GS 106-1 PDF

GS 106-1
CEMENT-MORTAR LINED STEEL PIPE

AND FITTINGS
October 1995
Copyright The British Petroleum Company p.l.c.

Copyright The British Petroleum Company p.l.c.
All rights reserved. The information contained in this document is subject to the
terms and conditions of the agreement or contract under which the document was
supplied to the recipient's organisation. None of the information contained in this
document shall be disclosed outside the recipient's own organisation without the
prior written permission of Manager, Standards, BP International Limited, unless
the terms of such agreement or contract expressly allow.
BP GROUP RECOMMENDED PRACTICES AND SPECIFICATIONS FOR ENGINEERING
Issue Date October 1995

Doc. No. GS 106-1 Latest Amendment Date
Document Title
CEMENT-MORTAR LINED STEEL PIPE
AND FITTINGS
Doc. No.
(Replaces BP Engineering Std 106)
RP 32-5
APPLICABILITY
Regional Applicability: International
SCOPE AND PURPOSE
This Guidance for Specification specifies BPs requirements for the lining of steel pipe
and fittings with sulphate-resisting cement-mortar for use with water which would
otherwise corrode the bare pipe.
AMENDMENTS
Amd Date Page(s) Description
___________________________________________________________________
CUSTODIAN (See Quarterly Status List for Contact)

Pipelines & Subsea Engineering, XFE
Issued by:-
Engineering Practices Group, BP International Limited, Research & Engineering Centre
Chertsey Road, Sunbury-on-Thames, Middlesex, TW16 7LN, UNITED KINGDOM
Tel: +44 1932 76 4067 Fax: +44 1932 76 4077 Telex: 296041
CONTENTS
Section Page
FOREWORD........................................................................................................................... iv
1. INTRODUCTION ............................................................................................................... 1
1.1 Scope ..................................................................................................................... 1
2. PIPE AND FITTINGS......................................................................................................... 1

2.1 Pipe ..................................................................................................................... 1
2.2 Fittings ..................................................................................................................... 2
2.3 Joints ..................................................................................................................... 4
3. CEMENT-MORTAR LINING ........................................................................................... 8

3.1 Surface Preparation ........................................................................................................ 8
3.2 Surface Finish ................................................................................................................ 8
3.3 Lining Methods .............................................................................................................. 8
3.4 Mortar Mix ..................................................................................................................... 9
3.5 Lining Thickness ............................................................................................................ 9
3.6 Curing 10
3.7 Repair of Damaged Cement-Mortar Lining................................................................. 10
3.8 Cutting Cement-Mortar Lined Pipe ............................................................................. 11
4. DAMAGE PROTECTION ............................................................................................... 11

4.1 Handling 11
4.2 Transportation .............................................................................................................. 11
4.3 Pipe Ends and Branch Connections ............................................................................. 11
4.4 Installation 12
5. IDENTIFICATION ........................................................................................................... 13
FIGURE 1 ............................................................................................................................... 14
FLANGED CONNECTIONS WITH CLASS 150 FLANGES ......................................... 14
FIGURE 2 ............................................................................................................................... 15
90 BENDS ................................................................................................................... 15
FIGURE 3 ............................................................................................................................... 16
BENDS OTHER THAN 90 ............................................................................................. 16
FIGURE 4 ............................................................................................................................... 17
ECCENTRIC REDUCER ASSEMBLIES ........................................................................ 17
FIGURE 5 ............................................................................................................................... 18
GS 106-1
CEMENT MORTAR LINED STEEL PIPE PAGE i
AND FITTINGS
TEE BRANCH CONNNECTIONS WITH CLASS 150 FLANGES................................ 18
FIGURE 6 ............................................................................................................................... 19
ONE-PIECE SLEEVE JOINT FOR NOMINAL PIPE SIZES 3 INCH UP TO
AND INCLUDING 24 INCH ............................................................................................ 19
FIGURE 7 ............................................................................................................................... 20
HALF-SLEEVE JOINT FOR NOMINAL PIPE SIZES OVER 24 INCH BUT
UNDER 48 INCH .............................................................................................................. 20
FIGURE 8 ............................................................................................................................... 21
HALF-SLEEVE JOINT FOR NOMINAL PIPE SIZES 48 INCH AND LARGER ......... 21
FIGURE 9 ............................................................................................................................... 22
DETAILS OF CUTTING ANGLES FOR TUNGSTEN CARBIDE TIPPED
TOOLS FOR CEMENT-MORTAR LINED STEEL PIPES............................................. 22
FIGURE 10 ............................................................................................................................. 23
MINIMUM BENDING RADII FOR STEEL PIPE .......................................................... 23
FIGURE 11 ............................................................................................................................. 24
3/4 INCH AND 1 INCH BRANCH FITTINGS FOR NOMINAL PIPE SIZES 3
INCH UP TO AND INCLUDING 24 INCH ..................................................................... 24
FIGURE 12 ............................................................................................................................. 25
3/4 INCH AND 1 INCH BRANCHES FOR NOMINAL PIPE SIZES OVER 24
INCH ................................................................................................................... 25
FIGURE 13 ............................................................................................................................. 26
TYPICAL ARRANGEMENT OF CEMENT-MORTAR LINED .................................... 26
STEEL PIPES AND FITTINGS ........................................................................................ 26
FIGURE 14 ............................................................................................................................. 27
TYPICAL CONNECTION BETWEEN CEMENT MORTAR LINED PIPE AND
RUBBER LINED BUTTERFLY VALVE ........................................................................ 27
FIGURE 15 ............................................................................................................................. 28
TYPICAL DESIGN FOR SPECIAL SLEEVE JOINT ..................................................... 28
FIGURE 16 ............................................................................................................................. 29
TYPICAL DESIGN FOR REYNOLDS JOINT ................................................................ 29
APPENDIX A ......................................................................................................................... 30
DEFINITIONS AND ABBREVIATIONS ........................................................................ 30
GS 106-1
CEMENT MORTAR LINED STEEL PIPE PAGE ii
AND FITTINGS
APPENDIX B ......................................................................................................................... 31
LIST OF REFERENCED DOCUMENTS ........................................................................ 31
GS 106-1
CEMENT MORTAR LINED STEEL PIPE PAGE iii
AND FITTINGS
FOREWORD
Introduction to BP Group Recommended Practices and Specifications for Engineering
The Introductory Volume contains a series of documents that provide an introduction to the
BP Group Recommended Practices and Specifications for Engineering (RPSEs). In
particular, the 'General Foreword' sets out the philosophy of the RPSEs. Other documents in
the Introductory Volume provide general guidance on using the RPSEs and background
information to Engineering Standards in BP. There are also recommendations for specific
definitions and requirements.
Value of this Guidance for Specification
This Guidance for Specification provides users with a proven method of protecting steel
pipes from internal corrosion by saline or fresh water. The specification has been updated
based on feedback from both installers and operators of cement-mortar lined pipe systems
Application
This Guidance for Specification is intended to guide the purchaser in the use or creation of a
fit-for-purpose specification for enquiry or purchasing activity.
Text in italics is Commentary. Commentary provides background information which

