Tyco - Sintakote - Design_manual_nov2004edition (2)

SINTAKOTE Steel pipeline systemsDesign Manual

SINTAKOTE Steel pipeline systemsDesign Manual

Tyco Water Regional Marketing Offices

Divisional OfficeTyco Water Pty LtdABN 75 087 415 745 ACN 087 415 745

Regional Marketing OfficesBrisbane39 Silica Street Carole Park 4300

Dursley Road Yennora 2161 PO Box 141 Fairfield New South Wales 1860 Telephone 61 2 9721 6600 Facsimile 61 2 9721 6601 [email protected] www.tycowater.com

PO Box 162 Carole Park Queensland 4300 Telephone 07 3712 3625 Facsimile 07 3271 3128 [email protected]

SydneyDursley Road Yennora 2161 PO Box 141 Fairfield New South Wales 1860 Telephone 02 9721 6600 Facsimile 02 9721 6601 [email protected]

Melbourne60A Maffra Street Coolaroo 3048 PO Box 42 Dallas Victoria 3047 Telephone 03 9301 9115 Facsimile 03 9309 0577 [email protected]

Perth45 Guthrie Street Osborne Park 6017 PO Box 1495 Osborne Park BC Western Australia 6916 Telephone 08 9346 8555 Facsimile 08 9346 8501 [email protected]

Steel Pipeline Systems Design ManualFirst Edition 1992 Second Edition 2003 Third Edition 2004 This manual has been prepared by Tyco Water to assist qualified engineers and contractors in the selection of the Companys 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 Companys 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 qualities and suitability of the products and conditions surrounding each specific installation. 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 representation in this manual are made negligently or otherwise except to the extent it is prevented by law from doing so. The manual is not an offer to trade and shall not form any part of the trading terms in any transaction. Tyco Waters trading terms contain specific provisions which limit the liability of Tyco Water to the cost of replacing or repairing any defective product. SINTAKOTE , SINTAJOINT and SINTAPIPE are registered trademarks. Copyright Tyco Water Pty Ltd This manual is a publication of Tyco Water Pty Ltd, ABN 75 087 415 745 / ACN 087 415 745, and must not be copied or reproduced in whole or part without the Companys prior written consent. This manual is and shall remain as the Companys property and shall be returned to the company on its request. The Company reserves the right to make changes to any matter at any time without notice.

CONTENTS

Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Section 10 Section 11 Section 12 Section 13 Section 14 Section 15 Section 16

Introduction Technical Specifications and Manufacturing Standards Coatings Linings Pipe Data Jointing Systems Fittings Design General Considerations Structural Properties of Pipe Hydraulic Characteristics of Pipe and Fittings Water Hammer Anchorage of Pipelines Structural Design for Buried Pipelines Free Span and Structural Loading Appurtenance Design Typical Installation Conditions

8 12 16 22 26 36 44 48 58 70 80 88 94 102 114 118

Appendices Appendix A Appendix B Appendix C Appendix D Appendix E Glossary SI Conversion Factors Material Properties References Standards Referenced in Text

126 128 132 135 136 137

Introduction

8

section

1

1.1 Steel design manualOur communities today depend heavily on the continual supply of high quality water for both domestic and industrial purposes. For these applications the community requires a pipeline that will deliver good quality water in sufficient quantity and with adequate pressure, year after year. This must be achieved under prevalent operating conditions embracing static and transient operating pressures and external loads acting on the pipeline, including earth pressure and live loads due to vehicular traffic.

Products are also available for other applications including: slurry pipelines, aggressive fluids, and tubular piling and structural applications.

1.4 Installation trainingExtensive research has shown that by following proper installation procedures, Tyco Water Steel Pipeline Systems can readily achieve operational lifetimes of over 100 years. Tyco Water and its predecessors have promoted quality pipeline installation through its SINTAKOTE PIPELINES PROGRAM. This provides training in the installation of steel pipe and accreditation to competent pipeline laying personnel. Most Australian water authorities now regard this as a mandatory competency requirement. Tyco Water Training is a Registered Training Organisation (RTO). The course has been designed to meet some outcomes of the NTIS Unit of Competency UTWNSWS390A/02 Construct/install drains, pipes and associated fittings, and is accredited to the Vocational Education and Training Board (NSW).

Satisfaction of these criteriaTo perform as required the pipeline system must not only be capable of being handled, transported and installed with little or no damage but also must be resistant to degradation or damage through corrosion, ageing and other external effects. The community expects these criteria to be met in the most economical way, that is at minimum cost over the lifetime of the pipeline. The superior material properties of steel, combined with worldclass corrosion protection systems, ensure that Tyco Water Steel Pipeline Systems provide the answer for water supply and many other applications.

1.5 Manufacture of mild steel cement mortar lined (MSCL) pipeTyco Water Pty Ltd manufactures MSCL pipe using the spiral forming method. In this process, a coil of steel having the required width and thickness is placed on the spiral pipe-making machine, where it is uncoiled and fed continuously through the machine. The strip is formed to the required pipe diameter and continuously welded internally and externally using the Submerged Arc Welding process. The welds so produced form a spiral, hence the name of the process. The pipe so formed is then fed onto the output table where it is cut to the length required. The pipe is then removed from the machine to an area where each pipe is inspected. After inspection, the pipe ends are machined square before proceeding to the pipe end-forming machine. Here the ends of the pipe are formed to produce the socket for the SINTAJOINT rubber ring joint or the spigot and socket for the Ball and Socket Joint (B & S). The SINTAJOINT end is formed by rolling the shape on the pipe ends. The socket and spigot of the B & S joint are formed by expansion. Spherical Slip-in Joint ends (SSJ) are formed by expanding and collapsing the ends on specially made dies on the hydrostatic testing machine.

1.2 HistoryThroughout Australia and the rest of the world, steel pipelines have long been used in water supply, particularly where high pressures, difficult laying conditions or security of supply, have required the strength and toughness of steel. Tyco Water and its predecessors have traditionally been at the forefront of developments in the water industry. Today, Tyco Waters products and services cover a broad range of industry needs, offering a total solution approach to its Customers. Tyco Waters operations extend across Australia, South East Asia and the Pacific.

1.3 ApplicationsTyco Water Steel Pipeline Systems, (TWSPS), offers products for all water industry applications, including: potable water systems, industrial water systems, sewage rising mains and trunk sewers.10 | S E C T I O N1

SECTION 1

Introduction

Each pipe is then hydrostatically tested. Water is pumped into the pipe whilst all air is purged out. When the pipe is full of water, the pressure is increased so as to induce a hoop stress in the pipe shell equivalent to 90% of the nominal minimum yield strength (MYS) of the steel that the pipe is made from, as required by AS1579. Note that the maximum pressure that can be applied is limited to 8.5 MPa, as dictated by the pressure test equipment. After testing, the pipe is dried and the external surface is blast cleaned to remove all rust and mill scale prior to application of the external corrosion protection system (SINTAKOTE). Note that for SINTAPIPE, the internal surface of the pipe is also blast cleaned at this stage. The pipe is then placed into a preheat oven where the temperature of the steel is raised to processing temperature. It is then picked up and dipped into a fluidised bath containing polyethylene powder. On contact, the powder melts and fuses to the pipes external surface. This pipe is rotated and held in the bath until the required coating thickness is reached. This is the SINTAKOTE fusion bonding process. For SINTAPIPE, the internal lining and external coating operations are carried out simultaneously. For SSJ and B & S pipes, the external coating is set back from the ends of the pipe to allow for field jointing and welding. In the case of SINTAJOINT pipe, the external coating is carried around the ends of the spigot and socket to actually cover part of the internal surface of the pipe at each end. After coating, pipes are cement mortar lined. The pipe is spun at high speed so as to generate a high g force. This centrifugal force compacts the mortar around the inside surface of the pipe whilst removing excess water from the mortar. The process results in a dense and firm lining. For field assembly the lining is set back from the ends as required by AS1281. After the lining operation the pipe is removed from the machine and placed on curing ramps. Each pipe is fitted with plastic end-caps in order to protect against the formation of shrinkage cracks, caused by rapid drying. The SINTAKOTE is checked to ensure that no damage has occurred and that it is free from holes in the coating, known as holidays. The pipe is stored for a minimum period of four days to ensure adequate cure before dispatch. During this period, the plastic end covers are retained to prevent loss of moisture from the lining. The completed SINTAJOINT pipe is rubber ring jointed, with SINTAKOTE applied externally and around the pipe ends, allowing the cement mortar lining to overlap the SINTAKOTE. The pipe is

Preparation of pipe ends at the end trimming station. completely protected with the factory applied SINTAKOTE and cement mortar lining. It requires no field joint coating or lining. Pipes and fittings are manufactured in accordance with the relevant Australian Standard. Each production plant operates under a certified Quality Assurance system to AS/NZS ISO 9001 / 9002. Tyco Water can also provide other types of coatings and linings, e.g. epoxy paint, seal coatings etc, to suit the clients requirements. Short runs of pipe can also be made using bending rolls to form cans that are then welded together to form specific lengths of pipe. Pipe fittings, such as mitre bends, off-takes, bifurcations etc. are also available. Tyco Water supplies a range of pipe from 114mm to 2500mm OD. The wall thickness ranges from 4mm to 16mm and lengths can be made in 6, 9, 12.2 and 13.5m. Please contact your nearest Regional Marketing Office for further details.SECTION 1

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Technical Specifications & Manufacturing Standards

12

section

2

SECTION 2

Technical Specifications and Manufacturing Standards

2.1 SteelSteel pipe and fittings for water pipe are manufactured in accordance with the following Australian Standards: AS 1594: Hot-rolled steel flat products AS 3678: Hot-rolled structural steel plates, floor plates and slabs Steel pipe for the Water Industry is usually specified in wall thicknesses from 4.0 to 12.7mm. The analysis grades HXA1016 steel to AS1594 are normally used. HXA1016 materials are supplied by the steel maker with prescribed chemical analysis limits. The mechanical property values associated with the chemical analysis have been identified by statistical means and are given in Section 8.5 Table 8.4. For a thickness greater than 12.7mm, steel to AS3678 is usually used with a minimum yield strength (MYS) of 250 MPa. Other grades of steel can be specified provided that the carbon equivalent (CE) calculated by using the following equation does not exceed 0.40%: CE =%C + %Mn + %Cr+%Mo+%V + %Ni+%Cu 0.40% 6 5 15 Refer to AS 1579 for further details.

2.2 Steel pipe manufactureAS 1579: Arc welded steel pipes and fittings for water and waste water. Pipe manufactured by Tyco Water must pass a mandatory hydrostatic pressure test in accordance with AS1579, ensuring fitness for purpose and quality of manufacture.

