GOST R 57385-2017

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  ГОСТ Р 57385-2017

GOST R 57385−2017 Trunk pipeline transport of oil and oil products. The construction of main oil and product pipelines. Thermal insulation of pipes and fittings

GOST R 57385−2017

NATIONAL STANDARD OF THE RUSSIAN FEDERATION

Trunk pipeline transport of oil and oil products

THE CONSTRUCTION OF THE OIL TRUNK PIPELINES AND OIL PRODUCT PIPELINES.

Thermal insulation of pipes and fittings

Trunk pipeline transport of oil and oil products. Construction of oil and oil products trunk pipelines. Thermal insulation of pipes and fittings

OKS 23.040
OKP 13 0300

Date of introduction 2017−09−01

Preface

1 was DEVELOPED by limited liability company «Scientific-research Institute of transport of oil and oil products Transneft» (JSC «NII Transneft»)

2 INTRODUCED by Subcommittee SC 10 «Construction and capital repair of objects of the oil and gas industry» Technical Committee for standardization TC 23 «Oil and gas industry"

3 APPROVED AND put INTO EFFECT by the Federal Agency for technical regulation and Metrology from February 1, 2017 N 29th St

4 INTRODUCED FOR THE FIRST TIME


Rules for the application of this standard is established in article 26 of the Federal law from June 29, 2015 N 162-FZ «On standardization in Russian Federation». Information about the changes to this standard is published in the annual (as of January 1 of the current year) reference index «National standards» and the official text changes and amendments — in monthly index «National standards». In case of revision (replacement) or cancellation of this standard a notification will be published in the upcoming issue of the monthly information index «National standards». Relevant information, notification and lyrics are also posted in the information system of General use — on the official website of the Federal Agency for technical regulation and Metrology on the Internet (www.gost.ru)

1 Scope

1.1 this standard specifies the characteristics of heat insulation of pipes and fittings used in the construction of oil pipelines and oil product pipelines aboveground and underground installation with outer diameter from 159 to 1420 mm.

1.2 this standard applies to thermal insulation of the factory and EN-route of application of the linear part of trunk oil pipelines and oil product pipelines, including thermal insulation of welded joints.

1.3 this standard does not apply to thermal insulation of tanks, process pipelines and mehanicheskogo equipment.

1.4 this document is intended for use by manufacturers of thermal insulation of pipes and fittings, as well as organizations engaged in the construction and repair of main oil pipelines and oil product pipelines in thermal insulation.

2 Normative references

This standard uses the regulatory references to the following standards:

GOST 409 Plastic and cellular rubber sponge. Method of determination of apparent density

GOST EN 826 thermal insulating Products used in construction. Methods for determination of compression characteristics

GOST EN 1602 thermal insulating Products used in construction. Method of determination of apparent density

GOST 7076 the construction Materials and products. Method of determination of thermal conductivity and thermal resistance at a stationary thermal mode

GOST EN 12087 thermal insulating Products used in construction. Methods for determination of water absorption by prolonged immersion

GOST 17177 Materials and products building insulation. Test methods

GOST 24297 Verification of the purchased products. Organization and control methods

GOST 25880 Materials and products building insulation. Packing, marking, transportation and storage

GOST 30244 construction Materials. Methods of test for Flammability

GOST 30732 Pipe and fittings with thermal insulation from polyurethane foam with a protective shell. Specifications

GOST 31448 steel Tubes with a protective outer coating for main gas and oil pipelines. Specifications

GOST R 51164 steel pipe mains. General requirements for corrosion protection

GOST R 52246 rolled sheet hot-dip galvanized. Specifications

GOST R 53327 Insulation design of industrial pipelines. Test method for flame spread

GOST R 53691 Resources. Waste management. Passport of waste I-IV class of danger. Basic requirements

Note — When using this standard appropriate to test the effect of reference standards in the information system of General use — on the official website of the Federal Agency for technical regulation and Metrology on the Internet or in the annual information index «National standards» published as on January 1 of the current year, and the editions of the monthly information index «National standards» for the current year. If replaced with a reference standard, which was given an undated reference, then it is recommended to use the current version of this standard, taking into account all enabled in this version modifications. If replaced with a reference standard, which is given a dated reference, it is recommended to use the version of this standard referred to above by year of approval (acceptance). If after approval of this standard in the reference standard, which is given a dated reference, a change affecting a provision to which reference, the provision is recommended to be applied without taking into account this change. If the reference standard is cancelled without replacement, the position in which reference is made to him, recommended to be used in part not affecting this link.

