanged joint would nornall$ be used. Alternativel$, the lining ma$ be applied to butt welded pipe strings or insitu lengths of linepipe. @ointing methods are described in section >.=.
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( ) >.).; The minimum pipe wall thicBness for s$stems within the ANS! B)+.A 3lass )A* rating shall be as detailed below. These wall thicBnesses ma$ be increased if necessar$ to overcome difficulties in handling, transportation and installation. C%($$ 150 r(ti) 2(%% t!ic;)e$$ = inch to + inch NS Standard &Schedule ;*, C inch to )C inch NS Schedule >* >* inch to ;* inch NS <.A mm ;> inch NS and above To be calculated >.).A The ends of longitudinall$ welded pipe which are to be fitted with a sleeve joint shall have the outside weld ground flush with the surface of the pipe for a distance of half the sleeve length plus >A mm.
3*3 Fitti)$ >.>.) 5elded assemblies shall compl$ with B .roup .S ))C1A and ma$ use fittings to one of the following standards. &a, ANS! B)+.<, made from carbon steel to ASTM A >=; with carbon content restricted to *.>AL ma#imum. &b, BS )+;* art =, made from materials to the applicable standards listed below. Seamless pipe ASTM A )*+ .rade A or B &with carbon contentrestricted to *.>AL ma#imum, 'olled late BS )A*)1)+) .rade ;=* ?orgings ASTM A )*A &with carbon content restricted to *.>ALma#imum, BS )A*=1)+;1;<* ?inal assembl$ dimensions shall be as shown in ?igures ), >, =, ;, A and )). >.>.> ?langes up to and including >; inch NS shall compl$ with ANS! B)+.A or BS )A+* art >.
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( > ?langes over >; inch NS should compl$ with A! +*A. Alternativel$, for siKes over >; inch NS up to and including ;C inch NS, flanges in accordance with BS =><= ma$ be used. Dowever the use of BS =><= shall be subject to checB calculation to ensure the suitabilit$ of the design, taBing account of the h$drostatic test pressure. !f flanges in a non1standard siKe are re0uired the$ shall be regarded as special items. ?langes ma$ be forged from material selected from the following standards- &a, ASTM A )*A 3arbon content shall be restricted to *.>AL ma#imum &b, BS )A*=1)+;1;<* >.>.= ?langes ma$ be either weld1necB or slip1on. >.>.; 5here a rubber1lined butterfl$ valve &flanged or wafer t$pe, is to be fitted in a cement1mortar lined pipe s$stem, the pipe flanges shall be flat1faced in order to avoid damage to the valve lining. See ?igure );. >.>.A Branch connections below > inch NS shall consist of socBet welded or screwed =***lb half1couplings in general accordance with ANS! B)+.)) or BS =6<< and made from stainless steel to BS )A*= 'eference Nos. =)+S)= or =>*S==. The$ shall be welded to the pipe in accordance with B .roup .S ))C16 as it applies to austenitic stainless steel, using austenitic electrodes to BS ><>+ 3omposition code >*.<.= with electrode covering T$pe '. The branch siKe shall be selected from those shown in ?igures )) and )>. If possible the branch connections shall be fitted to the pipe before the cement- mortar lining is applied. >.>.+ 5elded joints within assemblies, for e#ample eccentric reducers to ?igure ;, shall be in accordance with B .roup .S ))C1A. The terminal ends shall be cut at right1angles to the pipe a#is and after completion of all welding, out1of1roundness shall be within the limits specified b$ A! Spec A". >.>.6 5here pulled bends to ?igure )* are used, the selected overall dimensions shall permit lining b$ hand trowelling. The forming of pulled bends prior to lining shall be in accordance with B .roup .S ))C1A. 3*4 <oi)t$ >.=.) .eneral
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( = ipes which have been cement1mortar lined cannot be butt welded together in the normal wa$ as the mortar adjacent to the weld will be damaged b$ heat. Dowever there are several t$pes of joint design available to suit particular applications and these are described below. The normal method of joining lengths of lined pipe shall be b$ sleeve joints and these are described below and in ?igures +, 6 and C. ?langes shall also be used where necessar$, for e#ample at pumps and valves. ipe lengths ma$ also be butt welded into strings prior to lining. The length of welded pipe string which can be successfull$ lined will depend on the diameter and lining techni0ue used. After the pipe strings have been lined the$ shall be joined, either b$ sleeve joints or b$ 'e$nolds joints, both of which are described below. All joints described in this document shall be designed in accordance with ASM( B=).=. >.=.> Sleeve @oints >.=.>.) .eneral &a, Sleeve joints shall be of the following t$pes- &i, ?or pipes = inch NS up to >; inch NS inclusive, a one1piece sleeve joint to ?igure + shall be used. See also >.=.>.>. &ii, ?or pipes over >; inch NS but under ;C inch NS, a half1sleeve joint to ?igure 6 shall be used. &iii, ?or pipes ;C inch NS and over, a half1sleeve joint to ?igure C shall be used. &b, ipe used for sleeves shall be in accordance with >.).) or >.>.) &b,. &c, late used for sleeves shall be in accordance with BS ;=+* .rade ;=B or BS )A*)1)+) .rade ;=*. &d, !n no case shall the radial weld gap between the pipe and sleeve of an assembl$ e#ceed = mm. &e, An$ internal welds of sleeves shall be ground flush without undercutting the parent metal. &f, Sleeves shall be fabricated in accordance with B .roup .S ))C1A.