2.3 SINTAKOTEAS 4321: Fusion bonded medium density polyethylene coatings and linings for pipes and fittings.

2.4 Cement mortar liningAS 1281: Cement mortar lining of steel pipes and fittings.

2.5 SINTAJOINT rubber ringsAS 1646: Elastomeric seals for waterworks purposes.

2.6 Other materials and specificationsOther materials and specifications can be accommodated if required. Please contact your nearest Tyco Water Regional Marketing Office for further details.SECTION 2

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Coatings

16

section

3

3.1 Brief historyA wide variety of systems have been used to provide external corrosion protection of steel water supply pipelines, for both above ground and below ground installations. Above ground treatments have consisted of various types of industrial paints such as inorganic zinc silicates and epoxies. For underground applications bitumen paints were commonly used in the early days. Coal tar enamel became the preferred coating in the 1950s.

Its properties were enhanced by incorporating glass fibre mat and an outer wrapping of coal tar impregnated felt. Coal tar enamel was in common use for underground applications through the 1960s and 1970s and into the early 1980s. Coal tar enamel generally performed well. However there were occasional problems during storage, handling and deterioration in service. Tyco Water carried out extensive research to develop an improved system, the result of which was the introduction of

PropertyCoating Material Colour Service Temperature Range Thermal Stability (100C for 100 days) Bond Strength Tensile Strength at Yield Indentation Hardness Penetration resistance - 23C - 70C

Test standardsAS 4321

Typical test resultsComplies Black: To impart maximum protection against UV radiation when used above ground

AS 4321 AS 4321 AS 4321 AS 4321 ASTM D2240 AS 4321 ASTM C177 AS 4321 AS 4321 AS 4321 (100 days, 23C) IEC 60093 IEC 60243 ASTM G13, 219mm OD coated pipe, av. thickness 1.6mm AS 4321/ASTM G14, 219mm OD coated pipe, 2.3mm thick ASTM D4060 (C17, 1000g, 1000 cycles) AS 4321

-40C to 70C < 35% change in MFI 5-10 N/mm 18 MPa 61 Shore hardness D 0.1mm indentation 0.2mm indentation 0.34 Wm-1 K-1 F50 >100 hrs 940 kg/m3 < 0.1% m/m water absorbed approx. 1019 ohm cm 20kV/mm (on base polymer, without carbon black) No holidays after 10 successive drops

Thermal Conductivity (Compression moulded specimen) Environmental Stress Crack Resistance Density Water Absorption Electrical Volume Resistivity (1000 sec. polarisation, on base polymer) Dielectric Strength (Specimen 3mm thick, on base polymer) Impact Resistance (Limestone drop test) Impact Resistance (Falling tup test) Abrasion Resistance (Tabor) Cathodic Disbondment

Mean impact strength 20J

8mg loss due to abrasion 8-14mm radial disbonded length

Chemical Resistance: SINTAKOTE is resistant to all the normal chemicals, compounds and solutions commonly encountered in water industry applications including muriatic acids, as well as marine organisms and compounds found in aggressive soils. Table 3.1 SINTAKOTE (fusion bonded medium density polyethylene) - Properties & performance18 | S E C T I O N3

SECTION 3

Coatings

SINTAKOTE in 1972. Once the performance of this coating was recognised, coal tar enamel was progressively phased out.

The recommended thickness of the coating varies with the diameter of the pipe. See Table 3.2. The molten SINTAKOTE can be strewn with sand to provide a shear key for concrete encasement when requested. A range of conventional fittings can be coated in a similar manner as the pipe itself to achieve the same high quality finished coating. Quality control is maintained through routine tests for thickness, adhesion and coating continuity.

3.2 SINTAKOTE

SINTAKOTE is a registered trademark. A black polyethylene coating is fusion bonded directly to the steel pipe, hence the coating is also known as Fusion Bonded Polyethylene (FBPE). Properties and performance under various test standards are given in Table 3.1. Features of the coating include: Excellent adhesion High impact and load resistance Excellent chemical resistance High dielectric strength High electrical resistivity Low water absorption Resistance to soil stresses Wide service temperature range - temperatures from minus 40C to plus 70C have no detrimental effect on SINTAKOTE Ability to accept cold bending of the pipe in accordance with AS 2885 without damage to the coating. SINTAKOTE is ideally suited to below ground applications, including installations where pipes must be thrust bored under roads and railways. It is also ideal for sub-sea installations such as the protection of tubular steel wharf piling. SINTAKOTE is supplied in accordance with AS 4321: Fusion-bonded medium-density polyethylene coating and lining for pipes and fittings.

RepairsMinor damage may occur when SINTAKOTE pipe is mishandled. Such damage can be repaired using a particular method suited to the area of the damaged section. Small areas can be repaired by the application of a patch whereas large areas are repaired by the application of tapes or heat shrinkable polyethylene sleeves. Details are given in the SINTAKOTE Steel Pipeline Systems Handling and Installation Reference Manual available from any of our Regional Marketing Offices. Note: Oxygen and acetylene should not be used to heat SINTAKOTE as heating in this way can degrade SINTAKOTE.

Cathodic protectionCathodic protection (CP) is a method of providing secondary corrosion protection to coated pipelines. High-pressure oil and gas pipelines are protected by CP as the danger and costs of leaks are so high that secondary protection is required by statutory authorities. Most water pipelines that utilise SINTAJOINT pipes are not cathodically protected. The choice of cathodic protection for water pipelines is one of strategic importance and cost. When using SINTAJOINT pipe it is likely to be more cost effective not to apply cathodic protection. Normal CP costs include joint bonding cables, anodes, ground-beds, transformer rectifiers and associated installation and maintenance. Minimum thickness

The SINTAKOTE processThe bare steel surface of the pipe is cleaned and profiled by grit blasting to ensure an excellent bond between the steel and the coating. The pipe is then heated in an oven and dipped into a fluidised bath of polyethylene powder that fuses directly onto the heated surface. Pipe outside diameter (Note 1) 273 (250 DN) >273 508 (500 DN)` >508 762 (750 DN) >762 Notes: 1 Nominal pipe sizes are shown in brackets.

Coating 1.6 1.8 2.0 2.3

Lining 1.0 1.0 1.0 1.0 2 See Figure 3.1 for joint region. 3 RRJ available for 324mm OD.

Elastomeric ring joint region (Note 2) (Note 3) 0.8 1.0 1.0

Table 3.2. SINTAKOTE - Coating and Lining Thickness (millimetres)SECTION 3

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CP is however, completely compatible with SINTAKOTE. The high electrical resistivity of SINTAKOTE is maintained during its life due to the very low water absorption of SINTAKOTE. Its high resistance to impact and deterioration whilst in service make it the ideal coating choice for critical installations where CP is deemed essential.

Handling, storing and layingSINTAKOTE pipes should be cradled and packed using appropriate dunnage. The FBPE will remain unaffected when stored above ground over a lengthy period of time due to the inbuilt ultra violet stabiliser, as well as its high resistance to temperature. Because of the strength, toughness and damage resistance of SINTAKOTE the bedding, backfill composition and compaction procedures are not as critical as those for alternative coatings. Please refer to the SINTAKOTE Steel Pipelines Handling and Installation Reference Manual for further details.

Chemical resistanceSINTAKOTE is resistant to all the relevant chemicals, compounds and solutions commonly encountered in water industry applications including muriatic acids, as well as marine organisms and compounds found in aggressive soils.

SINTAKOTE thicknessSINTAKOTE coating and lining thicknesses conform to AS 4321. See Table 3.2 and Fig. 3.1.

Coating

Joint regionLiningJoint reg ion

Coating

Lining

Figure 3.1: Designation of SINTAJOINT joint region.

20 | S E C T I O N

3

SECTION 3

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Linings

22

section

4

4.1 GeneralFerrous potable water pipelines will corrode internally if not protected. The rate of corrosion is generally quite low due to the low conductivity, neutral pH and low dissolved oxygen content of potable water. Internal corrosion does not usually lead to pipe failure, but can result in head loss or reduced flow due to an increase in surface roughness caused by the growth of corrosion products. Water quality can also be a problem due to increased concentrations of iron in the water. The predominant lining used for potable water and sewage rising mains is cement mortar lining. Cement mortar lining is not suitable for sewage pipelines that are septic and produce sulphuric acid. Note that pipelines can be designed to minimise the generation of sulphuric acid (see ref. 7). Pipe with alternative linings, such as SINTAPIPE described in Section 4.3, or Calcium Aluminate (CA) cement mortar lining provide suitable protection against acid attack. Cement mortar linings are often used to convey petroleum products from ships and the pipelines are usually left filled with seawater when not in use. Other common applications include bore field collectors and ground water transmission lines. For high saline applications where total dissolved solids exceed 35,000 ppm or aggressive water conveyance, customers should contact Tyco Water Marketing Offices. Pipe OD (mm) 100 OD 273 762 CML (mm) 9 12 16 19 Tolerance (mm) +/3 4 4 4

273 < OD

762 < OD 1219 1219 < OD 1829

Table 4.1 - Cement mortar lining (CML) thicknesses today as it produces the highest quality lining. It is the method used in all our steel pipe plants. Cement mortar linings provide long-term protection at a low cost and consequently they remain the standard lining for potable water mains.

Mechanism of corrosion protectionCement mortar linings provide active protection of the steel pipe by creating a high pH environment, typically pH12, at the steel-mortar interface. At pH values above approximately 9, a stable hydroxide film is formed on the inside steel surface. While this passive film remains intact no corrosion occurs.

Lining appearanceWhen leaving our pipe manufacturing plants the linings may contain superficial hairline cracks. If the pipes are stored for extended periods, say more than two months, especially in hot weather, drying shrinkage can lead to the formation of larger cracks. For potable water pipelines cracks up to 2mm wide should not be repaired as they will close and heal when immersed in water. When the pipes are rewetted, the mortar typically absorbs up to 8%

4.2 Cement mortar liningHistoryCement mortar has been used to line pipe since the 1840s when it was introduced in France and the USA. The techniques for application took some time to develop and it was not until the 1920s that the process of centrifugal spinning (originally known as the Hume process) came into being. This process allowed the rapid application of linings to the entire pipe surface by placing a mixture of sand, cement and water into the pipe and rotating it at high speed. The centrifugal forces distribute the lining around the pipe circumference and compact it against the pipe wall. At the same time excess water in the mixture migrates to the surface of the lining. After spinning, this excess water is removed leaving a smooth surfaced mortar with a water to cement ratio of 0.25 to 0.40. The high density, low void content and low water content results in a strong, low permeability cement mortar lining.

Chemical species

Tolerable Concentration for SR Cement (mg/L) 5000 max 300 max 30 6.0 min

Tolerable Concentration for CA Cement (mg/L) no limit no limit no limit 4.0 min no limit no limit 10 max

Sulphate, SO42Magnesium, Mg2+ Free aggressive carbon dioxide, CO2 pH Ammonium, NH Calcium, Ca2+ Hydrogen Sulphide, S4+

30 max 1.0 min 0.5 max

Current practiceThe centrifugally spun process remains the preferred lining method24 | S E C T I O N4

Table 4.2 - Chemical resistance of cement mortar linings

SECTION 4

Linings

SINTAKOTE pipe crossing the Bli Bli Bridge in Queensland. moisture and expands, reducing crack widths by around 50%. Further hydration closes the cracks in a process sometimes referred to as autogenous healing. The mechanism of high pH providing protection and the ability of cement mortar to continue to hydrate and cure during service means that minor cracks in the lining can be tolerated. However, for aggressive conveyants the 2mm maximum crack width may need to be reduced. mortar lined pipelines, where the water is aggressive and the flow rate is low, resulting in a long residence time. To overcome this potential problem seal coatings have been developed to restrict leaching from the cement mortar lining. Pipes can be supplied with cement mortar lining and bitumen seal coat if required. This must be specified at time of quotation.

