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壳牌标准 Shell DEP 30.48.30.31 Cement lining of

pipes

TECHNICAL SPECIFICATION
LINING OF PIPES

30.48.30.31-Gen.
1998

(DEP Circular 15/03 has been incorporated)

AND ENGINEERING PRACTICE

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This document is confidential. Neither the whole nor any part of this document
may be disclosed to any third party without the prior written consent of Shell
International Oil Products B.V. and Shell International Exploration and
Production B.V., The Hague, The Netherlands. The copyright of this document is
vested in these companies. All rights reserved. Neither the whole nor any part
of this document may be reproduced, stored in any retrieval system or
transmitted in any form or by any means

(electronic, mechanical, reprographic, recording or otherwise) without the prior

written consent of the copyright owners.

(Design and Engineering Practice) publications reflect the views, at the time of
publication, of:://www.51wendang.com/doc/a3982b5f992fb00995fa666farGlobal
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Solutions International B.V. (Shell GSI)

International Exploration and Production B.V. (SIEP)

International Chemicals B.V. (SIC)

Service Companies.
are based on the experience acquired during their involvement with the design,
construction, operation and maintenance of processing units and facilities, and
they are supplemented with the experience of Group Operating companies. Where
appropriate they are based on, or reference is made to, international, regional,
national and industry standards.
objective is to set the recommended standard for good design and engineering
practice applied by Group companies operating an oil refinery, gas handling
installation, chemical plant, oil and gas production facility, or any other such
facility, and thereby to achieve maximum technical and economic benefit from
standardization.
://www.51wendang.com/doc/a3982b5f992fb00995fa666frThe information set forth in
these publications is provided to users for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every
requirement or diversity of condition at each locality. The system of DEPs is
expected to be sufficiently flexible to allow individual operating companies to
adapt the information set forth in DEPs to their own environment and
requirements.
Contractors or Manufacturers/Suppliers use DEPs they shall be solely responsible
for the quality of work and the attainment of the required design and
engineering standards. In particular, for those requirements not specifically
covered, the Principal will expect them to follow those design and engineering
practices which will achieve the same level of integrity as reflected in the
DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without
detracting from his own responsibility, consult
thhttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fe Principal or its
technical advisor.
right to use DEPs is granted by Shell GSI, SIEP or SIC, in most cases under
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Service Agreements primarily with companies of the Royal Dutch/Shell Group and
other companies receiving technical advice and services from Shell GSI, SIEP,
SIC or another Group Service Company. Consequently, three categories of users of
DEPs can be distinguished:

) Operating companies having a Service Agreement with Shell GSI, SIEP, SIC or
other Service Company. The
of DEPs by these operating companies is subject in all respects to the terms and
conditions of the relevant Service Agreement.
parties who are authorized to use DEPs subject to appropriate contractual
arrangements (whether as part of a Service Agreement or otherwise).
/subcontractors and Manufacturers/Suppliers under a contract with users referred
to under 1) or 2) which requires that tenders for
prhttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fojects, materials
supplied or - generally - work performed on behalf of the said users comply with
the relevant standards. 2) 3)
to any particular terms and conditions as may be set forth in specific
agreements with users, Shell GSI, SIEP and SIC disclaim any liability of
whatsoever nature for any damage (including injury or death) suffered by any
company or person whomsoever as a result of or in connection with the use,
application or implementation of any DEP, combination of DEPs or any part
thereof, even if it is wholly or partly caused by negligence on the part of
Shell GSI, SIEP or other Service Company. The benefit of this disclaimer shall
inure in all respects to Shell GSI, SIEP, SIC and/or any company affiliated to
these companies that may issue DEPs or require the use of DEPs.
prejudice to any specific terms in respect of confidentiality under relevant
contractual arrangements, DEPs shall not,
whttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fithout the prior written
consent of Shell GSI and SIEP, be disclosed by users to any company or person
whomsoever and the DEPs shall be used exclusively for the purpose for which they
have been provided to the user. They shall be returned after use, including any
copies which shall only be made by users with the express prior written consent
of Shell GSI, SIEP or SIC. The copyright of DEPs vests in Shell GSI and SIEP.
Users shall arrange for DEPs to be held in safe custody and Shell GSI, SIEP or
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SIC may at any time require information satisfactory to them in order to
ascertain how users implement this requirement.
administrative queries should be directed to the DEP Administrator in Shell GSI.
OF CONTENTS

.1

.2

.3

.4

.1

.2

.1

.2

.3

.4

.1
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.2

.3

.4

.5://www.51wendang.com/doc/a3982b5f992fb00995fa666f
.