supports the requirements of the Specification, and may discuss alternative options. It also
gives guidance on the implementation of any 'Specification' or 'Approval' actions; specific
actions are indicated by an asterisk (*) preceding a paragraph number.
This document may refer to certain local, national or international regulations but the
responsibility to ensure compliance with legislation and any other statutory requirements lies
with the user. The user should adapt or supplement this document to ensure compliance for
the specific application.
Specification Ready for Application
A Specification (BP Spec 106-1) is available which may be suitable for enquiry or
purchasing without modification. It is derived from this BP Group Guidance for
Specification by retaining the technical body unaltered but omitting all commentary,
omitting the data page and inserting a modified Foreword.
Principal Changes from Previous Edition
1. This document has been re-written in the new GS format (original document was BP
Standard 106).
2. The cement-mortar curing time has been reduced from 28 to 7 days.
GS 106-1
CEMENT MORTAR LINED STEEL PIPE PAGE iv
AND FITTINGS
3. The original Standard 106 specified the application of cement-mortar to lengths of
revolving pipe. This specification now allows for other methods of application
whereby the pipe lengths are stationary.
4. This specification describes additional methods of joining lengths of cement-mortar

lined pipe which allows for installation by pulling.
Feedback and Further Information
Users are invited to feed back any comments and to detail experiences in the application of
BP RPSE's, to assist in the process of their continuous improvement.
For feedback and further information, please contact Standards Group, BP International or
the Custodian. See Quarterly Status List for contacts.
GS 106-1
CEMENT MORTAR LINED STEEL PIPE PAGE v
AND FITTINGS
1. INTRODUCTION
1.1 Scope
This document specifies BPs requirements for the lining of steel pipe
and fittings with sulphate-resisting cement-mortar for use with saline
and fresh water, where analysis shows that the water would otherwise
corrode the bare pipe. In some applications, e.g. tanker ballast or
produced water, the pipe may also contain hydrocarbons.
Its use is limited to the following pressure and temperature ranges:
(a) Pressures within class 150 flange rating as defined by ANSI

B16.5.
(b) Temperatures between 0 and 90C.
1.2 The specification does not limit the maximum pipe size which may be
lined and is equally applicable to onshore plant and offshore platform
piping as well as onshore and offshore pipelines.
2. PIPE AND FITTINGS
2.1 Pipe
2.1.1 Pipe shall be either:
(a) API Spec 5L Grade A or B, seamless.

or
(b) Automatic electric fusion welded, to API 5L Grade B,

longitudinal seam submerged arc welded.
All sizes of pipe shall be ordered with square-cut ends unless it is to be

butt welded.
* The choice of seamless or welded pipe shall depend on availability and

cost. The use of an alternative, eg. electric welded or spirally-welded
pipe, shall be subject to approval by BP.
2.1.2 The design and specification of pipe material and wall thickness shall
take account of the effect on the lining of deflections due to handling,
transportation and installation. Refer also to Clause 2.1.4 and Section
4, Damage Protection.
2.1.3 Lined sections of pipe shall be joined by either sleeve type or Reynolds
type joints, except where a flanged joint would nornally be used.
Alternatively, the lining may be applied to butt welded pipe strings or
GS 106-1
CEMENT MORTAR LINED STEEL PIPE PAGE 1
AND FITTINGS
insitu lengths of linepipe. Jointing methods are described in section
2.3.
2.1.4 The minimum pipe wall thickness for systems within the ANSI B16.5
Class 150 rating shall be as detailed below. These wall thicknesses
may be increased if necessary to overcome difficulties in handling,
transportation and installation.
Class 150 rating Wall thickness
3 inch to 6 inch NPS Standard (Schedule 40)
8 inch to 18 inch NPS Schedule 20
20 inch to 40 inch NPS 9.5 mm
42 inch NPS and above To be calculated
2.1.5 The ends of longitudinally welded pipe which are to be fitted with a
sleeve joint shall have the outside weld ground flush with the surface
of the pipe for a distance of half the sleeve length plus 25 mm.
2.2 Fittings
2.2.1 Welded assemblies shall comply with BP Group GS 118-5 and may
use fittings to one of the following standards.
(a) ANSI B16.9, made from carbon steel to ASTM A 234 with
carbon content restricted to 0.25% maximum.
(b) BS 1640 Part 3, made from materials to the applicable

standards listed below.
Seamless pipe ASTM A 106 Grade A or B

(with carbon contentrestricted to 0.25%
maximum)
Rolled Plate BS 1501-161 Grade 430
Forgings ASTM A 105 (with carbon content

restricted to 0.25%maximum)
BS 1503-164-490
Final assembly dimensions shall be as shown in Figures 1, 2, 3, 4, 5