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( ; &g, %uring assembl$ of a welded sleeve, with pipe or fitting, the weld should be located at least <* degrees clear of an$ adjacent longitudinal weld. &h, 3are shall be taBen when welding on a sleeve, that the inside of the pipe is not heated sufficientl$ to damage the lining. >.=.>.> Sleeves for ipes = inch NS up to >; inch NS !nclusive. &a, Sleeves for the full range of pipe siKes ma$ be manufactured b$ machining the bore of pipe, of suitable wall thicBness, to the dimensions specified in ?igure +. Alternative methods of manufacture are given in >.=.>.> &b, and &c, below for specific ranges of pipe siKes. &b, ?or joining lined pipes up to and including C inch NS, sleeves shall be of seamless or welded pipe selected from the siKe and thicBness ranges listed in A! Spec A" or ASTM A )*+ as appropriate and as specified in ?igure +. To ensure that the radial weld gap between pipe and sleeve is in accordance with ?igure +, the pipe for sleeves shall be selected to suit the pipe to be used for line pipe or fittings. The dimensional tolerances specified in API Spec 5L and ASTM A 106 necessitate selection b meas!rement of deli"ered pipe. Selection b reference to listed nominal si#es is not possible. &c, ?or joining pipes )* inch NS up to and including >; inch NS, the sleeves shall be manufactured b$ using an$ of the following materials and methods, which are listed in order of preference. &i, Seamless pipe selected as in >.=.>.> &b,. &ii, 5elded pipe selected as in >.=.>.> &b,. &iii, Seamless pipe of the ne#t siKe larger than the pipe the sleeve is to join, reduced to the re0uired internal diameter b$ the removal of a longitudinal strip, rolling to siKe and finall$ welding. &iv, 5elded pipe reduced as in >.=.>.> &c, &iii,. The strip removed should preferabl$ be at least <* degrees clear of the original pipe weld and in no case shall the separation between the original weld and a new weld be less than )A* mm. 5here a strip including the original weld is removed, the width of strip shall e#tend at least + mm from each side of the original weld.
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( A &v, ?abricated from plate, with a single weld. >.=.= Special @oints >.=.=.) .eneral Special joints shall be used for applications outside the capabilit$ of normal sleeve joints as described in >.=.> above. The common application for a special joint is where a pipeline is installed b$ pulling and the sleeve joint fillet weld has insufficient strength to withstand the pulling force. >.=.=.> Special Sleeve @oints 5here the pipeline pulling force is too high for a normal sleeve joint weld, the joint ma$ be strengthened b$ increasing the welded length, for e#ample b$ castellation, as shown in ?igure )A. >.=.=.= 'e$nolds @oints Another method of increasing the joint strength is the use of a 'e$nolds joint. This t$pe of joint, shown in ?igure )+, allows the lined pipe lengths to be butt welded without damaging the lining. >.=.; @ointing Material for the "ining at Sleeve @oints >.=.;.) ?or joints in pipes = inch NS up to and including >; inch NS &?igure +,, an epo#$ pipe jointing compound s$stem shall be used. An e$ample of an epo$ pipe %ointing compo!nd is Peridite. This compo!nd &as de"eloped specificall for this application and can be obtained from Acalor Protecti"e Materials Limited' (orthampton' )*. It consists of PS+65, -ase' P./,60 1ardener and P./,20 accelerator. >.=.;.> ?or joints in pipes over >; inch but under ;C inch NS &?igure 6,, an epo#$ pipe jointing compound is preferred, but cement1mortar ma$ be used as an alternative. >.=.;.= ?or joints in pipe ;C inch NS and larger &?igure C,, cement1mortar shall be used with reinforcement as shown. The cement1mortar joint mi# shall consist of e0ual parts b$ weight of sulphate1resisting ortland cement generall$ compl$ing with the re0uirements of BS ;*>6 and clean fine sand, mi#ed with clean fresh water. The sand shall generall$ compl$ with the re0uirements of grading limit ? in Table A of BS CC>, e#cept that the ma#imum siKe of aggregate shall not e#ceed one third of the thicBness of the lining. To meet this latter re0uirement, an$ additional sieving shall emplo$ sieves compl$ing with BS ;)*.
