SINTAKOTE Steel PiPeline Sy StemS Handling and inS tallation Handling_Installation Manual... ·...

SINTAKOTE®

Steel PiPeline SyStemSHandling and inStallation8TH EDITION

SINTAKOTE®

Steel PiPeline SyStemSHandling and inStallationRefeRence manual8TH EDITION

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diSclaimeR

This manual has been prepared by Pentair Water Solutions to assist qualified Engineers and Contractors in the use of the Company’s product, and is not intended to be an exhaustive statement on pipeline design, installation or technical matters. Any conclusions, formulae and the like contained in the manual represent best estimates only and may be based on assumptions which, while reasonable, may not necessarily be correct for every installation.

Successful installation depends on numerous factors outside the Company’s control, including site preparation and installation workmanship. Users of this manual must check technical developments from research and field experience, and rely on their knowledge, skill and judgement, particularly with reference to the quality and suitability of the products and conditions surrounding each specific installation.

When pipeline construction is being carried out for any water authority, as Principal, that water authority’s standards, specifications or drawings, if at variance to any recommendation made in this manual, override the recommendations made in the manual.

The Company disclaims all liability to any person who relies on the whole or any part of this manual and excludes all liability imposed by any statute or by the general law in respect of this manual whether statements and representations in this manual are made negligently or otherwise except to the extent it is prevented by law from so doing.

The manual is not an offer to trade and shall not form any part of the trading terms in any transaction. Pentair Water Solutions trading terms contain specific provisions which limit the liability of Pentair Water Solutions to the cost of replacing or repairing any defective product. Trading terms are readily available on request.

© Pentair Ltd

This manual is a publication of Pentair Water Solutions Pty Ltd, and must not be copied or reproduced in whole or part without the Company’s prior written consent. This manual is and shall remain the Company’s property and its request. The Company reserves the right to make changes to any matter at any time without notice. Eighth Edition published 2013.

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contentS

SEcTION PAgE

1. Transportation 12

2. Site Preparation 13

3. Unloading and Handling 14

4. Stacking and Storage 16

5. Stringing 19

6. Trenching 31

7. Bedding 23

8. Laying and Jointing 24

9. Backfilling 45

10. Fittings 49

11. Anchorage of Pipelines 50

12. Hydrostatic Field Test 52

13. Commissioning Water Pipelines 54

APPENDICES

APPENDIX A 53 Field Repair and Joint Reinstatement of SINTAKOTE®

APPENDIX B 65 Field Repair and Joint Reinstatement of Cement Mortar Linings and Guidelines for Pipe Hydration and Fitting End Caps

APPENDIX C 72 Field Application of Electrical Cables to CP Lugs

APPENDIX D 74 Safe Operating Procedure for Holiday Testing

APPENDIX E 76 Field Application of Seal Coat to CML Pipe

APPENDIX F 78 General Data

APPENDIX G 85 SINTAKOTE Repair Kit

APPENDIX H 86 References

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contentS (continued)

LIST Of fIgurES & TAbLES

Figure 1.1 - Securing pipes for transport 12Figure 3.1 - Twin slings or spreader bar 15Figure 4.1 - Pipe support 16Table 4.1 - Minimum pipe support area 17Figure 4.2 - Pipe bearing area 17Figure 4.3 - Stacking pipes using timber bolsters 20Figure 5.1 - Single stringing of pipes 20Figure 5.2 - Multiple stringing of pipes 20Table 6.1 - Minimum trench widths 21Figure 6.1 - Trench excavation machinery 22Figure 7.1 - Bedding layer minimum depth 23Figure 7.2 - Spreading bedding 23Figure 8.1 - Jointing systems 24Figure 8.2 - Pulling SINTAJOINT® pipes “home” to joint 25Figure 8.3 - Fitting rubber rings into sockets 27Figure 8.4 - Alignment of pipes during jointing 28Table 8.1 - Permissible misalignment and offsets during entry 29Figure 8.5 - Temporary construction and pipe permanent SINAJOINT operating deflection 30Figure 8.6 - Axial offset measurement created by joint deflection 31Figure 8.7 - External inspection of assembled SINTAJOINT 32Figure 8.8 - “D” Series Rubber Ring joint direction 32Figure 8.9 - Section view of a SINTALOCK® welding joint 34Figure 8.10 - Welded ball and socket or spherical slip-in join t field assembly 34Figure 8.11 - Raised face type flanges 36Figure 8.12 - Matched o-ring type flanges 36Figure 8.13 - Star pattern tightening sequence 36Table 8.2 - Recommended gasket composition for transport of general domestic liquids including brine and sewage 34Table 8.3a - Recommended Class 16 bolt sizes, bolt types and gasket types 39Table 8.3b - Recommended Class 21 bolt sizes, bolt types and gasket types 40Table 8.3c - Recommended Class 35 bolt sizes, bolt types and gasket types 41Table 8.4 - Indicative k Values 42Table 8.5 - Required tension and torque values 43

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contentS (continued)

LIST Of fIgurES & TAbLES (cONTINuED)

Figure 9.1 - Zones of backfill and compaction 45Figure 9.2 - Ring deflection limits 47Table 9.1 - Maximum allowable vertical deflection for inspection of SKCL buried pipe 48Figure 10.1 - Common fittings - welded pipe lines 49Figure 10.2 - Common fittings - SINTAJOINT® pipe lines 49Figure 11.1 - Anchor blocks for horizontal thrust restraint 50Figure 11.2 - Anchor blocks for vertical thrust restraint 51Figure 11.3 - Pier support for above ground SINTAJOINT pipelines 51Figure 12.1 - Static head allowance for hydrostatic test with alternative pressure gauge locations 52Figure A.1 - Flow chart for determining appropriate SINTAKOTE® repair method 56Figure A.2 - Joint region for Drader welding repair. 60Figure A.3 - Drader gun assembly 61Figure A.4 - Drader gun tip selection 62Figure A.5 - Build up of material on cut end 63Figure A.6 - Care required when trimming 63Figure B.1 - Typical cement mortar lining crack greater than 2mm 68Figure B.2 - Enlarge crack to 4 - 6mm 68Figure B.3 - Completed repair 68Figure C.1 - Field Application of Electrical Cables to CP Lugs - Align lugs 72Figure C.2 - Field Application of Electrical Cables to CP Lugs - Strip SINTAKOTE 72Figure C.3 - Field Application of Electrical Cables to CP Lugs - Bare cable ends 72Figure C.4 - Field Application of Electrical Cables to CP Lugs - Crimp cable 73Figure C.5 - Field Application of Electrical Cables to CP Lugs - Heat crimp joint 73Figure C.6 - Field Application of Electrical Cables to CP Lugs - Apply sealant 73Table F.1 - SINTAKOTE Thicknesses 78Table F.2 - Cement Mortar Lining (CML) Thickness 78Table F.3 - SINTAKOTE Steel Pipe Bores and Weights 78Table F.4 - Manufacturing test pressure and rated pressure of MSCL pipe 82Table F.5 - SINTALOCK® Joint Rated Pressure 84

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SintaKote® tRaining PRogRam

The SINTAKOTE® Quality Pipeline Installation Program was introduced by Pentair in 1989 and, to date, over 8,000 Water Industry personnel have participated. This program assesses individuals through competency-based training and assessment, the application of an adherence to Quality, Safety, Environmental and Risk Systems.

In line with Pentair Water Solutions commitment to continuous improvement, the program is accredited by the Australian Skills Quality (ASQA).

The program has been running for many years and is recognised as an Industry Leader. The Accreditation can be seen as a QA measure to ensure training for steel pipeline systems meets the most appropriate specifications.

The basis for the Program and the Accreditation is the Pentair Water Solutions Handling and Installation Manual and the Pipeline Installation Quality System, commonly known as the PIQS Manual.

PENTAIr WATEr SOLuTIONS TrAININg & AuDITINg - rEgISTErED TrAININg OrgANISATION

SERVICES

– On-site auditing assessment

– Technical & systems support

– Pre qualification of installers

– On site and off site training

bENEfITS

TO CUSTOMER

– Confidence in installers

– Reduce unscheduled maintenance

– Traceability

– Confidence in asset performance

– Asset longevity

– Lower risk rating

TO INSTALLER

– Certification of workers

– Ability to tender for more work

– Lower risks

– Increase efficiencies

– Confidence in work

– Less re-work

– Lower injury rates

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RiSK & Safety

Pentair Water Solutions is a strong advocate of Safety in the Workplace and believes that safety is paramount in all that we do.

All contractors and installers should commit to providing a work environment where everyone in the workplace is safe at all times and recognise people as their greatest asset.

The safe handling and installation of the SINTAKOTE® Steel Pipeline System in all applications relies on all personnel having a high level of safety awareness, reducing risk and improving site preparation and planning.

STEPS TO SAfETy

1. RESPONSIBILITIES FOR WORKPLACE SAFETy

- Be aware who has specific responsibilities.

2. PLAN TO WORK SAFELy

- Identify tasks and procedures, which control the risks arising from work activities.

3. INVOLVE EMPLOyEES

- Display information in your workplace concerning health & safety. All employees should talk about ways to contribute to decisions that affect their safety in the workplace.

4. DEVELOP PROCEDURES

- Identify hazards in your workplace and assess any risks associated with them. (Mitigate these hazards through developing processes to eliminate or control).

5. INFORM AND TRAIN EMPLOyEES

- Inform employees about hazards in their job.

6. MONITOR AND REVIEW

- Adjust, review and address any workplace or legislative changes. Processes change, staff change and so may the risks.

7. PLANT & EQUIPMENT

- Regularly assess and inspect equipment and maintain records.

- Ensure appropriate Licences are held for Plant in use.

The above steps to safety may be undertaken throughout and continued through the On-Site Inductions, Toolbox Meetings, or Site Assessments.

Remember you may have Principal Contractor’s obligations whereby you may be responsible for:

Injury or accidents to members of the public, employees and other on site contractors, at or near a construction site or workplace.

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RiSK & Safety

ENvIrONmENTAL

Pentair Water Solutions embraces environmental protection and ensures its operations comply with relevant environmental legislation.

Accordingly, Pentair Water Solutions as well as SINTAKOTE® pipeline installers and contractors have a responsibility to ensure your work activities do not harm the environment.

you are expected to take all reasonable and practical measures to ensure that:

– Waste (spoil, concrete, off-cuts, etc) is minimised and disposed of in the correct manner.

– Water quality is not affected and contaminated run-off from site is prevented.

– Soil erosion and sediment control is reduced.

– Soil does not become contaminated (either from imported fill or excavation material).

– Care is taken when handling and using hazardous substances.

– The effect on air quality is minimised, through dust and pollution control measures.

– The effect on air quality is minimised, through

dust and pollution control measures.

– Minimise disturbance to existing flora and fauna. Restore vegetation on completion of the works.

– Disruptions to surrounding services are to be minimised.

– Noise emissions are kept within required limits.

– Traffic and the movement of plant & equipment around the site does not impact the environment.

– Vibration to adjacent buildings and area should be minimised.

– Impact on heritage and archaeological sites should be minimised.

– Report any environment incidents to environmental authorities or units.

Further details can be gained from State Government, Environment Agencies, Local Councils and also from industry bodies.

rISK mANAgEmENT

Legislation in all states and territories requires an employer to identify all hazards in their workplace and to assess the likelihood and severity of harm that may arise from such hazards. The International Risk Management Standard

AS/NZS 150 31000 contains greater details regarding the Risk Management Process.

Risk Management means looking at the work and processes you are about to undertake that could cause injury (entrapment), making a judgement on the consequence and likelihood of what could happen as a result (death or injury to persons in an excavation), and doing something about it.

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ThIS mANuAL hAS bEEN PrEPArED by PENTAIr WATEr SOLuTIONS PTy LTD

It is intended to provide guidance on the field practices of handling and installation of SINTAKOTE® steel pipelines.

Adherence to these guidelines should ensure that the SINTAKOTE steel pipeline system will have the capacity to perform in excess of one hundred years.

There may be aspects of handling and installation not covered in this manual which may become subject to revision. For this reason and in the interests of continuous improvement, feedback on the manual is encouraged.

Inquiries or contributions should be directed to the Strategy & Marketing Director - Water Projects, Steel Pipeline Systems,

Pentair Water Solutions PO Box 162 Carole Park, Qld, 4300 Australia.

Or email [email protected]

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1. tRanSPoRtation

SEcurE ThE LOAD

All pipes must be secured by straps or other suitable means to prevent movement during transit and be in compliance with all local and state regulations regarding load restraint.

PrOTEcT ThE PIPE AND cOATINg

Factory installed toms are installed in some pipe sizes and should be maintained in place until after installation.

All supports, restraints and packing bearing on pipe surfaces should be covered or wrapped with material suitable to prevent chafing and shock damage during transit.

In the case of rail transport, end protection should be provided against shunting shocks. Rubber mats, carpet etc. are suitable for this purpose.

If bolsters are utilised only two per pipe length should be used. Each should be placed 0.2 to 0.25 of the length from each pipe end (outside quarter points). See Figure 1.1

The width of bolster must provide sufficient area of support to protect the pipe coating. A minimum bolster width of 150mm is required.

Double scalloped bolsters should be used to separate layers of stacked pipe and pipes in the same row spaced so that they do not touch.

Scallops must be cut to suit the outside diameter of the

pipe and have a minimum saddle angle of 90 degrees.

The bottom bolsters should be securely anchored to the floor or side of the road truck or rail carriage. The load should be strapped securely at a minimum of two locations, not more than 500 mm from the bolsters and using webbing straps with a minimum lashing capacity of 2000kg. Multiple straps may be necessary at each location. See Figure 1.1.

The strapping should be securely anchored with approved ratchet type devices and should be checked for tension at regular intervals not exceeding 300 kilometres of travel. Chains shall not be used to tie down pipes or piles.

Bolster locations 0.2 to 0.25 of the pipe length from each end. This may be varied to suit vehicle load requirements.Bolsters must have

ropes on ends to aid manual handling.

figure 1.1 - Securing pipes for transport

500mm 500mm

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2. Site PRePaRation

Good site preparation maximises safety and can save time and money

SITE chEcKS

While preparing sites remember to check for :

VEHICLE ACCESS

– road conditions

– warning signs

– traffic control

– load limitations

– all weather access

STORAGE COMPOUNDS

– convenience of location

– security

– site dunnage availability

– protection from weather

STACKING AREAS

– uneven surfaces that may require grading

– stability in bad weather

– clear of grass in case of fire

– overhead power lines

– other services

GENERAL

– local traffic

– overhead powerlines

– location of other services

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Personnel involved in unloading and handling should always wear PPE as required by the Occupational Health and Safety Act; such as hardhat, safety shoes, safety glasses, high visibility vest and other equipment.

Attention to the following items improves efficiency of the operation, maximises safety and minimises risk of damage.

Steel pipes are not susceptible to breakage but poor handling can result in damaged coatings and/or linings and damage to the pipe ends.

Damage to pipeline components will be prevented by:

– adequate support and restraint during

– transportation to site;

– proper use of handling equipment;

– use of suitable handling equipment;

– correct site storage;

– unloading on even ground; and

– correct handling of load.

When factory fitted cathodic protection (CP) lugs are provided, extra care must be taken to ensure that the lugs are not damaged and that pipes are not bumped together as the lugs may damage coating on adjacent pipes.

bEfOrE uNLOADINg

Choose a central storage site for general use, storage of small components and gaskets etc.

Choose and prepare suitable pipe storage sites along the pipeline route.

If possible, select unloading and storage areas which are clear of overhead powerlines.

Make sure the truck is on level ground before releasing the straps.

uNLOADINg

(See also Section 5: Stringing)

Immediately upon receipt, all items should be visually examined for damage to:

– the pipe itself, particularly the ends;

– cement mortar lining;

– external coating;

– rubber rings; and

– lubricant containers.

All repair work should be carried out promptly.

Refer Appendices A: Field repair and joint reinstatement of SINTAKOTE® and B: Field repair and joint reinstatement of cement mortar linings.

Check that the correct quantities of materials have been received.

Unload the truck evenly to keep it stable.

LIfTINg OPErATIONS

All lifting operations must meet legal and occupational, health and safety requirements applicable to the site.

Qualified personnel must be employed for crane operation.

When unloading by mobile crane, a licenced dogman must be present.

Lifting should be done smoothly without sudden jerking motions. Pipe movement should be controlled by use of guide ropes and care taken not to bump other pipes or equipment. See Figure 3.1.

Lifting and placing must be carried out so that the stability of the pipe stack, crane or vehicle is maintained.

3. unloading and Handling

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3. unloading and Handling

When conditions are suitable, forklifts may be used. The contact surfaces of the tynes must be protected with thick rubber with a minimum durometer hardness (Shore D) of 45.

chOOSINg EquIPmENT

When choosing lifting equipment consider:

– pipe weights; (Appendix D: General data; Table D.3)

– type of stacking;

– outreach; and

– site conditions.

AccESSOrIES

SLINGS

Pipes should be handled one at a time.

Use twin slings, spreader bar or other approved lifting devices. See Figure 3.1.

Slings and lifting devices must comply and be used in accordance with the appropriate safety requirements.

The slings shall be of nylon or synthetic material of sufficient width so not to damage the coated surface of the pipe or pipe fitting.

VACUUM LIFTING DEVICES

Vacuum lifting devices are available to lift pipes. These should be used in accordance with the manufacturer’s specifications.

HOOKS

Hooks should not be used for lifting pipes or fittings.

figure 3.1 - twin slings or spreader bar

Guide ropes

Twin sling

Spreader bar

Guide ropes

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STOrAgE ArEA

The storage area should:

– have a firm foundation for pipe stacks and vehicle operation;

– have suitable access for road vehicles;

– be free of overhead power lines wherever possible; and

– be barricaded if necessary.

PIPE SuPPOrT

Coated pipes should at all times be supported clear of the ground. Beware of protruding rocks and uneven ground.

If pipes are provided with factory fitted CP lugs ensure that pipes are stored with lugs at the top.

The pipe should be supported at two locations, 2.5 to 3.0 metres or 0.2 to 0.25 of the pipe length from each end. See Figure 4.1.

Each support shall provide adequate bearing area. The bearing area on the pipes should not be less than that shown in Table 4.1. See Figure 4.2.

4. StacKing and StoRage

Minimum Support Bearing Area (mm )Pipe OD (mm) 6m Length 9m Length 12 - 13.5m Length

813 10,000 10,000 10,000>813 to 1403 10,000 15,000 20,000>1403 to 1753 15,000 20,000 30,000

> 1753 20,000 30,000 40,000

figure 4.1 - Pipe support

Two supports 2.5 to 3.0 metres or 0.2 to 0.25 of the pipe

length from each end

CP Lugs if provided

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It is recommended that pipes be supported on sand/sawdust filled bags or sand/soil mounds. The supports should be positioned to ensure that each pipe is stable. For long term storage, mounds should be protected from erosion.

The entire pipe must be kept clear of the ground to protect the coating from damage at a clearance of approximately 100mm off the ground minimum.

It is recommended that pipes be separated from each other for ease of

inspection and to minimise the potential for damage during handling.

STAcKINg hEIghTS fOr LONg TErm STOrAgE

Pipes 610 mm OD and larger should be stored in single layers only. Pipes less than 610 mm OD may be stacked. To prevent damage to the SINTAKOTE® and for safety and handling reasons pipe stacks must not exceed 2m in height.

Stacks should never be higher than they are wide.

Timber bolsters of minimum cross section dimensions: 150mm wide x 150mm clear depth between scallops, should be used to separate layers. The scallops shall have a minimum saddle angle of 90 degrees.