and 11.
GS 106-1
AND FITTINGS
2.2.2 Flanges up to and including 24 inch NPS shall comply with ANSI
B16.5 or BS 1560 Part 2.
Flanges over 24 inch NPS should comply with API 605. Alternatively,
for sizes over 24 inch NPS up to and including 48 inch NPS, flanges in
accordance with BS 3293 may be used. However the use of BS 3293
shall be subject to check calculation to ensure the suitability of the
design, taking account of the hydrostatic test pressure.
If flanges in a non-standard size are required they shall be regarded as

special items.
Flanges may be forged from material selected from the following

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

maximum
(b) BS 1503-164-490
2.2.3 Flanges may be either weld-neck or slip-on.
2.2.4 Where a rubber-lined butterfly valve (flanged or wafer type) is to be

fitted in a cement-mortar lined pipe system, the pipe flanges shall be
flat-faced in order to avoid damage to the valve lining. See Figure 14.
2.2.5 Branch connections below 2 inch NPS shall consist of socket welded
or screwed 3000lb half-couplings in general accordance with ANSI
B16.11 or BS 3799 and made from stainless steel to BS 1503
Reference Nos. 316S13 or 320S33. They shall be welded to the pipe
in accordance with BP Group GS 118-7 as it applies to austenitic
stainless steel, using austenitic electrodes to BS 2926 Composition
code 20.9.3 with electrode covering Type R. The branch size shall be
selected from those shown in Figures 11 and 12.
If possible the branch connections shall be fitted to the pipe before the cement-
mortar lining is applied.
2.2.6 Welded joints within assemblies, for example eccentric reducers to

Figure 4, shall be in accordance with BP Group GS 118-5. The
terminal ends shall be cut at right-angles to the pipe axis and after
completion of all welding, out-of-roundness shall be within the limits
specified by API Spec 5L.
2.2.7 Where pulled bends to Figure 10 are used, the selected overall
dimensions shall permit lining by hand trowelling. The forming of
pulled bends prior to lining shall be in accordance with BP Group GS
118-5.
GS 106-1
AND FITTINGS
2.3 Joints
2.3.1 General
Pipes which have been cement-mortar lined cannot be butt welded

together in the normal way as the mortar adjacent to the weld will be
damaged by heat. However there are several types of joint design
available to suit particular applications and these are described below.
The normal method of joining lengths of lined pipe shall be by sleeve
joints and these are described below and in Figures 6, 7 and 8.
Flanges shall also be used where necessary, for example at pumps and
valves.
Pipe lengths may also be butt welded into strings prior to lining. The
length of welded pipe string which can be successfully lined will
depend on the diameter and lining technique used.
After the pipe strings have been lined they shall be joined, either by
sleeve joints or by Reynolds joints, both of which are described below.
All joints described in this document shall be designed in accordance

with ASME B31.3.
2.3.2 Sleeve Joints
2.3.2.1 General
(a) Sleeve joints shall be of the following types:
(i) For pipes 3 inch NPS up to 24 inch NPS inclusive, a

one-piece sleeve joint to Figure 6 shall be used. See
also 2.3.2.2.
(ii) For pipes over 24 inch NPS but under 48 inch NPS, a
half-sleeve joint to Figure 7 shall be used.
(iii) For pipes 48 inch NPS and over, a half-sleeve joint to

Figure 8 shall be used.
(b) Pipe used for sleeves shall be in accordance with 2.1.1 or 2.2.1
(b).
(c) Plate used for sleeves shall be in accordance with BS 4360

Grade 43B or BS 1501-161 Grade 430.
(d) In no case shall the radial weld gap between the pipe and sleeve
of an assembly exceed 3 mm.
GS 106-1
AND FITTINGS
(e) Any internal welds of sleeves shall be ground flush without
undercutting the parent metal.
(f) Sleeves shall be fabricated in accordance with BP Group GS

118-5.
(g) During assembly of a welded sleeve, with pipe or fitting, the

weld should be located at least 90 degrees clear of any adjacent
longitudinal weld.
(h) Care shall be taken when welding on a sleeve, that the inside of
the pipe is not heated sufficiently to damage the lining.
2.3.2.2 Sleeves for Pipes 3 inch NPS up to 24 inch NPS Inclusive.
(a) Sleeves for the full range of pipe sizes may be manufactured by
machining the bore of pipe, of suitable wall thickness, to the
dimensions specified in Figure 6. Alternative methods of
manufacture are given in 2.3.2.2 (b) and (c) below for specific
ranges of pipe sizes.
(b) For joining lined pipes up to and including 8 inch NPS, sleeves
shall be of seamless or welded pipe selected from the size and
thickness ranges listed in API Spec 5L or ASTM A 106 as
appropriate and as specified in Figure 6.
To ensure that the radial weld gap between pipe and sleeve is in
accordance with Figure 6, the pipe for sleeves shall be selected
to suit the pipe to be used for line pipe or fittings.
The dimensional tolerances specified in API Spec 5L and ASTM A 106

necessitate selection by measurement of delivered pipe. Selection by
reference to listed nominal sizes is not possible.
(c) For joining pipes 10 inch NPS up to and including 24 inch

NPS, the sleeves shall be manufactured by using any of the
following materials and methods, which are listed in order of
preference.
(i) Seamless pipe selected as in 2.3.2.2 (b).
(ii) Welded pipe selected as in 2.3.2.2 (b).
(iii) Seamless pipe of the next size larger than the pipe the
sleeve is to join, reduced to the required internal
diameter by the removal of a longitudinal strip, rolling
to size and finally welding.
(iv) Welded pipe reduced as in 2.3.2.2 (c) (iii). The strip

removed should preferably be at least 90 degrees clear
GS 106-1
AND FITTINGS
of the original pipe weld and in no case shall the
separation between the original weld and a new weld be
less than 150 mm.
Where a strip including the original weld is removed,

the width of strip shall extend at least 6 mm from each
side of the original weld.
(v) Fabricated from plate, with a single weld.
2.3.3 Special Joints
2.3.3.1 General
Special joints shall be used for applications outside the capability of

normal sleeve joints as described in 2.3.2 above. The common
application for a special joint is where a pipeline is installed by pulling
and the sleeve joint fillet weld has insufficient strength to withstand the
pulling force.
2.3.3.2 Special Sleeve Joints
Where the pipeline pulling force is too high for a normal sleeve joint
weld, the joint may be strengthened by increasing the welded length,
for example by castellation, as shown in Figure 15.
2.3.3.3 Reynolds Joints
Another method of increasing the joint strength is the use of a

