Large Diameter Steel Piping

8/10/2019 Large Diameter Steel Piping

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TCE CONSULTING ENGINEERS LIMITED SECTION: TITLETCE.M6-ME-590-424 DESIGN GUIDE FOR

LARGE DIAMETER STEEL PIPING SHEET (i) OF (iv)

REV. NO. R0 R1 R2

INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.ISSUE

PPD. BY VBS Sd/- SMM Sd/- PV

CKD. BY RKC Sd/- PV Sd/- VBS

APP. BY SJB Sd/- SCM/RL Sd/-Sd/- PDG/RL

DATE 19.04.1991 25.03.2000 29.01.2003

R2

TCE FORM NO. 020R2

DESIGN GUIDE FOR

LARGE DIAMETER STEEL PIPING

FILE NAMES: M6ME424R2.DOC AND M6ME424R2.DWG


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TCE CONSULTING ENGINEERS LIMITED SECTION CONTENTSTCE.M6-ME-590-424 DESIGN GUIDE FOR

LARGE DIAMETER STEEL PIPINGSHEET (ii) OF (iv)

TCE FORM NO. 120 R1

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CONTENTS

SL. NO. DESCRIPTION SH. NO.

1.0 INTRODUCTION 1

2.0 INPUT DATA 1

3.0 MATERIALS 1

4.0 HYDRAULICS OF PIPELINES 2

5.0 DETERMINATION OF PIPE WALLTHICKNESS

3

6.0 SUPPORTS 6

7.0 WATER HAMMER 9

8.0 ANCHORS 9

9.0 SPECIALS 10

10.0 PIPE JOINTS 12

11.0 TESTING OF PIPE LINES 14

12.0 PROTECTIVE COATING 14

13.0 REFERENCES 15

FIGURES

Fig.1, Fig. 2 a TYPES OF SUPPORTS 16

Fig. 2 b & Fig.3 TYPES OF SUPPORTS 17

Fig. 4 a TO Fig. 4 c DIRECTION OF FORCES IN VARIOUSFITTINGS

18

Fig. 5 a TO Fig. 5 c TYPES OF ANCHORS 19


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TCE CONSULTING ENGINEERS LIMITED SECTION CONTENTSTCE.M6-ME-590-424 DESIGN GUIDE FOR

LARGE DIAMETER STEEL PIPINGSHEET (iii) OF (iv)

TCE FORM NO. 120 R1

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Fig. 5 d TO Fig. 5 g TYPES OF ANCHORS 20

Fig. 6 TYPES OF FLANGES 21

Fig.7 PAD TYPE REINFORCEMENT 21

Fig. 8 EXPANSION JOINT ASSEMBLY 22

Fig. 9 VARIOUS PIPE JOINTS 23


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TCE CONSULTING ENGINEERS LIMITED SECTION: REV. STATUSTCE.M6-ME-590-424 DESIGN GUIDE FOR

LARGE DIAMETER STEEL PIPINGSHEET (iv) OF (iv)

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REVISION STATUS

REV. NO. DATE DESCRIPTION

R0 19.04.1991 --

R1 25.03.2000 REVISED TO CONVERT THEDOCUMENT IN MS-WORDAND FEW TECHNICALDETAILS ADDED. TITLE OFTHE GUIDE REVISED.

R2 29.01.2003 MINOR REVISION CARRIEDOUT


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TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UPTCE.M6-ME-590-424 DESIGN GUIDE FOR

LARGE DIAMETER STEEL PIPINGSHEET 1 OF 23

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1.0 INTRODUCTION

This design guide covers the criteria for design of large diameter steel pipes > 400 NB for the benefit of practising water works Engineers.

2.0 INPUT DATA

The following input are required for the design of large diameter steel pipelines for systems like cooling water, water supply etc :

(a) Normal and maximum flow and flow for any future expansion

if any.

(b) Operating and maximum internal pressure envisaged.

(c) Design pressure

(d) External pressure.

(e) Soil conditions and related data.

(f) Water hammer pressure/Vacuum

(g) Normal, minimum and maximum temperature of the water.

(h) Ambient temperature variations.

(i) Quality of the water in circulation.

(j) Any additional loading, as applicable.

