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T/SP/F/14

SPECIFICATION FOR

GROUTED TEES FOR HOT TAP AND STOPPING OFF


CONNECTIONS (FOR OPERATING PRESSURES
7 BAR TO 100 BAR INCLUSIVE)

OCTOBER 2005
J312 ( Rev 10/05 )
© National Grid Gas plc 2005- All Rights Reserved
T/SP/F/14

CONTENTS

Page

FOREWORD iii

BRIEF HISTORY iii

1. SCOPE 1

2. REFERENCES 1

3 DEFINITIONS 1

4. DESIGN 2

4.1 General 2

4.2 Fitting life 2

4.3 Fitting loads 2

4.4 Fitting configuration 2

4.5 Temperature range 2

4.6 Dimensions and tolerances 2

4.7 Flanges 2

4.8 Bolt head and nut clearances 2

4.9 Tell-tale holes and grout feed riser 2

5. MATERIALS 2

5.1 Fitting shell and branch 2

5.2 Branch flanges 3

5.3 Fasteners and jointing materials 3

5.4 Branch seal 3

5.5 Grout containment seal 3

5.6 Grout 3

5.7 Chemical properties 4

5.8 Documentation 4

6. MANUFACTURE 4

6.1 General 4

6.2 Weld procedures 4

6.3 Backing strips 4

6.4 Weld design 4

© National Grid Gas plc 2005- All Rights Reserved


J312 ( Rev 10/05 ) -i-
T/SP/F/14

Page

6.5 Stress relieving 4

6.6 Manufacturing strategy 4

7. NON DESTRUCTIVE TESTING AND ACCEPTANCE LEVELS 5

7.1 General requirements 5

7.2 Acceptance levels 5

8. HYDROSTATIC PRESSURE TESTING 5

9. MARKING AND COATING 5

9.1 Die stamped markings 5

9.2 Identification details 5

10. CORROSION PROTECTION 6

10.1 General 6

10.2 Fittings for buried installations 6

10.3 Fittings for above ground installations 6

11. PROTECTION AND TRANSPORT 6

12. VARIANTS 6

13. STORAGE 6

14. INSTALLATION PROCEDURES 6

14.1 Pipe surface preparation 6

14.2 Branch seal 6

14.3 Grout containment seal 6

14.4 Grout 7

APPENDICES

A LIST OF REFERENCES 9

B PREFERRED SUPPLIERS 10

C INFORMATION SUPPLIED BY NATIONAL GRID GAS FOR FITTING DESIGN 11

D FITTING CONFIGURATION 12

E COMPONENT DIMENSIONS AND BOLT LOADING 17

F GROUT FEED RISER AND TELL TALE HOLES 25

G DEFECT ACCEPTANCE LEVELS FOR THE STARTING MATERIAL 26

H DEFECT ACCEPTANCE LEVELS FOR THE FINISHED PRODUCT 27

© National Grid Gas plc 2005- All Rights Reserved


- ii - J312 ( Rev 10/05 )
T/SP/F/14

FOREWORD
th.
This Specification was approved by the Transmission Standards Manager, on 6 October 2005 for use
by managers, engineers and supervisors throughout National Grid Gas.

National Grid Gas documents are revised, when necessary, by the issue of new editions. Users should
ensure that they are in possession of the latest edition by referring to the Gas Documents Library
available on infonetUK (company intranet.)

Compliance with this document does not confer immunity from prosecution for breach of statutory or
other legal obligations.

BRIEF HISTORY

First Published as T/SP/F/14 October 2005 EPSG/A051/10205

KEY CHANGES (Identify the changes from the previous version of this document)

Section Amendments

DISCLAIMER
This document is provided for use by National Grid Gas and such of its contractors as are obliged by the
terms and conditions of their contracts to comply with this document. Where this document is used by any
other party it is the responsibility of that party to ensure that this document is correctly applied.

MANDATORY AND NON-MANDATORY REQUIREMENTS


In this document:

must: indicates a mandatory requirement.

should: indicates best practice and is the preferred option. If an alternative method is used then a
suitable and sufficient risk assessment must be completed to show that the alternative method delivers
the same, or better, level of protection.

© National Grid Gas plc 2005- All Rights Reserved


J312 ( Rev 10/05 ) - iii -
T/SP/F/14

© National Grid Gas plc 2005- All Rights Reserved


- iv - J312 ( Rev 10/05 )
T/SP/F/14

SPECIFICATION FOR
GROUTED TEES FOR HOT TAP AND STOPPING OFF
CONNECTIONS (FOR OPERATING PRESSURES 7 BAR TO
100 BAR INCLUSIVE)

1. SCOPE
This specification details the requirements for the materials, manufacture and inspection of grouted tee
fittings intended for use on the National Grid Gas transmission gas pipeline system up to a maximum
operating pressure of 100 bar. The fittings covered in this specification are full encirclement split tees,
attached to the pipeline by bolting together of split shells and then grouting the annular space between the
assembled shells and outer surface of the pipeline with an epoxy resin.

The procedure for the pipeline installation of fittings conforming to this specification is given in National
Grid Gas specification T/PR/P/19.

2. REFERENCES
This specification makes reference to the documents listed in Appendix A. Unless otherwise specified the
latest edition of the documents, including all addenda and revisions, must apply.

3. DEFINITIONS
For the purposes of this specification the following definitions must apply:

Contractor: the person, firm or company with whom National Grid Gas enters into a contract to which
this specification applies, including the Contractor’s personal representatives, successors and permitted
assigns.

Fitting: the Grouted Tee connection, including the branch seal, grout containment seal, grout, and all
fittings.

Body Shell: the top or bottom half shells, excluding the branch pipe.

Branch: the branch connection pipe.

