HYDROSTATIC TEST PRESSURE FORMULA P = 20 x k x s x t / D (bar) P = internal unites pressure (bar) S = minimum yield strength (MPa) D = outside diameter of pipe (mm) t = wall thickness of pipe (mm) k = the percentage of yield strength included in the calculation k values acc. to API 5L For Grade A and B k=0,60 For Grade X42-X80 Outside diameter <5 9/16 inch k=0,60 Outside diameter 6 5/8 -8 5/8 inch k=0,75 Outside diameter 10 3/4 -18 inch k=0,85 Outside diameter >20 inch k=0,90 RELATIONSHIP BETWEEN DESIGN PRESSURE AND WALL THICKNESS Pdesign = 2 x S x t x F x L x J x T / D (CSA Z662-03) Pdesign = 2 x S x t x F x J x T / D (ASME B31.8) Pdesign = 2 x S x t x F x J / D (ASME B31.4) Pdesign = pipeline design pressure (psi) S = minimum yield strength (psi) D = pipeline outside diameter of pipe (inches) t = wall thickness of pipe (inches) F = design factor L = location factor J = longitudinal joint factor T = temperature derating factor CSA = The Canadian Standards Association ASME = American National Standard Institute • The design factor (F) – Gas Application CSA Z662-03 ASME B31.8-B31.4 F x L F Class1 Class2 Class3 Class4 Class1 Class2 Class3 Class4 General 0,80 0,72 0,56 0,44 0,80 0,60 0,50 0,40 Roads 0,60 0,50 0,50 0,40 0,60 0,50 0,50 0,40 Railways, 0,50 0,50 0,50 0,40 0,60 0,50 0,50 0,40 Station 0,50 0,50 0,50 0,40 0,50 0,50 0,50 0,40 • The location factor (L) 1
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HYDROSTATIC TEST PRESSURE FORMULA
P = 20 x k x s x t / D (bar)
P = internal unites pressure (bar)S = minimum yield strength (MPa)D = outside diameter of pipe (mm)t = wall thickness of pipe (mm)k = the percentage of yield strength included in the calculation k values acc. to API 5L For Grade A and B k=0,60For Grade X42-X80Outside diameter <5 9/16 inch k=0,60Outside diameter 6 5/8 -8 5/8 inch k=0,75Outside diameter 10 3/4 -18 inch k=0,85Outside diameter >20 inch k=0,90
RELATIONSHIP BETWEEN DESIGN PRESSURE AND WALL THICKNESS
Pdesign = 2 x S x t x F x L x J x T / D (CSA Z662-03)Pdesign = 2 x S x t x F x J x T / D (ASME B31.8)Pdesign = 2 x S x t x F x J / D (ASME B31.4)
Pdesign = pipeline design pressure (psi)S = minimum yield strength (psi)D = pipeline outside diameter of pipe (inches)t = wall thickness of pipe (inches)F = design factorL = location factorJ = longitudinal joint factorT = temperature derating factorCSA = The Canadian Standards AssociationASME = American National Standard Institute
a For each reduction of 0.01% below the specified maximum carbon content, an increase of 0.05% above the specified max-imum manganese content is permissible, up to a maximum of 1.50% for Grades X42 through X52, up to a maximum of 1.65% for grades higher than X52 but less than X70, and up to 2.00% for Grades X70 and higher.
c Columbium [niobium], vanadium, titanium, or combinations thereof may be used at the discretion of the manufacturer.
d The sum of the columbium [niobium], vanadium, and titanium contents shall not exceed 0.15%.
e The sum of the columbium [niobium], vanadium and titanium contents shall not exceed 0.06% except that, by agreement between the purchaser and manufacturer, an alternative maximum may be established.
f Other chemical compositions may be furnished by agreement between purchaser and manufacturer, providing that the limits of Footnote d, and the tabular limits for phosphorus
and sulfur are met.