3.0 MATERIALS

Materials depend upon the type of fluid which is being handled. Normally carbon steel pipes are used with internal lining, if applicable.The normally used internal lining material is mortar. This is especiallyapplicable for service like sea water and in case of water supplysystem. For details chapter on 'Protective Coating & Lining' inAWWA Manual-M11 shall be referred.

4.0 HYDRAULICS OF PIPELINES

4.1 SELECTION OF DIAMETER

The criteria for design is that the pipeline should convey the requiredquantity of water at the lowest capitalised cost i.e. the cost inclusive of


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initial installation and cost loading for power. For preliminary sizingof the piping, a velocity of 2 m/sec may be used. The recommendedvelocity range is 1.25 m/sec to 3 m/sec. Additional flow requirementin the line in future, if any, due to plant expansion shall be consideredfor pipe sizing in consultation with the client.

4.2 DESIGN PRESSURE

The design pressure to be adopted for designing the pipelines willdepend on the following factors.

(a) Normal operating pressure

(b) Maximum pressure encountered in the system that is pump shutoff head plus static head, if any.

(c) Water hammer pressure.

It is uneconomical to design the pipelines for water hammer pressure.Suitable means should be provided to reduce the water hammer effectto the minimum. The design pressure shall correspond to (b) abovesince the water hammer pressure is a transient phenomenon. The stressin the pipe should be checked to ensure that stresses under water

hammer pressure are within 75% of minimum yield strength.

Depending on the hydraulic gradient of the system, if any portion issubjected to vacuum during operation, corresponding portion shall bedesigned for the maximum envisaged vacuum. However it is normal

practice to provide double acting air release valve which preventsvacuum formation and also release air while filling the line. Vacuumcould also be due to water hammer phenomena.

4.3 FRICTION LOSS IN PIPE LINES

The most popular formula for computation of friction loss in the pipelines is Hazen-Williams formula which is given below :

F = 6.815 x V 1.852 x 1 1.167 x L C D

where -

F = Total friction loss in pipe in MWC

V = Flow velocity in metre/sec

D = Internal pipe diameter in metres


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C = Hazen-Williams coefficient (For C values refer document No. TCE.M6-ME-613-212).

L = Length of the pipe in metres

Bends, fittings and valves also constitute a major part of the frictionloss in the system. The loss in the system shall be calculated on thefollowing basis :

Friction loss = k V 2

2g

where -

k is the friction factor depending on the type of fitting.

V is the velocity in m/sec through the fitting

g is the accleration due to gravity in m/sec 2

The k value for different fittings shall be taken from the design guideTCE-M6-ME-613-212 for "Calculation of Hydraulic Losses for Water

in Pipes, Fittings and Valves."

5.0 DETERMINATION OF PIPE WALL THICKNESS

The wall thickness of steel pipe is governed by the following designcriteria :

5.1 UNDERGROUND PIPING

5.1.1 Wall thickness shall be such that under worst combination of externalloads, where internal pressure is atmospheric or sub-atmospheric, theradial deflection of the pipe shell with or without support of surrounding soil, is within safe prescribed limits.

5.1.2 Wall thickness shall be such that the compressive stress in the pipeshell under external loads with the negative internal pressure is within

prescribed limit of allowable stress.Allowable deflection for variouslining and coating system that are often accepted as:Mortar lined & coated - 2% of pipe diameter Mortar lined & flexible coated - 3% of pipe diameter Flexible lined & coated - 5% of pipe diameter


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5.1.3 Wall thickness shall be such that the tensile stress in the pipe shellunder external loads with the internal pressure, is within prescribedlimit of allowable stress.

The allowable stress in the pipe shell shall be related to yield stress (fy)of pipe material making due allowance for weld efficiency of the joint.

(a) Working stress for combined bending and direct tensile stressshall not exceed 60% of yield stress of the material making dueallowance for efficiency of welded joints.

(b) Working stress for combined bending and direct compressivestress shall not exceed 50% of yield stress making due

allowance for efficiency of welded joints.The joint efficiency factor shall be selected based on the following:

Degree of Radiographic Inspection Joint Efficiency %

Single and double welded butt jointscompletely radiographed

100

Single Welded butt joints with backingstrips completely radiographed

90

Double welded butt joints without anyradiography examination.

80

Single or double butt welded joints withspot radiography

85

For detail design engineering for underground piping, AWWA publication No. M11 may be referred.