In termite infested areas, timber bolsters may not last unless the area is treated. Otherwise, the bottom bolster should be made from steel. Bottom bolsters must also be placed on firm ground and must be level.


figure 4.2 - Pipe bearing area

Sand/Sawdust bags Sand/Soil mounds

Bolster locations 2.5 to 3.0 metres or 0.2 to 0.25 of the pipe length from each end.

500mm 500mm

figure 4.3 - Stacking pipes using timber bolsters.

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STOrAgE

Small fittings, rubber rings and lubricant should be stored in a secure convenient area. Lubricant must not be stored for lengthy periods in direct sunlight.

Rubber rings should be stored in bags, out of the sun and away from petroleum products. They should be stored in a manner that prevents them from being subject to high compressive or tensile strains.

Rubber rings should be used within 12 months. If rubber rings are stored for longer periods they should be discarded.

STOrAgE Of cEmENT mOrTAr LINED PIPES

Cement mortar lining may crack and possibly disbond when stored in hot, dry conditions. The longer the storage period in such conditions, the wider the cracks will be and the greater the extent of any disbondment (drumminess).

Cracks up to 2mm in width (as allowed in AS1281, “Cement Mortar Lining of Steel Pipes and Fittings”) are acceptable for pipes conveying potable water as these cracks close and heal

on exposure to water.

When pipes greater than 800mm in diameter are stored for more than a few weeks in hot, dry conditions, cracks may develop in excess of the 2mm allowable under AS 1281 and the lining may disbond.

In such circumstances precautions should be taken such as end capping (to reduce airflow and thus rate of cracking) and adding water to the pipes (to reduce the width of cracks).

Guidelines for end capping are found in Appendix B - Field Repair and joint reinstatement off cement mortar linings and guidelines for pipe hydration and fitting end caps.

Guidelines for repair when cracks or disbondment exceeds 2mm are found in Appendix B - Field repair and joint reinstatement of cement mortar linings.

Seal coated CML pipe can also deteriorate during storage for long periods. The main component of the seal coat, bitumen, can deteriorate, when exposed to ultraviolet radiation, and when exposed to high temperatures, and/or cyclic temperatures for long periods of time, both deterioration and delamination of the seal coat can occur.

Where this occurs it is usually first evident at pipe ends, where it’s exposed to ultraviolet radiation.

Typically when stored for more than 3 months, seal coated pipes should be regularly inspected to ensure deterioration is not occurring. If there is evidence of deterioration this can be controlled by the same measures indicated above for control of CML cracking by providing end capping. A small amount of deterioration (<5% area on <5% of pipes) is normally acceptable as it would not be expected to significantly affect pH control of the pipeline.

Generally pipes smaller than 800mm diameter are not affected. However the same precautions apply.


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bEfOrE PIPE DELIvEry

Plan stringing before arrival of the pipe

and consider:

– the construction programme;

– the ground conditions; and

– the safety of workers and the general public.

WHERE TO STRING

Pipe should be located to minimise handling during the laying operation. Pipes should be properly supported. Refer Section 4: Stacking and storage.

Large fittings and valves should be put adjacent to where they will be needed.

Small fittings, gaskets, nuts and bolts should be kept in a secure storage area until they are needed.

WHAT EQUIPMENT TO USE

Cranes, forklifts or other appropriate equipment approved by the relevant State Occupational Health & Safety Authority may be used.

Always use approved slings and accessories. For large pipes, twin slings should be used, Refer to Section 3: Unloading and handling; Accessories.

Guide ropes should be used to control the pipe. See Figure 3.1.

METHOD OF STRINGING PIPES

Keep pipes close to the ground while they are being moved.

Pipes should be near enough to the trench for the laying crew, but far enough away so they don’t interfere with equipment access, trench digging or excavated spoil.

When single stringing, pipes should be in line with the trench with sockets facing the direction of laying such that when laying, a spigot is inserted into an already laid socket.

This is the recommended technique for jointing and allows the entry of the spigot into the socket to be more easily seen and controlled. It also minimises the risk of scooping bedding material into the joint and onto mating surfaces. See figure 5.1.

5. StRinging

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When laying pipe on steep slopes, construction should start at the bottom and proceed up hill. In this way the weight of the pipes is

used to advantage when jointing. Pipes should thus be strung with sockets facing uphill. See Figure 5.1.

When multiple stringing, groups of pipes should be in line with the trench with their sockets all facing the direction of laying.

Groups of pipes should be separated by the distance covered by the number of pipes in the group. See Figure 5.2.

5. StRinging

figure 5.1 - Single stringing of pipes

figure 5.1 - Single stringing of pip figure 5.2 - multiple stringing of pipes es

PLAN

PLAN

Pipes strung with sockets facing direction of laying

Pipes strung with sockets facing direction of laying

Pipes laid in trench

Pipes laid in trench

Pipe support

Pipe support

LAyING

LAyING

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bEfOrE ExcAvATION

Locate and mark other underground utility service lines. Check whether the water table needs to be lowered with dewatering equipment. Assess trench stability and shoring requirements.

hOW WIDE ShOuLD ThE TrENch bE?

The trench width should be as narrow as practicable, consistent with the need to ensure:

proper laying and jointing of the pipe, eg.

– joint stations for welder in welded joint pipelines;

– application of joint wrapping for welded joint pipelines;

– where a change in direction is being made at a joint, the trench should be wide enough to allow the joint to be made with the pipes aligned. The pipe should then be deflected after jointing;

– proper haunch support and compaction of the backfill in accordance with the design specification; and

– use of common size backhoe / excavation bucket widths which are 300, 450, 600, 750, 900, 1100 and 1200 mm.

– trench widths may need to differ depending on your site conditions i.e. grade of material

As a guide, trench minimum widths can be found in Table 6.1.

hOW DEEP ShOuLD ThE TrENch bE?

The depth of the trench will depend on a number of factors in addition to pipe diameter.

Other considerations include:

– location of other services,

– particularly in urban areas;

– future change in levels due to road

– regrading or other civil works;

– required cover; and

– valve pits etc.

The minimum depth of cover recommended is 600 mm provided none of the other considerations require a greater depth.

In rocky ground, the trench should be excavated at least 50 mm deeper than required and replaced with compacted bedding as described in Section 9: Backfilling.

Where the ground below the bedding is unstable, additional excavation should be made and backfilled as described in Section 9: Backfilling.

6. tRencHing

table 6.1 - minimum trench widths

Pipe Sizes Trench WidthPipe OD less than or equal to 450mm = Pipe OD+ 400mmPipe OD above 450mm up to 900mm = Pipe OD+ 600mmPipe OD above 900mm up to 1500mm = Pipe OD+ 700mmPipe O D greater than 1500mm = 1.5 x Pipe OD

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6. tRencHing

hOW TO ExcAvATE

Usually an excavator or backhoe with bucket attachment is used. Only authorised people should operate this equipment. A trencher may be used if conditions permit. This can be a faster method. See Figure 6.1

SAfETy

If working under power lines, check with the electricity supply authority and the government safety authority. you may need to: arrange for overhead cables to be diverted or protected with insulating covers;

– arrange for electricity to be cut off;

– put up goal post type barriers or; and

– use lung stops on the machine.

Remember there is greater sag in power lines on hot days.

Barricades should be used if there is a danger of anybody falling into the trench.

Occupation, Health and Safety regulations must be observed.

ShOrINg ThE TrENch

It is generally necessary to shore the trench if it is deeper than 1.5 metres. Refer to the relevant authority on safe excavation practice.

It may still be necessary to use shoring in trenches less than 1.5 metres deep if there is a risk of a trench wall collapse as a result of:

– poor soil strength;

– vibration from machinery;

– use of explosives;

– placement of spoil adjacent to the

– trench and/or materials; or

– water inflow.

Back hoe Excavator Trencher

figure 6.1 - trench excavation machinery

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Why bEDDINg?

Bedding evenly supports the pipe and protects the external coating.

Bedding should be spread evenly along the trench with socket holes or welding stations provided at each joint. The socket holes should be deep enough to stop the socket of the pipe bearing any weight. Welding stations should also be big enough to allow welding and wrapping at welded joints.

bEDDINg IN WET Or uNSTAbLE grOuND

In wet or unstable ground, it may be necessary to form a foundation layer. A barrier geotextile material may then be placed over this and the bedding material placed on top. The geotextile moving into the spaces between the gravel and subsequent loss of support for the pipe.

bEDDINg IN rOcK

The trench should be excavated to ensure that there is space for a minimum of 50 mm compacted bedding beneath the pipe and to accommodate appropriate

joint stations for welding

and reinstatement if required.

The bedding layer under the pipe should be at least 50 mm thick when compacted See Figure 7.1.

WhAT TO uSE fOr bEDDINg

Bedding should be granular material complying with AS/NZS 2566.2. The maximum particle size should not exceed 26.5 mm. If the natural soil is not suitable, bedding should be brought in.

hOW TO PuT bEDDINg

INTO A TrENch

Bedding is usually put into a trench with a front end loader or backhoe. It should be evenly spread along the trench. See Figure 7.2.

Bedding should be compacted to ensure a firm, even base for pipe laying.

ALLOWANcE fOr SLINg WIThDrAWAL

Consideration should be given to making a small depression in the bedding where slings used to lift the pipe will come to rest after lowering and jointing.

This will allow slings to be withdrawn from under the pipe more easily.

When using an excavator, there is a risk of damage to the coating on the pipe when the sling is pulled out.

7. Bedding

figure 7.1 - Bedding layer minimum depth

figure 7.2 - Spreading bedding

Lift pipe such that base of

pipe is at top of bedding

50mm min

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gENErAL

The majority of water pipelines are laid below ground. However there are also above ground applications, such as at pumping stations, treatment works, over creeks, along bridges or where the cost of trenching is too expensive.

Work is often carried out in congested conditions. Observe good housekeeping and safe working practices to avoid injury. Inspect all lifting and pulling equipment regularly for signs of wear and deterioration.

All occupational health and safety requirements, including conned space legislation, should be complied with and take precedence over working methods recommended herein.

JOINT TyPES

A number of common jointing configurations are available for steel pipe:

– Rubber ring joint, SINTAJOINT®;

– Rubber ring joint with external fillet weld , SINTALOCK®;

– Ball and socket welded joint;

– Butt welded joint;

– Butt welded joint with band or collar; and

– Flanged joint.

See Figure 8.1

SINTAKOTE® pipes and fittings are factory formed/assembled for site installation without further site adjustment. Where, as a result of site conditions or damage to pipe, pipes must be cut to length on site, the following should be noted.

Pipes with welded joints can be cut and joints welded in accordance with this section.

Pipe ends to be joined should be prepared in accordance with site welding procedure and joint areas reinstated in accordance with Appendices A and B.

SINTAJOINT pipe, where cut, can only be joined by welding in accordance with above. Do not attempt to use a cut end in a rubber ring joint.

SINTAPIPE® pipe should not be cut for jointing. Normally design is carried out to avoid the need for cutting on site.

Where SINTAKOTE pipe with welded joint, SINTAJOINT or SINTAPIPE is to be cut and installed with a free end in a corrosive situation, such as in sewer manholes, it is recommended that a Pentair Water Solutions representative is consulted.

8. laying and Jointing

Spherical slip-on joint

figure 8.1 - Jointing systems

SINTAJOINT®

Plain butt joint

Ball and socket joint Common flange joint

Butt joint with collar SINTALOCK®

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JOINTINg EquIPmENT

ANCHOR SLING

Reversed eye, synthetic webbing slings or round slings (of endless fibre construction) are recommended for use in the assembly of SINTAJOINT® pipes. Woven synthetic slings must be sheathed to prevent penetration of the fabric by grit, abrasion and deterioration. The slings are fitted to the pipe using a “choker” hitch and in this configuration the sling is rated to the SWL limit marked on the webbing. See Figure 8.2.

Assembly forces will vary depending on the relative dimensions of the ends being joined, and to a lesser extent, the diameter and wall thickness of the pipe.

It is expected that these forces would be between 20 and 50 kN.

The length of the sling is generally pipe circumference plus 400 mm.

PULLER

A winch block of 30-50kN pulling capacity fitted with hooks on both ends is adequate.

RUBBER MATS

Typically 500 x 500 x 6 – 12 mm thick pieces of conveyor

belt or similar should be placed between equipment and pipe where the coating is likely to be damaged during joint

RAGS

To clean sockets and spigots immediately before joint assembly.

INSPEcTION Of PIPE bEfOrE LAyINg

GENERAL

All pipes are factory inspected, however, damage may occur in handling, transport or site storage. Pipes must be reinspected on site before laying. The inspection should include pipe coating and lining and

pay particular attention to pipe ends on SINTAJOINT pipes.

PIPE ENDS

Pipe ends must be inspected visually for any damage that may have occurred during transport, site storage or handling.

SINTAKOTE® AT PIPE ENDS

Should the coating or lining of the pipe ends (socket or spigot end) be damaged, it must be repaired in an approved manner before the pipe is laid. See Appendix A for methods of assessment of damage to SINTAKOTE and methods of repair.


figure 8.2 - Pulling SintaJoint® pipes

After assembly

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TESTINg Of SINTAKOTE®

All surfaces coated with SINTAKOTE® are factory tested for pin holes and other defects.

SINTAKOTE is a tough coating with a high resistance to handling and transport damage. However coating damage can occur through poor handling or incorrect storage.

To ensure that the highest quality coating system is placed in the ground, it is recommended that field high voltage holiday inspection be carried out on all coated surfaces immediately prior to the pipe being laid in the trench. SINTAKOTE can be tested at high voltage without any detrimental effect on coating properties. The voltage for the testing should be set at12,000V-14,000V and testing undertaken in accordance with AS 3894.1or AS 4321 “Fusion-bonded medium-density polyethylene coating & lining for pipes and fittings”. Note that the safety procedures detailed in the standard must be strictly followed.

With SINTAJOINT® pipes, the earth should be clamped to a metal plate, laid on the cement mortar lining. The 12,000V-14,000V test voltage

is specified for all coating and lining thicknesses.

For SINTAPIPE® pipes, ie. pipes that are totally coated and lined with SINTAKOTE, the method specified in AS4321 shall be used.

rubbEr rINgS

The rings must be visually inspected for any damage which may have occurred after leaving the manufacturer. Damaged rings must not be used.

LUBRICANT

Inspect lubricant tins for damage and replace if contaminated. Use only the lubricant supplied by Pentair Water Solutions.

LAyINg AND JOINTINg Of PIPE

SINTAJOINT PIPE

The laying of SINTAJOINT (RRJ) pipes is simple and very high laying rates can be achieved. The equipment is inexpensive, light and easily handled.

To ensure high laying rates and watertight joints, attention to detail and the following recommended laying practices are essential.

The guidelines below are additional to other good practices which should be observed when preparing a trench, storing and laying steel pipes and backfilling.

The pipe is manufactured to close tolerances assuring a consistent joint profile.

The rubber rings are also supplied to a strict specification, for dimensions, hardness and formulation.

These features produce joints with assembly properties easily recognised by the laying team. The ease of spigot entry and the jointing force are so consistent that the laying crew quickly identities any significant variation. An additional check for correct joint assembly can then be made.

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The recommended method for joint assembly is to pull the pipe being laid into the socket of the previously laid pipe, using anchor slings and winch blocks or pullers. See Figure 8.2.

Another joint assembly method is easing the pipe into the joint by slewing the excavator or crane. This method is acceptable, provided it does no damage to the pipe, including the external coating or internal lining. RRJ-D Series SINTAJOINT® need to be assembled with an excavator. Winch blocks or pullers are not adequate. Driving the excavator gives better control than using the slewing movement of the boom.

The slewing action must be controlled to ensure alignment of the pipe. Care must be taken not to drive the spigot past the witness mark as this may damage the coating and/or lining.

If the pipe is to be cathodically protected, it will be supplied with cathodic protection lugs on both the socket and spigot. Ensure the pipe is installed with these located at the very top of the pipe, to enable connection of joining cable across the joint.

PrEPArATION

Start with the free socket end of the previous assembly which should be sitting over a scooped out area of bedding.

Measure out the location where the next socket end will fall in the trench, scoop out the bedding; so that after laying there will be sufficient clearance for the socket.

Fit the anchor sling behind the socket.

rubbEr rINg

Clean the inside of the socket with a clean rag, then fit the rubber ring. Always inspect the rubber ring for damage or tears prior to inserting in the socket. The rubber ring is first placed in the invert and then inserted into the groove by progressively placing it and compressing until the last part snaps in the groove.

A simple clamp can assist with holding the ring firm allowing two hands free to fit the balance of the ring.

The placement of rubber rings in pipes larger then 1000mm OD may require two people.

LubrIcATION

Lift the next pipe and t an anchor sling over the spigot positioning it about 2 metres from the end.

Clean the spigot while it is suspended in the slings.

On the spigot, the lubricant should be sparingly applied to the area from the spigot end to the witness mark, providing 100% cover.

Lubricate the internal socket lip, the rubber ring and the spigot end of the pipe to be inserted. Use only lubricant supplied by Pentair Water Solutions suitable for use with SINTAKOTE® pipe.

figure 8.3 - fitting rubber rings into sockets

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Experience has shown that this is a critical aspect of rubber ring joint field assembly procedures. Using an incorrect lubricant may cause failure of the rubber ring or SINTAKOTE®.

The lubricant must cover every exposed part of the internal surface of the socket lip and rubber ring. Unlubricated areas can cause the rubber ring to be displaced from the groove. Care should be taken to ensure lubricant does not get behind or under the rubber ring.

High temperatures may cause the lubricant to lose its consistency and become very fluid. Only lubricate the spigot end when operating in high temperatures. High temperatures may also cause premature drying of the lubricant

after application. Lubricant should therefore be applied immediately before jointing the pipes.

In cold conditions it may be necessary to warm the lubricant to a brushable consistency by standing the lubricant container in warm water.

JOINT ASSEmbLy WITh PuLLEr

Align the pipe with the previously laid pipe. This alignment is necessary to ensure that the rubber ring is not displaced from its seat during joint assembly. See Figure 8.4.

Where field conditions prevent straight axial entry, the spigot can still be entered with a maximum deflection shown in Table

8.1. Jointing will be easier with smaller deflection. Hook on the puller between the anchor slings, and before applying the pulling force, place protective mats under the puller and hooks to prevent damage to the coating.

Carefully pull joint into full entry position. The witness mark should be visible and inline with the face of the socket.

figure 8.4 - alignment of pipes during jointing

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When in line with the witness mark, hold in position for a moment to allow the rubber ring to go back to its original profile. Failure to do so will result in the pipe ‘popping back’.

Do not over engage to compensate for this.

The final entry position for undeflected joints is ideally at the line with a tolerance of ±5mm. Insufficient entry that exposes the line by more than 5mm after relaxation could result in a leaking joint (Note: when the pipe is deflected, the entry line may be exposed by up to a maximum of 25mm). Entry greater than the line will not lead to a leaking joint, but may prevent deflection of the joint. In addition, if entered the full amount, this may result in damage to the spigot end if the pipe “bottoms”.

With the puller load on, deflect the pipe to the required grade and direction on the sand bedding.

The maximum permanent deflections for SINTAJOINT® pipes are shown in Figure 8.5 (solid line in figure) after any ground settlement has taken place.

Please Note: If more precise figures are required, please contact a Pentair Water Solutions Regional Marketing Office.

The puller load must not be released until sufficient backfill is placed around the pipe to ensure that joint movement will not occur. Care should be taken when withdrawing slings from under bedded pipes to avoid damage to the SINTAKOTE® from sling eyes or hooks. See Section 7: Bedding; Allowance for sling withdrawal.

ImPOrTANT NOTE fOr cONcAvE chANgES IN DIrEcTION

To satisfy the requirement that rubber ring joints be assembled with the pipes

axially aligned, the free end of a pipe just laid in a concave trench must be raised, so increasing the deflection of the previously assembled joint.

