Vol

SPECIFICATION FOR FLUSHING AND TESTING

SPECIFICATION NO. MEC/S/05/62/11

(PROCESS & PIPING DESIGN SECTION) MECON LIMITED NEW DELHI 110 016 ,1999

PROCESS & PIPING DESIGN SECTION NEW DELHI

MECON LIMITED REGD. OFF: RANCHI (BIHAR)

TITLE

Flushing and Testing

STANDARD SPECIFICATION

SPECIFICATION NO.

PAGE 1 OF 9

MEC/S/05/62/11

REVISION 0

CONTENTS 1.0

SCOPE

2.0

INSPECTION

3.0

FLUSHING

4.0

TESTING

4.1

EXTENT OF TESTING

4.2

GENERAL REQUIREMENT/TEST PREPARATION FOR TESTING

4.3

TESTING MEDIA, TEST PRESSURE AND TEST PRESSURE GAUGES.

4.4

TESTING PROCEDURE

4.5

COMPLETION OF TESTING

4.6

TEST RECORDS

PREPARED BY

CHECKED BY

APPROVED BY

MECON LIMITED REGD. OFF: RANCHI (BIHAR)

TITLE

1.0

PROCESS & PIPING DESIGN SECTION NEW DELHI

Flushing and Testing

STANDARD SPECIFICATION

SPECIFICATION NO.

PAGE 2 OF 9

MEC/S/05/62/11

REVISION 0

SCOPE This specification covers the general requirements for Inspection, flushing and testing of piping systems. However testing of steam lines falling under IBR shall also be governed by Indian Boiler Regulations. Flushing and testing of all piping system shall be witnessed by the Engineer-inCharge.

2.0

Inspection During various stage and after completion fabrication and erection, the piping system shall be inspected by the Engineer- in - Charge to ensure that :

3.0

-

Proper piping material has been used.

-

Piping has been erected as per drawings and the instruction of the engineer- in charge.

-

All supports have been installed correctly.

-

Test preparations mentioned in this specification have been carried out.

Flushing Flushing of all lines shall be done before pressure testing. Flushing shall be done by fresh potable water or dry compressed air, wherever water flushing is not desirable, to clean the pipe of all dirt, debris or loose foreign materials. Required pressure of water, flushing shall meet the fire hydrant pressure or utility water pressure. For air flushing the line, system will be pressurised by compressed air at the required pressure which shall be 50 psi maximum. The pressure shall then be released by quick opening of a valve, already in the line for this purpose. This procedure shall be repeated as many times as required till the inside of the pipe is fully cleaned.

MECON LIMITED REGD. OFF: RANCHI (BIHAR)

TITLE

PROCESS & PIPING DESIGN SECTION NEW DELHI

Flushing and Testing

STANDARD SPECIFICATION

SPECIFICATION NO.

PAGE 3 OF 9

MEC/S/05/62/11

REVISION 0

In line instruments like control valves, orifice plates, rotameters, safety valves and other instruments like thermowells which may interfere with flushing shall not be included i m the flushing circuit. From all permanent strainers the screens/meshes shall be removed before flushing. Screens/meshes shall be re- installed after flushing but before testing. In case an equipment such as column, vessel, exchanger etc. forms part of a piping circuit during flushing, this shall be done with the approval of Engineer- in Charge. However equipment thus included in the circuit, shall be completely cleaned and dried with comprss4ed air, after flushing is completed. During flushing discharged water/air shall be drained at the place directed the Engineer- in - Charge. If necessary, proper temporary drainage shall be provided by the contractor. Care shall be taken during flushing so as not to damage/spoil work of other agencies. Precautions shall also be taken to prevent entry of water/foreign matter into equipment, electric motors, instruments, electrical installations etc. in the vicinity of lines being flushed. The contractor shall carry out all the activities required before, during and after the flushing operation, arising because of flushing requirements, such as but not limited to the following. Dropping of valves, specials, distance pieces, online instruments and any other piping part before flushing. The flanges to disengaged for this purpose shall be envisaged by the contractor and approved by the Engineer-in-Charge. These flanges shall be provided with temporary gaskets at the time of flushing. After flushing is completed and approved, the valve, distance pieces, piping specials etc. shall be re-installed by the contractor with permanent gaskets. However, flanges of equipment nozzles and other places where isolation is required during testing, only temporary gaskets shall be provided.

MECON LIMITED REGD. OFF: RANCHI (BIHAR)

TITLE

PROCESS & PIPING DESIGN SECTION NEW DELHI

Flushing and Testing

STANDARD SPECIFICATION

SPECIFICATION NO.

PAGE 4 OF 9

MEC/S/05/62/11

REVISION 0

Records in triplicate shall be prepared and submitted by the Contractor for each piping system for the flushing done in the proforma in Exhibit F. 4.0

Testing

4.1

Extent of testing With the exclusion of instrumentation. piping system fabricated or assembled in the field shall be tested irrespective of whether or not they have been pressure tested prior to site welding of fabrication. To facilitate the testing of piping systems, vessels and other equipments may be included in the system with the prior approval of Engineer-in-charge, if the test pressure specified is equal to or less than that for the vessels and other equipments. Pumps, compressors and other votary equipments shall not be subjected to field test pressures. Lines which are directly open to atmosphere such as vents, drains, safety valves, discharge need not be tested, but all joints shall be visually inspected wherever necessary such lines shall be tested by continuous flow of fluid to eliminate the possibility of blockage. However, such lines if provided with block valve shall be pressure tested upto the first block valve. Seats of all vales shall not be subjected to a pressure in excess of the maximum cold welding pressure of the valve. Test pressure applied to vales shall not be grater than the manufacturer is recommendation nor less than that required by the applicable code. Where desirable set pressure is less than test pressure, test shall be made through an open valve. Instruments in the system to be tested, shall be excluded from the test by isolation or removal, unless approved otherwise by the Engineer-in-charge. Restrictions which interfere with filling, venting and drawing such as orifice plates etc. shall not be installed unless testing is complete. Control valves shall not be included in the test system. Where by-passes are provided test shall be performed through the by-pass end/or necessary spool shall be used in place of the control valve.

MECON LIMITED REGD. OFF: RANCHI (BIHAR)

TITLE

PROCESS & PIPING DESIGN SECTION NEW DELHI

Flushing and Testing

STANDARD SPECIFICATION

SPECIFICATION NO.

PAGE 5 OF 9

MEC/S/05/62/11

REVISION 0

Pressure gauges which are part of the finished system, but cannot withstand test pressure shall not be installed until the system has been tested. Where piping systems to be tested are directly connected at the battery limits to piping for which the responsibility tests with other agencies, the piping to be tested shall be isolated from such piping by physical disconnection such as valves or blinds. 4.2

General Requirement/Test preparation for Testing Test shall be carried out with permanent gaskets installed unless specified otherwise or instructed by the Engineer-in- charge. No pressure test shall be carried out against close valve unless approved by the Engineer-in-charge. The Engineer-in-charge shall be notified in advance by the contractor, of the testing sequence and programme, to enable him to be present for witnessing the test. The contractor shall be fully responsible for making arrangements with the local boiler inspector to witness the tests for steam lines falling under IBR. IBR certificates for these tests shall be obtained in the relevant IBR forms and furnished to the Engineer-in-charge. Before testing, all piping shall be cleaned by flushing to make it free from dist loose scale, debris and other loose foreign materials. All piping systems to be hydrostatically tested shall be vented at the high points and the systems purged of air before the test pressure is applied. Wherever in the line any void is existing due to any reasons, for absence of control valve, safety valve, check valves etc. it shall be filled with temporary spools. All joints welded, screwed or flanged shall be left exposed for examination during the test. Before pressuring the lines, each weld joint shall be cleaned by wire brush to free it from rest and any other foreign matter. Where a system is to be isolated of a pair of companion flanges, a blank shall be inserted between the companion flanges. Minimum thickness of the blank shall be designed in accordance with applicable design code.

MECON LIMITED REGD. OFF: RANCHI (BIHAR)

TITLE

PROCESS & PIPING DESIGN SECTION NEW DELHI

Flushing and Testing

STANDARD SPECIFICATION

SPECIFICATION NO.

PAGE 6 OF 9

MEC/S/05/62/11

REVISION 0

Open ends of piping system where blanks cannot be used, such as pumps, compressors, turbines or wherever equipment or pipe spool have been receivered or disconnected prior to hydrostatic testing, shall be blinded – off by using standard blind flanges of same rating as the piping system being tested. Pressure gauges used in testing shall be installed as close as possible to the lowest point in the piping system to be tested, to avoid overstressing of any of the lower portion of the system. For longer lines and vertical lines, two or more pressure gauges shall be installed at locations selected by the Engineer-in-charge. For lines containing check valves any of the following alternatives shall be adopted for pressure testing. Wherever possible pressurise up-stream side of valve. Replace the valve by a temporary spool and re-install the valve after testing. Provide blind on valve flanges and test the upstream and downstream of the line separately and remove the blind after testing. All these flanges, temporary gaskets shall be provided during testing and shall be replaced by permanent gaskets subsequently. For check valves in lines 1-1/2" and below, flapper or seat shall be removed during testing (if possible). After completion of testing the flopper/ seat shall be refitted. Gas lines when hydrostatically tested shall be provided with additional temporary supports during testing as directed by Engineer-in-charge. Piping which is spring or counter – weight supported shall be temporarily supported, where the weight of the fluid would overload the support. Retaining pins for spring supports shall be removed only after testing is completed and test fluid is completely drained. When testing any piping system, air or steam of approximately 2 kg/cm2 (g) may be used as preliminary test to detect missing gaskets etc. as this avoids the necessity of purging the gas to make repairs. However, this method may not be used for this purpose, if the steam temperature is more than the design temp. of the line.

MECON LIMITED REGD. OFF: RANCHI (BIHAR)

TITLE

PROCESS & PIPING DESIGN SECTION NEW DELHI

Flushing and Testing

STANDARD SPECIFICATION

SPECIFICATION NO.

PAGE 7 OF 9

MEC/S/05/62/11

REVISION 0

For jacketed pipes testing of core pipes shall be done on individual pieces where the pipe is continuously packed, before it is jacketed. The outer jacket shall be tested separately as a system for piping with discontinuous jacketing, the eore pipe and the jacket shall be tested as separate system. 4.3

Testing Modes, Test pressure and Test Pressure Gauges

4.3.1

Testing Modes In general all pressure test shall be hydrostatic using iron free water, which is clean and free of silt. Maximum clorine content in water for hydrostatic testing for MS piping shall be 15-20 ppm. Air shall be used for testing only if water would cause corrosion of the system or overloading of supports etc. in special cases as directed by Engineer-in-charge. Where air/water tests are undesirable substitute fluid such as gas, oil, methanol etc. shall be used as the testing medium, with due consideration to the hazards involved. These test fluids shall be specified in the line list given to the contractor.

4.3.2

Test Pressure The hydrostatic/pneumatic test pressure shall be as indicated in the line list or as per the instruction of Engineer-in-charge. The selection of the piping system for one individual test shall be based on the following :Test pressure required as per line list. Maximum allowable pressure for the material of construction of piping depending upon the above requirements and based on construction progress, maximum length of piping shall be included in each test.

4.3.3

Test Pressure Gauge All gauge used for field testing shall have suitable range so that the test pressure of the various system falls in 40% to 60% of gauge scale range. Gauge shall be of a good quality and in first class working condition.

MECON LIMITED REGD. OFF: RANCHI (BIHAR)

TITLE

PROCESS & PIPING DESIGN SECTION NEW DELHI

Flushing and Testing

STANDARD SPECIFICATION

SPECIFICATION NO.

PAGE 8 OF 9

MEC/S/05/62/11

REVISION 0

Prior to the start of any test or periodically during the field test programmes, all test gauges shall be calibrated using a standard dead weight gauge tester or other suitable approved testing apparatus. Any gauge having an incorrect zero reading or error of more than ± 2% of full scale range shall be discarded. The Engineer-in-charge shall check the accuracy of master pressure gauge used for calibration. 4.4

Testing Pressure

4.4.1

Hydrostatic Test All vents and other connections used as vents shall be kept open while filling the line with test fluid for complete removal of air. For pressurising and depressurising the system, temporary isolating valves shall be provided if valves, vents, drains do not exist in the system. Pressure shall be applied only after the system/line is ready and approved by the Engineer-in-charge. Pressure shall be applied by means of a suitable test pump or other pressure source which shall be isolated from the system as the desired test pressure is reached and stabilised in the system. A pressure gauge shall be provided at the pump discharge for guiding system to the required pressure.

the

The pump shall be attended constantly during the test by an authorised person. The pump shall be isolated from the system wherever the pump is to be left unattended. Test pressure shall be maintained for a sufficient length of time to permit through inspection of all joints for leakage or signs of failure. Any joint found leaking during a pressure test, shall be re-tested to the specified pressure after repair. Test period shall be maintained for a minimum of three hours. The pump and the piping system to be tested are to be provided with separate pressure indicating test gauges. There gauges are to be checked by the standard test gauge before each pressure test.

MECON LIMITED REGD. OFF: RANCHI (BIHAR)

PROCESS & PIPING DESIGN SECTION NEW DELHI

TITLE Flushing and Testing

STANDARD SPECIFICATION

SPECIFICATION NO.

PAGE 9 OF 9

MEC/S/05/62/11

REVISION 0

Care shall be taken to avoid increase in the pressure due to atmospheric variation during the test. 4.4.2

Air Test When testing with air, pressure shall be supplied by means of a compressor. The compressor shall be portable type with a receiver after cooler & oil separator. Piping to be tested by air shall have joints covered with a soap and water solution so that the joints can be examined for leaks. All other activities shall be same as per hydrotesting procedure (specified above).