Reynolds joint. This type of joint, shown in Figure 16, allows the lined
pipe lengths to be butt welded without damaging the lining.
2.3.4 Jointing Material for the Lining at Sleeve Joints
2.3.4.1 For joints in pipes 3 inch NPS up to and including 24 inch NPS (Figure
6), an epoxy pipe jointing compound system shall be used.
An example of an epoxy pipe jointing compound is Peridite. This compound was

developed specifically for this application and can be obtained from Acalor
Protective Materials Limited, Northampton, UK. It consists of PS3654 Base, PZ2469
Hardener and PZ2470 accelerator.
2.3.4.2 For joints in pipes over 24 inch but under 48 inch NPS (Figure 7), an
epoxy pipe jointing compound is preferred, but cement-mortar may be
used as an alternative.
2.3.4.3 For joints in pipe 48 inch NPS and larger (Figure 8), cement-mortar
shall be used with reinforcement as shown.
GS 106-1
AND FITTINGS
The cement-mortar joint mix shall consist of equal parts by weight of
sulphate-resisting Portland cement generally complying with the
requirements of BS 4027 and clean fine sand, mixed with clean fresh
water.
The sand shall generally comply with the requirements of grading limit
F in Table 5 of BS 882, except that the maximum size of aggregate
shall not exceed one third of the thickness of the lining. To meet this
latter requirement, any additional sieving shall employ sieves
complying with BS 410.
2.3.4.4 The exact proportions of the jointing ingredients and the advantages of
using a wetting agent with cement-mortar, shall be determined by the
results obtained by trial application in the field.
2.3.4.5 Only enough of the jointing material shall be prepared at one time for
two hours use with a cement mix or four hours use with an epoxy pipe
jointing compound. Mixes and compounds shall not be used if they
have taken their initial set.
2.3.4.6 Where the joint is made with a cement mix, this shall be cured by
maintaining it in a moist condition as called for in 3.7.3.
2.3.5 Procedure for Welding Sleeve Joints on Site
2.3.5.1 The joint faces shall be smooth, square cut and free from any surplus
cement-mortar from the lining operation. The unlined areas shall be
cleaned thoroughly and if degreasing is required, a strong detergent
solution shall be used followed by a clean fresh water rinse.
2.3.5.2 When an epoxy pipe jointing compound is to be used, the joint faces
shall be dry and dust-free and the compound shall be applied with a
small trowel or spatula. When cement-mortar mix is to be used, the
joint faces shall be dust-free and moistened with clean fresh water.
Immediately after moistening, the cement-mortar mix shall be applied
using a small trowel.
2.3.5.3 With a sleeve joint to either Figure 6 or Figure 7, the thickness of the
jointing material shall be kept to a minimum and all surplus material
shall be removed as far as practicable flush with the bore of the pipe.
However, sufficient jointing material shall be used to ensure that all
voids are filled.
2.3.5.4 For pipes 3 inch NPS up to and including 24 inch NPS using a sleeve
joint (Figure 6), the joint faces of the mating pipe ends shall be pulled
together, using a suitable mechanical means which shall ensure that the
pipe ends remain in this position until the tack weld has been applied.
After tacking, the fillet welds shall be applied using the conventional
uphand technique, with electrodes to BS 639 not exceeding 4 mm
diameter. The current values employed and the size of the runs of
GS 106-1
AND FITTINGS
weld metal deposited shall be such as to minimise the heat input and
interpass temperature.
2.3.5.5 For pipes over 24 inch NPS the lining joint and welded joint shall be
completed as shown in Figure 7 or Figure 8 as applicable. The
longitudinal seam in the half-sleeve joints shown in Figures 7 and 8
shall be located for welding on the horizontal diameter of the pipe and
the same precautions as specified in 2.3.5.4 for fillet welds shall be
observed in order to minimise heat input and interpass temperature.
Fillet welds shall be applied using the same technique as in 2.3.5.4 to
ensure that the cement-mortar lining is not affected. For joints to
Figure 8, the unlined area shall be filled, after the pipe has cooled, with
a cement-mortar jointing mix with steel mesh reinforcement, generally
as described in 2.3.5.1 and 2.3.5.2
The final surface shall be smooth, hard and flush with the lined pipe.
Any imperfections in the internal lining shall be repaired, as described
in 3.7.
3. CEMENT-MORTAR LINING
3.1 Surface Preparation
3.1.1 The surfaces to be lined shall be cleaned immediately before the

mortar is applied. Scale, rust and debris as well as all coatings of dirt,
oil and grease shall be removed.
3.1.2 For lining methods where the pipe revolves, pipe rotation must be
concentric. For longitudinally welded pipe, any protruding weld metal
in contact with the rotating machine rollers must be ground flush with,
but not below, the pipe surface.
3.2 Surface Finish
The interior surface of the lining shall be smooth and flat with an even
distribution of sand and cement throughout the lining thickness.
3.3 Lining Methods
3.3.1 Pipe
Where practicable the lining shall be applied by either the centrifugal

process, whereby the pipe is stationary, or by a process which includes
rotating the pipe.
If the centrifugal method is used, the pipe may be lined either as

individual joints, as strings of multiple joints or as an insitu length of
linepipe, any of which may include bends. However the degree of
bend which may be included will depend on the pipe diameter.
GS 106-1
AND FITTINGS
When the lining is to be applied by the pipe rotation method, the length
of pipe must be fabricated to within the maximum and minimum
lengths which can be accommodated in the lining machine. Pipe
lengths shorter than this minimum may be butted or flange-bolted
together before lining.
3.3.2 Special Fittings
Special fittings shall be such as to permit lining by hand trowelling.