Branch Seal: the elliptical seal inside the shell around the branch aperture.

Grout Containment Seal: the annular epoxy putty seal between pipe and shell at each end of the fitting.

Specialist Assessment: Technical assessment carried out by persons responsible for the design of the
Grouted Tee or competent person/body nominated by the specialist contractor.

Specialist Contractor: the company approved by National Grid Gas for carrying out a specialist
assessment.

Preferred Supplier: the list of preferred suppliers for the components required for the Fitting is given in
Appendix B.

NDT: non-destructive testing

PWHT: post weld heat treatment

MT: magnetic particle inspection

UT: ultrasonic testing

RT: Radiography

© National Grid Gas plc 2005- All Rights Reserved


J312 ( Rev 10/05 ) -1-
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4. DESIGN
4.1 General
The design of the Fitting must be based on information provided by National Grid Gas as detailed in
Appendix C.

The fitting must be suitable for operating at pressures up to 100 barg.

4.2 Fitting life


The fitting must provide an effective seal for at least 50 years, in the internal and external environment
present in and around the pipeline. The design must be capable of tolerating the effects of corrosive
ground conditions.

4.3 Fitting Loads


Fittings must be capable of accommodating internal pressure, subsequent pipe movements and resisting
external applied loads without failure. The design factor for the combined loadings between pipe
movements and internal pressure must be in accordance with IGE/TD/1 and IGE/TD/12.

4.4 Fitting Configuration


The general configuration is shown in appendix D. The branch must be perpendicular to the body shell.

4.5 Temperature range


The fitting must be designed for the temperature range of -20 °C to 50 °C.

4.6 Dimensions and Tolerances


The fitting should conform to the dimensions in Appendix E. In circumstances where variations are
required, a design study sufficient to demonstrate fitness for purpose must be performed by the Specialist
Contractor, prior to fabrication and installation.

4.7 Flanges
The flanges on the Fitting branch must be ANSI Class 600 and in accordance with T/SP/F/1.

4.8 Bolt head and nut clearances


The fitting must be designed to provide adequate clearance for ring spanners, socket spanners and
torque wrenches used for assembly.

4.9 Tell-tale holes and grout feed riser.


Tell-tale holes and grout feed riser positions as indicated in Appendix F must be as detailed in
engineering drawings produced by a specialist contractor approved by National Grid Gas.

5. MATERIALS
5.1 Fitting shell and branch
The steel plate used for the Body Shell, and the longitudinal flanges, must conform to the requirements of
BS EN 10028-3 Grade P460 NL1.

The Branch must conform to the requirements of EN 10208-2, or National Grid Gas TS-C4Gas-PIP0
specification. If submerged-arc welded pipe is used, the seam weld must be located away from the high-
stress crotch area.

Alternative materials for either the shell or branch may be proposed by the Contractor for consideration as
a variant by National Grid Gas or its approved specialist contractor.

Materials specified in T/SP/F/4 may be used as an alternative.

© National Grid Gas plc 2005- All Rights Reserved


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T/SP/F/14

5.2 Branch flanges


Any flange incorporated in the fitting must comply in accordance with T/SP/F/1.

5.3 Fasteners and jointing materials


The bolts for fastening the Body Shells together must be to BS 4882 Grade MB7.

The nuts for fastening the Body Shells together must be to BS 4882 Grade M2H.

The washers for the above bolts must be to BS 4320 BRT finish.

Spreader plates and shims must be fastened using hex socket head screws to BS EN ISO

10642 Grade 12.9 and nuts to BS 3692 Grade 8.8

Alternative sizes or grades may be proposed by the Contractor for consideration as a variant by National
Grid Gas or its approved Specialist Contractor.

5.4 Branch seal


The branch seal must conform to the dimensions given in engineering drawings supplied by the specialist
contractor approved by National Grid Gas, and be sourced from the specialist contractor’s Preferred
Supplier: FTL, and manufactured to their approved design.

The material must be based on high grade nitrile (HNBR) with a Shore hardness of 70.

The containment ring supporting the main branch seal must conform to the requirements of BS EN
10028-3 Grade P460 NL1.

5.5 Grout containment seal.


The grout containment seal must be sourced from the Preferred Supplier: SBD. The material must be
certite putty.

Alternative materials may be proposed by the Contractor for consideration as a variant by National Grid
Gas or its approved specialist contractor.

5.6 Grout
The grout must be sourced from the Preferred Supplier: SBD. The grout is a three component pourable
grout based on a Bisphenol A/F epoxy resin, blended aliphatic polyramine hardeners and a blended silica
sands and inert fillers containing very small quantities of respirable silica.

The grade of grout must be as given below:

SBD-DG 38 Installation temperature range 5 to 20 °C


SBD-DG 118 Installation temperature range 15 to 35 °C
SBD-DG 2088 Installation temperature range 30 to 50 °C

Alternative materials may be proposed by the Contractor for consideration as a variant by National Grid
Gas or its approved specialist contractor. The selected grout must have the following properties:

Potting time 30 minutes minimum


Exothermic characteristics 15 °C maximum above ambient
Volume shrinkage 0.58% maximum
Working temperature range 5 °C to 45 °C
Tensile Adhesion 12 MN/m² minimum at 22 °C
Compressive Strength 62 MN/m² minimum at 22°C
Viscosity 1000 to 1500 cP at 15°C

© National Grid Gas plc 2005- All Rights Reserved


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Ultimate tensile strength 18 MN/m² minimum at 10 °C


Tensile modulus 7 GN/m² minimum
Curing time 90% of tensile strength after 12 hours

5.7 Chemical properties


For any alternative steels offered to National Grid Gas or its approved specialist contractor for
consideration, the carbon equivalent must not exceed 0.53 for the Body Shell, and 0.43 for the Branch,
using the formula in BS EN 1011-2 Annex C.

