IS 3589

I S 3589 : 2001Ed i t ion 4.2 (2003-10) B U R E A U O F I N D I A N S T A N D A R D S MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG NEW DELHI 110002 P r i ce Gr ou p 7 © BIS 2003 Indian S tandard STEEL PIPES FOR WATER AND SEWAGE (168.3 TO 2 540 mm OUTSIDE DIAMETER) — SPECIFICATION ( Third Revision ) (Incor por at ing Amendment Nos. 1 & 2) ICS 77.140.30;41.140.60;91.140.80 St eel Tubes, Pipes and Fit t ings Sect ional Commit t ee, MTD 19 FOREWORD This Indian St andar d (Thir d Revision) was adopt ed by t he Bur eau of Indian St andar ds, aft er t he dr aft finalized by t he St eel Tubes, Pipes and Fit t ings Sect ional Commit t ee had been appr oved by t he Met allur gical Engineer ing Division Council. This st andar d was or iginally published in 1966, fir st r evised in 1981 and subsequent ly in 1991. While r eviewing t his st andar d in t he light of t he exper ience gained dur ing t hese year s, t he commit t ee felt t o r evise t he same, t aking not e of t he pr esent pr act ices being followed in t he count r y and also over seas st andar ds exist ing on t he subject . In t he r evision of t his st andar d t he following main modificat ions have been made: a) Pr ovision of out side diamet er s and t hicknesses of pipes have been r evised in accor dance wit h t he pr ovisions, of Int er nat ional St andar ds. b) Exhaust ive t ables for chemical composit ion of st eels t o be used and t ensile pr oper t ies of t he pipes have been incor por at ed. c) Annexes A t o D as t he guideline for ‘Pr ot ect ion Against Cor r osion’ have been added which r ecommend met hods of pr ot ect ing pipes against cor r osion. It cover s ext er nal as well as int er nal pr ot ect ion. Separ at e Indian St andar ds incor por at ing var ious t ypes of pr ot ect ive coat ings and mat er ials t her eof ar e expect ed t o be published in due cour se of t ime. In t he for mulat ion of t his st andar d due weight age has been given t o int er nat ional coor dinat ion among t he st andar ds pr evailing in differ ent count r ies in addit ion t o t he pr act ices in t he count r y. This has been met by der iving assist ance fr om t he following publicat ions: This edit ion 4.2 incor por at es Amendment No. 1 (May 2002) and Amendment No. 2 (Oct ober 2003). Side bar indicat es modificat ion of t he t ext as t he r esult of incor por at ion of t he amendment s. For t he pur pose of deciding whet her a par t icular r equir ement of t his st andar d is complied wit h, t he final value, obser ved or calculat ed, expr essing t he r esult of a t est or analysis, shall be r ounded off in accor dance wit h IS 2 : 1960 ‘Rules for r ounding off numer ical values ( revised )’. The number of significant places r et ained in t he r ounded off value should be t he same as t hat of t he specified value in t his st andar d. ISO 559-1991 St eel t ubes for wat er and sewage ( second edit ion ), Int er nat ional Or ganizat ion for St andar dizat ion. ISO 4200 : 1991 Plain end st eel t ubes, welded and seamless — Gener al t ables of dimensions and masses per unit lengt h. Int er nat ional Or ganizat ion for st andar dizat ion. BS 534 : 1990 St eel pipes and specials for wat er and sewage. Br it ish St andar ds Inst it ut ion. I S 3589 : 2001 1 Indian S tandard STEEL PIPES FOR WATER AND SEWAGE (168.3 TO 2 540 mm OUTSIDE DIAMETER) — SPECIFICATION ( Third Revision ) 1 SCOP E This st andar d applies t o seamless and welded car bon st eel pipes for wat er and sewage of out side diamet er fr om 168.3 t o 2 540 mm. 2 REF ERENCES The following Indian St andar ds cont ain pr ovisions which t hr ough r efer ence in t his t ext const it ut e pr ovisions of t his st andar d. At t he t ime of publicat ion, t he edit ions indicat ed wer e valid. All st andar ds ar e subject t o r evision and par t ies t o agr eement s based on t his st andar d ar e encour aged t o invest igat e t he possibilit y of applying t he most r ecent edit ions of t he st andar ds indicat ed below: 3 TERMI NOLOGY For t he pur pose of t his st andar d, t he following definit ions shall apply. 3.1 P i p e (Tu b e ) A long hollow open ended object of cir cular cr oss-sect ion. The t er m t ube is synonymous wit h t he t er m pipe. 3.2 Hyd r ost a t ic Te st P r e ssu r e Test pr essur e for hydr aulic t est ing at t he wor ks. 3.3 Ra n d om Len gt h s The t er m r andom lengt h denot es t he nor mal manufact ur ing lengt h falling wit hin a r ange agr eed t o bet ween t he pur chaser and t he manufact ur er . 3.4 Exa ct Le n gt h s Pipes cut t o a specified lengt h on which only a small t oler ance is allowed. 3.5 Effe ct ive Len gt h The act ual lengt h t hat a pipe cont r ibut es when cor r ect ly assembled in a r un of piping. This dimension excludes t he addit ional lengt h cont r ibut ed by a slip-on t ype coupling when t hat is used. 4 I NF ORMATI ON TO BE SUP P LI ED BY THE P URCHASER WHI LE P LACI NG ORDER 4.1 Ma n d a t or y I n for ma t ion s a) t he quant it y or der ed (t ot al t onnage, t ot al lengt h or number of t ubes); b) t he number of t his st andar d; c) t he gr ade of st eel; d) t he out side diamet er and t hickness; e) t he lengt h of pipes; f ) t he end pr epar at ion (bevelled ends or special joint s); and g) t he t ype of ext er nal coat ing and/or int er ior lining as agr eed pr eviously wit h t he manufact ur er . 4.2 Op t i on a l Req u i r emen t s Cer t ain opt ional and supplement ar y r equir ement s may also be specified as under : a) t he st eel making pr ocesses and deoxidat ion pr ocedur es; b) t he t ube making pr ocess; c) deliver y condit ion; d) ladle analysis; e) deliver y lengt hs; and f ) end pr epar at ion. IS No. Title 228 Met hods of chemical analysis of st eels (issued in var ious par t s) 1608 : 1995 Met hods for t ensile t est ing of st eel pr oduct s ( second revision ) 2328 : 1983 Met hod for flat t ening t est on met allic t ubes ( first revision ) 3803 (Par t 1) : 1989/ISO 2566 : 1984 Met hod for elongat ion conver sions for st eel: Par t 1 Car bon and low alloy st eels ( second revision ) 4711 : 1974 Met hods for sampling of st eel pipes, t ubes and fit t ings ( first revision ) 4736 : 1986 Hot -dip zinc coat ings on mild st eel t ubes ( first revision ) I S 3589 : 2001 2 5 DESI GNATI ON 5.1 The pipes shall be designat ed by t he met hod of manufact ur e followed by t he gr ade number cor r esponding t o t he minimum specified t ensile st r engt h in MPa following t he symbol Fe as given in Table 1. Example: ERW —Fe410 indicat es elect r ic r esist ance welded or induct ion welded st eel pipe having a minimum t ensile st r engt h of 410 MPa. Ta b le 1 Desi gn a t i on of t h e Gr a d e s of t h e P i p e s 5.2 The size of t he pipes shall be designat ed by t heir out side diamet er s in mm. 6 QUALI TY OF STEEL Pipes shall be manufact ur ed wit h t he st eel pr oduced by t he open hear t h or elect r ic fur nace or one of t he basic oxygen pr ocesses. Ot her pr ocesses may be used by agr eement bet ween t he pur chaser and t he manufact ur er . 7 MANUFACTURE OF THE P RODUCT The pipes shall be manufact ur ed by one of t he following pr ocesses. 7.1 Sea ml e ss P i p e s The pipes shall be manufact ur ed by using a seamless pr ocess and shall eit her be hot or cold finished. 