Handling, storing, layingCement mortar lined pipes should be handled with due care. Mistreatment, poor handling and unloading practice can result in lining damage. Details of repair are given in the SINTAKOTE Steel Pipeline Systems Handling and Installation Reference Manual available from any of our Tyco Water Regional Marketing Offices.

Cement mortar lining (CML) thicknessesCement mortar linings are manufactured to the thicknesses and tolerances contained in AS 1281. See Table 4.1.

PerformanceThe dense mortar produced by our centrifugal lining process offers good chemical resistance to potable waters and can also be used in saline and wastewater applications. Cement mortar lining using Sulphate resistant (SR) and Calcium Aluminate (CA) cements are resistant to the water chemistries shown in Table 4.2. Ordinary potable cement performs similarly to SR cement, except the limit on sulphate concentration is reduced to 500 mg/L. Note that CAC should not be used for potable water pipelines. When the water chemistry is outside these limits, please discuss with a Tyco Water Regional Marketing Office.

4.3 SINTAPIPESINTAPIPE is a registered trademark. SINTAKOTE is applied to both the outside and the bore of rubber ring jointed steel pipe to make SINTAPIPE. Possible because of innovation in the fusion bonding processes, it provides a wide range of opportunities for steel pipe options for aggressive water applications. SINTAPIPE properties and performance under various test standards are given in Table 3.1.SECTION 4

Bitumen seal coatHigh pH can develop in water, especially in small diameter cement

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Pipe Data

26

section

5

Grit blasting in preparation for SINTAKOTE application.

5.1 Preferred sizes and dimensionsTable 5.1 contains a comprehensive range of pipe diameters and wall thicknesses supplied by Tyco Water. For details of pipe diameters and wall thicknesses most readily available and for pipe diameters in excess of 2200mm nominal bore, clients are advised to contact Tyco Water Regional Marketing Offices.

where: D = outside diameter of steel shell t = steel wall thickness T = cement mortar lining thickness ts = SINTAKOTE thickness

mm mm mm mm

Steel wall thicknessesPlease note steel wall thicknesses shown in Table 5.1 represent plate thicknesses supplied by the steel maker as preferred thicknesses. Intermediate and greater wall thicknesses can be supplied but these may incur additional costs and longer lead times.

Approximate material densities used in these formulae are: Steel: 7850 kg/m3 Cement mortar: 2400 kg/m3 SINTAKOTE: 940 kg/m3

5.4 Pipe lengthsPipes are normally supplied in 6, 9, 12.2 and 13.4m effective laying lengths. Minimum length is usually 6 metres, such pipes being used to facilitate road crossings in busy areas as well as to allow minor changes in direction without the need to provide fittings. Lengths in excess of 13.5 metres can be manufactured upon request.

5.2 Hydraulic boresHydraulic bores are given in Table 5.1 with CML bores based on mean cement mortar lining thicknesses given in Table 4.1.

5.3 Pipe massesTo calculate masses per metre for pipes with dimensions not included in the tables use the following formulae: Plain steel shell: Cement mortar lining: SINTAKOTE:28 | S E C T I O N5

5.5 Buoyant weights (empty, closed submerged weight)kg/m kg/m kg/m Table 5.2 lists masses of water filled pipes and buoyant weights of pipes. Where buoyant weight values are negative, precautions should be taken against flotation effects on empty pipelines, particularly during construction. The density of water used in the calculation of these tables is 1000 kg/m3.

M1 = 0.02466(D-t)t M2 = 0.00755T(D-2t-T) M3 = 0.00295Dts

SECTION 5

Pipe Data

Section Dimensions Steel Shell OD mm 114 168 168 190 190 219 240 257 273 290 305 324 324 337 337 356 356 406 406 419 419 457 457 457 457 502 502 502 508 508 508 508 559 559 559 559 610 610 610 t mm 4.8 4.5 5 4.5 5 5 5 5 5 5 5 5 6 5 6 5 6 5 6 5 6 5 6 8 10 5 6 8 5 6 8 10 5 6 8 10 5 6 8 CML T mm 9 9 9 9 9 9 9 9 9 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 SK ts mm 1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 2.0 2.0 2.0 2.0 2.0 2.0 2.0

Pipe Bore Steel CML Steel M1 mm 104 159 158 181 180 209 230 247 263 280 295 314 312 327 325 346 344 396 394 409 407 447 445 441 437 492 490 486 498 496 492 488 549 547 543 539 600 598 594 mm 86 141 140 163 162 191 212 229 245 256 271 290 288 303 301 322 320 372 370 385 383 423 421 417 413 468 466 462 474 472 468 464 525 523 519 515 576 574 570 kg/m 12.9 18.1 20.1 20.6 22.8 26.4 29 31.1 33 35.1 37 39.3 47.1 40.9 49 43.3 51.8 49.4 59.2 51.0 61.1 55.7 66.7 88.6 110.2 61.3 73.4 97.5 62.0 74.3 98.6 122.8 68.3 81.8 108.7 135.4 74.6 89.4 118.8

Mass/metre CML M2 kg/m 6.5 10.2 10.1 11.7 11.6 13.6 15.0 16.2 17.3 24.3 25.6 27.4 27.2 28.5 28.4 30.3 30.1 34.8 34.6 36.0 35.8 39.4 39.2 38.9 38.5 43.5 43.3 42.9 44.0 43.9 43.5 43.1 48.7 48.5 48.1 47.7 53.3 53.1 52.7 SK M3 kg/m 0.5 0.8 0.8 0.9 0.9 1.0 1.1 1.2 1.3 1.5 1.6 1.7 1.7 1.8 1.8 1.9 1.9 2.2 2.2 2.2 2.2 2.4 2.4 2.4 2.4 2.7 2.7 2.7 2.7 2.7 2.7 2.7 3.3 3.3 3.3 3.3 3.6 3.6 3.6 Total MTOT kg/m 19.9 29.1 31.0 33.2 35.3 41.0 45.1 48.5 51.6 61.0 64.3 68.4 76.0 71.3 79.1 75.4 83.8 86.4 96.0 89.2 99.1 97.6 108.4 129.9 151.2 107.4 119.4 143.1 108.8 120.8 144.8 168.6 120.3 133.6 160.1 186.4 131.5 146.1 175.1 6m Tonne 0.12 0.17 0.19 0.20 0.21 0.25 0.27 0.29 0.31 0.37 0.39 0.41 0.46 0.43 0.47 0.45 0.5 0.52 0.58 0.54 0.59 0.59 0.65 0.78 0.91 0.64 0.72 0.86 0.65 0.72 0.87 1.01 0.72 0.80 0.96 1.12 0.79 0.88 1.05

Mass/Pipe Pipe Length 9m Tonne 0.26 0.28 0.30 0.32 0.37 0.41 0.44 0.46 0.55 0.58 0.62 0.68 0.64 0.71 0.68 0.75 0.78 0.86 0.80 0.89 0.88 0.98 1.17 1.36 0.97 1.07 1.29 0.98 1.09 1.30 1.52 1.08 1.20 1.44 1.68 1.18 1.31 1.58 1.05 1.17 1.09 1.21 1.19 1.32 1.58 1.84 1.31 1.46 1.75 1.33 1.47 1.77 2.06 1.47 1.63 1.95 2.27 1.60 1.78 2.14 1.45 1.61 1.93 1.47 1.63 1.96 2.28 1.62 1.80 2.16 2.52 1.77 1.97 2.36 12.2m Tonne 13.5m Tonne

Table 5.1 Pipe DataSECTION 5

| 29

Section Dimensions Steel Shell OD mm 610 648 648 648 648 660 660 660 660 700 700 700 700 711 711 711 711 762 762 762 762 800 800 800 800 813 813 813 813 889 889 889 889 895 895 895 895 914 914 914 914 96030 | S E C T I O N

Pipe Bore SK ts mm 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 mm 590 638 636 632 628 650 648 644 640 690 688 684 680 701 699 695 691 752 750 746 742 790 788 784 780 803 801 797 793 879 877 873 869 885 883 879 875 902 898 894 890 948 mm 566 614 612 608 604 626 624 620 616 666 664 660 656 677 675 671 667 728 726 722 718 758 756 752 748 771 769 765 761 847 845 841 837 853 851 847 843 870 866 862 858 916 Steel CML Steel M1 kg/m 148 79.3 95.0 126.3 157.3 80.8 96.8 128.6 160.3 85.7 102.7 136.5 170.2 87.0 104.3 138.7 172.9 93.3 111.9 148.7 185.4 98.0 117.5 156.2 194.8 99.6 119.4 158.8 198.0 109.0 130.6 173.8 216.8 109.7 131.5 175.0 218.2 134.3 178.7 222.9 266.9 141.2

Mass/metre CML M2 kg/m 52.4 56.7 56.5 56.2 55.8 57.8 57.6 57.3 56.9 61.4 61.2 60.9 60.5 62.4 62.2 61.9 61.5 67.0 66.9 66.5 66.1 93.5 93.3 92.8 92.3 95.1 94.8 94.3 93.9 104.3 104.0 103.5 103.0 105.0 104.7 104.3 103.8 107.0 106.5 106.1 105.6 112.6 SK M3 kg/m 3.6 3.8 3.8 3.8 3.8 3.9 3.9 3.9 3.9 4.1 4.1 4.1 4.1 4.2 4.2 4.2 4.2 4.5 4.5 4.5 4.5 5.4 5.4 5.4 5.4 5.5 5.5 5.5 5.5 6.1 6.1 6.1 6.1 6.1 6.1 6.1 6.1 6.2 6.2 6.2 6.2 6.5 Total MTOT kg/m 203.9 139.8 155.4 186.3 217.0 142.5 158.3 189.8 221.1 151.3 168.1 201.5 234.8 153.7 170.8 204.8 238.6 164.9 183.2 219.8 256.1 197.0 216.2 254.5 292.6 200.2 219.8 258.7 297.4 219.3 240.7 283.4 325.9 220.8 242.4 285.3 328.1 247.6 291.5 335.2 378.7 260.3 6m Tonne 1.22 0.84 0.93 1.12 1.30 0.85 0.95 1.14 1.33 0.91 1.01 1.21 1.41 0.92 1.02 1.23 1.43 0.99 1.10 1.32 1.54 1.18 1.30 1.53 1.76 1.20 1.32 1.55 1.78 1.32 1.44 1.70 1.96 1.32 1.45 1.71 1.97 1.49 1.75 2.01 2.27 1.56