4.5

Completion of Testing After the hydrostatic test has been completed, pressure shall be released in a manner and at a rate so as not to endanger personnel or damage equipments. All vents and drains shall be opened before the system is to be drained and shall remain open till all draining is complete, so as to prevent formation of vacuum in the system. After draining lines/systems shall be dried by air. After testing is completed the test blinds shall be removed and equipment/piping isolated during testing shall be connected using the specified gaskets, bolts and nuts. These connections shall be checked for tightness in subsequent pneumatic tests to be carried out by the contractor for complete loop/circuit including equipments (except rotary equipments). Pressure tests shall be considered complete only after approved by the Engineer-in-charge. Defects, if any, noticed during testing shall be rectified immediately and retesting of the system/line shall be done by the contractor at his cost.

4.6

Test Records Records in triplicate shall be prepared and submitted by the contractor for each piping system, for the pressure test done.

SPECIFICATION FOR CASING INSULATORS AND END SEALS

SPECIFICATION NO. MEC/S/05/62/12

(PROCESS & PIPING DESIGN SECTION)

MECON LIMITED DELHI - 110 092

D:\SPECIFICATIONS\TECHNICAL SPECIFICATIONS\LAYING OR INSTALLATION\MAINLINE\WORD,ACAD\12 Casing seal and Insulator.doc

MECON LIMITED REGD. OFF: RANCHI (BIHAR)

TITLE

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

CASING INSULATORS AND END

SPECIFICATION NO.

PAGE 1 OF 6

SEALS

MEC/S/05/62/12

REVISION 0

CONTENTS

PART-A

PART-B

PART-C

CASING INSULATIONS 1.0

SCOPE

2.0

FUNCTION

3.0

DESIGN

4.0

MATERIAL

5.0

INSPECTION AND TESTING

CASING END-SEALS 1.0

SCOPE

2.0

FUNCTION

3.0

DESIGN

4.0

MATERIAL

5.0

INSPECTION AND TESTING

SUPPLEMTARY REQUIREMENTS

PREPARED BY

CHECKED BY

D:\SPECIFICATIONS\TECHNICAL SPECIFICATIONS\LAYING OR INSTALLATION\MAINLINE\WORD,ACAD\12 Casing seal and Insulator.doc

APPROVED BY

MECON LIMITED REGD. OFF : RANCHI (BIHAR)

TITLE

PROCESS & PIPING DESIGN SECTION NEW DELHI

CASING INSULATORS AND END

SPECIFICATION NO.

PAGE 2 OF 6

SEALS

MEC/S/05/62/12

REVISION

PART-A 1.0

STANDARD SPECIFICATION

0

CASING INSULATORS

SCOPE This specification covers the minimum requirements of design, material, manufacture and supply of casing insulators intended to be used for cased pipeline crossings.

2.0

FUNCTION Pipeline insulators shall be used to support the carrier pipe inside the casing pipe and electrically isolate the carrier pipe from the casing pipe at the cased crossings. The casing insulators shall:

3.0

-

Resist cold flow and will not soften at design temperature.

-

Resist corrosion

-

Resist mechanical damage while being pulled into the casing.

-

Have high electrical insulating value and low water absorption, thus preventing leakage and maintain electrical isolation between carrier and casing pipes

-

Have high compressive strength in order to assure a permanent support to the carrier pipe.

DESIGN The arrangement of insulator shall be generally in accordance with Fig. 3.0. It shall be made in segments duly held together with cadmium plated bolts and nuts, to be supplied with casing insulators. The number of segments shall be two for pipe diameters upto 12” (generally). For larger diameters, the number of segments may be more than two, but their number shall be kept minimum. The skid height shall be such that it is slightly less than the value obtained by following formula.

D:\SPECIFICATIONS\TECHNICAL SPECIFICATIONS\LAYING OR INSTALLATION\MAINLINE\WORD,ACAD\12 Casing seal and Insulator.doc

MECON LIMITED REGD. OFF : RANCHI (BIHAR)

TITLE

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

CASING INSULATORS AND END

SPECIFICATION NO.

PAGE 3 OF 6

SEALS

MEC/S/05/62/12

REVISION

0

Casing internal dia-carrier outer dia 2 Manufacturer shall obtain prior approval from COMPANY on casing insulators drawings/designs. 4.0

MATERIAL Casing insulators shall be made of injection moulded high density polyethylene or other material equivalent or superior as approved by COMPANY and shall meet the following specifications:

5.0

Property

Value

ASTM Test Method

Dielectric strength

450-500 Volts/Mil

D-149

Compresssive strength

3200 psi

D-695i

Tensile strength

3100-5000

D-638, D-651

Impact strength

4.Oft. 1b./inch of notch D-256

Water Absorption

0.01%

D-570

INSPECTION AND TESTING Manufacturer shall furnish material test certificates of the components used in the assembly of casing insulations as per the requirements of clause 4.0 of this specification.

D:\SPECIFICATIONS\TECHNICAL SPECIFICATIONS\LAYING OR INSTALLATION\MAINLINE\WORD,ACAD\12 Casing seal and Insulator.doc

MECON LIMITED REGD. OFF : RANCHI (BIHAR)

TITLE

PROCESS & PIPING DESIGN SECTION NEW DELHI

CASING INSULATORS AND END

SPECIFICATION NO.

PAGE 4 OF 6

SEALS

MEC/S/05/62/12

REVISION

PART-B 1.0

STANDARD SPECIFICATION

0

CASING END-SEALS

SCOPE This specification covers the minimum requirements of design, material, fabrication and supply of casing end-seals intended to be used for pipeline cased crossings.

2.0

FUNCTION Casing end seals are intended to be used for sealing the annular space between casing pipe and carrier pipe at casing ends so as to prevent ingress of moisture and water.

3.0

DESIGN The scale shall be suitable for the casing and carrier pipe diameters as applicable for each case. The casing end-seal shall be flexible to cater for the expansion and contraction of carrier and casing pipes and shall be able to tolerate both angular and concentric misalignment of casing pipe without loss of sealing efficiency. The design of the casing end-scale shall permit easy installation of the seal to the cased pipeline crossing. It shall provide moisture-proof seals when installed for the entire anticipated life of the buried pipeline. Manufacturer shall obtain prior approval from COMPANY on casing end seals design/drawings.

4.0

MATERIAL The casing end-scale shall be made of head shrink high density radiation crosslinked polyethylene with an adhesive having a melt point suitable for the pipeline service temperature and ambient temperatures foreseen during construction. End-seals material shall be resistant to heat, cold, vibration, impact, abrasion, corrosive fluids, disbonding, organic and bio-deterioration. Manufacturer shall confirm compatibility of end seals with carrier pipe coating.

D:\SPECIFICATIONS\TECHNICAL SPECIFICATIONS\LAYING OR INSTALLATION\MAINLINE\WORD,ACAD\12 Casing seal and Insulator.doc

MECON LIMITED REGD. OFF : RANCHI (BIHAR)

TITLE

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

CASING INSULATORS AND END

SPECIFICATION NO.

PAGE 5 OF 6

SEALS

MEC/S/05/62/12

REVISION

0

Casing end seals shall meet following minimum property requirements: Property

Minimum Value

Test Method

a) Backing (Sleeve and closure patch) Tensile strength

2200 psi

ASTM D-638

Ultimate Elongation

400%

ASTM D-638

Heat Shock

No visual cracks, flow or drips (at 225°C, 4 hours)

ASTM D-2671

Ring and Ball softening point

90°C

ASTM E-28

Lap Shear

60°C - 25 psi 23°C - 250 psi (2 inch/min)

ASTM D-1002

5 pli (10 inch/min.)

ASTM D-1000

b) Adhesive

c) System (as applied) Peel strength (To casing and carrier pipe and closure patch)

5.0

INSPECTION AND TESTING Manufacturer shall furnish material test certificates of the components used in the assembly of casing end-seals as per the requirements of this specification.

D:\SPECIFICATIONS\TECHNICAL SPECIFICATIONS\LAYING OR INSTALLATION\MAINLINE\WORD,ACAD\12 Casing seal and Insulator.doc

MECON LIMITED REGD. OFF : RANCHI (BIHAR)

TITLE

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

CASING INSULATORS AND END

SPECIFICATION NO.

PAGE 6 OF 6

SEALS

MEC/S/05/62/12

REVISION

PART-C

0

SUPPLEMENTARY REQUIREMENTS

1.0

The Manufacturer shall replaces, at no extra cost, any material not conforming to the material and performance requirements of this specification.

2.0

Manufacturer shall submit detailed specification of the materials used in the assemblies, along with instructions for handling, use and installation of the material for COMPANY approval prior to procurement.

3.0

Manufacturer shall submit all the documents, test reports, records and other information in six copies to the COMPANY for record after approval as per clause 2.0 above.

D:\SPECIFICATIONS\TECHNICAL SPECIFICATIONS\LAYING OR INSTALLATION\MAINLINE\WORD,ACAD\12 Casing seal and Insulator.doc

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

PROJECT TECHNICAL SPECIFICATION FOR FILED JOINT COATING (ON – SHORE PIPELINE)

SPECIFICATION NO. : MEC/PTS/05/62/13

D:\old data\Vijyant\GSPL\Tender\Const\vol II of V\spec\pdf\PDF Final\013-Field Joint Coating Spec.(PTS).doc

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

CONTENTS Sl.No.

Description

Page No.

1.0

SCOPE

1

2.0

REFERENCE DOCUMENTS

1

3.0

MATERIAL AND EQUIPMENT

2-5

4.0

APPLICATION PROCEDURE

5–8

5.0

INSPECTION & TESTING

8 - 10

6.0

REPAIR

10

7.0

DOCUMENTATION

11

D:\old data\Vijyant\GSPL\Tender\Const\vol II of V\spec\pdf\PDF Final\013-Field Joint Coating Spec.(PTS).doc

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

1.0

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

SCOPE This specification covers the minimum requirements of materials, equipment and installation of field joint anti-corrosion coating of buried onshore pipelines factory coated with either three layer polyethylene or fusion bonded epoxy coating, byheat shrink wraparound sleeves conforming to DIN 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” and the requirements of this specification. Unless modified/ replaced by this specification, all requirements of DIN EN 12068 shall remain fully applicable and complied with. This specification shall be read in conjunction with the conditions of all specifications and documents included in the Contract between COMPANY and CONTRACTOR. Unless specified otherwise, all section of this specification shall apply to all specifications referred in this specification.

2.0

REFERENCE DOCUMENTS Reference has been made to the latest edition (edition enforce at the time of floating the enquiry) of the following standards, codes and specifications: a)

ASTM D-149

:

Standard Test Methods of Dielectric Breakdown voltage and Dielectric Strength of solid electrical insulating materials at commercial frequencies.

b)

ASTM D-257

:

Standard Test Methods for D-C Resistance or conductance of insulating materials.

c)

ASTM D-570

:

Standard Method of Test for Water Absorption of Plastics

d)

ISO 8502-3

:

Preparation of Steel Stubstrates before Application of Paints and Related Products – Part-3 –Assessment of Dust on Steel Surfaces Prepared for Painting (Pressure Sensitive Tape Method).

e)

ISO:8503-1

:

Part-1 : Specification and definitions for ISO surface profile comparator for the assessment of abrasive blast cleaned surfaces.

f)

ISO:8503-4

:

Part-4 : Methods for calibration of ISO surface profile comparator and for the determination of surface profile – Stylus instrument procedure.

D:\old data\Vijyant\GSPL\Tender\Const\vol II of V\spec\pdf\PDF Final\013-Field Joint Coating Spec.(PTS).doc

Page 1 of 11

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Tender Doc. No.: 05/51/23JT/GSPL/CP/001

Gujarat State Petronet Ltd.

MECON LIMITED

g)

SIS-055900

:

Pictorial surface Preparation Standard for Painting Steel Surfaces.

h)

SSPC-SP 1

:

Steel Structure Painting Council.

In case of conflict between the requirements of this specification and that of above referred documents, the requirements of this specification shall govern. The Contractor shall be familiar with the requirements of these documents and shall make them readily available at the site to all personnel concerned with carrying out the works specified in this specification. 3.0

MATERIALS AND EQUIPMENT

3.1

Field Joint Corrosion Coating Material Field joint anti-corrosion coating material shall be heat shrinkable wraparound sleeve suitable for a maximum operating temperature of (-)20 to (+) 60 ° C and shall conform to designation EN 12068 – C HT 60 UV. In addition the field joint anticorrosion coating shall comply the requirements specified in para 3.2 of this specification.

3.1.1

Heat Shrinkable Wraparound Sleeve Heat shrinkable wraparound sleeve shall consist of radiation cross-linked thermally stabilised, ultraviolet resistant semi-rigid polyolefin backing with a uniform thickness of high shear strength thermoplastic/copolymer hot melt adhesive. The joint coating system may consist of a solvent free ep oxy primer applied to the pipe surface prior to sleeve application. The backing shall be coated with thermochrome paint which will change colour when the desired heat during shrinking is attained. The wraparound sleeve shall be supplied in pre-cut sizes to suit the diameter and the requirements of overlap. The total thickness of heat shrinkable wraparound sleeve in the as applied condition shall be as follows : Pipe Size (Specified Outside Diameter)

Over 10¾” (273.1mm) to below 20” (508.0mm)

D:\old data\Vijyant\GSPL\Tender\Const\vol II of V\spec\pdf\PDF Final\013-Field Joint Coating Spec.(PTS).doc

Thickness (mm) On Pipe Body On Weld Bead Average Min. (Min.) 2.5

2.5

1.8

Page 2 of 11

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

The heat shrink wraparound sleeve shall have the required adhesive properties when applied on various commercial pipe-coating materials. The pre-heat and application temperatures required for the application of the shrink sleeve shall not cause loss of functional properties of the pipe coating. 3.2

Functional Requirements of Field Joint Coating

3.2.1

Properties of the PE backing shall be as follows : Sl. No. a) b) c) d) e)

3.2.2

Property Tensile Strength at @+25°C Ultimate Elongation @+ 25°C Dielectric withstand with 1000 Volts/sec Water absorption @+ 25°C for 24 hours Volume Resistivity @+25°C

Unit

Requirement

Test Method

N/mm2 % kv

≥12 ≥250 ≥30

ASTM D-638 ASTM D-638 ASTM D 149

%

≤0.05

ASTM D 570

Ohm-cm

≥1015

ASTM D 257

Functional Properties of Joint Coating System (As applied) As applied field joint coating system shall comply the requirements of DIN EN 12068. Table 1 and 2 corresponding to designation DIN EN 12068 – C HT 60 UV, except as modified below : a)

Cathodic Disbondment Resistance at Tmax i.e. 60°Cshall be 20mm when tested as per Annexure K of DIN EN 12068. Test shall be carried out at (+) 60°C.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

b)

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

Peel Strength shall be as follows : Peel Strength

Inner to Inner + Outer to Inner Outer to Outer To Pipe Surface To Factory Coating

Unit

@23°C @Tmax @23°C @Tmax @23°C @Tmax @23°C @Tmax

N/mm N/mm N/mm N/mm N/mm N/mm N/mm N/mm

Requirement for Mech Resistance Class C (Minimum) 1.5 0.3 1.5 0.3 3.5 0.3 3.5 0.3

Test Method as per DIN EN 12068

Annexure-B

Annexure-C

(Tmax shall be (+) 60°C) Contractor shall obtain prior approval from Company regarding the manufacturer of the joint coating material. Complete technical details alongwith test certificates complying with the requirements of clause 3.2.1 and 3.2.2 shall be submitted to Company for this purpose. The Contractor shall furnish test certificates from an independent DIN recognized/ approved laboratory for all the properties required for the specified EN designation of field joint coating and the requirements of this specification. 3.3

The materials shall not be older than their period of validity at the time of application by CONTRACTOR. Deteriorated/ decomposed material shall be disposed of and replaced by CONTRACTOR at his own expense. CONTRACTOR shall ensure that the coating materials supplied by him are properly packed and clearly marked with the following : -

3.4

Manufacturer’s name Material qualification Batch number Date of manufacturing and date of expiry.