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( + >.=.;.; The e#act proportions of the jointing ingredients and the advantages of using a wetting agent with cement1mortar, shall be determined b$ the results obtained b$ trial application in the field. >.=.;.A 9nl$ enough of the jointing material shall be prepared at one time for two hours use with a cement mi# or four hours use with an epo#$ pipe jointing compound. Mi#es and compounds shall not be used if the$ have taBen their initial set. >.=.;.+ 5here the joint is made with a cement mi#, this shall be cured b$ maintaining it in a moist condition as called for in =.6.=. >.=.A rocedure for 5elding Sleeve @oints on Site >.=.A.) The joint faces shall be smooth, s0uare cut and free from an$ surplus cement1mortar from the lining operation. The unlined areas shall be cleaned thoroughl$ and if degreasing is re0uired, a strong detergent solution shall be used followed b$ a clean fresh water rinse. >.=.A.> 5hen an epo#$ pipe jointing compound is to be used, the joint faces shall be dr$ and dust1free and the compound shall be applied with a small trowel or spatula. 5hen cement1mortar mi# is to be used, the joint faces shall be dust1free and moistened with clean fresh water. !mmediatel$ after moistening, the cement1mortar mi# shall be applied using a small trowel. >.=.A.= 5ith a sleeve joint to either ?igure + or ?igure 6, the thicBness of the jointing material shall be Bept to a minimum and all surplus material shall be removed as far as practicable flush with the bore of the pipe. Dowever, sufficient jointing material shall be used to ensure that all voids are filled. >.=.A.; ?or pipes = inch NS up to and including >; inch NS using a sleeve joint &?igure +,, the joint faces of the mating pipe ends shall be pulled together, using a suitable mechanical means which shall ensure that the pipe ends remain in this position until the tacB weld has been applied. After tacBing, the fillet welds shall be applied using the conventional uphand techni0ue, with electrodes to BS +=< not e#ceeding ; mm diameter. The current values emplo$ed and the siKe of the runs of weld metal deposited shall be such as to minimise the heat input and interpass temperature. >.=.A.A ?or pipes over >; inch NS the lining joint and welded joint shall be completed as shown in ?igure 6 or ?igure C as applicable. The longitudinal seam in the half1sleeve joints shown in ?igures 6 and C shall be located for welding on the horiKontal diameter of the pipe and the same precautions as specified in >.=.A.; for fillet welds shall be observed in order to minimise heat input and interpass temperature. ?illet welds shall be applied using the same techni0ue as in >.=.A.; to ensure that the cement1mortar lining is not affected. ?or joints to ?igure C, the unlined area shall be filled, after the pipe has cooled, with
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( 6 a cement1mortar jointing mi# with steel mesh reinforcement, generall$ as described in >.=.A.) and >.=.A.> The final surface shall be smooth, hard and flush with the lined pipe. An$ imperfections in the internal lining shall be repaired, as described in =.6. 4* CEMENT-MORTAR LINING 4*1 S&r8(ce Prep(r(tio) =.).) The surfaces to be lined shall be cleaned immediatel$ before the mortar is applied. Scale, rust and debris as well as all coatings of dirt, oil and grease shall be removed. =.).> ?or lining methods where the pipe revolves, pipe rotation must be concentric. ?or longitudinall$ welded pipe, an$ protruding weld metal in contact with the rotating machine rollers must be ground flush with, but not below, the pipe surface. 4*3 S&r8(ce Fi)i$! The interior surface of the lining shall be smooth and flat with an even distribution of sand and cement throughout the lining thicBness. 4*4 Li)i) Met!o0$ =.=.) ipe 5here practicable the lining shall be applied b$ either the centrifugal process, whereb$ the pipe is stationar$, or b$ a process which includes rotating the pipe. !f the centrifugal method is used, the pipe ma$ be lined either as individual joints, as strings of multiple joints or as an insitu length of linepipe, an$ of which ma$ include bends. Dowever the degree of bend which ma$ be included will depend on the pipe diameter. 5hen the lining is to be applied b$ the pipe rotation method, the length of pipe must be fabricated to within the ma#imum and minimum lengths which can be accommodated in the lining machine. ipe lengths shorter than this minimum ma$ be butted or flange1bolted together before lining. =.=.> Special ?ittings Special fittings shall be such as to permit lining b$ hand trowelling. As a guide, the ma#imum length of pipe that can be readil$ hand lined is )A* mm for = inch, ; inch and + inch NS, and ;A* mm for C inch to >; inch NS.