CALCULATION OF CARBON EQUIVALENT,
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For PSL 2 pipe, carbon equivalent (CE) calculations shall be based on the product analyses and shall be calculated as follows. All carbon equivalent results shall be reported: a. When the carbon content is less than or equal to 0.12%, the carbon equivalent shall be calculated using the following formula for CE(Pcm):
If the heat analysis indicates a boron content less than0.001%, then the product analysis need not include boron, and the boron content can be considered as zero for the CE(Pcm) calculation.
b. When the carbon content is greater than 0.12%, the carbon equivalent shall be calculated using the following formula for CE(IIW)
MAXIMUM CARBON EQUIVALENT,The carbon equivalent shall not exceed the following:a.For Grade X80 pipe, for all grades of seamless pipe having a specified wall thickness greater than 0.800 in. (20.3 mm) and for pipe designated by
the purchaser as high carbon equivalent pipe, the value agreed upon between the purchaser and the manufacturer.b.For pipe not covered in Item a above, a CE(Pcm) of 0.25%or a CE(IIW) of 0.43%, whichever is applicable.
Note 1: The CE(Pcm) formula for low carbon steel is commonlyc alled the Ito-Bessyo formula. CE (Pcm) is in fact the chemical portion of the full formula. Reference: Y. Ito & K. Bessyo, “Weldability Formula of High Strength Steels Related to Heat Affected Zone Cracking, Journal of Japanese Welding Society, 1968, 37, (9), 938.
Note 2: The CE(IIW) formula is commonly called the IIW [International Institute of Welding] formula. Reference: Technical Report,1967, IIW doc. IX-535-67.
Size Tolerancea (with respect to specified outside diameter)
< 2 3/8 + 0.016 in. - 0.031 in. (+ 0.41mm, - 0.79 mm)
≥2 3/8 and, ve ≤4 ½ , continuous welded ± %1.00
> 2 3/8 and <20 ± % 0.75
> 20, seamless ± % 1.00
> 20 ve < 36, welded + %0.75, - % 0.25
> 36, welded + ¼ in. - 1/8 in. (+ 6.35 mm, - 3.20 mm)
a In the case of pipe hydrostatically tested to pressures in excess of standard test pressures, other tolerances may be agreed upon between the manufacturer and the purchaser
TOLERANCE FOR DIAMETER AT PIPE ENDS FOR API 5L
Size Minus Tolerance Plus Tolerance End-to-End Tolerance
Out-of-RoundnessDiameter, Axis Tolerance (Percent of Specified OD)a
Maximum Differential Between Minimum and Maximum Diameters (Applies Only to Pipe With D/t ≤ 75)
<10 ¾ 1/64(0.40 mm) 1/16 (1.59 mm) - - -
>10¾ ve <20 1/32 (0.79 mm) 3/32 (2.38 mm) - - -
>20 ve <42 1/32 (0.79 mm) 3/32 (2.38 mm) b ± 1 % < 0.500 in. (12.7 mm)
> 42 1/32 (0.79 mm) 3/32 (2.38 mm) b ± 1 % < 0.625 in. (15.9 mm)
a Out-of-roundness tolerances apply to maximum and minimum diameters as measured with a bar gage, caliper, or device measuring actual maximum and minimum diameters. b The average diameter (as measured with a diameter tape) of one end of pipe shall not differ by more than 3/32 in. (2.38 mm) from that of the other end.
TOLERANCES FOR WALL THICKNESS FOR API 5L
Size Type of Pipe Tolerancea (Percent of Specified Wall Thickness)
Grade B or Lower Grade X42 or Higher
< 2 7/8 All + 20.0, - 12.5 + 15.0, - 12.5
> 2 7/8 ve <20 All + 15.0, - 12.5 + 15.0, - 12.5
>20 Welded + 17.5, - 12.5 + 19.5, - 8.0
> 20 Seamless + 15.0, - 12.5 + 17.5, - 10.0
a Where negative tolerances smaller than those listed are specified by the purchaser, the positive tolerance shall be increased to the applicable total tolerance range in percent less the wall thickness negative tolerance.
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EN 10025:2004 MECHANICAL PROPERTIES FOR FLAT AND LONG PRODUCTS
Designation,
Deoxidation
Old Standard Subgroup Minimum Yield Strength ReH in N/mm² Tensile Strength Rm in N/mm²
TOLERANCE OF DIAMETER AND WALL THICKNESS FOR EN 10217-1
Size Outside Diameter Wall thickness, Et kalınlığı *
T≤5 5<T≤40
D≤219.1±% 1 or, veya ±0.5 Which one greater,
hangisi büyükse ±% 10 or, veya ± 0.3 Which one greater,
hangisi büyükse
±% 8 or, veya ± 2 Which one smaller,
hangisi küçükseD>219.1
±% 0.75 or, veya ±6Which one smaller,
hangisi küçükse* Not included weld area for plus tolerance.
