GS106-1

WARNINGThis document is a master copy of the BP Group RPSE. If text is edited please remember to re-number the document and delete the data page and foreword.

GS 106-1

CEMENT-MORTAR LINED STEEL PIPE AND FITTINGS

October 1995

Copyright The British Petroleum Company p.l.c.Copyright The British Petroleum Company p.l.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, BP International Limited, unless the terms of such agreement or contract expressly allow.BP GROUP RECOMMENDED PRACTICES AND SPECIFICATIONS FOR ENGINEERINGIssue DateOctober 1995Doc. No. GS 106-1Latest Amendment Date

Doc. No.RP 32-5 Document TitleCEMENT-MORTAR LINED STEEL PIPEAND FITTINGS(Replaces BP Engineering Std 106)APPLICABILITY Regional Applicability:InternationalSCOPE AND PURPOSE

This Guidance for Specification specifies BPs requirements for the lining of steel pipe and fittings with sulphate-resisting cement-mortar for use with water which would otherwise corrode the bare pipe.AMENDMENTSAmdDate Page(s)Description___________________________________________________________________CUSTODIAN (See Quarterly Status List for Contact)Pipelines & Subsea Engineering, XFEIssued by:-Engineering Practices Group, BP International Limited, Research & Engineering CentreChertsey Road, Sunbury-on-Thames, Middlesex, TW16 7LN, UNITED KINGDOMTel: +44 1932 76 4067Fax: +44 1932 76 4077Telex: 296041CONTENTSSectionPage TOC \o FOREWORD GOTOBUTTON _Toc381689660 PAGEREF _Toc381689660 iv1. INTRODUCTION GOTOBUTTON _Toc381689661 PAGEREF _Toc381689661 11.1 Scope GOTOBUTTON _Toc381689662 PAGEREF _Toc381689662 12. PIPE AND FITTINGS GOTOBUTTON _Toc381689663 PAGEREF _Toc381689663 12.1 Pipe GOTOBUTTON _Toc381689664 PAGEREF _Toc381689664 12.2 Fittings GOTOBUTTON _Toc381689665 PAGEREF _Toc381689665 22.3 Joints GOTOBUTTON _Toc381689666 PAGEREF _Toc381689666 43. CEMENT-MORTAR LINING GOTOBUTTON _Toc381689667 PAGEREF _Toc381689667 83.1 Surface Preparation GOTOBUTTON _Toc381689668 PAGEREF _Toc381689668 83.2 Surface Finish GOTOBUTTON _Toc381689669 PAGEREF _Toc381689669 83.3 Lining Methods GOTOBUTTON _Toc381689670 PAGEREF _Toc381689670 93.4 Mortar Mix GOTOBUTTON _Toc381689671 PAGEREF _Toc381689671 93.5 Lining Thickness GOTOBUTTON _Toc381689672 PAGEREF _Toc381689672 103.6 Curing GOTOBUTTON _Toc381689673 PAGEREF _Toc381689673 103.7 Repair of Damaged Cement-Mortar Lining GOTOBUTTON _Toc381689674 PAGEREF _Toc381689674 103.8 Cutting Cement-Mortar Lined Pipe GOTOBUTTON _Toc381689675 PAGEREF _Toc381689675 114. DAMAGE PROTECTION GOTOBUTTON _Toc381689676 PAGEREF _Toc381689676 114.1 Handling GOTOBUTTON _Toc381689677 PAGEREF _Toc381689677 114.2 Transportation GOTOBUTTON _Toc381689678 PAGEREF _Toc381689678 114.3 Pipe Ends and Branch Connections GOTOBUTTON _Toc381689679 PAGEREF _Toc381689679 124.4 Installation GOTOBUTTON _Toc381689680 PAGEREF _Toc381689680 125. IDENTIFICATION GOTOBUTTON _Toc381689681 PAGEREF _Toc381689681 13FIGURE 1 GOTOBUTTON _Toc381689682 PAGEREF _Toc381689682 14FLANGED CONNECTIONS WITH CLASS 150 FLANGES GOTOBUTTON _Toc381689683 PAGEREF _Toc381689683 14FIGURE 2 GOTOBUTTON _Toc381689684 PAGEREF _Toc381689684 1590symbol 176 \f "Symbol" BENDS GOTOBUTTON _Toc381689685 PAGEREF _Toc381689685 15FIGURE 3 GOTOBUTTON _Toc381689686 PAGEREF _Toc381689686 16BENDS OTHER THAN 90symbol 176 \f "Symbol" GOTOBUTTON _Toc381689687 PAGEREF _Toc381689687 16FIGURE 4 GOTOBUTTON _Toc381689688 PAGEREF _Toc381689688 17ECCENTRIC REDUCER ASSEMBLIES GOTOBUTTON _Toc381689689 PAGEREF _Toc381689689 17FIGURE 5 GOTOBUTTON _Toc381689690 PAGEREF _Toc381689690 18TEE BRANCH CONNNECTIONS WITH CLASS 150 FLANGES GOTOBUTTON _Toc381689691 PAGEREF _Toc381689691 18FIGURE 6 GOTOBUTTON _Toc381689692 PAGEREF _Toc381689692 19ONE-PIECE SLEEVE JOINT FOR NOMINAL PIPE SIZES 3 INCH UP TO AND INCLUDING 24 INCH GOTOBUTTON _Toc381689693 PAGEREF _Toc381689693 19FIGURE 7 GOTOBUTTON _Toc381689694 PAGEREF _Toc381689694 20HALF-SLEEVE JOINT FOR NOMINAL PIPE SIZES OVER 24 INCH BUT UNDER 48 INCH GOTOBUTTON _Toc381689695 PAGEREF _Toc381689695 20FIGURE 8 GOTOBUTTON _Toc381689696 PAGEREF _Toc381689696 21HALF-SLEEVE JOINT FOR NOMINAL PIPE SIZES 48 INCH AND LARGER GOTOBUTTON _Toc381689697 PAGEREF _Toc381689697 21FIGURE 9 GOTOBUTTON _Toc381689698 PAGEREF _Toc381689698 22DETAILS OF CUTTING ANGLES FOR TUNGSTEN CARBIDE TIPPED TOOLS FOR CEMENT-MORTAR LINED STEEL PIPES GOTOBUTTON _Toc381689699 PAGEREF _Toc381689699 22FIGURE 10 GOTOBUTTON _Toc381689700 PAGEREF _Toc381689700 23MINIMUM BENDING RADII FOR STEEL PIPE GOTOBUTTON _Toc381689701 PAGEREF _Toc381689701 23FIGURE 11 GOTOBUTTON _Toc381689702 PAGEREF _Toc381689702 243/4 INCH AND 1 INCH BRANCH FITTINGS FOR NOMINAL PIPE SIZES 3 INCH UP TO AND INCLUDING 24 INCH GOTOBUTTON _Toc381689703 PAGEREF _Toc381689703 24FIGURE 12 GOTOBUTTON _Toc381689704 PAGEREF _Toc381689704 253/4 INCH AND 1 INCH BRANCHES FOR NOMINAL PIPE SIZES OVER 24 INCH GOTOBUTTON _Toc381689705 PAGEREF _Toc381689705 25FIGURE 13 GOTOBUTTON _Toc381689706 PAGEREF _Toc381689706 26TYPICAL ARRANGEMENT OF CEMENT-MORTAR LINED GOTOBUTTON _Toc381689707 PAGEREF _Toc381689707 26STEEL PIPES AND FITTINGS GOTOBUTTON _Toc381689708 PAGEREF _Toc381689708 26FIGURE 14 GOTOBUTTON _Toc381689709 PAGEREF _Toc381689709 27TYPICAL CONNECTION BETWEEN CEMENT MORTAR LINED PIPE AND RUBBER LINED BUTTERFLY VALVE GOTOBUTTON _Toc381689710 PAGEREF _Toc381689710 27FIGURE 15 GOTOBUTTON _Toc381689711 PAGEREF _Toc381689711 28TYPICAL DESIGN FOR SPECIAL SLEEVE JOINT GOTOBUTTON _Toc381689712 PAGEREF _Toc381689712 28FIGURE 16 GOTOBUTTON _Toc381689713 PAGEREF _Toc381689713 29TYPICAL DESIGN FOR REYNOLDS JOINT GOTOBUTTON _Toc381689714 PAGEREF _Toc381689714 29APPENDIX A GOTOBUTTON _Toc381689715 PAGEREF _Toc381689715 30DEFINITIONS AND ABBREVIATIONS GOTOBUTTON _Toc381689716 PAGEREF _Toc381689716 30APPENDIX B GOTOBUTTON _Toc381689717 PAGEREF _Toc381689717 31LIST OF REFERENCED DOCUMENTS GOTOBUTTON _Toc381689718 PAGEREF _Toc381689718 31FOREWORDIntroduction to BP Group Recommended Practices and Specifications for Engineering