3 Terms and definitions

This standard applies the following terms with respective definitions:

3.1 protective shell: the Design is mounted on the outer surface of the thermal insulation of pipes and fittings tubing for protection from mechanical damage and environmental influences.

3.2 apparent density in the core: the density of the material, taking into account the volume of closed pores and without surface layers.

3.3 linear part of main pipeline: a set of objects of the main pipeline, including the pipeline, including crossings, natural and artificial obstacles, valves and other fittings, installation of electrochemical protection from corrosion, route the lines, facilities, technological connection, additional devices and facilities, which ensures safe and reliable operation, and designed to transfer oil between the site objects of the main pipeline.

3.4 the main pipeline (to transport oil/petroleum products):Production and technological complex, intended for transportation of prepared oil and petroleum products.

3.5 metal shell: Metal protective shell pipes underground strip coated with a plastic polymer or a thermoset coating.

3.6 fire insert: the Insert on the main pipeline made of non-combustible insulating materials which is an obstacle to the spread of fires.

3.7 shell: insulation material in the form of a sector of a cylinder, the inner radius of which is subject to tolerances corresponds to the radius of the insulated pipe or part.

3.8 connecting a pipe: a pipe member which changes the direction of the axis of the pipeline branch from him, sealing ends, change of pipe diameter or wall thickness.

Note — For fittings include elbows, reducers, bottoms, tees, adapter rings, etc.

3.9 insulation material: the Material used in the insulation of the structure to perform the function of the main thermal resistance.

3.10 centering bearing: a Device that allows you to center the pipe/fittings tubing relative to the protective sheath prior to application of polyurethane foam.

4 Reduction

This standard applies the following abbreviations:

AKP — anti-corrosion coating;

MP — metal protective shell;

ND — normative document;

OTS — protective shell made of galvanized steel;

PUF — polyurethane foam;

SDT — pipeline fittings.

5 General provisions

5.1 Thermal insulation of pipes and SDT should be implemented in the construction of pipelines to maintain the temperature of the product being pumped and to prevent the thawing of the soil.

5.2 Heat insulation (hereinafter insulation) of the piping shall be done in the following ways:

— using prefabricated insulated in the factory pipes and SDT with the subsequent insulation of welded joints of the pipeline field;

— applying thermal insulation on the pipeline field.

5.3 the Need for use of thermal insulation in the construction of the main pipeline should be determined by design documentation. The estimated thickness of insulation shall be determined on the basis of thermal calculations.

5.4 During the construction of the linear part of the pipeline used should preferably be of pipes with factory insulation.

Field are as follows:

— insulation of joints and installation of inserts;

— repair of thermal insulation in service;

— insulation of existing or mothballed pipeline, previously constructed without insulation (with proper feasibility study).

5.5 According to customer’s requirement insulation pipes/SDT overhead laying shall be tested with the aim of identifying groups of flame propagation according to GOST R 53327. Information about the group of flame propagation must be specified in the technical documentation of the manufacturer.

5.6 Documentation used in the manufacture, control, inspection and repair of thermal insulation of pipes and SDT must meet the requirements of the standards establishing the requirements to a single system of documentation of ESTD, of espd, ESKD.

5.7 When ordering pipes/SDT in the factory insulation, in addition to information about steel pipe/SDT, must contain the following information:

— the symbol of the ACP;

— the symbol of the insulating coating;

— the nominal thickness of the insulating coating, mm;

— the symbol of the protective shell;

— the length of the ends of the pipe free of insulation;

designation of this document.

5.8 When ordering materials for thermal insulation of pipeline field must contain the following information:

— outer diameter of the pipeline;

— the conditions of the pipeline;

— the symbol of the insulating coating;

the number of layers and nominal thickness of the insulating coating, mm;

— the symbol of the protective shell;

designation of this document.

5.9 the Above requirements for entry in order can be supplemented with the features of the construction of a concrete pipeline.

6 specifications

6.1 factory insulation of pipes and fittings ground installation, insulation of welded joints of pipelines of above-ground routing

6.1.1 factory insulation of pipes and SDT overhead strip must be made of casting polyurethane foam in a protective shell.