The joint design allows for this temporary ‘over deflection’ which, must not exceed the limits shown on the joint drawing. See also Figure 8.5.

Similar remarks apply when laying pipes on changes in direction.

This temporary ‘over deflection’ in concave changes in grade is achieved by lifting the pipe end and placing a padded packer (a bag filled with sand or sawdust) under it.

After completion of the next joint assembly the packer is removed to allow the pipe to rest back on the bedding.

The packer is then transferred to the free end of the pipe just laid and the operation is repeated.

table 8.1 - Permissible misalignment of offsets during entry

Pipe size OD (mm)

Max permissible misalignment (degrees)

Max permissible offset (mm) pipe length (m)

6m 9m 12m 13.5m<_ 813 0.5 50 75 100 112> 813 0.25 25 40 50 56

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S I N T A K O T E® S T E E L P I P E L I N E S

100

0.5º

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1400

1600

1700

1800

1500

1º1.5º2º2.5º3º3.5º

Max

imum

Pip

ePe

rman

ent O

pera

ting

Defle

ctio

n

Tem

pora

ry co

nstr

uctio

n de

flect

ion

D. O

utsid

e di

amet

er in

mill

imet

res

Deflection angle in degrees

figure 8.5 - temporary construction and pipe permanent operating SintaJoint® deflection

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During this operation, to ensure that the ‘over deflected’ joint does not come apart, it will be necessary to leave the puller load on at the joint and use a second puller to assemble the new joint.

After removal of the temporary ‘overdeflection’, place a quantity of backfill over the pipe before releasing the puller load.

Remove the pipe handling sling and if the pipe is laid on a down grade, place a quantity of backfill over the middle part of the pipe and also compact backfill at the sides to stop joint separation.

The placement of the backfill for pipes negotiating concave changes in grade, or changes in grade, or changes in direction, must be delayed until the assembly as described above is completed.

Remove pulling gear and prepare for jointing the next pipe.

INSPEcTION Of ASSEmbLED JOINT

By observing the required pulling force and ease of spigot entry up to the witness mark, laying

teams quickly develop the skill to assess correct joint assembly. These assessments are generally very reliable, however correct assembly should be verified by inspection.

The following inspection methods are recommended to check that each joint is correctly assembled.

figure 8.6 - axial offset measurement created by joint deflection.

S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S

0 0.50 1.00 1.50 2.00 2.50 3.00

800

700

600

500

400

300

200

100

00 0.50 1.00 1.50 2.00 2.50 3.00

800

700

600

500

400

300

200

100

0

13.5m length

6m length

Deflection Angle (degrees)

AxialOffset(mm)

9m length

12m length

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ExTErNAL chEcK

(see Figure 8.7 and 8.8)

Gap: Visual inspection of the gap between the lip of the socket and the spigot end surface. It should be uniform and in the range 0–1.5mm.

Entry: Entry witness marks applied by the manufacturer and those applied during laying are to confirm entry is correct and no disassembly movement has occurred after laying.

INTErNAL chEcK

When regulations and pipe sizes allow entry to the pipe, the assembled joint should be inspected from inside the pipe.

This inspection gives the assurance that the rubber ring remains properly seated in its groove.

It must be ensured that no part of the rubber ring protrudes past the spigot end of the pipe.

On smaller pipe lengths, where access is not practicable, inspection from the end of the pipe using appropriate lighting, must be performed on each joint.

Telescopic or video equipment may be used. This procedure should detect most instances of rubber ring displacement.

Joints indicating rubber ring displacement or excessive gap must be pulled apart, cleaned of all lubricant and re-assembled using a new rubber ring.

“D” SErIES SINTAJOINT®

“D” Series SINTAJOINT® is used for pipe diameters of 1200mm OD and larger and pipe wall thickness of 10mm and larger, in these diameters.

Rings must be installed as shown in Figure 8.8. Failure to install the rings in the correct orientation could result in difficulty assembling the joint and/or failure to achieve a seal under pressure.

After installing the ring in the groove apply lubricant to the entire exposed surface of the ring and the spigot of the pipe before entry.

SummAry Of ImPOrTANT POINTS fOr LAyINg AND JOINTINg:

SINTAJOINT PIPES

Use recommended assembly equipment and a method which allows the laying team to develop a feel


figure 8.7 - external inspection of assembled SintaJoint®

Hard section of ringArrows to be visible and pointing towards this end of the pipe

figure 8.8 - “d” Series Rubber Ring Joint direction

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for correct joint assembly. Use light gear which can be handled easily. Use protection for the coating if there is any possibility it could be damaged by equipment.

Inspect the pipe ends for damage before assembly.

Inspect the joint and rubber ring. Ensure they are clean and lubricate them correctly just before the assembly.

Use the correct joint assembly procedures. Inspect the assembled joint to confirm successful and correct spigot entry.

If movement of the assembled joint is possible, take appropriate precautions.

Only lubricants specifically recommended for use with SINTAKOTE® should come in contact with the coating.

Be sure the laying crew have a current drawing of the joint as supplied for the contract.

SINTALOcK® PIPES ASSEmbLy PrOcEDurE

JOINING OF PIPES

Prior to inserting the rubber ring into the socket, the socket should be clean and free of debris. A banister brush or clean rag should be used to remove any dirt or foreign particles.

Using the Pentair Water

Solutions lubricant, apply a light film of lubricant from the pipe end to the witness mark of the spigot end. Lubricant shall be applied to the spigot end only.

Ensure the rubber ring is seated correctly, and align spigot to socket. Ensure entry misalignment does not exceed specified limits. Refer Table 8.1, P.26.

Slowly insert the spigot into the socket until the spigot witness mark has reached the socket face; tolerance ±5mm. Release tension of the sling, ensuring that the spigot does not withdraw from the socket.

If a deflection is required, it shall be done so after the spigot has been inserted, but prior to welding. Always ensure deflection limits are not exceeded.

WELDING OF JOINT

Prepare the joint area for welding by removing any excess lubricant, rust protection paint or surface rust from the weld region and whole joint.

Heat shrink sleeves should not be applied over rust preventative paint or over surface rust. Steel needs to be cleaned before application of a heat shrink sleeve. Heat shrink sleeves should be applied in accordance with procedure A1 of this document.

Ensure all welding equipment is maintained in a safe working order.

Ensure a good earth onto the exposed steel - tack weld earth lead to exposed steel region.

Using welding processes MMAW or FCAW and procedures as per AS1554-SP category weld the joint.

FCAW Electrode Flux cored Lincoln Innershield 1.7mm NR 211 - MP DCEP ( electrode DC-) Position - Vertical down Voltage - 27V Current - 200 Amps

MMAW Electrode - E4311 4.0mm Current - 120 Amps Position - Vertical down

Direction of welding to be downhand, vertical down and overhead. No vertical up welding is permitted.

Welding is to be performed as per joint drawing ensuring a maximum interpass temperature of no more than 70oC, keeping the heat input as low as possible.

Number of passes - dependent on wall thickness, 5 and 6mm may be completed in one pass while 7 to 11mm may require up to 3 passes.

Upon completion of the weld, all slag and spatter is to be removed in preparation for the heat shrink sleeve.


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TESTING OF THE WELD JOINT (IF APPLICABLE)

After completion of the welding, remove the test plug and connect pressure pump and gauge. All welds shall be subject to a field air test of 80 kPa and hold time should be for a minimum of 120 second (2 minutes). Pressurise the test area to 80 kPa.

Check to ensure there is no pressure drop over the specified period period of time. If welding is sound, remove the pressure pump connection and re insert the test plug until flush with the pipe shell. Lightly weld the plug in place, and then grind flush.

JOINT COATINGApply joint coating as specified in Appendix A

WELDED JOINTS

Note: When welding, ensure adequate ventilation to draw off welding fumes.

Lay pipes with sockets facing the direction of laying. It’s easier to locate a pipe spigot correctly into a socket than a socket over a spigot. There is also less chance of entrapping soil in the joint as the spigot is punched home. For picking up the pipe, refer Section 3: Unloading and handling.

BALL & SOCKET/SPHERICAL SLIP-IN JOINT FIELD ASSEMBLy PROCEDURE

With Ball & Socket (B&S) and Spherical Slip-in joints (SSJ) joints, in particular

those with large diameters, it is not possible to achieve nominal entry by ‘slewing’ the pipe home.

There are two common methods to achieve correct joint entry:

1. Tirfor or come-along method.

2. The ‘Hinge Method.’ This procedure outlines the correct installation using the ‘Hinge method’ which is widely used.

Before starting:

1. If pipes have been supplied with factory installed toms ensure that they are maintained in place until after installation.

2. Remove rust preventative paint and/or surface rust from the pipe ends.

3. Have on hand, a joint dimension drawing for the contract.

4. For ‘vertical down’ deflections, the test hole must be positioned at/or near the side of the pipe (springline). For all other deflections including ‘vertical up’, the test hole remains on the crown of the pipe.

JOINTING

1. On the ball/ spigot end of the pipe, mark a line (approx 100mm long) on the top, bottom and both sides of the pipe to the same

figure 8.10 - Welded ball and socket or spherical slip-in joint field assembly

2. Lower onto bed to give correct entry and complete weld.

1. Insert pipe at slight angle spigot end down. Tack weld/stitch weld top.

Tack weld/stitch weld

First Pass

Second Pass

figure 8.9 - Section view of welding a Sintalock welded joint

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nominal entry as on the joint dimension drawing.

2. Pick up the pipe and insert as straight as possible (without a deflection) the ball/ spigot end into the socket of the previously installed socket as far as it will enter without force. There will be a gap between the socket lip and the witness mark.

3. Gently lift the pipe until the witness mark at the top of the pipe is in line with the socket face.

4. At this alignment, (on top of pipe) weld the joint for approx 50mm. See Fig. 8.10. The length and fillet size of the weld is dependant upon the welding process i.e. MMAW/MIG or INNERSHIELD and the diameter/wall thickness/ length of the pipe. For example, a 502mm x 5mm x 6.13m pipe might require less than 50mm as opposed to a 1750mm x 12mm x 13.5m pipe that may require more than 50mm.

5. Gently lower the pipe onto the bedding material. See Fig. 8.10. The socket lip should now be in line with the four witness marks taking into consideration the entry tolerance as per the joint dimension.

6. If no deflection is required, the joint is now ready to

be fully welded as per the qualified weld procedure.

7. Ensure external coating and internal cement mortar lining (if internally welded) are reinstated.

Refer to Appendix A & B.

DEFLECTING

1. If a small deflection in the joint is required, break the weld with an angle grinder and deflect to the desired deflection degree. Tack weld in several locations around the circumference to maintain the position prior to fully welding.

2. F or a large deflection (ensure not to exceed the maximum as per the joint dimension drawing) place on the two pivot points across the joint on the two pipes pre fabricated plates. These plates are to be cut to the profile of the joint. Generally 50mm x 6mm x 500mm at bar is sufficient. Weld on either side of the joint and on one side only approx. 50mm. The purpose of the plates is to maintain joint entry when deflecting but will bend to the deflection angle.

3. Break the weld at the top of the pipe with an angle grinder and deflect to the desired deflection angle.

4. To ensure the maximum deflection (per joint dimension drawing) has not been exceeded, run

a stringline along the top dead centre or 90 degrees to this point (spring line) of the pipe (depending on the deflection direction) and physically measure the deflection with a tape measure. (Refer to Figure 8.6).

5. Tack weld in several locations around the circumference of the pipe to maintain the position prior to fully welding.

6. Break off the two prefabricated plates and grind areas smooth.

7. The joint is now ready to be fully welded as per the qualified weld procedure.

8. Ensure external coating and internal cement mortar lining (if internally welded) are reinstated whenever possible. Refer to Appendix A & B.

Note: Pipelaying contractors should ascertain from the pipeline designer whether an internal weld is required. Pentair Water Solutions recommends external and internal lining reinstatement wherever possible.

Where a SINTAKOTE® pipe is cut for welding, the pipe should be stripped back to the steel for a minimum distance of 100 mm. The SINTAKOTE must be tapered over a length of at least 7mm to ensure a smooth transition for the field coating.

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fLANgED JOINTS

Flanged joints are completely rigid and should not be used for applications where movement of the pipeline is expected, unless special provision is made to accommodate it by, for example, the inclusion of expansion joints.

Flanged joints are used mainly for above ground applications, e.g. pumping stations, water and sewage treatment plants and for industrial pipework. They are also used to facilitate the installation and removal of valves in SINTAJOINT® and welded pipelines and for valve bypass arrangements.

If buried, flanges should have an additional corrosion protection system applied, such as Petrolatum tape wrap.

For assembly of flanged joints no field welding or other special equipment

is required. Flange dimensions are normally in accordance with AS 4087 and are currently supplied in Class 16, Class 21 or Class 35.

For access covers and other blank flange joints Pentair Water Solutions recommends the use of o-ring type gaskets because of their low requirement for assembly stress and trouble free operation.

O-ring flanged joints have these same advantages in other flanged joint situations. It must be remembered that the use of o-ring type flanges requires full knowledge of all of the mating components to avoid a joint situation with two o-ring groove ends joining each other. The correct matching is shown in Figure 8.12.


to

figure 8.11 - Raised face type flanges figure 8.12 - matched o-ring type flanges

figure 8.13 - Star pattern tightening sequence

14

10

62 15

3

134

8

1612

9

15

7

11

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Where it is not possible or desirable to use o-ring type flanges, Pentair Water Solutions recommends the use of raised face steel flanges. See Figure 8.11. The use of at-faced steel flanges is not preferred except when the mating flange is cast iron. This situation may occur at a pump housing, but current practice is for most pipeline components to be manufactured in steel or ductile iron. Experience has shown that at-faced flanges are generally more susceptible to sealing problems and successful sealing is heavily dependent upon assembly technique.

Where the required flange sizes are larger than DN 1200 or are outside the normal pressure rating, special flanges must be designed. In this situation o-ring type flanges are recommended as being the best option for medium to high pressure situations.

GASKETS

Gaskets may be either elastomeric or compressed fibre type. Elastomeric gaskets are only recommended for the Class 16 flanges.

Compressed fibre gaskets are recommended for Class 21 and Class 35 flanges. Compressed fibre gaskets can also be used with Class 16 flanges but will require the use of high strength bolts because of the higher initial compression necessary.

Table 8.2 details the recommended type of gasket to be used for various classes of raised face steel flanges. Generally full face gaskets (that incorporate holes for the flange bolts) can be used with raised face flanges as only the raised face area inside the bolt holes is clamped. The full face gasket enables better location of the gasket compared to a ring type gasket. (If rigid compressed fibre type gaskets are used the use of ring type gaskets is normal).

For other liquids, temperatures or pressures contact a Pentair Water Solutions Regional Marketing Office.

LUBRICATION

The selection of a lubricant for flange bolting can have a significant effect on the resultant bolt tension. After testing various lubricants Pentair Water Solutions favours the use of Loctite 771.

FLANGE BOLTS ASSEMBLy TORQUE

Bolting used on flanges is usually galvanised steel or stainless steel. Commercial grade bolts are used with Class 16 flanges with rubber gaskets, whilst high strength bolts/studs are required for use with compressed fibre gaskets.

Poor assembly technique is by far the greatest single cause of flange joint failure and use of the correct technique and selection of the suitable bolt torque is vital.


table 8.2 - Recommended gasket composition for transport of general domestic liquids including brine and sewage

Maximum Operating Pressure

MPa

Maximum Temperature

˚CGasket Composition

1.6 50 Solid EPDM Rubber 3mm thick3.5 50 Solid EPDM Rubber O-Ring 10mm dia.

3.5 80 TEADIT NA1000 Composite Fibre 1.5mm thick or Klinger C6327 Composite Fibre 1.5mm thick

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Tables 8.3 a, b, and c detail the combination for DN, gasket type, bolt size and bolt material. In addition, estimated torques are provided in Table 8.5, however, note that the required torque is difficult to calculate accurately.

It should be noted that the actual bolt torque required to produce the desired tension in the bolt is affected by many factors such as the surface finish on the threads of the bolts and nuts, the material of the bolts and nuts, the hardness of the bolting components, the size of the bolts used, the type of lubricant used and the technique used in the application. For these reasons the following tables

can only be considered as guidelines and a specific torque/tension test is recommended to obtain the correct “IT” factor for the particular application.

Torque is directly related to the k value, which is influenced by environmental factors, coatings, surface finish, material type and hardness, thread series and efficacy of lubrication etc. In most situations, it is challenging to give reliable allowable torque values for bolted assemblies. For the most accurate data we recommend field testing the intended assemblies, using a calibrated torque wrench and a load indicating device, e.g. Skidmore Wilhelm Load Indicating Device, to equate actual torque to the desired

tension. Additionally, extra care needs to be taken when using stainless steel bolts as they are subject to galling, which can significantly reduce bolt tension.

Note we recommend the use of Loctite 771 (a nickel/graphite anti-seize lubricant) for both galvanised steel and stainless steel bolts to achieve the indicated k values.

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taBle 8.3a - Recommended class 16 Bolt Sizes, Bolt types and gasket types

Flange DN

Bolt Size

Pipe OD mmFlange type Recommended

Gasket TypesGrade 4.6 bolts SS Class 50 bolts

100 M16 114 114 Raised face EPDM Rubber

150 M16 168, 178 168, 178 Raised face EPDM Rubber

200 M16 178, 190, 219 178, 190, 219 Raised face EPDM Rubber

225 M16 219, 235, 240, 257 219 Raised face EPDM Rubber

250 M20 235, 240, 257, 273, 290

235, 240, 257, 273,290

Raised face EPDM Rubber

300 M20 290, 305, 324, 337 290, 305, 324, 337 Raised face EPDM Rubber o-ring

350 M24 324, 337, 356, 368 324, 337, 356, 368 R

aised face EPDM Rubber o-ring

375 M24 356, 368, 406 356, 368, 406, 419 Raised face EPDM Rubber o-ring

400 M24 406, 419 406, 419, 457 Raised face EPDM Rubber o-ring

450 M24 457 457 Raised face EPDM Rubber o-ring

500 M24 457, 502, 508, 559 457, 502, 508 Raised face EPDM Rubber o-ring

Grade 8.8 bolts SS Class 70 bolts

100 M16 114 114 Raised face Compressed Fibre

150 M16 168, 178 168, 178 Raised face Compressed Fibre

200 M16 190, 219 - Raised face Compressed Fibre

225 M16 219 - Raised face Compressed Fibre

250 M20 257, 273, 290 273 Raised face Compressed Fibre

300 M20 290, 305, 324, 337 305, 324, 337 Raised face Compressed Fibre o-ring

350 M24 324, 337, 356, 368 337, 356, 368 Raised face Compressed Fibre o-ring

375 M24 356, 368, 406 406, 419 Raised face Compressed Fibre o-ring

400 M24 406, 419 406, 419 Raised face Compressed Fibre o-ring

450 M24 457, 502, 508 502, 508 Raised face Compressed Fibre o-ring

500 M24 502, 508, 559 559 Raised face Compressed Fibre o-ring

600 M27 600, 610, 648, 660 648, 660 Raised face Compressed Fibre o-ring

700 M27 660, 700, 711, 762 - Raised face Compressed Fibre o-ring

750 M30 762, 800, 813 - Raised face Compressed Fibre o-ring


900 M33 889, 914, 959, 965, 972

914, 959, 965, 972 Raised face Compressed Fibre o-ring

1000 M33 959, 965, 972, 1016

- Raised face Compressed Fibre o-ring

1000 M33 1035, 1067 - Raised face Compressed Fibre o-ring

12000 M33 1200, 1219, 1283, 1290

- Raised face Compressed Fibre o-ring

1. Bolts. Grade 4.6 or 8.8 galvanised steel or Class 50 or 70 Grade 316 stainless steel.2. Full face flanges are not recommended.