.1

.2

.3

.4

.5

.1

.2

.3

.4
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.5

.1

1
2
JOINTS..........................................................................
.........................22 TYPICAL DETAILS OF FLANGED PIPE-TO-PIPE
CONNECTIONS.............25
INTRODUCTION....................................................................
.....................................4
SCOPE...........................................................................
.............................................4 DISTRIBUTION, INTENDED USE AND
REGULATORY CONSIDERATIONS..........4
DEFINITIONS.....................................................................
........................................4 CROSS
REFERENCES.......................................................http://www.51we
ndang.com/doc/a3982b5f992fb00995fa666f.......................................5
CONTRACT
STRATEGY........................................................................
...................6 CONTRACTOR
INVOLVEMENT.....................................................................
...........6 SELECTION OF CEMENT LINING
MANUFACTURER.............................................6 DESIGN OF CEMENT
LINED PIPING SYSTEMS.....................................................7
GENERAL.........................................................................
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..........................................7 SERVICE
CONDITION.......................................................................
........................7 SIZING
CRITERIA........................................................................
..............................7
PIPING..........................................................................
..............................................7 APPLICATION OF CEMENT
LINING.http://www.51wendang.com/doc/a3982b5f992fb00995fa666f....................
...................................................9 SURFACE
PREPARATION.....................................................................
...................9 LINING DESIGN AND CEMENT
MORTAR................................................................9
INSTALLATION OF SHOP CEMENT
LINING............................................................9
CURING..........................................................................
............................................9 LINING
REPAIR..........................................................................
..............................10 COATING OF CEMENT-LINED
PIPES....................................................................11
HANDLING OF CEMENT-LINED
PIPE....................................................................12
FIELD-
JOINTING........................................................................
..............................13
GENERALhttp://www.51wendang.com/doc/a3982b5f992fb00995fa666f....................
................................................................................
.............13 BUTT-
JOINTING........................................................................
...............................13 SLEEVE
JOINTING........................................................................
..........................13 CUTTING TO SIZE IN
SITU............................................................................
.........13 FIELD
WELDING.........................................................................
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.............................14 QUALITY
CONTROL.........................................................................
.......................15
GENERAL.........................................................................
........................................15 PROCEDURE QUALIFICATION
TEST....................................................................15
QUALITY CONTROL DURING SHOP
APPhttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fLICATION................
.............................15 QUALITY CONTROL DURING FIELD-
JOINTING...................................................16 PRODUCTION
TESTS...........................................................................
..................16 TESTS AND INSPECTION
CRITERIA.....................................................................17
GENERAL.........................................................................
........................................17 FABRICATION
REPORT..........................................................................
...............19
REFERENCES......................................................................
....................................20

. INTRODUCTION

.1 SCOPE
DEP specifies requirements and gives recommendations for the cement lining of
carbon steel pipes from nominal size DN 100 to DN 900. This includes applying
the cement mortar in the
shhttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fop, joining the lined
pipes in situ and applying cement mortar by hand at the field joints. This DEP
is a revision of the DEP of the same number dated December 1990. This DEP
complements the requirements of DIN 2614.
in-situ lining of piping systems, other than the above mentioned joints, is
outside the scope of this DEP and reference is made for this purpose to NSI/AWWA
C602 issued by the American Waterworks Association.
cement lining is usually applied to prevent internal corrosion of carbon steel
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cooling water or fire-fighting water piping systems containing sea-water or
brackish water at ambient temperatures. These systems can be installed above and
below ground. If an above ground lined piping system is drained for a prolonged
period, special precautions are required to prevent cracking of the lining due
to high or low temperatures and/or variations in temperature or humidity. The
special precautions thttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fo be
taken are outside the scope of this DEP.
to cement lined carbon steel piping for sea-water and brackish water service are
glass-reinforced epoxy (GRE) piping, concrete piping or epoxy coated/lined
piping, their selection depending on local/process conditions and life-cycle
costs.