WELDING WIRES, Kaynak telleri Asfil EN 756 (TS 5387) AWS A5.17 AWS A5.23S1 S1 (S 38 2 AB S1 – flux 860) EL 12 --S2 S2 (S 35 2 AB S2 – flux 860) EM 12 --S2 Si S2 Si (S 46 2 MS S2Si – flux 761) EM 12K --S2 Mo S2 Mo (S 46 4 AB S2Mo – flux 223) -- EA 2
Aluminate-Rutile ARAluminate-Basic ABAluminate-Silica AS
Aluminate-Fluoride-Basic
AF
Fluoride-Basic FBOther-Types, Diğer
TiplerZ
WELDING FLUX, Kaynak tozu
EN 760 A AB 1 67 AC H5 (P223)
Surface Preparation Standards
There are several National and International Standards which define the visual assessment of surface cleanliness of steel before application of paint and related products.
The equivalence of the Standards is summarized in the following table:
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Charpy Impact Energy,-40ºC, 47J
Tensile strength
SAW wire-flux combination
Standard name and number,
Metallurgical values (Si-6, Mn-7)
Hydrogen for 100 gr welding metal
Class
Flux type (Aluminate-Basic)
Current type (alternating current)
Flux production type (F,A,M)
Standard name and number
ISO 8501-1 (1988) BS 7079:A1 (1988)
Swedish Standard SIS055900 (1967)
SSPC (1982)
NACE
White MetalSa 3 Sa 3 SP5 1
Near White MetalSa 2.5 Sa 2.5 SP10 2
Commercial BlastSa 2 Sa 2 SP6 3
Brush-Off BlastSa 1 Sa 1 SP7 4
SURFACE PROFILE AND ABRASIVE SELECTION
Reference Comparator G and S to ISO 8503-1 are available for the visual assessment of grit&shot blasted surfaces.
Comparator G Comparator S RemarksFine(G) Fine (S) 1≥ Segment > 2
Medium (G) Medium (S) 2 ≥ Segment > 3Coarse (G) Coarse (S) 3 ≥ Segment > 4
Further detailed information relating to surface preparation may be obtained from the relevant specifications listed as follows:1. International Standard ISO 8501-1:1988 “Specification for rust grades of uncoated steel substrates and of steel substrates after overall
removal of previous coating” (BS 7079:Part A1:1994).2. International Standard ISO 8503-2:1988 “Method for the grading of surface profile of abrasive blast-cleaned steel. Comparator Procedure”
(BS 7079:Part C2:1989).3. Swedish Standard SIS O5 59 00 (1967) - “Pictorial Surface Preparation Standards for Painting Steel Surfaces”
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4. Steel Structures Painting Council (SSPC) Volume 2 Systems & Specifications.
ISO 11124-3 SIZE GRADING FOR STEEL GRIT
Product Size (mm)
% : min & max cumulative percentages allowed on corresponding sieves
G12 0%
80%min
90%min
1.7 -2.4
G14 0%
80%min
90%min
1.4 -2.0
G16 0%
75%min
85%min
1.2 -1.7
G18 0%
75%min
85%min
1.0 -1.4
G25 0%
70%min
80%min
0.71 -1.2
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G40 0%
70%min
80%min
0.42 -1.0
G50 0%
65%min
75%min
0.3 -0.71
G80 0%
65%min
75%min0.18 -0.42
SAE Sieve No
7 8 10 12 14 16 18 20 25 30 35 40 45 50 80 120
Aperture
2.8
0
2.3
6
2.0
0
1.7
0
1.4
0
1.1
8
1.0
0
0.8
5
0.7
1
0.6
0
0.5
0
0.4
25
0.3
55
0.3
0
0.1
8
0.1
25
ISO 11124-3 SIZE GRADING FOR STEEL SHOT
Product Size (mm)
% : min & max cumulative percentages allowed on corresponding sieves
S7802.0 -2.8
0% 85%min
97%min
S6601.7 -2.4
0% 85% min
97% min
S5501.4 -2.0
0% 85% min
97% min
S4601.2 -1.7
0% 5% max
85% min
96% min
S3901.0 -1.4
0% 5% max
85% min
96% min
S3300.85 -1.2
0% 5% max
85% min
96% min
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S2800.71 -1.0
0% 5% max
85% min
96% min
S2300.6 0 0.85
0% 10% max
85% min
97% min
S1700.42 -0.71
0% 10% max
85% min
97% min
S1100.3 -0.5
0% 10% max
80% min
90% min
S700.18 -0.35
0% 10% max
80% min
90% min
SAE Sieve No
7 8 10 12 14 16 18 20 25 30 35 40 45 50 80 120
Aperture
2.8
0
2.3
6
2.0
0
1.7
0
1.4
0
1.1
8
1.0
0
0.8
5
0.7
1
0.6
0
0.5
0
0.4
25
0.3
55
0.3
0
0.1
8
0.1
25