5.2 ABOVE GROUND PIPE LINES

The wall thickness of steel pipe is governed by the internal pressureand external pressure.

5.2.1 Internal PressureThe wall thickness of straight pipelines for internal pressure is foundusing the following formula:

t = pd2 f

where -t = minimum wall thickness in mm

p = design pressure in kg/cm 2 (g) (Refer para 4.2)


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f = allowable design stress in kg/cm 2

d = internal pipe diameter in cm

A design stress equal to 50% of the specified minimum yield strengthis adopted. Also refer para 4.2 if water hammer phenomena isapplicable.

5.2.2 External Pressure

Procedure outlined in paras UG-28, UG-29 and UG-30 of ASME

Section VIII Division 1 may be adopted for determining the wallthickness and stiffening requirements for straight pipe under external pressure.

5.3 GENERAL

5.3.1 AWWA C-208, Dimensions for Fabricated Steel Water Pipe Fittingsmay be referred for dimensions of fabricated pipe fittings.However adequacy of thickness of fittings like mitre shall be checked based onthe guidelines given in ANSI B 31.1-Code for Power Piping.

5.3.2 Corrosion Allowance

Internal corrosion of unlined pipes depends upon the nature of water carried. It is preferable to design the required wall thickness of pipe asdetermined by above considerations, then select linings, coatings andcathodic protection as necessary to provide the required level of corrosion protection. However, if measures are not made to combatthe corrosion, a minimum corrosion allowance of 1.5 mm shall beadded to the net wall thickness found as per above paras 5.1 and 5.2.

5.3.3 Minimum Wall Thickness

From handling point of view, minimum plate thickness is based onfollowing formula :

t = _D_ for pipe size upto 1350 mm ID288

t = D+508 for pipe sizes greater than 1350 mm ID 400

where-

t = Minimum plate thickness in mmD = Internal diameter in mm


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However the requirements of minimum thickness with relevantstandards like API 5L / IS:1916 shall be checked.

6.0 SUPPORTS

6.1 UNDERGROUND PIPE LINE

Underground pipe line is laid either in trench or under embankment.Underground pipe is generally subjected to any one or all of thefollowing external loads.

(a) Fill load

(b) Surcharged load due to concentrated wheel load or sur chargeduniform load

(c) Load due to water in the pipe

(d) Self load due to weight of pipe and its lining and coating.

6.2 ABOVE GROUND PIPE

Pipes are supported in various ways, depending on size, circumstances,and economics. Pipes are normally supported on suitable concretesaddles or RCC sleeper with insert plate or by means of ring girders.

6.2.1 Saddle Supports

The pipe shell carried on saddles can be divided into two classes :

(a) Unstiffened pipe shell as shown in Fig. 1

(b) Stiffened pipe with stiffener rings as shown in Fig. 2 a. Inwater supply installations, both these methods of constructionare used, though unstiffened pipes are more common.

6.2.2 Unstiffened Pipe Shell

Saddle supports cause high local stresses both longitudinally andcircumferentially in unstiffened, comparatively thin-wall pipes at thetips and edges of the supports. Stresses are dependent on themagnitude of load or reaction at the support and the subtended angle indegrees (B), being small for larger value of (B). The width of thesaddle does not, however, influence these stresses. In practice, thesubtended angle varies from 90 to 120 .


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The pipe should be held in each saddle by a steel hold-down strap bolted to the concrete. Secure anchorages must be provided atintervals in multiple-span installations.

The maximum value of the localised stresses in a pipe that fits thesaddle well is given by the following formula :

f L = k P log e R t2 twhere -f L = the localised stress in kg/cm 2

P = the total saddle reaction in kg.

R = the pipe outer radius in mm

t = the pipe thickness in mm

k = factor = 0.02 - 0.00012 (B - 90) where B is in degrees

In addition to the above stress, pipe shell also develops flexural stress(fb) due to beam action while spanning across saddle supports, as alsoring stress f r due to internal pressure. Thus the total stress f t in the

pipe shell will be f t = f L + fr + f b where f r represents 25% of maximum hoop stress.

f b = bending stress = Bending momentSection modulus

Maximum stress will, therefore, occur at the support where localisedstress and bending stress are maximum.