CONTRACTOR shall ensure that the manufacturer has carried out all quality control tests on each batch and manufacturer shall provide test certificates to certify that the supplied materials meet the manufacturer’s specifications as indicated in the purchase order and as approved by COMPANY. Certificates and data sheets certifying the qualities of the coating materials shall be submitted by CONTRACTOR to COMPANY prior to application. COMPANY reserves the right to have the materials tested by an independent laboratory.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

3.5

Materials shall be stored in sheltered storage in the manufacturer’s original packing and away from direct sunlight and in accordance with manufacturer’s instructions.

3.6

CONTRACTOR shall provide and maintain mobile facilities which contains all necessary equipment and its spares for cleaning, coating repairs, inspection and tests.

3.7

CONTRACTOR shall furnish sufficient number of the following equipment and the required spares as a minimum for inspection and test purpose for each crew. a) b) c) d)

Fully automatic full circle adjustable holiday detector with a visible and audible signal system for inspection of coatings. Thickness gauge for measuring thickness. Contact type temperature recording thermometer. Roughness profile measuring (Stylus) instrument.

4.0

APPLICATION PROCEDURE

4.1

General

4.1.1

The application procedure qualification shall be in accordance with manufacturer's instruction and the minimum requirements specified below whichever are most stringent and shall be demonstrated to and approved by the company. Manufacturer’s expert shall supervise the application and shall be available at site upon request during qualification of application procedure and during construction at CONTRACTOR’S cost.

4.1.2

Operators for coating application shall be given necessary instructions and training before start of work, by the CONTRACTOR. To verify and qualify the application procedures, all coating applied during the qualification test, shall be removed for destructive testing as detailed subsequently in this specification. Contractor shall only utilize those operators who have been approved/ pre-qualified by the field joint coating manufacturer.

4.1.3

Oil, grease, salt shall be removed from steel surface by wiping with rags soaked with suitable solvents such as naphtha or benzene. Kerosene shall not be used for this purpose. Solvent cleaning procedure according to SSPC-SP 1 shall be followed.

4.1.4

Each field joint shall be blast cleaned using a closed cycle blasting unit or an open expendable blasting equipment. With the first equipment type, steel or chilled shot and iron grit shall be used and Garnet material with the second one. During blast cleaning the pipe surface temperature shall be simultaneously more than 5° and more than 3°C above ambient Dew Point, while the ambient Relative Humidity shall not be greater than 85%. Prior to surface cleaning the surface shall be completely dry. The surface shall be cleaned to a grade Sa 2½ in accordance with Swedish Standard SIS-055900 with a roughness profile of 50-70 microns. Surface roughness profile shall be measured using an approved profile comparator in accordance with ISO 8503-1 and shall be calibrated prior to the start of the work in accordance with

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Page 5 of 11

PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

ISO:8503-3 or ISO:8503-4. The blast cleanliness shall be checked on every joint and the roughness profile shall be checked 1 every 10 joints. Dust girt or foreign matter shall be removed from the cleaned surface by an industrial vacuum cleaner. The dust contamination allowed shall be of a rating max 2 as per ISO:8502-3. The frequency of checking for dust contamination shall be 1 every 10 joints. Blast cleaned field joint shall be coated within 2-4 hours according to the conditions below : -

Relative Humidity (RH) > 80% Relative Humidity (RH) > 70-80% Relative Humidity (RH) > 80%

-

2 Hours 3 Hours 4 Hours

Pipes delayed beyond this point or pipes showing any visible rust stain shall be blast cleaned again. 4.1.5

The field joint surface shall be inspected immediately after blast cleaning and any feature of the steel surface such as weld spatter, scabs, laminations or other imperfections considered injurious to the coating integrity made visible during blast cleaning shall be reported to the Company Representative and on permission from Company Representative, such defects shall be removed by filing or grinding. Pipes affected in this manner shall be then re-blast cleaned if the defective area is larger than 50 mm in diameter.

4.1.6

The ends of existing pipe protective coating shall be inspected and chamfered. Unbounded portions of the coating shall be removed and then suitably trimmed. Portions where parent coating is removed shall be thoroughly cleaned as specified. The adjacent chamfered areas of the line pipe coating shall be cleaned and abraded, to expose a clean uniform fresh surface of uncontaminated factory applied coating.

4.1.7

All steel joint surfaces shall be thoroughly examined before the application of the coating in order to ensure the surfaces are free of oil, grease, rust, mud, earth or any other foreign matter. All these substances shall be removed before coating, to the procedures herein described.

4.1.8

Protection coating shall be applied on the joints immediately after the completion of cleaning operation.

4.2

Application of Heat Shrink Wraparound / Sleeves In addition to the general requirements stated above, following shall be taken into account –

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

4.2.1

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

The wrap around sleeve shall be of a size such that a minimum overlap of 50mm before applying is ensured (after shrinking) on both sides of the yard applied corrosion coating of pipes. In the cases where carrier pipe is installed by direct boring/ jacking, the overlap on the mill coating for the leading edges of the joints shall be minimum 200mm. When this extra overlap is achieved by providing an additional patch of heat shrink tape/ wraparound, it shall be applied in such a manner that the square edge of the patch on the joint coating is in the direction opposite to the direction of boring/ jacking.

4.2.2

Before centering the wraparound sleeve, the bare steel surface shall be preheated with torch moved back and forth over the surface or by induction heating. The minimum preheat temperature shall be as recommended by manufacturer and shall be checked by means of contact type temperature recording thermometer. Temperature indicating crayons shall not be used Pre-heat temperature shall be checked on every joint. Care shall be taken to ensure that the entire circumference of the pipe is heated evenly. Temperature measuring instruments shall be calibrated immediately before the start of the works and thereafter at intervals recommended by the manufacturer of the instrument.

4.2.3

Upon pre-heating the pipe surface shall be applied with two pack epoxy primer of wet film thickness 100 microns or as per manufacturer’s recommendation whichever is higher, to cover the exposed bare metal of the welded field joint and 10mm min. onto the adjacent pipe coating if recommended by the manufacturer. The wet film thickness of the primer shall be checked or every joint with a wet film thickness gauge prior to installation of sleeve. Thickness gauge shall be calibrated once per shift.

4.2.4

Immediately after application of epoxy primer, the wraparound sleeve shall be entirely wrapped around the pipe within the stipulated time recommended by the manufacturer. Sleeve shall be positioned such that the closure patch is located to one side of the pipe in 10 or 2 O’clock position, with the edge of the undergoing layer facing upward and an overlap of min. 50mm. Gently heat by appropriate torch the backing and the adhesive of the closure and press it firmly into place.

4.2.5

A heat shrinking procedure shall be applied to shrink the sleeve in such a manner to start shrinkage of the sleeve beginning from the center of the sleeve and heat circumferentially around the pipe. Continue heating from the center towards one end of the sleeve until recovery is completed. In a similar manner, heat and shrink the remaining side. Shrinking has been completed when the adhesive begins to ooze at the sleeve edges all around the circumference. The complete shrinking of the entire sleeve shall be obtained without undue heating of existing pipe coating and providing due bonding between pipe, sleeve and pipe coating. The installed sleeve shall not be disturbed until the adhesive has solidified.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

4.3

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

Pre-Qualification of Field Joint Coating System The field joint coating system materials and the procedures proposed by the Contractor shall be pre-qualified during the sleeve installation start-up phase. Five joints (5) shall be coated with the requirements of this specification and then inspected and tested in accordance with the requirements of this specification with respect to the following : -

-

Surface preparation cleanliness, roughness profile and dust contamination Pre-heat temperature (as applicable) Primer thickness As applied coating thickness Holiday detection Peel test at (+) 23°C & (+) 60°C on pipe surface & factory applied coating and at over laps (as applicable). If required to achieve the temperature of (+) 60°C, suitable thermal blanket may be used. Visual appearance and void after installation on the body, area adjoining the weld and area adjoining the factory applied coating. (To establish voids adjoining the weld and factory coating a strip of 50mm wide and 200mm long shall be stripped and examined).

Company Representative shall witness the tests and inspection. Regular application of field joint coating shall commence only upon successful completion of the prequalification testing. After successful completion of the pre-qualification testing as above, the entire field joint coating shall be removed, the pipe surface re-blasted and field joint coating reapplied as per the requirements of this specification. 5.0

INSPECTION & TESTING

5.1

Visual Inspection Visual inspection of the as applied coating shall be carried out on every joint, for the following : -

Mastic extrusion on either ends of the sleeve shall be examined.

-

There shall be no sign of punctures or pinholes or bend failure. The external appearance of the sleeve shall be smooth, free of dimples, air entrapment or void formation. All sleeves shall be tested for the presence of voids by knocking on the sleeves. A hollow sound compared to the remainder of the sleeve may indicate the presence of voids under the sleeve. Such sleeve shall be tested for adhesion at the discretion of the Company Representative.

-

Weld bead profile shall be visible through the sleeve.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

5.2

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

Visual indicator provided on the backing and the closure patch showing desired heat is achieved.

Holiday Inspection The holiday detector used shall be checked and calibrated daily with an accurate DC voltmeter. The detector electrode shall be in direct contact with the surface of coating to be inspected. The entire surface of the joint section shall be inspected by means of a full circle holiday detector approved by COMPANY set to a DC voltage applicable as per the requirements of factory applied mainline coating specification of Company. Inspection of the sleeves shall be conducted only after the joint has cooled below 50°C. The holiday detector used shall be checked and calibrated daily with an accurate DC voltmeter. The detector electrode shall be in direct contact with the surface of coating to be inspected. No field joint shall be covered or lowered in the trench until it has been approved by the COMPANY.

5.3

As-applied Coating Thickness Coating thickness shall be checked by non-destructed methods for each field joint. Average thickness of the as-applied coating on pipe body shall be established based on measurement at min. eight locations i.e. four measurement on either sides of the girth weld at 3, 6, 9, & 12 O’clock positions. To establish the minimum thickness on the girth weld, four measurement shall be taken on apex on the weld at 3, 6, 9 & 12 O’clock positions. All such measurements shall be recorded. Company Representative reserves the right to ask for additional measurement at any location on the field joint coating, whenever doubt arises.

5.4

Peel Strength Testing

5.4.1

One out of every 50 joint coatings or one joint coating out of every day’s production whichever is stringent shall be tested to establish the peel strength on steel and factory applied coating. Contractor shall carry out such testing in the presence of Company Representative.

5.4.2

From each test sleeve selected as above, one or more strips of size 25mm x 200mm shall be cut perpendicular to the pipe axis and slowly peeled off. The required peel strength shall meet the requirements of this specification as applicable for (+) 23°C or (+) 60°C whichever is feasible. This test shall be conducted between wrapping & metal and mill coating & between layers at overlap with joint coating (wherever applicable). After removal of strip, the bulk of adhesive shall remain adhered to the pipe showing no bare metal, otherwise, test shall be

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

considered failed. The adhesive layer that remains on the pipe surface shall generally be free of voids resulting from air or gas inclusion. In case the peel strength test at a different temperature than that specified in warranted due to the ambient site conditions, then the peel strength shall comply the recommendation of the manufacturer. Manufacturer shall be asked to furnish peel strength values corresponding to various expected temperatures, prior to start of the works. 5.4.3

If the sleeve does not meet the requirements of clause 5.4.2 the adjacent two sleeves shall also be tested. If the adjacent two sleeves are acceptable the test rate shall be increased to one sleeve every twenty five until Company’s Representative is satisfied. The test rate can then be reduced as per clause 5.4.1. If either or both of the adjacent two sleeves do not meet the requirements of clause 5.4.2, the field joint shall be stopped.

5.4.4

Company Representative reserve the right of 100% removal of sleeves if he is not convinced that the requirements of clause 5.4.2 are achieved.

6.0

REPAIRS

6.1

If a field joint is detected to be unacceptable after testing as per section 5.0 of this specification the Contractor shall, at his own cost : -

-

Determine the cause of the faulty results of the field coating.

-

Mobilise the expert of manufacturer, if required.

-

Test to be complete satisfaction of the COMPANY, already completed field coatings. Stop field coating until remedial measures are taken against the causes of such faults, to the entire satisfaction of the Company.

6.2

CONTRACTOR shall replace all joint found or expected to be unacceptable as per section 5.0 of this specification.

6.3

CONTRACTOR shall, at his own cost repair all areas where the coating has been removed for testing by COMPANY.

6.4

After the coating work on welded joints, fittings and repairs to the coating have been completed the coating as a whole shall be tested with a spark-tester before lowering or jacking the pipeline.