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( C 4*5 Mort(r Mi= =.;.) The mortar shall be a mi#ture of the following- &a, 9ne part b$ weight of sulphate1resisting ortland cement generall$ compl$ing with the re0uirements of BS ;*>6 or e0uivalent. &b, 9ne part b$ weight of clean fine sand, generall$ compl$ing with the re0uirements of BS CC>, Table A, grading limit ?, or e0uivalent, e#cept that the siKe of an$ aggregate present must not be greater than one third of the thicBness of the lining. !f additional sieving is re0uired to meet this latter re0uirement, the sieve shall compl$ with BS ;)*, or e0uivalent. &c, 3lean fresh water with the sulphate and chloride contents limited in accordance with BS =);C or e0uivalent. =.;.> The ambient temperature during application of the lining shall be between A and =A3 in accordance with BS C))* or e0uivalent. =.;.= The mortar shall be mi#ed to a consistenc$ suitable for bonding to the pipe surface. =.;.; Mortar which has attained it's initial set shall not be used. 4*5 Li)i) T!ic;)e$$ =.A.) The lining shall be s0uare cut and flush with the pipe end or, when internal field welds are to be made, prepared in accordance with ?igure C. The lining thicBness shall be as given below. No'i)(% Pipe Si>e i)c!e$ No'i)(% Li)i) T!ic;)e$$ To%er()ce = 4 ; A mm M M: ).A mm 1) mm +, C 4 )* +.A mm M )>, ); 4 )+ C mm M M:= mm 1) mm )C, >* 4 >> )* mm M >; and over )) mm :A mm 1* =.A.> 5here a wafer butterfl$ valve is installed in cement1mortar lined pipe, the valve disc must not foul the lining. !f necessar$ the lining at the flange face shall be chamfered in accordance with ?igure );.
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( < 4*6 C&ri) =.+.) 3uring of the lined pipe and fittings shall continue for an ade0uate period, normall$ at least seven da$s, before the$ are moved. %uring the curing period the lining shall be maintained in a moist atmosphere and at a temperature between )*N3 and A*N3. The lining shall be regularl$ inspected and water added to aid curing, if re0uired. =.+.> 5hen curing is complete the lining shall be inspected to ensure the surface is clean, smooth and flat. A mandrel or disc shall be passed through the pipe bore to checB that the lining thicBness is within the re0uired tolerance. 4*6 Rep(ir o8 D('(e0 Ce'e)t-Mort(r Li)i) =.6.) A pipe surface that has been e#posed b$ spalling or cracBing of the lining shall be cleaned in accordance with >.=.A.). =.6.> 5hen an epo#$ pipe jointing compound is to be used for the repair, the surfaces shall be dr$ and dust1free and a coating of the compound shall be applied with a small trowel or spatula. 5hen cement1mortar mi# is to be used, the surfaces shall be dust1free and moistened with clean fresh water. !mmediatel$ after moistening, the cement1mortar mi# shall be applied using a small trowel. !f necessar$ a brush can be used for Ofeathering inO the surface edges of the repair. =.6.= 5here cement1mortar is used for the repair, the adjacent lining shall be coated far enough bacB to cover an$ visible cracBs and shall be maintained in a moist condition for three da$s using a wet hessian sacB or similar means. Alternativel$, if the line can be filled, it shall be put into use after the initial set has taBen place. =.6.; 5henever e#tensive patching is essential, the repaired lining shall be reinforced with >A mm # )* mm # ) mm diamond steel mesh, tacB1 welded to the pipe. 4*7 C&tti) Ce'e)t-Mort(r Li)e0 Pipe =.C.) ?or cutting lined pipe, a slitter saw supported as necessar$ and containing a n$lon bonded carborundum disc shall be used. Alternativel$, a rigid pipe cutting machine using tungsten carbide1tipped tools ground to the cutting angles given in ?igure < shall be used. =.C.> 9n fusion welded steel pipes, the e#ternal weld shall be removed flush with, but not below, the face of the pipe for the width of the cutters, and if necessar$ for the complete width of the cutting machine. =.C.= The section to be removed and the adjacent pipe ends shall be suitabl$ supported to avoid imposing an$ weight on the concrete lining when breaBing through.
