Pdvsa: Engineering Design Manual

PDVSA
ENGINEERING DESIGN MANUAL

VOLUME 13–II
ENGINEERING SPECIFICATION
PDVSA N° TITLE
H–241 FABRICATION AND INSTALLATION OF

CEMENT LINED STEEL PIPING
0 APR.01 APPROVED 8 Y. K. A. A. E. C.
REV. DATE DESCRIPTION PAG. REV. APPD. APPD.
APPD.BY Alexis Arévalo DATE APR.01 APPD.BY Enrique Carmona DATE APR.01
E PDVSA, 1983 ESPECIALISTAS

ENGINEERING SPECIFICATION PDVSA H–241
PDVSA
REVISION FECHA
FABRICATION AND INSTALLATION OF CEMENT
LINED STEEL PIPING 0 APR.01
Página 1
.Menú Principal Indice manual Indice volumen Indice norma
Index
1 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 STANDARDS, CODES AND REFERENCES . . . . . . . . . . . . . . . . . . . 2
3.1 Petróleos de Venezuela S.A (PDVSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.2 American Society of Mechanical Engineers (ASME) . . . . . . . . . . . . . . . . . 2
3.3 American Water Works Association (AWWA) . . . . . . . . . . . . . . . . . . . . . . . . 2
4 FABRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5 LINING THICKNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6 EXCAVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7 HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8 TOLERANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9 JOINTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
9.4 Plastic Compound Sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
10 WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10.2 General Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10.3 Welding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
11 CURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
13 HYDROSTATIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PDVSA
REVISION FECHA
Página 2
1 PURPOSE
The purpose of this engineering especification is to establish the minimum
requirements for fabrication, installation and testing of cement lined steel piping.
2 SCOPE
This specification covers the normal methods and procedures to be employed in
the fabrication and installation of cement lined steel piping. It includes both
mandatory requirements and recommendations and shall be used in conjunction
with PDVSA H–221.
3 STANDARDS, CODES AND REFERENCES

The following codes and standards apply to this specification. When an edition
date is not indicated for a code or standard, the latest edition in force at the time
of purchase shall apply.
3.1 Petróleos de Venezuela S.A (PDVSA)

H–221 Piping Materials
PI–02–08–01 Pruebas Hidrostáticas y Neumáticas para Sistemas de Tuberías
3.2 American Society of Mechanical Engineers (ASME)

B31.1 Power Piping
B31.3 Process Piping
B31.4 Liquid Transportation Systems for Hydrocarbons, Liquid
Petroleum Gas, Anhydrous Ammonia, and Alcohols.
B31.8 Gas Transmission and Distribution Piping Systems
3.3 American Water Works Association (AWWA)

C104 Cement – Mortar Lining for Cast–Iron and Ductile Cast–Iron
Pipes and Fittings for Water
4 FABRICATION
Steel pipe, buttweld fittings and welding neck flanges in sizes four inches and
larger shall be internally cement lined in accordance with AWWA C104. Lining
thickness for steel piping shall be as listed in Section 5. Curing method shall be
wet cure and not by seal coating.
5 LINING THICKNESS
5.1 The cured lining thickness shall be considered acceptable when the lining
thickness is:
PDVSA
REVISION FECHA
Página 3
Normal Pipe Size Lining Thickness Tolerance

4 inches 3,2 mm (1/8 inch) + 3,2 mm (1/8 inch)
10 inches or larger 9,5 mm (3/8 inch) + 4,7 mm (3/16 inch)
5.2 These are minimum acceptable thickness with “plus” tolerances. There are no
“minus” tolerances to these figures.
6 EXCAVATION
6.1 The narrowest practicable trench width possible, which will permit proper backfill
compaction as well as access for jointing operations, shall be used. Normally the
minimum width, at the top, should be the pipe OD plus 18 inches. A one–inch thick
(minimum) sand pad shall be used for the trench bottoms.
6.2 Material for backfill and bedding shall be ”sweet sand” and only fresh water will be
permitted for compacting or washing operations. Compactness shall be Class C
–90% minimum.
6.3 If vibrating equipment is used, it shall not be allowed to come into direct contact
with the pipe.
7 HANDLING
7.1 While the cement lining is not extremely fragile, it will develop cracks after curing
and during handling. Flexing of the pipe shall be limited and should be lifted with
a minimum of 2 point slings. Maximum stack height, to preclude undue flexing,
shall be limited to five high through 10 inch size, three high for 12 inch and 14 inch,
two high for 16 inch through 20 inch, and one high for larger sizes.
7.2 Pipe may be transported on flat beds with the pipe supported throughout its length.
7.3 Any crack wider than 1,6 mm (1/16 inch) should be repaired by removing the
cement and replacing manually. Cracks up to, and including, 1,6 mm (1/16 inch)
will heal after being put into service.
8 TOLERANCES
8.1 Each pipe–to–pipe or fitting end shall be matched before welding. A maximum
overlap of cement is absolutely necessary. In order to achieve a proper joint
PDVSA
REVISION FECHA
Página 4
match, out–of–roundness shall be not greater than 3,2 mm (1/8–inch) on the