.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

otherwise authorised by SIOP and SIEP, the distribution of this DEP is confined
to companies forming part of or managed by the Royal Dutch/Shell Group. It may
be distributed to Contractors and Manufacturers/Suppliers nominated by them.
DEP is intended for use in oil refineries, chemical plants, gas plants,
exploration and production facilities and supply/marketing installations.
national and/or legal regulations exist in which some of the requirements may be
more stringent than in this DEP, the Contractor shall determine by
carefulhttp://www.51wendang.com/doc/a3982b5f992fb00995fa666f scrutiny which of
the requirements are the more stringent and which combination of requirements
will be acceptable as regards safety, economic and legal aspects. In all cases
the Contractor shall inform the Principal of any deviation from the requirements
of this document which is considered to be necessary in order to comply with
national and/or local regulations. The Principal may then negotiate with the
Authorities concerned with the objective of obtaining agreement to follow this
DEP as closely as possible.

.3 DEFINITIONS

.3.1 General definitions

Contractor is the party which carries out all or part of the design,
engineering, procurement, construction, commissioning or management of a project
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or operation of a facility. The Principal may undertake all or part of the
duties of the Contractor.
Manufacturer/Supplier is the party which manufactures or supplies equipment and
services to perform http://www.51wendang.com/doc/a3982b5f992fb00995fa666fthe
duties specified by the Contractor.
Principal is the party which initiates the project and ultimately pays for its
design and construction. The Principal will generally specify the technical
requirements. The Principal may also include an agent or consultant authorised
to act for, and on behalf of, the Principal.
word shall indicates a requirement.
word should indicates a recommendation.

.4 CROSS REFERENCES
cross references to other parts of this DEP are made, the referenced section
number is shown in brackets. Other documents referenced in this DEP are listed
in (10).

. CONTRACT STRATEGY

.1 CONTRACTOR INVOLVEMENT
Contractor shall prepare a detailed specification for the Manufacturer of
cement-lined piping. Additional detailed drawings shall be prepared if the
details are not covered by the appendices of this DEP or the referenced Standard
Drawings.://www.51wendang.com/doc/a3982b5f992fb00995fa666fpar
.2 SELECTION OF CEMENT LINING MANUFACTURER
Manufacturer selected shall be able to design and install complete systems,
procure the required piping materials and provide technical services related to
the products. In addition the Manufacturer shall be responsible for the proper
application of the cement lining to the field-joints. Pre-qualification tests
shall be performed in accordance with (8). The final selection of Manufacturer
is subject to the Principal's approval.
to the lining may occur during the application of the shop painting, handling,
transport and storage of the pipes. The Manufacturer of the cement lining shall
therefore be responsible for the shop-painting and/or wrapping of the outside of
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the pipe.

. DESIGN OF CEMENT LINED PIPING SYSTEMS

.1 GENERAL
design shall be in accordance with ASME B31.3.
cement lining shall be designed for a life of at
lhttp://www.51wendang.com/doc/a3982b5f992fb00995fa666feast 20 years.
cement lining shall be designed so that no repairs will be needed within the
first five years’ service.

.2 SERVICE CONDITION
Principal shall specify the service conditions for which the cement-lined pipe
shall be suitable (normally sea water and/or brackish water at an operating
temperature between minus 5 °C and plus 60 °C).
Contractor shall obtain from the Principal a chemical analysis of the fluid to
be conveyed.
composition of the lining shall be agreed with the Principal.
per
15/03
lining applied shall have a design life of at least 20 years.

.3 SIZING CRITERIA
diameter of cement-lined piping systems shall be chosen so that the maximum
water velocity inside the lined piping shall not exceed 3 m/s for pipes larger
than DN 150 and 2 m/s for sizes DN 150 and DN 100.
minimum outside diahttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fmeter
for piping and fittings to be cement lined is DN 100. The maximum diameter shall
be DN 900. The straight length of the pipes shall be between 6 m and 13 m.
carrying capacity is of importance, calculations shall be made to determine the
maximum friction and loss of water head.
a greater thickness has been specified, the lining thickness after curing shall
be in accordance with DIN 2614 section 6.5.3.
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.4 PIPING

.4.1 Materials
, flange, fitting and valve materials shall be in accordance with piping class
11011 (see DEP 31.38.01.12-Gen).

.41 Welding ends

DN 650 and larger shall have butt welding ends in accordance with ASME B16.25.
Smaller sizes shall have plain ends, with a sleeve coupling externally welded to
one end. Valves and fittings shall have sleeve couplings externally welded to
both ends.