Mass/Pipe Pipe Length 9m Tonne 1.84 1.26 1.40 1.68 1.95 1.28 1.42 1.71 1.99 1.36 1.51 1.81 2.11 1.38 1.54 1.84 2.15 1.48 1.65 1.98 2.30 1.77 1.95 2.29 2.63 1.80 1.98 2.33 2.68 1.97 2.17 2.55 2.93 1.99 2.18 2.57 2.95 2.23 2.62 3.02 3.41 2.34 12.2m Tonne 2.49 1.71 1.90 2.27 2.65 1.74 1.93 2.32 2.70 1.85 2.05 2.46 2.86 1.87 2.08 2.50 2.91 2.01 2.24 2.68 3.12 2.40 2.64 3.10 3.57 2.44 2.68 3.16 3.63 2.68 2.94 3.46 3.98 2.69 2.96 3.48 4.00 3.02 3.56 4.09 4.62 3.18 13.5m Tonne 2.75 1.89 2.10 2.51 2.93 1.92 2.14 2.56 2.98 2.04 2.27 2.72 3.17 2.07 2.31 2.76 3.22 2.23 2.47 2.97 3.46 2.66 2.92 3.44 3.95 2.70 2.97 3.49 4.02 2.96 3.25 3.83 4.40 2.98 3.27 3.85 4.43 3.34 3.94 4.53 5.11 3.51

CML T mm 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16

t mm 10 5 6 8 10 5 6 8 10 5 6 8 10 5 6 8 10 5 6 8 10 5 6 8 10 5 6 8 10 5 6 8 10 5 6 8 10 6 8 10 12 65

SECTION 5

Pipe Data

Section Dimensions Steel Shell OD mm 960 960 960 972 972 972 972 1016 1016 1016 1016 1035 1035 1035 1035 1067 1067 1067 1067 1086 1086 1086 1124 1124 1124 1145 1145 1145 1200 1200 1200 1219 1219 1219 1283 1283 1283 1290 1290 1290 1404 t mm 8 10 12 6 8 10 12 6 8 10 12 6 8 10 12 6 8 10 12 8 10 12 8 10 12 8 10 12 8 10 12 8 10 12 8 10 12 8 10 12 8 CML T mm 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 19 19 19 19 19 19 19 SK ts mm 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3

Pipe Bore Steel CML Steel M1 mm 944 940 936 960 956 952 948 1004 1000 996 992 1023 1019 1015 1011 1055 1051 1047 1043 1070 1066 1062 1108 1104 1100 1129 1125 1121 1184 1180 1176 1203 1199 1195 1267 1263 1259 1274 1270 1266 1388 mm 912 908 904 928 924 920 916 972 968 964 960 991 987 983 979 1023 1019 1015 1011 1038 1034 1030 1076 1072 1068 1097 1093 1089 1152 1148 1144 1171 1167 1163 1229 1225 1221 1236 1232 1228 1350 kg/m 187.8 234.3 280.5 142.9 190.2 237.2 284.1 149.4 198.9 248.1 297.1 152.3 202.6 252.8 302.7 157.0 208.9 260.7 312.2 212.7 265.3 317.8 220.2 274.7 329.1 224.3 279.9 335.3 235.2 293.5 351.6 238.9 298.1 357.2 251.5 313.9 376.1 252.9 315.6 378.2 275.4

Mass/metre CML M2 kg/m 112.1 111.6 111.1 114 113.6 113.1 112.6 119.4 118.9 118.4 117.9 121.6 121.2 120.7 120.2 125.5 125 124.5 124.1 127.3 126.8 126.4 131.9 131.4 130.9 134.5 134.0 133.5 141.1 140.6 140.1 143.4 142.9 142.4 179.0 178.5 177.9 180.0 179.5 178.9 196.4 SK M3 kg/m 6.5 6.5 6.5 6.6 6.6 6.6 6.6 6.9 6.9 6.9 6.9 7.0 7.0 7.0 7.0 7.3 7.3 7.3 7.3 7.4 7.4 7.4 7.7 7.7 7.7 7.8 7.8 7.8 8.2 8.2 8.2 8.3 8.3 8.3 8.7 8.7 8.7 8.8 8.8 8.8 9.6 Total MTOT kg/m 306.4 352.4 398.2 263.6 310.3 356.9 403.3 275.7 324.6 373.4 421.9 280.9 330.8 380.5 430.0 289.8 341.2 392.5 443.5 347.4 399.6 451.6 359.7 413.8 467.7 366.6 421.7 476.6 384.4 442.2 499.9 390.6 449.3 507.9 439.3 501.1 562.7 441.7 503.9 565.9 481.3 6m Tonne 1.84 2.11 2.39 1.58 1.86 2.14 2.42 1.65 1.95 2.24 2.53 1.69 1.98 2.28 2.58 1.74 2.05 2.35 2.66 2.08 2.40 2.71 2.16 2.48 2.81 2.2 2.53 2.86 2.31 2.65 3.00 2.34 2.70 3.05 2.64 3.01 3.38 2.65 3.02 3.40 2.89

Mass/Pipe Pipe Length 9m Tonne 2.76 3.17 3.58 2.37 2.79 3.21 3.63 2.48 2.92 3.36 3.80 2.53 2.98 3.42 3.87 2.61 3.07 3.53 3.99 3.13 3.60 4.06 3.24 3.72 4.21 3.30 3.79 4.29 3.46 3.98 4.50 3.52 4.04 4.57 3.95 4.51 5.06 3.98 4.53 5.09 4.33 12.2m Tonne 3.74 4.30 4.86 3.22 3.79 4.35 4.92 3.36 3.96 4.55 5.15 3.43 4.04 4.64 5.25 3.53 4.16 4.79 5.41 4.24 4.87 5.51 4.39 5.05 5.71 4.47 5.14 5.81 4.69 5.39 6.10 4.76 5.48 6.20 5.36 6.11 6.86 5.39 6.15 6.90 5.87 13.5m Tonne 4.14 4.76 5.38 3.56 4.19 4.82 5.44 3.72 4.38 5.04 5.70 3.79 4.47 5.14 5.80 3.91 4.61 5.30 5.99 4.69 5.39 6.10 4.86 5.59 6.31 4.95 5.69 6.43 5.19 5.97 6.75 5.27 6.07 6.86 5.93 6.76 7.60 5.96 6.80 7.64 6.50| 31

SECTION 5

Section Dimensions Steel Shell OD mm 1404 1404 1416 1416 1416 1422 1422 1422 1440 1440 1440 1451 1451 1451 1500 1500 1500 1575 1575 1575 1600 1600 1600 1626 1626 1626 1750 1750 1750 1829 1829 1829 1981 1981 1981 2159 2159 2159 t mm 10 12 8 10 12 8 10 12 8 10 12 10 12 16 10 12 16 10 12 16 10 12 16 10 12 16 10 12 16 10 12 16 10 12 16 10 12 16 CML T mm 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 SK ts mm 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3

Pipe Bore Steel CML Steel M1 mm 1384 1380 1400 1396 1392 1406 1402 1398 1424 1420 1416 1431 1427 1419 1480 1476 1468 1555 1551 1543 1580 1576 1568 1606 1602 1594 1730 1726 1718 1809 1805 1797 1961 1957 1949 2139 2135 2127 mm 1346 1342 1362 1358 1354 1368 1364 1360 1386 1382 1378 1393 1389 1381 1442 1438 1430 1517 1513 1505 1542 1538 1530 1568 1564 1556 1692 1688 1680 1771 1767 1759 1923 1919 1911 2101 2097 2089 kg/m 343.8 411.9 277.8 346.7 415.5 279.0 348.2 417.2 282.5 352.6 422.6 355.4 425.8 566.2 367.4 440.3 585.5 385.9 462.5 615.1 392.1 469.9 625.0 398.5 477.6 635.2 429.1 514.3 684.2 448.6 537.7 715.3 486.0 582.7 775.3 529.9 635.3 845.5 CML M2 kg/m 195.8 195.2 198.1 197.5 197.0 199.0 198.4 197.8 201.5 201.0 200.4 202.6 202.0 200.8 209.6 209.0 207.9 220.3 219.8 218.6 223.9 223.4 222.2 227.7 227.1 225.9 245.4 244.9 243.7 256.8 256.2 255.1 278.6 278.0 276.9 304.1 303.5 302.4

Mass/metre SK M3 kg/m 9.6 9.6 9.6 9.6 9.6 9.7 9.7 9.7 9.8 9.8 9.8 9.9 9.9 9.9 10.2 10.2 10.2 10.7 10.7 10.7 10.9 10.9 10.9 11.1 11.1 11.1 11.9 11.9 11.9 12.5 12.5 12.5 13.5 13.5 13.5 14.7 14.7 14.7 Total MTOT kg/m 549.1 616.7 485.5 553.9 622.1 487.6 556.3 624.7 493.9 563.4 632.8 567.8 637.7 776.9 587.2 659.5 803.6 617.0 693.0 844.5 626.9 704.2 858.1 637.2 715.8 872.2 686.4 771.1 939.8 717.8 806.3 982.8 778.1 874.2 1065.7 848.8 953.6 1162.6 6m Tonne 3.29 3.70 2.91 3.32 3.73 2.93 3.34 3.75 2.96 3.38 3.80 3.41 3.83 4.66 3.52 3.96 4.82 3.70 4.16 5.07 3.76 4.22 5.15 3.82 4.29 5.23 4.12 4.63 5.64 4.31 4.84 5.90 4.67 5.24 6.39 5.09 5.72 6.98

Mass/Pipe Pipe Length 9m Tonne 4.94 5.55 4.37 4.99 5.60 4.39 5.01 5.62 4.44 5.07 5.69 5.11 5.74 6.99 5.29 5.94 7.23 5.55 6.24 7.60 5.64 6.34 7.72 5.74 6.44 7.85 6.18 6.94 8.46 6.46 7.26 8.85 7.00 7.87 9.59 7.64 8.58 10.46 12.2m Tonne 6.70 7.52 5.92 6.76 7.59 5.95 6.79 7.62 6.02 6.87 7.72 6.93 7.78 9.48 7.16 8.05 9.80 7.53 8.45 10.30 7.65 8.59 10.47 7.77 8.73 10.64 8.37 9.41 11.47 8.76 9.84 11.99 9.49 10.66 13.00 10.35 11.63 14.18 13.5m Tonne 7.41 8.33 6.55 7.48 8.40 6.58 7.51 8.43 6.67 7.61 8.54 7.67 8.61 10.49 7.93 8.90 10.85 8.33 9.36 11.40 8.46 9.51 11.58 8.60 9.66 11.78 9.27 10.41 12.69 9.69 10.89 13.27 10.50 11.80 14.39 11.46 12.87 15.70

32 | S E C T I O N

5

SECTION 5

Pipe Data

Section DimensionsSteel Shell OD t mm mm CML T mm SK ts mm

Water Filled MassSteel SKCL shell steel shell +water +water kg/m kg/m

Submerged Weight emptySteel shell kN/m SKCL steel shell kN/m




114 168 168 190 190 219 240 257 273 290 305 324 324 337 337 356 356 406 406 419 419 457 457 457 457 502 502 502 508 508 508 508 559 559 559 559 610 610 610 610 648 648 648 648 660 660