7.2 El ect r i c Resi st a n ce We ld ed P ip es The pipes shall be manufact ur ed fr om plat e, sheet or st r ip welded cont inuously by t he passage of an elect r ic cur r ent acr oss t he abut t ing edges longit udinally or spir ally. The finished pipes shall not include welds used for joining lengt hs of t he hot or cold, flat r olled st r ips pr ior t o t ube for ming. The ext er nal weld bead shall be r emoved complet ely. 7.3 Su b me r ge d Ar c We ld e d P ip e s The pipes shall be manufact ur ed fr om plat e, sheet or st r ip wit h eit her a single or double longit udinal seam or a spir al seam and welded acr oss t he abut t ing edges by an aut omat ic submer ged ar c welding pr ocess using at least t wo r uns, one of which shall be on t he inside of t he pipes. 7.4 Rep a i r b y We l d i n g 7.4.1 Injur ious defect s in pipe wall, pr ovided t heir dept h does not exceed one t hir d of t he specified wall t hickness, shall be r epair ed by welding. 7.4.1.1 Defect s in t he welds, such as sweat s and leaks, unless ot her wise specified may be r epair ed or piece r eject ed at t he opt ion of t he manufact ur er for submer ged ar c welded pipes. 7.4.1.2 Welds of t he elect r ic r esist ance welded pipes may be r epair ed only by agr eement bet ween t he pur chaser and t he manufact ur er . 7.4.1.3 Repair s of t his nat ur e shall be made by complet ely r emoving t he defect , cleaning t he cavit y and t hen welding. 7.4.2 All r epair ed pipes shall be r et est ed hydr aulically in accor dance wit h 10. 8 CHEMI CAL COMP OSI TI ON 8.1 La d l e An a lysis The ladle analysis of st eel shall be as given in Table 2. The analysis of st eel shall be car r ied out eit her by t he met hod specified in IS 228 and it s r elevant par t s or any ot her est ablished inst r ument al/chemical met hod. In case of disput e t he pr ocedur e given in IS 228 and it s r elevant par t s, shall be t he r efer ee met hod. However , wher e t he met hod is not given in IS 228 and it s r elevant par t s, t he r efer ee met hod shall be as agr eed t o bet ween t he pur chaser and t he manufact ur er . 8.2 P r od u ct An a lysis Per missible var iat ions in t he case of pr oduct analysis fr om t he limit s specified in Table 2 shall be as given in Table 3. 9 MECHANI CAL P ROP ERTI ES 9.1 Te n sil e St r en gt h The t ensile pr oper t ies of st r ip cut longit udinally (excluding t he weld) fr om select ed pipes shall show t he pr oper t ies as given in Table 4 in r espect t o specific t ype of pipes as manufact ur ed. The per cent age elongat ion shall be det er mined on a gauge lengt h of 5.65 . If ot her gauge lengt hs ar e used conver sion shall be made as in IS 3803 (Par t 1). 9.2 F la t t e n i n g or Ben d Test 9.2.1 Flat tening Test for ERW Pipes At t he opt ion of t he manufact ur er flat t ening or bend t est shall be car r ied out depending upon t he t hickness and out er diamet er of t he pipes. Met h od of Ma n u fa ct u r e of P i p e Refe- r e n ce St eel Gr a d e s Ap p li ca b le (1) (2) (3) (4) (5) Seamless S Fe330 Fe410 Fe450 Elect r ic r esist ance including induct ion welded ERW Fe330 Fe410 Fe450 Submer ged ar c welded (including spir ally welded) SAW Fe330 Fe410 Fe450 NOTE —Met hod of manufact ur e of pipe and st eel gr ades ot her t han specified above shall be as agr eed t o bet ween t he manufact ur er and t he pur chaser . ¹ ¹ ¹ ¹ ¹ ' ¹ ¹ ¹ ¹ ¹ ¹ S o I S 3589 : 2001 3 Ta b le 2 Ch e mi ca l comp osit i on ( Clauses 8.1 and 8.2 ) Ta ble 3 P e r mi ss i ble Va r i a t i on for P r od u ct An a lys i s ( Clause 8.2 ) The t est shall be made on a r ing sample not less t han 40 mm in lengt h cut fr om t he ends of select ed t ubes which shall be flat t ened bet ween par allel plat es keeping t he weld at 90° t o t he dir ect ion of t he for ce. No opening shall occur by fr act ur e in t he weld unt il t he dist ance bet ween t he plat es is less t han 75 per cent of t he or iginal out side diamet er of t he pipe and no cr acks or br eaks on t he met al elsewher e t han in t he weld shall occur unt il t he dist ance bet ween t he plat es is less t han 60 per cent of t he or iginal out side diamet er . 9.2.2 Bend Test for ERW Pipes No bend t est is applicable t o ERW pipes. Ta b le 4 Mech a n i ca l P r op er t i es a t Room Temp er a t u r e ( Clause 9.1 ) 9.2.3 Flat tening Test for S eamless Pipes This t est shall be car r ied out in accor dance wit h IS 2328. A r ing, not less t han 40 mm long, cut fr om one end of each select ed pipe shall when cold be flat t ened bet ween t wo par allel flat sur faces wit hout showing eit her cr ack or flaw, unt il t he dist ance bet ween plat es H (in mm) measur ed under load, is not gr eat er t han t he value given by t he following equat ion: wher e a = specified t hickness of t he pipe (mm), St ee l Gr a d e Me t h od of Ma n u fa ct u r e Ch emi ca l Comp osi t i on (La d l e An a lysi s) C Max Mn Max P Max S Max CE Max Fe 330 Fe 330 Fe 330 Fe410 Fe410 Fe 410 Fe 450 Fe 450 Fe 450 Seamless (S) Welded (ERW) Welded (SAW) Seamless (s) Welded (ERW) Welded (SAW) Seamless(s) Welded (ERW) Welded (SAW) 0.16 0.16 0.16 0.20 0.20 0.20 0.25 0.25 0.25 1.20 1.20 1.20 1.30 1.30 1.30 1.20 1.20 1.30 0.040 0.040 0.040 0.040 0.040 0.040 0.040 0.040 0.040 0.040 0.040 0.040 0.040 0.040 0.040 0.040 0.040 0.040 — — — 0.45 0.45 0.45 0.45 0.45 0.45 ¹ ¹ ¹ ¹ ¹ ¹ ¹ ¹ ¹ ¹ ¹ ¹ ¹ ' ¹ ¹ ¹ ¹ ¹ ¹ ¹ ¹ ¹ ¹ ¹ ¹ ¹ Con st i t u en t Va r i a t i on Over Sp eci fi ed Li mi t , P er ce n t , Max (1) (2) Car bon 0.02 Manganese 0.04 Sulphur 0.005 Phosphor us 0.005 St eel Gr a d e Met h od R m Ten s i l e St r en gt h MP a Min R e Yi el d St r es s MP a Min A El on ga t i on P er ce n t GL5.65 Min Fe330 ERW, Seamless and SAW 330 195 1) 20 Fe410 ERW, Seamless and SAW 410 235 1) 18 Fe450 ERW, Seamless and SAW 450 275 1) 15 1) Yield st r ess values ar e for design pur poses only eit her t he upper yield st r ess ReH, or t he 0.5 per cent of pr oof st r ess (t ot al elongat ion) ReH 0.5 is t o be det er mined. S o H 1 C + ( ) a C a/D + ------------------------ = I S 3589 : 2001 4 D = specified out side diamet er of t he pipe (mm), C = a const ant dependent on t he st eel gr ade value of C, = 0.09 for Fe330 = 0.07 for Fe410 and Fe450. NOTES 1 If any flaw appear s dur ing flat t ening t est , it may be r emoved by gr inding or filing. In such cases if t he r emaining wall t hickness is not less t han t he minimum per mit t ed t hickness as per clause t he sample shall be accept ed. 2 Super ficial r upt ur e r esult ing fr om sur face imper fect ions shall not be a cause of r eject ion. 9.3 Gu i d e d Ben d Test (For SAW P i p e s) St r ips not less t han 40 mm wide, cut cir cumfer ent ially fr om pipes per pendicular t o weld seam wit h t he weld near t he middle of t he sample shall, wit hout fr act ur e, be doubled over a r ound bar t he diamet er of which shall be calculat ed as given below. The weld r einfor cement shall be r emoved fr om t he faces. 