The Introductory Volume contains a series of documents that provide an introduction to the BP Group Recommended Practices and Specifications for Engineering (RPSEs). In particular, the 'General Foreword' sets out the philosophy of the RPSEs. Other documents in the Introductory Volume provide general guidance on using the RPSEs and background information to Engineering Standards in BP. There are also recommendations for specific definitions and requirements.

Value of this Guidance for Specification

This Guidance for Specification provides users with a proven method of protecting steel pipes from internal corrosion by saline or fresh water. The specification has been updated based on feedback from both installers and operators of cement-mortar lined pipe systems

Application

This Guidance for Specification is intended to guide the purchaser in the use or creation of a fit-for-purpose specification for enquiry or purchasing activity.

Text in italics is Commentary. Commentary provides background information which supports the requirements of the Specification, and may discuss alternative options. It also gives guidance on the implementation of any 'Specification' or 'Approval' actions; specific actions are indicated by an asterisk (*) preceding a paragraph number.

This document may refer to certain local, national or international regulations but the responsibility to ensure compliance with legislation and any other statutory requirements lies with the user. The user should adapt or supplement this document to ensure compliance for the specific application.

Specification Ready for Application

A Specification (BP Spec 106-1) is available which may be suitable for enquiry or purchasing without modification. It is derived from this BP Group Guidance for Specification by retaining the technical body unaltered but omitting all commentary, omitting the data page and inserting a modified Foreword.

Principal Changes from Previous Edition

1.This document has been re-written in the new GS format (original document was BP Standard 106).

2.The cement-mortar curing time has been reduced from 28 to 7 days.