.4.3 Fittings
the selection and overall
dihttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fmensions of fabricated
fittings see Standard Drawings S 38.070 and S 38.071.
typical details of a set-on branch for cement lined fittings see Standard
Drawing S 38.076.
dimensions of sleeves see Standard Drawing S 38.074.
made butt welding fittings shall be in accordance with ASME B16.9.

.4.4 Flanges
shall be ASME rating class 150, raised face, except where flat face flanges are
required for replacement in existing installations.
on flanges should be installed in pipe sizes from DN 100 through DN 600. For
pipe sizes DN 650 and larger, welding neck flanges shall be used. Flanges from
DN 100 through DN 600 shall be in accordance with ASME B16.5 and flanges DN 650
and larger shall be in accordance with ASME B16.47.
facing finish shall be in accordance with ASME B16.5.
flanged ends (slip-on) for cement-lined pipe and fittings, see Standard
Drhttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fawing S 38.075.

.4.5 Gaskets
shall be 3 mm thick, reinforced chloroprene rubber with a Shore A hardness of
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70. The inside diameter of the gasket shall be equal to the inside diameter of
the cement lining (Appendix 2, Figure 6). On some pipe-to-pipe valve connections
the cement lining I.D. is tapered to equal the pipe I.D. at the gasket position
to prevent possible interference of the valve disc with the cement lining
(Appendix 2, Figure 7).
face gaskets shall be used for connecting flat face flanges.

. APPLICATION OF CEMENT LINING

.1 SURFACE PREPARATION
inside of the pipe shall be cleaned of all grease, mill scale, loose rust or
other foreign materials, by blast cleaning to at least Sa2, or by power tool
cleaning to St3, in accordance with ISO 8501-1.

.2 LINING DESIGN AND CEMENT MORTAR

lining design concept, constituents of the cement mortar, mortar
typehttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fs and preparation and
testing shall be in accordance with DIN 2614 sections 2, 3, 5, 6 and 7.

.3 INSTALLATION OF SHOP CEMENT LINING

.3.1 General
sections of pipes, diameters from DN 100 up to and including DN 900, length 6 m
to 13 m, shall be lined by the spinning method. The interior surface shall be
smooth, straight and true and the sand/cement particles shall be equally
distributed throughout the lining thickness, after completion of the lining
process.

.3.2 Spinning Method

lining shall be applied by a spinning machine specifically designed and built
for the purpose of applying cement mortar linings to the interior of steel pipe
by means of centrifugal forces and rotation of the pipe. To prevent distortion
or vibration during spinning, each section of pipe shall, if required, be braced
with external or internal supports. The entire quantity of mortar required for
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the lining of onehttp://www.51wendang.com/doc/a3982b5f992fb00995fa666f section
of pipe shall be placed without interruption. The pipe shall be rotated slowly
until the mortar has been equally distributed along the inside periphery of the
pipe.
the rotation speed shall be increased to produce a dense lining with a smooth
surface and a minimum of shrinkage. Provisions shall be made for removal of
surplus of water.

.3.3 Bends and fittings

and fittings which cannot be machine lined in accordance with (4.3.2) may
receive a hand-applied mortar lining. Hand-applied mortar shall have a uniform
surface. Cement mortar for hand work shall be of the same consistency and
material as the mortar for machine method. Surfaces to be lined shall be cleaned
in accordance with (4.1) and damped with water immediately prior to placing the
hand-applied mortar. Steel finishing trowels shall be used for the hand
application of cement mortar.

.4 CURING

.4.1 General
://www.51wendang.com/doc/a3982b5f992fb00995fa666fe lining shall be cured in
accordance with DIN 2614 section 4.
application of the lining, the pipe and/or fittings shall be sealed with plastic
caps and left to cure in situ, or they may be transferred carefully to a curing
yard.
curing area shall be sheltered so that lined pipes and fittings are protected
from harmful climatic conditions (e.g. exposure to direct sun, frost, etc.).
Within 24 hours after application of the cement lining the bores shall be
inspected and water added to aid curing if required. Curing will take place for
a period of at least 7 days after application of the cement lining.
the final inspection, the ends of the pipes and fittings shall be re-capped with
the plastic caps. These covers shall not be removed within 14 days after cement
lining in order to protect the lining from drying out.
or fittings shall not be removed from the curing yard until the curing
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prohttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fcedure is completed and
the mortar has reached its specified strength.

.4.2 Normal Curing

lining shall be protected from drying out as specified above for the whole
period of the hardening process of the mortar in order to minimise shrinkage
cracks. The minimum period of hardening shall be 28 days.