5.8 Documentation
The Contractor must make available to National Grid Gas, for review and approval by the specialist
contractor, all documentation, including:

§ Test certificates
§ Material certificates
§ Welder and weld procedure qualification test certificates including NDT and PWHT records
§ Certificates of conformity, necessary to prove compliance with the requirements of this
specification.

6. MANUFACTURE
6.1 General
Before production commences, the proposed welding and manufacturing processes and procedures,
together with any repair procedures must be approved by National Grid Gas or its approved specialist
contractor.

The Contactor must ensure that the dimensions of equipment manufacture, components, and assembly
including welding, comply with the approved drawings and specifications.

6.2 Weld procedures


Weld procedure specification, and qualification test records must be submitted to National Grid Gas or its
approved specialist contractor for approval before commencement of production welding. All weld
procedures must be qualified in accordance with clause 5.2 in PD 5500.

6.3 Backing strips


Permanent backing strips must not be used.

6.4 Weld design


The weld design must require that full penetration butt-welds are obtained in all cases. Where possible,
back chipping of the weld root to sound metal and back filling must be carried out.

All back chipping must be proven sound by the use of MT.

Weld root penetration in the bore of the Fitting must be carefully controlled and all welds must be
sufficiently ground to ensure satisfactory crack detection.

6.5 Stress relieving


All fittings must be supplied in the stress-relieved condition. The PWHT must be performed after all
welding has been completed. Stress relief heat treatment must be in accordance with PD 5500.

6.6 Manufacturing strategy


The Contractor may opt to manufacture the Body Shells for a range of common line pipe sizes and then
complete the manufacture of the Branch and flange. In this instance the relevant parts of clauses 6 to 9
inclusive must be applicable after all manufacturing processes are completed.

© National Grid Gas plc 2005- All Rights Reserved


-4- J312 ( Rev 10/05 )
T/SP/F/14

7. NON-DESTRUCTIVE TESTING PROCEDURES AND ACCEPTANCE LEVELS


7.1 General requirements
Unless otherwise specified, all NDT must be carried out after all processing and PWHT, including final
stress relieving and machining where applicable.

The Contractor must submit procedures on the appropriate National Grid Gas forms, for all applicable
NDT techniques before production commences.

All operators of NDT equipment must have a thorough knowledge of the operation of the equipment to be
used and must be required to demonstrate their ability to carry out the agreed procedure methods to the
satisfaction of National Grid Gas or its approved specialist contractor.

The Contractor must use MT, and UT or RT for all welds as required and agreed with National Grid Gas
or its approved specialist contractor. Where RT is applied, this must be X-radiography.

All NDT carried out on the fittings must be in accordance with the relevant BS EN Standards. In addition
the Contractor must supply National Grid Gas or its approved specialist contractor with the inspection
procedures and inspection reports for each inspection technique used.

7.2 Acceptance levels


Defects disclosed by NDT and exceeding the limits specified in Appendices G and H, must be deemed
unacceptable.

8. HYDROSTATIC PRESSURE TESTING


The Branch, branch seal and flange must be subjected to pre-installation hydrostatic pressure testing,
after the completion of all machining, welding and stress relieving.

The pressure test must be held for a period of not less than 30 min. The test pressure must be 150 barg;
1.5 times the maximum rated design pressure of the fitting.

All test instrumentation used must be covered by approved calibration certificates issued within the
previous six months. These certificates must be made available to National Grid Gas or its approved
specialist contractor.

9. MARKING AND COATING


9.1 Die stamped markings
Die stamped markings must not be permitted.

9.2 Identification details


The following identification details must be attached, or marked on to, the Fitting:

a) Name or mark of Contractor.


b) Fitting size: Shell NB x Branch NB
c) Design pressure in bar: 100 barg
d) Test pressure in bar: 150 barg
e) National Grid Gas order number.

Marking and attachment of the details to the Fitting must be by suitable means, and should be clearly
visible after coating. The method used must be compatible with the fitting material and must not have a
deleterious effect on it.

© National Grid Gas plc 2005- All Rights Reserved


J312 ( Rev 10/05 ) -5-
T/SP/F/14

10. CORROSION PROTECTION


10.1 General
Corrosion protection must be as stated in the purchase order. Where corrosion protection is not specified,
the fitting must be supplied bare and free from oil and metal turnings. When corrosion protection is
specified, the procedure must be as clause 10.2 and 10.3.

10.2 Fittings for buried installations


Fittings for buried installations must comply with the following:

§ After completion of all tests, both the inside and outside surfaces of the fittings must be grit
blasted in accordance with BS 7079, Sa 2.5 quality.
§ Within 4 hours of grit blasting, the external surface must receive an approved coating
and/or wrapping using National Grid Gas approved coatings, in accordance with the
instructions set out in the National Grid Gas specification CW5 and supplements, and
conform to BS EN 12068:1999.

The installation may be protected in accordance with BS EN 12954:2001, and BS 7361-1:1991, generally
by the use of a sacrificial anode system. If a sacrificial anode is used this allows a reduction in the
frequency functional checks in comparison to an impressed current system.

10.3 Fittings for above ground installations


Fittings for above ground installations must comply with the following:

§ After completion of all tests, both the inside and outside surfaces of the Fitting must be grit
blasted in accordance with BS 7079, Sa 2.5 quality.
§ Within 4 hours of grit blasting, the external surface must be coated in accordance with
National Grid Gas specification PA/10.

11. PROTECTION AND TRANSPORT


The Contractor must provide adequate packaging of Fitting to prevent damage by normal handling,
transportation and storage.