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taBle 8.3b - Recommended class 21 Bolt Sizes, Bolt types and gasket types

Flange DN

Bolt Size



100 M16 114 114 Raised face Compressed Fibre

150 M20 168,178 168,178 Raised face Compressed Fibre

200 M20 178,190,219 178,190,219 Raised face Compressed Fibre

225 M24 219,235,240,257 219,235,240,257 Raised face Compressed Fibre

250 M24 235, 240, 257, 273, 290

235, 240, 257, 273, 290

Raised face Compressed Fibre

300 M24 290, 305, 324, 337 290,305,324,337 Raised face Compressed Fibre o-ring

350 M27 324, 337, 356, 368 324, 337, 356, 368 Raised face Compressed Fibre o-ring



450 M30 457, 502, 508 457, 502, 508 Raised face Compressed Fibre o-ring






900 M36 889, 914, 959, 965, 972

889, 914, 959, 965, 972

Raised face Compressed Fibre o-ring

1000 M36 959, 965, 972, 1016 959, 965, 972, 1016, Raised face Compressed Fibre o-ring

1000 M36 1035, 1067 1035, 1067, 1086 Raised face Compressed Fibre o-ring

1200 M39 1067, 1086, 1124, 1145, 1200

1145, 1200, 1219, 1283, 1290


1200 M39 1219, 1283, 1290 - Raised face Compressed Fibre o-ring 1. Bolts. Grade 8.8 galvanised steel or Class 70 Grade 316 stainless steel.2. Full face flanges are not recommended.

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taBle 8.3c - Recommended class 35 Bolt Sizes, Bolt types and gasket types

Flange DN

Bolt Size



100 M16 114 114 Raised face Compressed Fibre o-ring

150 M20 168,178 168,178 Raised face Compressed Fibre o-ring

200 M20 178,190 178,190,219 Raised face Compressed Fibre o-ring

225 M24 219 219,235 Raised face Compressed Fibre o-ring



350 M27 324, 337 324, 337, 356, 368 Raised face Compressed Fibre o-ring



450 M30 457 457 Raised face Compressed Fibre o-ring



700 M33 648, 660, 700, 711 648, 660 Raised face Compressed Fibre o-ring



900 M36 889, 914 889, 914, 959, 965 Raised face Compressed Fibre o-ring

1000 M36 959, 965, 972 959, 965, 972, 1016, 1035




1200 M39 1219, 1283, 1290 - Raised face Compressed Fibre o-ring 1. Bolts. Grade 8.8 galvanised steel or Class 70 Grade 316 stainless steel.2. Full face flanges are not recommended.


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taBle 8.4 - indicative k Values

Lubrication/Bolt material Indicative k valuewithout insulation

Indicative k value with fibrereinforced insulation washers

Well lubricated galvanised 0.12 - 0.14 0.08 - 0.1

Well lubricated stainless steel 0.12 - 0.14 0.08 - 0.1

1. The k values provided are only estimates and are inuenced by a number of factors. For the most accurate information, field testing is required.

2. To achieve the “well lubricated” condition it is recommended that Loctite 771 is used on all threads and the face of the nut and washer.

3. The k value estimated when using insulated compressed bre washers is very much less than for metallic washers. This is due to the much lower coecient of compressed bre washers. If a lower k value is not used there is the possibility of over-tensioning bolts and distorting flanges.

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taBle 8.5 - Required tension and torque Values

Bolt Size

Minimum Bolt Grade Tension (kN)

Newton Metre (Nm)Torque for k Factor =

EPDM Rubber o-ring Compressed Fibre 0.08 0.1 0.12 0.14 0.16 0.18 0.2

M 16 Gr 4.6 Gr 4.6 18 23 29 35 40 46 52 58

M 16 Cl 50 SS Cl 50 SS 18 23 29 35 40 46 52 58

M 16 Gr 8.8, Cl 80 SS 75 96 120 144 168 192 216 240

M 16 Cl 70 SS 50 64 80 96 112 128 144 160

M 20 Gr 4.6 Gr 4.6 30 48 60 72 84 96 108 120

M 20 Cl 50 SS Cl 50 SS 25 40 50 60 70 80 90 100

M 20 Gr 8.8, Cl 80 SS 95 152 190 228 66 304 342 380

M 20 Cl 70 SS 75 120 150 180 210 240 270 300

M 24 Gr 4.6 Gr 4.6 40 77 96 115 134 154 173 192

M 24 Cl 50 SS Cl 50 SS 35 67 84 101 118 134 151 168

M 24 Gr 8.8, Cl 80 SS 135 259 324 289 454 518 583 648

M 24 Cl 70 SS 100 192 240 288 336 384 432 480

M 27 Gr 4.6 Gr 4.6 50 108 135 162 189 216 243 270

M 27 Cl 50 SS Cl 50 SS 45 97 122 146 170 194 219 243

M 27 Gr 8.8, Cl 80 SS 175 378 473 567 662 756 851 945

M 27 Cl 70 SS 130 281 351 421 491 562 632 702

M 30 Gr 4.6, Cl 50 SS 65 156 195 234 273 312 351 390

M 30 Gr 8.8, Cl 80 SS 200 480 600 720 840 960 1080 1200

M 30 Cl 70 SS 160 384 480 576 672 768 864 960

M 33 Gr 4.6, Cl 50 SS 75 198 248 297 347 396 446 495

M 33 Gr 8.8, Cl 80 SS 260 686 858 1030 1201 1373 1544 1716

M 33 Cl 70 SS 195 515 644 772 901 1030 1158 1287

M 36 Gr 4.6, Cl 50 SS 85 245 306 367 428 490 551 612

M 36 Gr 8.8, Cl 80 SS 270 778 972 1166 1361 1555 1750 1944

M 36 Cl 70 SS 205 590 738 886 1033 1181 1328 1476

M 39 Gr 4.6, Cl 50 SS 100 312 390 468 546 624 702 780

M 39 Gr 8.8, Cl 80 SS 320 998 1248 1498 1747 1997 2246 2496

M 39 Cl 70 SS 260 811 1014 1217 1420 1622 1825 2028

Note. From the pipe OD, pressure class and flange size, the required bolt size is determined. Choices in terms of bolt material and gasket can then be made from tables 8.3a, 8.3b and 8.3c. The k value is determined either from Table 8.4 (indicative value) or by experiment. The required tension and torque is then determined from this table.


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JOINTINg INSTrucTIONS fOr fLANgED JOINTS

1. Use a scraper or wire brush to thoroughly clean the flange faces to be jointed, ensuring there is no dirt, particles or foreign matter, protrusions or coating build-up on the mating surfaces.

2. Ensure that the mating threads of all nuts and bolts are clean and in good condition.

3. Evenly apply a suitable lubricant to all mating threads, including the nut load bearing face and washer (e.g. Loctite 771 a nickel/graphite anti-seize lubricant).

4. Align the flanges to be joined and ensure that the components are satisfactorily supported to avoid bending stress on the anged joint during and after assembly.

5. Insert four bolts in locations 1 to 4 as indicated in Figure 8.13 and position the insertion gasket on the bolts, taking care not to damage the gasket surface.

6. Oer the adjoining flange to the bolts, taking care to maintain support and alignment of the components.

7. Tighten nuts to nger tight and check alignment of

flange faces and gasket.

8. Insert the remaining bolts and tighten nuts to nger tight.

9. Estimate the required bolt torque considering bolt type and allowable tension, flange type and rating, gasket material and max/min compression, and the pipeline’s maximum pressure (operating/test pressure).

10. Tighten nuts to 20% of estimated torque using the star pattern; see Figure 8.13.

11. Tighten to 50% of estimated torque using the same tightening sequence.



14. Repeat the tightening procedure on all nuts until little or no movement can be achieved on each nut. (particularly important on elastomeric gaskets).

– Bolt tensions need to counter the force due to expected internal pressure and to provide an adequate sealing stress without exceeding the maximum allowable gasket stress at the time of installation.

– The application of excessive torque at the time of installation may overstress the gasket causing crushing or extrusion, which can lead to leakage at operating pressures.

– The surface conditions of the threads as a result of rust, plating, coating and lubrication are the predominant factors inuencing the torque / tension relationship. However, there are many others including thread fit, surface texture and the speed and continuity of tightening.

– The flange faces are assumed to have a surface roughness of Ra = 10 -12.5 μm.

– A torque wrench is most commonly utilised to achieve the required bolt tension, however in critical applications an hydraulic tensioner should be used.


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Why bAcKfILLINg?

Backfill as the work progresses, or at least at the end of each day. If the trench is left unfilled, it must be barricaded so it is safe and secure. In wet conditions, the pipe may ‘float’ if the trench is not backfilled after laying.

In badly drained ground or where heavy rain is expected, finished sections should not be left unlled as there is a risk that the pipeline could be moved by floatation.

The materials used for backfilling the trench and their compaction should be specified by the designer and should be in compliance with AS/NZS 2566. Proper support and protection of the pipe should be considered together with the future ground loading and activity.

For small diameter pipe laid in an area where surface settlement is not a problem, minimum backfill compaction is normally adequate. However as the depth of cover increases or where vehicle traffic occurs, and especially for large diameter thin wall pipes, the degree of compaction becomes critical to ensure the long term performance of the pipeline.

ZONES Of bAcKfILL AND cOmPAcTION

The soil surrounding the pipe can be considered as three Zones shown in Figure 9.1.

ZONE A- BEDDING

A minimum 50 mm thick compacted bedding layer of sand, non cohesive native soil or imported fill (100% less than 26.5mm) should

be provided under the pipe as bedding.

Bedding material may need to be imported or the native soil may be suitable.

Bedding provides even support for the pipe along its entire length and protects the SINTAKOTE®.

ZONE B - BACKFILL FOR HAUNCH SUPPORT, SIDE SUPPORT AND OVERLAy

The haunch and side support areas provide support for the pipeline and prevent sharp objects imparting stresses onto the pipeline coating. Backfill should consist of non-cohesive native soil, or imported fill or washed rock sand, etc or particle size not greater than 32mm.

9. BacKfilling

figure 9.1 - Zones of backfill and compaction

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9. BacKfilling

The degree of compaction required will depend on the loading for which the pipeline has been designed and the ring stiffness of the pipe.

Ring stiness depends on the pipe wall thickness and diameter; a thick walled small diameter pipe is stier than a thin walled large diameter pipe. An indication of stiffness can be taken from the diameter/steel wall thickness ratio or D/t ratio.

For steel pipes equal to or less than 914mm OD, with a D/t less than 120, only moderate compaction may be required to achieve the necessary support. Pipes with D/t values greater than 120, or greater than 914 mm OD may need more support from the side fill tocarry the soil and trac loads and the level of compaction specified should reect this.

When high levels of compaction are specified for these low stiness pipes, it is essential that backfill be well compacted between the sides of the pipe and the trench. Particular care should be taken in compacting the material under the haunches of the pipe. The backfill should be built up in 150 mm layers evenly on both sides of the pipe.

Backfilling in layers should proceed until there is an overlay of at least 150 mm above the top of the pipe. This layer provides a zone of material to prevent sharp/large objects imparting high point loads on the coating.

When a pipeline is to be cathodically protected, material should not be too high in electrical resistivity as this may reduce the effectiveness of the protection. Generally sand or soil is suitable. Stone and gravel can be too high in resistivity. Hence a well graded mix of sand and gravel is preferred on cathodically protected lines where imported backfill is required.

ZONE C - OVERBURDEN TRENCH FILL

Material in this zone builds the trench up to the original ground level and the materials used and extent of compaction depends on the allowable future surface settlement. Under road pavements the load bearing capacity of the ground surface is important and backfill must be compacted in layers all the way to the surface.

Where the trench is across open land, the compaction requirements of this zone are not normally so important and the surface

can usually be built up to allow for some future settlement.

The material used in Zone C, would normally be the excavated trench material, but where a high degree of compaction is needed in bad natural ground, imported material may be required.

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cOmPAcTION

The level of compaction to achieve in-situ ground conditions, may require 65% Relative Density for sand or 90% Standard Proctor Density for clay type (cohesive) soils.

Soil density is usually specified as “Standard Proctor Density” for clay type soils and “Relative Density” for granular soils (cohesionless).

Standard tests are available for determining the density of compacted soils.

rINg DEfLEcTION LImITS

To ensure serviceability of the pipeline, ring deflection must be limited as shown in

Table 9.1 and illustrated below in Figure 9.2.

SINTAJOINT® (RRJ)

The design limit for RRJ pipe is similar to that of welded pipe joints. The lower maximum deflection for RRJ pipe (as shown in Table 9.1) is due to the higher stiffness of those joints (resulting in less deflection in the joint area). These limits ensure that the annular gap between the spigot and socket is not so distorted as to cause significant reductions in gasket contact pressure.

9. BacKfilling

Note: Vertical deflection shown left is greatly exaggerated for clarity of terms

Bedding reaction

Pipe section after backfill and

compaction loading

figure 9.2 - Ring deflection limits

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9. BacKfilling

Table 9.1 - Maximum Allowable Vertical Deflection for Inspection of Buried SKCL Pipe

Outside Diameter

(mm)

Wall Thickness

(mm)

Maximum Δy Maximum Δy

SSJ, B&S, SINTALOCK®

(mm)

SINTAJOINT® SSJ, B&S, SINTALOCK

(%)

SINTAJOINT

RRJ-S (mm)

RRJ-D (mm)

RRJ-S (%)

RRJ-D (%)

324 5 9 9 2.7 2.7324 6 7 7 2.3 2.3337 5 10 10 2.8 2.8337 6 8 8 2.4 2.4356 5 11 11 3.0 3.0356 6 9 9 2.5 2.5406 5 14 13 3.4 3.2406 6 12 12 2.8 2.8419 5 15 13 3.5 3.2419 6 12 12 2.9 2.9457 5 18 15 3.8 3.2457 6 15 15 3.2 3.2508 5 20 16 4.0 3.2508 6 18 16 3.6 3.2559 5 22 18 4.0 3.2559 6 22 18 3.9 3.2610 5,6 24 20 4.0 3.2648 5,6 26 21 4.0 3.2648 8 22 21 3.4 3.2660 5,6 26 21 4.0 3.2660 8 23 21 3.5 3.2700 5,6 28 22 4.0 3.1700 8 26 22 3.7 3.1711 5,6 28 22 4.0 3.1711 8 27 22 3.7 3.1762 5,6,8 30 23 4.0 3.0800 6,8 32 24 4.0 3.0813 6,8 33 24 4.0 2.9889 6,8 36 25 4.0 2.8914 6,8 37 25 4.0 2.8960 8 38 26 4.0 2.7960 10 32 26 3.4 2.71016 8 41 27 4.0 2.61016 10 36 27 3.6 2.61035 8 41 27 4.0 2.61035 10 37 27 3.6 2.61067 8 43 27 4.0 2.51067 10 40 27 3.7 2.51086 8 43 27 4.0 2.51086 10 41 27 3.8 2.51124 8 45 27 4.0 2.41124 10 44 27 3.9 2.41145 8,10 46 28 4.0 2.41200 8,10 48 28 38 4.0 2.3 3.21200 12 42 38 3.5 3.21219 8,10 49 28 39 4.0 2.3 3.21219 12 43 39 3.6 3.21290 10 52 28 41 4.0 2.2 3.21290 12 49 41 3.8 3.21404 10,12 56 45 4.0 3.21422 10,12 57 46 4.0 3.21440 10,12 58 46 4.0 3.21500 10,12 60 48 4.0 3.21575 10,12 63 50 4.0 3.21626 12 65 52 4.0 3.21750 12 70 56 4.0 3.21829 12 73 59 4.0 3.2

Note: RRJ-S & RRJ-D deflection requirements are only specified for the joint area, within ± 150mm of the pipe joint. Measurements at the joint should only be taken when at least half a pipe length is buried on both sides of the joint.

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Good planning at the design stage can result in improved installation eciency. This is particularly true for pipelines requiring numerous fittings.

For fully welded lines, fittings should be ordered to suit and can be fabricated from SINTAKOTE® pipe.

For rubber ring joint pipelines, consideration needs to be given to anchorage at change in direction, dead ends, tapers or tees. See Section 11: Anchorage of pipelines.

For rubber ring pipe joints under maximum allowable deflection (see Figure 8.6) thorough compaction of

the embedment zone on the outside of the joint is required.

For directional changes greater than that achieved by deflection of a pipe joint, fittings are required.

For commonly used fittings (see Figures 10.1 and 10.2.)

10. fittingS

Hockey Stick

1 metre short Mitred Bend

Reducer Tee Air valve or Scour Flanged Offtake

figure 10.1 - common fittings - welded pipelines note that tees, angle Branches and y-Pieces may require reinforcing.

figure 10.2 - common fittings - SintaJoint® pipelines note that reducers may require a thrust flange.

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STATIc ThruSTS

All pressure pipelines having unanchored exible joints, require anchorage at changes of direction, changes in diameter, tees, valves and at blank ends to resist the thrusts developed by internal pressure.

Additional dynamic thrusts are created by moving water but are usually negligible unless the ow velocity is extremely high.

Refer to Water Supply Code of Australia - WSA03 for details on t hrust block design.

ANchOrAgE Of burIED mAINS

Anchorage to resist thrusts must be designed for the maximum pressure expected in the main in service or during test. Anchorage can be provided in several ways:

– Anchor blocks;

– Ties to concrete blocks; or

– Pipe surface friction.

The most common method is the use of concrete anchor blocks. These should be poured immediately after excavation for the block to ensure that the soil bearing strength does not deteriorate. Where possible concrete anchor blocks should be of such a shape as to allow sufficient space for the joints to be pulled apart, pipe or fittings replaced and reassembled.

There is no need for additional corrosion protection barrier between SINTAKOTE® and the concrete. SINTAKOTE is a MDPE polyethylane barrier corrosion protection coating and as such forms the barrier. Care should be taken to not pour concrete directly onto SINTAKOTE to reduce risk of damage.

ANchOr bLOcKS fOr hOrIZONTAL ThruST-burIED mAINS

The horizontal thrust developed in buried mains must be transferred to the undisturbed soil of the trench wall by anchor blocks poured against the soil face. The thrust is distributed over the total bearing area of the block to ensure that the safe bearing pressure of the trench wall is not exceeded. See Figure 11.1

ANchOr bLOcKS fOr vErTIcAL ThruST rESTrAINT

Downward vertical thrusts are transferred to the undisturbed ground by anchor blocks in the same manner as horizontal thrusts.

11. ancHoRage of PiPelineS

figure 11.1 - anchor blocks for horizontal thrust restraint

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11. ancHoRage of PiPelineS

Upward vertical thrusts are counteracted by the weight of the concrete anchor block.

If the water table in the area is likely to reach

the level of the anchor block, the submerged

weight of the block must be sufficient to counteract the thrust. If the natural ground is of sufficient strength ie., rock, special anchor blocks can be cast into the rock to resist upward thrust forces. See Figure 11.2

TIES TO cONcrETE bLOcKS

Ties are rarely used except where there is limited space or lack of bearing area behind the pipe fitting.

PIPE SurfAcE frIcTION

Thrust resistance can be achieved by utilising the skin friction between the pipe and soil surround. This requires the welding or

harnessing of several pipe lengths, the length of which must be determined by the pipeline design engineer.

AbOvE grOuND PIPES

For above ground applications all steel pipes must be supported and anchored. Where relative movement of the pipe support and anchorage is likely, the bearing materials should be chosen to allow for this. See Figure 11.3

Anchor block for vertical slope Anchor block for vertical bend

Hold down over bearing material

Bearing material toaccommodate

expansion movementwhere necessary

figure 11.3 - Pier support for above ground SintaJoint® pipelines

figure 11.2 - anchor blocks for vertical thrust restraint

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A pipeline is subjected to a field pressure test primarily to check that all joints are watertight. At the same time the test checks the integrity of all fittings and appurtenances, as well as construction work such as anchorages.