9.3.1 One face bend and one r oot bend specimen, bot h confor ming t o Fig. 1 shall be bent appr oximat ely 180° in a jig subst ant ially in accor dance wit h Fig. 2 for any combinat ion of diamet er , wall t hickness and gr ade. The maximum value for jig dimension A may be calculat ed by t he for mula given below. The manufact ur er shall use a jig based on t his dimension or a smaller dimension at his opt ion. wher e 9.3.2 The specimens shall not fr act ur e complet ely. Cr acks 6.35 mm or less in lengt h at t he edge of t he specimen or 3.18 mm or less in lengt h in t he cent r e of t he specimen shall be disr egar ded. Any cr ack gr eat er t han 3.18 mm in lengt h and r egar dless of dept h locat ed wit hin t he weld met al shall be a cause for r eject ion. Any pop-out gr eat er t han 3.18 mm in lengt h (6.35 mm at t he edge) and 12.5 per cent or less of t he specified wall t hickness in dept h and locat ed in t he par ent met al, t he heat affect ed zone, or t he fusion line, shall not be t he cause for r eject ion. Any t est specimen t hat shows defect ive pr epar at ion, or mat er ial imper fect ion unr elat ed t o t he int ent of t he par t icular mechanical t est whet her obser ved befor e or aft er t est ing, may be discar ded and r eplaced by anot her specimen fr om t he same lengt h of t he pipe. 9.3.3 On examinat ion of t he bent specimen, opening out of a slight defect due t o incomplet e r oot penet r at ion or lack of r oot fusion need not be consider ed a cause for r eject ion pr ovided t he defect has sound met al at t he back and on eit her side of it . In bor der line cases, fur t her t est s shall be made on specimens fr om t he same weld adjacent t o t he or iginal t est specimen. 10 HYDRAULI C P RESSURE TEST Each pipe shall be hydr aulically t est ed at t he manufact ur er ’s wor ks befor e t he pipe is coat ed, wr apped and lined. 10.1 The hydr aulic t est pr essur e shall be t he pr essur e calculat ed as per t he following for mula: wher e 10.1.1 The hydr aulic t est pr essur e shall be applied for 5 s. 10.2 The hydr aulic t est may be subst it ut ed by a Non-Dest r uct ive Test at t he opt ion of t he manufact ur er . 10.2.1 Met hod of NDT and t he accept ance level shall be as agr eed t o bet ween t he manufact ur er and t he pur chaser . 11 DI MENSI ONS AND MASS P ER METRE RUN OF P I P ES 11.1 Pr efer r ed out side diamet er and t hickness of t he pipes ar e specified in t he Table 5. The t able also pr ovides t he nominal mass per met r e r un of t he pipes against each dimension. NOTE —Table 5 gives a select ion of pr efer r ed out side diamet er s and t hicknesses, ot her sizes not included, in t he t able may be supplied as specified by t he pur chaser . 1.15 = peaking fact or , D = specified OD in mm, t = specified wall t hickness in mm, and e = st r ain in mm = 0.132 5 for Gr ade Fe330, = 0.127 5 for Gr ade Fe410 and Gr ade Fe450. A 1.15 D 2t – ( ) eD t ------- 2e – 1 – ----------------------------------- = P = hydr aulic t est pr essur e MPa, D = specified out side dia of t he pipe in mm, T = specified t hickness of t he t ube in mm, and S = st r ess 60% of t he specified minimum yield st r ess in MPa. Th e ma xi mu m t e st p r es s u r e t o b e li mi t ed t o 5 MP a wh e r e ve r a p p li ca b le . P 2S T D ------------ = I S 3589 : 2001 5 FIG. 1 GUIDED BEND TEST SPECIMEN FIG. 2 J IG FOR GUIDED BEND TEST 11.1.1 Mass per met r e r un of t he pipes can also be wor ked out by t he for mula as under : M = ( D – T ) × T × 0.024 661 5 wher e 12 TOLERANCES 12.1 Tole r a n ce on Ma ss The t oler ance on mass per car t load of 10 t onnes or above shall be ± 7.5 per cent on t he nominal t heor et ical mass of t he t ubes. 12.2 Ge n er a l The t oler ance on t he dimensions of t he pipes shall be as specified in 12.3 and 12.4. M = mass of t he pipe kg/met r e, D = nominal out side diamet er of t he t ube in mm, and T = Nominal t hickness of t he t ube in mm. I S 3589 : 2001 6 Ta b le 5 P r efer r ed Di men si on s a n d Ma ss p e r Me t r e Len gt h of P i p e s ( Clause 11.1 ) 12.3 Ou t si d e Di a met e r , Th i ck n e ss a n d He igh t of I n t er n a l We ld Be a d or Rei n for cemen t 12.3.1 The t oler ance on out side diamet er shall include ovalit y except for submer ged ar c welded pipes. The t oler ance on t he specified out side diamet er of pipe wall shall be as given in Table 6. Ta b le 6 Tol er a n ce s on Ou t sid e Di a me t e r of P i p e s 12.3.2 Thickness The t hickness t oler ance shall not apply t o t he weld ar ea. The maximum height of t he weld bead on t he int er nal sur face of t he pipe shall not exceed 60 per cent of nominal wall t hickness. The t oler ance on t he specified wall t hickness shall be as follows: 12.3.3 Ovality 12.3.3.1 Ovalit y shall not exceed 1 per cent of t he specified out side diamet er for pipes having diamet er t o t hickness r at io not exceeding 100. Wher e t he diamet er t o t hickness r at io exceeds Ou t si d e Di a met er OD Th i ck n es s Ma s s Ou t si d e Di a met er OD Th i ck n es s Ma s s Ou t si d e Di a met er OD Th i ck n e s s Ma s s mm mm kg/m mm mm kg/m mm mm kg/m 168.3 219.1 273 323.9 355.6 406.4 457 2.6 3.2 4.0 4.5 2.6 3.6 4.5 6.3 3.6 4.0 5.0 6.3 4.0 4.5 5.6 7.1 4.0 5.0 5.6 8.0 4.0 5.0 6.3 8.8 4.0 5.0 6.3 10.0 10.6 12 16.2 18.2 13.9 19.1 23.8 33.1 23.9 26.5 33 41.1 31.8 35.4 44 55.5 34.7 43.2 48.3 68.6 39.7 49.5 62.2 86.3 44.7 55.7 70 110 508 610 711 813 914 1 016 1 067 1 118 5.0 5.6 6.3 11.0 5.8 6.3 12.5 6.3 7.1 14.2 7.1 8.0 18.0 8.0 8.8 10.0 17.5 8.8 10.0 20.0 8.8 10.0 11.0 8.8 10.0 11.0 62 69.4 77.9 135 83.5 93.8 184 109 123 244 141 159 314 179 196 223 387 219 248 491 230 251 286 241 273 300 1 219 1 422 1 626 1 829 2 032 2 235 2 540 10.0 11.0 12.5 12.5 14.2 14.2 16.0 14.2 16.0 17.5 16.0 17.5 20.0 17.5 20.0 22.2 20.0 22.2 25.0 298 328 372 435 493 564 635 634 715 782 795 869 992 957 1 093 1 211 1 243 1 379 1 551 Ou t s i d e Di a (F or Al l Si ze s ) Toler a n ce (1) (2) For seamless pipes ± 1% For ERW & SAW pipes ± 0.75% ERW pipe — ± 10% SAW and seamless pipe — % + 20 – 12.5 . , | ` I S 3589 : 2001 7 100 t he t oler ance on ovalit y is not specified and should be agr eed bet ween t he manufact ur er and t he pur chaser . 12.4 Ra n d om Le n gt h 12.4.1 St eel t ubes shall be supplied in single r andom lengt hs fr om 4 t o 7 m or double r andom lengt h of 7 t o 14 m. For or der s over 200 m of any one size of pipes, it shall be per missible t o supply shor t r andom lengt hs fr om 2 t o 4 m for single r andom lengt hs and 4 t o 7 m for double r andom lengt hs pr ovided t he t ot al of such lengt hs does not exceeds 7.5 per cent of t he t ot al lengt h. 12.4.2 Wher e lengt h is specified as ‘exact ’ or ‘cut lengt hs’ t he per missible var iat ions shall be mm for lengt h up t o and including 6 m. 12.4.3 Supply in any lengt h and t he t oler ances ot her t han t he above specified shall be mut ually agr eed t o bet ween t he manufact ur er and t he pur chaser . 12.5 St r a i gh t n e ss 12.5.1 Finished pipe shall not deviat e fr om st r aight ness by mor e t han 0.2 per cent of t he t ot al lengt h. 12.5.2 Checking shall be car r ied out using a t aut st r ing or wir e fr om end t o end, along t he side of t he pipe t o measur e, t he gr eat est deviat ion. 13 NUMBER, SELECTI ON AND P REP AR- ATI ON OF SAMP LES AND TEST P I ECES 13.1 Unless ot her wise agr eed t o bet ween t he manufact ur er and t he pur chaser t he pr ocedur e for sampling of pipe for var ious t est s and cr it er ia for confor mit y shall be as given in IS 4711. 13.1.1 The t est samples shall be cut fr om pipes in t he final condit ion of supply. 13.1.2 One set of mechanical t est s as specified in 9 shall be car r ied out fr om samples t aken of each t ube. 13.1.3 For t he t ensile t est , t he dimensions of t he t est piece shall comply wit h t he appr opr iat e r equir ement s of IS 1608. For welded pipes t he t ensile t est piece shall not include t he weld unless t he pipe is t est ed in full sect ion. NOTE —For t he t ensile t est , t he piece may be t aken eit her longit udinally or t r ansver sely fr om t he pipe at t he opt ion of t he manufact ur er . 