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( )* 5* DAMAGE PROTECTION 5*1 ?()0%i) Dandling of lined pipe lengths shall be b$ means of slings such that the pipes are supported )GA of their length from each end. ipes shall not be lifted using hooBs inserted in the pipe ends. 5*3 Tr()$port(tio) ;.>.) "ined pipes being transported shall be ade0uatel$ supported in a level horiKontal position in order to minimise fle#ing and prevent induced bending and damage to the lining. ;.>.> ipes shall be protected from direct or indirect impact b$ means of suitable cushioning material. ;.>.= ipes shall not be transported using tractor units with trailing bogies or other methods offering no central support. 5*4 Pipe E)0$ ()0 #r()c! Co))ectio)$ ;.=.) %uring transportation and storage, pipe lengths shall have end caps or other suitable means of protection, with sufficient holes to permit air circulation, provided this does not cause dr$ing out and cracBing of the lining. Means shall be taBen to ensure that the end protection remains securel$ fastened, especiall$ during transportation. ;.=.> Branch connections shall be suitabl$ plugged or capped as described above. 5*5 I)$t(%%(tio) ;.;.) The re0uirements for handling and transportation of individual pipe lengths so as to avoid damage are as described in ;.) and ;.> above. Similar care shall be taBen when handling jointed lengths of pipe and pipestrings to ensure that induced bending and the possibilit$ of damage to the lining is minimised. ;.;.> %uring pipeline installation, when handling, lifting and la$ing pipe, the spacing of lifting points and supports shall not be greater than the ma#imum support spacing shown in the table below. Also when installing pipe on above ground supports or piperacBs, the support spacing shall be not more than shown in the table. 5hen la$ing pipelines, the radii of an$ curves in the horiKontal or vertical plane due to the ground profile shall be not less than those listed in the table.
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( )) No'i)(% Pipe Si>e @i)c!e$A Mi)i'&' #e)0 R(0i&$ @'etre$A M(=i'&' S&pport Sp(ci) @'i%%i'eter$A = A=* A>;* ; 6** A<C* + )*A* +<+* C );** 6=>* )* )66* 66=* )> >))* C*C* ); >=)* C6>* )+ >+A* C<C* )C ><<* <>;* >* ==>* <C<* >> =+C* )**<* >; ;*** )*=>* >+ ;=A* )*;6* >C ;+<* )*+** =* and larger )6> # inside diameter of steel pipe )*6>* Note- No allowance has been made for the additional weight of valves and fittingsI where these are used, additional supports shall be provided. 5* IDENTIFICATION (ach item of pipe and fittings shall be marBed or labelled with the siKe, order number and pipeline item number. (ach item shall also be clearl$ identified as cement1mortar lined pipe to ensure that it is not subjected to shocB loads, for e#ample hammer testing after installation.
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( )> S"((E( A TH( ) A TH( = A TH( > TH( ; A S"((E( ?"AT ?A3( No'i)(% Pipe Si>e @i)c!e$A A @''A No'i)(% Pipe Si>e @i)c!e$A A @''A = )6* >+ =)* ; )C* >C =)* + >)* =* =)* C >A* => =)* )* >6* =; =>* )> >C* =+ =>* ); =** =C =>* )+ =>* ;* =>* )C ==* ;> =>* >* =A* ;; =>* >> Non Std ?lange ;+ =>* >; =A* ;C =6* ;> Non Std ?lange A+ Non Std ?lange +* =C* +; Non Std ?lange Notes- ). ?or details of sleeves see the following figures-1 ?igure + ?or pipe siKes = to >; inch ?igure 6 ?or pipe siKes >; to ;+ inch ?igure C ?or pipe siKes ;C inch and larger FIG+RE 1 FLANGED CONNECTIONS 2IT? CLASS 150 FLANGES
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( )= TYPE 1 TYPE 2 R = 11/2 X NORMAL PIPE SIZE A A R A SLEEVE A R A
No'i)(% Pipe Si>e @i)c!e$A A @''A No'i)(% Pipe Si>e @i)c!e$A A @''A = >>* >+ ))6* ; >+* >C )>A* + =A* =* )=>* C ;A* => );** )* AA* =; );6* )> +;* =+ )AA* ); 6>* =C )+=* )+ C** ;* )6** )C CC* ;> )6C* >* <+* ;; )C+* >> )*;* ;+ )<=* >; ))>* ;C >*A* Notes- ). Bends shall be fabricated using long radius elbows to ANS! B)+.< or BS )+;* >. ?or pipes over ;C inch nominal siKe the bend shall be detailed and fabricated as part of the relevant project. =. ?or details of sleeves see the following figures-1 ?igure + ?or pipe siKes = to >; inch ?igure 6 ?or pipe siKes >+ to ;+ inch ?!gure C ?or pipe siKes ;C inch and larger FIG+RE 3 90 #ENDS