It is recommended that a hydrostatic test is carried out on the first 200m of pipe laid to confirm that laying practices are effective.

It is then tested at a maximum of 1000mm intervals or as specified by the customer.

Where concrete anchor blocks are installed, a reasonable time must be allowed for the concrete to cure before testing commences.Cement

mortar lined pipe should be completely filled with water of approved quality and allowed to stand for at least 24 hours. This permits maximum absorption of water by the lining and release of any air. Additional water should be added to replace the quantity absorbed.

The pipeline should be filled slowly to prevent water hammer and to minimise entrapment of air. If the pipeline section to be tested is not provided with isolation valves then the ends must be fitted with bulkheads. Pipes or bulkheads must be fitted with the necessary outlets for incoming water and outgoing air.

The procedure in AS/NZS 2566.2 should be followed. The following is a summary of those procedures. The hydrostatic test usually commences after the 24 hour standing period.

The water pressure should be raised to the specified field test pressure, such pressure being measured at the lowest point of the section under test. Alternatively a static head allowance may be made between the lowest point and the point of the section under test. See Figure 12.1.

12. HydRoStatic field teSt

Location A Location BTest pressure 200m Test pressure 175m

200m test pressure required at Location AGauge at A should read 200mGauge at B should read 175m

25m static head

Pipeline section under test

figure 12.1 - Static head allowance for hydrostatic test with alternative pressure gauge locations

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12. HydRoStatic field teSt

Field hydrostatic test pressures are specified by the Design Engineer after consideration of the working pressure of the pipeline.

The test pressure should be maintained for at least 2 hours.

If the pressure has dropped at the end of the test, the volume of water needed to restore the original pressure should be measured. The test should be repeated a number of times with any make-up volume being measured. This make-up volume may result from pipe movement and compression of small quantities of entrapped air. Some leakage may be permitted to accommodate field constructed mechanical joints, and seals on fittings and appurtenances.

ALLOWAbLE mAKE-uP vOLumE

Any allowable make-up volume should be specified by the designer.

A generally accepted make-up volume rate is:

Allowable make-up rate ( L/hr) =

1.4 x 10 -7 x D x L x H

Where D = Pipe OD (mm);

L = Pipeline length (m); and

H = Average test head (m).

If the specified allowable make-up volume is exceeded the following procedure should be followed.

Ensure that all air has been expelled and the 24 hour standing period has elapsed.

Check all valves for full closure and sealing.

Check all mechanical joints, gibaults and flanges. Bolts should be uniformly tight and full sealing achieved.

If subsequent testing still results in unacceptable make-up volume, the ground above the line should be inspected for signs of obvious leakage. If none are apparent the line should be tested in halves with the failing section being subsequently halved and tested until the leak is located.

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Prior to commissioning ensure the removal of any solid material from the inside of the pipeline including rubbish, dirt, welding stubs and other foreign matter.

This may be achieved by placing a swab or “pig” through the line or in the case of larger diameter pipes, by operators travelling through the line. Only soft foam swabs (with no scouring pad attachments) should be used on seal coated pipelines.

WATEr TESTINg

New water mains must be constructed to minimise the risk of contamination of the water.

The drinking water from new mains must be tested for compliance.

The water quality compliance requirements are provided by the relevant Water Agency.

Water mains greater than or equal to (>+) 225mm diameter must be disinfected prior to sampling and testing.

A pipeline which will carry potable water should be sterilised with chlorinated water in accordance with the water authority’s requirements.

The water from all disinfected mains must be neutralised before discharge to the environment.

13. commiSSioning WateR PiPelineS

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SINTAKOTE® STEEL PIPELINES

APPENDIX A 53 FIELD REPAIR AND JOINT REINSTATEMENT OF SINTAKOTE®

APPENDIX B 65 FIELD REPAIR AND JOINT REINSTATEMENT OF CEMENT MORTAR LININGS AND GUIDELINES FOR PIPE HyDRATION AND FITTING END CAPS

APPENDIX C 72 FIELD APPLICATION OF ELECTRICAL CABLES TO CP LUGS

APPENDIX D 74 SAFE OPERATING PROCEDURE FOR HOLIDAy TESTING

APPENDIX E 76 FIELD APPLICATION OF SEAL COAT TO CML PIPE

APPENDIX F 78 GENERAL DATA

APPENDIX G 85 SINTAKOTE REPAIR KIT

APPENDIX H 86 REFERENCES

APPENDIcES

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Mild steel cement mortar lined pipe is supplied with SINTAKOTE, a fusion bonded medium density polyethylene coating.

Fittings may be fabricated from SINTAKOTE pipe.

In order to determine whether or not a damaged area requires repair, the following assessment should be made:

Continuity test at 12kV. If a holiday is detected then repair.

Determine the coating thickness. If less than 1.0 mm then repair.

Figure A.1 has been devised to determine the best method for field

repair of SINTAKOTE for buried service at ambient temperature.

Heat shrink sleeves are the preferred method of protection of field welds.

Enclosed are the procedures for heat shrink sleeve coating (A1), tape wrap coating (A2), adhesive patch repair (A3), Drader gun welding repair (A4) and SINTAPIPE® end repairs (A5).

The use of petrolatum tape protection systems is not recommended for the repair or field joint coating of SINTAKOTE.

This is primarily due to their very poor resistance to soil stresses.

The techniques detailed in this Appendix do not apply to pipelines operating at temperatures above 40oC, nor do they apply to piles/pipelines used in above ground situations. For above ground applications use Canusa KLO heat shrink sleeve in accordance with the Canusa technical data sheet. (Please contact Pentair Water Solutions for information).

is repair a welded

field joint?

figure a.1 - flow chart for determining appropriate SintaKote repair method

choose either heat shrink sleeve (preferred) or tape wrap field joint coating

choose either heat shrink sleeve (preferred) or tape wrap

field joint coating

Repair is at SintaJoint ends,

use drader welding repair method

use either adhesive patch, heat shrink sleeve or tape wrap

coating method

is repair away from

SintaJoint® ends?

is repair area

>10,000mm2? (100x100mm)

yES

NO

NO

NO

yES yES

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The application of heat shrink sleeves will give the optimum field protection (particularly protection from soil stresses). However, personnel applying sleeves need to be fully trained and experienced. The following sleeves relate to buried pipeline installations.

rEcOmmENDED SLEEvES

The recommended sleeves are:

1. CANUSA KLS. The primer is UCC Protek Butyl (Multi) primer.*

APPLIcATION PrOcEDurE

1. Bevel the edges of the SINTAKOTE® so that there is a tapered transition of at least 5 mm between the full coating thickness and the exposed steel.

2. Remove any coating or corrosion products on the steel and abrade the steel surface (if necessary) to produce a clean, non-corroded, roughened surface. Suitable abrasives are emery paper or a steel file.

3. Prepare the area to be repaired (to be free from dirt, dust and other contaminates) in accordance with the recommendations of the shrink sleeve manufacturer.

4. Solvent wipe the SINTAKOTE with a clean cloth (isopropanol is a suitable solvent for cleaning).

5. Apply the shrink sleeve in accordance with the application procedures of the manufacturer with the following changes:

i. Preheat the steel and adjacent SINTAKOTE to 3°C above ambient or to a minimum of 30°C.

ii. Thoroughly mix the primer and then brush apply a thin film of primer onto the steel surface and onto the SINTAKOTE for a distance of 100mm.

ii. While the primer is tacky (typically within 20 minutes), apply the sleeve ensuring that it overlaps the SINTAKOTE for a minimum width of 100mm.

Note that the specified preheat, post heat and use of primer is necessary to ensure satisfactory bonding of the sleeve. A roller should be used to eliminate voids from under the sleeve.

6. The repair should be visually inspected to ensure that it is in intimate contact with the pipe and that a bead of mastic has exuded from each end of the sleeve for the full pipe circumference. (If this is not in evidence additional heating is required).

* canusa sleeves and primer are available exclusively from Pentair for the water industry.

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This tape system provides a thick coating repair or field joint coating with similar impact resistance to that of SINTAKOTE. Thinner coating systems may not provide the same degree of protection.

The outerwrap of a thin PVC tape is provided to reduce soil stresses as far as is possible with a tape wrap system. A heat shrink sleeve repair/joint protection is recommended for optimum resistance to soil stresses.

rEcOmmENDED TAPE WrAP

The following tape system or equivalent is recommended:

Primer - UCC Dekotec Butylen primer or Denso Butyl primer.

Primary tape - UCC AS40 or Denso S43.

Outerwrap - UCC PVC Overwrap or Denso PVC SA.

Secondary tape - UCC PCS R20 HT or Denso R23.

These products are available from Universal Corrosion Coatings Pty Ltd and Denso Ltd.

Note that petrolatum based tapes are not recommended to coat field joints.


The method of application should be in accordance with the tape manufacturer’s recommended procedures with the following additions:-

PrEPArATION

Use a knife to remove all burrs/stubs from the parent coating. Solvent wipe the SINTAKOTE with a clean cloth (isopropanol is a suitable solvent for cleaning). The steel and coating area should be clean and dry before application of the primer.

PrOcEDurE

1. Cut out a piece of the primary tape to fit into the bare steel area. (This is used for repair, it is not necessary for field joint coating).

2. Using a brush, apply a thin even coat of primer onto the steel and onto the SINTAKOTE by 100mm.

3. Allow a few minutes for the primer to tack dry. Insert into the repair the cut piece of tape.

4. Spirally apply the primary tape at 55% overlap to the repair area ensuring a 100mm overlap onto the SINTAKOTE. Note that the primary tape must be applied whilst the primer is tacky (typically within 20 minutes).

5. Spirally apply the secondary tape at 10% overlap to completely cover the first layer of tape coating.

7. Some tension should be applied when applying the tapes to ensure that air voids, wrinkles etc. are not with a clean cloth (isopropanol is a suitable) solvent for cleaning). The steel and coating area should be clean and dry before application of the primer overlap onto the SINTAKOTE. Note that the primary tape must be applied whilst the primer is tacky (typically within 20 minutes).

6. Spirally apply the outerwrap tape at 10% overlap to completely cover the second layer. Complete the wrapping with one complete wrap over itself.

7. Some tension should be applied when applying the tapes to ensure that air voids, wrinkles etc. are not present after wrapping. Avoid undue tension on the outerwrap PVC tape.

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This method is recommended for repair areas up to 10,000mm2 (i.e. 100 x 100mm). It is only recommended for field use. The method uses a mastic filler, a heat fused repair patch and an overwrap tape. The tape overwrap is provided to reduce the effect of soil stresses on the patch coating. A heat shrink sleeve coating is recommended for optimum resistance to soil stresses (see A1).

Note: Rolls of Canusa CRP Repair Patch material should not be left in the sun as the product can heat up and cause the layers in the roll to fuse together.

rEcOmmENDED mATErIALS

The following system or equivalent is recommended:

– Filler - Canusa UCC Butyl Mastic Strip

– Patch - Canusa CRP Repair Patch

– Overwrap - Canusa UCC PVC Overwrap

*canusa sleeves and primer are available exclusively from Pentair for the water industry.


Recommended adhesive repair patches:

1. Clean and dry the area to be repaired (free from dirt, dust and other contaminates). At all the coating interfaces with bare steel, the coating must be bevelled to an angle of ≤30o to the steel.

2. Cut a patch from the Canusa CRP Repair Patch roll big enough to extend 80mm beyond the damaged area on all sides. The corners of the Canusa CRP patch should be rounded to at least a 30mm radius.

3. Slightly roughen the SINTAKOTE® around the repair for a minimum distance of 80mm from the edge of the coating damage, using 120 grit emery. Solvent wipe the SINTAKOTE with a clean cloth (acetone and isopropanol are suitable solvents for cleaning).

4. Preheat the entire region to be covered by the patch (including the exposed bare metal), to a minimum temperature of 60oC, with a yellow flame from a propane/air gas torch. The temperature can be measured with a melt stick.

5. Place a pre-cut piece of UCC Butyl Mastic Strip to cover the area of exposed steel. Heat the mastic and smooth it with a flame heated paint scraper type blade to cover all bare metal and

to exclude all air. Do not smear the mastic over the SINTAKOTE. Any excess mastic should be removed so that the mastic just fills the damaged region.

6. Apply a yellow flame to the SINTAKOTE to warm the surface.

7. Apply a yellow flame to the adhesive side of the Canusa CRP Repair Patch until it appears glossy.

8. Immediately apply the patch to the damaged area centring the Canusa CRP Repair Patch with respect to the damage.

9. Heat, using the gas torch, from the centre of the CRP Repair Patch, and use rubber coated or Teflon roller to eliminate any entrapped air. Continue heating and rolling until adhesive is observed exuding from all areas of the CRP Repair Patch.

10. Ensure the area to be tape wrapped is clean and free from any dirt/contamination. If in doubt, solvent wipe.

11. Spirally apply the Canusa UCC PVC Overwrap tape around the full circumference of the pipe, with tension applied, to completely cover the patch repair and overlap it by at least 80mm on all sides. The tape overlap should not be less than 10% of the tape width.

PRoceduRe a3 - adHeSiVe PatcH RePaiR metHod

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For use only where damaged SINTAKOTE® surfaces occur in the jointing region shown in Figure A2. The Shrink Sleeve method or Adhesive Patch method should be used where damage occurs away from the joint region.

This method is the only approved method for repairing the spigot end and socket end of SINTAJOINT pipe or fittings.

When properly executed, this method will ensure good fusion between the filler material and existing SINTAKOTE.

quALIfIcATIONS

Each operator who is to make repair welds upon coatings should be suitably practised and should be able to achieve adequate fusion in practice welds. Such welds can be evaluated by removing full thickness sections

perpendicular to the weld.

These sections can then be bent one way and then the other, through an angle of approximately 30º to place the internal and external surfaces the coating in tension. Any lack of fusion indicates an unsatisfactory weld.

WELDINg EquIPmENT

1. Drader extrusion welder and suitable welding tips. Refer Figure A.3 & A.4.

2. 240 V extension lead and power supply

3. Air supply 550 to 700 kPa (80 to 100 psi)

4. Thick leather gloves

5. Wraparound tip

mATErIALS

1. A 4mm nominal diameter extruded medium density polyethylene filler rod

PRoceduRe a4 - dRadeR Welding RePaiR metHod (foR field RePaiR at SintaJoint® PiPe endS only)figure a.2 - Joint Region for drader welding repair

50 | A P P E N D I X A A P P E N D I X A | 56

Back hoe Excavator Trencher

Figure 6.1 - Trench excavation machinery

How to excavateUsually an excavator or backhoe with bucket

attachment is used. Only authorised people

should operate this equipment. A trencher

may be used if conditions permit. This can be

a faster method. See Figure 6.1

SafetyIf working under power lines, check with the

electricity supply authority and the government

safety authority. You may need to:

arrange for overhead cables to be diverted

or protected with insulating covers;

arrange for electricity to be cut o�;put up goal post type barriers or; and

use lu�ng stops on the machine.

Remember there is greater sag in power lines

on hot days.

Barricades should be used if there is a danger

of anybody falling into the trench.

Occupation, Health and Safety regulations

must be observed.

Shoring the trenchIt is generally necessary to shore the trench if

it is deeper than 1.5 metres. Refer to the

relevant authority on safe excavation practice.

It may still be necessary to use shoring in

trenches less than 1.5 metres deep if there is

a risk of a trench wall collapse as a result of:

poor soil strength;

vibration from machinery;

use of explosives;

placement of spoil adjacent to the

trench and/or materials; or

water in�ow.

19 | C H A P T E R 6

T r e n c h i n g , i f u n s u r e ? S h o r e !F e n c e o f f w o r k a n d s t o r a g e a r e a s .

S I N T A K O T E ® S T E E L P I P E L I N E S S I N T A K O T E ® S T E E L P I P E L I N E S

(for �eld repair at SINTAJOINT pipe ends only)

For use only where damaged SINTAKOTE

surfaces occur in the jointing region shown

in Figure A2. The Shrink Sleeve method or

Adhesive Patch method should be used

where damage occurs away from the joint

region.

This method is the only approved method for

repairing the spigot end and socket end of

SINTAJOINT pipe or �ttings.

When properly executed, this method will

ensure good fusion between the �ller material

and existing SINTAKOTE.

Quali�cationsEach operator who is to make repair welds

upon coatings should be suitably practised

and should be able to achieve adequate

fusion in practice welds. Such welds can be

evaluated by removing full thickness

sections perpendicular to the weld.

These sections can then be bent one way

and then the other, through an angle of

and external surfaces of the coating in

tension. Any lack of fusion indicates an

unsatisfactory weld.

Welding equipment1. Drader extrusion welder and suitable

welding tips. Refer Figure A.3 & A.4.

2. 240 V extension lead and power supply

3. Air supply 550 to 700 kPa (80 to 100 psi)

4. Thick leather gloves

5. Wraparound tip

Figure A.2 - Joint Region for Drader welding Materials repair 1. A 4 mm nominal diameter extruded

medium density polyethylene �ller rod supplied

by Tyco Water. (SINTAKOTE �ller rod).

2. Clean cotton rags and isopropanol cleaningsolution.

General Instructions1. The Drader Injectiweld can produce sound

weld deposits of various shapes that are

e�ectively bonded to the original surface

provided the correct technique is used.

2. Temperature setting – The welder unit

should be preset to 270ºC initially and no

further adjustment is necessary

3. Select the correct tip and �t to the gun as

follows:

Remove the retaining nut with the tool

provided. This will require the gun to be

switched on and heated up for a few minutes.

Remove the previous tip being careful to

locate the aluminium washer that is �tted

between the tip and the body of the gun.

4. Figure A.3 shows the gun with tip removed.

Always replace the washer: Failure to replace the

washer before �tting the new tip will allow

extruded material to be forced down these holes

and possibly damage the heater and/or sensor.

Jointing Region

200mm

Jointing Region

approximately 30º to place the internal

Procedure A4 - Drader welding repair method supplied by Pentair Water Solutions. (SINTAKOTE® filler rod).

2. Clean cotton rags and isopropanol cleaning solution.

gENErAL INSTrucTIONS

1. The Drader Injectiweld can produce sound weld deposits of various shapes that are effectively bonded to the original surface provided the correct technique is used.

2. Temperature setting – The welder unit should be preset to 270ºC initially and no further adjustment is necessary

3. Select the correct tip and fit to the gun as follows:

– Remove the retaining nut with the tool provided. This will require the gun to be switched on and heated up for a few minutes.

– Remove the previous tip being careful to locate the aluminium washer that is fitted between the tip and the body of the gun.

4. Figure A.3 shows the gun with tip removed. Always replace the washer: Failure to replace the washer before fitting the new tip will allow

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5. Apply a small amount of the ‘Heat transfer’ paste to the top of the washer and the threads of the body to enable them to be easily removed later. Place the gun on a horizontal surface so that it is pointed up and place the tip over the end so that it ts snugly over the washer and pin. Occasionally the tip may not engage correctly because the locating holes are filled of plastic. In this case wait until the tip heats up and melts the plastic in the holes. Ensure that the tip sits firmly on the washer and place the retaining nut over the tip and push it down until it engages the thread (use thick gloves and/or cotton rags to prevent burning hands – all of these components will get hot).

6. Never place the tip into the retaining nut first and screw it onto the gun. This could break o the locating pin making it very difficult to repair.

7. Screw the retaining nut up tight with the tool provided. This process may need to be repeated a few times as the components heat up and the retaining nut expands. (It may also be necessary to heat up the gun to replace a tip later).