The stresses in the shell in the region of support can be further reduced by welding a reinforcing pad to pipe shell, at the support as shown inFig. 2 b.

6.2.3 Stiffened Pipe Shell

Pipeline laid on saddles can be strengthened to span across supports placed at greater interval than those adopted for unstiffened pipe line, by providing stiffener rings centrally or on either side of the supports.For configuration in Fig.2a, minimum two rings are provided, one oneach side of saddle at spacing not exceeding radius nor closer than1.285 rt.

Where r = Internal radius of pipe & t = Thickness of pipe6.2.4 Ring-Girder Construction


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When large diameter steel pipe is laid above ground or across ravinesor streams, rigid ring girders spaced at relatively long intervals, have

been found to be very effective supports. Typical ring girder supportdetail is given in Fig. 3. The stresses developed in shell as a result of internal pressure and gravity load due to weight of shell and water areas follows :

(a) Hoop stress

(b) Stress due to beam action

(a)

Rim bending stress

For detail calculations for supports refer design guide no. TCE.M6-CV-HS-G-010 - Design Guide For High Pressure Exposed SteelConduits.

7.0 WATER HAMMER

The problem of water hammer in a pipeline consists of containing the pressure and dissipating the water flow energy. When the water-hammer wave loads the pipe wall, the strain in the wall increases

slightly faster than in strict proportion to stress within the elastic regionand on release of the loading, the reverse occurs. If the pressure rise inthe pipe is sufficient, the walls may be stressed into the plastic regionand experience a permanent set. The water hammer of the system shall

be worked out considering the characteristics of pumps, types andvalves used, distribution system details ,duration of valve closure etc.

The phenomenon of water hammer is extremely complex. Suitablemeans like surge tank, surge damper or hydropneumatic chamber,spring loaded check valve / zero velocity valve should be provided toreduce the water hammer effect, if required. For further details refer design guide for Water Hammer Analysis for Pumping Mains TCE.M6-CV-HS-G-019.

8.0 ANCHORS

The necessity for anchors or thrust blocks arise at angle points, sideoutlets, and valves and on steep slopes. When water transmission isunder internal pressure, unbalanced forces develop at these points.These forces act in the direction bisecting the angle of bend, outwardlycausing development of stresses in pipe shell. The magnitude of thethrust force for tees and bulk head is equal to the product of theinternal pressure and the cross sectional area of the pipe. At elbows or

bends, the resultant force is given by


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T = 2 PA sin

2where -

T = the thrust force in kg.

P = internal pressure kg/cm 2 (g)

A = cross sectional areas of the pipe in sq.cm.

= Angle of deflection in degrees.

The above forces are shown in Fig. 4. In addition there are also smallunbalanced forces at bends caused by the velocity of water flow withinthe pipeline. In general this velocity is so low in transmission or distribution system that its effect is negligible and the thrust forcecaused by velocity is not considered.

The anchorages commonly used on pipelines are classified under following four categories, viz.

(a) Solid or gravity type anchor block (refer Fig 5 a).

(b) Solid type of thrust block for above ground pipe line(refer Fig.5b)

(b) Open type anchor blocks (refer Fig 5c).

(c) Frame anchors (refer Fig 5 d).

(c) Ground anchors (refer Fig 5e).

(d) Gravity block(full block) (refer Fig.5f)

(e) Gravity block(half block)(refer Fig.5g)

Frame anchors are generally adopted for ring girder pipelines for resisting unbalanced forces due to friction in expansion joints and atsupports. Anchor indicated in Fig. 5 g is used where the soil is hard or the terrain is rocky.

Pipelines laid on slopes, particularly above ground, always have atendency to creep downhill. It is necessary to provide anchor blocks

placed against undisturbed earth at sufficiently frequent intervals on along, steep slope to reduce the weight of pipe supported at eachanchorage to a safe figure.


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9.0 SPECIALS

Various types of fixtures adopted in pipeline for ensuring proper functioning, such as, flanges, branches, expansion joints etc. Thedesign aspects of some of these fixtures are given in the ensuring

paragraphs.

9.1 FLANGES

Flanges commonly used on pipelines for fixing appurtenances, such asvalves, are of slip ring type or loose rings. These flange rings areeither of unsupported construction or of supported type as illustrated in

the Figs. 6 .