All nuts, bolts and other loose items must be parcelled and tagged with appropriate information

12. VARIANTS
A Contractor must only propose variants to this specification where the text indicates that variants would
be considered by National Grid Gas or its approved specialist contractor.

13. STORAGE
Storage of grout and branch seal must conform to the manufacturer's specifications.

14. INSTALLATION PROCEDURES


14.1 Pipe surface preparation
The fitting must be installed where the pipe surface preparation has been carried out in accordance with
T/PR/P/19. This preparation must have no deleterious effect on the carrier pipe.

14.2 Branch seal


The branch seal must be selected in accordance with the engineering drawings supplied by National Grid
Gas or its approved specialist contractor. Installation of the branch seal must be in accordance with
T/PR/P/19.

14.3 Grout containment seal


The grout containment seal must be installed in accordance with T/PR/P/19.

© National Grid Gas plc 2005- All Rights Reserved


-6- J312 ( Rev 10/05 )
T/SP/F/14

14.4 Grout
The grout must be injected in accordance with T/PR/P/19.

© National Grid Gas plc 2005- All Rights Reserved


J312 ( Rev 10/05 ) -7-
T/SP/F/14

© National Grid Gas plc 2005- All Rights Reserved


-8- J312 ( Rev 10/05 )
T/SP/F/14

APPENDIX A
LIST OF REFERENCES
This specification makes reference to the documents listed below (see clause 2):

Institution of Gas Engineers


IGE TD/1 Steel pipelines for high pressure gas transmission.
IGE TD/12 Pipework stress analysis for gas industry plant.

European Standards
BS EN 10028-3 Specification for flat products made of steels for pressure purposes. Part
3. Weldable fine grain steels, normalized.
BS EN 10208-2 Steel Pipes for pipelines for combustible fluids – Technical delivery
conditions. Part 2 Pipes of requirement class 2.
BS EN 1092 Flanges and their joints. Circular flanges for pipes, valves, fittings and
accessories, PN designated. Steel flanges.
BS EN 1011-2 Recommendations for welding of metallic materials. Arc welding of
ferritic steels.
BS EN 12068 Cathodic protection. External organic coatings for the corrosion
protection of buried or immersed steel pipelines used in conjunction with
cathodic protection. Tapes and shrinkable materials.
BS EN 12954 Cathodic protection of buried or immersed metallic structures. General
principles and application for pipelines.
BS EN ISO 12944 Paints and varnishes.

British Standards
BS 4882 Specification for bolting for flanges and pressure containing purposes.
PD 5500 Specification for unfired fusion welded pressure vessels.
BS EN 10160 Specification for acceptance levels for internal imperfections in steel
plate, strip and wide flats, based on ultrasonic testing.
BS 7079 Preparation of steel substrates before application of paints and related
products.
BS 7361 Cathodic protection. Code of practice for land and marine applications.

National Grid Gas specifications


T/SP/CW/5 Code of practice for the selection and application of field applied external
pipework coatings.
T/SP/F/1 Technical specification for carbon and carbon manganese steel forgings
and forged components for operating pressures greater than 7 bar.
T/SP/F/4 Technical specification for hot tap and stopping off connections (for
operating pressures 7 to 70 bar inclusive).
T/SP/PA/10 Technical specification for new and maintenance painting at works and
site for above ground pipeline and plant installations. (Re-issued edition
of Parts 1 and 2 and the Supplements CS 1 to CS 17 inclusive of
BG/PS/PA10 dated June 1987).
TS-C4Gas-PIP0 Steel Pipes for Pipelines.
T/PR/P/19 Work procedure for the installation of grouted tees on transmission
pipelines in service.

© National Grid Gas plc 2005- All Rights Reserved


J312 ( Rev 10/05 ) -9-
T/SP/F/14

APPENDIX B
PREFERRED SUPPLIERS
1. FTL Seals Technology Ltd ……………..…… (For supply of main primary branch seal)
Bruntcliffe Avenue
Leeds 27 Business Park
Morley
Leeds
LS27 0TG

2. SBD Limited…………………………….…… (For supply of epoxy grout)


Dickens House
Maulden Road
Flitwick
Bedford
MK45 5bY

3. Waring Engineering Limited………………… (For fabrication of the shells)


Unit 2,
Welshcroft Close
Kirkby-in-Ashfield
Nottinghamshire
NG17 8EP

© National Grid Gas plc 2005- All Rights Reserved


- 10 - J312 ( Rev 10/05 )
T/SP/F/14

APPENDIX C
INFORMATION SUPPLIED BY NATIONAL GRID GAS FOR FITTING DESIGN
The following information is required to define the requirements specification for the Grouted Tee
connection:

1. Reference order number

2. Line pipe characteristics

Outside diameter of pipe (mm).

3. Branch line pipe characteristics

3.1 Outside diameter (mm)


3.2 Wall thickness (mm)

4. Fitting Nominal Size

4.1 Nominal Shell Diameter


4.2 Nominal Branch Diameter

5. Type of fitting required:

5.1 Grouted Tee stopple (Required Lok-O-Ring plugs)


5.2 Grouted Tee offtake
5.3 Plug requirement.

6. Maximum Working Pressure (bar).

7. Type of branch flange (Raised Face or Ring Type Joint)

8. Orientation of installation:

8.1 Vertical tapping


8.2 Horizontal tapping

9. Type of corrosion protection required after installation

© National Grid Gas plc 2005- All Rights Reserved


J312 ( Rev 10/05 ) - 11 -
T/SP/F/14
APPENDIX D
FITTING CONFIGURATION
Figure D.1 - Assembly
© National Grid Gas plc 2005- All Rights Reserved
- 12 - J312 ( Rev 10/05 )
T/SP/F/14