As a guide, the maximum length of pipe that can be readily hand lined
is 150 mm for 3 inch, 4 inch and 6 inch NPS, and 450 mm for 8 inch to
24 inch NPS.
3.4 Mortar Mix
3.4.1 The mortar shall be a mixture of the following:
(a) One part by weight of sulphate-resisting Portland cement

generally complying with the requirements of BS 4027 or
equivalent.
(b) One part by weight of clean fine sand, generally complying

with the requirements of BS 882, Table 5, grading limit F, or
equivalent, except that the size of any aggregate present must
not be greater than one third of the thickness of the lining. If
additional sieving is required to meet this latter requirement,
the sieve shall comply with BS 410, or equivalent.
(c) Clean fresh water with the sulphate and chloride contents
limited in accordance with BS 3148 or equivalent.
3.4.2 The ambient temperature during application of the lining shall be

between 5 and 35C in accordance with BS 8110 or equivalent.
3.4.3 The mortar shall be mixed to a consistency suitable for bonding to the
pipe surface.
3.4.4 Mortar which has attained it's initial set shall not be used.
3.5 Lining Thickness
3.5.1 The lining shall be square cut and flush with the pipe end or, when
internal field welds are to be made, prepared in accordance with Figure
8. The lining thickness shall be as given below.
Nominal Nominal Tolerance

Pipe Size inches Lining Thickness
GS 106-1
AND FITTINGS
3&4 5 mm }
}+ 1.5 mm -1 mm
6, 8 & 10 6.5 mm }
12, 14 & 16 8 mm }
}+3 mm -1 mm
18, 20 & 22 10 mm }
24 and over 11 mm +5 mm -0
3.5.2 Where a wafer butterfly valve is installed in cement-mortar lined pipe,

the valve disc must not foul the lining. If necessary the lining at the
flange face shall be chamfered in accordance with Figure 14.
3.6 Curing
3.6.1 Curing of the lined pipe and fittings shall continue for an adequate
period, normally at least seven days, before they are moved. During
the curing period the lining shall be maintained in a moist atmosphere
and at a temperature between 10C and 50C. The lining shall be
regularly inspected and water added to aid curing, if required.
3.6.2 When curing is complete the lining shall be inspected to ensure the
surface is clean, smooth and flat. A mandrel or disc shall be passed
through the pipe bore to check that the lining thickness is within the
required tolerance.
3.7 Repair of Damaged Cement-Mortar Lining
3.7.1 A pipe surface that has been exposed by spalling or cracking of the
lining shall be cleaned in accordance with 2.3.5.1.
3.7.2 When an epoxy pipe jointing compound is to be used for the repair, the
surfaces shall be dry and dust-free and a coating of the compound shall
be applied with a small trowel or spatula. When cement-mortar mix is
to be used, the surfaces shall be dust-free and moistened with clean
fresh water. Immediately after moistening, the cement-mortar mix
shall be applied using a small trowel. If necessary a brush can be used
for "feathering in" the surface edges of the repair.
3.7.3 Where cement-mortar is used for the repair, the adjacent lining shall be
coated far enough back to cover any visible cracks and shall be
maintained in a moist condition for three days using a wet hessian sack
or similar means. Alternatively, if the line can be filled, it shall be put
into use after the initial set has taken place.
3.7.4 Whenever extensive patching is essential, the repaired lining shall be

reinforced with 25 mm x 10 mm x 1 mm diamond steel mesh, tack-
welded to the pipe.
GS 106-1
AND FITTINGS
3.8 Cutting Cement-Mortar Lined Pipe
3.8.1 For cutting lined pipe, a slitter saw supported as necessary and
containing a nylon bonded carborundum disc shall be used.
Alternatively, a rigid pipe cutting machine using tungsten carbide-
tipped tools ground to the cutting angles given in Figure 9 shall be
used.
3.8.2 On fusion welded steel pipes, the external weld shall be removed flush
with, but not below, the face of the pipe for the width of the cutters,
and if necessary for the complete width of the cutting machine.
3.8.3 The section to be removed and the adjacent pipe ends shall be suitably
supported to avoid imposing any weight on the concrete lining when
breaking through.
4. DAMAGE PROTECTION
4.1 Handling
Handling of lined pipe lengths shall be by means of slings such that the
pipes are supported 1/5 of their length from each end. Pipes shall not
be lifted using hooks inserted in the pipe ends.
4.2 Transportation
4.2.1 Lined pipes being transported shall be adequately supported in a level

horizontal position in order to minimise flexing and prevent induced
bending and damage to the lining.
4.2.2 Pipes shall be protected from direct or indirect impact by means of

suitable cushioning material.
4.2.3 Pipes shall not be transported using tractor units with trailing bogies or
other methods offering no central support.
4.3 Pipe Ends and Branch Connections
4.3.1 During transportation and storage, pipe lengths shall have end caps or
other suitable means of protection, with sufficient holes to permit air
circulation, provided this does not cause drying out and cracking of the
lining. Means shall be taken to ensure that the end protection remains
securely fastened, especially during transportation.
4.3.2 Branch connections shall be suitably plugged or capped as described

above.
GS 106-1
AND FITTINGS
4.4 Installation
4.4.1 The requirements for handling and transportation of individual pipe