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( ); TYPE 2 TYPE 1 A A
A A
SLEEVE No'i)(% Pipe Si>e @i)c!e$A A @''A No'i)(% Pipe Si>e @i)c!e$A A @''A = )*+ >+ )6< ; )*C >C )C= + )>) =* )66 C );A => )C) )* )+< =; )6A )> )C= =+ )6C ); )C6 =C )C> )+ )<* ;* )6+ )C )<; ;> )C* >* )<C ;; )C; >> >*> ;+ )66 >; >*+ ;C )C) Notes- ). Bends shall be cut from long radius elbows to ANS! B)+.< or BS )+;* with being specified as part of the project design. 5hen is ;A, standard fittings ma$ be used >. ?or pipes over ;C inch nominal siKe the bend shall be detailed and fabricated as part of the relevant project. =. ?or details of sleeves see the following figures-1 ?igure + ?or pipe siKes = to >; inch ?igure 6 ?or pipe siKes >+ to ;+ inch ?!gure C ?or pipe siKes ;C inch and larger FIG+RE 4 #ENDS OT?ER T?AN 90
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( )A L TYPE 1 TYPE 2 SLEEVE A L TYPE 3 TYPE 4 SLEEVE A SLEEVE SLEEVE No'i)(%Pipe Si>e No'i)(% @i)c!e$A A L @i)c!e$A A L M(Bor Mi)or @''A @''A M(Bor Mi)or @''A @''A ; = )*C =>* >+ >;1)C )6< )*** + ;1= )>) =6* >C >+1)C )C= )*** C +1; );A ;>* =* >C1>* )66 )*** )* C1; )+< ;<A => =*1>; )C) )*** )> )*1+ )C= AAA =; =>1>; )6A )*** ); )>1+ )C6 6** =+ =;1>; )6C )*** )+ );1C )<* 6=A =C =+1>+ )C> <6* )C )+1)* )<; 6+A ;* =C1=* )6+ <6* >* )C1)> )<C <** ;> ;*1=* )C* <6* >> >*1); >*> <)* ;; ;>1=+ )C; <6A >; >>1)+ >*+ <>* ;+ ;;1=C )66 )*6A ;C ;+1;* )C) )*6A Notes- ). 5here the re0uired reduction cannot be achieved using one standard reducer then two or more assemblies in series shall be used. >. 'educers for pipe siKes greater than ;C inch shall be regarded as specials and detailed as part of the relevant project. =. ?or details of sleeves see the following figures-1 ?igure + ?or pipe siKes = to >; inch ?igure 6 ?or pipe siKes >+ to ;+ inch ?!gure C ?or pipe siKes ;C inch and larger FIG+RE 5 ECCENTRIC RED+CER ASSEM#LIES
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( )+ B P P A S(T 9N T(( TH( ) B P P A S(T 9N T(( TH( > B P P A ?9'.(% T(( 5!TD S"! 19N ?"AN.( TH( = B P P A S(T 1 9N T(( 5!TD 5("%!N. 1 N(38 ?"AN.( TH( ; B P P A S(T 1 9N T(( 5!TD S"! 9N ?"AN.( TH( A M(i) No'i)(% Pipe Si>e @i)c!e$A A @''A # @''A For A%% #r()c! Si>e$ M(i) No'i)(% Pipe Si>e @i)c!e$A A @''A # @''A For A%% #r()c! Si>e$ = =C* )<* >C );** 6)* ; ;=* >)A =* );6* 6A* + A=* >+A => )AA* 6<* C ++* ==* =; )+>* C=A )* 66* =CA =+ )6** C6* )> C6* ;=A =C )6C* <)* ); <=* ;+A ;* )CA* <A* )+ <C* ;<* ;> )CC* <+A )C )*6* A=A ;; )<C* )*)A >* ))+* AC* ;+ >*A* )*AA >> )>;* +>* ;C >);* ));* >; )>C* +;* Above ;C Set1on tees onl$. To be detailed >+ )=A* +C* during project design Notes- ). %imension QB/ is e0uall$ applicable to a raised face or a flat faced flange. This dimension ma$ be varied, e.g. to suit a probe length. >. The combination of forged tee and welding1necB flange shall be regarded as special and shall be detailed as part of the relevant project. =. ?ittings re0uiring reinforcement shall be regarded as special and shall be detailed as part of the project. Dowever, the design shall be suitable to accommodate the sleeves specified in Note ; ;. Sleeves in accordance with the following figures ma$ be fitted to an$ plain end without affecting effective pipe lengths-1 ?igure + ?or pipe siKes = to >; inch ?igure 6 ?or pipe siKes >+ to ;+ inch ?!gure C ?or pipe siKes ;C inch and larger FIG+RE 5 TEE #RANC? CONNNECTIONS 2IT? CLASS 150 FLANGES
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( )6 Pipe S%ee:e Nominal &mm, S &mm, B &mm, ipe SiKe Min Ma# Min Ma# Min &inches, = CC.* C<.A Measured Measured ))* ; ))=.A ))A.* 9utside 9utside ))A + )+6.A )+<.A %iameter %iameter )>A C >)6.A >>*.A 9f ipe 9f ipe )=A )* >6).A >6A.* : )mm : +mm );A )> =>).A =>+.* &See note =, &See note =, )AA ); =A=.* =AC.* )+* )+ ;*=.A ;*<.* )6* )C ;A;.* ;+*.* )C* >* A*=.* A)=.* )<A >> AA=.A A+;.A )<A >; +*;.* +)+.* )<A Notes- ). ipe outside diameters are derived from the dimensions and tolerances stated in A! Spec A". >. Minimum wall thicBness of sleeve shall be ).> # thicBness of pipe. =. The measured outside diameter of pipe shall be that of the pipe delivered for a specific job or project. ;. ipes shall be centralised with slip wedges before welding. FIG+RE 6 ONE-PIECE SLEE9E <OINT FOR NOMINAL PIPE SICES 4 INC? +P TO AND INCL+DING 35 INC?
