SECTION_33_05_24_-_Welded_Steel_Pipe___Fittings_R1_0004.pdf

BUREAU OF INDIAN AFFAIRS OGLALA DAM SPILLWAY AND OUTLET WORKS

OGLALA DAM SPILLWAY AND OUTLET WORKS SECTION 33 05 24

JUNE 2023 WELDED STEEL PIPE AND FITTINGS

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SECTION 33 05 24

WELDED STEEL PIPE AND FITTINGS

GENERAL

1.01 SCOPE OF WORK

A. This Section specifies the requirements for furnishing and installing welded steel pipe for the outlet facilities, including fittings, flanges, gaskets and bolts.

1.02 REFERENCES

A. American Water Works Association (AWWA)

AWWA C200 Steel Water Pipe 6 Inches and Larger

AWWA C205 Cement-Mortar Protective Lining and Coating for Steel Water Pipe - 4 inches and Larger Shop Applied

AWWA C206 Field Welding of Steel Water Pipe

AWWA C207 Steel Pipe Flanges for Waterworks Service

AWWA C208 Dimensions for Fabricated Steel Water Pipe Fittings

AWWA C210 Liquid Epoxy Protective Coatings and Linings for Steel Water Pipelines

AWWA C222 Polyurethane Coatings for the Interior and Exterior of Steel Water Pipe and Fittings

AWWA M-11 Steel Water Pipe - A Guide for Design and Installation

NSF Std. 61 Listing of Certified Drinking Water System Components

B. American Petroleum Institute (API)

API 1104 Field Welding of Steel Water Pipe

C. American Society of Mechanical Engineers (ASME)

ASME – Boiler and Pressure Vessel Code

D. ASTM International (ASTM)

ASTM A20 Standard Specification for General Requirements for Steel Plates for Pressure Vessels

ASTM A36 Standard Specification for Carbon Structural Steel

ASTM A139 Standard Specification for Electric-Fusion (Arc)-Welded Steel Pipe (NPS 4 and over)

BUREAU OF INDIAN AFFAIRS SECTION 33 05 24

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ASTM A283 Standard Specification for Low and Intermediate Tensile Strength Carbon Steel Plates

ASTM A370 Standard Test Methods and Definitions for Mechanical Testing of Steel Products

ASTM A384 Standard Practice for Safeguarding Against Warpage and Distortion During Hot-Dip Galvanizing of Steel Assemblies

ASTM A385 Standard Practice for Providing High-Quality Zinc Coatings (Hot-Dip)

ASTM A516 Standard Specification for Pressure Vessel Plates, Carbon Steel, for Moderate- and Lower-Temperature Service

ASTM A572 Standard Specification for High-Strength Low Alloy Columbium Vanadium Structural Steel

ASTM A1011 Standard Specification for Steel, Sheet and Strip, Hot-Rolled, Carbon, Structural, High-Strength Low-Alloy, High Strength Low-Alloy with Improved Formability, and Ultra-High Strength

ASTM C150 Specification for Portland Cement

ASTM F3125 Standard Specification for High-Strength Structural Bolts and Assemblies, Steel and Ally Steel, Heat Treated, Inch Dimensions 120 ksi and 150 ksi Minimum tensile Strength, and Metric Dimensions 830 MPa and 1040 MPa Minimum tensile Strength

E. American Welding Society (AWS):

AWS D1.1 Structural Welding Code, Steel

1.03 SUBMITTALS

A. Shop Drawings

Certified dimensioned drawings of pipe, fittings, and appurtenances including cylinder thickness and joint details. Include the location, type, size, and extent of all welds; and the limits of restrained and/or welded joints.

Material lists which include and describe all materials to be utilized.

B. Quality Control

Certifications: Furnish test data, records, and certified affidavits of compliance for all steel pipe furnished, including:

a. Physical and chemical properties of all steel.

b. Hydrostatic test reports.

c. Results of weld tests meeting AWWA C200 and ASTM A139.

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1.04 QUALITY CONTROL

A. Inspection: All pipe shall be subject to inspection.

B. Tests: Except as modified herein, all materials used in the manufacture of the pipe shall be tested in accordance with and shall meet the requirements of ASME Boiler and Pressure Vessel Code, Section VIII, Division 1, Parts UG, UW, and UCS, or API 5L as applicable.