13.1.4 For a bend t est on t he weld, t wo pieces shall be pr epar ed, one for a face bend t est and one for a r oot bend t est . Bot h t est pieces shall be not less t han 40 mm wide and cut per pendicular t o t he weld line fr om one end of each select ed pipe so t hat t he weld is in t he middle of t he t est piece and 90° t o t he longer sides. The weld r einfor cement shall be r emoved fr om bot h faces. The lengt h of t he t est pieces shall be select ed by t he manufact ur er t o suit t he equipment used for t he t est . NOTE —The t est pieces may be flat t ened befor e t est ing. 14 VI SUAL I NSP ECTI ON, AP P EARANCE AND WORKMANSHI P 14.1 The pipes shall be clean and fr ee fr om such defect s as can be est ablished by visual inspect ion in accor dance wit h t his st andar d. 14.2 It shall be per mit t ed t o dr ess by gr inding or machining sur face mar ks and imper fect ions such as scabs, seams, t ear s, laps, sliver s or gouges pr ovided t hat t he t hickness of t he t ube aft er dr essing does not fall below t he nominal t hickness by mor e t han t he t oler ance specified in t his st andar d. 14.3 All dr essed ar eas shall blend smoot hly int o t he cont our of t he pipe. 14.4 For pipes which have a t hickness t o diamet er r at io equal t o or less t han 0.03, isolat ed dent s shall not be cause for r eject ion pr ovided t hat t hey do not exceed a dept h gr eat er t han 6 mm maximum for pipes below 610 mm OD and not exceed 1 per cent of OD for pipes over 610 mm OD measur ed as a gap bet ween t he point of t he dent and a pr olongat ion of t he or iginal cont our of t he pipe. The lengt h of t he dent in any dir ect ion shall not exceed one half t he pipe diamet er . 14.5 The ends shall be cut nominally squar e wit h t he axis of t he pipe and shall be fr ee fr om excessive bur r s. 15 CONDI TI ON OF SUP P LY Subject t o t he agr eement bet ween t he manufact ur er and t he pur chaser t he pipes may be supplied bar e or wit h ant i r ust coat ings. 16 GUI DELI NES OF COATI NG 16.1 Any t ype of pr ot ect ive coat ing, if r equir ed, may be agr eed t o bet ween t he manufact ur er and t he pur chaser . Guidelines for t he t ypes of coat ing ar e given in Annexes A t o D. 16.2 Wher e t ubes ar e r equir ed t o be galvanized t he zinc coat ing on t ubes shall be in accor dance wit h IS 4736. 17 J OI NTS AND ENDS 17.1 The t ype of joint s and ends of pipes shall be specified by t he pur chaser . The t ypes of joint s and ends r ecognized under t his st andar d ar e: a) Plain ends or bevelled ends for but t welding ( see Fig. 3A and 3B ) unless ot her wise agr eed, bevelled ends shall be bevelled t o an angle of 30 degr ee measur ed fr om a line dr awn + 10 – 0 + 5 – 0 I S 3589 : 2001 8 per pendicular t o t he axis of t he pipe. The r oot face shall be 1.6 ± 0.8 mm. b) J oint s wit h sleeves joint or swelled and plain ends for welding ( see Fig. 4 ). NOTE —The r oot face of t he bevel may be pr epar ed by hand fit t ing, if r equir ed. 17.1.1 Pipe wit h sleeve welded joint s shall be supplied wit h t he plain and par allel end and sleeve and t aper ed t o appr oximat ely 3 mm per 100 mm. The ends shall be sized and gauged so as t o ensur e t hat t he plain end will fr eely ent er t he sleeve and t her eaft er be capable of being for ced home. 17.2 All sleeves shall be made so t hat t he plain end shall ent er t he specified minimum dept h given in Table 7. The manufact ur er shall make available t o inspect ion at t he wor ks met al gauges of suit able dimensions t o enable t he pur chaser or his r epr esent at ive t o ascer t ain t hat t he sleeve and plain end comply wit h t he r equir ement s of t he specificat ion. Ta b l e 7 De p t h of sle e ve , X a n d clea r a n ce Y for we ld e d t u b es ( Clause 17.2 ) 18 MARKI NG 18.1 Each pipe shall be legibly mar ked wit h t he following det ails: a) Manufact ur er ’s name or t r ade-mar k; FIG. 3 TYPES OF ENDS Dep t h of Sle eve , X Ou t si d e Di a met e r of P i p e Toler a n ce (1) (2) (3) mm mm mm 50 168.3 upt o 406.4 ± 6 60 457.0 upt o 1 219.0 ± 6 75 1321.0 upt o 2 540.0 ± 6 Clear ance Y, bet ween t he plain ends, mm Max 4 168.3 upt o 1 219.0 — 6 1321.0 upt o 2 540.0 — I S 3589 : 2001 9 FIG. 4 SLEEVE J OINT OR SWELLED AND PLAIN END FOR WELDING b) Out side diamet er and specified wall t hickness; and c) Pipe designat ion. Example: For a pipe manufact ur ed under t r ade name ABC having 508 mm out side diamet er 8 mm specified wall t hickness confor ming t o SAW 410 gr ade shall be legibly mar ked as follows: ABC – 508.0 – 8 – SAW 410 18.2 BI S St a n d a r d Ma r k The pipes may also be mar ked wit h t he St andar d Mar k. 18.2.1 The use of t he St andar d Mar k is gover ned by t he pr ovisions of t he Bureau of Indian S tandards Act, 1986 and t he Rules and Regulat ions made t her eunder . The det ails of condit ions under which a licence for t he use of t he St andar d Mar k may be gr ant ed t o manufact ur er s or pr oducer s may be obt ained fr om t he Bur eau of Indian St andar ds. ANNEX A ( Foreword and Clause 16.1 ) GUI DELI NES F OR P ROTECTI ON AGAI NST CORROSI ON A-1 CEMENT-MORTAR P ROTECTI VE LI NI NG AND COATI NG FOR STEEL P I P E SHOP AP P LI ED The inside of all pipe shall r eceive a cement -mor t ar lining applied by cent r ifugal spinning or by a met hod known t o pr ovide equivalent r esult s. The out side of pipe shall r eceive a r einfor ced cement -mor t ar coat ing applied by mechanical placement , pneumat ic placement , or a met hod known t o pr ovide equivalent r esult s. A-2 REI NF ORCEMENT Spir al-wir e r einfor cement for pipe coat ing. St eel wir e shall be a minimum size of 3 mm. The wir e shall confor m t o t he r equir ement s of IS 432 (Par t 1). Reinfor cing wir e need not be galvanized unless ot her wise specified by t he pur chaser . Reinfor cement shall be 50 × 100 mm welded wir e fabr ic. The wir e shall confor m t o t he r equir ement s of IS 1566. Unless ot her wise specified by t he pur chaser , wir e fabr ic r einfor cement may be eit her cr imped or uncr imped. A-3 P ORTLAND CEMENT Por t land cement shall confor m t o t he r equir ement s of IS 269/IS 8041/IS 1489/IS 8112 for cement , or as ot her wise specified by t he pur chaser . The minimum cement cont ent shall be 330 kg/m 3 . A-3.1 Sa n d Sand shall consist of iner t mat er ials having har d, st r ong, dur able uncoat ed gr ains confor ming t o t he r equir ement s t o IS 2116. A-4 MI XI NG WATER Wat er shall be clean, colour less, and fr ee fr om injur ious quant it ies of or ganic mat t er , alkali, salt , or ot her impur it ies t hat might r educe t he st r engt h, dur abilit y, or ot her desir able qualit ies of t he mor t ar , t he maximum wat er cement r at io shall not exceed 0.5:1. A-5 SEAL COAT P AI NT The paint or ot her wise mat er ials used t o pr event t he r ust ing of st eel sur faces and pr oviding seal coat of mor t ar lining or coat ing befor e pipe inst allat ion shall be a quick dr ying, cor r osion-r esist ant mat er ial wit h good bonding pr oper t ies t o st eel and shall dr y t ackfr ee and smoot h wit hin 4 h aft er applicat ion. The paint I S 3589 : 2001 10 mat er ial applied t o t he int er ior of pipe or fit t ings shall be fr ee fr om cont aminant s t hat may be har mful t o t he end user of t he pot able wat er . A-6 LI NI NG A-6.1 Ce me n t Mor t a r Cement mor t ar shall be composed of cement , sand and wat er , well mixed and of pr oper consist ency t o obt ain a dense, homogeneous lining t hat will adher e fir mly t o t he pipe sur face. Pr