Figure D.2 – Branch Half-Shell

© National Grid Gas plc 2005- All Rights Reserved


J312 ( Rev 10/05 ) - 13 -
T/SP/F/14

Figure D.3 – Lower Half-Shell

© National Grid Gas plc 2005- All Rights Reserved


- 14 - J312 ( Rev 10/05 )
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Figure D.4 – Spreader Plate and Shims

© National Grid Gas plc 2005- All Rights Reserved


J312 ( Rev 10/05 ) - 15 -
T/SP/F/14

Figure D.5 – Containment Ring

© National Grid Gas plc 2005- All Rights Reserved


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APPENDIX E
COMPONENT DIMENSIONS AND BOLT LOADING
Table E.1 – Shell and Branch Details
Grouted Tee Size Shell Details Branch Details
Branch
Pipe Branch
Shell Wall Branch Wall Length from
Nominal Nominal Shell ID Shell Length Branch ID
Thickness Thickness top of shell to
Size Size
flange weld
(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)
50 131 300 10 55 7 45
100
100 131 300 10 105 7 45
50 185 300 10 55 7 45
150 100 185 300 10 105 7 45
150 185 450 10 156 10 60
100 236 300 12 105 7 45
200
200 240 600 15 205 10 60
100 290 300 15 105 7 45
250 150 290 450 15 156 10 60
250 294 750 18 256 12 75
100 341 300 18 105 7 45
300 150 341 450 18 156 10 60
300 352 900 20 305 15 90
100 373 350 18 105 7 45
350 200 377 600 20 205 10 60
350 384 1050 20 337 15 90
100 423 400 18 105 7 45
400 300 434 900 25 305 12 75
400 434 1200 25 388 18 110
150 474 450 25 156 10 60
450 300 485 900 25 305 15 90
450 491 1350 25 437 20 120
150 525 500 25 156 10 60
500 300 536 900 30 305 15 90
500 542 1500 30 488 20 120
150 627 600 25 156 10 60
600 300 638 900 30 305 15 90
600 646 1800 35 589 25 150
200 783 750 30 205 10 60
750 450 796 1350 35 437 20 120
750 798 2250 45 742 25 150
200 935 900 35 205 10 60
900 450 948 1350 40 437 20 120
900 950 2700 50 894 35 210
250 1088 1050 40 256 10 60
1050 600 1103 1800 50 589 25 150
1050 1119 3000 60 1040 40 240
300 1248 1220 45 305 15 90
1220 900 1256 2700 60 894 40 240
1220 1272 3600 60 1193 55 330

© National Grid Gas plc 2005- All Rights Reserved


J312 ( Rev 10/05 ) - 17 -
Grouted Tee Size Longitudinal Flange Details (See Figure D.2)

- 18 -
Pipe Branch Outer edge Distance
Flange Flange Bolt Number of Pitch of Bolt Hole Bolt Bolt
T/SP/F/14

Nominal Nominal of flange to between


Thickness Width Centres Bolt Holes Bolt Holes Diameter Diameter Length
Size Size hole CL flanges

A B C D E
(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)
50 25 50 18 120 184 4 75 18 M16 100
100
100 25 50 18 120 184 4 75 18 M16 100
50 30 90 44 174 266 4 75 26 M24 130
150 100 30 90 44 174 266 4 75 26 M24 130
150 30 90 44 174 266 6 75 26 M24 130
100 30 90 44 228 320 4 75 26 M24 130
200
200 30 90 44 232 324 8 75 26 M24 130
100 30 90 44 282 374 4 75 26 M24 130
250 150 30 90 44 282 374 6 75 26 M24 130
250 35 90 41 284 382 10 75 26 M24 140
100 50 100 42 326 442 4 75 32 M30 190
300 150 50 100 42 326 442 6 75 32 M30 190
Table E.2a – Flange Details

300 50 100 42 336 452 12 75 32 M30 190


100 50 100 42 358 474 4 75 32 M30 190
350 200 50 100 42 362 478 8 75 32 M30 190
350 50 100 42 370 486 14 75 32 M30 190
100 50 100 42 410 526 4 100 32 M30 190
400 300 60 110 38 416 560 12 75 38 M36 220
400 60 110 38 416 560 16 75 38 M36 220

J312 ( Rev 10/05 )


© National Grid Gas plc 2005- All Rights Reserved
Grouted Tee Size Longitudinal Flange Details (See Figure D.2)

Pipe Branch Outer edge Distance


Flange Flange Bolt Number of Pitch of Bolt Hole Bolt Bolt
Nominal Nominal of flange to between
Thickness Width Centres Bolt Holes Bolt Holes Diameter Diameter Length
Size Size hole CL flanges

J312 ( Rev 10/05 )


A B C D E
(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)
150 60 110 38 458 602 6 75 38 M36 220
450 300 60 110 38 468 612 12 75 38 M36 220
450 60 110 38 476 620 18 75 38 M36 220
150 60 110 38 510 654 6 80 38 M36 220

© National Grid Gas plc 2005- All Rights Reserved


500 300 70 120 40 516 676 12 75 38 M36 240
500 70 120 40 522 682 20 75 38 M36 240
150 70 120 40 610 770 8 75 38 M36 240
600 300 70 130 43 622 796 12 75 38 M36 240
600 70 130 43 630 804 24 75 38 M36 240
200 70 130 43 770 944 10 75 38 M36 240
750 450 80 150 55 778 968 14 95 44 M42 280
750 80 150 48 780 984 26 85 44 M42 280
200 80 150 48 920 1124 10 90 44 M42 240
Table E.2b – Flange Details continued.