3.The original Standard 106 specified the application of cement-mortar to lengths of revolving pipe. This specification now allows for other methods of application whereby the pipe lengths are stationary.

4.This specification describes additional methods of joining lengths of cement-mortar lined pipe which allows for installation by pulling.

Feedback and Further Information

Users are invited to feed back any comments and to detail experiences in the application of BP RPSE's, to assist in the process of their continuous improvement.

For feedback and further information, please contact Standards Group, BP International or the Custodian. See Quarterly Status List for contacts.

1.INTRODUCTION1.1ScopeThis document specifies BPs requirements for the lining of steel pipe and fittings with sulphate-resisting cement-mortar for use with saline and fresh water, where analysis shows that the water would otherwise corrode the bare pipe. In some applications, e.g. tanker ballast or produced water, the pipe may also contain hydrocarbons.

Its use is limited to the following pressure and temperature ranges:

(a)Pressures within class 150 flange rating as defined by ANSI B16.5.

(b)Temperatures between 0 and 90symbol 176 \f "Symbol"C.

1.2The specification does not limit the maximum pipe size which may be lined and is equally applicable to onshore plant and offshore platform piping as well as onshore and offshore pipelines. 2.PIPE AND FITTINGS2.1Pipe2.1.1Pipe shall be either:

(a)API Spec 5L Grade A or B, seamless.or(b)Automatic electric fusion welded, to API 5L Grade B, longitudinal seam submerged arc welded.

All sizes of pipe shall be ordered with square-cut ends unless it is to be butt welded.

*The choice of seamless or welded pipe shall depend on availability and cost. The use of an alternative, eg. electric welded or spirally-welded pipe, shall be subject to approval by BP. 2.1.2The design and specification of pipe material and wall thickness shall take account of the effect on the lining of deflections due to handling, transportation and installation. Refer also to Clause 2.1.4 and Section 4, Damage Protection.

2.1.3Lined sections of pipe shall be joined by either sleeve type or Reynolds type joints, except where a flanged joint would nornally be used. Alternatively, the lining may be applied to butt welded pipe strings or insitu lengths of linepipe. Jointing methods are described in section 2.3.

2.1.4The minimum pipe wall thickness for systems within the ANSI B16.5 Class 150 rating shall be as detailed below. These wall thicknesses may be increased if necessary to overcome difficulties in handling, transportation and installation.

Class 150 ratingWall thickness3 inch to 6 inch NPSStandard (Schedule 40)8 inch to 18 inch NPSSchedule 2020 inch to 40 inch NPS9.5 mm42 inch NPS and aboveTo be calculated2.1.5The ends of longitudinally 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 25 mm. 2.2Fittings2.2.1Welded assemblies shall comply with BP Group GS 118-5 and may use fittings to one of the following standards.

(a)ANSI B16.9, made from carbon steel to ASTM A 234 with carbon content restricted to 0.25% maximum.

(b)BS 1640 Part 3, made from materials to the applicable standards listed below.

Seamless pipeASTM A 106 Grade A or B (with carbon contentrestricted to 0.25% maximum)

Rolled PlateBS 1501-161 Grade 430

ForgingsASTM A 105 (with carbon content restricted to 0.25%maximum)

BS 1503-164-490

Final assembly dimensions shall be as shown in Figures 1, 2, 3, 4, 5 and 11.

2.2.2Flanges up to and including 24 inch NPS shall comply with ANSI B16.5 or BS 1560 Part 2.

Flanges over 24 inch NPS should comply with API 605. Alternatively, for sizes over 24 inch NPS up to and including 48 inch NPS, flanges in accordance with BS 3293 may be used. However the use of BS 3293 shall be subject to check calculation to ensure the suitability of the design, taking account of the hydrostatic test pressure.

If flanges in a non-standard size are required they shall be regarded as special items.

Flanges may be forged from material selected from the following standards:

(a)ASTM A 105 Carbon content shall be restricted to 0.25% maximum

(b)BS 1503-164-490

2.2.3Flanges may be either weld-neck or slip-on.

2.2.4Where a rubber-lined butterfly valve (flanged or wafer type) is to be fitted in a cement-mortar lined pipe system, the pipe flanges shall be flat-faced in order to avoid damage to the valve lining. See Figure 14.

2.2.5Branch connections below 2 inch NPS shall consist of socket welded or screwed 3000lb half-couplings in general accordance with ANSI B16.11 or BS 3799 and made from stainless steel to BS 1503 Reference Nos. 316S13 or 320S33. They shall be welded to the pipe in accordance with BP Group GS 118-7 as it applies to austenitic stainless steel, using austenitic electrodes to BS 2926 Composition code 20.9.3 with electrode covering Type R. The branch size shall be selected from those shown in Figures 11 and 12.

If possible the branch connections shall be fitted to the pipe before the cement-mortar lining is applied.

2.2.6Welded joints within assemblies, for example eccentric reducers to Figure 4, shall be in accordance with BP Group GS 118-5. The terminal ends shall be cut at right-angles to the pipe axis and after completion of all welding, out-of-roundness shall be within the limits specified by API Spec 5L.

2.2.7Where pulled bends to Figure 10 are used, the selected overall dimensions shall permit lining by hand trowelling. The forming of pulled bends prior to lining shall be in accordance with BP Group GS 118-5.