After fabrication is completed and prior to lining with poly-urethane, each length or special of pipe shall be shop-tested to a pressure of at least 75 percent of the specified yield strength of the pipe steel, except that the highest test pressure shall be 150 percent of the design pressure.

In addition to the tests required in the referenced ASME and API codes, all butt weld tests shall be conducted on 100 percent length of welds and at any other locations where there is a change in the grade of steel, welding procedure, or welding equipment.

C. Welding Requirements: Welding procedures, welders, and welding operators for shop welding shall be qualified in accordance with Section IX – ASME Boiler Pressure Vessel Code. Welding procedures, welders and welding operators for field welding shall be qualified in accordance with the requirements of API 1104.

D. Welder Qualifications: All welding shall be done by skilled welders and welding operators who have had adequate experience in the methods and materials to be used. Welders and welding operators for shop welding shall be qualified under the provisions of Section XI – ASME Boiler and Pressure Vessel Code.

PRODUCTS

2.01 GENERAL

A. Polyurethane lined steel pipe shall conform to AWWA C200, C205, C208, C209, C214, ASTM A139, A516, ASME Boiler and Pressure Vessel Code Section VIII, Division 1, or

API 5L.

B. All specials and bends shall be provided as indicated in the Drawings. The pipe shall be furnished complete with welded joints, as indicated on the Drawings.

C. The nominal pipe thickness shall be 3/8 inches.

D. The lined pipe shall be certified per NSF Standard 61 for potable water conveyance.

E. Legibly mark pipe and specials with the word “top” on the outside top of each pipe end.

F. Handle pipe by use of wide slings, padded cradles, or other devices, acceptable to the BIA Representative and designed to prevent damage to the pipe and/or exterior coating.

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G. CONTRACTOR shall be fully liable for the cost of replacement or repair of pipe which is damaged.

H. Stockpiled pipe shall be supported on sand or earth berms free of rock. The pipe shall not be rolled and shall be secured to prevent accidental rolling.

I. Finish: The pipe shall have smooth dense interior surfaces and shall be free from fractures, excessive interior surface crazing and roughness.

2.02 MATERIALS

A. Polyurethane: Interior lining shall be 100% solids polyurethane conforming to the requirements of AWWA C222. Approved Manufacturers:

Life Last DuraShield 210-61.

BIA Representative approved equivalent.

B. Steel for Cylinders and Fittings: Pipe shall be fabricated from plate or coil conforming to the requirements of ASTM A20 or ASTM A139 and the requirements herein. The steel shall be kilned steel with fine austenitic grain size. Longitudinal and girth seams, whether straight or spiral, shall be full penetration butt double welded using an approved process with filler metal added. Longitudinal seam welds, whether spiral or straight, shall be made with submerged arc (SA), or gas metal arc (GMA) processes or a combination of the two.

If coil steel is used, the mill producing the coil must furnish certified chemical analysis of each heat. All physical test samples may be taken from the coil or the completed pipe. The spiral weld manufacturer must furnish certified reports of the physical tests per Part 1.04 of this specification.

For steel containing greater than 0.13 weight percent carbon, the maximum carbon equivalent shall be 0.40 percent (ladle and product analysis). The carbon equivalent (CE) shall be calculated from the following equation:

CE = C + Mn/6 + (Cr + Mo + V)/5 + (Ni + Cu)/15

For steel with carbon contents of 0.13 percent and below, then the Ito and Bessyo Carbon Equivalent (Pcm) for this steel shall not exceed 0.24 when calculated by the following formula:

Pcm = C + SI/30 + Mn/20 + Cu/20 + Ni/60 + Cr/20 + Mo/15 + V/10 + 5B

2.03 DESIGN OF PIPE

A. The pipe furnished shall be 48-inch diameter steel pipe, with a minimum pressure class of 150 psi, a shop applied polyurethane lining, and no coating.

B. All fittings shall match the adjacent pipe nominal inside diameter after lining and shall be designed for the design pressure of the adjacent pipe.

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C. Supply pipe with lap fillet welded slip joints. Butt-strap closure joints may be used when required or if shown on the Drawings. The joints shall have the same or higher pressure rating as the abutting pipe with consideration of weld joint efficiency. Alternatively, flanged joints with Class D pipe flanges may be used for field installation where allowed by the COR.