8. Fit the Ø4 mm plastic wire into the hole at the base of the gun and rotate the feed nut to engage the wire. The wire should not be able to be pulled out from the gun when correctly engaged. Never operate the feed trigger without plastic wire being engaged. This could result in damage to the feed mechanism.

vArIOuS cONcAvE TIPS fOr WrAP ArOuND END rEPAIr

These specially developed tips are designed to repair the SINTAJOINT®

wraparound ends in a single pass. They produce a nished end that generally only needs one side trimmed, (outside of the spigot or inside of the socket)

The technique used for the repair of end damage requires a determination of the extent of the damage. Small damage such as punctures or dents might be repaired with a number of tips including the Cone tip, Ball end tip, the 3/16’ Fillet weld tip or one of the butt weld tips.

Large damage which involve more than 25mm long repairs to the end will be best repaired with the concave tip that suits the particular plate thickness.

These tips are identied as W06 for 6mm pipe wall thickness, W08 for 8mm pipe wall thickness etc. The following procedure describes the use of these concave tips.

PRoceduRe a4 - dRadeR Welding RePaiR metHod (foR field RePaiR at SintaJoint® PiPe endS only)

figure a.3 - drader gun assembly

barrel

gunhandle

SensorIndexing Pin

heater

AluminiumWasher

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If there is a split in the coating away from the end of the pipe this should be first repeated with a butt weld tip before attempting this repair.

Operators who attempt this repair technique should have attended a SINTAKOTE® repair training course and be certied as being competent in the use of the equipment.

1. Clean the aected area to ensure that all the dust and foreign matter is removed from the repair area. Use a le or knife to remove any coating that may be sticking out.

2. The transition area from full thickness at the start and nish of the defect should be tapered over about 40 mm to enable the tip to travel smoothly without catching on any step. This is best done with a sharp knife or rasp.

3. Fit the Concave tip that suits the pipe wall thickness to the gun. Experience has shown that it is better to t the tip so that the groove is horizontal when the gun is held out with the handle vertical. This means that the gun travels sideways and gives the operator a better view of the repair area both in front of and behind the weld.

4. Ensure that the heating tip has reached the correct temperature and that the LED is flashing.

5. Test the feed rate by pressing the trigger for several seconds until a quantity of plastic extrudes out of the end of the tip. Adjust the feed rate to give a moderate ow (no more than 2 pulses per second has been found to give good results). Remove the extrudate with a knife or suitable tool.

6. Determine the line of weld that the repair should be laid along and place the welding tip about one tip length before the transition to the defect. This ensures that any lack of bond on start up is outside the original defect area. The gun should be held so that it remains straight out from the pipe end but angled sideways (about 15o) in the direction of the weld as determined by the angle of the tip, keeping the full face of the tip in contact with the end of the pipe at all times. Make certain that the surface beneath the tip begins to melt before commencing the weld.

7. Hold down the trigger and start moving the welder in the required direction at a constant speed to ensure smooth feeding of the weld pool.

8. Use a travel speed that will give good build up of material and good coverage of the coating on both sides (see Figure A.5). Failure to get good fusion on either or both sides will result in further more complicated repairs. (Generally good fusion will result when the build up on either side of the end is about the same). If there is still poor fusion then the travel speed is too fast.

PRoceduRe a4 - dRadeR Welding RePaiR metHod (foR field RePaiR at SintaJoint® PiPe endS only)figure a.4 - drader gun tip selection

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PRoceduRe a4 - dRadeR Welding RePaiR metHod (foR field RePaiR at SintaJoint® PiPe endS only)

9. It is important to complete the line of weld without stopping until the tip is beyond the defect area otherwise a new transition will have to be prepared before restarting repairs.

10. When the run is completed, angle the gun so that it is perpendicular to the end of the pipe and continue to extrude material as the tip is withdrawn from the surface. This will reduce any plasticised defects caused by the tip.

11. When the weld has solidied, the excess material can be removed using a suitable tool, being careful not to cut below the original surface level (see Figure A.6).

12. Remove material from the end in the start and nish zone where double thickness has been applied.

13. Do not remove any material from the end in the defect zone. (Wood rasps and planer can be used for this purpose). It is only necessary to

remove excess material from the outside of the spigot. It is better to remove the excess from both the inside (necessary) and outside of the socket to give a better appearance.

14. Visually examine the nished area for defects and repair if necessary using a suitable tip.

15. Check the repair using a High Voltage Holiday Detector. Repair any defects and retest.

EQUIPMENT Refer to Procedure A.4

MATERIALS Refer to Procedure A.4

GENERAL INSTRUCTIONS Refer to Procedure A.4

Various concave tips for wrap around end reinstatement

1. Identication Marks SP05, SP06, SP08, SP10 SP11 etc. for 5, 6, 8, 10 and 11 mm wall thickness pipes.

2. These specially developed tips are designed to reinstate the SINTAKOTE® around the end in a single pass. It will produce a sound repair that is

bonded to the external and internal coating.

figure a.5 – Build up of material on cut end figure a.6 – care required when trimming

Welding tip

Plastic depositOutside

Trim excessive material

PRoceduRe a5 - WRaPaRound ReinStatement ofSintaPiPe® afteR field cutting

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It is assumed that the pipe has been cut with a suitable machine and is presented with the coating and lining flush with the end of the pipe.

Operators who attempt this repair techniquenshould have attended a Sintakote repair training course and be certified as being competent in the use of the equipment.

1. Clean the affected area with isopropanol to ensure that all the dust and foreign matter is coating that may be sticking out.

2. Fit the Concave tip that suits the pipe wall thickness to the gun. Experience has shown that it is better to fit the tip so that the groove is horizontal when the gun is held out with the handle vertical. This means that the gun travels sideways and gives the operator a better view of the repair area both in front of and behind the weld.

3. Ensure that the heating tip has reached the correct temperature (i.e. the LED is flashing.)

4. Test the feed rate by pressing the trigger for several seconds until a quantity of plastic extrudes out of the end of the tip. Adjust the feed

rate to give a moderate flow (no more than 2 pulses per second has been found to give good results). Remove the extrudate with a knife or suitable tool.

5. The gun should be held so that it remains straight out from the pipe end but angled sideways (about 15º) in the direction of the weld as determined by the angle of the tip. Keep the full face of the tip in contact with the end of the pipe at all times. Make certain that the surface beneath the tip begins to melt before commencing the weld.

6. Hold down the trigger and start moving the welder the required direction at a constant speed to ensure smooth feeding of the weld pool.

7. Use a travel speed that will give good build up of material and good coverage of the coating on both sides (see Figure A.5). Failure to get good fusion on either or both sides will result in further more complicated repairs.

(Generally good fusion will result when the build up on either side of the end is about the same). If there is still poor fusion then the travel speed is too fast.

8. It is recommended to complete as much welding as possible without stopping as a new transition will have to be prepared for each start. The start area must be feathered back to the surface to remove any unbonded areas and to provide a smooth area for finishing the weld.

9. To complete the run make sure that the bead finishes past the initial start area to ensure a complete seal.

10. When the weld has solidified the excess material can be removed using a suitable tool being careful not to cut below the original surface level (see Figure A.6).

11. Visually examine the finished area for defects and repair if necessary using a suitable tip.

12. Check the repair using a High Voltage Holiday Detector. Repair any defects and retest. The finished end should now be suitable for the attachment of a pipe coupling.

PRoceduRe a5 - WRaPaRound ReinStatement ofSintaPiPe® afteR field cutting

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The cement mortar lining of steel pipes in factory production is carried out in accordance with Australian Standard AS 1281- Cement mortar lining of steel pipes and fittings using a centrifugal process. This method ensures a dense, low water/cement ratio mortar in close contact with the steel. In the factory, all pipes are end capped and held for several days to enable the mortar to cure.

Pipe fittings are lined in the factory either using a centrifugal mortar applicator, by hand lining or by a combination of centrifugally lined pipe with the joints reinstated by hand. Lined fittings are end capped and allowed to cure before delivery.

In order to determine whether or not the mortar requires repair, the following procedure should be followed:

1. Use a 2.0 mm feeler gauge and see if it can be inserted to a depth greater than half the thickness of the lining. If it can, the mortar should be repaired as described in Procedure B2.

2. Use the feeler gauge to determine if the mortar has disbonded to give a gap in excess of 2 mm between the mortar and the steel pipe. This can be measured by attempting to insert the feeler gauge into the gap (at the ends of pipe) or to check if the step between adjacent sections of the lining (at a crack) is greater than 2 mm. If the disbondment is greater than 2 mm break out the disbonded lining and repair as described in B1.

Disbonded (drummy) linings are acceptable provided the above criteria are not exceeded or if potable water is placed inside the pipe and water absorption leads to total loss of the drumminess.

Cement mortar lining repairs and pipe joint reinstatement are usually done by hand application of the cement mortar.

Are cracks in cement mortar lining normal?

yes. These cracks are caused by the fact that steel and cement have different thermal expansion coefficients. As the

temperature changes prior to installation these cracks can occur. These cracks are normal and are of little concern due to a process called autogenous healing. Autogenous healing is the ability of cement to heal itself. In the presence of moisture, cement extrudes calcium hydroxide which, upon exposure to the atmosphere, is converted to calcium carbonate which seals the crack. These calcium carbonate crystals are formed when the carbon dioxide in the air and water carbonated the free calcium oxide in the cement and the calcium hydroxide liberated by the hydration of the tricalcium silicate of the cement.

aPPendiX B - field RePaiR and Joint ReinStatementof cement moRtaR liningS

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When using weld collar band thickness and how well the fillet weld is profiled, there may be a need to address the sharp edge of steel band and the drop down area from top of band collar to pipe surface:

- Sharp edges can be a source of puncturing the protective heat shrink corrosion coating

- Drop down in surface area can cause a void reulting in no intimate coating to steel

1. From experience, heat shrink sleeves alone should cope with weld band collars up to 10mm thick, provided weld collar edges are chamfered with a grinder and the weld bead itself sits at about 8-10mm high.

2. Outside of these parametres it is best to pre profile both edges on the weld collar with

UCC Round Section Butyl Mastic Strip.

3. Profile weld collar step downs by introducing the UCC Round Section Butyl Mastic Strip hard up against the weld bead. Press the mastic firmly into the intersection so it levels flush with the top of the weld collar and flows evenly down the pipe substrate.

4. Mastic will flow further into the void during the heating / shrinking process and will eliminate tenting. (Provided the correct heat shrinking procedure is followed).

5. The standard profiling medium is UCC 17mm Dia Round Section Butyl Mastic Strip 17mm diamtre x 3.6m coil length.

PRoceduRe a6 Weld collaR SteP doWn PRofiling - Butyl maStic

figure a.7 - Suggested Profiling for Weld collar Joints

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PRoceduRe B1 - cement moRtaR lining RePaiR metHod

uSINg EZILINE PrEmIxED mATErIALS (fOr fIELD rEPAIr/JOINT rEINSTATEmENT)

The EZILINE Mortar Mix is a high performance product specifically designed for compatability and use in reinstating the field joints and repair of Pentair Water Solutions cement mortar lined steel pipes

mATErIALS

Available from Pentair Water Solutions in kit form.

DRy MIX - PART A

Type SR blended cement in compliance with AS 3972 and sand in full compliance with AS 2758.1.

LIQUID - PART B

The liquid is a high performance acrylic modier.

Primer - Liquid Part B is used undiluted as the primer.

For safe use of the product, refer to the MSDS.

APPLIcATION INSTrucTIONS

1. Ensure all surfaces are free of grease oil, paint, loose or flaking materials and the steel surface is cool. This may be achieved by wetting the surface with water (mortar will not adhere to a hot surface).

2. Wet the adjacent mortar, leaving the surface damp, but with no excess/pooled water.

3. Brush apply a primer coat of Part B (liquid) to cover the steel and adjacent mortar.

Note: Do not dilute . The mortar can be applied when this coat is wet or dry, but must be applied the same day, otherwise apply another prime coat.

4. Thoroughly manually mix Part A (do not use a cement mixer) and as much of Part B required to form a sti workable mixture. Do not add water. Ensure there is no dry mixture present.

Note: The working time reduces with temperature, and is approx. 20 minutes at 30oC.

5. Apply the mortar, compacting it into place to the level of the adjacent mortar.

6. Finish with a metal trowel to provide a smooth even finish.

7. The mortar should be protected from excessive heat, water and sub-zero temperatures during the first 24 hours from placement. It least 7 days prior to service.

8. Open bags of mortar not used within 24 hours should be discarded thoughtfully.

9. Dispose of packaging and waste material appropriately after use.

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This method is applicable to repair of cracks in cement mortar lined (CML) pipes. It is used to repair cracks that are greater than the 2.0mm width allowed in AS 1281.

mATErIALS

Pentair Water Solutions EZILINE mortar mix.

PrEPArATION

The CML should be dry at the time of undertaking the repair.

Enlarge the crack to a width of 4 to 6mm using a 100 mm angle grinder (or equivalent) tted with a diamond tipped cutting blade nominally 3.2mm in width. The depth of the groove should be set at 2mm less than the lining thickness. The depth should be checked with a ruler.

APPLIcATION

1. Apply EZILINE material in accordance with procedure B1 up to and including Application Instruction 4.

2. With a spatula or knife applicator press the mortar into the groove to exclude all air.

3. Follow procedure B1 Application Instructions 5 to 9.

PRoceduRe B2 - RePaiR of cement moRtaR lining cRacKS uSing eZiline

EZILINE

4 – 6mm

Steel pipe

Crack

Cementmortar lining

figure B.1 - typical cement mortar lining crack greater than 2mm

figure B.2 - enlarge crack to 4 – 6mm

figure B.3 - completed repair

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PrE STArT / SET uP

1.0 Always check the pipe is placed securely on the dunnage supplied with the pipe.

1.1 Always wear the correct and appropriate PPE.

1.2 Ensure any issues with equipmemt or safety are reported to the Person in charge immediately.

1.3 Ensure all tools and equipment are fit for purpose at all times.

1.4 Ensure water is available for concrete hydration.

OPErATION fOr NOrmAL WEAThEr cONDITIONS

MATERIALS REQUIRED FOR NORMAL WEATHER CONDITIONS

– Black builders film 100um

– Signet 15mm polypropylene strap

– Signet 15mm plastic buckle

- PVC black or grey duct tape 48mm wide

TOOLS REQUIRED

- Knife

- Torch

- Portable water dispenser

2.0 PIPE END 1

2.1 Check the material being used is the correct size for the pipe diameter.

2.2 Hold the centre of the black builders film 100um plastic against the end of the pipe and fold the ecess along the outside of the pipe.

2.3 Wrap the 15mm polypropylene strapping complete with assembled buckle around the pipe and only tension enough to hold the plastic in place for now.

2.4 Pull each corner evenly and apply PVC black or grey duct tape x 48mm wide to the pipe.

2.5 Even out the plastic between the corners and then wrap tape around the full circumference missing the plastic in the middle between corners so as tape sticks to the pipe (see picture)

2.6 Reposition the strapping to a minimum of 150-200mm from the pipe end and re-tension tightly without breaking the strap or buckle.

PIPE END 2

2.7 On the opposite end throw a minimum of four ltrs of clean potable water into the pipe as far as possible and repeat process.

2.8 When conditions dictate, 19mm black HD400 poly strapping may be required and used with a metal buckle only and tensioned with the use of an approved tensioner.

OPErATION fOr ExTrEmE WEAThEr cONDITIONS

MATERIALS REQUIRED FOR EXTREME WEATHER CONDITIONS


– Signet 19mm HD400polypropylene strap

– Signet 19x3 15mm metal buckle


TOOLS REQUIRED

- Signet polystrap tensioner

- Knife

- Torch


OPTION A: USING SIGNET 19MM BLACK HD400 POLy STRAPPING

3.0 PIPE END 1

3.1 Cut black builders film 100um plastic and 19mm black HD400 poly

PRoceduRe B3 - guidelineS foR PiPe HydRation and fitting end caPS

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strapping to appropriate lengths and place the plastic over the pipe end.

3.2 Loosely place strapping over plastic around the whole pipe without tightening.

3.3 Using the SIgnet polystrap tensioner tool to tighten the Signet 19mm HD400 poly strapping arounbd the pipe. Ensure that the plastic is tight before the final tension is completed.

3.4 Cut the excess plastic that hangs out from the strapping making sure a small amount of over hang remains. (Do not sut the plastic laying on the pipe as it will cause damage to the coating)

3.5 Using the PVC black or grey duct tape x 48mm wide, begin taping the plastic to the pipe. Fold the excess plastic back over the strapping as you tape over it and the pipe coating.

3.6 Repeat the wrapping process overlapping with the PVC black or grey duct tape x 48mm wide each time for approximately three (3) wraps. Make sure that no loose pieces of plastic strapping are exposed.

PIPE END 2

3.7 On the opposite end when required throw a minimum of four ltrs of water into the pipe as far as possible and repeat process.

OPErATION fOr ExTrEmE WEAThEr cONDITIONS (ALWAyS uSE fOr SOuTh AuSTrALIA)

MATERIALS REQUIRED FOR EXTREME WEATHER CONDITIONS


– Signode 19mm green Tenex 2225 polyester strapping


TOOLS REQUIRED

- Signode BXT-2-19 polyester tensioner

- Knife

- Torch


OPTION B: USING 19MM GREEN TENEX 2225 POLyESTER STRAPPING

4.0 PIPE END 1

4.1 Cut black builders film 100um plastic and 19mm green Tenex 2225 polyester strapping to

appropriate lengths and place the plastic over the pipe end.

4.2 Loosely place strapping over plastic around the whole pipe.

4.3 Using the SIgnode BXT-2-19 polyester tensioner tool to tighten the Signet 19mm green Tenex 2225 polyester strapping around the pipe. Ensure that the plastic is tight before the final tension is completed.

4.4 Cut the excess plastic that hangs out from the strapping making sure a small amount of over hang remains. (Do not sut the plastic laying on the pipe as it will cause damage to the coating)

4.5. Using the PVC black or grey duct tape x 48mm wide, begin taping the plastic to the pipe. Fold the excess plastic back over the strapping as you tape over it and the pipe coating.

4.6 Repeat the wrapping process overlapping with the PVC black or grey duct tape x 48mm wide each time for approximately three (3) wraps. Make sure that no loose pieces of plastic strapping are exposed.

PIPE END 2

4.7 On the opposite end when required throw a

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minimum of four ltrs of water into the pipe as far as possible and repeat process.

PIPES muST bE rEguArLy chEcKED fOr rEhyDrATION AfTEr ThE END cAPS hAvE bEEN fITTED

5.0 Subject to heat temperatures and the possibility of water loss through end cap leakage, checks must be done on a weekly basis.

5.1 When satisfied that a loss of water is not ocurring, the time frame can be adjusted accordingly to a maximum of four weeks.

chEcKINg Of hyDrATION AfTEr END cAPS hAvE bEEN fITTED fOr A PErIOD Of TImE

6.0 Make a cut in the plastic large enough so the torch can be used to see inside and add clean potable water if required.

6.1 When finished close and seal the hole with a piece of grey / black duct tape.

6.2 When the next inspection is required cut through the duct tape and reseal when finished.

cLEAN uP Of ArEA

6.0 Place all rubbish in bins and dispose of properly

6.1 All tools should be cleaned and stored in their designated areas.

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mATErIAL

- Cable cutter suitable for 25mm2 copper cable (ALM type ME 11-65 Wattmaster ME 60 or equivalent).

- Hand crimping tool (Wattmaster MK 80, Utilux No. 20, for example CABAC Hexagonal Crimper 6.50mm2 K05 or equivalent. (See picture below.)

Note: Hydraullic type crimpers are not suitable for crimping this style of lug.

- Cable (19/1.35 (25 mm2) single core double insulated P.V.C.

- Shrink tube 100 long (Raychem WCSM 28/9/1200).

- Knife or stripping tool (For cable and 9.5 mm dia lug).