.4.3 Water Curing

lining shall be kept totally submerged for the total period of the hardening
process of the mortar in order to minimise shrinkage cracks. The minimum period
of hardening shall be 4 days.

.4.4 Steam Curing

curing shall only be applied if required and approved by the Principal.
Recording thermometers shall be installed.

.4.5 Membrane Curing

curing by application of any moisture-retaining liquid is not permitted.

.5 LINING REPAIR
, spalled and excessively cracked areas etc. in fully accessible pipes shall be
removed and rephttp://www.51wendang.com/doc/a3982b5f992fb00995fa666faired by
hand to the required thickness of the lining.
with a width less than 0.8 mm may be left, providing they will not impair the
stability of the lining, as the self-healing effect will set them tight as soon
as the pipes are in operation. Cracks with a width greater than 0.8 mm can be
washed in by means of soft brush with a liquid sand/cement mixture consisting of
one part cement and one part fine sand (0.1 mm). The mixture should be liquid
similar to heavy paint.
local damages, other than cracks, shall be repaired by removing all loose
particles, old mortar, grease and dirt by brushing with a stiff/wire brush. All
traces of oil and grease shall be removed with a suitable de-greasing agent. The
sides of the existing cement lining shall be primed with a multi-purpose
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adhesive, based on synthetic resin.
damaged area shall be filled with a ready mixed mortar. The repaired lining
shall be finishttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fhed by means
of a trowel or a spatula and brushed flush with the original cement, and shall
be kept moist for at least three days. Minor damage can be repaired by means of
a multi-purpose adhesive.

. COATING OF CEMENT-LINED PIPES

faces shall be coated with Shell Ensis Fluid “G”, after which they shall be
provided with protective covers.
the pipe is to be externally wrapped it shall be done before installing the
lining.
painting of the outside surface of the pipe shall be done after installing and
curing the cement lining.

6. HANDLING OF CEMENT-LINED PIPE

pipes and fittings shall be handled carefully to avoid internal damage to the
cement lining.
end caps shall be kept in place during transport and storage in order to prevent
dust, dirt, foreign matter etc. entering the pipe.
loading and unloading of very heavy pipes, it is
recommhttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fended to use slings
with cushion pads or a suitable fork arrangement placed at the centre of the
joints. Hooks or other devices which are inserted into the ends of the pipe
shall not be used. A flat-bed trailer provides the best support for the lined
pipes during transport. During loading or unloading, lined pipes shall not be
dropped onto or off the transporting vehicle.
prevent bending of the pipes which can cause damage to the lining, supports
shall be used during storage and shipping. The distance between the supports
shall not exceed 3 m.
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shall be stored in supported tiers. The height of the tiers depends on the
diameter of the pipes and shall be as follows: Pipe nominal size

< DN 150
200 to DN 400

> DN 400 Maximum number of pipes per tier 10 6 4

7. FIELD-JOINTING

.1 GENERAL
shall be in accordance with DEP 31.38.01.31-Gen.
pipes and fhttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fittings shall be
joined in-situ by field welds or flanges.
welds shall be used for pipe diameters DN 650 and larger (with the joint
location internally lined in-situ after welding).
joints shall be used for pipe diameters smaller than DN 650.
Contractor and Principal shall agree upon the type of multi-purpose adhesive and
the ready mixed mortar to be used for assembling the pipes.
methods for field jointing of cement lined pipes and fittings (e.g. with
impregnated gaskets etc.) are subject to approval of the Principal.

.2 BUTT-JOINTING
bevelled ends of the cement lined pipes shall be thoroughly cleaned see (4.1)
and all loose particles of the cement lining shall be removed over 20 mm at both
ends of the pipe, i.e. 20 mm on either side of the joint (Figure 4 of Appendix
1). After the welding has been completed, a hand-applied mortar shall be used to
finish the http://www.51wendang.com/doc/a3982b5f992fb00995fa666fcement lining on
the inside surface of the steel pipe at the location of the field weld (see
Figure 5 of Appendix 1).
another method has been agreed, the sides of the existing cement lining shall be
sealed with a priming coat consisting of one part of a multi-purpose adhesive,
based on synthetic resin, and one part of potable water. After this priming coat
has become tacky (20-30 minutes), the ready mixed mortar shall be applied.
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application of the adhesive and ready mixed mortar shall be in accordance with
the Manufacturer's specifications. The hand applied mortar shall be finished by
means of a trowel or spatula and shall be brushed flush after which a curing
compound shall be applied. Pressure testing of a pipe section with site-applied
cement lining shall be delayed until 28 days after application or until the
minimum compression strength has been reached (this will require an earlier
compressive strengthhttp://www.51wendang.com/doc/a3982b5f992fb00995fa666f test
in addition to the 28 day test, (9.1.4)).