2.3Joints2.3.1General

Pipes which have been cement-mortar lined cannot be butt welded together in the normal way as the mortar adjacent to the weld will be damaged by heat. However there are several types of joint design available to suit particular applications and these are described below. The normal method of joining lengths of lined pipe shall be by sleeve joints and these are described below and in Figures 6, 7 and 8.

Flanges shall also be used where necessary, for example at pumps and valves.

Pipe lengths may also be butt welded into strings prior to lining. The length of welded pipe string which can be successfully lined will depend on the diameter and lining technique used.

After the pipe strings have been lined they shall be joined, either by sleeve joints or by Reynolds joints, both of which are described below.

All joints described in this document shall be designed in accordance with ASME B31.3.

2.3.2Sleeve Joints

2.3.2.1General

(a)Sleeve joints shall be of the following types:

(i)For pipes 3 inch NPS up to 24 inch NPS inclusive, a one-piece sleeve joint to Figure 6 shall be used. See also 2.3.2.2.

(ii)For pipes over 24 inch NPS but under 48 inch NPS, a half-sleeve joint to Figure 7 shall be used.

(iii)For pipes 48 inch NPS and over, a half-sleeve joint to Figure 8 shall be used.

(b)Pipe used for sleeves shall be in accordance with 2.1.1 or 2.2.1 (b).

(c)Plate used for sleeves shall be in accordance with BS 4360 Grade 43B or BS 1501-161 Grade 430.

(d)In no case shall the radial weld gap between the pipe and sleeve of an assembly exceed 3 mm.

(e)Any internal welds of sleeves shall be ground flush without undercutting the parent metal.

(f)Sleeves shall be fabricated in accordance with BP Group GS 118-5.

(g)During assembly of a welded sleeve, with pipe or fitting, the weld should be located at least 90 degrees clear of any adjacent longitudinal weld.

(h)Care shall be taken when welding on a sleeve, that the inside of the pipe is not heated sufficiently to damage the lining.

2.3.2.2Sleeves for Pipes 3 inch NPS up to 24 inch NPS Inclusive.

(a)Sleeves for the full range of pipe sizes may be manufactured by machining the bore of pipe, of suitable wall thickness, to the dimensions specified in Figure 6. Alternative methods of manufacture are given in 2.3.2.2 (b) and (c) below for specific ranges of pipe sizes.

(b)For joining lined pipes up to and including 8 inch NPS, sleeves shall be of seamless or welded pipe selected from the size and thickness ranges listed in API Spec 5L or ASTM A 106 as appropriate and as specified in Figure 6.

To ensure that the radial weld gap between pipe and sleeve is in accordance with Figure 6, 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 by measurement of delivered pipe. Selection by reference to listed nominal sizes is not possible.

(c)For joining pipes 10 inch NPS up to and including 24 inch NPS, the sleeves shall be manufactured by using any of the following materials and methods, which are listed in order of preference.

(i)Seamless pipe selected as in 2.3.2.2 (b).

(ii)Welded pipe selected as in 2.3.2.2 (b).

(iii)Seamless pipe of the next size larger than the pipe the sleeve is to join, reduced to the required internal diameter by the removal of a longitudinal strip, rolling to size and finally welding.

(iv)Welded pipe reduced as in 2.3.2.2 (c) (iii). The strip removed should preferably be at least 90 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 150 mm.

Where a strip including the original weld is removed, the width of strip shall extend at least 6 mm from each side of the original weld.

(v)Fabricated from plate, with a single weld.

2.3.3Special Joints

2.3.3.1General

Special joints shall be used for applications outside the capability of normal sleeve joints as described in 2.3.2 above. The common application for a special joint is where a pipeline is installed by pulling and the sleeve joint fillet weld has insufficient strength to withstand the pulling force.

2.3.3.2Special Sleeve Joints

Where the pipeline pulling force is too high for a normal sleeve joint weld, the joint may be strengthened by increasing the welded length, for example by castellation, as shown in Figure 15.

2.3.3.3Reynolds Joints

Another method of increasing the joint strength is the use of a Reynolds joint. This type of joint, shown in Figure 16, allows the lined pipe lengths to be butt welded without damaging the lining.

2.3.4Jointing Material for the Lining at Sleeve Joints

2.3.4.1For joints in pipes 3 inch NPS up to and including 24 inch NPS (Figure 6), an epoxy pipe jointing compound system shall be used.

An example of an epoxy pipe jointing compound is Peridite. This compound was developed specifically for this application and can be obtained from Acalor Protective Materials Limited, Northampton, UK. It consists of PS3654 Base, PZ2469 Hardener and PZ2470 accelerator.

2.3.4.2For joints in pipes over 24 inch but under 48 inch NPS (Figure 7), an epoxy pipe jointing compound is preferred, but cement-mortar may be used as an alternative.

2.3.4.3For joints in pipe 48 inch NPS and larger (Figure 8), cement-mortar shall be used with reinforcement as shown.

The cement-mortar joint mix shall consist of equal parts by weight of sulphate-resisting Portland cement generally complying with the requirements of BS 4027 and clean fine sand, mixed with clean fresh water.

The sand shall generally comply with the requirements of grading limit F in Table 5 of BS 882, except that the maximum size of aggregate shall not exceed one third of the thickness of the lining. To meet this latter requirement, any additional sieving shall employ sieves complying with BS 410.