opor t ion 2 par t s of sand t o 1 par t cement , by weight . The soluble chlor ide-ion (Cl) cont ent of t he cement mor t ar mix shall not exceed 0.15 per cent , expr essed as a per cent age of cement weight . A-6.2 Th i ck n ess of Li n i n g Cement mor t ar lining shall be unifor m in t hickness, except of joint s or ot her discont inuit ies in t he pipe wall. Lining t hickness shall be as list ed in Table 8 or as specified by t he pur chaser . Ends of lining shall be left squar e and unifor m wit h r egar d t o t he longit udinal axis of t he pipe, and t he lining holdback shall be as specified by t he pur chaser for t he t ype of joint s r equir ed. Ta b l e 8 Th ick n e ss of Ce me n t Mor t a r Li n i n g A-6.3 Eq u i p men t A-6.3.1 Lining St r aight sect ions of pipe shall be lined by use of a spinning machine specifically designed and built for t he pur pose of r ot at ing t he pipe sect ion and cent r ifugally applying cement mor t ar lining t o t he int er ior of st eel pipe or by a met hod known t o pr ovide equivalent r esult . A-6.3.2 Mixing The mor t ar shall be mixed in bat ches. The amount of cement and sand ent er ing int o each bat ch shall be measur ed by weight . The quant it y of wat er ent er ing t he mixer shall be measur ed aut omat ically by an adjust able device, or it shall be ot her wise measur ed t o ensur e t hat t he cor r ect quant it y of wat er is being added. A-6.4 Ma ch i n e Lin i n g A-6.4.1 Bracing When r equir ed t o pr event dist or t ion or vibr at ion dur ing t he spinning, each sect ion of pipe shall be suit ably br aced wit h ext er nal or int er nal suppor t s appr opr iat e t o t he equipment . A-6.4.2 Finish Aft er t he mor t ar has been dist r ibut ed t o a unifor m t hickness, t he r ot at ion speed shall be incr eased t o pr oduce a dense mor t ar wit h a smoot h sur face. A-6.4.3 S urplus Water Pr ovision shall be made for r emoval of sur plus wat er by air blowing, t ilt ing of t he pipe or ot her met hods appr oved by t he pur chaser . A-6.5 De fe ct i ve Lin i n g A-6.5.1 General All defect s, including but not r est r ict ed t o sand pocket s, voids, over sanded ar eas, blist er s, and cr acking as a r esult of impact s, shall be cut out and r eplaced by hand or pneumat ic placement t o t he same t hickness as r equir ed for t he mor t ar lining. A-6.5.2 Lining Cracks Temper at ur e and shr inkage cr acks in t he mor t ar lining less t han 1.5 mm in widt h need not be r epair ed. A-6.6 Cu r i n g of Li n i n g Immediat ely aft er complet ion of spinning, t he pipe sect ions, may be moved t o a cur ing ar ea. Car e shall be exer cised at all t ime t o pr event damage t o t he lining. At t he opt ion of t he manufact ur er , linings shall be eit her acceler at ed cur ed or moist cur ed. A-6.6.1 Moist Curing On ar r ival at t he cur ing ar ea, but not lat er t han 30 min aft er complet ion of t he lining oper at ion, pipe ends shall be cover ed wit h plast ic or wet bur lap for a minimum per iod of 24 h befor e applying t he ext er ior coat ing, if such coat ing is specified. If a cement mor t ar ext er ior coat ing is not specified, t he lining shall be kept moist for four days befor e shipment . In eit her case, t he lining shall be cur ed for a t ot al per iod of four days befor e shipment . The ends of t he pipe sect ions shall be kept closed dur ing t he cur ing per iod, wit h plast ic end caps, except when spr inkling hands ar e used, t he r einfor cement and out side coat ings ar e being applied or acceler at ed cur ing is being subst it ut ed. If t he plast ic end caps ar e inst alled at t hat t ime, t hey can be used for shipping t o t he jobsit e. The manufact ur er shall exer cise car e and diligence t o avoid dr ying t o or cr acking of t he lining. Ou t si d e Di a of St e el P i p e Mi n i mu m Th i ck n e ss of Li n i n g Tol er a n ce mm mm mm (1) (2) (3) 168.3 t o 323.9 6 + 2 – 0 355.6 t o 610 7 + 2 – 0 660 t o 1 219 9 + 2 – 0 1 321 t o 2 540 12 + 3 – 0 I S 3589 : 2001 11 A-6.6.2 Accelerat ed Curing Acceler at ed cur ing may begin immediat ely on ar r ival of t he pipe at t he cur ing ar ea, but t he t emper at ur e of t he pipe shall not exceed for 3 h or unt il t he mor t ar has t aken it s init ial set , whichever occur es fir st . The ambient vapour shall t hen be maint ained at a t emper at ur e bet ween 45°C and 65°C at a r elat ive humidit y of not less t han 85 per cent for a minimum cur ing per iod of 6 h, aft er which t he ext er ior coat ing may be applied, if such coat ing is specified. If cement mor t ar coat ing is not specified, t he lining shall be cur ed for 18 h befor e shipment . In eit her case, t he lining shall be cur ed for a t ot al per iod of 18 h befor e shipment . A-7 MORTAR LI NI NG TEST CYLI NDERS A-7.1 Mor t a r Te st Cyli n d e r s A set of at least t wo st andar d t est cylinder s, 50 mm in diamet er by 300 mm in lengt h, shall be made each day. The t est cylinder s shall be cur ed wit h t he pipe at t he same t emper at ur e and for t he same t ot al lengt h of t ime. Ot her sizes cylinder s, such as 50 mm × 100 mm may be used t o t est compr essive st r engt h. If t he 7-day t est r equir ement s, t hen t he 28-day t est need not be complet ed. A-7.2 Ce n t r i fu ga l Te st Cyl in d e r s Cent r ifugally spun t est cylinder s may be subst it ut ed for mor t ar t est cylinder s, at t he opt ion of t he manufact ur er . Test cylinder s shall be spun about t heir longit udinal axes in 150 mm diamet er by 300 mm long st eel molds at a speed t hat will simulat e t he compact ion of mor t ar in t he lining t o pr oduce a spun cylinder wall t hickness of at least 35 mm. The net cr oss-sect ional ar ea of t he hollow cylinder shall be used t o det er mine it s compr essive st r engt h. Damaged cylinder s shall not be t est ed. A-7.3 St r en gt h of Mor t a r Li n i n g Mor t ar t est cylinder s shall obt ain a minimum compr essive st r engt h of 18 MPa in 7 days and 31 MPa in 28 days. Pipe made wit h mor t ar lining t hat does not meet t he st r engt h r equir ement s set for t h her ein shall be subject t o r eject ion. The aver age of any 10 consecut ive st r engt h t est s of cylinder s r epr esent ing each mor t ar mix shall be equal t o or gr eat er t han t he specified st r engt h, and not mor e t han 20 per cent of t he st r engt h t est s shall have values less t han t he specified st r engt h. No cylinder t est r esult shall be less t han 80 per cent of t he specified st r engt h. A-8 COATI NG A-8.1 Gen e r a l When specified, t he ext er nal pr ot ect ion of st eel pipe shall be a r einfor ced cement mor t ar coat ing applied over t he out er sur faces of t he pipe sect ions. If t he pipe has been mor t ar lined, t he cur ing t imes specified above must elapse befor e t he coat ing is applied. A-8.2 Cemen t Mor t a r Cement mor t ar applied by mechanical placement or by t he st eampneumat ic pr ocess shall consist of not mor e t han 3 par t s sand t o 1 par t cement , by weight . The wat er in t he mixt ur e shall be car efully cont r olled so t hat t he mor t ar will not r un, sag, or segr egat e. The soluble chlor ide-ion (Cl) cont ent of t he cement mor t ar mix shall not exceed 0.15 per cent , expr essed as a per cent age of cement weight . A-8.3 Th i ck n ess Cement mor t ar coat ing shall be unifor m in t hickness except in joint s or ot her discont inuit ies in t he pipe. Coat ings shall be 20 mm minimum t hickness for all sizes of pipe up t o unless