6.5

COMPANY shall be entitled to check the coating on buried pipelines or parts of pipelines with equipment such as the "Pearson Meter" and the resistance meter. If the Coating defects are established, the Contractor shall be responsible for excavations at such points repair the coating, spark testing and back filling the excavations without extra charge.

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PADMALA – GODHARA GAS PIPELINE PROJECT Tender Document for EPC Contracts Gujarat State Petronet Ltd.

Tender Doc. No.: 05/51/23JT/GSPL/CP/001

MECON LIMITED

7.0

DOCUMENTATION

7.1

Prior to procurement of coating materials, Contractor shall furnish the following information for qualification of the manufacturer and material : i. ii. iii.

Complete information as per clause 5.2, DIN EN 12068 alongwith descriptive technical catalogues. Test certificates and results of previously conducted tests, for all properties listed in clause 3.2 of this specification. Reference list of previous supplies, in last 5 years, of the similar material indicating the project details such as diameter, quantity, operating temperature, year of supply, project name, contact person and feed back on performance.

Once the Company’s approval has been given, any change in material or Manufacturer shall be notified to Company, whose approval in writing of all changes shall be obtained before the materials are manufactured. 7.2

Prior to shipment of materials from the Manufacturer’s works. Contractor shall furnish the following documents : i. ii. iii.

7.3

Test certificates/ results as per Manufacturer’s Quality Control Procedure for each batch of materials. Specific application instructions with pictorial illustrations. Specific storage and handling instructions.

All documents shall be in English language only.

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SPECIFICATION FOR 3-LAYER POLYETHYLENE COATING OF LINEPIPES

SPECIFICATION NO. : MEC/S/05/62/014, Rev-2

MECON LIMITED DELHI - 110 092

\\Akjha\work contrac\standard TS for Pipe Line WC (Vol-II) MASTER FOLDER\14 3-layer pe coated line pipe\3-LPE Coating of Linepipes-TS-R2 14.doc

CONTENTS

1.0

SCOPE

2.0

REFERENCE DOCUMENTS

3.0

PLANT SCALE AND INSTALLATION

4.0

MATERIALS

5.0

FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING

6.0

MEASUREMENT AND LOGGING

7.0

COATING PROCEDURE AND QUALIFICATION

8.0

PIPE SURFACE PREPARATION

9.0

COATING APPLICATION

10.0

INSPECTION AND TESTING

11.0

HANDLING, TRANSPORTATION AND STORAGE

12.0

REPAIR OF COATING

13.0

MARKING

14.0

QUALITY ASSURANCE

ANNEXURE-I

:

COATING SYSTEM/ MATERIAL PRE-QUALIFICATION

\\Akjha\work contrac\standard TS for Pipe Line WC (Vol-II) MASTER FOLDER\14 3-layer pe coated line pipe\3-LPE Coating of Linepipes-TS-R2 14.doc

1.0

SCOPE This specification covers the minimum requirements for supply/ arrangement of all materials, plant, equipment, plant sites, consumables, utilities and application including all labour, supervision, inspection and tests etc. for application of external anti-corrosion coating of pipes by using 3 Layer Side Extruded Polyethylene Coating conforming to DIN-30670, 1991, `Polyethylene Coating of Steel Pipes and Fittings' and the requirements of this specification.

2.0

REFERENCE DOCUMENTS Reference has also been made to the latest edition of the following standards, codes and specifications. The edition enforce at the time of floating the enquiry shall be termed as latest edition. a.

ASTM D-149

:

Standard Test Methods of Dielectric Breakdown voltage and Dielectric strength of solid electrical insulating materials at commercial frequencies.

b.

ASTM D-257

:

Standard Test Methods for D-C Resistance or conductance of insulating materials.

c.

ASTM D-543

:

Standard Method of Test for Ressistance of Plastics to Chemical Reagents.

d.

ASTM D-570

:

Standard Method of Absorption of Plastics.

e.

ASTM D-638

:

Standard Test Method for Tensile Properties of Plastics.

f.

ASTM D-792

:

Standard Test Method of Specific Gravity and Density of Plastics by Displacement.

g.

ASTM D-1238

:

Test Method for Low Rate of Thermoplastics by Extrusion.

h.

ASTM D-1525

:

Test Method for Vicat Softening Temperature of Plastics

i.

ASTM D-1603

:

Test Method for Carbon Black in Olefin Plastics

j.

ASTM D-1693

:

Test Method for Environmental Stress Cracking of Ethylene Plastics

\\Akjha\work contrac\standard TS for Pipe Line WC (Vol-II) MASTER FOLDER\14 3-layer pe coated line pipe\3-LPE Coating of Linepipes-TS-R2 14.doc

Test

for

Water

Page 1 of 35

k. ASTM D-2240

:

Test Method for Rubber Property – Durometer Hardness

l.

:

Test Method for Oxidative – Induction Time of Polyolefins by Differential Scanning Calorimetry

ASTM D-3895

m.

ASTM G-42

:

Tentative Methods for Cathodic disbonding of Pipeline Coatings Subjected to Elevated or Cyclic Temperatures.

n.

API RP 5L1

:

Recommended Practice Transportation of Linepipe.

o.

API RP 5LW

:

Transportation of Line Pipe on barges and marine vessels

p.

DIN EN 10204

:

Metallic Products – Types of Inspection Documents

q.

DIN 53735

:

Testing of Plastics : Determination of Melt Index of Thermoplastics.

r.

ISO 8502-3

:

Preparation of Steel Stubstrates before Application of Paints and Related Products – Part-3 – Assessment of Dust on Steel Surfaces Prepared for Painting (Pressure Sensitive Tape Method)

s.

ISO 9002

:

Quality Systems : Specification of Production and Installation

t.

ISO 11124

:

Preparation of Steel Substrates Before Application of Paints and Related Products

u.

SIS 055900

:

Preparation of Steel Substrates before Application of Paints and Related Products – Visual Assessment of Surface Cleanliness.

v.

APL 5L

:

Specification for Line Pipe

w.

ASME B 31.8

:

Gas Transmission and Distribution Piping Systems

x.

ASME B 31.4

:

Liquid Transportation systems for Hydrocarbons, Liquid petroleum Gas Anhydrous ammonia, and Alcohols

\\Akjha\work contrac\standard TS for Pipe Line WC (Vol-II) MASTER FOLDER\14 3-layer pe coated line pipe\3-LPE Coating of Linepipes-TS-R2 14.doc

for

Railroad

Page 2 of 35

y.

CSA Z245.20-98

:

External Fusion Bond Epoxy Coating for Steel Pipe

The CONTRACTOR shall be familiar with the requirements of these documents and shall make them readily available at the coating plant to all persons concerned with carrying out the works specified in this specification. 3.0

PLANT SCALE AND INSTALLATION

3.1

CONTRACTOR shall size coating plant(s) after evaluating the scale of work and the time schedule required for the works. Coating plant(s), shall be installed into a yard whose geometry and dimensions are such as to allow the execution of a continuous work schedule. For this purpose the CONTRACTOR shall ensure non stop work execution owing to prohibitive adverse weather conditions and when required CONTRACTOR shall install requisite equipment and plant in roofed and adequately weather protected areas.

3.2

Plant equipment, machinery and other facilities shall be in first class operating condition to atleast meet the job requirements of quality and production. Worn out and improvised plants are not acceptable.

3.3

CONTRACTOR shall, at his own responsibility and cost, provide and prepare all necessary area for the storage of bare and coated pipe and all other materials, for coating yard, stock-piling and other temporary installation. For each area, CONTRACTOR shall provide to stipulate servitude agreements as required with the relevant Authorities, and, on work completion, to clean, restore and pay servitude and claims for damages, as applicable.

3.4

CONTRACTOR shall at its own responsibility and cost, provide for water and power supply and other utilities and consumables and obtain authorisation regarding access roads and other permits required for the execution of works conforming to all the requirements of the governing authorities.

3.5

CONTRACTOR shall at its own expense provide a fully equipped laboratory and test facilities with adequate inventory to carry out tests required for the procedure qualification and during regular production. Outside testing for qualification and regular production is not acceptable to COMPANY.

3.6

The CONTRACTOR shall be fully responsible for adherence to all statutory regulations applicable for handling and disposal of the hazardous chemicals during the coating works.

3.7

The CONTRACTOR shall be responsible for obtaining all statutory approvals/ clearances from relevant Authorities including Pollution Control Board, as applicable for the coating plant(s).

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Page 3 of 35

4.0

MATERIALS

4.1

The three layer coating system shall comprise of a powder epoxy primer, polythylene adhesive and a polyethylene top coat. Coating materials shall be suitable for the service conditions and the pipe sizes involved. The coating materials i.e. epoxy powder, adhesive and polyethylene compound shall have proven compatibility. The coating system and materials shall be pre-qualified and approval COMPANY in accordance with provision Annexure-I of this specification. CONTRACTOR shall obtain prior approval from COMPANY for the coating system and coating of all materials.

4.2

The coating materials Manufacturer shall carry out tests for all properties specified in para 5.3.1 and 5.3.2 for each batch of epoxy, adhesive and polyethylene compound. In addition, the Manufacturer shall also furnish Infra-red Scan for each batch of epoxy powder. The coating materials manufacturer shall issue test certificates as per DIN EN 10204, 3.1B for each batch of materials supplied to CONTRACTOR and the same shall be submitted to COMPANY for approval prior to their use.

4.3

In addition to Manufacturer’s certificate, the CONTRACTOR shall draw samples from each batch of epoxy, adhesive and polyethylene in the presence of COMPANY Representative and test for the following properties at the coating yard at least one week prior to its use, to establish compliance with the Manufacturer’s certificates. a)

Epoxy Powder i. ii. iii. iv.

b)

Adhesive i. ii. iii.

c)

Gel Time Cure Time Moisture Content Thermal Characteristics (Tgl, Tg2, ∆H)

Specific Gravity Melt Flow Rate Vicat Softening Point

Polyethylene i. ii. iii. iv. v.

Melt Flow Rate Specific Gravity Vicat Softening Point Moisture Content Oxidative Induction Time

In case of failure of any of the above tests in a batch, that batch of material shall be tested for all other tests required as per para 5.3.1 and 5.3.2 including the tests

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Page 4 of 35

which failed. If all tests pass, the batch shall be accepted for coating. If any of the tests fail, entire batch of material shall be rejected and shall not be used for the coating. 4.4

All materials to be used shall be supplied in sealed, damage free containers and shall be suitably marked and identifiable with the following minimum information: a. b. c. d. e. f.

Name of the manufacturer Type of material Batch Number Place and Date of Manufacture Shelf Life/ Expiry Date (if applicable) Quantity

All materials noted to be without above identification shall be deemed/ suspect and shall be rejected by COMPANY. Such materials shall not be used for coating and shall be removed from site and replaced by CONTRACTOR at its expense. 4.6

CONTRACTOR shall ensure that all coating materials properly stored in accordance with the Manufacturer’s recommendation at all times, to prevent damage and deterioration in quality prior to use.

4.7

CONTRACTOR shall be required to use all materials on a date received rotation basis, i.e. first in-first used basis.

5.0

FUNCTIONAL REQUIREMENTS AND PROPERTIES COATING

5.1

The coating must be able to withstand a maximum in service operating temperature of +65°C and shall conform to `S’ Type of coating as per DIN 30670. In addition, in open storage the coating must be able to withstand a temperature of atleast +80°C, without impairing its serviceability and properties specified.

5.2

The top coat polyethylene used shall be black readymade compound, fully stabilized against influence of ultraviolet radiation (.e. sunlight), oxygen in air and heat (due to environmental temperature as specified above). No appreciable changes shall occur during exposure to such environments up to at least a period of 6000 hours. The CONTRACTOR shall submit certificate from Manufacturer in this regard.

5.3

Properties Properties of coating system and coating material shall comply the requirements indicated in subsequent paragraph. In case the coating/ material properties are tested as per test methods/ standards other than specified herein below, the same may be accepted provided the test procedures and test conditions are same or more stringent than the specified.

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Page 5 of 35

5.3.1

Properties of Epoxy Powder and Adhesive CONTRACTOR shall choose such a brand of epoxy powder and adhesive that will achieve the functional requirements and properties of coating system as specified in para 5.1 and 5.3.3 of this specification respectively. Epoxy powder properties shall be as per CSA Z245.20.98. The colour of epoxy powder shall be either green or dark red or any other colour approved by COMPANY except grey colour. Copoymer grafted adhesive shall have the following properties. Sl. No. a. b. c.

5.3.2

Properties

Unit

Requirement

Test Method

Melt Flow Rate (190°C / 2.16 kg) Vicat Softening Point Specific Gravity

g/10 minutes °C -

1.0 90 min. 0.926 min.

ASTM D1238 ASTM D1525 ASTM D792

Properties of Polyethylene Compound Sl. No.

Properties

Units

Requirement

Test Method

a.

Tensile Strength @+25°C

N/mm2

17 min.

ASTM D 638

b.

Melt Flow Rate

g/10 minute

0.25 min.

ASTM D 1238 or DIN 53735

-

0.941 min. (HDPE)

ASTM D 792

Shore D

50 min.

ASTM D 2240

%

0.05 max

ASTM D 570

Ohm-cm

1015 min

ASTM D 257

Volts/ mm

30,000 min

ASTM D 149

(190°C / 2.16 kg) c.

Specific Gravity @+25°C

d.

Hardness @+25°C

e.

Water Absorption, 24 hours, @+25°C

f.

Volume Resistivity @+25°C

g.

Dielectric withstand,1000 Volt/sec rise @+25°C

h.

Vicat Softening Point

°C

110 min.

ASTM D 1525

i.

Elongation

%

600 min.

ASTM D 638

j.

Oxidative Induction Time in Oxygen at 220°C, Aluminium pan, no screen

Min

10

ASTM D3895

j.

Environmental Stress Crack Resistance (ESCR) (for F50) Medium Density, Condition “C” High Density, Condition “B” Carbon Black Content

Hours

l.

%

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ASTM D1693 300 300 2 min.