2.3.4.4The exact proportions of the jointing ingredients and the advantages of using a wetting agent with cement-mortar, shall be determined by the results obtained by trial application in the field.

2.3.4.5Only enough of the jointing material shall be prepared at one time for two hours use with a cement mix or four hours use with an epoxy pipe jointing compound. Mixes and compounds shall not be used if they have taken their initial set.

2.3.4.6Where the joint is made with a cement mix, this shall be cured by maintaining it in a moist condition as called for in 3.7.3.

2.3.5Procedure for Welding Sleeve Joints on Site

2.3.5.1The joint faces shall be smooth, square cut and free from any surplus cement-mortar from the lining operation. The unlined areas shall be cleaned thoroughly and if degreasing is required, a strong detergent solution shall be used followed by a clean fresh water rinse.

2.3.5.2When an epoxy pipe jointing compound is to be used, the joint faces shall be dry and dust-free and the compound shall be applied with a small trowel or spatula. When cement-mortar mix is to be used, the joint faces shall be dust-free and moistened with clean fresh water. Immediately after moistening, the cement-mortar mix shall be applied using a small trowel.

2.3.5.3With a sleeve joint to either Figure 6 or Figure 7, the thickness of the jointing material shall be kept to a minimum and all surplus material shall be removed as far as practicable flush with the bore of the pipe. However, sufficient jointing material shall be used to ensure that all voids are filled.

2.3.5.4For pipes 3 inch NPS up to and including 24 inch NPS using a sleeve joint (Figure 6), 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 tack weld has been applied. After tacking, the fillet welds shall be applied using the conventional uphand technique, with electrodes to BS 639 not exceeding 4 mm diameter. The current values employed and the size of the runs of weld metal deposited shall be such as to minimise the heat input and interpass temperature.

2.3.5.5For pipes over 24 inch NPS the lining joint and welded joint shall be completed as shown in Figure 7 or Figure 8 as applicable. The longitudinal seam in the half-sleeve joints shown in Figures 7 and 8 shall be located for welding on the horizontal diameter of the pipe and the same precautions as specified in 2.3.5.4 for fillet welds shall be observed in order to minimise heat input and interpass temperature. Fillet welds shall be applied using the same technique as in 2.3.5.4 to ensure that the cement-mortar lining is not affected. For joints to Figure 8, the unlined area shall be filled, after the pipe has cooled, with a cement-mortar jointing mix with steel mesh reinforcement, generally as described in 2.3.5.1 and 2.3.5.2

The final surface shall be smooth, hard and flush with the lined pipe. Any imperfections in the internal lining shall be repaired, as described in 3.7.3.CEMENT-MORTAR LINING3.1Surface Preparation3.1.1The surfaces to be lined shall be cleaned immediately before the mortar is applied. Scale, rust and debris as well as all coatings of dirt, oil and grease shall be removed.

3.1.2For lining methods where the pipe revolves, pipe rotation must be concentric. For longitudinally welded pipe, any protruding weld metal in contact with the rotating machine rollers must be ground flush with, but not below, the pipe surface.

3.2Surface FinishThe interior surface of the lining shall be smooth and flat with an even distribution of sand and cement throughout the lining thickness.

3.3Lining Methods3.3.1Pipe

Where practicable the lining shall be applied by either the centrifugal process, whereby the pipe is stationary, or by a process which includes rotating the pipe.

If the centrifugal method is used, the pipe may be lined either as individual joints, as strings of multiple joints or as an insitu length of linepipe, any of which may include bends. However the degree of bend which may be included will depend on the pipe diameter.

When the lining is to be applied by the pipe rotation method, the length of pipe must be fabricated to within the maximum and minimum lengths which can be accommodated in the lining machine. Pipe lengths shorter than this minimum may be butted or flange-bolted together before lining.

3.3.2Special Fittings

Special fittings shall be such as to permit lining by hand trowelling. As a guide, the maximum length of pipe that can be readily hand lined is 150 mm for 3 inch, 4 inch and 6 inch NPS, and 450 mm for 8 inch to 24 inch NPS.

3.4Mortar Mix3.4.1The mortar shall be a mixture of the following:

(a)One part by weight of sulphate-resisting Portland cement generally complying with the requirements of BS 4027 or equivalent.

(b)One part by weight of clean fine sand, generally complying with the requirements of BS 882, Table 5, grading limit F, or equivalent, except that the size of any aggregate present must not be greater than one third of the thickness of the lining. If additional sieving is required to meet this latter requirement, the sieve shall comply with BS 410, or equivalent.

(c)Clean fresh water with the sulphate and chloride contents limited in accordance with BS 3148 or equivalent.

3.4.2The ambient temperature during application of the lining shall be between 5 and 35C in accordance with BS 8110 or equivalent.

3.4.3The mortar shall be mixed to a consistency suitable for bonding to the pipe surface.

3.4.4Mortar which has attained it's initial set shall not be used.

3.5Lining Thickness3.5.1The lining shall be square cut and flush with the pipe end or, when internal field welds are to be made, prepared in accordance with Figure 8. The lining thickness shall be as given below.

NominalPipe Size inchesNominal Lining ThicknessTolerance3 & 45 mm}}+ 1.5 mm -1 mm6, 8 & 106.5 mm}12, 14 & 168 mm}}+3 mm -1 mm18, 20 & 2210 mm}24 and over11 mm+5 mm -03.5.2Where a wafer butterfly valve is installed in cement-mortar lined pipe, the valve disc must not foul the lining. If necessary the lining at the flange face shall be chamfered in accordance with Figure 14.