ot her wise specified by t he pur chaser . Ends of coat ings shall be unifor m and squar e t o t he longit udinal axis of t he pipe, and t he coat ing holdback shall be as specified by t he pur chaser for t he t ype of joint r equir ed. A-9 REI NF ORCEMENT A-9.1 Ge n er a l Unless ot her wise specified by t he pur chaser , t he r einfor cement of t he coat ing of pipe sect ions may be spir al wir e, wir e fabr ic, or wir e mesh (r ibbon mesh). Reinfor cement shall be fr ee of oil, gr ease, and ot her cont aminant s t hat might r educe t he adher ence bet ween t he coat ing and r einfor cement . All r einfor cement shall be placed in t he middle t hir d of t he coat ing. When cement mor t ar coat ing is applied over a dielect r ic under coat , t he r einfor cement shall not be at t ached t o or ot her wise be in cont act wit h t he st eel pipe. A-9.2 Sp i r a l Wi r e At t achment of ends and splices in t he wir e shall be by welding or ot her suit able means accept able t o t he pur chaser . Maximum spacing of t he wir e shall be 35 mm. The wir es on 50 mm spacing on t he 50 mm × 100 mm fabr ic shall ext end cir cumfer ent ially ar ound t he pipe. A-9.3 Wir e Me sh At t achment of ends and splices in t he wir e shall be as appr oved by t he pur chaser . When 25 mm × 25 mm, 8 mm t he spir al lap shall be 35 mm and t he spliced lap 110 mm minimum. A-10 AP P LI CATI ON OF MORTAR COATI NG A-10.1 Ap p li ca t i on Mor t ar coat ing shall be applied by mechanical I S 3589 : 2001 12 or pneumat ic placement t o t he specified t hickness in one or mor e cont inuous applicat ion(s). Allowance shall be made for splices of r einfor cing wir e. If applied in mor e t han one cour se, t he int er val bet ween t he fir st and last cour se shall be not mor e t han 2 h. The mor t ar shall be pr oject ed at high velocit y against t he ext er ior sur faces of t he pipe or shall be applied by an equivalent met hod t o pr oduce a har d, t ight adher ing coat ing of t he specified t hickness. A-10.2 De fe ct i ve Coa t i n g A-10.2.1 S and Pockets and Porous S pots If any sand pocket s or por ous spot s occur , t hey shall be complet ely cut out and r eplaced by pneumat ic placement or hand applicat ion of mor t ar in t he pr opor t ion of 2 par t s sand t o 1 par t cement , by weight . A-10.2.2 Coating Cracks Car e shall be exer cised t o minimize t he occur r ence of cr acks in t he mor t ar coat ing. However , hair line cr acks need not be r epair ed. Repair pr ocedur es shall include t he br ushing or wiping of neat cement int o t he cr acks, aut ogenous healing of t he cr acks by addit ional moist cur ing, t he paint ing of t he cr acks wit h an epoxy coat ing, or a combinat ion of t hese met hods. NOTE —Repair pr ocedur e involving ext ensive chipping or r out ing of t he cr acks should be avoided as t his pr ocedur e t ends t o deepen and lengt hen t he exist ing cr acks and may damage t he bond or adhesion bet ween t he coat ing and t he cylinder . A-10.3 Cu r i n g of Coa t i n g A-10.3.1 General Aft er t he init ial set has t aken place, t he mor t ar coat ing shall be cur ed by t he moist or acceler at ed cur ing met hods or unless ot her wise specified by t he pur chaser , a membr ane mat er ial may be applied immediat ely following t he coat ing applicat ion. Moist and acceler at ed cur ing may be used int er changeably on a t ime r at io basis of 5 h or moist cur ing t o 1 h of acceler at ed cur ing, except cur ing t emper at ur es shall not exceed t he maximum allowable for dielect r ic under coat mat er ial. The coat ing shall be kept cont inually moist by int er mit t ent or cont inuous spr aying for a per iod of at least four days. Moist cur ing may be used only if t he minimum ambient t emper at ur e exceeds 5°C cont inuously dur ing t he minimum r equir ed cur ing per iod, and no cr edit shall be allowed for any t ime dur ing which t he t emper at ur e dr ops below 10°C. A-10.4 Accel er a t e d Cu r i n g Acceler at ed cur ing of t he pipe or special may begin immediat ely aft er complet ion of t he coat ing oper at ion or wit hin 6 h t her eaft er . The t emper at ur e of t he pipe or special shall not exceed 30°C unt il t he cement mor t ar coat ing has t aken it s init ial set or unt il a per iod of 3 h has elapsed, whichever occur es fir st . The r elat ive humidit y shall be not less t han 85 per cent at a t emper at ur e bet ween 45 t o 65°C for at least 18 h. A-10.5 Me mb r a n e Cu r i n g Membr ane cur ing shall consist of t he complet e encapsulat ion of t he coat ing by applicat ion of a mat er ial t hat will r et ain t he moist ur e of t he applied cement mor t ar coat ing. A-10.6 Ma n u fa ct u r e Dur ing t he ent ir e per iod of t he applicat ion of t he lining and coat ing and t he cur ing t her eof, t he sect ion shall be car efully suppor t ed and handled t o avoid damage t o t he mor t ar . If a pipe sect ion must be moved, such oper at ion shall be done wit h ever y r easonable pr ecaut ion t o pr ot ect against damage. Any damaged por t ion of t he lining or coat ing shall be cut out and r eplaced. I S 3589 : 2001 13 ANNEX B ( Foreword and Clause 16.1 ) LI QUI D-EP OXY COATI NG SYSTEMS F OR THE I NTERI OR AND EXTERI OR OF STEEL P I P ELI NES B-1 COATI NG AND LI NI NG SYSTEMS Unless specified ot her wise by t he pur chaser , t he coat ing and lining syst ems may consist of any of t he following t hr ee t ypes: (1) t wo-par t , chemically cur ed epoxy pr imer and one or mor e coat ings of a differ ent t wo-par t , chemically cur ed epoxy t opcoat ; (2) t wo or mor e coat s of t he same t wo-par t , chemically cur ed epoxy coat ing, in which case t he fir st coat shall be consider ed as t he pr ime coat ; or (3) a single coat of a t wo-par t , solvent fr ee, chemically cur ed epoxy coat ing. B-1.1 Liq u id -Ep oxy Coa t i n gs The coat ings used shall be based on liquid, chemically cur ed epoxies. The cur ing agent may be an amine, amine-adduct , or polyamide; and t he epoxy may be modified wit h t he coal r at , phenolic, or ot her modifier s. Mat er ials used in bot h t he pr imer and finish coat (s) shall be pr oduct s of one manufact ur er . B-1.2 Coa t in g Th i ck n e ss Unless ot her wise specified by t he pur chaser , t he minimum dr y film t hickness DFT pr ovided shall be at least 406 µm. Aft er cur ing but pr ior t o bur ial, t he coat ing syst em shall be a cont inuous film, fr ee of t hin spot s and ot her imper fect ions as defined and shall pass elect r ical inspect ion. B-1.3 Coa t in g Ap p li ca t i on B-1.3.1 General The pipe coat ing shall be applied in accor dance wit h t he manufact ur er ’s r ecommendat ions. Applicat ion by air less spr ay or cent r ifugal wheel equipment is pr efer r ed. B-2 P I P E P REP ARATI ON B-2.1 Cl ea n i n g Pr ior t o adbr asive blast cleaning, sur faces shall be inspect ed and, if r equir ed, cleaned accor ding t o r emove oil, gr ease, or ot her for eign mat t er . Only appr oved solvent s t hat do not leave a r esidue shall be used. Pr eheat ing t o r emove oil, gr ease, mill scale, wat er and ice may be used pr ovided all pipe is pr eheat ed in a unifor m manner t o avoid dist or t ing t he pipe. B-2.2 Ab r a si ve Bla st Cle a n i n g The ext er ior pipe sur faces shall be abr asive blast cleaned t o achieve a near whit e met al sur face. The int er ior pipe sur faces shall be abr asive blast cleaned t o achieve a whit e met al sur face. Abr asive blast ing and coat ing shall only be per for