The standard flanges used for fixing appurtenances are of unsupportedtype, generally conforming to the requirements of IS 6392 or BS 4504(Part I), in regard to drilling pattern, number of bolts, diameter of bolts,thickness, PCD etc. for different pressure ratings.

Non standard flanges, where adapted, are designed for specific pressure operating in the pipeline, meeting the requirements of allowable stresses in the flange, bolt and gasket material, as per

relevant codes.

9.2 BRANCHESFor the purpose of dividing or combining flow in pressure pipelines,

branch assembly, such as, tees, wyes and headers are used. These branches are often reinforced to take care of unbalanced forcesdeveloped in the shell, due to removal of pipe shell portion at the

junction of the arms of the branch.

These branches are usually fabricated from thicker plates than thoserequired from hoop stress consideration. They are generally reinforced,where required, with saddle type reinforcement.In saddle type reinforcement, steel is added, if necessary, to make upfor the area lost in the cutting within the prescribed zone, equal to half the diameter of opening on either side of main pipe, such that, the hooptension that would be taken by the metal lost in cutting would now betaken by this reinforcement along with the spare thickness available inthe main pipe and the branch pipe, as shown in the Fig. 7.

Referring to Fig. 7, the area removed by the opening of the branch iscompensated by the spare area available in pipe shell and branch wallin the figure as well as by saddle reinforcement and the welds. If required, reinforcement pad calculation shall be carried out as per


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ASME Section-VIII, Div.1. Complicated branch-off especially on high pressure lines require finite element analysis.

9.3 EXPANSION JOINTS

Steel pipelines when laid above ground require expansion joints atspecified intervals to absorb the effect of expansion and contractiontaking place in the metal particularly when the pipeline is empty.Expansion joints may be located midway between the anchors if the

pipeline is laid level. On slope, the joint is usually best placed adjacentto or on the downhill side of the anchor point. If such expansion jointsare not provided, the pipeline when it expands is likely to shift away

from its alignment and if such lateral movement is prevented by providing anchorages, the pipe shell is likely to be subjected to heavystresses necessitating the thickness of pipes being considerablyincreased. Cost of pipes with thick shells and bulky anchorages would

be high as compared to installation of expansion joints at requiredintervals. The most common type of expansion joint used in water mains of telescopic construction, which accommodate the expansionand contraction movement of the pipe by suitable displacement of inner stake, Fig. 8 gives the details of telescopic expansion joints. It isalso recommended to provide guide support after the expansion jointwith the first guide at a distance not exceeding 4 times outside

diameter of pipe.

9.4 MANHOLES

For inspection and maintenance of the pipelines sufficient number of manholes are to be provided. The most common type in water work iscircular, having a short, flanged neck and a flat, bolted cover.Manholes will be most useful if located close to valves in the line andsometimes close to the low points that might need to be pumped outfor inspection or repair. Manholes shall preferably be located at aspacing of 300 to 500 m.

10.0 PIPE JOINTS

Steel pipe lengths can be joined together in the field by many differentmethods to effect rigid or flexible connections, though this type of

joints are not normally used in our office, details are enclosed for information only:.

Bell & Spigot Lap Welded Joint

Bell & Spigot rubber Gasket Joint

Butt Welded Joints


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Butt strap joint for welding

Mechanically Coupled Joints

Flanged joint for Bolting

For details of each joint indicated above refer Fig 9

10.1 BELL & SPIGOT LAP WELDED JOINTS

The Bell and Spigot lap welded joint is widely used because of itsflexibility, ease in forming and joining, water-tightness and simplicity,

small angle changes can be made in this joint. The joint is welded oneither the inside, or outside with properly sized weld.

10.2 BELL & SPIGOT RUBBER GASKET JOINT

(a) Formed rubber gasket joint, usually applied to large diameter water pipe

(b) Rolled-groove rubber gasket joint, usually applied to smalldiameter water pipe

Bell and Spigot Rubber Gasket Joints simplify laying the pipe andrequire no field welding. They permit flexibility, water-tightness,lower installation costs, elimination of bell-holes, etc. Gasketsconform to AWWA Standards. But these require anchors to preventopening out due to internal pressure.