internal surface.
8.2 When the pipe is first received and stacked, but before lining, all ends shall be
inspected and rerounded as necessary. Shorter than single or double random
sections may be cut and lined to minimize the rework of out–of–round section cut
from longer length pipe after lining.
9 JOINTING
9.1 Joints shall be made by butt–welding, and except for manually or in situ lined joints
made after welding, shall be made utilizing a quick setting plastic compound,
suitable for use in cement lined pipe welded joints to seal the cement portion.
“Special Formula No. 2 X–Pando,” “Weld–crete” or “Tie–bond”, or equivalents are
acceptable.
Note: Compound will set in approximately one hour or less at room temperature
and also from welding heat. It may be kept pliable for up to 20 to 30 minutes by
working.
9.2 Twenty–four inch and larger stack lined joints will be cut back 50 to 100 mm (2 to
4 inches) and shall be cement–lined manually after welding is completed.
9.3 All weld neck flanges shall be manually lined after welding. Care shall be
exercised in as much as tapering of cement may be necessary to permit butterfly
or check valve discs to move freely.
9.4 Plastic Compound Sealer

9.4.1 Plastic compound sealer shall be obtained in ten pound cans preferable.
9.4.2 Prepare the plastic compound sealer in accordance with supplier instructions.
9.4.3 The compound can best be applied to the cement at the ends of the pipe by
squeezing if from a plastic squeeze type bottle or similar applicator. Apply a
continuous layer or bead of compound to the cement liner on the end of both
lengths of pipe to be welded.
Use enough compound to form a small continuous bead of excess compound in
the welding groove when the pipe ends are butted together. Using too much
compound will cause a large bead of compound inside the pipe. This is
unnecessary and wastes material. The compound mixture should be thin enough
to be squeezed through the nozzle of the applicator, but not thin enough to run off
the pipe after it is applied.
PDVSA
REVISION FECHA
Página 5
9.4.4 Welding heat does not damage the cement nor the special compound but arc
pressure could cause the compound to be forced out of the joint if too much
pressure is applied before compound is set.
10 WELDING
10.1 Correct preparation of the ends to be joined is a must. Squareness of the cement
can be attained by using the same compound which is to be used to seal the joint.
10.2 General Procedure

10.2.1 All welding shall be performed by qualified welders in accordance with the
requirements of specific welding procedures and this specification.
10.2.2 Pipe wall thickness 0.187 inch and under shall no be beveled. Pipe wall thickness
over 0.187 inch shall be beveled approximately 30 degrees with 1,6 mm
(1/16–inch) land.
10.2.3 The metal of the pipe ends shall be cleaned of all cement, dirt, paint, oil, moisture,
scale or burned metal before welding is started.
10.2.4 The end of the cement lining shall be square with the pipe and flush with the land
of the pipe for sizes 20 inches and smaller lined ”in–stacks.”
10.2.5 The lengths of pipe shall first be butted together and checked for alignment and
good contact of the cement lining and pipe ends. Then the pipe ends shall be
separated and a layer or bead of compound applied to the end surfaces of the
cement lining. The pipe ends shall then be tightly butted together, leaving no
space between the metal ends. Excess compound shall be removed from the
welding groove (A wire brush dipped in a small quantity of dry cement works very
well). See Figure 1.
10.2.6 Tack weld the two lengths together in at least two places, one near the top of the
pipe and one on the opposite side of the pipe from the first welding pass. This is
necessary to prevent a gap between the pipe ends opposite the first welding pass.
Tack weld pipe at 4, 8 and 12 o’clock positions.
PDVSA
REVISION FECHA
Página 6
Fig 1. COMPOUND APPLICATION AND WELDING
10.3 Welding Procedure