med when t he met al t emper at ur e is mor e t han 3°C above dew point . B-2.3 Su r fa ce I n sp e ct i on The ext er ior and int er ior pipe sur faces shall be inspect ed for sur face imper fect ions, such as sliver s, scabs, bur r s, weld spat t er , and gouges, shall be r emoved by gr inding. B-2.4 I n t e r i or Cle a n i n g If abr asives or ot her loose for eign mat t er has ent er ed t he int er ior of t he pipe, t hen clean, dr y oil fr ee compr essed air shall be used t o r emove t he loose for eign mat t er in a manner t hat does not adver sely affect t he cleaned sur face. Alt er nat ively, vacuum cleaning or ot her met hods may be used in place of compr essed air . B-2.5 P ip e En d s for Non -wel d e d F i el d J oi n t s When r ubber gasket ed joint s or mechanical couplings ar e used, t he coat ing shall ext end t o t he ends of t he pipe. The coat ing t hickness on t he pipe sur faces t hat r eceive r ubber sealing gasket s shall not exceed what is r ecommended by t he manufact ur er of t he coupling. However , t he coat ing syst em’s dr y film t hickness shall not be less t han 406 µm. B-2.6 Ap p li ca t ion Te mp e r a t u r e The t emper at ur e of t he mixed coat ing mat er ial and of t he pipe at t he t ime of applicat ion shall not be lower t han 10°C. Pr eheat ing of t he coat ing mat er ial, t he use of in line heat er s t o heat t he coat ing mat er ial; or heat ing of t he pipe, fit t ings or specials may be used t o facilit at e t he applicat ion. Heat ing shall confor m t o t he r ecommendat ions of t he coat ing manufact ur er . B-2.7 Ap p li ca t ion of Ep oxy Coa t i n g Syst e m If mor e t han one coat is applied, t he second coat shall be applied wit hin t he t ime limit s, sur face condit ions, and t emper at ur e r ecommended by t he manufact ur er , if t he per iod bet ween coat s is exceeded, t hen a r epair pr ocedur e shall be obt ained fr om t he coat ing manufact ur er and it s r ecommendat ions followed. B-3 CURE Aft er applicat ion, t he coat ing syst em shall be t est ed for cur e. I S 3589 : 2001 14 B-4 ELECTRI CAL I NSP ECTI ON F OR CONTI NUI TY Aft er cur ing, but pr ior t o inst allat ion, t he coat ing syst em applied t o t he pipe shall be t est ed for holidays accor ding t o t he pr ocedur es and using t he volt age set t ings. Any holidays indicat ed by t he det ect or shall be mar ked wit h chalk or felt -t ip mar ker t o ident ify t he ar ea t o be r epair ed. B-5 COATI NG REP AI R Accessible ar eas of pipe r equir ing coat ing r epair s shall be cleaned t o r emove debr is and damaged coat ing using sur face gr inder s or ot her means accept able t o t he pur chaser . The adjacent coat ing shall be feat her ed by sanding, gr inding, or ot her met hods appr oved by t he pur chaser . Accumulat ed debr is shall be r emoved by vacuum, blowing, or wiping wit h clean r ags. Ar eas not accessible by coat ing r epair , such as int er ior sur faces of small diamet er pipe, shall be r epr ocessed and r ecoat ed. Repair s shall be elect r ically inspect ed using a holiday det ect or . The coat ed pipe shipped fr om t he plant shall be holiday fr ee. B-6 WELDED F I ELD J OI NTS B-6.1 P r e p a r a t i on The weld joint shall be cleaned so as t o be fr ee fr om mud, oil, gr ease, welding flux, weld spat t er , and ot her for eign cont aminant s. The cleaned met al sur faces of t he weld joint shall t hen be abr asive blast ed, vacuum blast ed, or abr aded using r ot ar y abr ading pads. The adjacent liquid epoxy coat ing shall be feat her ed by adbr ading t he coat ing sur face for a dist ance of 25 mm. B-6.2 Ele ct r i ca l I n sp e ct i on Aft er cur ing, t he coat ing syst em applied t o t he welded joint s shall be holiday t est ed. Any holidays indicat ed by t he det ect or shall be mar ked wit h chalk or felt -t ip mar ker t o ident ify t he ar ea for r epair . B-6.3 Be e d i n g a n d Tr e n ch Ba ck fi ll Wher e t he t r ench t r aver ses r ocky gr ound cont aining har d object s t hat could penet r at e t he pr ot ect ive coat ing, a layer of scr eened ear t h, sand, or r ounded r iver r un gr avel not less t han 150 mm t hick wit h a maximum par t icle size of 20 mm shall be placed in t he bot t om of t he t r ench pr ior t o inst allat ion of t he coat ed ar t icle. ANNEX C ( Foreword and Clause 16.1 ) FUSI ON-BONDED EP OXY COATI NG F OR THE I NTERI OR AND EXTERI OR OF STEEL P I P ELI NES C-1 MATERI AL The epoxy powder shall consist of a one- component , fusion bonded mat er ial consist ing of epoxy r esin, cur ing agent s, cat alyst s, filler s, colour ant s, flow cont r ol agent s, and ult r aviolet light r esist ant agent s t hat when applied t o t he pr eheat ed subst r at e, will unifor mly coalesce and cur e t o pr oduce a homogeneous film t hat complies wit h t he r equir ement s of t his st andar d. Applicat ion capabilit y, when applied by elect r ost at ic spr ay, fluidized bed, or air spr ay t o t he pr eheat ed ar t icle and subsequent ly cur ed, t he epoxy powder shall pr oduce a unifor m pr ot ect ive coat ing. C-2 P I P E COATI NG AP P LI CATI ON C-2.1 Ge n e r a l When bot h an int er nal and an ext er nal coat ing ar e t o be applied, it is pr efer able t o pr eheat t he pipe t o t he specified t emper at ur e and apply t he int er nal coat ing fir st , immediat ely followed by t he ext er nal coat ing, since elevat ed t emper at ur es ar e r equir ed dur ing pr ocessing, fusion bonded epoxy coat ing must be applied pr ior t o t he applicat ion of ot her coat ings or linings unless t hose coat ings and linings ar e r esist ant t o t he pr ocessing heat . C-2.2 Su r fa ce Con d i t i on Sur faces t o be coat ed shall be fr ee fr om mud, mill lacquer , wax, coal t ar , asphalt , oil, gr ease, chlor ides, or any ot her delet er ious mat er ial. Pr ior t o blast cleaning, sur faces shall be inspect ed and, if r equir ed, pr ecleaned, t o r emove oil, gr ease, and loosely adher ing deposit s. Heat ing t o r emove oil, gr ease, mill scale, wat er , and ice may be used pr ovided t he pipe sect ion, is pr eheat ed in a unifor m manner t o avoid dist or t ion. C-2.3 Bla s t Clea n i n g The pipe sur faces t o be coat ed shall be blast cleaned t o achieve a near whit e sur face. C-2.4 Su r fa ce I n sp e ct i on The cleaned ext er ior and int er ior pipe sur faces shall be inspect ed for adequat e sur face I S 3589 : 2001 15 pr epar at ion. Sur face imper fect ions such as sliver s, scabs, bur r s, weld spat t er , and gouges shall be r emoved by hand filing or gr inding t o pr event holidays in t he applied coat ing. C-2.5 I n t e r i or Clea n i n g If abr asives or ot her loose for eign mat t er have ent er ed t he int er ior of t he pipe, t hen clean, dr y, oil-fr ee compr essed air shall be used t o r emove t he loose for eign mat t er in a manner t hat does not affect t he sur face of t he pipe t hat is t o be coat ed. Vacuum cleaning or ot her met hods may be used in place of compr essed air cleaning. C-2.6 P r eh ea t i n g Pr eheat t emper at ur e should be in accor dance wit h t he coat ing manufact ur er ’s r ecommendat ions but shall not exceed 250°C. C-2.7 P i p e En d s Coat ing shall be held back in fr om t he ends of pipe sect ions t o be joined by field welding. This r equir ement applies t o bot h t he int er ior and ext er ior sur faces of t he pipe. When r ubber gasket ed joint s or mechanical couplings ar e used, t he coat ing shall ext end t o t he ends of t he pipe unless ot her