10.3 BUTT-WELDED JOINTS

Butt-welded joints will develop full strength, but will require morecare in cutting and fitting up in the field if changes in alignment or

profile occur frequently. Where welded joints are used, the pipe should be left bare a sufficient distance back from the ends to avoid damagingthe protective coating by the heat produced during welding. These

joints should be field coated after welding.

10.4 BUTT STRAP JOINT FOR WELDING

The butt strap is closure-joint used for joining ends of pipe whenadjustments are required in the field. This is used for cement lined

piping.


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10.5 MECHANICAL COUPLINGS

Mechanical couplings provide ease of installation and flexibility andare represented by the sleeve and clamp type of coupling.

10.6 FLANGED JOINTS

Flanged joints are not generally used for field joints on large diameter steel pipe because of their high cost and lack of flexibility. They areadvantageous, however, for special conditions, such as connections toflanged valves, bridge crossings walls etc.

10.7

Besides above mentioned joints, Harness joints and Carnagie Shaperubber gasket joints are also used.

11.0 TESTING OF PIPE LINES

Factory and field testing requirements of pipe lines shall be as per AWWA M11.

12.0 PROTECTIVE COATINGS

Interior and exterior surfaces of both above ground and underground

pipes may get corroded depending on several factors. It is the duty of the design engineer to know the principles and causes of corrosion andadopt sufficient protective measures to combat the same.

12.1 PROTECTIVE COATINGS FOR EXTERNAL SURFACE

12.1.1 Above Ground Piping

The exterior surface of the above ground pipes is generally protectedfrom atmospheric corrosion by paints. Two coats of red lead primer and one coat of an approved paint is generally suitable for averagewater works conditions .However based on the site conditions like

proximity to sea etc. the application may vary and suitable protectionmethods shall be adopted based on the same.

12.1.2. Buried Piping

Many factors influence underground soil corrosion. The single mostimportant factor, however, which is readily measured is the resistivityof the soil.

Coatings have long been used to inhibit the corrosion process. TheAmerican Water Works Association presently recognises two coatingsmaterials - coal tar enamel and cement mortar - for steel water pipes.


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Coal tar enamel has a long and successful record of performance. It provides high electrical resistivity, is impervious to water, is stable andchemically inert, has good electrical strength, is easy to install, and isreasonable in cost. Coal tar enamel is an insulating type coating that

bonds tightly to the pipe surface, depending upon its excellent physicaland chemical characteristics for its insulative protective action.

Cement mortar coatings provide protection by shielding steel from thesoil and providing a highly alkaline environment at the steel mortar interface which tends to passivate the steel. This passivation reducesthe corrosion current flow by polarisation.

Coatings cannot usually be depended upon to provide perfect coverageof the exterior metal surface, and therefore, corrosion can continue ona coated pipeline at the voids or holidays on the coating. While thesecoatings will always reduce the overall corrosion problem, they canactually increase the intensity of the pitting attack at their holidays.Cathodic protection is used to complete the corrosion protection.Cathodic protection is the physical act of reversing the electro-mechanical corrosive force and stopping the destructive process whichattacks the ferrous metal at the coating holidays. Normally Cathodic

protection is recommended when the soil resistance is 2000 ohm/cc or less, For further details refer IS:10221. In case of pipes where

Cathodic protection is provided, insulating joints are provide at the junction where the pipe becomes above ground.

12.2 PROTECTIVE COATINGS FOR INNER SURFACE

The effectiveness of internal corrosion control provided for steel water pipes is well established. AWWA has approved two materials - CoalTar Enamel (generally 500NB & above) and Cement Mortar - for lining steel water pipe. The prime function of this lining in a pipelineis to provide and sustain a high hydraulic flow capacity. The flowcapacity is maintained by preventing a build up of tubercles, and

providing a smooth surface inside the pipe. Lining materials applied inaccordance with AWWA standards provide a minimum Hazen-Williams flow coefficient (C) of 140.

13.0 REFERENCES

The following literature can be referred if further details are requirewith respect to large diameter piping:

(a) American Society of Civil Engineers - ASCE Manuals andReports on engineering practice no. 79 - steel penstock.

(b) AWWA - M11


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(c) AWWA C208

(d) TCE Design Guides:

TCE.M6-ME-613-212

TCE.M6-CV-HS-G-010

TCE.M6-CV-HS-G-019

Large Diameter Steel Piping

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