- Battery operated hand drill and 6.5 mm bit (17/64”).

- Solvent (Methylated Spirits, isopropanol or acetone) and clean rags.

- Propane/Butane heating torch with primus 2956 burner or equivalent.

PrOcEDurE

1. When making the joint make sure that both lugs are aligned as close as possible (Fig. 1), preferably, at the top of the pipe.

2. Strip the SINTAKOTE® for a distance of 25 mm from the end of the lug by cutting around the full circumference of the lug and twisting the loosened SINTAKOTE® cap. (See Fig. 2)

Using the battery drill on low speed insert the 6.5 mm drill bit into the hole in the end of the lug to remove any residual SINTAKOTE® and clean the inside copper surface.

3. Cut the length of cable to the required length (distance between the lugs including room to bend the cable) using the cable cutters. Bare both ends of the cable for a distance of 20 mm taking care to avoid damaging the ends of the copper cable. See Fig 3.

aPPendiX c - field aPPlication of electRical caBleS to cP lugS

figure c.1 - align lugs

figure c.2 - Strip SintaKote®

figure c.3 - Bare cable ends

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aPPendiX c - field aPPlication of electRical caBleS to cP lugS

4. Slide two lengths of shrink tube over the cable and insert the ends into the hole on the lugs of each pipe.

5. Adjust the screw on the crimp tool for 25 mm2 cable and while holding the cable rmly into the lug make a crimp close to the end of the lug. The crimp must be made from the top with the tool at 90o to the pipe surface. Repeat this operation adjacent to the first crimp. (see Fig. 4)

6. Clean the surface of the lug and at least 50 mm of cable next to the lug using methylated spirits and a clean rag.

7. Slide the shrink tube down to the surface of the pipe and using a low ame heat the sleeve around the location of the crimp join as shown in Fig 5. Move the ame outwards, towards the cable end of the tube whilst heating the tube all around. When this is completed a small amount of adhesive/sealant will squeeze from the end of the tube.

Repeat this operation towards the pipe end until sealant squeezes out from that end. See Fig 6.

8. Repeat procedure 6 and 7 on the other lug and cable end to complete the joining operation.

figure c.4 - crimp cable

figure c.5 - Heat crimp joint

figure c.6 - apply sealant

(In the diagram above the crimp appears on the top of the lug for illustration purposes, - In practice it will be on the sides of the lug).

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aPPendiX d - Safe oPeRating PRoceduRe Holiday teSting

This procedure applies to SPy Holiday test equipment (recommended equipment).

1. PrE STArT / SETuP

1.1 Always check the spark tester first thing each day before using it for testing.

1.2 Check the calibration of the unit is up to date.

1.3 Check the voltage is set to 12 kv per Australian Standard AS4321.

1.4 Aways use a fully charged battery.

2. cONNEcTINg ThE bATTEry TO ThE DETEcTOr

2.1 Place battery in case with terminals facing up.

Check voltage is correct before sliding battery case onto the detector.

2.2 Align the battery case with the detector guide rails and slide across.

2.3 Slide battery until it reached the stop and the rear latch is engaged.

3. ATTAch ThE WAND AND EArThINg cONNEcTIONS

3.1 Align wand to detector (keyed).

3.2 Slowly push wand into detector.

3.3 Align earting pin to detector.

3.4 Insert earthing pin and twist clockwise to lock.

3.5 Attach brush and eath lead to spark tester, attach the earth lead to a test plate. Switch the spark tester “ON” and wipe brush over the test plate.

OR

3.6 Wrap the coil around the pipe by placing it at the end of the pipe at waist level and then attach it to the spark tester.

3.7 Attach the earth lead by clamp to either exposed metal OR the CML on the spigot end of the pipe.

3.8 Switch spark tester “ON” and bring the coil into contact with the earth.

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aPPendiX d - Safe oPeRating PRoceduRe Holiday teSting

3.9 Once the test is completed return the earth back to initial lining.

3.9 Always use a fully charged battery. If tester’s ability to spark is reduced, replace the bettery. Do not adjust the calibration.

3.10 DO NOT position oneself under a suspended load to attach the coil.

3.11 Always check that personel are well clear of contact to the pipe before switching the spark tester “ON”.

3.12 DO NOT use a spark tester in a wet environment, grass must be trimmed to a minimum height of 100mm, 2m from each side of the pipe footprint.

NOTE: Any person with a heart condition or pacemaker should not use a spark tester. Please notify your manager if this condition exists.

4. OPErATION

4.1 The maximum speed for spark testing is 5 seconds per metre while moving along the pipe.

4.2 Visually check coating for defects: Look for any coating damage.

4.3 Check the external coating using a “Holiday” spark tester and attaching the brush for checking ends and the external coating: If the spark tester jeeps then there is a defect in the coating.

When a defect is found it must be recorded with a description of the defect.

4.4 Pipe must be spark tested immediately before it is placed in the ground to ensure fitness for purpose.

5. Removing spark tester off pipe

5.1 When finished, release the spak test coil by lifting the tester coil approximately 1cm off the pipe and twisting.

Ensure that the coil end is released to go downwards and the releaseing hand is slid up.

The remainder of the coil end is released to go downwards and the releasing hand is slid up.

5.2 When operatin is complete check the sprk tester is tured off and remove the battery and place on charger.

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INTrODucTION

This specification is for the field joint coating/repair of Pentair seal coat applied to cement mortar lined (CML) steel pipes. This bitumen based seal coat is normally applied to CML pipe to reduce the extent of leaching of alkalis into the water, which could otherwise give rise to an unacceptable increase in the pH of the water.

Bare CML can be exposed on seal coated pipes that are cut in the field, where the CML is damaged, or where an internal CML field joint lining is made after pipes are field welded. The need for field joint coating/repair depends on the extent of exposure of bare CML. As a general rule all sealcoated pipes CML joint linings should be seal coated.

PrEPArATION Of cEmENT mOrTAr LININg

The CML surface shall be relatively smooth, and free of surface water, dirt, loose dust and particulate material, and any extraneous material that affects the bond of the seal coat. In general exposed CML should be seal coated as soon as practicable

after it is exposed. Such prompt application prevents contamination of the CML that might lead to a reduction in bond of the seal coat. Seal coats should only be applied to CML joint linings after overnight drying / curing of the CML.

Visual observation is sufficient to determine whether or not the surfce is dry. Any loose material or rough surfaces can be easily removed/smoothed with a trowel and a bristle brush.

rEPAIr Of DAmAgED SEAL cOAT - SubSTrATE PrEPArATION

Loose and flaking seal coat paint should be removed with a wire brush until a firm substrate is provided for bonding the new seal coat. Adhesion of residual paint should be tested with duct tape and the surface brushed until no loose or flaking paint adheres to the tape. The surface is then ready for seal coating.

SEAL cOAT APPLIcATION

The bitumen seal coat used shall be Pentair Sealcoat. No other product shall be used. It shall not be thinned as this negates its water

contact approval. Prior to any application the product should be thoroughly stirred/mixed, as it will settle during transport.

Seal coat shall be applied in accordance with the relevant product data sheet and these instructions. The pipe seal coat is applied to the CML by Pentair Water Solutions to give a dry film by thickness in the range 100-150μm. However it may be difficult to achieve such a high thickness by manual application in the field. In order to gauge the correct amount of coating to apply, applicators should practice by coating steel panels, and checking the thickness applied with a wet film gauge. The wet film thickness should be in the range 190 - 290μm to achieve a 100 - 150μm dry film thickness (the solids content is 53% v/v). The technique of visual thickness cmparison is satisfactory when coating the cut ends of pipe or for small repair areas.

When coating internal CML joint linings the best method is to measure out the required volume of seal coat to be used for the joint. The required volume of seal coat for a joint = πx D x L x t / 1000 where:-

D = Internal pipe diameter in millimetres

L = length of field joint in

aPPendiX e - tHe field aPPlication/RePaiR of PentaiR Seal coat to cml PiPe

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aPPendiX e - tHe field aPPlication/RePaiR of PentaiR Seal coat to cml PiPe

millimetres

t = average wet film coating thickness in millimetres = 0.226mm (equivalent to an average dry film thickness of 120μm).�

Hence the required quantity per joint = 0.711 x D x L ÷ 1000 mL. As an example a 100mm length of reinstatement on a pipe with an internal diameter of 1. A convenient disposable container should be used, with a set fill point, to metre 97mL of Interline for each joint. (This should achieve an average dry film thickness of 100 - 120μm on each joint, allowing up to 20% in loses). A wet film gauge can also be used to gauge unifority of thickness, although this is a poor technique for accurately measuring the thickness of coatings on CML, due to the very high uncertainty of measurment.

The seal coat shall be allowed to dry for at least 24 hours prior to any loading or being placed into servcie, Note that when walking on Pentair seal coated CML, care will need to be taken to ensure the seal coat is not damaged. This will necessitate cleaning of boots, using clean equipment, etc when entering pipes.

quALITy cONTrOL TESTS

Seal coat shall only be applied when the ambient temperature, the CML temperature, and the seal coat temperature are all ≥5� at the time of application.

The thickness applied shall be visually inspected for repairs to cuts and small areas. There should be no runs or uncoated areas. For field joint reinstatements a set quantity (equivalent to an average dry film thickness of 120μm) shall be applied at each joint. A wet film gauge can be used to check uniformity of application.

An adhesion test shall only be performed on field joint seal coatings. The frequency of testing shall be one in every 10 seal joints seal coated. A tape bond tes is used to determine coating adhesion. The test shall be undertaken in accordance with ASTM D3359 Method A with the folliwng exceptions:-

1. The tape shall be 3M Tape 389y 50mm in width. The contact length shall be 150mm.

2. The test shall be performed a minimum of 24 hours after application of the seal coat.

3. The assessment shall be on the basis of the area of delamination of the seal coat, which shall be less that 8% of the total contact area of the tape (ie; up to 600mm2 in 7500mm2). Cohesive failure within the seal coating material does not constitute delamination.

4. No cross-cuts into the coating are required.

If the seal coat adhesion test fails then every field joint seal coating in the batch represented shall be tested. Those joint seal coats that fail the test should be rejected.

Rejected seal coating shall be removed, the surface shall be re-prepared and a new seal coat shall be applied. All recoated field joints shall be tested for adhesion.

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aPPendiX f - geneRal data

table f.1- SintaKote® thickness

Pipe OD (mm)

SINTAKOTE Thickness (mm)

273 1.6>273 to 508 1.8>508 to 762 2.0>762 2.3

table f.3 - SintaKote thickness

Tonnes per Pipe SKCL

6m 9m 12m 13.5m

114 4.8 1.6 9 86 19.9 19.4 0.1168 5 1.6 9 140 31.0 30.2 0.2 0.3190 5 1.6 9 162 35.3 34.4 0.2 0.3

219 5 1.6 9 191 41.0 40.0 0.2 0.4240 5 1.6 9 212 45.1 44.0 0.3 0.4257 5 1.6 9 229 48.5 47.2 0.3 0.4273 5 1.6 9 245 51.6 50.3 0.3 0.5290 5 1.8 12 256 61.0 59.4 0.4 0.5

324 4.5 1.8 12 291 64.6 62.9 0.4 0.6324 5 1.8 12 290 68.4 66.7 0.4 0.6324 6 1.8 12 288 76.0 74.2 0.5 0.7337 4.5 1.8 12 304 67.3 65.5 0.4 0.6337 5 1.8 12 303 71.3 69.5 0.4 0.6337 6 1.8 12 301 79.1 77.3 0.5 0.7356 4.5 1.8 12 323 71.2 69.4 0.4 0.6356 5 1.8 12 322 75.4 73.5 0.5 0.7356 6 1.8 12 320 83.8 81.9 0.5 0.8

406 1.8 12 373 81.6 79.4 0.5 0.7 1.0406 5 1.8 12 372 86.4 84.2 0.5 0.8 1.0406 6 1.8 12 370 95.9 93.8 0.6 0.9 1.2406 8 1.8 12 366 114.9 112.8 0.7 1.0 1.4419 4.5 1.8 12 386 84.3 82.1 0.5 0.8 1.0419 5 1.8 12 385 89.2 87.0 0.5 0.8 1.1419 6 1.8 12 383 99.1 96.9 0.6 0.9 1.2419 8 1.8 12 379 118.7 116.5 0.7 1.1 1.4457 4.5 1.8 12 424 92.1 89.7 0.6 0.8 1.1457 5 1.8 12 423 97.6 95.1 0.6 0.9 1.2457 6 1.8 12 421 108.4 106.0 0.7 1.0 1.3457 8 1.8 12 417 129.9 127.4 0.8 1.2 1.6

table f.2- cement mortar lining (cml) thickness

Pipe OD (mm)

CML Thickness (mm)

≤273 9 ± 3>273 to 762 12 ± 4>762 to 1219 16 ± 4>1219 19 ± 4

Outs

ide

Diam

eter

(mm

)

CML

Th

ickn

ess

(mm

)

Wal

l Th

ickn

ess

(mm

)

CML

Bore

(mm

)

SIN

TAKO

TETh

ickn

ess

(mm

)

SKCL

kg/

m

UCC

L g/

m

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6m 9m 12m 13.5m

502 4.5 1.8 12 469 101.5 98.8 0.6 0.9 1.2 1.4502 5 1.8 12 468 107.4 104.8 0.6 1.0 1.3 1.5502 6 1.8 12 466 119.4 116.7 0.7 1.1 1.4 1.6502 8 1.8 12 462 143.1 140.4 0.9 1.3 1.7 1.9508 4.5 1.8 12 475 102.7 100.0 0.6 0.9 1.2 1.4508 5 1.8 12 474 108.7 106.1 0.7 1.0 1.3 1.5508 6 1.8 12 472 120.8 118.1 0.7 1.1 1.4 1.6508 8 1.8 12 468 144.8 142.1 0.9 1.3 1.7 2.0559 4.5 2 12 526 113.6 110.3 0.7 1.0 1.4 1.5559 5 2 12 525 120.3 117.0 0.7 1.1 1.4 1.6559 6 2 12 523 133.6 130.3 0.8 1.2 1.6 1.8559 8 2 12 519 160.1 156.8 1.0 1.4 1.9 2.2

610 4.5 2 12 577 124.2 120.6 0.7 1.1 1.5 1.7610 5 2 12 576 131.5 127.9 0.8 1.2 1.6 1.8610 6 2 12 574 146.1 142.5 0.9 1.3 1.8 2.0610 8 2 12 570 175.1 171.5 1.1 1.6 2.1 2.4610 9.5 2 12 567 196.7 193.1 1.2 1.8 2.4 2.7648 4.5 2 12 615 132.0 128.2 0.8 1.2 1.6 1.8648 5 2 12 614 139.8 136.0 0.8 1.3 1.7 1.9648 6 2 12 612 155.3 151.5 0.9 1.4 1.9 2.1648 8 2 12 608 186.3 182.4 1.1 1.7 2.2 2.5648 9.5 2 12 605 209.3 205.5 1.3 1.9 2.5 2.8660 4.5 2 12 627 134.5 130.6 0.8 1.2 1.6 1.8660 5 2 12 626 142.5 138.6 0.9 1.3 1.7 1.9660 6 2 12 624 158.3 154.4 0.9 1.4 1.9 2.1660 8 2 12 620 189.8 185.9 1.1 1.7 2.3 2.6660 9.5 2 12 617 213.3 209.4 1.3 1.9 2.6 2.9

700 4.5 2 12 667 142.8 138.7 0.9 1.3 1.7 1.9700 5 2 12 666 151.3 147.1 0.9 1.4 1.8 2.0700 6 2 12 664 168.1 163.9 1.0 1.5 2.0 2.3700 8 2 12 660 201.5 197.4 1.2 1.8 2.4 2.7700 9.5 2 12 657 226.5 222.4 1.4 2.0 2.7 3.1700 12 2 12 652 267.9 263.8 1.6 2.4 3.2 3.6711 5 2 12 677 153.7 149.5 0.9 1.4 1.8 2.1711 6 2 12 675 170.7 166.6 1.0 1.5 2.0 2.3711 8 2 12 671 204.8 200.6 1.2 1.8 2.5 2.8711 9.5 2 12 668 230.1 225.9 1.4 2.1 2.8 3.1711 12 2 12 663 272.2 268.0 1.6 2.4 3.3 3.7762 5 2 12 728 164.9 160.4 1.0 1.5 2.0 2.2762 6 2 12 726 183.2 178.7 1.1 1.6 2.2 2.5762 8 2 12 722 219.7 215.2 1.3 2.0 2.6 3.0762 9.5 2 12 719 247.0 242.5 1.5 2.2 3.0 3.3762 12 2 12 714 292.2 287.7 1.8 2.6 3.5 3.9

800 5 2.3 16 758 197.0 191.5 1.2 1.8 2.4 2.7800 6 2.3 16 756 216.2 210.7 1.3 1.9 2.6 2.9800 8 2.3 16 752 254.4 249.0 1.5 2.3 3.1 3.4800 9.5 2.3 16 749 283.0 277.6 1.7 2.5 3.4 3.8800 12 2.3 16 744 330.4 325.0 2.0 3.0 4.0 4.5813 5 2.3 16 771 200.2 194.7 1.2 1.8 2.4 2.7813 6 2.3 16 769 219.7 214.2 1.3 2.0 2.6 3.0813 7 2.3 16 767 239.2 233.7 1.4 2.2 2.9 3.2813 8 2.3 16 765 258.7 253.2 1.6 2.3 3.1 3.5813 9.5 2.3 16 762 287.7 282.2 1.7 2.6 3.5 3.9813 12 2.3 16 757 335.9 330.4 2.0 3.0 4.0 4.5

Outs

ide

Diam

eter

(mm

)

CML

Th

ickn

ess

(mm

)

Wal

l Th

ickn

ess

(mm

)

CML

Bore

(mm

)

SIN

TAKO

TETh

ickn

ess

(mm

)

SKCL

kg/

m

UCC

L g/

m

SINTA

KOTE

® ST

EEL P

IPELIN

E SYS

TEMS

80




6m 9m 12m 13.5m

914 6 2.3 16 870 247.6 241.4 1.5 2.2 3.0 3.3914 7 2.3 16 868 269.6 263.4 1.6 2.4 3.2 3.6914 8 2.3 16 866 291.5 285.3 1.7 2.6 3.5 3.9914 10 2.3 16 862 335.2 329.0 2.0 3.0 4.0 4.5914 12 2.3 16 858 378.7 372.5 2.3 3.4 4.5 5.1960 6 2.3 16 916 260.3 253.7 1.6 2.3 3.1 3.5960 8 2.3 16 912 306.4 299.9 1.8 2.8 3.7 4.1960 10 2.3 16 908 352.4 345.9 2.1 3.2 4.2 4.8960 12 2.3 16 904 398.2 391.7 2.4 3.6 4.8 5.4972 6 2.3 16 928 263.6 257.0 1.6 2.4 3.2 3.6972 8 2.3 16 924 310.3 303.7 1.9 2.8 3.7 4.2972 10 2.3 16 920 356.9 350.3 2.1 3.2 4.3 4.8972 12 2.3 16 916 403.3 396.7 2.4 3.6 4.8 5.4