SURFACE ROUGHNESS PARAMETERS
Parameters Defined in ASME B46.1 Corresponding Parameters in ISO 4287, Ra Arithmetic Average Deviation of the Assessed Profile RaRq Root Mean Square Deviation of the Assessed Profile RqRp Maximum Profile Peak Height RpRz Average Maximum Height of the Profile RyRmax Maximum Roughness Depth ---
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LENGTH EQUIVALENTS
Convert, Meters Inches Feet Millimeters Miles Square Kilometers
U.S. METRIC Pounds (Avoirdupois) x 0.45359 = KilogramsTons (2000 pounds) x 0.90718 = Metric TonsTons (2240 pounds) x 1.01605 = Metric TonsInches x 2.54001 = CentimetersInches x 25.4001 = MillimetersFeet x 0.304801 = MetersSquare Inches x 6.45163 = Square CentimetersSquare Feet x 0.0929 = Square MetersCubic Inches x 16.38716 = Cubic CentimetersCubic Feet x 0.02832 = Cubic MetersPounds per Foot x 1.48816 = Kilos per MeterOunces per Square Foot x 0.030515 = Grams per Square CentimeterOunces per Square Foot x 305.15 = Grams per Square MeterPounds per Square Inch x 0.07031 = Kilograms per Square CentimeterPounds per Square Inch x 0.0007031 = Kilograms per Square MillimeterPounds per Square Foot x 4.88241 = Kilograms per Square MeterPounds per Cubic Foot x 16.01837 = Kilograms per Cubic Meter
METRIC U.S.Kilograms x 2.20462 = Pounds (Avoirdupois)Metric Tons x 1.10231 = Tons (2000 pounds)Metric Tons x 0.98421 = Tons (2240 pounds)Centimeters x 0.3937 = InchesMillimeters x 0.03937 = InchesMeters x 3.280833 = FeetSquare Centimeters x 0.155 = Square InchesSquare Meters x 10.76387 = Square FeetCubic Centimeters x 0.06102 = Cubic Inches
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Cubic Meters x 35.31445 = Cubic FeetKilograms Per Meter x 0.67197 = Pounds per FootGrams per Square Centimeter x 32.771 = Ounces per Square FtGrams per Sq Meter x 0.0032771 = Ounces per Square FtKilograms per Square Centimeter x 14.2234 = Pounds per Sq InchKilograms per Square Millimeter x 1422.34 = Pounds per Sq InchKilos per Sq Meter x 0.20482 = Pounds per Sq InchKilos per Cubic Meter x 0.06243 = Pounds per Cubic Foot
CONVERSION CONSTANTS
To Convert From To Multiply By
Gallons Pounds of water 8.33 Pounds of water Gallons 0.12004
Ounces Pounds 0.0625 Pounds Ounces 16
Inches of water Pounds per square inch 0.0361 Inches of water Inches of mercury 0.0735 Inches of water Ounces per square inch 0.578 Inches of water Pounds per square foot 5.2
Inches of mercury Inches of water 13.6 Inches of mercury Feet of water 1.1333 Inches of mercury Pounds per square inch 0.4914
Ounces per square inch Inches of mercury 0.127 Ounces per square inch Inches of water 1.733 Pounds per square inch Inches of water 27.72 Pounds per square inch Feet of water 2.310 Pounds per square inch Inches of mercury 2.04 Pounds per square inch Atmospheres 0.0681
Feet of water Pounds per square inch 0.434 Feet of water Pounds per square foot 62.5 Feet of Water Inches of mercury 0.8824 Atmospheres Pounds per square inch 14.696 Atmospheres Inches of mercury 29.92 Atmospheres Feet of water 34
Long tons Pounds 2240 Short tons Pounds 2000 Short tons Long tons 0.89285
A : Surface aread : Arithmetic mean of the two diagonals, d1 and d2 in mmF : Load in kgfHV : Vickers hardness
To convert HV to MPa multiply by 9.807
Vickers hardness numbers are reported as 440HV30 :
440 : the hardness numberHV : gives the hardness scale (Vickers)30 : the load used in kgf
SURFACE AREA AND VOLUME FORMULAS
Geometric Shape Surface Area
Prism
Prism (general) SA=2B+Ph
SA=2lw + (2l + 2w)h
SA=6s²
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Pyramid
Regular Pyramid (general), SA=B+n(0,5 bs)
SA=B + n(0,5 s) bSA=b² + 4(0,5)(4) s