4.8 4.5 5 4.5 5 5 5 5 5 5 5 5 6 5 6 5 6 5 6 5 6 5 6 8 10 5 6 8 5 6 8 10 5 6 8 10 5 6 8 10 5 6 8 10 5 6

9 9 9 9 9 9 9 9 9 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12

1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 2 2 2 2 2 2 2 2 2 2 2 2 2 2

21.5 38.0 39.7 46.3 48.3 60.7 70.5 79.0 87.4 96.7 105.3 116.8 123.5 124.9 131.9 137.3 144.7 172.6 181.1 182.4 191.2 212.7 222.3 241.3 260.2 251.4 262.0 283.0 256.8 267.5 288.8 309.9 305.1 316.9 340.3 363.6 357.4 370.3 395.9 421.4 399.0 412.7 440.0 467.1 412.6 426.6

25.8 44.7 46.4 54.0 55.9 69.7 80.4 89.7 98.7 112.4 121.9 134.5 141.1 143.4 150.3 156.9 164.2 195.1 203.5 205.7 214.4 238.1 247.6 266.5 285.2 279.5 289.9 310.7 285.2 295.8 316.9 337.8 336.8 348.5 371.7 394.8 392.1 404.9 430.3 455.6 436.0 449.6 476.6 503.5 450.3 464.1

0.03 -0.04 -0.02 -0.08 -0.05 -0.11 -0.16 -0.20 -0.25 -0.30 -0.35 -0.42 -0.35 -0.47 -0.39 -0.55 -0.47 -0.79 -0.69 -0.85 -0.75 -1.06 -0.95 -0.74 -0.53 -1.34 -1.22 -0.99 -1.38 -1.26 -1.02 -0.78 -1.74 -1.61 -1.34 -1.08 -2.14 -1.99 -1.70 -1.42 -2.46 -2.30 -2.00 -1.69 -2.56 -2.41

0.1 0.1 0.1 0.0 0.1 0.0 0.0 0.0 -0.1 -0.1 -0.1 -0.2 -0.1 -0.2 -0.1 -0.3 -0.2 -0.4 -0.4 -0.5 -0.4 -0.7 -0.6 -0.4 -0.2 -0.9 -0.8 -0.6 -0.9 -0.8 -0.6 -0.4 -1.3 -1.1 -0.9 -0.6 -1.6 -1.5 -1.2 -0.9 -1.9 -1.8 -1.4 -1.1 -2.0 -1.8

660 660 700 700 700 700 711 711 711 711 762 762 762 762 800 800 800 800 813 813 813 813 889 889 889 889 895 895 895 895 914 914 914 914 960 960 960 960 972 972 972 972 1016 1016 1016 1016 1035

8 10 5 6 8 10 5 6 8 10 5 6 8 10 5 6 8 10 5 6 8 10 5 6 8 10 5 6 8 10 6 8 10 12 6 8 10 12 6 8 10 12 6 8 10 12 6

12 12 12 12 12 12 12 12 12 12 12 12 12 12 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3

454.4 491.7 482.0 519.2 459.7 474.5 504.0 533.4 473.0 488.1 518.1 547.9 537.5 553.7 585.9 617.9 588.3 605.2 639.1 672.7 606.1 623.4 657.8 692.o 715.9 734.8 772.5 809.9 725.0 744.0 781.9 819.6 773.4 812.2 850.7 889.1 847.1 887.8 928.3 968.7 866.8 908.1 949.1 990.0 941.2 984.4 1027.3 1070.1 974.3 499.7 514.4 543.7 572.8 513.7 528.7 558.4 588.1 581.2 597.2 629.2 661.0 648.3 665.1 698.7 732.0 667.2 684.3 718.4 752.3 782.8 801.6 839.0 876.2 792.3 811.2 848.9 886.3 842.1 880.6 918.9 957.0 919.4 959.8 1000.0 1040.1 940.0 981.0 1021.8 1062.4 1017.8 1060.7 1103.3 1145.8 1052.4

-2.09 -1.78 -2.94 -2.77 -2.44 -2.11 -3.04 -2.87 -2.53 -2.20 -3.56 -3.38 -3.02 -2.66 -3.97 -3.78 -3.40 -3.02 -4.12 -3.92 -3.54 -3.15 -5.02 -4.81 -4.39 -3.96 -5.10 -4.88 -4.46 -4.03 -5.12 -4.68 -4.25 -3.82 -5.72 -5.26 -4.80 -4.35 -5.88 -5.41 -4.95 -4.49 -6.49 -6.00 -5.52 -5.04 -6.76

-1.5 -1.2 -2.3 -2.2 -1.8 -1.5 -2.4 -2.3 -1.9 -1.6 -2.9 -2.7 -2.4 -2.0 -3.1 -2.9 -2.5 -2.1 -3.2 -3.0 -2.6 -2.2 -4.0 -3.8 -3.4 -3.0 -4.1 -3.9 -3.4 -3.0 -4.1 -3.6 -3.2 -2.8 -4.6 -4.2 -3.7 -3.3 -4.8 -4.3 -3.8 -3.4 -5.3 -4.8 -4.4 -3.9 -5.6

Table 5.2 SINTAKOTE steel pipe water filled masses and submerged weights of closed and empty pipeSECTION 5

| 33







1035 1035 1035 1067 1067 1067 1067 1086 1086 1086 1124 1124 1124 1145 1145 1145 1200 1200 1200 1219 1219 1219 1283 1283 1283 1290 1290 1290 1404 1404 1404 1416 1416 1416 1422 1422 1422 1440 1440 1440 1451 1451 1451 1500 1500 1500 1575 1575 1575

8 10 12 6 8 10 12 8 10 12 8 10 12 8 10 12 8 10 12 8 10 12 8 10 12 8 10 12 8 10 12 8 10 12 8 10 12 8 10 12 10 12 16 10 12 16 10 12 165

16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19

2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3

1018.2 1062.0 1105.6 1031.3 1076.6 1121.7 1166.7 1112.0 1157.9 1203.7 1184.5 1232.1 1279.5 1225.5 1274 1322.4 1336.3 1387.2 1437.9 1375.7 1427.4 1478.9 1512.5 1566.9 1621.2 1527.8 1582.6 1637.2 1788.7 1848.4 1907.8 1817.4 1877.5 1937.5 1831.8 1892.2 1952.4 1875.3 1936.5 1997.5 1963.9 2025.4 2147.8 2088.0 2151.6 2278.3 2285.3 2352.1 2485.3

1096.0 1139.5 1182.8 1111.8 1156.8 1201.7 1246.4 1193.7 1239.4 1284.9 1269.2 1316.5 1363.6 1311.8 1360.1 1408.1 1426.9 1477.4 1527.9 1467.7 1519.1 1570.3 1625.7 1679.8 1733.8 1641.7 1696.1 1750.4 1912.9 1972.2 2031.4 1942.7 2002.5 2062.1 1957.6 2017.7 2077.6 2002.8 2063.7 2124.4 2092.0 2153.2 2275.0 2220.6 2283.8 2409.9 2424.7 2491.2 2623.6

-6.27 -5.77 -5.28 -7.23 -6.72 -6.22 -5.71 -7.00 -6.49 -5.97 -7.58 -7.04 -6.51 -7.90 -7.36 -6.81 -8.79 -8.22 -7.65 -9.11 -8.53 -7.95 -10.22 -9.60 -8.99 -10.34 -9.73 -9.11 -12.49 -11.82 -11.15 -12.73 -12.05 -11.37 -12.85 -12.17 -11.49 -13.21 -12.52 -11.83 -12.74 -12.05 -10.67 -13.73 -13.02 -11.59 -15.33 -14.58 -13.08

-5.1 -4.6 -4.1 -6.0 -5.5 -5.0 -4.5 -5.8 -5.2 -4.7 -6.3 -5.8 -5.2 -6.6 -6.0 -5.5 -7.4 -6.8 -6.3 -7.7 -7.1 -6.6 -8.5 -7.9 -7.3 -8.6 -8.0 -7.4 -10.6 -9.9 -9.2 -10.8 -10.1 -9.4 -10.9 -10.2 -9.6 -11.2 -10.6 -9.9 -10.8 -10.1 -8.7 -11.7 -11.0 -9.6 -13.2 -12.4 -10.9

1600 1600 1600 1626 1626 1626 1750 1750 1750 1829 1829 1829 1981 1981 1981 2159 2159 2159

10 12 16 10 12 16 10 12 16 10 12 16 10 12 16 10 12 16

19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19

2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3

2353.0 2420.9 2556.2 2424.5 2493.5 2631.1

2494.6 2562.2 2696.9 2568.5 2637.2 2774.0

-15.88 -15.12 -13.60 -16.46 -15.69 -14.14 -19.39 -18.55 -16.89 -21.38 -20.50 -18.76 -25.47 -24.52 -22.63 -30.72 -29.69 -27.62

-13.7 -12.9 -11.4 -14.2 -13.5 -11.9 -17.0 -16.2 -14.5 -18.9 -18.0 -16.3 -22.7 -21.8 -19.9 -27.7 -26.7 -24.7

2780.0 2935.2 2854.4 3009.3 3002.6 3156.8 3019.1 3181.5 3096.9 3258.9 3251.9 3413.2 3506.7 3682.8 3591.0 3766.8 3759.1 3934.2 4123.9 4316.1 4215.8 4407.7 4399.2 4590.5

SK, CML abbreviations for SINTAKOTE and cement mortar lining respectively. Calculations based on: Masses: Steel shell: M1 = 0.02466(D-t)t Cement lining: M2 = 0.00755T(D-2t-T) SINTAKOTE: M3 = 0.00295Dts Pipe Mass = M1 +M2 +M3 Water filled bare pipe: Pipe mass + /4((D-2t)/1000) 2 p Water filled SKCL pipe: Pipe mass + /4((D-2t-2T)/1000)2 p Weights: Buoyant weight bare pipe: (Pipe mass- /4 (D/1000)2 p)g/1000 Buoyant weight SKCL pipe: (Pipe mass- /4 ((D+2ts )/1000)2 )g/1000 where D = outside diameter of pipe t = steel wall thickness T = cement mortar lining thickness ts = SINTAKOTE thickness p = density of water g = gravitational acceleration Total mass may carry minor round-off error. kN/m kN/m mm mm mm mm 1000 kg/m3 9.81 m/s kg/m kg/m kg/m kg/m kg/m kg/m

34 | S E C T I O N

Jointing Systems

36

section

6

6.1 GeneralPipes can be supplied with any of the joint configurations described below. A variety of mechanical jointing systems to suit specialist requirements can also be supplied. Jointing systems for fittings can also be specified in these configurations. They are however, subject to geometrical and practical considerations. Clients are advised to contact Tyco Water Regional Marketing Offices to discuss detailed requirements.

for pipes and fittings. Each joint provides angular deflection up to approximately 3 depending on diameter. See Graph 6.1. Due to its insulating properties, the joint is ideal for applications where induced current may be a design consideration, for example, within power transmission easements.