lengths so as to avoid damage are as described in 4.1 and 4.2 above.
Similar care shall be taken when handling jointed lengths of pipe and
pipestrings to ensure that induced bending and the possibility of
damage to the lining is minimised.
4.4.2 During pipeline installation, when handling, lifting and laying pipe, the
spacing of lifting points and supports shall not be greater than the
maximum support spacing shown in the table below. Also when
installing pipe on above ground supports or piperacks, the support
spacing shall be not more than shown in the table. When laying
pipelines, the radii of any curves in the horizontal or vertical plane due
to the ground profile shall be not less than those listed in the table.
GS 106-1
AND FITTINGS
Nominal Minimum Bend Maximum
Pipe Size Radius Support Spacing
(inches) (metres) (millimeters)
3 530 5240
4 700 5980
6 1050 6960
8 1400 7320
10 1770 7730
12 2110 8080
14 2310 8720
16 2650 8980
18 2990 9240
20 3320 9890
22 3680 10090
24 4000 10320
26 4350 10470
28 4690 10600
30 and larger 172 x inside 10720
diameter of steel
pipe
Note: No allowance has been made for the additional weight of valves and
fittings; where these are used, additional supports shall be provided.
5. IDENTIFICATION
Each item of pipe and fittings shall be marked or labelled with the size, order number and
pipeline item number. Each item shall also be clearly identified as cement-mortar lined pipe
to ensure that it is not subjected to shock loads, for example hammer testing after installation.
GS 106-1
AND FITTINGS
A A
TYPE 1 FLAT TYPE 3

FACE
SLEEVE
SLEEVE
A A
TYPE 4
TYPE 2
Nominal Pipe Size A Nominal Pipe Size A

(inches) (mm) (inches) (mm)
3 170 26 310
4 180 28 310
6 210 30 310
8 250 32 310
10 270 34 320
12 280 36 320
14 300 38 320
16 320 40 320
18 330 42 320
20 350 44 320
22 Non Std Flange 46 320
24 350 48 370
42 Non Std Flange
56 Non Std Flange
60 380
64 Non Std Flange
Notes:
1. For details of sleeves see the following figures:-

Figure 6 For pipe sizes 3 to 24 inch
Figure 8 For pipe sizes 48 inch and larger
FIGURE 1
FLANGED CONNECTIONS WITH CLASS 150 FLANGES
GS 106-1
AND FITTINGS
A A
SLEEVE
R R
A A
TYPE 1 TYPE 2
R = 11/2 X NORMAL PIPE SIZE

3 220 26 1170
4 260 28 1250
6 350 30 1320
8 450 32 1400
10 550 34 1470
12 640 36 1550
14 720 38 1630
16 800 40 1700
18 880 42 1780
20 960 44 1860
22 1040 46 1930
24 1120 48 2050
Notes:
1. Bends shall be fabricated using long radius elbows to ANSI B16.9 or BS 1640
2. For pipes over 48 inch nominal size the bend shall be detailed and fabricated as part
of the relevant project.

FIgure 8 For pipe sizes 48 inch and larger
FIGURE 2
90 BENDS
GS 106-1
AND FITTINGS
A A A A
SLEEVE
TYPE 1 TYPE 2

3 106 26 179
4 108 28 183
6 121 30 177
8 145 32 181
10 169 34 175
12 183 36 178
14 187 38 182
16 190 40 176
18 194 42 180
20 198 44 184
22 202 46 177
24 206 48 181
Notes:
1. Bends shall be cut from long radius elbows to ANSI B16.9 or BS 1640 with being
specified as part of the project design. When is 45, standard fittings may be used
2. For pipes over 48 inch nominal size the bend shall be detailed and fabricated as part
of the relevant project.

FIGURE 3
BENDS OTHER THAN 90
GS 106-1
AND FITTINGS
L
L
SLEEVE
TYPE 1
A
TYPE 3
A
SLEEVE
SLEEVE
TYPE 2 SLEEVE
TYPE 4
NominalPipe Size Nominal

(inches) A L (inches) A L
Major Minor (mm) (mm) Major Minor (mm) (mm)
4 3 108 320 26 24-18 179 1000
6 4-3 121 370 28 26-18 183 1000
8 6-4 145 420 30 28-20 177 1000
10 8-4 169 495 32 30-24 181 1000
12 10-6 183 555 34 32-24 175 1000
14 12-6 187 700 36 34-24 178 1000
16 14-8 190 735 38 36-26 182 970
18 16-10 194 765 40 38-30 176 970
20 18-12 198 900 42 40-30 180 970
22 20-14 202 910 44 42-36 184 975
24 22-16 206 920 46 44-38 177 1075
48 46-40 181 1075
Notes:
1. Where the required reduction cannot be achieved using one standard reducer then two
or more assemblies in series shall be used.
2. Reducers for pipe sizes greater than 48 inch shall be regarded as specials and detailed
as part of the relevant project.

FIGURE 4
ECCENTRIC REDUCER ASSEMBLIES
GS 106-1
AND FITTINGS
B
B
= = = = = =
A A A
SET ON TEE SET ON TEE FORGED TEE WITH
TYPE 1 TYPE 2 SLIP -ON FLANGE
TYPE 3
B
B
= = = =
A A
SET - ON TEE WITH SET - ON TEE WITH
WELDING - NECK FLANGE SLIP ON FLANGE
TYPE 4 TYPE 5
Main Nominal A B (mm) Main Nominal A B (mm)

Pipe Size (mm) For All Branch Pipe Size (mm) For All Branch
(inches) Sizes (inches) Sizes
3 380 190 28 1400 710