3.6Curing3.6.1Curing of the lined pipe and fittings shall continue for an adequate period, normally at least seven days, before they are moved. During the curing period the lining shall be maintained in a moist atmosphere and at a temperature between 10C and 50C. The lining shall be regularly inspected and water added to aid curing, if required.

3.6.2When 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 check that the lining thickness is within the required tolerance.

3.7Repair of Damaged Cement-Mortar Lining3.7.1A pipe surface that has been exposed by spalling or cracking of the lining shall be cleaned in accordance with 2.3.5.1.

3.7.2When an epoxy pipe jointing compound is to be used for the repair, the surfaces shall be dry and dust-free and a coating of the compound shall be applied with a small trowel or spatula. When cement-mortar mix is to be used, the surfaces shall be dust-free and moistened with clean fresh water. Immediately after moistening, the cement-mortar mix shall be applied using a small trowel. If necessary a brush can be used for "feathering in" the surface edges of the repair.

3.7.3Where cement-mortar is used for the repair, the adjacent lining shall be coated far enough back to cover any visible cracks and shall be maintained in a moist condition for three days using a wet hessian sack or similar means. Alternatively, if the line can be filled, it shall be put into use after the initial set has taken place.

3.7.4Whenever extensive patching is essential, the repaired lining shall be reinforced with 25 mm x 10 mm x 1 mm diamond steel mesh, tack-welded to the pipe.

3.8Cutting Cement-Mortar Lined Pipe3.8.1For cutting lined pipe, a slitter saw supported as necessary and containing a nylon bonded carborundum disc shall be used. Alternatively, a rigid pipe cutting machine using tungsten carbide-tipped tools ground to the cutting angles given in Figure 9 shall be used.

3.8.2On fusion welded steel pipes, the external weld shall be removed flush with, but not below, the face of the pipe for the width of the cutters, and if necessary for the complete width of the cutting machine.

3.8.3The section to be removed and the adjacent pipe ends shall be suitably supported to avoid imposing any weight on the concrete lining when breaking through.4.DAMAGE PROTECTION4.1HandlingHandling of lined pipe lengths shall be by means of slings such that the pipes are supported 1/5 of their length from each end. Pipes shall not be lifted using hooks inserted in the pipe ends.

4.2Transportation4.2.1Lined pipes being transported shall be adequately supported in a level horizontal position in order to minimise flexing and prevent induced bending and damage to the lining.

4.2.2Pipes shall be protected from direct or indirect impact by means of suitable cushioning material.

4.2.3Pipes shall not be transported using tractor units with trailing bogies or other methods offering no central support.

4.3Pipe Ends and Branch Connections4.3.1During 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 drying out and cracking of the lining. Means shall be taken to ensure that the end protection remains securely fastened, especially during transportation.

4.3.2Branch connections shall be suitably plugged or capped as described above.

4.4Installation4.4.1The requirements for handling and transportation of individual pipe lengths so as to avoid damage are as described in 4.1 and 4.2 above. Similar care shall be taken when handling jointed lengths of pipe and pipestrings to ensure that induced bending and the possibility of damage to the lining is minimised.

4.4.2During pipeline installation, when handling, lifting and laying pipe, the spacing of lifting points and supports shall not be greater than the maximum support spacing shown in the table below. Also when installing pipe on above ground supports or piperacks, the support spacing shall be not more than shown in the table. When laying pipelines, the radii of any curves in the horizontal or vertical plane due to the ground profile shall be not less than those listed in the table.Nominal Pipe Size (inches)Minimum Bend Radius (metres)Maximum Support Spacing(millimeters)35305240470059806105069608140073201017707730122110808014231087201626508980182990924020332098902236801009024400010320264350104702846901060030 and larger172 x inside diameter of steelpipe10720Note: No allowance has been made for the additional weight of valves and fittings; where these are used, additional supports shall be provided. 5.IDENTIFICATIONEach item of pipe and fittings shall be marked or labelled with the size, order number and pipeline item number. Each item shall also be clearly identified as cement-mortar lined pipe to ensure that it is not subjected to shock loads, for example hammer testing after installation.

Nominal Pipe Size(inches)A(mm)Nominal Pipe Size(inches)A(mm)31702631041802831062103031082503231010270343201228036320143003832016320403201833042320203504432022Non Std Flange46320243504837042Non Std Flange56Non Std Flange6038064Non Std FlangeNotes:

1.For details of sleeves see the following figures:-Figure 6For pipe sizes 3 to 24 inchFigure 7For pipe sizes 24 to 46 inchFigure 8For pipe sizes 48 inch and larger

FIGURE 1FLANGED CONNECTIONS WITH CLASS 150 FLANGES Nominal Pipe Size(inches)A(mm)Nominal Pipe Size(inches)A(mm)3220261170426028125063503013208450321400105503414701264036155014720381630168004017001888042178020960441860221040461930241120482050Notes:

1.Bends shall be fabricated using long radius elbows to ANSI B16.9 or BS 1640

2.For pipes over 48 inch nominal size the bend shall be detailed and fabricated as part of the relevant project.