Deep entry SINTAJOINTTo accommodate abnormal angular rotation and axial displacements, rubber ring joints can be supplied with a modified socket profile featuring a deeper, wider throat. Design Engineers should contact one of Tyco Water Regional Marketing Offices to discuss detailed requirements. An example of this joint application is in mine subsidence areas where ground strain can be high, typically in the range 3 to 7 mm/m.

6.2 SINTAJOINTAdvantages of rubber ring joints (RRJ) over welded joints include faster laying rates, less field plant and maintenance, and speedier backfilling as this can be done immediately the joint has been laid and checked. In the case of SINTAJOINT pipe, no joint corrosion protection is necessary. Therefore minimal excavation at joints is required, allowing trenching to proceed without interruption. See Figure 6.1. SINTAJOINT is available from 324mm to 1626mm outside diameter

Laying SINTAJOINT pipeRecommended practices for laying rubber ring joint steel pipes are provided in the SINTAKOTE Steel Pipeline System Handling and Installation Reference Manual. Design engineers in particular should be familiar with these practices for consideration in design. test point

Figure 6.1 SINTAJOINT rubber ring joint

Figure 6.2 Spherical slip-in joint

Figure 6.3 Ball and socket joint

Figure 6.4 - Butt joint with collar38 | S E C T I O N6

Figure 6.5 - Plain butt joint

SECTION 6

Jointing Systems

6.3 Welded jointsWelded joints ensure 100% structural integrity. Where an internal and external weld is used they can also permit a pneumatic test of the weld integrity in the field during construction. Complete internal and external circumferential welds are necessary however, and a drilled and tapped hole accessing the air space between the welds must also be provided for an air nozzle to be attached. The weld is then daubed with a soap solution and the annulus pressurised to around 100 kPa. The welds are then examined for bubbles of escaping air and rectified if necessary. For large pipelines this test can assure integrity as construction progresses eliminating the time and cost of a major hydrostatic field test. See Figure 6.3 for a typical arrangement. The integrity of spherical slip-in and ball and socket welded joints may be assessed by this test. See our separate Handling and Installation manual for further details.1700

1600

1500 Temporary construction deflection

1400

1300

1200

1100

Spherical slip-in joint (SSJ)OD. Outside diameter in millimetres

Permanent deflection

This pipe joint is available in sizes 168 to 1422mm OD, in wall thicknesses up to 12mm with deflections up to 3 available in the smaller diameters. Deflections are based on proprietary calculations and can be obtained from your nearest Tyco Water Regional Marketing Office. Field welding may be carried out internally as well as externally in pipes large enough to provide adequate internal access. Generally, pipes above 813mm OD will allow this. See Figure 6.2.

1000

900

800

700

Ball and socket joint (B&S)This pipe joint is available in sizes 806mm OD and allows 3 deflection per joint prior to welding. See Figure 6.3.

600

Butt joint with collarSquare end preparation is required. Pipes and collar are easy to align and the configuration is often used in closing lengths. See Figure 6.4. It can also be used for smaller diameter pipes to eliminate internal gaps in cement mortar lining.

500

400

300

Butt jointThe plain butt joint may be satisfactorily welded from one side using a root fill and hot-pass method, if required, provided that the joint is NDT inspected in accordance with AS 1554. Note that pipe ends must be bevelled to achieve a reasonable weld, and the ends of the cement mortar lining must have been prepared as indicated. This method is particularly useful for small diameter pipes where internal reinstatement of the cement mortar lining cannot be performed by hand. See Figure 6.5.200

3.5

3

2.5

2

1.5

1

0.5

Deflection angle in degrees

Graph 6.1 - SINTAJOINT RRJ angular deflectionsSECTION 6

| 39

6.4 Flanged jointsFlanged 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 Table 6.1 Recommended gasket composition for transportation of general domestic liquids including brine and sewage Maximum Maximum Operating Pressure, Temperature, MPa C 1.6 50 3.5 80 Gasket Composition Solid EPDM Rubber 3mm thick Composite fibre 1.5mm thick TEADIT NA1000 C6327 or equivalent)

and removal of valves in SINTAJOINT and welded pipelines and for valve bypass arrangements. 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 Tyco Water 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 but 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 6.7. Where it is not possible or desirable to use o-ring type flanges, Tyco Water recommends the use of raised face steel flanges. See Figure 6.6. The use of flat-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 wholly steel or ductile iron.

TABLE 6.2 - Recommended Bolt Torques for Steel Flanges Class 16 with EPDM Solid Rubber Gaskets Gasket - Full Face 3mm EPDM Solid Rubber for raised face flanges - Ring type 3mm EPDM Solid Rubber for flat face flanges Grade 4.6 Galvanised Steel Bolts & Nuts, or Stainless steel Bolts & Nuts Property Class 50 (min) Estimated Torque Lightly Oiled Galvanised, or Flange DN Pipe OD No. of Bolts mm 100 150 200 225 250 300 350 375 400 450 500 60040 | S E C T I O N6

Well Lubricated Galvanised Steel Studs or Bolts k = 0.15 Nm 50 50 50 50 90 90 175 175 175 175 175 280

Bolt Size

Bolt Tension

Well Lubricated Stainless Steel Studs or Bolts k = 0.22

kN 4 8 8 8 8 12 12 12 12 12 16 16 M16 M16 M16 M16 M20 M20 M24 M24 M24 M24 M24 M27 20 20 20 20 30 30 48 48 48 48 48 68

Nm 75 75 75 75 135 135 255 255 255 255 255 405

114 168 178, 190, 219 235, 240 257, 273 290, 305, 324 337, 356 368 406, 419 457 502, 508, 559 610, 648, 660

Experience has shown that flat-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.

GasketsGaskets 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 6.1 details the recommended type of gasket and bolt 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 Tyco Water Regional Marketing Office.

Flange bolts and assembly torqueBolting used on flanges is usually galvanised steel or stainless

TABLE 6.3 - Recommended Bolt Torques for Raised Face Steel Flanges Class 21 with Compressed Fibre Gaskets Gasket - Full Face 1.5mm TEADIT NA1000 Compressed Fibre. Grade 8.8 Galvanised Steel Studs and Nuts, or Stainless Steel Studs and Nuts, Property class 70 Estimated Torque Lightly Oiled Galvanised, or Flange DN Pipe OD No. of Bolts mm 100 150 200 225 250 300 350 375 400 450 500 600 700 750 800 900 1000 1200 114 168, 178 190, 219 235, 240, 257 257, 273, 290 305, 324, 337 356, 368 406, 419 419 457, 502, 508 559 610, 648, 660 700, 711, 762 800, 813 889 914, 959, 965, 972 1016, 1035, 1067, 1086 1124, 1145, 1200, 1219, 1238, 1290SECTION 6

Well Lubricated Galvanised Steel Studs or Bolts k = 0.15 Nm 100 135 225 290 310 310 405 405 405 505 505 745 795 795 795 1030 1030 1815

Bolt Size

Bolt Tension

Well Lubricated Stainless Steel Studs or Bolts k = 0.22

kN 8 12 12 12 12 16 16 16 20 20 24 24 24 28 28 32 36 40 M16 M20 M20 M24 M24 M24 M27 M27 M27 M30 M30 M33 M33 M33 M33 M36 M36 M39 40 44 75 80 86 86 100 100 100 112 112 150 160 160 160 190 190 310

Nm 145 195 330 425 455 455 595 595 595 740 740 1090 1165 1165 1165 1505 1505 2660

| 41

TABLE 6.4 - Recommended Bolt Torques for O-Ring Steel Flanges Class 35 Gasket - Elastomeric O-Ring Grade 8.8 Galvanised Steel Studs & Nuts, or Stainless steel Studs & Nuts Property Class 70 Estimated Torque Lightly Oiled Galvanised, or Flange DN Pipe OD No. of Bolts Bolt Size Bolt Tension Well Lubricated Stainless Steel Studs or Bolts k = 0.22 mm 300 350 375 400 450 500 600 700 750 800 900 1000 1200 290, 305, 324, 337 337, 356, 368 368, 406, 419 406, 419 457, 502, 508 502, 508, 559 559, 610, 648, 660 660, 700, 711 762, 800, 813 762, 800, 813 889, 914, 959, 965, 972 972, 1016, 1035, 1067, 1086 1124, 1145, 1200, 1219, 1238, 1290 1. 2. 3. 4. 'Lightly oiled' refers to the application of a good quality lubricating oil and is the usual as received condition of fasteners. 'Well lubricated' refers to the application of molybdenum disulphide or Koprkote grease. The estimated torques provided in the table are based on the friction factor (k) indicated. Where other factors apply, alternative torques should be calculated. Required bolt tensions and estimated torques have been assumed using established engineering principles. However, variation in installation procedures may result in different requirements. 40 M39 97 835 570 16 16 16 20 20 24 24 24 28 28 32 36 M24 M27 M27 M27 M30 M30 M33 M33 M33 M33 M36 M36 kN 35 45 45 45 56 56 69 69 69 69 81 81 Nm 185 270 270 270 370 370 505 505 505 505 645 645 Well Lubricated Galvanised Steel Studs or Bolts k = 0.15 Nm 130 185 185 185 255 255 345 345 345 345 440 440

steel. Commercial grade bolts are used with the Class 16 flanges and rubber gaskets while high strength studs and nuts 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. Tables 6.2 to 6.4 may be used as a guide for determining the final torque setting for any flange within the specified range.42 | S E C T I O N6

Special Note: The use of stainless steel bolting has become common on flange joints. While stainless steel may provide an additional benefit from a corrosion protection viewpoint in certain circumstances it also presents certain hazards. Firstly the friction factors on stainless steel exceed those of galvanized steel by 30% to 60%, requiring greater assembly torque. Secondly stainless steel

SECTION 6

Jointing Systems

has a tendency to gall (locking on the threads) and thereby not transmit the applied torque into bolt tension. Galling is not prevented by using only slightly differing grades of stainless steel e.g. 304 and 316 for the nut and bolt. Good lubrication of stainless steel is vital to the successful flange joint installation. Tyco Water recommends the liberal application of Koprkote grease to the threads and between the nut and washer.

types and gasket material can be obtained from Tyco Water. 10. Tighten nuts to 20% of estimated torque using the star pattern; see Figure 6.8. 11. Tighten to 50% of estimated torque using the same tightening sequence. 12. Tighten to 75% of estimated torque using the same tightening sequence. 13. Tighten to 100% 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 influencing 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 m. A torque wrench is most commonly utilised to achieve the required bolt tension, however in critical applications an hydraulic tensioner should be used.