ASTM D1603

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5.3.3 Sl. No. a.

b.

c.

d.

Properties of Coating System Properties Bond Strength (using Type 2 Test Assembly i.e. Dynamometer) @ 20±5°C @ 60±5°C Impact Strength (min. of 30 impacts on body along the length. No breakdown allowed when tested at 25 kV) Indentation Hardness

Unit

Requirement

Kg/cm 8.0 min 5.0 min. 7 min

Joules per mm of coating thickness mm

DIN 30670 0.2 max

@ 70±2°C

0.3 max

Elongation at Failure Coating Resistivity (*)

f.

%

DIN 30670

DIN 30670

@ 23±2°C

e.

Test Method

300 min. 2

8

DIN 30670

Ohm-m

10 min.

DIN 30670

Heat Ageing (*)

-

Melt flow rate shall not deviate by more than 35% of original value

DIN 30670

g.

Light Ageing (*)

-

Melt flow rate shall not deviate by more than 35% of original value

DIN 30670

h.

Cathodic Disbondment @+65°C after 30 days

mm radius of disbondment

15 max.

(**)

7 max.

@+65°C after 48 hrs i.

ASTM G42

Degree of Cure of Epoxy Percentage Cure, ∆H

%

95

∆Tg

°C

+3/ -2

CSA Z245.2098(*)

(*)

Test carried out in an independent laboratory of national/ international recognition on PE top coat is also acceptable. (**) Disbondment shall be equivalent circle radius of total unsealed area as per ASTM G42. (***) Temperature to which the test specimens are to be heated during cyclic heating shall however be as per the recommendations of epoxy powder manufacturer. 6.0

MEASUREMENT AND LOGGING CONTRACTOR shall maintain records in computer using MS ACCESS database Software containing all the relevant data of individual pipe and pipe coating including heat number, diameter, length, wall thickness, defects, pipe number, batches of materials, materials balance, sampling, testing, damages, repairs, rejects and any other information that COMPANY considers to be relevant and required for all incoming bare pipes and COMPANY approved outgoing coated

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pipes as applicable. CONTRACTOR shall submit this information in the form of a report at the agreed intervals. The above data shall also be provided in MS EXCEL/MS ACCESS formant in Compact Disc (CD). CONTRACTOR shall provide a Computer Terminal to COMPANY Representative for monitoring/tracking of the above. The CONTRACTOR shall also submit the material balance details to COMPANY for information at the end of shift. 7.0

COATING PROCEDURE AND QUALIFICATION

7.1

Upon the award of the CONTRACT, the CONTRACTOR shall submit within two(2) weeks for COMPANY approval, a detailed report in the form of bound manual outlining, but not limited to the following: a. b.

c. d. e. f g

Details of plant(s), locations, layout, capacity and production rate(s). Details of the equipment available to carry out the coating works including surface preparation, epoxy powder application and its recycling system, adhesive & polyethylene extrusion, moisture control facilities available for coating materials. Details of process control and inspection equipment required for the coating process such as temperature control, thickness control, holiday testers, etc. Details of chemicals pre-treatment facilities including process control and inspection equipment for phosphoric acid wash, de-ionised-ionised water wash and chromate wash. Facilities in the yard for unloading, handling, transport, production, storage, stockpiling, loading of bare and coated pipes and warehouses for storage of other coating materials. Plant Organogram Chart and availability of manpower including coating specialist. Details of utilities/facilities such as water, power, fuel, access roads and communication etc.

After approval has been given by COMPANY, no change in plant set-up shall be made. However, unavoidable changes shall be executed only after obtaining written approval from COMPANY. 7.2

At least four(4) weeks prior to the commencement of production coating, a detailed procedure of CONTRACTOR's methods, material proposed, etc., shall be formulated by CONTRACTOR and submitted for COMPANY's approval in the form of a bound manual. The procedure shall include, but not limited to the following information and proposals: a. b. c.

Pipe inspection at the time of bare pipe receipt. Steel surface preparation, including preheating, removal of steel defects, method of pipe cleaning, dust removal, abrasive blast cleaning and surface profile, methods of measurements and consumables. Complete details of chemical pre-treatment viz phosphoric acid wash, deionised water wash, and chromate wash including product data sheets,

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d. e. f. g. h. i. j. k. l. m. n. o. p. q. r.

health and safety sheets and manufacturer’s recommended application procedure. Pipe heating, temperatures and control prior to epoxy application. Complete details of raw materials including current data sheets showing values for all the properties specified together with quality control and application procedure recommendation from manufacturer(s). Application of FBE powder, adhesive and polyethylene, including characteristics, temperature, line speed, application window, curing time, etc. Quenching and cooling, including time and temperature. Quality assurance system, Inspection and testing methods and reporting formats, including instrument and equipment types, makes and uses etc. Detailed method of repair of coating defects duly classified depending upon nature and magnitude of defects and repairs thereof including coating stripping technique. Details of instrument and equipment calibration methods including relevant standards and examples of calibration certificates. Complete details and inventory of laboratory and equipment for procedure qualification and regular production. Pipe handling and stock piling procedures. Sample of recording and reporting formats, including laboratory reports, certificates and requirement as per clause 6.0 of this specification. Complete details of test certificates for raw materials including test methods standards used. Test certificates from PE compound manufacturer for tests for thermal aging coating resistivity and aging under exposure to light. These test certificates shall not be older than three years. Health, safety and environment plans. Storage details of coating materials and chemicals. Continuous temperature monitoring at various stages of coating.

Procedure Qualification Tests (PQT) shall be carried out only after obtaining written approval of the above procedure from COMPANY. No change in the procedure shall be made after approval has been given by the COMPANY. However, unavoidable changes shall be executed only after obtaining written approval from COMPANY. 7.3

Prior to start of production, CONTRACTOR shall, at his expense, carry out a coating procedure qualification trial for each pipe diameter, and for each plant, to prove that his plant, materials, and coating procedures result in a quality of end product conforming to the properties stated in clause 5.3, relevant standards, specifications and material manufacturer’s recommendations. CONTRACTOR shall give seven(7) working days notice to witness procedures and tests. A batch representing a normal production run, typically 15 pipes, shall be coated in accordance with the approval coating procedure and the coating operations witnessed by COMPANY Representative. Out of these pipes, at least one pipe

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shall be coated partly with epoxy and partly with both epoxy and adhesive layers. Atleast 5 (five) test pipes shall be selected by Company Representative for coating procedure approval tests and shall be subjected to procedure qualification testing as described hereinafter. All tests shall be witnessed by COMPANY’s representative. Out of 5(five) test pipes 1(one) pipe shall be coated partly with epoxy and partly with both epoxy and adhesive layers. Remaining 4(four) test pipes shall be coated with all three layers. During PQT, the CONTRACTOR shall qualify various procedures forming a part of coating operations as detailed subsequently. 7.4

Qualification of Procedures

7.4.1

Epoxy Powder Application & Recycling During pre-qualification, air pressure in the epoxy spray guns, satisfactory functioning of monitoring system, line speed vs coating thickness, etc. shall be established. Dew point of air used to supply the fluidised bed, epoxy spray system and epoxy recycling system shall be recorded during the PQT. Also, the CONTRACTOR shall remove samples of reclaimed powder from the reclamation system. These of reclaimed powder shall be subject to a detailed visual examination, thermal analysis and moisture content tests. The properties of the reclaimed powder shall be within the range specified by the Manufacturer of epoxy powder. In case the properties of the reclaimed powder are out of the range specified by the Manufacturer, CONTRACTOR shall not the use the reclaimed powder during the regular production.

7.4.2

Pipe Pre-Heating The CONTRACTOR shall establish the temperature variation due to in-coming pipe temperature, line speed variation, wall thickness variation, emissivity, interruptions, etc. and document the same during the PQT stage. During PQT, proper functioning of pipe temperature monitoring and recording system including alarm/ hooter shall be demonstrated to the COMPANY Representative.

7.4.3

Surface Preparation The procedure to clean and prepare the pipe surface shall be in accordance with the requirements of this specification. The ratio to shots to grits shall be established during procedure qualification testing, such that the resultant surface profile is not dished and rounded. The qualification shall be performed through a visual inspection, measurement of roughness and check of the presence of dust in the abrasive blast cleaned pipe surface.

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7.4.4

Chemical Pre-Treatment

7.4.4.1

Phosphoric Acid Wash followed by De-ionised Water Wash The procedure to apply the chemical pre-treatment viz. phosphoric acid wash followed by de-ionised water wash shall be in accordance with the recommendation of the manufacturer and shall result in intended cleaning requirements of this specification. Working solution preparation, maintaining concentration, application procedure including method of spreading, spreading rate, drying times, etc. depending upon the cleanliness/ temperature of the incoming pipe and the line speed shall be established. Temperature of the chemical, pipe pre-heat temperature vs line speed vs dwell time, rinsing procedure, testing & control, rectificatory measures, drying procedure etc. shall be clearly established during PQT. Also the quality of the deionised water shall be established during PQT.

7.4.4.2

Chromate Treatment The procedure to apply the chromate treatment shall be in accordance with the recommendation of the manufacturer. Working solution preparation, maintaining concentration, application procedure including method of spreading, spreading rate, drying times, etc. depending upon the temperature of the incoming pipe and the line speed shall be established. Temperature of the chemical, pipe preheat temperature vs line speed, pipe heating after chromating and time limit within which the pipe to be heated, testing & control, rectificatory measures, shall be clearly established during PQT.

7.4.5

Coating Application The COMPANY Representative will check the correctness of each coating application operation, values of the main parameters of each operation, preheating pipe surface temperature prior to epoxy powder application temperature, line speed, fusion bonded epoxy curing time, temperature and flow rate of copolymer adhesive and polyethylene etc. and the same shall be recorded. These values shall be complied with during regular production.

7.5

Qualification of Applied Coating

7.5.1

Tests on pipe coated partly with epoxy and partly with epoxy & adhesive Layers a.

Degree of Cure Epoxy film samples (min 4 Nos.) shall be scrapped from the coated pipe using hammer and cold chisel and the samples shall be taken for cure test using Differential Scanning Calorimatry (DSC) procedure. Care shall be taken to remove the samples of full film thickness avoiding inclusion of

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steel debris. Glass transition temperature differential (∆Tg) and % cure (∆H) shall comply the specified requirements. b.

Epoxy Layer Thickness Epoxy layer thickness shall be checked at every one meter spacing at 3, 6, 9 and 12 o’clock positions. The thickness shall comply the specified thickness requirements.

c.

Adhesive Layer Thickness Adhesive layer thickness shall be checked at every one meter spacing at 3, 6, 9 and 12 o’clock positions. The thickness shall comply the specified thickness requirements.

d.

Holiday Inspection Entire pipe shall be subject to holiday inspection and the test voltage shall be set to exceed 5 v/micron of epoxy thickness specified for the portion coated only with epoxy layer.

e.

Adhesion Test i) ii)

f.

Adhesion Test (24 hrs or 48 hrs) shall be carried out on the epoxy coated pipe. Test method, no. of test specimen and acceptance criteria shall comply CSA Z.245,20-98, Table 4. Adhesion of FBE shall also be separately determined at ambient temperature at two locations by the “St Andrews Cross” method and the test shall comply with the specified requirements.

2.5° Flexibility Test 2.5° Flexibility test shall be carried out on the epoxy coated pipe at test temperature of 0°C. Test method, no. of test specimen and acceptance criteria shall comply CSA Z.245,20-98, Table-4.

g.

Cross-section & Interface Porosity Test Cross section porosity and interface porosity tests shall be carried out on the epoxy coated pipe. Test method, no. of test specimen and acceptance criteria shall comply CSA Z.245,20-98, Table-4.

7.5.2

Tests on pipes coated only with all three layers a.

Bond Strength Three test pipes shall be selected for bond strength tests. On each of the selected pipes, three bond strength test shall be performed for each

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specified temperature i.e. one at each end and one in the middle of the pipe and specified requirements shall be complied with, i.e. bond strength as well as mode of separation. Length of peel shall be minimum 65mm. None of these samples shall fail. b.

Impact Strength Three test pipes shall be selected for impact strength test and the test shall meet the requirement.

c.

Indentation Hardness Two samples for both the temperatures from all pipes shall be taken. If any one of these samples fail to satisfy the requirements, then the test shall be repeated on four more samples. In this case, none of the samples must fail.

d.

Elongation at Failure Six samples each from two coated pipes i.e. 18 samples in all shall be tested and the test shall comply the specified requirement. Only one sample per pipe may fail.

e.

Cathodic Disbondment Test Two CD test shall be carried out for the total lot of test pipes having all three layers. One test shall be carried out for 30 days duration and another test for 45 hours duration The tests shall comply the specified requirement. Whenever Procedure Qualification is necessitated for different pipe size with same coating material combination, 48 hours test only be conducted. 30 days CD test is not mandatory in this case.

f.

Holiday Inspection All the pipes shall be subject to holiday inspection. The test voltage shall be as specified in para 10.4(b)

g.

Coating Thickness Measurement All pipes shall be subject to coating thickness measurement. Acceptance criteria shall be as per para 10.3

h.

Air Entrapment One sample each from pipe body and on weld (if applicable) shall be taken from all four coated pipes and the specified requirements shall be complied with.

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i.

Degree of Cure Epoxy film samples (minimum 4 no., equally spaced) shall be scrapped from one coated pipe and the samples shall be taken for cure test using Differential Scanning Calorimetry (DSC) procedure. Care shall be taken to remove the samples of full film thickness avoiding inclusion of steel debris. Glass transition temperature differential (∆Tg) and % cure (∆H) shall comply with the specified requirements.

7.5.3

Inspection of all test pipes All pipes shall be subject to the following inspections: a. b. c. d.

surface cleanliness, surface roughness measurements and dust control immediately after second abrasive blast cleaning and salt test immediately after De-ionised water wash. pH of pipe surface before and after phosphoric acid wash. visual inspection of chromate coating. visual inspection of finished coating, cut back dimension, internal/ external cleanliness, end sealing and bevel inspection.