3.For details of sleeves see the following figures:-Figure 6For pipe sizes 3 to 24 inchFigure 7For pipe sizes 26 to 46 inchFIgure 8For pipe sizes 48 inch and largerFIGURE 290symbol 176 \f "Symbol" BENDSNominal Pipe Size(inches)A(mm)Nominal Pipe Size(inches)A(mm)31062617941082818361213017781453218110169341751218336178141873818216190401761819442180201984418422202461772420648181Notes:

1.Bends shall be cut from long radius elbows to ANSI B16.9 or BS 1640 with being specified as part of the project design. When is 45symbol 176 \f "Symbol", standard fittings may be used

2.For pipes over 48 inch nominal size the bend shall be detailed and fabricated as part of the relevant project.

3.For details of sleeves see the following figures:-Figure 6For pipe sizes 3 to 24 inchFigure 7For pipe sizes 26 to 46 inchFIgure 8For pipe sizes 48 inch and largerFIGURE 3BENDS OTHER THAN 90symbol 176 \f "Symbol"NominalPipe SizeNominal(inches)AL(inches)ALMajorMinor(mm)(mm)MajorMinor(mm)(mm)431083202624-18179100064-31213702826-18183100086-41454203028-201771000108-41694953230-2418110001210-61835553432-2417510001412-61877003634-2417810001614-81907353836-261829701816-101947654038-301769702018-121989004240-301809702220-142029104442-361849752422-162069204644-3817710754846-401811075Notes:

1.Where the required reduction cannot be achieved using one standard reducer then two or more assemblies in series shall be used.

2.Reducers for pipe sizes greater than 48 inch shall be regarded as specials and detailed as part of the relevant project.

3.For details of sleeves see the following figures:-Figure 6For pipe sizes 3 to 24 inchFigure 7For pipe sizes 26 to 46 inchFIgure 8For pipe sizes 48 inch and larger

FIGURE 4ECCENTRIC REDUCER ASSEMBLIESMain Nominal Pipe Size(inches)A(mm)B (mm)For All Branch SizesMain Nominal Pipe Size(inches)A(mm)B (mm)For All Branch Sizes338019028140071044302153014707506530265321550790866033034162083510770385361700870128704353817809101493046540185095016980490421880965181070535441980101520116058046205010552212406204821401140241280640Above 48Set-on tees only.To be detailed261350680during project designNotes:

1.Dimension B is equally applicable to a raised face or a flat faced flange. This dimension may be varied, e.g. to suit a probe length.2.The combination of forged tee and welding-neck flange shall be regarded as special and shall be detailed as part of the relevant project.3.Fittings requiring reinforcement shall be regarded as special and shall be detailed as part of the project. However, the design shall be suitable to accommodate the sleeves specified in Note 44.Sleeves in accordance with the following figures may be fitted to any plain end without affecting effective pipe lengths:-Figure 6For pipe sizes 3 to 24 inchFigure 7For pipe sizes 26 to 46 inchFIgure 8For pipe sizes 48 inch and largerFIGURE 5TEE BRANCH CONNNECTIONS WITH CLASS 150 FLANGES

PipeSleeveNominalP (mm)S (mm)B (mm)Pipe SizeMinMaxMin MaxMin(inches)388.089.5MeasuredMeasured1104113.5115.0OutsideOutside1156167.5169.5DiameterDiameter1258217.5220.5Of PipeOf Pipe13510271.5275.0+ 1mm+ 6mm14512321.5326.0(See note 3)(See note 3)15514353.0358.016016403.5409.017018454.0460.018020503.0513.019522553.5564.519524604.0616.0195Notes:1.Pipe outside diameters are derived from the dimensions and tolerances stated in API Spec 5L.2.Minimum wall thickness of sleeve shall be 1.2 x thickness of pipe.3.The measured outside diameter of pipe shall be that of the pipe delivered for a specific job or project.4.Pipes shall be centralised with slip wedges before welding.FIGURE 6ONE-PIECE SLEEVE JOINT FOR NOMINAL PIPE SIZES 3 INCH UP TO AND INCLUDING 24 INCH

Notes:

1.Minimum size of fillet welds = Pipe wall thickness as specified in 2.1.4 of this specification.

FIGURE 7HALF-SLEEVE JOINT FOR NOMINAL PIPE SIZES OVER 24 INCH BUT UNDER 48 INCH

Variable DimensionsNominal Pipe Size G (mm)NL(inches)MINMAX(mm)(mm)48 up to 603275250100Over 6032100300120Notes:

1.Minimum size of fillet welds = 3/4 T.2.Minimum sleeve thickness = T

FIGURE 8HALF-SLEEVE JOINT FOR NOMINAL PIPE SIZES 48 INCH AND LARGER

3 REQUIRED PER CUTTING UNIT(1 EACH TYPE OF BLADE A, B & C)

FIGURE 9DETAILS OF CUTTING ANGLES FOR TUNGSTEN CARBIDE TIPPED TOOLS FOR CEMENT-MORTAR LINED STEEL PIPES EMBED Visio.Drawing.4 Nominal Pipe Size(inches)R(mm)A(mm)3270106435010865001218800145101100169121300183141600187161800190182100194202700198223100202243700206Notes:

1.The tangent lengths and the radii given are minimum values, actual dimensions shall be detailed as part of the relevant project.