900 450 90 200 70 930 1190 10 135 68 M64 340


900 110 200 65 924 1194 20 135 68 M64 420
250 80 150 48 1076 1280 10 105 44 M42 280
1050 600 90 250 100 1088 1388 12 150 68 M64 360
1050 120 270 115 1092 1402 20 150 68 M64 440
300 80 200 80 1236 1476 12 100 44 M42 280
1220 900 140 300 140 1224 1544 20 135 68 M64 480
1220 140 300 140 1240 1560 24 150 68 M64 480

- 19 -
T/SP/F/14
Grouted Tee Size Seal Details Load Spreader Plate Details Elliptical seal containment ring

- 20 -
Total
Seal Contact ID along
Pipe Branch combined ID around pipe
Identification Seal Seal Seal angle pipe
T/SP/F/14

Nominal Nominal Length Width thickness Circumferential Thickness Width


Number, # OD ID Thickness from Longitudinal
Size Size of plates axis
(*) BDC axis
required
(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (deg) (mm) (mm) (mm) (mm)
50 4 161 137 12 150 75 9 0 145 179 6 12
100
100 4 161 137 12 150 75 9 0 145 179 6 12
50 4 161 137 12 150 75 9 0 145 179 6 12
150 100 4 161 137 12 150 75 9 0 145 179 6 12
150 6 225 201 12 200 75 9 0 196 245 6 12
100 4 161 137 12 150 75 9 0 145 179 6 12
200
200 8 323 273 15 300 100 11 0 305 342 8 12
100 4 161 137 12 150 75 9 0 145 179 6 12
250 150 6 225 201 12 200 75 9 0 196 245 6 12
250 10 384 334 15 350 100 11 0 356 408 8 12
100 4 161 137 12 150 75 9 0 145 179 6 12
300 150 6 225 201 12 200 75 9 0 196 245 6 12
300 12 510 420 20 500 100 14 0 490 527 10 15
100 4 161 137 12 150 75 9 0 145 179 6 12
350 200 8 323 273 15 300 100 11 0 305 342 8 12
Table E.3a – Seal and Spreader Plate Details

350 14 556 466 20 550 200 14 0 537 573 10 15


100 4 161 137 12 150 75 9 0 145 179 6 12
400 300 12 510 420 20 500 150 14 0 490 527 10 15
400 16 620 530 20 600 200 14 0 588 645 10 15
(*) = Seal identification number which identifies seal sizes for Grouted Tee suitable on main carrier pipe size with equivalent or smaller branch
(For example - #4 seal is suitable for Grouted Tee used for main pipe 100mm (i.e. 4 inches nominal) with equivalent branch or smaller

J312 ( Rev 10/05 )


© National Grid Gas plc 2005- All Rights Reserved
Grouted Tee Size Seal Details Load Spreader Plate Details Elliptical seal containment ring
Total
Seal Contact ID along
Pipe Branch combined ID around pipe
Identification Seal Seal Seal angle pipe
Nominal Nominal Length Width thickness Circumferential Thickness Width
Number, # OD ID Thickness from Longitudinal
Size Size of plates axis
(*) BDC axis
required

J312 ( Rev 10/05 )


(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (deg) (mm) (mm) (mm) (mm)
150 6 225 201 12 200 75 9 0 196 245 6 12
450 300 12 510 420 20 500 150 14 30 490 527 10 15
450 18 693 563 24 650 200 17 30 637 765 12 20
150 6 225 201 12 200 75 9 0 196 245 6 12
500 300 12 510 420 20 500 150 14 30 490 527 10 15

© National Grid Gas plc 2005- All Rights Reserved


500 20 796 666 24 750 200 17 30 766 839 12 20
150 6 225 201 12 200 75 9 30 196 245 6 12
600 300 12 510 420 20 500 150 14 30 490 527 10 15
600 24 890 760 26 800 200 18 30 789 985 12 20
200 8 323 273 15 300 100 11 30 305 342 8 12
750 450 18 693 563 24 650 200 17 30 637 765 12 20
750 30 1084 954 26 900 200 18 30 942 1209 12 25
200 8 323 273 15 300 100 11 30 305 342 8 12
900 450 18 693 563 24 650 200 17 30 637 765 12 20
900 36 1355 1225 26 1200 200 18 30 1266 1432 12 25
250 10 384 334 15 350 100 11 30 356 408 8 12
1050 600 25 890 760 26 800 200 18 30 789 985 12 20
Table E.3b – Seal and Spreader Plate Details continued

1050 42 1531 1371 37.5 1350 200 26 30 1340 1670 20 30


300 12 510 420 20 500 150 14 30 490 527 10 15
1220 900 366 1355 1225 26 1200 200 18 30 1266 1432 12 25
1220 48 1709 1549 37.5 1500 200 26 30 1493 1894 20 30
(*) = Seal identification number which identifies seal sizes for Grouted Tee suitable on main carrier pipe sizes with equivalent or smaller branch
(For example - #4 seal is suitable for Grouted Tee used for main pipe 100mm (i.e. 4 inches nominal) with equivalent branch 100 mm or smaller

- 21 -
T/SP/F/14
Grouted Tee Size BOLT LOADING DETAILS

- 22 -
Pipe Branch Number Of Tensile Target Bolt Minimum Bolt Maximum
Flange Bolt Bolt Effective
T/SP/F/14

Nominal Nominal Bolt Holes Stress Load Load Bolt Load


Thickness Diameter Length Length
Size Size Per Flange Area (75% SMYS) (70% SMYS) (80% SMYS)