Acceptance criteria for all inspection and testing shall be as specified in this specification. 7.6

After completion of the qualification tests and inspection as per para 7.4 and 7.5 above, the CONTRACTOR shall prepare and issue to COMPANY for approval a detailed report of the above tests and inspection including test reports/ certificates of all materials and coatings tested. Only upon written approval from COMPANY, CONTRACTOR shall commence production coating.

7.7

On successful completion of PQT, coating of all five(5) test pipes shall be removed and completely recycled as per the approval coating procedure specification, at CONTRACTOR’s expense. Remaining pipes will be accepted by COMPANY provided they meet the requirements of this specification and need not be stripped and re-cycled.

7.8

The CONTRACTOR shall re-establish the requirements of qualification and in a manner as stated before or to the extent considered necessary by COMPANY, in the event of, but not limited to, the following : • • • •

Every time there is a change in the previously qualified procedure. Every time there is a change in the manufacturer and change in formulation of any of the raw materials and change in location of raw material manufacture. Every time the coating yard is shifted from one location to the other or every time the critical coating equipments (induction heater, epoxy spray system, extruder, etc) are shifted. Any change in line speed during coating application.

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•

Any time when in COMPANY’s opinion the properties are deemed to be suspect during regular production tests.

7.9

COMPANY reserves the right to conduct any or all the test required for qualification through an independent laboratory or agency at the cost of CONTRACTOR when in COMPANY’s opinion, the results are deemed suspect. COMPANY’s decision shall be final.

8.0

PIPE SURFACE PREPARATION

8.1

Unless specified otherwise, the pipes shall be supplied free from mill applied oils but may be subject to contamination occurring during transit.

8.2

Prior to cleaning operation, CONTRACTOR shall visually examine the pipes and shall ensure that all defects, flats and other damages have been repaired or removed. The CONTRACTOR shall also remove marking stickers, if any, present within the pipe. Record shall be kept of such marking on the stickers of ensure traceability of pipe after coating.

8.3

Any oil, grease, salt or other contaminants detrimental to the formation of a good coating bond or coating quality shall be removed prior to coating application. Contaminants may be removed by the use of non-oily solvents. Gasoline or kerosene shall not be used for this purpose. Visible oil and grease spots shall be removed by solvent wiping. Solvents cleaning shall be in accordance with SSPC-SP1. Steel surface shall be allowed to dry before abrasive cleaning.

8.4

All pipes shall be preheated to a temperature 65°C to 85°C prior to abrasive blast cleaning. The external surface of the pipe shall be cleaned using 2 no. dry abrasive blasting cleaning units to achieve the specified surface cleanliness and profile. After first abrasive blast cleaning, chemical pre-treatment with phosphoric acid solution as per para 8.6 shall be carried out prior to second abrasive blast cleaning. However at the option of CONTRACTOR, chemical pretreatment with phosphoric acid solution as per para 8.6 may be carried out after the second abrasive blaster. The abrasive blast cleaning units shall have an effective dust collection system to ensure total removal of dust generated during blast cleaning from the pipe surface. The equipment used for abrasive blast cleaning shall meet the specified requirements and shall be free from oil, water soluble salts and other forms of contamination to ensure that the cleaning process is not impaired. Traps, separators and filters shall be checked for condensed water and oil at the start of each shift and emptied and cleaned regularly. During abrasive blast cleaning the metallic abrasive shall be continuously sieved to remove “fines” and “contaminates” and the quality checked at every four hours. Abrasive used for blast cleaning shall comply ISO- 11124.

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8.5

Suitable plugs shall be provided at both pipe ends to prevent entry of any shot/grit into pipe during blast cleaning operations. These plugs shall be removed after blast cleaning. Alternatively the CONTRACTOR may link pipes suitably together to prevent the entry of any short/grit into the pipe.

8.6

Chemical Pre-treatment with Phosphoric Acid Solution

8.6.1

All pipes shall provided chemical pre-treatment with phosphoric acid solution. 10% solution of phosphoric acid, Oakite 31 / 33 or equivalent, shall be used to remove all soluble salts and other soluble contaminations. The CONTRACTOR shall provide data sheets and supporting documentation for the phosphoric acid to be used. The documentation shall verify that the phosphoric acid is suitable for the treatment of line prior to the application of the specific fusion bonded epoxy powder being applied and the final wil meet fully the requirements of this specification.

8.6.2

The pipe temperature immediately prior to the phosphoric acid treatment shall be in the range of 45 to 75 °C. Phosphoric acid treatment shall be followed immediately by washing with de-ionised water. Deionised water used shall conform to the following requirements : Sl. No. a. b. c. d. e. f. g.

Properties Turbidity Conductivity Hardness Total Alkalinity as CaCO3 Chloride as Cl Sulphate as SO4= PH

Unit

Requirement

NTU µmho/cm mg/l mg/l mg/l -

1 max. 5 max. Nil 2 to 3 1 max. 1 max. 6.5 to 7.5

Tests to determine the above properties shall be carried out in accordance with “Standard Methods for the Examination of Water and Wastewater” published jointly by American Public Health Association, American Water Works Association and Water Pollution Control Federation. Quality of the deionised water shall be monitored at the start of each shift and at every four hours interval. Non-compliance of deionised water wrt the above requirements shall cause for stoppage of the operations. 8.6.3

The pH of the pipe surface shall be determined both before and after the deionised water rinse initially on each pipe and in case of consistent results, the frequency may be relaxed to once per hour at the discretion of COMPANY Representative. The measured pH shall be as follows : Before de-ionised water wash After de-ionised water wash

: :

1 to 2 6 to 7

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8.6.4

After the de-ionised water wash, the pipe shall be dried with dry air and preheated to a temperature of 65°C to 85°C.

8.6.5

The salt tests shall be carried out after de-ionised water rinse. One test shall be carried out at one end of each pipe. The acceptance criteria shall be 2µg/cm2. An approved salt meter (SCM 400 or equivalent) shall be used to carry out salt tests and shall be calibrated in accordance with the equipment manufacturer’s recommendation.

8.7

Abrasive cleaning carried out shall be such that the resultant surface profile is not dished and rounded when viewed with 30X magnification. The standard of finish for cleaned pipe shall conform to near white metal finish to Sa 2½ of Swedish Standard SIS 055900 latest edition. Surface of pipe after abrasive blast cleaning shall have an anchor pattern of 50 to 70 microns(Rz). This shall be measured for each pipe by a suitable instrument such as surface profile depth gauge. In addition the pipe surface after blast cleaning shall be checked for the degree of cleanliness (Sa 2½), degree of dust and shape of profile. Degree of dust shall comply the requirements of ISO:8502 – 3. Acceptance limit shall be either quality rating 2 or Class 2.

8.8

All pipes shall be visually examined for presence of any shot/ grit/ loose material left inside the pipe during blast cleaning. Suitable mechanical means (stiff brush) shall be employed to remove the same before the pipes are processed further. In addition, inside surface of the pipe shall also be visually inspected for presence of any foreign material or shots and grit (free or embedded/ sticking to pipe inside surface). The pipe inside surface shall be examined using sharp floodlight focused at the middle of the pipe at one end while inspection is carried out visually from other end. Any foreign material or shots/ grit present in the pipe shall be completely removed by mechanical/ brush, high pressure air jets, by tilting of pipe etc.

8.9

At no time shall the blast cleaning be performed when the relative humidity exceeds 85%. The CONTRACTOR shall measure the ambient conditions at regular intervals during blast cleaning and coating operations and keep records of prevailing temperature, humidity and dew point.

8.10

The blast cleaned surface shall not be contaminated with dirt, dust, metal particles, oil, water or any other foreign material, nor shall be surface or its anchor pattern be scarred or burnished. All blast cleaned pipe surface shall be kept in dust free enclosure prior to coating. After blast cleaning, all surfaces shall be thoroughly inspected under adequate lighting to determine anchor pattern, quality of blasting and identify any surface defects prior to coating application. All surface defects such as slivers, scab, burns, laminations, welds spatters, gouges, scores, indentations, slugs or any other defects considered injurious to the coating integrity made visible during blast cleaning shall be reported to the COMPANY Representative and on permission from COMPANY Representative, such defects shall be removed by filing or grinding. After any grinding or

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mechanical repairs, the remaining wall thickness shall be checked and compared with specified thickness. Ay pipes having thickness less than 95% of specified thickness shall be kept aside and disposed off as per the instructions of COMPANY Representative. The method employed to remove surface defects shall not burnish or destroy then anchor pattern or contaminate the surface. Pneumatic tools shall not be used unless they are fitted with effective air/ oil and water traps. Where burnishing results in destruction of anchor pattern, the anchor patter shall be restored by suitable means. Pipes which have damages repaired by grinding and have ground areas more than 50mm in diameter shall be recycling-blasted. Any dust or loose residues that have been accumulated during blasting and/ or during filing/ grinding operations shall be removed by vacuum cleaning. If contamination of surface occurs, the quality of blast cleaning method and process shall be examined. If the surface roughness is outside the specified limit, the blast cleaning material shall be checked and replaced. 8.11

Upon Completion of the blasting operations, the quality control supervisor shall accept the pipe for further processing or return for re-blasting after removal of defects/ imperfections. In case imperfections are considered detrimental to the coating quality, the same shall be reported to COMPANY’s Representative for final decision on rejection or re-blasting/ removal of defects. Re-blasting/ removal of defects or returning pipe to the yard shall be at the CONTRACTOR’s cost. COMPANY’s Representative, in additions, reserves the right to initiate any of the above actions during periodic inspections for oil, dust, salt, imperfections, surface defects, lack of white metal finish etc.

8.12

In order to ensure that pipe with defects are not processed further, provisions shall be available to lift the pipes from inspection stand.

8.13

Chemical Pre-treatment with Chromate Solution

8.13.1

Following completion of abrasive blast cleaning, all pipe surface shall be chemically Pre-treated with a 10% strength chromate solution.

8.13.2

The CONTRACTOR shall provide data sheets and supporting documentation for the chemical to be used. The documentation shall verify that the chemical is suitable for the treatment of line pipe prior to the application of the specific fusion bonded epoxy powder being applied and the final coating will meet fully the requirements of this specification.

8.13.3

The chemical pre-treatment shall be applied fully in accordance with the chemical suppliers’ instructions and in a manner that ensures 100% uniform coverage of the pipe surface without introducing surface contamination.

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8.13.4

The CONTRACTOR shall check that the concentration for the chemical pretreatment solution remains within the range recommended by the chemical manufacturer for the pipe coating process. The concentration shall be checked at the make up of each fresh solution and once per hour, using a method approved by the chemical manufacturer. The CONTRACTOR shall also ensure that the chemical pre-treatment solution remains free from contamination at all times. Recycling of chemical pre-treatment solution is not permitted.

8.13.5

The CONTRACTOR shall ensure that the temperature of the substrate is maintained between 40°C and 80°C and the chromate solution temperature does not exceed 60° or as recommended by the manufacturer.

8.13.6

The chromate coating shall be smooth, even, free from runs, drips or excessive application and lightly adherent with no flaking of the coating. The chromate coated steel must be thoroughly dried immediately after application and shall be achieved by boiling off any residual solution on the surface.

8.14

The total allowable elapsed time between completion of the blasting operations and commencement of the pre-coating and heating operations shall be such that no detectable oxidation of the surface occurs. Relative humidity readings shall be recorded every half on hour during the blasting operations in the immediate vicinity of the operations. The maximum elapsed time shall not exceed the duration given below : Relative Humidity % > 80 70 to 80 < 70

Maximum elapsed time 2 hours 3 hours 4 hours

Any pipe not processed within the above time-humidity requirement shall be completely re-blasted. Any pipe showing flash rusting shall be re-blasted even if the above conditions have not been exceeded. 8.15

Pipe handling between abrasive blasting and pipe coating shall not damage the surface profile achieved during blasting. Any pipe affected by the damage to the surface exceeding 200mm2 in area/ or having contamination of steel surface shall be rejected and sent for re-blasting.

9.0

COATING APPLICATION The external surface of the cleaned pipe conforming to clause 8.0 of this specification shall be immediately coated with 3-layer extruded polyethylene coating in accordance with the procedures approved by COMPANY, relevant standards and this specification. In general, the procedure shall be as follows :

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9.1

Pipe Heating

9.1.1

Immediately prior to heating of pipe, all dust and grit shall be removed from both inside and outside of the pipe by a combination of air blast, brushing and vacuum cleaning. Suitable arrangement shall be made to protect the bevel ends from getting damaged during the coating operation.

9.1.2

Induction heater or gas furnace shall be used for heating the pipe. The method shall be capable of maintaining uniform temperature along the total length of the pipe, and shall be such that it shall not contaminate the surface to be coated. In case of induction heating, appropriate frequency shall be used to ensure `deep heating’ and intense skin heating is avoided. Gas fired heating system shall be well adjusted so that no combustion products are deposited on the steel surface. This shall be demonstrated on bare pipes prior to start of PQT. Oxidation of the cleaned pipe surfaces prior to coating (in the form of bluing or other apparent oxide formation) is not acceptable.

9.1.3

External surface of the pipe shall be heated to about 190°C or within a temperature range (min. to max.) as recommended by the powder manufacturer. Required pipe temperature shall be maintained as it enters the coating chamber.

9.1.4

Temperature of the pipe surface shall be continuously monitored & recorded by using suitable instruments such as infrared sensors, contact thermometers, thermocouples etc. The recording method shall allow to correlate each line pipe. The monitoring instrument shall be able to raise an alarm/ activate audio system (hooter) in the event of tripping of induction heater/ gas fired heater or in the event of pipe temperature being outside the range recommended by the manufacturer. Any deviation from the application temperature range recommended by manufacturer shall be rectified. If immediate rectification is not feasible, the production shall be stopped until cause of deviation has been removed. Any pipe coated during the duration of temperature deviation shall be identified by marking and rejected. Such rejected pipes shall be stripped and recoated.

9.1.5

Temperature measuring & monitoring equipment shall be calibrated twice every shift and/ or as per COMPANY representative’s instruction.

9.1.6

Contractor shall ensure that pipe surface emissivity variations are minimised during pipe heating. To avoid significant variance, more than once blasted joints should be coated at the same time and not mixed with joints blasted only once.