2.The thickness of the pipe wall at any point on the finished bend shall not be less than the schedule thickness to the tolerance applicable for equivalent straight pipe.

3.The difference between maximum and minimum diameters on any common radial plane shall not be more than 5% of the outside diameter of the pipe.

4.When the bent pipe is to be butt-welded into the piping system the tolerance at the ends shall be in accordance with ANSI B16.9 or BS 1640.

5.Except as specified in the foregoing notes the bent pipe shall be to the specification, tolerances and tests stipulated for the piping system generally, or as given in the order.FIGURE 10MINIMUM BENDING RADII FOR STEEL PIPE

Nominal Pipe Size(inches)A(mm)32504260627082801029012300143101632018330203502235024350Notes:

1.Care shall be taken to ensure that all areas of piping material around the hole to the half coupling are adequately covered with cement-mortar lining.

2.For details of sleeves see Figure 6.FIGURE 113/4 INCH AND 1 INCH BRANCH FITTINGS FOR NOMINAL PIPE SIZES 3 INCH UP TO AND INCLUDING 24 INCH

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Main.Nominal Pipe SizeA(mm)Over 24 inchBut Under 48 Inch15048 Inch and Over225

Notes:

1.Damage to the cement-mortar lining caused whilst fitting the half-coupling shall be made good at site, and care taken to ensure that all areas of pipe material are covered.

FIGURE 123/4 INCH AND 1 INCH BRANCHES FOR NOMINAL PIPE SIZES OVER 24 INCH

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Notes:

1.Where alternative types of assembly are shown on the figures referred to above, selection shall be made during detailed design.

2.Butterfly valves used in pipes of nominal size 3 inch to 12 inch inclusive may be full bore or reduced bore. For nominal pipe sizes above 12 inch all valves shall have reduced bore. All valve bodies shall be vulcanised rubber lined.

FIGURE 13TYPICAL ARRANGEMENT OF CEMENT-MORTAR LINED STEEL PIPES AND FITTINGS

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FIGURE 14TYPICAL CONNECTION BETWEEN CEMENT MORTAR LINED PIPE AND RUBBER LINED BUTTERFLY VALVE

Notes:

1.Detail design of joint to suit the particular project.

2.Pipe jointing to be generally in accordance with Figures 6, 7 and 8 for different pipe-sizes.

FIGURE 15TYPICAL DESIGN FOR SPECIAL SLEEVE JOINT

Note:

1.Detailed design of joint to suit the particular project.

FIGURE 16TYPICAL DESIGN FOR REYNOLDS JOINTAPPENDIX ADEFINITIONS AND ABBREVIATIONS

Definitions

Standardised definitions may be found in the BP Group RPSEs Introductory Volume.

Abbreviations

ANSIAmercian National Standards InstituteAPIAmerican Petroleum InstituteASMEAmerican Society of Mechanical EngineersASTMAmerican Society for Testing MaterialsBSBritish StandardEEMUAEngineering Equipment and Materials Users AssociationNPSNominal pipe size

APPENDIX BLIST OF REFERENCED DOCUMENTS

A reference invokes the latest published issue or amendment unless stated otherwise.

Referenced standards may be replaced by equivalent standards that are internationally or otherwise recognised provided that it can be shown to the satisfaction of the purchaser's professional engineer that they meet or exceed the requirements of the referenced standards.

British Standards

BS 410Specification for Test SievesBS 639Specification for Carbon and Carbon Manganese Steel Electrodes for Manual Metal-Arc Welding (withdrawn).BS 882Aggregates from Natural Sources for Concrete.BS 1501Steels for Fired and Unfired Pressure Vessels (Replaced by BS EN 10028 & 10029).BS 1503Steel Forgings for Pressure Purposes. (ISO 2604-1)BS 1560Steel Pipe Flanges (1/2 inch to 24 inch) for the Petroleum Industry. (ISO 7005-3)BS 1640Steel Butt-Welding Pipe Fittings for the Petroleum Industry.BS 2926Chromium and Chromium-Nickel Steel Electrodes for Manual Metal-Arc Welding.BS 3293Carbon Steel Pipe Flanges (over 24 inch) for the Petroleum Industy.BS 3799Steel Pipe Fittings, Screwed and Socket-Welding for the Petroleum Industry.BS 4027Sulphate Resisting Portland Cement.BS 4360Weldable Structural Steels.

American

ANSI/ASME B16.11Forged Steel Fittings, Socket Welding and ThreadedANSI/ASME B16.5Steel Pipe Flanges and Flanged FittingsANSI/ASME B16.9Factory-Made Wrought Steel Butt-Welding FittingsAPI 605Large-Diameter Carbon Steel FlangesAPI Spec 5LSpecification for Line PipeASME B31.3Chemical Plant and Petroleum Refinery PipingASTM A105 Forgings, Carbon Steel, for Piping ComponentsASTM A106Seamless Carbon Steel Pipe for High-Temperature ServiceASTM A234Pipe Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures.

BP Group Documents

BP Group 118-5Fabrication of Carbon, Carbon Manganese and Low Alloy Ferritic Steel Pipework.BP Group 118-7Fabrication of Austenitic, Duplex, Cupro-Nickel and Nickel Base Alloy Steel Pipework.EEMUA

EEMUA Publication 142 Noise-acoustic insulation of pipes, valves and flanges

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