Jointing instructions for flanged joints1.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 (e.g. molybdenum disulphide) to all mating threads, including the nut load bearing face and washer. 4. Align the flanges to be joined and ensure that the components are satisfactorily supported to avoid bending stress on the flanged joint during and after assembly. 5. Insert four bolts in locations 1 to 4 as indicated in Figure 6.8 and position the insertion gasket on the bolts, taking care not to damage the gasket surface. 6. Offer the adjoining flange to the bolts, taking care to maintain support and alignment of the components. 7. Tighten nuts to finger tight and check alignment of flange faces and gasket. 8. Insert the remaining bolts and tighten nuts to finger 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 pipelines maximum pressure (operating/test pressure). Refer to tables 6.2 to 6.4 for recommended torque values. Information on the required bolt torque for other flange

12 8 4 14 10 6Fig 6.6 Raised face type flanges Fig 6.7 Matched o-ring type flanges

16

1

5 9 13 3 7

2

11 15

Figure 6.8 Star pattern tightening sequenceSECTION 6

| 43

Fittings

44

section

7

M

N

P

Mitred Bends

Q

30 min.

dS dTee

S

UAngled Branch Figure 7.1 Typical Fittings Y Piece

7.1 Preferred sizes, dimensions and typical configurationsFittings are normally fabricated from pipe. Pipe wall, coating and lining thicknesses, and outside diameters are therefore in accordance with Table 5.1.Concentric Reducer150mm ~4.5 x (D1 D2) 150mm

Table 7.1, Figure 7.1 and Figure 7.2 depict a range of cost effective fitting configurations manufactured by Tyco Water. Whilst these sizes are preferred, Tyco Water can make any size that is required.

7.2 SINTAJOINT fittingsSINTAJOINT fittings are available in sizes 324mm OD to 1626mm OD and allow construction of a complete rubber ring joint pipeline system. This eliminates welding entirely. In particular, no joint reinstatement or field joint overwrap of any kind is required and over excavation of the trench at joints for wrapping access is unnecessary. Tapers, tees and air valves or scour off-takes are also available.

D1

Eccentric Reducer150mm ~4.5 x (D1 D2) 150mm

D2

7.3 Welded joint SINTAKOTE fittingsMost welded joint fittings are available with SINTAKOTE, fusion bonded polyethylene coating.

D1

D2

Figure 7.2 Typical Reducers46 | S E C T I O N7

Typical fitting dimensions are shown in Table 7.1. Changes in pipeline direction can be achieved by the appropriate combination of joint deflection and specified bends.

SECTION 7

Fittings

7.4 Special fittingsTyco Water can fabricate and supply special fittings in addition to those indicated to suit your specific needs, for example: expansion joints, ring girders and support assemblies and complex fittings like bifurcations and trifurcations. Diameter < 22.5 d mm 200 250 300 350 400 450 500 550 600 650 700 750 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 M mm 300 375 375 450 450 450 450 525 525 525 525 600 600 600 750 750 825 825 825 825 900 900 900 900 900 900o

Technical assistance is readily available on request in connection with any problems relating to pipe specials. Although not illustrated we can also supply plate flanges to suit various specifications. Tee Angle Branch (30 minimum) Q mm 325 350 375 400 425 450 475 525 575 625 675 750 775 825 875 925 975 1025 1075 1125 1175 1225 1275 1325 1375 1425 S mm 250 250 250 250 250 250 300 300 300 300 300 300 300 350 400 400 500 500 500 600 600 600 600 600 600 600 U mm 850 1000 1100 1200 1300 1400 1500 1650 1800 1900 2000 2100 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200 4400 4600 4800o

Mitred Bends = 22.5 to 45 N mm 360 360 380 420 465 485 525 565 610 650 690 710 755 815 900 980 1065 1105 1190 1270 1355 1395 1500 1560 1645 1725o o

Y - Piece (45o) S mm 250 250 250 250 250 250 300 300 300 300 300 300 300 400 400 400 500 500 500 600 600 600 600 600 600 600 U mm 825 890 950 1025 1100 1150 1225 1300 1350 1425 1500 1550 1600 1750 1850 2000 2150 2275 2400 2550 2675 2800 2950 3050 3200 3325

= 45 to 90 P mm 650 650 700 800 900 950 1050 1150 1250 1350 1450 1500 1600 1750 1950 2150 2350 2450 2650 2850 3050 3150 3400 3550 3750 3950

o

o

R1 mm 500 500 550 650 750 800 900 1000 1100 1200 1300 1350 1450 1600 1800 2000 2200 2300 2500 2700 2900 3000 3250 3400 3600 3800

R2 mm 500 500 550 650 750 800 900 1000 1100 1200 1300 1350 1450 1600 1800 2000 2200 2300 2500 2700 2900 3000 3250 3400 3600 3800

Table 7.1 Fitting configurations manufactured by Tyco Water. Note: Mitred bend radii designed to restrict stress concentration at inside leg to max of 1.25 times hoop stress in pipe.

SECTION 7

| 47

Design General Considerations

48

section

8

DESIGN Location Route Topography Geology Flow requirements Future boosting Diameter Velocity Headloss Pressure Water hammer External loads Cover Traffic Water table Bedding Backfill Compaction Jointing Fittings Air valves Isolating valves Scour tees Anchor blocks Product standards Quality AS9001/2 External corrosion Internal corrosion Seasonality Temperature UV radiation Economics Finance Net present value

SUPPLY Availability Lead time Product standards Quality AS9001/2 Delivery period Transport Handling Storage Seasonality

CONSTRUCT Handling Storage Bedding Jointing Backfill Compaction Field test Repairs Temperature UV radiation Seasonality

OPERATE & MAINTAIN Water quality Operating costs Cleaning Air Valves Repairs Spares Availability Cut-ins/branches Exposure Anchor blocks Reinstatement Economics Finance Net present value

Table 8.1- Checklist of typical design factors

8.1 Safe designLong-term safety of buried pipelines will be achieved if, at the design stage, the following are known with a fair degree of confidence: the properties of the pipe material and of the pipe itself, as specified by standards and warranted by the manufacturer. the loads that the pipeline will be subjected to, as determined by adequate design methods, based on accepted theories and experimental evidence. the environment in which the pipeline will operate including its chemical nature and temperature. However, 100% confidence in accessing the conditions above is unachievable at reasonable cost. The Engineer thus uses a design safety factor in matching the pipe minimum strength to the expected loads. The real safety factor of the buried pipeline is usually larger than the design safety factor because: (i) the pipe minimum characteristics are generally exceeded, and50 | S E C T I O N8

(ii) the design method includes criteria which are conservative. Greater confidence in the design and its performance is thus justified knowing the formal factors of safety are associated with minimum product performance criteria and conservative design procedures.

8.2 Check list for pipeline designIn order to establish the diameter and wall thickness of a pipeline it is necessary to consider a number of interrelated factors. In some cases the operating pressure and flow requirements will determine these dimensions. On other occasions such factors as external loading, soil stability and type, conditions of support (above ground, bridge crossings, river crossings) as well as axial forces may influence the calculations and necessitate some local or overall increase in wall thickness. In certain situations the design operating criteria alone may result in a diameter to wall thickness ratio considered too high for mechanical stability of the pipe during manufacture, handling and installation.

SECTION 8


The additional wall thickness specified to overcome this represents a major benefit should a need arise to increase pipeline pressure and boost flow some time after the line has been in service. Integration of the numerous design principles is complicated and requires a systematic approach to optimise the design in terms of performance and cost effectiveness. A comprehensive design will consider factors of pipeline component

supply, construction, operation and maintenance and account for their effect on the viability, benefits and cost of the project. Table 8.1 is a checklist of some factors to consider for a typical pipeline.

8.3 General design procedure for buried pipelines

HYDRAULIC DESIGN OF PIPELINESACTION 1) Define pipeline Route Length Profile Jointing type COMMENTS Several solutions are normally possible and alternatives will need to be assessed financially or economically. Consider demand growth, staging, boosting. Pipeline jointing system RRJ or welded may affect profile, design flexibility and pressure limitation. 2) Trial HGL Identify boundary and intermediate HGL limits of operation. Trial possible HGL'S 3) Solve for diameter, given flow and headloss or flow, given headloss and diameter or headloss, given flow and diameter. 4) Define maximum pressure Add fittings and appurtenance headlosses. Static head Pump shut off head PRV settingSECTION 8

DESIGN MANUAL REFERENCES Section 8.2 and Table 8.1 Section 8.3 Chapter 6 and Table 5.1

Normally set by defined existing limitations: free water surface levels, terrain etc. Ignore fittings losses. Flow velocities generally between 1 and 2 m/s, Headlosses generally 2 to 7 m/km.

Identify optimum alternative. For pumped systems match "system curve" with pump characteristics and optimum duty point.

Chapter 10 - Section 10.1, 10.2. Graph 10.1, examples Section 10.5.

Consider a range of operating conditions. Check HGL always above pipe level.

Fittings losses see Section 10.4 and Table 10.1. Appurtenances Section 16.2. Recommended maximum internal pressures see Table 9.3

| 51

5) Estimate steel wall thickness t = PD/2f Check D/t < 165 for CML pipe, increase it if not, 6) Select available pipe Closest bore Closest steel wall thickness 7) Check water hammer P = 2ft/D or t = PD/2f From simple checks to full computer modelling. Increase t, reselect pipe if necessary.

Maximum static working stress [f = 0.72 MYS] D/t Pmax, increase pipe teq and/or soil modulus E.

Section 13.2

52 | S E C T I O N

8

SECTION 8


12) Determine maximum allowable buckling pressure (qmax) and critical buckling pressure. 13) Calculate design buckling pressure (q) q qmax ?

Consider buried and exposed ring buckling stability.

Section 9.4. Section 13.7.

Consider worst load case for buckling. Usually (dead load + vacuum) or (dead + live load). If q > qmax increase pipe teq and/or soil modulus E.

Section 13.7.

14) Structural design complete Specify pipeline.

Specify pipe dimensions and installation design.

O P E R AT I O N A L C O N S I D E R AT I O N SACTION 15) Grades COMMENTS Consider air entrapment. DESIGN MANUAL REFERENCES Section 8.6

16) Valves

Consider requirements for: Air valves Scour valves Isolating valves

Section 8.7

17) Anchorage of pipelines

Anchorage should be considered for all rubber ring jointed pipelines. Include field test pressure anchorage performance.

Section 12.