9.2

Pipe Coating

9.2 .1

Subsequent to pipe heating, coating consisting of following layers shall be applied onto the pipe.

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i. ii. iii.

Electrostatic application of epoxy powder of minimum dry film thickness 0.150 mm, unless otherwise specified. The maximum thickness shall not exceed the epoxy thickness specified by epoxy powder manufacturer. Grafted co-polymer adhesive applied by extrusion, minimum thickness 0.200 mm. Polyethylene coating by extrusion.

The coated pipe shall be subsequently quenched and cooled in water for a period which shall sufficiently lower the temperature of pipe coating to permit handling and inspection. 9.2.2

Minimum total thickness of finished coating shall be as under : Pipe Size Specified outside diameter (mm) Upto 10¾” (273.1) Over 10¾” (273.1) to below 20” (508.0) From 20” (508.0) to below 32” (813.0) (*)

Min. Coating Thickness (mm)(*) Normal Type (n) 1.8 2.0 2.25

HDPE material is to be used as top coat.

Required coating thickness shall be normal type (n), unless otherwise specified. 9.2.3

Coating materials shall be inspected in accordance with the manufacturer’s recommendation prior to coating application and it shall be ensured that the materials are moisture free. In case the relative humidity exceeds 80%, the adhesive and polyethylene material shall be dried using hot air as per the directions of COMPANY representative.

9.2.4

Prior to starting the application of fusion bonded epoxy powder, the recovery system shall be thoroughly cleaned to remove any unused powder remaining from a previous line pipe coating application. The use of recycled powder shall be permitted subjected to:

9.2.5

a)

satisfactory qualification of the reclaimed system during PQT stage

b)

the proportion of the reclaimed powder in the working mix does not exceed 20% at any one time.

c)

the quality of the recycled powder being routinely checked during production, at a minimum frequency of once per shift and consistently meets the requirements stated at para 5.3.1.

Dry air, free of oil and moisture shall be used in the coating chamber and spraying system and for this purpose filters, dehumidifier/ heater as required alongwith control & monitoring system shall be provided for this purpose. Dew point of air used to supply the fluidized bed, epoxy spray system and epoxy

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recycling system shall be at least (-) 40°C and this shall be shall monitored during the regular production. 9.2.6

Air pressure in the epoxy spray guns shall be controlled, continuously monitored and recorded by using suitable instruments. The air pressure shall be controlled within the limits established during coating procedure qualification. The monitoring system shall be able capable of raising an alarm/ activate audio system (hooter) in the event of change in air pressure beyond the set limits. Any deviation from the pre-set limits shall be rectified. If immediate rectification is not feasible, the production shall be stopped until cause of deviation has been removed. Any pipe coated during the duration of air pressure deviation shall be identified by suitable marking and rejected. Such rejected pipes shall be stripped and recoated.

9.2.7

Extruded adhesive layer shall be applied before gel time of the epoxy coating has elapsed. The application of the adhesive layer shall not be permitted after epoxy is fully cured. The CONTRACTOR shall establish, to the satisfaction of the COMPANY representative, that the adhesive is applied within the gel time window of epoxy and at the temperature recommended by the adhesive manufacturer. The CONTRACTOR shall state the minimum and maximum time interval between epoxy and adhesive application at the proposed pre-heat temperature and line speed.

9.2.8

Extruded polyethylene layer shall be applied over the adhesive layer within the time limit established during PQT stage and within the time/ temperature range recommended by the manufacturer. The extrusion temperatures of the adhesive and polyethylene shall be continuously recorded. The monitoring instruments shall be independent of the temperature control equipment. The instruments shall be calibrated prior to start of each shift.

9.2.9

CONTRACTOR shall ensure that there is no entrapment of air or void formation along the seam weld (where applicable) during application of coating. Air entrapment below the coating and also along the coating overlap shall be prevented by forcing the coating on to the pipe using high pressure roller of suitable design during coating application. In case it is not adequately achieved, CONTRACTOR shall supplement by other method to avoid air entrapment. The methods used shall be witnessed and approved by COMPANY.

9.2.10

Resultant coating shall have a uniform gloss and appearance and shall be free from air bubbles, wrinkles, holidays, irregularities, discontinuities, separation between layers of polyethylene & adhesive, etc.

9.2.11

Coating and/ or adhesive shall terminate 120mm (+)20/(-)0 mm from pipe ends. The adhesive shall seal the end of applied coating. CONTRACTOR shall adopt mechanical brushing for termination of the coating at pipe ends. Edge of the coating shall be shaped to form a bevel angle of 30° to 45°.

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9.2.12

Failure to comply with any of the above applicable requirement and of the approved procedure shall be cause for the rejection of the coating and such coating shall be removed in a manner approved by COMPANY at CONTRACTOR’s expense.

10.0

INSPECTION AND TESTING

10.1

General CONTRACTOR shall establish and maintain such quality assurance system as are necessary to ensure that goods or services supplied comply in all respects with the requirements of this specification. The minimum inspection and testing to be performed shall be as indicated subsequently herein.

10.2

Visual Inspection Immediately following the coated, each coated pipe shall be visually checked for imperfections and irregularities of the coating. The coating shall be of natural colour and gloss, smooth and uniform and shall be blemish free with no dust or other particulate inclusion. The coating shall not slow and defects such as blisters, pinholes, scratches, wrinkles, engravings, cuts swelling, disbonded zones, air inclusions, tears, voids or any other irregularities. Special attentions shall be paid to the areas adjacent to he longitudinal weld (if applicable), adjacent to the cut back at each of pipe and within the body of the pipe. In addition inside surface of the pipe shall also be visually inspected for presence of any foreign material or shots and grit (free or embedded/ sticking to pipe inside surface). The pipe inside surface shall be examined using sharp floodlight focussed at the middle of the pipe at line end while inspection is carried out visually form other end.

10.3

Coating Thickness a.

The coating thickness shall be determined by taking atleast 10 measurement at locations uniformly distributed over the length and periphery of each pipe. In case of weld pipes, five of the above readings shall be made at the apex of the weld seam, uniformly distributed over the length of the coated pipe. All the readings must meet the minimum requirements. However, localised coating thickness of less than the permissible minimum thickness can be tolerated on the condition that it does not attain a total extent of more than 5cm2 per meter length of coated pipe, and the actual coating thickness does not drop more than 10% below the permissible minimum coating thickness at these locations. The frequency of thickness measurement as stated above shall be initially on every pipe, which shall be further reduced depending upon consistency of results, at the sole discretion of COMPANY’s representative. Resultsof all measurement shall be recorded.

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10.4

10.5

b.

Thickness of epoxy and adhesive shall be measured at the beginning of each shift and whenever the plant re-starts after any stoppage for compliance. Coating of epoxy and adhesive on portion of pipe required for this purpose, stripping and recoating of such partly coated pipe shall be at CONTRACTOR’s expense.

c.

Coated pipes not meeting the above requirements shall be rejected. The CONTRACTOR shall remove the entire coating and the pipe shall be recycled to the cleaning and coating operations as per the approved procedure and shall be to CONTRACTOR’s expenses.

Holiday Detection a.

Each coated pipe length shall be checked over 100% of coated surface by means of a “holiday detector” of a type approved by COMPANY for detecting holidays in the finished coating.

b.

The holiday detector shall be a low pulse DC full circle electronic detector with audible alarm and precise voltage control with DIN VDE 0433 Part 2. The set voltage for inspection shall be 25 kV. Travel speed shall not exceed 300 mm/s.

c.

CONTRACTOR shall calibrate the holiday detector at least once every 4 hours of production. CONTRACTOR shall have necessary instruments or devices for calibrating the holiday detector.

d.

Any pipe coating shall be rejected if more than 1(one) holiday & area more than 100 cm2 in size are detected in its length attributable to coating process.

e.

Holidays which are lesser in number and size than those mentioned in (d) above, shall be repaired in accordance with a approved procedure and shall be to CONTRACTOR’s expense.

Bond Strength Test a.

CONTRACTOR shall conduct bond strength test for composite coating as per clause 5.3.3 (a) of this specification. A minimum of 65mm length shall be peeled. First 20mm and last 20mm shall not be counted for assessment of bond strength.

b.

The frequency of test for cut back portions shall be one pipe in every fifteen(15) pipes coated and for middle of pipe shall be one pipe in every sixty(60) pipes coated or one pipe per shift whichever is higher. On each selected pipe, bond strength shall be performed for each specified temperature. Test shall be performed at each cut back portion and one in the middle of pipe. The system shall disbond/ separate cohesively either in adhesive layer or in polyethylene layer. Majority of the peeled off

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area on the pipe shall show presence of adhesive. Disbondment/ separation at epoxy to steel interface or epoxy/ adhesive interface or adhesive/ polyethylene interface shall not be permitted. The failure mode shall be recorded for each test.

10.6

10.7

c.

In case the above tests do not comply with the above requirement, CONTRACTOR shall test all the preceding and succeeding coated pipes. If both pipes pass the test, then the remainder of the pipe joints in that shift shall be deemed satisfactory. If either pipe fails to meet the specified requirements, all pipes coated during the shift shall be tested until the coating is provided acceptable. Rejected coated pipes shall be stripped and re-coated in accordance with approved procedure, at CONTRACTOR’s expense.

d.

The frequency of bond strength test as per para 10.5(b) for cut back portion may be reduced depending upon the consistently of result to one pipe in every twenty five(25) instead of every fifteen pipes, at the sole discretion of the COMPANY Representative.

Impact Strength a.

Impact resistance test shall be conducted as per clause 5.3.3 (b) of this specification. Initially the frequency of test shall be 2(two) coated pipes per shift, which may be further reduced and/ or waived depending upon consistently acceptable results at the sole discretion of COMPANY’s representative.

b.

Minimum thirty(30) impacts located equidistant along the length of coated pipe shall be performed.

c.

Immediately after testing, the test area shall be subjected to holiday detection at the same voltage as used prior to impact strength test. The pipe shall be rejected if any holiday is noted in the test area.

d.

In case of test failure, retesting and disposal of coated pipe shall be as per 10.5(c) above.

Indentation Hardness a.

Indentation hardness test shall be as per clause 5.3.3 (c) of this specification. The frequency of test shall be initially 2(two) coated pipes per shift which shall be further reduced to one test each on 2 coated pipes per week at random after 1 week of consistently acceptable results. Two samples for each temperature shall be taken from the cut back portion of coated pipe and one in middle of the pipe for this test.

b.

In case of test failure, retesting and disposal of coated pipe shall be as per 10.5(c) above.

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10.8

10.9

Air Entrapment Test a.

Strips from bond strength tests or coated pipe may be used to help determine the porosity of the finished coating. Strip shall be also cut from longitudinal weld (if applicable) at cut back portion and examined for the presence of voids.

b.

Bond strength strip shall be viewed from the side and at the failure interface. At the pipe bond strength test location, utility knife shall be used to cut the edge of the coating to a 45° angle and view with a microscope. Similar examination shall be done in the coating cut back area.

c.

One sample each either on the bond strength strip or coated pipe and strip cut from the longitudinal weld (if applicable) shall be examined for air entrapment per shift. Strips shall be viewed from the side.

d.

All examination shall done using a 30X magnification hand-held microscope. The polyethylene and adhesive layers shall have no more than 10% of the observed area taken up with air entrapment (porosity or bubbles). Air entrapment shall not occupy more than 10% of the thickness in each case. Bubbles shall not link together to provide a moisture path to the epoxy layer.

e.

In case of test failure, retesting and disposal of coated pipe shall be as per 10.5(c) above.

Degree of Cure a.

Epoxy film samples shall be removed from cut back portion of the coated pipe using hammer and cold chisel and the samples shall be taken for cure test using DSC procedure. Care shall be taken to remove the samples of full film thickness avoiding inclusion of steel debris. Glass transition temperature differential (∆Tg) and % cure (∆H) shall comply the specified requirements.

b.

Frequency of this test shall be once per shift. Pipe shall be selected randomly by COMPANY Representative during the middle of a shift. Suitable provisions/ arrangements as per the instructions of COMPANY Representative shall be made by the CONTRACTOR for this purpose.

c.

In case of test failure, production carried out during the entire shift shall be rejected, unless the CONTRACTOR proposes a method to establish the compliance with the degree of cure requirements of all pipes coated during that shift.

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10.10

10.11

Epoxy Layer Adhesive Test a.

Adhesion of epoxy layer shall be determined at ambient temperature by the “St Andrews Cross” method i.e. by cutting two straight lines through the epoxy layer with a sharp knife. The incisions shall intersect at an angle of 30°/ 150°. The epoxy coating shall resist disbondment from the steel when attempts are made to flick/ lift the coating from the 30° angle with a sharp knife.

b.

Frequency of this test shall be once per shift. The test shall be carried out at the cut back portion of the pipe from which the Degree of Cure test has been carried out as per para 10.9 above.

c.

In case of test failure, retesting and disposal of coated pipe shall be as per 10.9(c) above.

Cathodic Disbondment Test a.

48 hours CD test shall be conducted as per clause 5.3.3. (h) of this specification.

b.

The frequency of this test shall be once in every two weeks or one test representing each batch of epoxy powder used, whichever is more frequent.

c.

In case the test fails to conform to the specified requirement, at the option of the CONTRACTOR, all pipes coated after the previous acceptable test and prior to next acceptable test shall be rejected or the test shall be repeated or the shall be repeated using two additional samples taken from the same end of the affected pipe. When both retests conform to the specified requirement, the lot of pipes shall be accepted. When one or both the retests fail to conform to the specified requirement, all coated pipes after previous acceptable test and prior to next acceptable shall be rejected. All rejected pipes shall be stripped, re-cleaned and re-coated. COMPANY may consider a further retest program to determine whether any of the affected pipe meet the criteria for acceptance upon written request by the CONTRACTOR.

10.12

Damages occurring to pipe coating during above tests shall be repaired in accordance with approved coating repair procedure.

10.13

Repairs occurring on account of the production test are however excluded from above mentioned limitations at para 10.4 (d) above.