.3 SLEEVE JOINTING
free-access length of the female part shall be determined prior to the jointing
and shall be marked on the male part over the full circumference (see Figures 2A
and 2B of Appendix

). The cut end of the pipe inside the sleeve coupling shall be thoroughly
cleaned, dry and free of dust and shall be provided with a concrete glue. This
type of glue shall be based on a two component solvent free epoxy-resin suitable
for application on moist mortar surfaces. Before installation of the male pipe
end part, the concrete glue shall be tapered with a minimum thickness at the
cement lining edge of 3 mm and with an angle of 75° (see also Figure 2 of
Appendix 1).
after the application of the concrete glue, the male part shall be carefully
pulled into the female part, without distorting the alignment (i.e. centre line)
of the pipe, ahttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fnd shall be
tack-welded in accordance with (7.5).

.4 CUTTING TO SIZE IN SITU

in-situ cutting is unavoidable, it shall be carried out at the required position
by means of a cutting disk 3 mm wide. Flame cutting shall not be used. The end
of the steel pipe shall be cut perpendicular to the pipe and bevelled (if
required) depending on the type of the field joint. For a sleeve joint, the cut
pipe end shall be used as the female part. For a butt-weld joint the cement
lining shall be cut over a length of at least 20 mm at the end of the pipe. In
both cases the cement lining shall be cut perpendicular to the pipe. Typical
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details of the pipe ends are shown in Appendix 1.

7.5 FIELD WELDING

pipes shall be tack-welded at three equidistant positions.
pipe shall be joined by the shielded metal arc welding process. The arc shall
not come in direct contact with the cement lining or seal
material.://www.51wendang.com/doc/a3982b5f992fb00995fa666frand stops shall be
staggered so as not to start or stop more than once in the same place. Welding
slag shall be cleaned from all weld passes.
procedures and welders shall be qualified in accordance with ASME IX; the
procedures shall be submitted to the Principal for approval.

8. QUALITY CONTROL

.1 GENERAL
production of the actual cement lining is started, the Manufacturer shall make
arrangements to execute line-up tests in order to demonstrate the suitability of
the equipment for an uninterrupted production process. All required materials
shall be supplied by the Manufacturer. The testing shall reflect the actual
application conditions.
entire process of applying cement mortar lining, at the Manufacturer's works and
at the construction site, shall be subject to continuous inspection by a QC
inspector appointed by the Contractor, but such inspections shall not
relievhttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fe the Manufacturer of
his responsibility to furnish material and perform the work in accordance with
this DEP.

.2 PROCEDURE QUALIFICATION TEST

to the installation of the shop cement lining, or if there is any variation in
the process or composition of the mortar or a change in any components, the
Manufacturer shall perform procedure tests to demonstrate that he is able to
produce a lining system in accordance with the design requirements. The
constituents, mortar and finished pipe shall be tested; the samples shall be
taken from one of the first finished test pipes or fittings, and testing shall
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be carried out as indicated below:
constituents of the mix:

cement/admixture;

sand;

water.
mortar test specimen:

density;

compressive strength;

flexural tensile strength;

water absorption.
product:

visuahttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fl inspection.
acceptance criteria for the tests shall be in accordance with (9). Successful
tests qualify the procedure for the installation of the actual lining.
record shall be made of the complete test procedure, including:

details of test piece;

batch identification of cement mortar;

test data and results;

acceptance by Principal.

.3 QUALITY CONTROL DURING SHOP APPLICATION

preparation and subsequent application of the cement mortar, a regular
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production sampling programme shall be established and maintained.
logbook shall be kept showing the portion of the completed lining which is
represented by the sample and all information regarding the sample preparation
and the operating parameters at the time of sample collection such as ambient
temperatures, water content, cement/sand ratio, mixing times. Preparation of the
samples shall be witnessed
byhttp://www.51wendang.com/doc/a3982b5f992fb00995fa666f the QC inspector.