(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm²) (kN) (kN) (kN)
50 25 4 16 100 66 157 82 77 88
100
100 25 4 16 100 66 157 82 77 88
50 30 4 24 130 84 353 185 173 197
150 100 30 4 24 130 84 353 185 173 197
150 30 6 24 130 84 353 185 173 197
100 30 4 24 130 84 353 185 173 197
200
200 30 8 24 130 84 353 185 173 197
100 30 4 24 130 84 353 185 173 197
250 150 30 6 24 130 84 353 185 173 197
250 35 10 24 140 94 353 185 173 197
100 50 4 30 190 130 561 294 275 314
300 150 50 6 30 190 130 561 294 275 314
300 50 12 30 190 130 561 294 275 314
Table E4a – Bolt Loading Details

100 50 4 30 190 130 561 294 275 314


350 200 50 8 30 190 130 561 294 275 314
350 50 14 30 190 130 561 294 275 314
100 50 4 30 190 130 561 294 275 314
400 300 60 12 36 220 156 817 429 400 457
400 60 16 36 220 156 817 429 400 457

J312 ( Rev 10/05 )


© National Grid Gas plc 2005- All Rights Reserved
Grouted Tee Size BOLT LOADING DETAILS

Pipe Branch Number Of Tensile Target Bolt Minimum Bolt Maximum


Flange Bolt Bolt Effective
Nominal Nominal Bolt Holes Stress Load Load Bolt Load
Thickness Diameter Length Length
Size Size Per Flange Area (75% SMYS) (70% SMYS) (80% SMYS)

J312 ( Rev 10/05 )


(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm²) (kN) (kN) (kN)
150 60 6 36 220 156 817 429 400 457
450 300 60 12 36 220 156 817 429 400 457
450 60 18 36 220 156 817 429 400 457
150 60 6 36 220 156 817 429 400 457
500 300 70 12 36 240 176 817 429 400 457

© National Grid Gas plc 2005- All Rights Reserved


500 70 20 36 240 176 817 429 400 457
150 70 8 36 240 176 817 429 400 457
600 300 70 12 36 240 176 817 429 400 457
600 70 24 36 240 176 817 429 400 457
200 70 10 36 240 176 817 429 400 457
750 450 80 14 42 280 202 1121 588 549 628
750 80 26 42 280 202 1121 588 549 628
200 80 10 42 280 202 1121 588 549 628
900 450 90 10 64 340 240 2750 1485 1356 1535
900 110 20 64 420 280 2750 1485 1356 1535
Table E.4b– Bolt Loading Details continued

250 80 10 42 280 202 1121 588 549 628


1050 600 90 12 64 360 240 2750 1485 1356 1535
1050 120 20 64 440 300 2750 1485 1356 1535
300 80 12 42 280 202 1121 588 549 628
1220 900 140 20 64 480 340 2750 1485 1356 1535
1220 140 24 64 480 340 2750 1485 1356 1535

- 23 -
T/SP/F/14
T/SP/F/14

Table E.4c– Bolt Loading Details continued

Grouted Tee Size Bolt Loading Details


Pipe Branch Approximate Target Bolt Load Torque Values
Nominal Nominal
Size Size Dry Light Oil Nickel Based Copper Based Molybdenum
(mm) (mm) (Nm) (Nm) (Nm) (Nm) (Nm)
50 340 261 198 189 124
100
100 340 261 198 189 124
50 1141 884 667 614 403
150 100 1141 884 667 614 403
150 1141 884 667 614 403
100 1141 884 667 614 403
200
200 1141 884 667 614 403
100 1141 884 667 614 403
250 150 1141 884 667 614 403
250 1141 884 667 614 403
100 2266 1756 1318 1213 793
300 150 2266 1756 1318 1213 837
300 2266 1756 1318 1213 837
100 2266 1756 1318 1213 837
350 200 2266 1756 1318 1213 837
350 2266 1756 1318 1213 837
100 2266 1756 1318 1213 837
400 300 3943 3075 2290 2107 1374
400 3943 3075 2290 2107 1374
150 3943 3075 2290 2107 1374
450 300 3943 3075 2290 2107 1374
450 3943 3075 2290 2107 1374
150 3943 3075 2290 2107 1374
500 300 3943 3075 2290 2107 1374
500 3943 3075 2290 2107 1374
150 3943 3075 2290 2107 1374
600 300 3943 3075 2290 2107 1374
600 3943 3075 2290 2107 1374
200 3943 3075 2290 2107 1374
750 450 5842 4917 3382 3109 2015
750 5842 4917 3382 3109 2015
200 5842 4917 3382 3109 2015
900 450 21687 17280 12511 11490 7421
900 21687 17280 12511 11490 7421
250 5842 4917 3382 3109 2015
1050 600 21687 17280 12511 11490 7421
1050 21687 17280 12511 11490 7421
300 5842 4917 3382 3109 2015
1220 900 21687 17280 12511 11490 7421
1220 21687 17280 12511 11490 7421

© National Grid Gas plc 2005- All Rights Reserved


- 24 - J312 ( Rev 10/05 )
T/SP/F/14
APPENDIX F
GROUT FEED RISER & TELL-TALE HOLES
Figure F.1
© National Grid Gas plc 2005- All Rights Reserved
J312 ( Rev 10/05 ) - 25 -
T/SP/F/14

APPENDIX G
DEFECT ACCEPTANCE LEVELS FOR THE STARTING MATERIAL
TABLE G.1 - Laminar defects in a single plane
Grade Minimum Intercept Maximum Area Of Total Defect Scan
Considered Individual Defect In Any Area 1 m x 1 m Interval

mm mm² mm² mm
A 13 3200 12 000 75

Note – In computing total defect area, consider defects in excess of 650 mm²

TABLE G.2 - Inclusion clusters - other than laminar defects referred to in Table F.1
Total Defect Area/
Minimum Intercept
Grade Plate Area Scan Interval
Considered

mm mm²/m² mm
1 50 3900 maximum 75

Notes

1. The minimum size of cluster which must be considered as an accountable defect and therefore
included in the ‘total defect area’ is 6500 mm²
2. After totalling the areas of inclusions and dividing by the area of the plate, the average distribution
must not exceed 3900 mm²/m²
3. Clusters of inclusions must be regarded as a continuous area, if the distance between individual
inclusions is less than 12 mm

Notes to Tables G.1 and G.2

1. Grades A and 1 correspond to BS EN 10160, except that edge testing is not required.

2. The 'minimum intercept considered', refers to the length of the scan line intercepted by a
discontinuity. If the length of the scan line intercepted is less than the value given in Table G.1.
the defect must be considered as an inclusion and assessed under Table G.2.