6.1.2 Design of pipes/SDT in heat insulation, is designed for ground installation includes:

— Automatic gearbox;

— centering support;

— thermal insulation coating of polyurethane foam;

— protective shell.

Allowed not to apply centering support with the use of technology, ensuring the alignment of the pipe and the protective shell.

Design of pipe insulation is shown in figure 6.1. Design of SDT in thermal insulation is shown in figure 6.2.

6.1.3 as automatic pipe should be used single-layer epoxy powder coating. Allowed automatic pipe polyethylene, polypropylene and polyurethane materials that meet the technical requirements to products with coating. The characteristics of the automatic gearbox must comply with GOST R 51164, GOST 31448, as well as interstate standards in force in the territory of the Russian Federation national standards of the Russian Federation and normative documents of the customer.

6.1.4 as ACP SDT should be used coating based on powder epoxy, liquid epoxy, or polyurethane materials. Branches of cold bending for the subsequent application of thermal insulation it is possible to produce from the pipes with a polyethylene coating.

6.1.5 Length of pipe ends/SDT-free, automatic gearbox, needs to be established in technical requirements for products with a coating and preservation coating at carrying out of welding works. The recommended value of the length of the pipe ends/SDT-free, automatic gearbox, is (120±20) mm.

6.1.6 For thermal insulation of pipes/SDT should be applied in casting polyurethane foam. For the production of polyurethane should be applied to the following systems:

— environmentally friendly freon-free polyurethane foam system;

— environmentally sonneratiaceae freon polyurethane foam system;

— ozone-depleting freon foam polyurethane system produced in accordance with the available quota for data usage of CFCs.

For thermal insulation of pipes/SDT the use of other heat-insulating filling materials.

6.1.7 the foam section must be a closed homogeneous fine structure. Void (cavity) larger than 1/3 of the thickness of the insulation are not permitted. The total area of voids (cavities) in any cross section of the insulating layer should not exceed 5% of the area of the insulating layer in this section. In the area of the centering poles, covering a distance of 50 mm from the edges of the supports, the total area of voids (cavities) is not defined. The control of foam section must be conducted for experienced pipe with the setup of the production line application of polyurethane foam. After adjusting the line the manufacturer must exercise control of each production unit in accordance with the volumes specified in process documentation.

Figure 6.1 — Design of pipe insulation

Figure 6.1 — Design of pipe insulation

Figure 6.2 — Design of SDT in insulation

Figure 6.2 — Design of SDT in insulation

6.1.8 Indicators of physico-mechanical properties of PUF are shown in table 6.1.


Table 6.1 — Indicators of physico-mechanical properties of foam

6.1.9 Length of pipe ends/SDT-free insulation should ensure the carrying out of welding works, as well as the safety of the insulation and be not less than 150 mm, depending on the method of welding. When working with welding machines recommended length of the free ends of the insulation ranges from 480 to 500 mm.

6.1.10 as a protective sheath pipe insulation shall be applied a spiral-locking pipe of galvanized steel. Scarf joint spiral castle of the tubes should be made in the form of internal single recumbent fold. The protective sheath shall be leakproof relative to the external environment. Leaking foam through the tool joint protective shell when casting is not allowed.

6.1.11 the Design of protective shell of SDT is determined by the geometry of the part. Protective jacket shall be made of segments of spiral-locking pipe from sheet steel with a zinc coating hot coating according to GOST R 52246.

6.1.12 Mechanical connection of the segments is carried out by the following methods:

— welding;

— exterior rolling;

connection with steel backing rings and self-tapping screws (rivets).

Allowed other types of mechanical connection of the segments.

6.1.13 the tightness of the joint segments is carried out using heat-shrinkable polymer ribbons or any other method which provides leak proof when casting polyurethane foam. Leaking foam through the tool joint or connection of the segments of the protective shell are not allowed. After pouring the foam and control leaks, the joints of the segments of the protective sheath should be closed by the annular plates of galvanized steel, similar to the characteristics of the material the protective shell. The ring pad is attached to the protective shell by using galvanized screws. The pads have to close the fastening elements (screws, rivets, tape, etc.) that connect segments of a protective shell. The scheme of fastening of the segments of the protective shell with the help of backing rings is presented in figure 6.3.

Figure 6.3 — Scheme of fastening segments of a protective shell with backing rings

Figure 6.3 — Scheme of fastening segments of a protective shell with backing rings

6.1.14 length of the protective sheath should correspond to the length of the insulating coating or be long it. The tolerance along the length of the protective shell must be specified in the specifications for pipe insulation and to determine the intended design of thermal insulation of the weld joint (shell or casting polyurethane foam).