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( )C Notes- ). Minimum siKe of fillet welds P ipe wall thicBness as specified in >.).; of this specification. FIG+RE 6 ?ALF-SLEE9E <OINT FOR NOMINAL PIPE SICES O9ER 35 INC? #+T +NDER 57 INC?
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( )< 9(ri(b%e Di'e)$io)$ No'i)(% Pipe Si>e . &mm, N " @i)c!e$A M!N MAR &mm, &mm, 57 &p to 60 => 6A >A* )** O:er 60 => )** =** )>* Notes- ). Minimum siKe of fillet welds P =G; T. >. Minimum sleeve thicBness P T FIG+RE 7 ?ALF-SLEE9E <OINT FOR NOMINAL PIPE SICES 57 INC? AND LARGER
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( >* = '(27!'(% (' 37TT!N. 7N!T &) (A3D TH( 9? B"A%( A, B 4 3, FIG+RE 9 DETAILS OF C+TTING ANGLES FOR T+NGSTEN CAR#IDE TIPPED TOOLS FOR CEMENT-MORTAR LINED STEEL PIPES
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( >) A R No'i)(% Pipe Si>e @i)c!e$A R @''A A @''A = >6* )*+ ; =A* )*C + A** )>) C C** );A )* ))** )+< )> )=** )C= ); )+** )C6 )+ )C** )<* )C >)** )<; >* >6** )<C >> =)** >*> >; =6** >*+ Notes- ). The tangent lengths and the radii given are minimum values, actual dimensions shall be detailed as part of the relevant project. >. The thicBness of the pipe wall at an$ point on the finished bend shall not be less than the schedule thicBness to the tolerance applicable for e0uivalent straight pipe. =. The difference between ma#imum and minimum diameters on an$ common radial plane shall not be more than AL of the outside diameter of the pipe. ;. 5hen the bent pipe is to be butt1welded into the piping s$stem the tolerance at the ends shall be in accordance with ANS! B)+.< or BS )+;*. A. (#cept as specified in the foregoing notes the bent pipe shall be to the specification, tolerances and tests stipulated for the piping s$stem generall$, or as given in the order. FIG+RE 10 MINIM+M #ENDING RADII FOR STEEL PIPE
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( >> STA!N"(SS ST((" S938(T 5("%(% 9' S3'(5(% DA"? 397"!N.. ?9' %(TA!"S S(( >.>.A. 9? TD!S S(3!?!3AT!9N. ?9' 5("%!N. %(TA!" S(( ?!.7'( )> TH( ) A TH( = A S"((E( S"((E( TH( > A S"((E( No'i)(% Pipe Si>e @i)c!e$A A @''A = >A* ; >+* + >6* C >C* )* ><* )> =** ); =)* )+ =>* )C ==* >* =A* >> =A* >; =A* Notes- ). 3are shall be taBen to ensure that all areas of piping material around the hole to the half coupling are ade0uatel$ covered with cement1mortar lining. >. ?or details of sleeves see ?igure +. FIG+RE 11 4D5 INC? AND 1 INC? #RANC? FITTINGS FOR NOMINAL PIPE SICES 4 INC? +P TO AND INCL+DING 35 INC?