SA=b² + 8s
Cylinder SA=2π r²+ πdh
ConeSA=π r²+ πrs
S=slant height
Sphere SA=4π r²h
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DIN 30670 MINIMUM COATING THICKNESS
Pipe size, mm
Min. Thickness of coating in mm,
Diameter, çap < DN 100 1.8100 ≤ Diameter, çap < 250 2.0250 ≤ Diameter, çap < 500 2.2500 ≤ Diameter, çap < 800 2.5
Diameter, çap ≥ 800 3.0
Along any 1 m length of pipe, the coating thickness may be up to 10% less than the minimum required, provided the thinner area does not cover more than 5 cm²
DIN 30670 TESTS
Surface Cleanliness Comparison = Sa 2 ½ - DIN 55928 Part 3
Bond Strength = at a test temperature of (20 ±5) ºC, be at least 35 N per cm of test piece width
at a test temperature of (50 ±5) ºC, be at least 15 N per cm of test piece width for type N coatings, and 25 N per cm type S coatings
Continuity (holiday) = 25 kV
Impact Strength = 30 impact, darbe
Indentation hardness = 0.3 mm (23 ±2 ºC)
Percentage elongation at failure= 200 %
Coating Resistivity = 108 Ω m²
Heat and light ageing = the melt flow rate shall not deviate by more than 35 % of the original value
APPLICATION PROCESS FOR PE COATING OF JOINT AREA
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1 Heat the steel surface to be insulated to 40-50ºC and clean to the purification degree 2 as per GOST 9.402. Treat the polyethylene coating with emery paper to provide sufficient surface roughness.
2 Heat the insulated surface and adjacent factory insulation coating to at least 90ºC (in summer) or 110 (+10) ºC. Apply the preliminary prepared epoxy primer onto the steel surface and the adjacent factory insulation coating over the entire insulated portion.
3 Wrap the sleeve around the weld joint so that the overlap with the factory coating is at least 75 mm at each side and the overlap of the sleeve ends is at least 100 mm.
4 Heat the glue layer with a soft flame on the closure plate and install the plate in the central position onto the sleeve end overlap by hitting it with a hand or rolling with a silicon roller. The closure plate should be located on the pipe circumference near the 2 or 10 o’clock position.
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5 Heat the sleeve with a soft flame from the center to the edges beginning from the bottom part of the weld joint to remove bubbles from the sleeve surface.
APPLICATION PROCESS FOR REPAIR OF PE COATING
1 Heat the repaired polyethylene coating portion to 100 (+10ºC) and remove the damaged factory coating with a spatula or a knife. Smooth the sharp edges of the coating and make the coating more rough (with emery paper) over a 75 mm area around the removed coating portion. Remove rust from the repaired pipe surface portion with emery paper.
2 Heat the steel surface to 60ºC and polyethylene surface of the repaired portion to 100 (+10) ºC (within a 100 mm area around the damaged spot). Apply the repair filler (preliminary cut to size) onto the steel and polyethylene pipe surfaces. Heat the filler with a gas burner, fill in the damaged portion with a spatula and uniformly distribute it with the spatula over the polyethylene surface (over a 75 mm area around the damaged spot).
3 Heat the adhesive layer (preliminary cut to ensure 40-45 mm overlap with the factory coating). Heat until the adhesive layer becomes lustrous.
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4 Install the tape onto the repaired pipe area so the tape adhesive layer extend from beneath the tape to at least 20 mm. Heat the tape with a gas burner and roll down with a roller remove glue blobs and air bubbles.
5Roll the tape down with a silicon roller to remove glue blobs and bubbles.