4 430 215 30 1470 750
6 530 265 32 1550 790
8 660 330 34 1620 835
10 770 385 36 1700 870
12 870 435 38 1780 910
14 930 465 40 1850 950
16 980 490 42 1880 965
18 1070 535 44 1980 1015
20 1160 580 46 2050 1055
22 1240 620 48 2140 1140
24 1280 640 Above 48 Set-on tees only. To be detailed
26 1350 680 during project design
Notes:
1. Dimension B is equally applicable to a raised face or a flat faced flange. This dimension may be varied,
e.g. to suit a probe length.
2. The combination of forged tee and welding-neck flange shall be regarded as special and shall be detailed as
part of the relevant project.
3. Fittings requiring reinforcement shall be regarded as special and shall be detailed as part of the project.
However, the design shall be suitable to accommodate the sleeves specified in Note 4
4. Sleeves in accordance with the following figures may be fitted to any plain end without affecting effective
pipe lengths:-
FIGURE 5
TEE BRANCH CONNNECTIONS WITH CLASS 150 FLANGES
GS 106-1
AND FITTINGS
Pipe Sleeve
Nominal P (mm) S (mm) B (mm)
Pipe Size Min Max Min Max Min
(inches)
3 88.0 89.5 Measured Measured 110
4 113.5 115.0 Outside Outside 115
6 167.5 169.5 Diameter Diameter 125
8 217.5 220.5 Of Pipe Of Pipe 135
10 271.5 275.0 + 1mm + 6mm 145
12 321.5 326.0 (See note 3) (See note 3) 155
14 353.0 358.0 160
16 403.5 409.0 170
18 454.0 460.0 180
20 503.0 513.0 195
22 553.5 564.5 195
24 604.0 616.0 195
Notes:
1. Pipe outside diameters are derived from the dimensions and tolerances stated in API Spec 5L.
2. Minimum wall thickness of sleeve shall be 1.2 x thickness of pipe.
3. The measured outside diameter of pipe shall be that of the pipe delivered for a specific job or project.
4. Pipes shall be centralised with slip wedges before welding.
FIGURE 6
ONE-PIECE SLEEVE JOINT FOR NOMINAL PIPE SIZES 3 INCH UP TO AND

INCLUDING 24 INCH
GS 106-1
AND FITTINGS
Notes:
1. Minimum size of fillet welds = Pipe wall thickness as specified in 2.1.4 of this
specification.
FIGURE 7
HALF-SLEEVE JOINT FOR NOMINAL PIPE SIZES OVER 24 INCH BUT UNDER
48 INCH
GS 106-1
AND FITTINGS
Variable Dimensions
Nominal Pipe Size G (mm) N L
(inches) MIN MAX (mm) (mm)
48 up to 60 32 75 250 100
Over 60 32 100 300 120
Notes:
1. Minimum size of fillet welds = 3/4 T.

2. Minimum sleeve thickness = T
FIGURE 8
HALF-SLEEVE JOINT FOR NOMINAL PIPE SIZES 48 INCH AND LARGER
GS 106-1
AND FITTINGS
3 REQUIRED PER CUTTING UNIT
(1 EACH TYPE OF BLADE A, B & C)
FIGURE 9
DETAILS OF CUTTING ANGLES FOR TUNGSTEN CARBIDE TIPPED TOOLS

FOR CEMENT-MORTAR LINED STEEL PIPES
GS 106-1
AND FITTINGS
A
R
Nominal Pipe R A
Size (mm) (mm)
(inches)
3 270 106
4 350 108
6 500 121
8 800 145
10 1100 169
12 1300 183
14 1600 187
16 1800 190
18 2100 194
20 2700 198
22 3100 202
24 3700 206
Notes:
1. The tangent lengths and the radii given are minimum values, actual dimensions shall
be detailed as part of the relevant project.
2. The thickness of the pipe wall at any point on the finished bend shall not be less than
the schedule thickness to the tolerance applicable for equivalent straight pipe.
3. The difference between maximum and minimum diameters on any common radial
plane shall not be more than 5% of the outside diameter of the pipe.
4. When the bent pipe is to be butt-welded into the piping system the tolerance at the
ends shall be in accordance with ANSI B16.9 or BS 1640.
5. Except as specified in the foregoing notes the bent pipe shall be to the specification,
tolerances and tests stipulated for the piping system generally, or as given in the
order.
FIGURE 10
MINIMUM BENDING RADII FOR STEEL PIPE
GS 106-1
AND FITTINGS
STAINLESS STEEL SOCKET WELDED
OR SCREWED HALF COUPLING.
FOR DETAILS SEE 2.2.5. OF THIS
SPECIFICATION. FOR WELDING DETAIL
SEE FIGURE 12
SLEEVE SLEEVE SLEEVE
A A A
TYPE 1 TYPE 2 TYPE 3
Nominal Pipe Size A

(inches) (mm)
3 250
4 260
6 270
8 280
10 290
12 300
14 310
16 320
18 330
20 350
22 350
24 350
Notes:
1. Care shall be taken to ensure that all areas of piping material around the hole to the
half coupling are adequately covered with cement-mortar lining.
2. For details of sleeves see Figure 6.
FIGURE 11
3/4 INCH AND 1 INCH BRANCH FITTINGS FOR NOMINAL PIPE SIZES 3 INCH
UP TO AND INCLUDING 24 INCH
GS 106-1
AND FITTINGS
Main. A
Nominal Pipe Size (mm)
Over 24 inch 150
But Under 48 Inch
48 Inch and Over 225
Notes:
1. Damage to the cement-mortar lining caused whilst fitting the half-coupling shall be
made good at site, and care taken to ensure that all areas of pipe material are covered.
FIGURE 12
3/4 INCH AND 1 INCH BRANCHES FOR NOMINAL PIPE SIZES OVER 24 INCH
GS 106-1
AND FITTINGS
Notes:
1. Where alternative types of assembly are shown on the figures referred to above,
selection shall be made during detailed design.
2. Butterfly valves used in pipes of nominal size 3 inch to 12 inch inclusive may be full
bore or reduced bore. For nominal pipe sizes above 12 inch all valves shall have
reduced bore. All valve bodies shall be vulcanised rubber lined.
FIGURE 13
TYPICAL ARRANGEMENT OF CEMENT-MORTAR LINED
STEEL PIPES AND FITTINGS
GS 106-1
AND FITTINGS
FIGURE 14
TYPICAL CONNECTION BETWEEN CEMENT MORTAR LINED PIPE AND