1016 8 2.3 16 968 324.6 317.7 1.9 2.9 3.9 4.41016 10 2.3 16 964 373.4 366.5 2.2 3.4 4.5 5.01016 12 2.3 16 960 421.9 415.0 2.5 3.8 5.1 5.71035 8 2.3 16 987 330.8 323.8 2.0 3.0 4.0 4.51035 10 2.3 16 983 380.5 373.4 2.3 3.4 4.6 5.11035 12 2.3 16 979 429.9 422.9 2.6 3.9 5.2 5.81067 8 2.3 16 1019 341.2 333.9 2.0 3.1 4.1 4.61067 10 2.3 16 1015 392.4 385.2 2.4 3.5 4.7 5.31067 12 2.3 16 1011 443.5 436.3 2.7 4.0 5.3 6.01085 8 2.3 16 1037 347.0 339.7 2.1 3.1 4.2 4.71085 10 2.3 16 1033 399.2 391.8 2.4 3.6 4.8 5.41085 12 2.3 16 1029 451.1 443.8 2.7 4.1 5.4 6.11125 8 2.3 16 1077 360.0 352.4 2.2 3.2 4.3 4.91125 10 2.3 16 1073 414.1 406.5 2.5 3.7 5.0 5.61125 12 2.3 16 1069 468.1 460.4 2.8 4.2 5.6 6.3

1200 8 2.3 16 1152 384.4 376.3 2.3 3.5 4.6 5.21200 10 2.3 16 1148 442.2 434.1 2.7 4.0 5.3 6.01200 12 2.3 16 1144 499.8 491.7 3.0 4.5 6.0 6.71219 8 2.3 16 1171 390.6 382.3 2.3 3.5 4.7 5.31219 9 2.3 16 1169 420.0 411.7 2.5 3.8 5.0 5.71219 10 2.3 16 1167 449.3 441.0 2.7 4.0 5.4 6.11219 12 2.3 16 1163 507.9 499.6 3.0 4.6 6.1 6.91283 8 2.3 19 1229 439.3 430.6 2.6 4.0 5.3 5.91283 10 2.3 19 1225 501.1 492.4 3.0 4.5 6.0 6.81283 12 2.3 19 1221 562.7 554.0 3.4 5.1 6.8 7.61283 16 2.3 19 1213 685.3 676.6 4.1 6.2 8.2 9.31290 8 2.3 19 1236 441.7 432.9 2.7 4.0 5.3 6.01290 10 2.3 19 1232 503.9 495.1 3.0 4.5 6.0 6.81290 12 2.3 19 1228 565.8 557.1 3.4 5.1 6.8 7.61290 16 2.3 19 1220 689.2 680.4 4.1 6.2 8.3 9.3

1404 10 2.3 19 1346 549.1 539.6 3.3 4.9 6.6 7.41404 12 2.3 19 1342 616.7 607.2 3.7 5.6 7.4 8.31422 10 2.3 19 1364 556.2 546.6 3.3 5.0 6.7 7.51422 11 2.3 19 1362 590.5 580.9 3.5 5.3 7.1 8.01422 12 2.3 19 1360 624.7 615.1 3.7 5.6 7.5 8.41440 10 2.3 19 1382 563.4 553.6 3.4 5.1 6.8 7.61440 12 2.3 19 1378 632.7 623.0 3.8 5.7 7.6 8.51440 16 2.3 19 1370 770.9 761.1 4.6 6.9 9.3 10.41451 10 2.3 19 1393 567.7 557.9 3.4 5.1 6.8 7.71451 12 2.3 19 1389 637.7 627.8 3.8 5.7 7.7 8.61451 16 2.3 19 1381 776.9 767.0 4.7 7.0 9.3 10.5

Outs

ide

Diam

eter

(mm

)

CML

Th

ickn

ess

(mm

)

Wal

l Th

ickn

ess

(mm

)

CML

Bore

(mm

)

SIN

TAKO

TETh

ickn

ess

(mm

)

SKCL

kg/

m

UCC

L g/

m

SINTA

KOTE

® ST

EEL P

IPELIN

E SYS

TEMS

81




6m 9m 12m 13.5m

1500 10 2.3 19 1442 587.2 577.0 3.5 5.3 7.0 7.91500 12 2.3 19 1438 659.5 649.3 4.0 5.9 7.9 8.91500 16 2.3 19 1430 803.6 793.4 4.8 7.2 9.6 10.81575 10 2.3 19 1517 617.0 606.3 3.7 5.6 7.4 8.31575 12 2.3 19 1513 693.0 682.3 4.2 6.2 8.3 9.41575 16 2.3 19 1505 844.4 833.7 5.1 7.6 10.1 11.4

1600 10 2.3 19 1542 626.9 616.0 3.8 5.6 7.5 8.51600 12 2.3 19 1538 704.1 693.3 4.2 6.3 8.4 9.51600 16 2.3 19 1530 858.0 847.2 5.1 7.7 10.3 11.61626 10 2.3 19 1568 637.2 626.2 3.8 5.7 7.6 8.61626 12 2.3 19 1564 715.7 704.7 4.3 6.4 8.6 9.71626 16 2.3 19 1556 872.2 861.2 5.2 7.8 10.5 11.8

1750 12 2.3 19 1688 771.1 759.2 4.6 6.9 9.3 10.41750 16 2.3 19 1680 939.8 927.9 5.6 8.5 11.3 12.7

1829 12 2.3 19 1767 806.3 793.9 4.8 7.3 9.7 10.91829 16 2.3 19 1759 982.8 970.4 5.9 8.8 11.8 13.3

1981 12 2.3 19 1919 874.1 860.7 5.2 7.9 10.5 11.81981 16 2.3 19 1911 1065.6 1052.2 6.4 9.6 12.8 14.4

2159 12 2.3 19 2097 953.5 938.9 5.7 8.6 11.4 12.92159 16 2.3 19 2089 1162.6 1147.9 7.0 10.5 14.0 15.7

Notes: Pipe masses may vary +/- 10 % due to material tolerances

Calculations based on:

Steel shell 0.02466(D-t)t Cement lining 0.00755T(D-2t-T) SINTAKOTE 0.00296Dts

where

D = outside diameter of pipe (mm) t = steel wall thickness (mm) T = cement lining thickness (mm) ts = SINTAKOTE thickness (mm)

Total mass may carry minor rounding error

Outs

ide

Diam

eter

(mm

)

CML

Th

ickn

ess

(mm

)

Wal

l Th

ickn

ess

(mm

)

CML

Bore

(mm

)

SIN

TAKO

TETh

ickn

ess

(mm

)

SKCL

kg/

m

UCC

L g/

m

SINTA

KOTE

® ST

EEL P

IPELIN

E SYS

TEMS

82


table f.4 - manufacturing test Pressure and Rated Pressure for mScl Pipes

114 4.8 8.5 866 6.8 693168 5 8.5 866 6.8 693190 5 8.5 866 6.8 693219 5 8.5 866 6.8 693559 6 5.8 591 4.6 473240 5 8.5 866 6.8 693257 5 8.5 866 6.8 693273 5 8.5 866 6.8 693290 5 8.5 866 6.8 693

324 4.5 7.5 765 6.0 612324 5 8.3 849 6.7 680324 6 8.5 866 6.8 693337 4.5 7.2 735 5.8 588337 5 8.0 817 6.4 653337 6 8.5 866 6.8 693356 4.5 6.8 696 5.5 557356 5 7.6 773 6.1 618356 6 8.5 866 6.8 693

406 4.5 6.0 610 4.8 488406 5 6.7 678 5.3 542406 6 8.0 813 6.4 651406 8 8.5 866 6.8 693419 4.5 5.8 591 4.6 473419 5 6.4 657 5.2 525419 6 7.7 788 6.2 631419 8 8.5 866 6.8 693457 4.5 5.3 542 4.3 434457 5 5.9 602 4.7 482457 6 7.1 723 5.7 578457 8 8.5 866 6.8 693

502 4.5 4.8 493 3.9 395502 5 5.4 548 4.3 439502 6 6.5 658 5.2 526502 8 8.5 866 6.8 693508 4.5 4.8 488 3.8 390508 5 5.3 542 4.3 433508 6 6.4 650 5.1 520508 8 8.5 867 6.8 693559 4.5 4.3 443 3.5 354559 5 4.8 492 3.9 394559 6 5.8 591 4.6 473559 8 7.7 788 6.2 630

610 4.5 4.0 406 3.2 325610 5 4.4 451 3.5 361610 6 5.3 541 4.2 433

610 8 7.1 722 5.7 578610 9.5 7.0 714 5.6 572648 4.5 3.8 382 3.0 306648 5 4.2 425 3.3 340648 6 5.0 510 4.0 408648 8 6.7 680 5.3 544648 9.5 6.6 672 5.3 538660 4.5 3.7 375 2.9 300660 5 4.1 417 3.3 334660 6 4.9 500 3.9 400660 8 6.5 667 5.2 534660 9.5 6.5 660 5.2 528

700 4.5 3.5 354 2.8 283700 5 3.9 393 3.1 315700 6 4.6 472 3.7 377700 8 6.2 629 4.9 503700 9.5 6.1 623 4.9 498700 12 7.7 786 6.2 629711 5 3.8 387 3.0 310711 6 4.6 465 3.6 372711 8 6.1 619 4.9 495711 9.5 6.0 613 4.8 490711 12 7.6 774 6.1 619762 5 3.5 361 2.8 289762 6 4.3 433 3.4 347762 8 5.7 578 4.5 462762 9.5 5.6 572 4.5 458762 12 7.1 722 5.7 578

800 5 3.4 344 2.7 275800 6 4.1 413 3.2 330800 8 5.4 550 4.3 440800 9.5 5.3 545 4.3 436800 12 6.8 688 5.4 550813 5 3.3 339 2.7 271813 6 4.0 406 3.2 325813 8 5.3 542 4.3 433813 9.5 5.3 536 4.2 429813 12 6.6 677 5.3 542813 7 4.6 474 3.7 379

914 6 3.5 361 2.8 289914 7 4.1 422 3.3 337914 8 4.7 482 3.8 385914 10 4.9 502 3.9 402914 12 5.9 602 4.7 482960 6 3.4 344 2.7 275960 8 4.5 459 3.6 367

Outs

ide

Diam

eter

(mm

)

Outs

ide

Diam

eter

(mm

)

Wal

l Th

ickn

ess

(mm

)

Wal

l Th

ickn

ess

(mm

)

Test

Pre

ssur

e (M

Pa)

Test

Pre

ssur

e (M

Pa)

Test

Pre

ssur

e (m

)

Test

Pre

ssur

e (m

)

Rate

d Pr

essu

re

(MPa

)

Rate

d Pr

essu

re

(MPa

)

Rate

d Pr

essu

re

(m)

Rate

d Pr

essu

re

(m)

SINTA

KOTE

® ST

EEL P

IPELIN

E SYS

TEMS

83


table f.4 - manufacturing test Pressure and Rated Pressure for mScl Pipes

960 10 4.7 478 3.8 382960 12 5.6 573 4.5 459972 6 3.3 340 2.7 272972 8 4.4 453 3.6 362972 10 4.6 472 3.7 378972 12 5.6 566 4.4 453

1016 8 4.3 433 3.4 3471016 10 4.4 451 3.5 3611016 12 5.3 542 4.3 4331035 8 4.2 425 3.3 3401035 10 4.3 443 3.5 3551035 12 5.2 532 4.2 4251067 8 4.0 413 3.2 3301067 10 4.2 430 3.4 3441067 12 5.1 516 4.0 4131086 8 4.0 406 3.2 3251086 10 4.1 423 3.3 3381086 12 5.0 507 4.0 406

1124 8 3.8 391 3.1 3131124 10 4.0 408 3.2 3261124 12 4.8 489 3.8 3911200 8 3.6 367 2.9 2941200 10 3.8 382 3.0 3061200 12 4.5 459 3.6 3671219 8 3.5 361 2.8 2891219 9 3.3 339 2.7 2711219 10 3.7 376 3.0 3011219 12 4.4 452 3.5 3611283 8 3.4 343 2.7 2751283 10 3.5 358 2.8 2861283 12 4.2 429 3.4 3431283 16 5.6 572 4.5 458

1290 8 3.3 341 2.7 2731290 10 3.5 356 2.8 2841290 12 4.2 427 3.3 3411290 16 5.6 569 4.5 455

1404 10 3.2 327 2.6 2611404 12 3.8 392 3.1 3141422 10 3.2 323 2.5 2581422 11 3.5 355 2.8 2841422 12 3.8 387 3.0 310

1440 10 3.1 319 2.5 2551440 12 3.8 382 3.0 3061440 16 5.0 510 4.0 408

1451 10 3.1 316 2.5 2531451 12 3.7 379 3.0 3031451 16 5.0 506 4.0 405

1500 10 3.0 306 2.4 2451500 12 3.6 367 2.9 2941500 16 4.8 489 3.8 3911575 10 2.9 291 2.3 2331575 12 3.4 349 2.7 2801575 16 4.6 466 3.7 373

1600 10 2.8 287 2.3 2291600 12 3.4 344 2.7 2751600 16 4.5 459 3.6 3671626 10 2.8 282 2.2 2261626 12 3.3 339 2.7 2711626 16 4.4 451 3.5 361

1750 12 3.0 301 2.4 2411750 16 4.1 419 3.3 336

1829 12 3.0 301 2.4 2411829 16 3.9 401 3.1 321

1981 12 2.7 278 2.2 2221981 16 3.6 370 2.9 2962159 12 2.5 255 2.0 2042159 16 3.3 340 2.7 272

Outs

ide

Diam

eter

(mm

)

Outs

ide

Diam

eter

(mm

)

Wal

l Th

ickn

ess

(mm

)

Wal

l Th

ickn

ess

(mm

)

Test

Pre

ssur

e (M

Pa)

Test

Pre

ssur

e (M

Pa)

Test

Pre

ssur

e (m

)

Test

Pre

ssur

e (m

)

Rate

d Pr

essu

re

(MPa

)

Rate

d Pr

essu

re

(MPa

)

Rate

d Pr

essu

re

(m)

Rate

d Pr

essu

re

(m)

Maximum test pressure = 90% of yield stress of steel, but not greater than 8.5 MPa.

Rated pressure = 72% of yield stress of steel, but not greater than 6.8 MPa.

yield stress of steel = 300MPa for t ≤ 8.0mm, 250MPa for t >8.0mm.

where t is steel wall thickness (mm).

Working pressure is determined by the designer after consideration of the Rated Pressure of the pipe and fittings and taking into account the various factors such as external loads and transient hydrostatic conditions.

SINTA

KOTE

® ST

EEL P

IPELIN

E SYS

TEMS

84


table f.5 - SintalocK® Joint Rated Pressures

324 4.5 300 3.75 4.69324 5 300 4.17 5.21324 6 300 5.00 6.25337 4.5 300 3.61 4.51337 5 300 4.01 5.01337 6 300 4.81 6.01356 4.5 300 3.41 4.27356 5 300 3.79 4.74356 6 300 4.55 5.69406 4.5 300 2.99 3.74406 5 300 3.33 4.16406 6 300 3.99 4.99419 4.5 300 2.90 3.62419 5 300 3.22 4.03419 6 300 3.87 4.83457 4.5 300 2.66 3.32457 5 300 2.95 3.69457 6 300 3.54 4.43457 8 300 4.73 5.91502 4.5 300 2.42 3.03502 5 300 2.69 3.36502 6 300 3.23 4.03502 8 300 4.30 5.38508 4.5 300 2.39 2.99508 5 300 2.66 3.32508 6 300 3.19 3.99508 8 300 4.25 5.31559 4.5 300 2.17 2.72559 5 300 2.42 3.02559 6 300 2.90 3.62559 8 300 3.86 4.83610 4.5 300 1.99 2.49610 5 300 2.21 2.77610 6 300 2.66 3.32610 8 300 3.54 4.43610 9.5 300 4.20 5.26648 4.5 300 1.88 2.34648 5 300 2.08 2.60648 6 300 2.50 3.13648 8 300 3.33 4.17648 9.5 300 3.96 4.95660 4.5 300 1.84 2.30660 5 300 2.05 2.56660 6 300 2.45 3.07660 8 300 3.27 4.09660 9.5 300 3.89 4.86700 4.5 300 1.74 2.17700 5 300 1.93 2.41

700 6 300 2.31 2.89700 8 300 3.09 3.86700 9.5 300 3.66 4.58711 5 300 1.90 2.37711 6 300 2.28 2.85711 8 300 3.04 3.80711 9.5 300 3.61 4.51762 5 300 1.77 2.21762 6 300 2.13 2.66762 8 300 2.83 3.54762 9.5 300 3.37 4.21813 5 300 1.66 2.08813 6 300 1.99 2.49813 7 300 2.32 2.91813 8 300 2.66 3.32813 9.5 300 3.15 3.94914 6 300 1.77 2.22914 7 300 2.07 2.58914 8 300 2.36 2.95914 10 300 2.95 3.69960 6 300 1.69 2.11960 8 300 2.25 2.81960 10 300 2.81 3.52972 6 300 1.67 2.08972 8 300 2.22 2.78972 10 300 2.78 3.47

1016 8 300 2.13 2.661016 10 300 2.66 3.321035 8 300 2.09 2.611035 10 300 2.61 3.261067 8 300 2.02 2.531067 10 300 2.53 3.161085 8 300 1.99 2.491085 10 300 2.49 3.111125 8 300 1.92 2.401125 10 300 2.40 3.001200 8 300 1.80 2.251200 10 300 2.25 2.811219 8 300 1.77 2.211219 9 300 1.99 2.491219 10 300 2.21 2.771283 8 300 1.68 2.101283 10 300 2.10 2.631290 8 300 1.67 2.091290 10 300 2.09 2.621404 10 300 1.92 2.401422 10 300 1.90 2.371440 10 300 1.88 2.34

Pipe

OD

(m

m)

Pipe

OD

(m

m)

Wal

l Th

ickn

ess

(mm

)

Wal

l Th

ickn

ess

(mm

)

Mat

eria

l yS

(MPa

)

Mat

eria

l yS

(MPa

)

SIN

TALO

CK A

OP

(MPa

)

SIN

TALO

CK A

OP

(MPa

)

SIN

TALO

CK

MAO

P (M

Pa)

SIN

TALO

CK

MAO

P (M

Pa)

SINTA

KOTE

® ST

EEL P

IPELIN

E SYS

TEMS

85

aPPendiX g - SintaKote® RePaiR Kit

Starter Repair Kits are available from Pentair Water Solutions. Please contact the Administration office for pricing.

Email: [email protected]

Tel: +61 3 9217 3124

Included are the following items:3 off rolls of emery paper1 off tube of sunscreen1 off piece of mastic for canusa CRP Repair Patch repairs1 off 500 x 500 Canusa Repair Patch1 off 3300 x 500 Canusa ITLS2 off closure patches for Canusa ITLS1 off silicone roller1 off Lino knife1 off Cold chisel1 off bootss knife2 off lengths of hard chalk1 off length of soft chalk1 off blue pen1 off white texta1 off temperature stick (73 deg C)1 off paint brush - 25mm2 off foam swabs1 off Eziline part A1 off Eziline part B1 off LPG torch kit - 4m hose and torch1 off LPG regulator2 off smooth and 2 class bastard1 off heavy duty welders’ gloves2 off safety gloves1 off pair of disposable gloves1 off Handling and Installation Manual1 off MSDS for Eziline part A & B1 off 250mm shifter assortment of clips and cable ties1 off flint gun

SINTA

KOTE

® ST

EEL P

IPELIN

E SYS

TEMS

86

1. Water Supply Code of Australia - WSA Ø3-2011

2. Australian/New Zealand Standard - AS/NZS 2566.2 “Burried flexible pipelines - Part 2: Installation”.

3. SINTAKOTE® Steel Pipelines - Pipeline Installation Quality System.

aPPendiX H - RefeRenceS

SINTA

KOTE

® ST

EEL P

IPELIN

E SYS

TEMS

87

noteS

SINTA

KOTE

® ST

EEL P

IPELIN

E SYS

TEMS

88

noteS

SINTA

KOTE

® ST

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SINTAKOTE Steel PiPeline Sy StemS Handling and inS tallation Handling_Installation Manual... ·...

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Transcript of SINTAKOTE Steel PiPeline Sy StemS Handling and inS tallation Handling_Installation Manual... ·...