3. BS EN 10160 defines the limits of a discontinuity classified as a lamination as 'the position


where the flaw echo is at least 50% of the first bottom echo'.

4. Guidance on assessment of defect level is given in BS EN 10160.

© National Grid Gas plc 2005- All Rights Reserved


- 26 - J312 ( Rev 10/05 )
T/SP/F/14

APPENDIX H
DEFECT ACCEPTANCE LEVELS FOR THE FINISHED PRODUCT
The defect acceptance levels for the finished product given in Tables H.1, H.2 and H.3 are generally in
accordance with PD 5500, but with certain alterations or additions.

Defects exceeding the limits, or different to types given, will be subject to agreement after due
consideration of material, stress and environmental factors.

Table H.1 - Defects in welds


Defect Type Permitted Maximum
Surface Breaking cracks and lamellar
Planar tears, lack of root, side, inter-run fusion Not permitted
Defects and root penetration
Isolated buried indications 1.25 mm maximum length
Isolated pores Diameter 3 mm but not more than 0.25 x
parent metal thickness*
Cavities
Uniformly distributed localized porosity 2% by area as seen on radiograph
Linear porosity (continuous) Not permitted
Individual inclusions parallel to major Length – less than parent metal
weld axis of butt welds (separated from thickness*
any other inclusion by a distance not
less than 2 x length of longest of the Width or depth - the lesser of 0.1 x parent
two inclusions) metal thickness* or 4 mm
The sum of individual lengths not to
exceed 0.1 x weld length
Where the separation of adjacent
inclusions is less than 2 x length of
Groups of inclusions parallel to major
longest inclusion, total lengths of such
axis of butt welds (separated from
pairs must not exceed the parent metal
each other at different lengths)
Slag thickness*
Inclusions The width or depth must be limited to the
lesser of 0.1 x parent metal thickness* or
4 mm
To be contained within a cylindrical
envelope of 3 mm diameter and
separated from any other such envelope
by at least 0.25 x parent metal thickness*
Random oriented individual or
overlapping inclusions Cylindrical envelope length must not
exceed parent metal thickness*

Total projected area to be limited to 2% by


area as seen on radiograph
Tungsten inclusions isolated or
Solid As for porosity
grouped
Inclusions
Copper inclusions Not permitted
* In the case of dissimilar metal thicknesses, the applicable parent metal thickness must be that of
the thinner component

© National Grid Gas plc 2005- All Rights Reserved


J312 ( Rev 10/05 ) - 27 -
T/SP/F/14

TABLE H.2 - Defects at weld end preparations and weld profiles


Location Defect Type Permitted Maximum
For fitting nominal sizes:
Lamination at weld end preparation
≤ 100 mm, 6 mm length
individual or isolated
> 100 mm, 13 mm length
Weld end Separation between adjacent laminations
Preparations to be not less than the longest lamination.
Laminations in line or separated
The sum of lamination lengths to be less
than 10% of total weld end preparation.
Weld end preparation shape and finish To allow relevant NDT application
Not permitted. Must be dressed smooth
Undercut, shrinkage grooves, root
with parent plate (or forging) provided that
concavity, excess penetration and
the wall thickness is not reduced to below
overlap
the specified minimum

Weld It must blend smoothly with the parent


Reinforcement shape material. Dressing not necessary unless
required by relevant NDT.
Accepted within the requirements of the
Linear misalignment specifications with correct tapering and
blending.

TABLE H.3 - Defects on finished product


Location Defect Type Permitted Maximum
Dents must not be greater than 6.35 mm
deep, measured as the gap between the
lowest point of the dent and a
prolongation of original contour of the
Dents pipe.

The length of the dent in any direction


At welded must not exceed one half the pipe
seams or body diameter
Subject to National Grid Gas Inspector’s
Scores, pitting corrosion, finish and discretion and evaluation, and not to
workmanship affect the intended service duty within the
specification
Surface laps and gouges Not permitted. Can be ground smooth
provided that the wall thickness is not
reduced to below the specified minimum

© National Grid Gas plc 2005- All Rights Reserved


- 28 - J312 ( Rev 10/05 )
T/SP/F/14

ENDNOTE
Comments
Comments and queries regarding the technical content of this document should be directed to:

Safety and Engineering Registrar


SHE Directorate
National Grid
National Grid House
Warwick Technology Park
Gallows Hill
Warwick
CV34 6DA

Buying documents
Contractors and other users external to National Grid Gas should direct their requests for further copies
of National Grid Gas Documents to the department or group responsible for the initial issue of their
contract documentation.

Copyright National Grid Gas plc 2005 ©, all rights reserved. No part of this publication may by reproduced
in any material form (including photocopying and restoring in any medium or electronic means and
whether or not transiently or incidentally) without the written permission of National Grid Gas plc except in
accordance with the provisions of the Copyright, Designs and Patents Act 1988

© National Grid Gas plc 2005- All Rights Reserved


J312 ( Rev 10/05 ) - 29 -