10.3.1 The pipe shall be joined by the shielded metal–arc welding process. The arc shall
not come in direct contact with the cement lining or compound seal material. A
minimum of stops shall be staggered so as not to start or stop in the same place.
Welding slag shall be cleaned from all weld passes.
10.3.2 When compound is used, pre–heat pipe to 200–250_F (to accelerate curing) and
in the normal horizontal pipe position, the method of applying passes shall be
”downhill.” The first pass shall be ”washed in” (closed arc method). The filler and
the finishing passes shall be applied at a high rate of travel. The completed weld
shall have 1,6 mm (1/16”) reinforcement above the surface at all points.
10.3.3 Welding electrode shall be E6013 for the first pass and E7018 for the remaining
passes.
10.3.4 The following table shows the size of electrode and the welding current to use for
each pass for the various pipe sizes and wall thickness ranges:
Wall Pipe (Wash) Stringer Filler Finish

Thickness Diameter
(Inches) (Inches) Pass Amps Pass Amps Pass Amps
0.125 to 0.250 2 to 4 1/8 90 to 100 1/8 100 to 110 5/32 100 to 110
0.125 to 0.250 4 –1/2 to 7 1/8 90 to 100 5/32 130 to 140 5/32 130 to 140
0.255 to 0.750 2 to 4 1/8 95 to 110 5/32 135 to 150 5/32 135 to 150
0.255 to 0.750 4–1/2 to 7 5/32 130 to 145 5/32 135 to 150 3/16 135 to 160
PDVSA
REVISION FECHA
Página 7
10.3.5 The welding current shall be checked with an appropriate ammeter. After the
welder has started welding, clamp the ammeter around the electrode cable 130
to 200 cm (4 to 6 feet) from the electrode holder and read the current. Adjust the
welding machine to delivery the amperage shown. Mark the position of the current
control knob on the welding machine.
11 CURE
11.1 The machine–lined piping shall be cured either with water or steam.
11.2 All manually lined sections, including repair areas, fittings, flanges and the cut
back areas at welds shall also be cured either with water or steam.
11.3 Fresh water shall be used for curing.
11.4 The lining, when applied manually or by machine, shall not be installed nor
permitted to be exposed to temperatures over 38 °C (100 °F). This includes
exposure of the metal portion to the sun. Use shade or sprinkle the outside with
water to keep below this temperature.
11.5 Salt water should be introduced as soon as possible in as much of the lined system
as possible throughout the entire installation period.
12 INSPECTION
12.1 Every joint must be inspected prior to welding to ensure at least the following:
12.1.1 End of cement is square and undamaged.

12.1.2 Proper alignment of both the steel and cement is achieved with maximum cement
overlap.
12.1.3 Compound is applied to all butt–welded joints 20 inches and smaller except
manually lined joints made after welding.
12.2 After joints are completed, a visual check shall be made on the internal section
(this may require special optical equipment). All defective joints shall be replaced.
12.3 This inspection by the installer shall be documented and be available to

CONTRACTOR upon request. These records shall include, but not be limited to
the following.
12.3.1 Line Number

PDVSA
REVISION FECHA
Página 8
12.3.2 Date Inspected

12.3.3 Repair if necessary
12.3.4 Results
13 HYDROSTATIC TEST
13.1 All lines shall be hydrotested (Service Test) per PDVSA PI–02–08–01, “Pruebas
Hidrostáticas y Neumáticas para Sistemas de Tuberías”, after cement lining.
13.2 When hydrotesting of a field weld is impracticable or excessively expensive, the

alternate method of 100 percent Radiographic (RT) examination will be permitted
in lieu of hydrotest.
13.3 Acceptance criteria shall be per applicable ASME code as indicated on 3.2.
13.4 Each case should be approved in advance by PDVSA representative.

Pdvsa: Engineering Design Manual

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

Pdvsa: Engineering Design Manual

Uploaded by

Copyright:

Available Formats

PDVSA

ENGINEERING DESIGN MANUAL

H–241 FABRICATION AND INSTALLATION OF

REV. DATE DESCRIPTION PAG. REV. APPD. APPD.

E PDVSA, 1983 ESPECIALISTAS

3 STANDARDS, CODES AND REFERENCES

3.1 Petróleos de Venezuela S.A (PDVSA)

3.2 American Society of Mechanical Engineers (ASME)

3.3 American Water Works Association (AWWA)

Normal Pipe Size Lining Thickness Tolerance

match, out–of–roundness shall be not greater than 3,2 mm (1/8–inch) on the

9.4 Plastic Compound Sealer

10.2 General Procedure

Fig 1. COMPOUND APPLICATION AND WELDING

10.3 Welding Procedure

Wall Pipe (Wash) Stringer Filler Finish

11.3 Fresh water shall be used for curing.

12.1.1 End of cement is square and undamaged.

12.3 This inspection by the installer shall be documented and be available to

12.3.1 Line Number

12.3.2 Date Inspected

13.2 When hydrotesting of a field weld is impracticable or excessively expensive, the

13.4 Each case should be approved in advance by PDVSA representative.

You might also like