6.1.15 the Outer diameter of the protective sheath is determined by the diameter of the pipe/STD, nominal insulation wall thickness of protective sheath. Maximum deviation of diameter of the protective sheath should be ±10 mm. Limit deviations of the thickness of insulation pipes/SDT are shown in table 6.2.


Table 6.2 — Limit deviations of the thickness of insulation pipes/SDT

Side 6.1.16 steel Thickness and zinc coating protective shell needs to provide the required service life of the insulating structure. The estimated service life of thermal insulation designs T, g, can be estimated by the formula

, (1)

where  — thickness of steel, mm;

 — steel corrosion rate, mm/g;

 — zinc coating thickness, µm;

 — the corrosion rate of the zinc coating, µm/g.

6.1.17 the recommended steel thickness is from 0.7 to 1.5 mm. the recommended thickness of zinc coating of 17 (grade 275 as per GOST R 52246) to 27 µm (450 class according to GOST R 52246).

6.1.18 For the alignment of the protective sheath relative to the tube/SDT and the nominal thickness of the foam should be applied centering of the support: a support made of polymeric material or segments of polyurethane foam. In the manufacture of pipes/SDT insulation, belonging to the group of flame-spread IUU fishing in accordance with GOST R 53327 should be used centering feet that when thermal effects do not form a melt and the burning drops of the melt.

6.1.19 allowed the use of the technology of manufacturing pipes in insulation without centering supports. These technologies must ensure the thickness of the insulation within the limits of deviation (see table 6.2).

6.1.20 the Centering supports of the segments, the polyurethane foam shall be made of casting polyurethane on physico-mechanical properties similar to the thermal insulation of the pipe. The mounting segments of the PPU should be self-adhesive polymer tape, polymer tape coupling with a lock or a metal tightening band with a lock.

6.1.21 When using the centering of the supports must satisfy the following conditions:

— the height of the centering supports and the distance between them needs to ensure the regulatory thickness insulation with tolerances in table 6.2;

— installation technology supports the centering needs to provide a fixed distance between them after installing the protective shell and fill, polyurethane foam.

6.1.22 the surface of the foam at the ends of the pipe/SDT for the period of transportation and storage should have a protective coating. The coating must provide protection to the foam at the ends for up to 24 months in the temperature range from minus 60°to plus 40 °C. For protection it is recommended to apply mastic coating on a polyurethane, bitumen or other basis; the use of other methods of protecting the ends of the PPU. According to customer’s requirement pipe/SDT can be supplied without a protective coating of polyurethane foam on the ends.

6.1.23 Pipe and SDT must be marked with paint on the inner surface. If necessary, identification of tubes/SDT in pipeline operation an additional marking with plates of stainless alloy, is installed on the outer surface of the products using a sealed exhaust rivets. The marking must include:

information about steel pipe/SDT;

— information on automatic gearbox;

— information on the insulation coating.

The volume parameters in the marking is determined by the requirements of the customer.

6.1.24 Design of thermal insulation of the weld joint of the pipeline above-ground strip includes:

— Automatic gearbox;

— thermal insulation coating of polyurethane foam;

— protective shell.

6.1.25 as automatic welded joints should be used heat-shrink sleeves or liquid epoxy and polyurethane materials. The characteristics of the automatic gearbox must comply with GOST R 51164, GOST 31448, as well as interstate standards in force in the territory of the Russian Federation national standards of the Russian Federation and normative documents of the customer.

6.1.26 as a heat-insulating coating of welded joints should be used the shell of polyurethane foam or polyurethane foam filling. The characteristics of the polyurethane foam shall conform to the values given in table 6.1.

6.1.27 the Shell of polyurethane foam should be composed of segments. The number of segments depending on the outer diameter of the pipe/SDT is shown in table 6.3.

6.1.28 the length of the segments should correspond to the distance between the ends of the foam of the two connected pipes/SDT. Tolerance of length of the segment is 50 mm. the Inner diameter of the shell must match the outside diameter of the steel pipe according to the thickness of the ACP pipe/SDT and the weld joint. Thickness of shell shall be designed taking into account the thickness of the ACP pipe/SDT and the weld joint so that when mounting the shell were on the same level with a protective sheath of the pipe. Tolerance of thickness of the shells or minus 5 mm.