Immediately after the final spin an inspection of the cement lining shall be
carried out by looking through the pipe from each end, using a strong light.
Lining defects, including but not restricted to sand pockets, voids, sags, over-
sanded areas, blisters, excessively cracked and dummy areas and unsatisfactory
thin spots, shall be removed before the initial set of the mortar.
areas encompassing the full diameter of the pipe shall be repaired by machine.
Small defects in pipes larger than DN 600 shall be repaired by hand to the full
required thickness of the cement lining. In pipes DN 600 and smaller, any
defective lining shall be removed before the initial set of the mortar.
Defective linings rejected after initial set shall be replaced or repaired by
the most practical method to be determined by the Manufacturer in accordance
with a procedure approved by the Principal.
crackihttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fng occurs when the
lining is allowed to dry out during curing, transportation and storage. The
inspector shall ensure that the lining is still moist after inspection and that
air-tight end caps are placed and maintained on the pipe.

.4 QUALITY CONTROL DURING FIELD-JOINTING

being assembled, the pipes and fittings shall be inspected for possible cracks
and damage. If required any cracks and damage shall be repaired prior to the
assembling of the piping system; see (4.5).
cement shall be the same as applied for the shop cement lining. The sand and
cement shall meet the requirements of DIN 2614.
lengths of pipe shall be butted together and checked for alignment and good
contact of the cement lining and pipe ends.
ready mixed mortar shall be used for the butt joints and butt joint lining
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repairs.
piping system should be inspected 8 days after completion of the cement
lining.://www.51wendang.com/doc/a3982b5f992fb00995fa666fpar
.5 PRODUCTION TESTS
testing shall be performed during manufacture of the pipe lining and tests and
inspections shall be carried out in accordance with the table below. All test
results shall be reported and submitted to the Principal. Test or inspection
/admixture
/cement ratio
ratio/times

strength
strength
temperature
inspection
thickness
and fitting ends
condition
structure

acceptance criteria for the tests shall be in accordance with (9). Frequency
once per batch delivered twice per day twice per day twice per day twice per day
twice per day once per day continuously 20% of pipes and fittings each pipe and
fitting each pipe and fitting once per week per week

9. TESTS AND INSPECTION CRITERIA

.1 GENERhttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fAL
bare pipes shall be inspected before cleaning and lining. The surface on which
the cement lining is to be installed shall be free from all grease, mill scale,
loose rust or other foreign materials prior to the installation of the cement
lining.
samples of the cement lining mortar shall be prepared by the Manufacturer. Each
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sample shall be clearly marked with the Contractor's code numbers for that
day/shift/crew and for sequence of production. The Manufacturer shall be
responsible for regular transport of samples to an independent qualified
laboratory, subject to Principal's approval.
the samples or completed lining do not meet the specified criteria, the
installed cement lining represented by the failed sample(s) shall be removed and
replaced.
lining not meeting the specified criteria of (9.1.7, 9.1.8, 9.1.9 and 9.1.10)
shall be rejected.

.1.1 Sand, cement and water

://www.51wendang.com/doc/a3982b5f992fb00995fa666fTest criteria shall be in
accordance with DIN 2614.

.1.2 Water/cement ratio

water/cement ratio shall be in accordance with DIN 2614 section 6.4.2,
determined in accordance with DIN 1048-1 "Drying to constant weight".

.1.3 Mixing ratio

mixing ratio shall be in accordance with DIN 2614 section 3.3.

.1.4 Compressive and flexural strength

compressive and flexural strength shall be tested in accordance with DIN 2614
section

.6.1 after a curing period of 28 days and the results shall be in accordance
with DIN 2614 section 6.6.1.

.1.5 Density
density, measured in a saturated, surface dry condition, shall be not less than

160 kg/m.

.1.6 Water absorption

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water absorption of the sample shall not exceed 10%.

.1.7 Lining thickness

thickness of the lining shall be measured in accordance with DIN 2614
sectiohttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fn 7.5.3.

.1.8 Pipe and fitting ends

and fitting ends of pipes and fittings DN 650 and larger assembled in-situ by
means of field welding shall have the cement lining removed over a length of 20
mm at each end of the pipe.
ends of the lined pipes shall be considered defective if the lining end is:
) not located as specified; or
) not perpendicular to the longitudinal axis of the pipe; or
) not square; or
) chipped or cracked; or

e) separated from the steel pipe surface; or

) not to the specified thickness.
addition to the above the welding bevel shall be free of cement.