RUBBER LINED BUTTERFLY VALVE
GS 106-1
AND FITTINGS
Notes:
1. Detail design of joint to suit the particular project.
2. Pipe jointing to be generally in accordance with Figures 6, 7 and 8 for different pipe-
sizes.
FIGURE 15
TYPICAL DESIGN FOR SPECIAL SLEEVE JOINT
GS 106-1
AND FITTINGS
Note:
1. Detailed design of joint to suit the particular project.
FIGURE 16
TYPICAL DESIGN FOR REYNOLDS JOINT
GS 106-1
AND FITTINGS
APPENDIX A
DEFINITIONS AND ABBREVIATIONS
Definitions
Standardised definitions may be found in the BP Group RPSEs Introductory Volume.
Abbreviations
ANSI Amercian National Standards Institute

API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing Materials
BS British Standard
EEMUA Engineering Equipment and Materials Users Association
NPS Nominal pipe size
GS 106-1
AND FITTINGS
APPENDIX B
LIST OF REFERENCED DOCUMENTS
A reference invokes the latest published issue or amendment unless stated otherwise.
Referenced standards may be replaced by equivalent standards that are internationally or

otherwise recognised provided that it can be shown to the satisfaction of the purchaser's
professional engineer that they meet or exceed the requirements of the referenced standards.
British Standards
BS 410 Specification for Test Sieves

BS 639 Specification for Carbon and Carbon Manganese Steel Electrodes for
Manual Metal-Arc Welding (withdrawn).
BS 882 Aggregates from Natural Sources for Concrete.
BS 1501 Steels for Fired and Unfired Pressure Vessels (Replaced by BS EN
10028 & 10029).
BS 1503 Steel Forgings for Pressure Purposes. (ISO 2604-1)
BS 1560 Steel Pipe Flanges (1/2 inch to 24 inch) for the Petroleum Industry.
(ISO 7005-3)
BS 1640 Steel Butt-Welding Pipe Fittings for the Petroleum Industry.
BS 2926 Chromium and Chromium-Nickel Steel Electrodes for Manual Metal-
Arc Welding.
BS 3293 Carbon Steel Pipe Flanges (over 24 inch) for the Petroleum Industy.
BS 3799 Steel Pipe Fittings, Screwed and Socket-Welding for the Petroleum
Industry.
BS 4027 Sulphate Resisting Portland Cement.
BS 4360 Weldable Structural Steels.
American
ANSI/ASME B16.11 Forged Steel Fittings, Socket Welding and Threaded

ANSI/ASME B16.5 Steel Pipe Flanges and Flanged Fittings
ANSI/ASME B16.9 Factory-Made Wrought Steel Butt-Welding Fittings
API 605 Large-Diameter Carbon Steel Flanges
API Spec 5L Specification for Line Pipe
ASME B31.3 Chemical Plant and Petroleum Refinery Piping
ASTM A105 Forgings, Carbon Steel, for Piping Components
ASTM A106 Seamless Carbon Steel Pipe for High-Temperature Service
ASTM A234 Pipe Fittings of Wrought Carbon Steel and Alloy Steel for Moderate
and Elevated Temperatures.
GS 106-1
AND FITTINGS
BP Group Documents
BP Group 118-5 Fabrication of Carbon, Carbon Manganese and Low Alloy Ferritic
Steel Pipework.
BP Group 118-7 Fabrication of Austenitic, Duplex, Cupro-Nickel and Nickel Base
Alloy Steel Pipework.
EEMUA
EEMUA Publication 142 Noise-acoustic insulation of pipes, valves and flanges
GS 106-1
AND FITTINGS

GS 106-1 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

GS 106-1 PDF

Uploaded by

Copyright:

Available Formats

GS 106-1

CEMENT-MORTAR LINED STEEL PIPE

Copyright The British Petroleum Company p.l.c.

Issue Date October 1995

SCOPE AND PURPOSE

CUSTODIAN (See Quarterly Status List for Contact)

2. PIPE AND FITTINGS......................................................................................................... 1

3. CEMENT-MORTAR LINING ........................................................................................... 8

4. DAMAGE PROTECTION ............................................................................................... 11

Introduction to BP Group Recommended Practices and Specifications for Engineering

Value of this Guidance for Specification

Text in italics is Commentary. Commentary provides background information which

Specification Ready for Application

Principal Changes from Previous Edition

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

4. This specification describes additional methods of joining lengths of cement-mortar

Feedback and Further Information

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

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

(b) Temperatures between 0 and 90C.

2. PIPE AND FITTINGS

2.1.1 Pipe shall be either:

(a) API Spec 5L Grade A or B, seamless.

(b) Automatic electric fusion welded, to API 5L Grade B,

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

* The choice of seamless or welded pipe shall depend on availability and

Class 150 rating Wall thickness

3 inch to 6 inch NPS Standard (Schedule 40)

8 inch to 18 inch NPS Schedule 20

20 inch to 40 inch NPS 9.5 mm

42 inch NPS and above To be calculated

(b) BS 1640 Part 3, made from materials to the applicable

Seamless pipe ASTM A 106 Grade A or B

Rolled Plate BS 1501-161 Grade 430

Forgings ASTM A 105 (with carbon content

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

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

Flanges may be forged from material selected from the following

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

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

2.2.4 Where a rubber-lined butterfly valve (flanged or wafer type) is to be

2.2.6 Welded joints within assemblies, for example eccentric reducers to

Pipes which have been cement-mortar lined cannot be butt welded

All joints described in this document shall be designed in accordance

2.3.2 Sleeve Joints

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

(i) For pipes 3 inch NPS up to 24 inch NPS inclusive, a

(iii) For pipes 48 inch NPS and over, a half-sleeve joint to

(c) Plate used for sleeves shall be in accordance with BS 4360

(f) Sleeves shall be fabricated in accordance with BP Group GS

(g) During assembly of a welded sleeve, with pipe or fitting, the

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

The dimensional tolerances specified in API Spec 5L and ASTM A 106

(c) For joining pipes 10 inch NPS up to and including 24 inch

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

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

(iv) Welded pipe reduced as in 2.3.2.2 (c) (iii). The strip

Where a strip including the original weld is removed,

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

2.3.3 Special Joints

Special joints shall be used for applications outside the capability of

2.3.3.2 Special Sleeve Joints

2.3.3.3 Reynolds Joints