wise specified by t he pur chaser . C-2.8 Th i ck n e ss The coat ing powder shall be applied t o t he pr eheat ed pipe at a unifor m cur ed-film t hickness of not less t han 300 micr ons on t he ext er ior and not less t han 375 micr ons on t he int er ior . C-2.9 Cooli n g Aft er t he coat ing has cur ed in accor dance wit h t he t ime/t emper at ur e r equir ement s of t he coat ing manufact ur er , t he coat ing may be cooled wit h air or wat er spr ay t o a t emper at ur e below 90°C t o facilit at e handling for inspect ion and r epair . C-2.10 I mp e r fe ct i on s On complet ion of t he coat ing oper at ion, t he coat ing shall be visually inspect ed for blist er s, bubbles, voids, or ot her discont inuit ies. The coat ings shall also be elect r ically inspect ed for holidays. Inspect ion and r epair may commence aft er t he pipe has cooled t o 90°C or below. C-3 COATI NG REP AI R C-3.1 Mi n or De fect s Coat ing r equir ing r epair due t o scar s, sliver s, coat ing imper fect ions and ot her small defect s shall be r epair ed using r epair mat er ials fr om t he same manufact ur er as t he fusion bonded epoxy or any ot her compat ible mat er ial appr oved by t he pur chaser and t he applicat or . C-3.2 Ma jor De fe ct s Pipe sect ions wit h coat ing defect s, such as par t icle coat ing, unbounded coat ing, or inadequat e film t hickness, shall be r epr ocessed st ar t ing wit h sur face pr epar at ion pr ocedur es. C-3.3 F ie l d Wel d e d J oi n t s The weld ar ea shall be heat ed t o a t emper at ur e not t o exceed 260°C using a cir cumfer ent ial induct ion heat ing coil of sufficient size, widt h, and power t o pr ovide t he r equir ed heat in t he weld zone and 55 mm back under t he fusion bonded pipe coat ing. Immediat ely aft er heat ing, t he weld shall be coat ed wit h a powder coat ing. The welded joint coat ing shall over lap t he or iginal pipe coat ing by no less t han 25 mm. The ext er ior of field welded joint s may be coat ed wit h hot applied t ape, cold applied t ape, liquid epoxy, or heat shr inkable coat ings. I S 3589 : 2001 16 ANNEX D ( Foreword and Clause 16.1 ) TAP E COATI NG SYSTEM D-1 GENERAL For cor r osion pr ot ect ion of met al pipes oft en sever al out er wr aps, hot or cold applied ar e used. For ver y cor r osive soil condit ion cold applied t apes ar e used on st eel pipes at sit e. In t he fact or y nor mally hot applied t ape coat ing ar e used. Unless t he t r anspor t at ion is made ver y car efully t hese fact or y applied t ape coat ing may get damaged. For nor mal const r uct ion consider at ions cold applied t apes ar e applied as a t hr ee layer syst em consist ing: a) Pr imer , b) Cor r osion pr event ive t ape (inner layer ), and c) Mechanical pr ot ect ive t ape (out er layer ). D-2 OUTER LAYER TAP E The out er layer shall consist of polyolefin backing wit h a laminat ed elast omer t ype adhesive. The out er layer t ape shall be compat ible wit h t he inner layer t ape. The funct ion of t he out er layer t ape shall be pr imar ily t o pr ovide mechanical and out door weat her ing pr ot ect ion t o t he t ape syst em and secondar ily, t o cont r ibut e t o t he over all cor r osion pr ot ect ion pr oper t ies of t he syst em. D-3 P RI MER The pr imer shall be applied t o t he pr oper ly pr epar ed pipe sur face befor e applicat ion of t he inner layer t ape. The fusion bonding medium bet ween t he pipe sur face and inner layer t ape. D-4 I NNER LAYER TAP E The inner layer t ape shall consist of a polyolefin backing wit h a lament ed adhesive. The inner layer t ape shall be applied aft er t he pr imer and befor e t he out er layer t ape. The pr imar y pur pose of t he inner layer t ape is t o pr ovide t he cor r osion pr ot ect ion coat ing. D-5 TOTAL COATI NG SYSTEM The t ot al t hickness of t he syst em made up of inner t ape and out er t ape may var y depending on pipe diamet er oper at ing condit ion and inst allat ion condit ions. In no case shall t he t hickness be less t han t hose given below: The t apes can be applied dir ect ly ont o t he pr imed pipe sur face by means of mechanical coat ing/wr apping equipment manually or by machine. The inner layer t ape shall be specially applied wit h over lap widt h and applicat ion t ensions as r ecommended by t he manufact ur er s. The minimum over lap shall be not less t han 25 mm when a new r oll of t ape is st ar t ed and t he ends shall be over lapped at least 150 mm measur ed cir cumfer ent ially. The over lap shall be smoot h and shall be locat ed t o ensur e t he cont inuit y of t he inner layer coat ing. The out er layer t ape shall be applied over t he inner layer t ape using t he same t echnique. The over lap of t he out er layer shall not coincide wit h t he over lap of t he inner layer t ape. The minimum over lap of t he applied t ape and minimum end t ap of t wo r olls shall be same as specified for inner t ape. Bu r ea u of I n d i a n St a n d a r d s BIS is a st at ut or y inst it ut ion est ablished under t he Bureau of Indian S tandards Act, 1986 t o pr omot e har monious development of t he act ivit ies of st andar dizat ion, mar king and qualit y cer t ificat ion of goods and at t ending t o connect ed mat t er s in t he count r y. Cop yr i gh t BIS has t he copyr ight of all it s publicat ions. No par t of t hese publicat ions may be r epr oduced in any for m wit hout t he pr ior per mission in wr it ing of BIS. This does not pr eclude t he fr ee use, in t he cour se of implement ing t he st andar d, of necessar y det ails, such as symbols and sizes, t ype or gr ade designat ions. Enquir ies r elat ing t o copyr ight be addr essed t o t he Dir ect or (Publicat ions), BIS. Revi ew of I n d i a n St a n d a r d s Amendment s ar e issued t o st andar ds as t he need ar ises on t he basis of comment s. St andar ds ar e also r eviewed per iodically; a st andar d along wit h amendment s is r eaffir med when such r eview indicat es t hat no changes ar e needed; if t he r eview indicat es t hat changes ar e needed, it is t aken up for r evision. User s of Indian St andar ds should ascer t ain t hat t hey ar e in possession of t he lat est amendment s or edit ion by r efer r ing t o t he lat est issue of ‘BIS Cat alogue’ and ‘St andar ds : Mont hly Addit ions’. This Indian St andar d has been developed fr om Doc : No. MTD 19 (4194) Amen d men t s I ssu ed Si n ce P u b li ca t i on Amen d No. Da t e of I ss u e Amd. No. 1 May 2002 Amd. No. 2 Oct ober 2003 BUREAU OF I NDI AN STANDARDS Headquar t er s: Manak Bhavan, 9 Bahadur Shah Zafar Mar g, New Delhi 110002. Telephones: 323 01 31, 323 33 75, 323 94 02 Telegr ams: Manaksanst ha (Common t o all offices) Regional Offices: Telephone Cent r al : Manak Bhavan, 9 Bahadur Shah Zafar Mar g NEW DELHI 110002 323 76 17 323 38 41 East er n : 1/14 C. I. T. Scheme VII M, V. I. P. Road, Kankur gachi KOLKATA 700054 337 84 99, 337 85 61 337 86 26, 337 91 20 Nor t her n : SCO 335-336, Sect or 34-A, CHANDIGARH 160022 60 38 43 60 20 25 Sout her n : C. I. T. Campus, IV Cr oss Road, CHENNAI 600113 235 02 16, 235 04 42 235 15 19, 235 23 15 West er n : Manakalaya, E9 MIDC, Mar ol, Andher i (East ) MUMBAI 400093 832 92 95, 832 78 58 832 78 91, 832 78 92 Br anches : AH ME DABAD. BAN GAL ORE . BH OP AL . BH U BAN E S H WAR. COI MBAT ORE . F ARI DABAD. GH AZI ABAD. GU WAH AT I . H YDE RABAD. J AI P U R. KAN P U R. LUCKNOW. NAGPUR. NALAGARH. PATNA. PUNE. RAJ KOT. THIRUVANANTHAPURAM. VISHAKHAPATNAM. ¹ ' ¹ ¹ ' ¹ ¹ ' ¹ ¹ ' ¹ ¹ ' ¹