.1.9 Surface condition

surface condition of the finished cement lining shall be smooth and even, not be
flattened at individual spots, not have loose sand, not have dummy, spalled or
excessively cracked areas and not exhibit waves or grooves. Single waves or
grohttp://www.51wendang.com/doc/a3982b5f992fb00995fa666foves are acceptable
providing the minimum specified lining thickness is maintained. However, the
maximum peak to trough height shall not exceed 1.0 mm. Aggregate grains may only
protrude at the surface sporadically. Hairline cracks and sporadically occurring
surface cracks up to 0.8 mm wide shall not be cause for rejection.
shall be no voids (i.e. locations where the cement lining is not continuous,
which occur during the spinning process when the cement does not distribute
evenly).
, appearing as large smooth lumps in the lining at the top of the pipe, are not
acceptable.

.1.10 Lining structure

polished section of a cement lined pipe sample shall not have visible pores and
the individual grains of the sand shall be surrounded on all sides with the
cementing agent.

10. FABRICATION REPORT

finishing the work as defined in the purchase order, the Contractor shall
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http://www.51wendang.com/doc/a3982b5f992fb00995fa666fprovide a fabrication
report with the following contents:

project references such as: location, project number, piping system;

bill of materials including lining;

reference drawings and specifications;

registration of date and time of application of all phases;

registration of the produced samples and tests results;

final inspection results;

welding procedures used.

report shall also include certificates for the following materials:

piping, fittings, flanges, gaskets and valves;

welding consumables;

sand.
mill test certificates shall be provided for each shipment of:

cement;

admixtures and additives;

adhesives, concrete glue and ready-mixed mortar.

11. REFERENCES

this DEP reference is made to the following publications.

: Unless specifically designated
byhttp://www.51wendang.com/doc/a3982b5f992fb00995fa666f date, the latest issue
of each publication shall be used (together with
amendments/supplements/revisions thereof).
STANDARDS
to DEPs and Standard Specifications
piping classes
and field fabrication of piping
DRAWINGS
of cement- lined fittings, nominal size
100 through DN 600
of cement-lined fittings, nominal size
650 through DN 900
for cement-lined pipe and fittings
ends for cement-lined pipe and fittings
detail of set-on branch for cement lined
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STANDARDS
Boiler and Pressure Vessel Code
IX: Qualification standard for welding and
procedures, welders, brazers, and welding
brazing operators
flanges and flanged fittings, NPS 1/2 through
24
mhttp://www.51wendang.com/doc/a3982b5f992fb00995fa666fade wrought steel butt
welding fittings
ends
diameter steel flanges, NPS 26 through NPS

plant and petroleum refinery piping

by:
Society of Mechanical Engineers

East 47th Street

York NY 10017

mortar lining of water pipelines - 4 inch (100

) and larger - in place
by:
Waterworks Association

West Quincy Avenue

80235
DEP 00.00.05.05-Gen. DEP 31.38.01.12-Gen. DEP 31.38.01.31-Gen. S 38.070 S
38.071 S 38.074 S 38.075 S 38.076 ASME IX ASME B16.5 ASME B16.9 ASME B16.25
ASME B16.47 ASME B31.3 NSI/AWWA C602

STANDARDS
concrete:
1 - Testing of fresh concrete
mortar linings for ductile iron and steel pipes
fittings; application, requirements
andhttp://www.51wendang.com/doc/a3982b5f992fb00995fa666f testing
by:
Verlag GmbH
6
, Berlin

STANDARDS
of steel substrates before application of
and related products. Visual assessment of
cleanliness
1: Specifications and definitions for ISO surface
comparators for the assessment of abrasive
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cleaned surfaces
by:
Organisation for Standardisation

, Rue de Varembé
Geneva 20

can also be obtained from national standards

.
30.48.30.31-Gen. December 1998 Page 21 DIN 1048-1 DIN 2614:1990 ISO
8501-1

APPENDIX 1 PIPE JOINTS

1, 2, 2A, 2B and 2C

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SLEEVE JOINTS

Figures 2D, 2E and 3

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://www.51wendang.com/doc/a3982b5f992fb00995fa666fSLEEVE JOINTS

Figures 4, 4A, 4B and 5

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BUTT JOINTS

APPENDIX 2 TYPICAL DETAILS OF FLANGED PIPE-TO-PIPE CONNECTIONS

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Pipe connection

DEP 30.48.30.31-Gen.
1998
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26
7

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Valve (butterfly) connection

page of this DEP

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