D. Hold back shop applied coatings from the ends of the pipe as required for the couplings used.

2.04 BOLTS

A. High-Strength Carbon Steel: ASTM F3125, Type 1, galvanized.

2.05 FLANGES AND FLANGE GASKETS

A. For nominal diameters of 18 inches or greater, conform to AWWA C207, Class B.

2.06 LININGS AND COATINGS

A. Line interior of pipe with polyurethane in accordance with AWWA C222.

B. Line fittings, specials, and flanges to match adjoining pipe. Do not apply lining materials to machined surfaces of flanges.

C. Polyurethane:

2-part system with 100% solids conforming to AWWA C218.

Minimum Dry Film Thickness: 25 mils

Apply three coats minimum; alternate colors between coats.

2.07 FABRICATION

A. General:

Conform to AISC Specification for Structural Steel Buildings and these Specifications.

Mark and match mark materials for field assembly.

B. Connections:

Shop Connections: Welded or bolted, as shown.

Field Connections: Welded or bolted, unless otherwise approved by BIA Representative.

Provide bolt length and thread length appropriate for the connection type shown, with hardened washers as required.

C. Welded Construction:

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Groove and Butt Joint Welds: Complete penetration, unless otherwise indicated.

EXECUTION

3.01 PREPARATION

A. Inspect each pipe, fitting, and special immediately prior to installation. Repair damage or defects before installation. Replace damaged pipe if necessary.

B. Do not place upon foundations into which frost has penetrated, or if there is potential for frost or ice formation within foundation materials.

C. Remove debris and foreign material from each pipe, fitting or special before installation.

D. Place temporary support and restraint frame.

E. The amount of field fabrication necessary for completion of the Work shall be limited to the extent practical.

3.02 INSTALLATION OF PIPE

A. All pipe, fittings, etc., shall be carefully handled and protected against damage to lining and coating/interior and exterior surfaces, impact shocks, and free fall.

B. Install to lines and grades shown on the Drawings, or as otherwise approved in writing by the COR.

C. Follow approved installation sequence.

D. Install pipe, fittings, specials, couplings, appurtenances, and accessories in accordance with manufacturer’s instructions.

E. Measure for grade at pipe invert, not at top of pipe.

F. Provide adequate support to prevent deflections in excess of specified tolerances.

G. Prevent debris and foreign material from entering pipe during and after installation.

H. Flanged Joints:

Install perpendicular to pipe centerline.

Install at locations shown on the Drawings or otherwise as approved in writing by the

COR.

Bolt Holes: Straddle vertical centerline, align with connecting flanges, or as shown on Drawings.

Use torque-limiting wrenches to provide uniform bearing and proper bolt tightness.

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I. Tolerances

Deflection from Horizontal Line: Maximum 1/2-inch.

Deflection from Vertical Line: Maximum 1/2-inch.

Circumferential Pipe Deflection: Maximum 5 percent of pipe diameter.

J. Conform to lining/coating manufacturer’s recommendations and applicable provisions of AWWA C210 and AWWA C218 for field-applied linings and coatings and field repairs.

3.03 QUALITY CONTROL

A. Welds

Butt Welds: Perform spot radiographic tests, using methods and acceptance criteria in API Standard 1104.

Butt-Strap and Double-Welded Lap Joints: Air test method in accordance with

AWWA C206.

Butt Joints: 50 percent of all welds with full circumference radiographic inspection, in accordance with AWWA C206.

Fillet Welds and Groove Welds: Perform ultrasonic testing on 100 percent of welds, using methods and acceptance criteria in AWS D.1.1, Section 6.14.5, Table 6.1.

Lap Joints: 50 percent of all welds using ultrasonic testing, in accordance with

AWWA C206.

The COR may conduct additional random inspections and non-destructive testing of welds and welded joints. Testing will be appropriate for the respective weld type, and will be performed in accordance with applicable provisions of AWWA C206.

The COR will perform field quality control testing of welds.

Repair all defective welds to satisfaction of the COR.

B. Shop Hydrostatic Testing

Conform to AWWA C200, with the additional requirements of this Section.

Perform tests before application of linings and coatings.

Maintain test pressure for a minimum of 5 minutes.

Test fittings and specials fabricated from un-tested straight pipe to the required test pressure for the adjoining pipe.

END OF SECTION

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