Table 6.3 Number of segments of shells depending on the outer diameter of the pipe

6.1.29 Segments must be grooved in the longitudinal direction. The scheme of location of the slots of the longitudinal joints of the segments of the shell shown in figure 6.4.

Figure 6.4 — scheme of an arrangement of grooves of the longitudinal joints of the segments of the shells

In — the width of the groove, H is slot height, S — thickness of the shell

Figure 6.4 — scheme of an arrangement of grooves of the longitudinal joints of the segments of the shells

6.1.30 the Width of the groove In the range 30 to 40 mm.

6.1.31 the height of the groove H is half the thickness of the shell 's. Tolerance the height and width of the grooves is ±5 mm.

6.1.32 When using shells of polyurethane foam for thermal insulation of the weld joint for the connection of the shells should be applied metal tie strips with lock, placed in at least two places along the length of the shells. As a protective sheath must be used the casing from one non-profiled sheet of galvanized steel. Sheet thickness should match the thickness of the protective sheath of the pipe. Longitudinal and transverse seams, formed during installation of the casing should be sealed to protect from falling rain. For installation of the casing should be applied to self-tapping screws or sealed rivets.

6.1.33 When using potting foam for thermal insulation of the junction as the starting components should be the system that meets the requirements of 6.1.6. As a protective sheath must be used galvanized steel shell. The thickness of the steel and the zinc coating of the shell should correspond to the thickness of the protective sheath of the pipe. Longitudinal and transverse joints formed by the installation of the shell must be sealed, hot-melt or mastic fillers before pouring the polyurethane foam components.

6.1.34 the Overlapping casing/shell on the protective sheath pipe/SDT — not less than 50 mm.

6.1.35 Materials for thermal insulation of the weld joint (shell, potting material, shielding, sealing materials, screws, rivets) shall be shipped complete.

6.2 factory insulation of pipes and fittings underground installation insulation of welded joints of pipelines underground strip

6.2.1 factory insulation of pipes and SDT underground strip must be made of casting polyurethane foam in a protective shell. The characteristics of the foam are shown in table 6.1.

6.2.2 the Design of piping/SDT in insulation is designed for underground installation includes:

— Automatic gearbox;

— centering support;

— thermal insulation coating of polyurethane foam;

— protective shell.

Allowed not to apply centering support with the use of technology, ensuring the alignment of the pipe and the protective shell. Pipe design and SDT in the insulation are shown in figures 6.1 and 6.2 respectively.

As automatic pipe must be used two-layer epoxy powder coating or three-layer polyethylene coating. Allowed the use of ACP pipes based on polypropylene (if the temperature of transportation, storage, installation and operation of pipes is not below minus 20°C) and polyurethane materials. The characteristics of the automatic gearbox must comply with GOST R 51164, GOST 31448, as well as interstate standards in force in the territory of the Russian Federation national standards of the Russian Federation and normative documents of the customer. On three-layer polyethylene coating may be applied to the additional rough layer to eliminate exfoliations of the polyurethane foam from the surface of the polyethylene.

A rough surface must be produced by additional powder-coating polyethylene on a tube with three-layer polyethylene coating process flow coating. The number of powder particles ranging in size from 150 to 500 µm — not less than 80% of the total powder.

6.2.3 as ACP SDT should be used coating based on powder epoxy, liquid epoxy or polyurethane materials. Branches of cold bending for the subsequent application of thermal insulation it is possible to produce from the pipes with a polyethylene coating.

6.2.4 Length of pipe ends/SDT-free coating (120±20) mm In accordance with customer requirements and contract terms and conditions for the supply of allowed other length, providing safety cover at carrying out of welding works.

6.2.5 Protective sheath in the insulation of pipes underground strip can be manufactured in two versions:

— polyethylene protective sheath;

— MP (spiral-castle steel pipe with applied three-layer polyethylene coating).

6.2.6 protective Polyethylene sheath shall be manufactured from high density polyethylene. Plastic protective shell has a limited resistance to frost, therefore, the work and operation may be performed at temperature not below minus 20 °C. temperature Limits must also be specified in the quality certificate of the manufacturer. The conditions of production and operation of pipes and SDT with insulation are given in table 6.4.


Table 6.4 conditions for the production and operation of pipes and SDT with heat insulation