18) Cathodic protection

Secondary protection

Section 3.2

8.4 Economic appraisalAs well as the physical aspects of pipeline design a combination of interrelated economic decisions must be taken, including pipeline diameter selection and choice of pipeline material. The objective is usually to minimise total cost (initial cost, operation and maintenance costs) by selecting the alternative that results in the least life-cycle cost. Factors influencing the economic decision include: Initial cost of pipeline components Initial installation costs Cost to increase capacity in future

Maintenance costs Cost of pipeline replacement Initial cost of pumping stations Annual power costs Projected life of pipeline

DCF methodsIt is generally considered that discounted cash flow (DCF) methods should be used in order to provide a rational basis for evaluating and ranking investment options. These DCF methods take account of both the magnitude and timingSECTION 8

| 53

years n 5 10 15 20 25 30 35 40 45 50 55 60 80 100 1 0.95147 0.90529 0.86135 0.81954 0.77977 0.74192 0.70591 0.67165 0.63905 0.60804 0.57853 0.55045 0.45112 0.36971 2 0.90573 0.82035 0.74301 0.67297 0.60953 0.55207 0.50003 0.45289 0.41020 0.37153 0.33650 0.30478 0.20511 0.13803

% Interest Rate or Discount Rate 3 0.86261 0.74409 0.64186 0.55368 0.47761 0.41199 0.35538 0.30656 0.26444 0.22811 0.19677 0.16973 0.09398 0.05203 4 0.82193 0.67556 0.55526 0.45639 0.37512 0.30832 0.25342 0.20829 0.17120 0.14071 0.11566 0.09506 0.04338 0.01980 5 0.78353 0.61391 0.48102 0.37689 0.29530 0.23138 0.18129 0.14205 0.11130 0.08720 0.06833 0.05354 0.02018 0.00760 6 0.74726 0.55839 0.41727 0.31180 0.23300 0.17411 0.13011 0.09722 0.07265 0.05429 0.04057 0.03031 0.00945 0.00295 7 0.71299 0.50835 0.36245 0.25842 0.18425 0.13137 0.09366 0.06678 0.04761 0.03395 0.02420 0.01726 0.00446 0.00115

Table 8.2 - Present value of a single sum

years n 5 10 15 20 25 30 35 40 45 50 55 60 80 100 1 4.8534 9.4713 13.8651 18.0456 22.0232 25.8077 29.4086 32.8347 36.0945 39.1961 42.1472 44.9550 54.8882 63.0289 2 4.7135 8.9826 12.8493 16.3514 19.5235 22.3965 24.9986 27.3555 29.4902 31.4236 33.1748 34.7609 39.7445 43.0984

% Interest Rate or Discount Rate 3 4.5797 8.5302 11.9379 14.8775 17.4131 19.6004 21.4872 23.1148 24.5187 25.7298 26.7744 27.6756 30.2008 31.5989 4 4.4518 8.1109 11.1184 13.5903 15.6221 17.2920 18.6646 19.7928 20.7200 21.4822 22.1086 22.6235 23.9154 24.5050 5 4.3295 7.7217 10.3797 12.4622 14.0939 15.3725 16.3742 17.1591 17.7741 18.2559 18.6335 18.9293 19.5965 19.8479 6 4.2124 7.3601 9.7122 11.4699 12.7834 13.7648 14.4982 15.0463 15.4558 15.7619 15.9905 16.1614 16.5091 16.6175 7 4.1002 7.0236 9.1079 10.5940 11.6536 12.4090 12.9477 13.3317 13.6055 13.8007 13.9399 14.0392 14.2220 14.2693

Table 8.3 - Present value of an annuity54 | S E C T I O N8

SECTION 8


of expected cash costs each year in the life of a project. Cash flows are discounted at a predetermined real discount rate. The resulting present worth of the DCF is the basis for comparing alternatives. For diameter selection total present value of alternatives can be obtained by adding present capital cost to net present value of future costs (eg. annual pumping costs, maintenance, scheme replacement). Table 8.2 enables the calculation of present values of future capital cost: Factors for calculating present value of a single sum. The present value of $1 in n years time, when discounted at interest rate ri per annum is: ri = % interest rate/100 (1+ri ) n where Table 8.3 enables the calculation of present values of annual operating costs.

Yield strength performance of the steel to make the pipe is assured by the hydrostatic test of each pipe after manufacture to 90% MYS (minimum yield strength). The hydrostatic factory test not only proves minimum steel strength but also tests the welding and ultimate fitness for purpose. Steel to other grades and specifications can be supplied if required. See Section 2.1. For pipe that is not hydrostatically tested in accordance with AS 1579, the design pressure rating of the pipe must be included in the design. The wall thickness of pipes that are non-hydrostatically tested shall be no less than 8.0mm. If pipes are not hydrostatically pressure tested, then all welds shall be 100% non-destructively tested in accordance with AS 1554.1, category SP, and the maximum hoop stress at the rated pressure shall not exceed 0.50 of the specified minimum yield stress of the steel. Other typical properties include: Modulus of elasticity: Est = 207000 Linear coefficient of thermal expansion: = 12 x 10-6 Thermal conductivity: k = 47 Density: = 7850 Melting temperature: approx 1520 Poisson ratio: = 0.27 MPa mm/mm/C W/(m C) kg/m3 C

Real discount rateThe discount rate used has a major effect on the result of present value calculations, and various rates should be used to provide a sensitivity analysis on any project. (See Table 8.3 - Present value of an annuity) The present value of $1 per annum for n years when discounted at interest rate ri per annum is: ri = % interest rate/100 (1-(1+ri)-n)/ri The amount per annum to redeem a loan of $1 at the end of n years and provide interest on the outstanding balance at ri per annum can be determined from the reciprocals of values in this table.

8.6 Air entrapmentIn a water supply pipeline air must be evacuated in order for the main to be filled and function properly. Air can be brought into the pipeline under pressure should pump glands or inlet pipe not be properly sealed. Dissolved air can be liberated at points where the pressure is lower, and move along the pipeline to accumulate at high points. The pipeline profile should be designed to facilitate expulsion of air at predetermined high points where a release valve can be located. Entrained air in a pipeline can give rise to: Drop in flow rate through a reduction in bore area caused by Product Standard AS1594 AS1594 AS1594 AS3678 Grade HA1016 HXA1016 HXA1016 250

8.5 Properties of steelSteel water pipe manufactured to AS 1579 is normally manufactured from AS 1594 analysis grade HA1016 & HXA1016 steel coil or flat plate to AS 3678 Grade 250. HA1016 & HXA1016 is supplied by the steel maker with prescribed chemical analysis limits. HA1016 & HXA1016 mechanical property limits are not guaranteed by the steel maker, but the statistical distributions associated with the chemical analysis limits are accurately known from historical data. Minimum mechanical property values associated with these limits have been identified and are included in Table 8.4. Thickness t mm t 6 10, consideration should be given to a reduction in the weight of soil on the pipe. For such an analysis using Marston's theory, designers should consult Spangler and Handy (ref 3) and AS 2566.1.

SECTION 12

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Structural Design for Buried Pipelines

94

section

13

13.1 General considerations and procedureThe following design procedures are based on flexible pipe behaviour under load. Lateral support is generated by the passive resistance of the soil, contributing to the load carrying performance of the pipe. A pipe placed in a trench must be strong enough to withstand all external loads which may act on it. In some instances, particularly when the internal pressure is low, these external loads may determine the wall thickness of the pipe in satisfying ring stiffness requirements.

Material

Unified Soil Classification symbol (see Table 13.2) CL, CH, ML, MH CL, CH, ML, MH GM, SM, GC, SC GU, GW, SW, GP, SP

Weight kN/m3 21 19 18 15

Saturated clay Normal clay Clayey sand Loose granular sand

Table 13.1 - Density of backfill materials Symbol Description

GW Well-graded gravels, gravel-sand mixtures, little or no fines GP Poorly graded gravels, gravel sand mixtures, little or no fines

Performance aspectsThe performance of the selected pipe is checked principally in two ways: 1. Ring deflection by verifying that the unpressurised pipe under trench backfill, other superimposed distributed loads and traffic loads will not suffer excessive ring deflection. 2. Ring buckling by verifying whether the pipe has adequate shell stability or resistance to buckling to resist local external loads and internal vacuum loads. The combined effects of ring bending stress due to external pressures and hoop stress due to internal pressure are generally not significantly greater than the effects of internal pressure alone. As a result, hoop stress only is normally adequate for determination of wall thickness. In addition it may be necessary to assess axial and beam bending loads. In rubber ring joint pipes correctly placed in a trench, the axial and bending loads are small and not usually taken into account. The following methods of load calculation and performance assessment are recommended for their ease of application and proven track record in practice.

GM Silty gravels, poorly graded gravel-sand-silt mixtures GL SW SP SM SC ML CL MH CH OL OH Pt Clayey gravels, poorly graded gravel-sand-clay mixtures Well-graded sands, gravely sands, little or no fines Poorly graded sands, gravely sands, little or no fines Silty sands, poorly graded sand-silt mixtures Clayey sands, poorly graded sand-clay mixtures Inorganic silts & very fine sand, silty or clayey fine sands Inorganic clays of low to medium plasticity Inorganic silts, micaceous or diatomaceous fine sandy or silty soils, elastic silts Inorganic clays of high plasticity, fat clays Organic silts and organic silt-clays of low plasticity Organic clays of medium to high plasticity Peat and other highly organic soils

Table 13.2 - Unified Soil Classification Source: Classification of Soils for Engineering Purposes. ASTM Standard D2487-9, ASTM, Philadelphia, Pa. (1969).

Load calculationCalculation of soil loads is based on Marston's theory (ref 6) for flexible pipe. Calculation of traffic wheel load effects is based on work by Boussinesq (ref 10) and the Bridge Design Code Section Two Design Loads Austroads (1992). It is to be noted that the transient loads from internal vacuum and surface live loadings are not usually considered simultaneously. Loads from groundwater and internal vacuum are hydrostatic in nature and do not generally affect pipe ring deflection, but a check should be made to ensure ring buckling stability of the shell.96 | S E C T I O N

Compaction and effective combined soil modulus EDepending on the ring deflection and surface settlement considerations of the installation, different levels of compaction can be specified to achieve the necessary effective combined soil modulus E. As a guide, non trafficable installations such as in open field would require compaction to achieve 60% density index in cohesionless materials or 90% dry density ratio in cohesive materials. Trafficable installations such as under road pavement may require compaction to achieve 70% density index in cohesive materials or 95% dry density ratio in cohesive soils.

13

SECTION 13

Structural Design for Buried Pipelines

Connecting a cable across a joint on a cathodically protected SINTAJOINT pipeline.

Deflection calculationA variety of methods have been developed for the evaluation of the structural strength of the pipe as well as the external loads acting on the pipe. A popular formula for calculation of pipe ring deflection is that developed by MG Spangler and later modified by Watkins and Spangler at the Iowa State University. Other methods of deflection estimation are available and vary in their degree of sophistication. Some require extensive calculation using computer programmes which require numerous soil parameters to be either estimated or measured in the field for input to the analysis. The degree of sophistication is questionable given the intrinsic variability of soil parameters, the difficulty in their consistent estimation, their often time dependent nature and the propensity for soil-pipe structures to be disturbed during their service life. Generally, the Spangler-Watkins formula is preferred because of its extensive history of successful application, ease of use and understanding.

support, whereas Moores equation is valid only where external soil support is present.

13.2 Design loads due to trench and embankment fillA rapid method of estimating the earth load on a flexible pipe due to trench and embankment fill is to assume that it is equal to the weight of the earth prism directly above the pipe: wg = H where wg = vertical design load pressure at top of pipe due to soil dead load = assessed unit weight of trench fill or embankment fill H = cover, vertical distance between the top of the pipe and the finished surface 10D D = pipe outside diameter For H > 10D results may be conservative.

kPa kN/m3 m m

Ring buckling stabilityThe ring buckling stability check where depth of cover is equal to or less than 0.5m is carried out using Timoshenkos equation. For cover greater than 0.5, the Moore equation, which yields similar factors of safety to those obtained from using the more conventional formulae based on Luschers equation, is adopted. Timoshenkos equation predicts a

Tyco - Sintakote - Design_manual_nov2004edition (2)

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