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( >= M(i)* No'i)(% Pipe Si>e A @''A 9ver >; inch But 7nder ;C !nch )A* ;C !nch and 9ver >>A Notes- ). %amage to the cement1mortar lining caused whilst fitting the half1coupling shall be made good at site, and care taBen to ensure that all areas of pipe material are covered. FIG+RE 13 4D5 INC? AND 1 INC? #RANC?ES FOR NOMINAL PIPE SICES O9ER 35 INC?
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( >; Notes- ). 5here alternative t$pes of assembl$ are shown on the figures referred to above, selection shall be made during detailed design. >. Butterfl$ valves used in pipes of nominal siKe = inch to )> inch inclusive ma$ be full bore or reduced bore. ?or nominal pipe siKes above )> inch all valves shall have reduced bore. All valve bodies shall be vulcanised rubber lined. FIG+RE 14 T,PICAL ARRANGEMENT OF CEMENT-MORTAR LINED STEEL PIPES AND FITTINGS
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( >+ Notes- ). %etail design of joint to suit the particular project. >. ipe jointing to be generall$ in accordance with ?igures +, 6 and C for different pipe1 siKes. FIG+RE 15 T,PICAL DESIGN FOR SPECIAL SLEE9E <OINT
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( >6 Note- ). %etailed design of joint to suit the particular project. FIG+RE 16 T,PICAL DESIGN FOR RE,NOLDS <OINT
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( >C APPENDI/ A DEFINITIONS AND A##RE9IATIONS De8i)itio)$ Standardised definitions ma$ be found in the B .roup 'S(s !ntroductor$ Eolume. Abbre:i(tio)$ ANS! Amercian National Standards !nstitute A! American etroleum !nstitute ASM( American Societ$ of Mechanical (ngineers ASTM American Societ$ for Testing Materials BS British Standard ((M7A (ngineering (0uipment and Materials 7sers Association NS Nominal pipe siKe
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( >< APPENDI/ # LIST OF REFERENCED DOC+MENTS A reference invoBes the latest published issue or amendment unless stated otherwise. 'eferenced standards ma$ be replaced b$ e0uivalent standards that are internationall$ or otherwise recognised provided that it can be shown to the satisfaction of the purchaser's professional engineer that the$ meet or e#ceed the re0uirements of the referenced standards. #riti$! St()0(r0$ BS ;)* Specification for Test Sieves BS +=< Specification for 3arbon and 3arbon Manganese Steel (lectrodes for Manual Metal1Arc 5elding &withdrawn,. BS CC> Aggregates from Natural Sources for 3oncrete. BS )A*) Steels for ?ired and 7nfired ressure Eessels &'eplaced b$ BS (N )**>C 4 )**><,. BS )A*= Steel ?orgings for ressure urposes. &!S9 >+*;1), BS )A+* Steel ipe ?langes &)G> inch to >; inch, for the etroleum !ndustr$. &!S9 6**A1=, BS )+;* Steel Butt15elding ipe ?ittings for the etroleum !ndustr$. BS ><>+ 3hromium and 3hromium1NicBel Steel (lectrodes for Manual Metal1 Arc 5elding. BS =><= 3arbon Steel ipe ?langes &over >; inch, for the etroleum !ndust$. BS =6<< Steel ipe ?ittings, Screwed and SocBet15elding for the etroleum !ndustr$. BS ;*>6 Sulphate 'esisting ortland 3ement. BS ;=+* 5eldable Structural Steels. A'eric() ANS!GASM( B)+.)) ?orged Steel ?ittings, SocBet 5elding and Threaded ANS!GASM( B)+.A Steel ipe ?langes and ?langed ?ittings ANS!GASM( B)+.< ?actor$1Made 5rought Steel Butt15elding ?ittings A! +*A "arge1%iameter 3arbon Steel ?langes A! Spec A" Specification for "ine ipe ASM( B=).= 3hemical lant and etroleum 'efiner$ iping ASTM A)*A ?orgings, 3arbon Steel, for iping 3omponents ASTM A)*+ Seamless 3arbon Steel ipe for Digh1Temperature Service ASTM A>=; ipe ?ittings of 5rought 3arbon Steel and Allo$ Steel for Moderate and (levated Temperatures.
GS 106-1 CEMENT MORTAR LINED STEEL PIPE AND FITTINGS A.( =* #P Gro&p Doc&'e)t$ B .roup ))C1A ?abrication of 3arbon, 3arbon Manganese and "ow Allo$ ?erritic Steel ipeworB. B .roup ))C16 ?abrication of Austenitic, %uple#, 3upro1NicBel and NicBel Base Allo$ Steel ipeworB. EEM+A ((M7A ublication );> Noise1acoustic insulation of pipes, valves and flanges