10.14

COMPANY, reserves the right to perform inspection and witness tests on all activities concerning the pipe coating operations starting from bare pipe to finished coated pipe ready for dispatch and also testing of raw materials.

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CONTRACTOR shall give reasonable notice of time and shall provide without charge reasonable access and facilities required for inspection to the COMPANY’s Representative. Inspection and tests performed or witnessed by COMPANY’s Representative shall in no way relieve the CONTRACTORs obligation to perform the required inspection and tests. 10.15

In case rate of defective or rejected pipes and/ or samples tests are 10% or more for a single shift (typically 8 hours), CONTRACTOR shall be required to stop production and carry out a full and detailed investigation and shall submit findings to COMPANY for approval. CONTRACTOR shall recommence the production only after getting the written permission from COMPANY. Under no circumstances any action or omission of the COMPANY’s representative shall relieve the CONTRACTOR of his responsibility for material and quality of coating produced. No pipes shall be transported from the coating plants unless authorised by COMPANY in writing.

11.0

HANDLING, TRANSPORTATION AND STORAGE

11.1

The CONTRACTOR shall be fully responsible for the pipe and for the pipe identification marking from the time of “taking over” of bare pipe from COMPANY until such time that the coated line pipes are `handed over’ and/ or installed in the permanent installation as the case may be according to the provisions of the Contract. At the time of “taking over” of bare pipes CONTRACTOR shall inspect and record all the relevant details referred above including pipe defects in the presence of COMPANY. All pipes shall be checked for bevel damages, weld seam height, dents, gouges, corrosion and other damages. COMPANY Representative shall decide whether pipe defects/ damages are suitable for repair. Damage to the pipes which occur after the CONTRACTOR has taken delivery such as dents, flats, or damage to the weld ends shall be cut off or removed and pipes rebevelled and repaired again as necessary. The cost of this work, as well as that of the pipe lost in cutting and repair shall be to the CONTRACTOR’s account. All such works shall be carried out after written approval of the COMPANY. Any reduction in length shall be indicated in the CONTRACTOR’s pipe tracking system.

11.2

The CONTRACTOR shall unload, load, stockpile and transport the bare pipes within the coating plant(s) using suitable means and in a manner to avoid damage to pipes. The CONTRACTOR shall stockpile the bare pipes at the storage area of the coating plant. The CONTRACTOR shall prepare and furnish to COMPANY a procedure/ calculation generally in compliance with API RP-5L1 for pipe stacking, which shall be approved by COMPANY prior to commencement.

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11.3

The CONTRACTOR shall load, unload, transport and stockpile the coated pipes within the coating plant using approved suitable means and in a manner to avoid damage to the pipe and coating. The procedure shall be approved by COMPANY prior to commencement of work.

11.4

Coated pipes may be handled by means of slings and belts of proper width (minimum 60mm) made of non-abrasive/ non-metallic materials. In this case, pipes to be stacked shall be separated row by row to avoid damages by rubbing the coated surface in the process of taking off the slings. Use of round sectional slings are prohibited. Fork lifts may be used provided that the arms of the fork lift are covered with suitable pads preferably rubber.

11.5

Bare/ coated pipes at all times shall be stacked completely clear from the ground so that the bottom row of pipes remain free from any surface water. The pipes shall be stacked at a slope so that driving rain does not collect inside the pipe. Bare/ coated pipes may be stacked by placing them on ridges of sand free from stones and covered with a plastic film or on wooden supports provided with suitable cover. This cover can, for example, consist of dry, germ free straw with a plastic film, otherwise foam rubber may be used. The supports shall be spaced in such a manner as to avoid permanent bending of the pipes. Stacks shall consist of limited number of layers such that the pressure exercised by the pipe’s own weight does not cause damages to the coating. CONTRACTOR shall submit calculations for COMPANY approval in this regard. Each pipe section shall be separated by means of spacers suitably spaced for this purpose. Stacks shall be suitably secured against falling down and shall consist of pipe sections having the same diameter and wall thickness. The weld seam of pipes shall be positioned always in a manner so as not to touch the adjacent pipes. The ends of the pipes during handling and stacking shall always be protected with bevel protectors.

11.6

The lorries used for transportation shall be equipped with adequate pipe supports having as many round hollow beds as there as pipes to be placed on the bottom of the lorry bed. Total width of the supports shall be at least 5% of the pipe length and min. 3 Nos. support shall be provided. These supports shall be lined with a rubber protection and shall be spaced in a manner as to support equal load from the pipes. The rubber protection must be free from all nails and staples where pipes are in contact. The second layer and all following layers shall be separated from the other with adequate number of separating layers of protective material such as straw in plastic covers or mineral wool strips or equivalent, to avoid direct touch between the coated pipes. All stanchions of lorries used for transportation shall be covered by non-abrasive material like rubber belts or equivalent. Care shall be exercised to properly cover the top of the stanchions and other positions such as reinforcement of the truck body, rivets, etc. to prevent damage to the coated surface. Slings or non-metallic

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straps shall be used for securing loads during transportation. They shall be suitable padded at the contact points with the pipe. 11.7

Materials other than pipes and which are susceptible of deteriorating or suffering from damages especially due to humidity, exposure to high thermal excursions or other advers weather conditions, shall be suitably stored and protected. Deteriorated materials shall not be used and shall be replaced at CONTRACTOR’s expenses. These materials, shall always be handled during loading, unloading and storage in a manner so as to prevent any damage, alteration and dispersion. When supplied in containers and envelopes, they shall bot be dropped or thrown, or removed by means of hooks, both during the handling operations till their complete use. During unloading transport and utilization, any contact with water earth, crushed stone and any other foreign material shall be carefully avoided. CONTRACTOR shall strictly follow Manufacturer’s instructions regarding storage temperature and methods for volatile materials which are susceptible to change in properties and characteristics due to unsuitable storage. If necessary the CONTRACTOR shall provide for a proper conditioning.

11.8

In case of any marine transportation of bare/ coated line pipes involved, the same shall be carried out in compliance with API RP 5LW. CONTRACTOR shall furnish all details pertaining to marine transportation including necessary drawings of cargo barges, storing/ stacking, sea fastening of pipes on the barges/ marine vessels to the COMPANY for approval prior to undertaking such transportation works. In addition CONTRACTOR shall also carry out requisite analyses considering the proposed transportation scheme and establish the same is safe and stable. On-deck overseas shipment shall not be allowed.

12.0

REPAIR OF COATING CONTRACTOR shall submit to COMPANY, its methods and materials proposed to be used for executing a coating repair and shall receive approval from COMPANY prior to use. In open storage the repair coating materials must be able to withstand a temperature of atleast +80°C, without impairing its serviceability and properties. CONTRACTOR shall furnish manufacturer’s test certificates for the repair materials clearly establishing the compliance of the repair materials with the applicable coating requirements indicated in this specification. All pipe leaving coating plant, shall have sound external coating with no holiday porosity on 100% of the surface. Defects, repairs and acceptability criteria shall be as follows : •

Pipes showing porosities or very small damage not picked up during holiday test and having a surface less than 0.5 cm2 or linear damage (cut) of less than 3 cm shall be repaired by stick welding using material of same quality.

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•

Damages caused to coating by handling such as scratches, cuts, dents, gouges, not picked up during holiday test, having a total reduced thickness on damaged portion not less than 2.0mm and an area not exceeding 20 cm2 shall be rebuild by heat shrink patch only and without exposing to bare metal.

•

Defects or size exceeding above mentioned area or holidays of width less than 300 mm shall be repaired with heat shrinks repair patch by exposing the bare metal surface.

•

Defects exceeding the above and in number not exceeding 2 per pipe and linear length not exceeding 500mm shall be repaired using heat shrinkable sleeves of HTLP80 or equivalent.

•

Pipes with bigger damage shall be stripped and recoated.

•

In case of coating defect close to coating cut back, CONTRACTOR shall remove the coating throughout the entire circumference of the pipe down to the steel surface and increase the coating cut back length. Now if the coating cut back exceeds 140mm of linear length of pipe then the coating shall be repaired by the use of heat shrinkable sleeves thereby making up the coating cut back length of 120mm.

Not withstanding the above, under no circumstances, if the defects exceeds 70mm from the original coating cut back length, the entire coating shall be removed and the pipe shall be recycled through the entire coating procedure. Irrespective of type of repair, the maximum nos of repair of coating shall be as follows : •

Holiday repair of size ≤ 100 cm2 attributable to process of coating application shall be maximum of one per pipe.

•

In addition to the above, defects to be repaired by heat shrink patch/ sleeve shall be maximum 2(two) per pipe.

Defects exceeding the above limits shall cause pipe coating rejection, stripping and recoating. The above is exclusive of the repairs warranted due to testing as per this specification. All repairs carried out to coating for whatever reason shall be to the account of CONTRACTOR. Cosmetic damages occurring only in the Polyethylene layer only need not be repaired by exposing upto steel surface, as deemed fit by the COMPANY representative. In any case the CONTRACTOR shall establish his material, methods and procedure of repair that results in acceptable quality of product by testing and shall receive approval from COMPANY prior to use.

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Testing of repairs shall be in the same form as testing coating. All repairs shall result in a coating thickness no less than the parent coating thickness. CONTRACTOR shall test repairs to coating as and when required by COMPANY. 13.0

MARKING CONTRACTOR shall place marking on the outside surface of the coating at one end of the coated pipe, and marking shall indicate, but not limited to the following information: a. b. c. d. e. f. g.

Pipe number, Heat number Diameter & Wall Thickness Coated Pipe Number Colour band Any other information considered relevant by COMPANY. Pipe Manufacturer Name Inspection Mark/ Punch

CONTRACTOR shall obtain prior approval on making procedure to be adopted from the COMPANY. 14.0

QUALITY ASSURANCE

14.1

The CONTRACTOR shall have established within the organisation and, shall operate for the contract, a documented Quality System that ensures that the requirements of this specification are met in all aspects. The Quality System shall be based upon ISO 9001/2 or equivalent.

14.2

The CONTRACTOR shall have established a Quality Assurance Group within its organisation that shall be responsible for reviewing the Quality System and ensuring that it is implemented.

14.3

The CONTRACTOR shall submit the procedures that comprise the Quality System to the COMPANY for agreement.

14.4

The CONTRACTOR’s Quality System shall pay particular attention to the control of Suppliers and sub-contractors and shall ensure that the requirements of this specification are satisfied by the Suppliers and Sub-contractors operating Quality system in their organisation.

14.5

The CONTRACTOR shall, prior to the commencement of work, prepare and issue a Quality plan for all of the activities required to satisfy the requirements of this specification. The plan shall include any sub-contracted work, for which the subcontractors Quality plans shall be submitted. The plan shall be sufficiently detailed to indicate sequentially for each discipline the requisite quality control, inspection , testing and certification activities with reference to the relevant procedures and the acceptance standards.

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14.6

The CONTRACTOR’s Quality system and associated procedures may, with due notice, be subject to formal audits. The application of quality control by the CONTRACTOR will be monitored by the COMPANY Representatives who will witness and accept the inspection testing and associated work required by this specification.

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Coating system/ Material Prequalification Coating material Manufacturers acceptable to Company are as follows : Epoxy

:

BASF/Basepox Jotun 3M Dupont Bitumese Speciaux, France

Adhesive

:

BASF/Basell Boresalis Dupont SK Corporation\

Polyethylene :

Novacorp BASF/Basell Boresalis/Borouge SK Corporation Malaysian Polyethylene Malaysia (ETILINAS) ELF ATOCHEM, FRANCE

Contractor shall propose coating system(s) indicating specific grade of epoxy, adhesive and polyethylene manufactured by any of the above mentioned material Manufactures and submit the details as per Table 1. The proposed costing system shall be capable of meeting the functional requirements and properties of coating indicated in this specification. The coating system must have been pre-qualified by the coating material Manufacturer by actual application on 5 pipes and must have been successfully subjected to the tests as indicated in Table 2. The tests must have been carried out by an independent test laboratory of national / international recognition. In case the Contractor proposes any coating system (combination of epoxy, adhesive and polyethylene) that has been previously approved by the company, the above tests need not be carried out by the coating material Manufacturer. Tests carried out in accordance with other coating standards may be used in so far as their procedures are the same or more stringent than the procedures in this document Such information shall include full reports on test procedures and results and be signed by the laboratory representatives and certification body.

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Table – 1 Manufacturers Data on Coating System and Materials Coating System data

Epoxy

Adhesive

Polyethylene Compound

Coating System Designation Coating Material combination (s) Technical Data Sheet covering all properties as per specifications Laboratory Test Reports in support of technical data

Manufacturer’s Name Product Trade Name

Manufacturer’s Name Product Trade Name

Manufacturer’s Name Product Trade Name

Technical Data sheet covering all properties as per specification Laboratory Test Reports in support of technical data Certificate of Compatibility with Adhesive Storage Instructions Shelf Life

Technical Data sheet covering all properties as per specification Laboratory Test Reports in support of technical data Certificate of Compatibility with epoxy and polyethylene Storage Instructions Shelf Life

Technical Data sheet covering all properties as per specification Laboratory Test Reports in support of technical data Certificate of Compatibility with Adhesive Storage Instructions Shelf Life

Safety Data Sheets and HSE instructions

Safety Data Sheets and HSE instructions

Safety Data Sheets and HSE instructions

Certificate of Compatibility of proposed materials Application Procedure

Table – 2 S.No 1. 2. 3. 4. 5. 6. 7. 8. 9.

Properties Bond Strength Impact Strength Indentation hardness Elongation at Failure Cathodic Disbondment Degree of Cure Coating Resistivety Heat Ageing Light Ageing

Frequency (1) 5 Pipes 3 Pipes 5 Pipes 3 Pipes 2 Pipes 2 Pipes 2 Pipes 2 Pipes 2 Pipes

Applicable Requirement Para 10.5 Para 10.6 Para 10.7 Para 5.3.3(d) & 7.5.2(d) Para 5.3.3(h) & 7.5.2(e)(2) Para 5.3.3(i) & Para 10.9(a) Para 5.3.3 (e)(3) Para 5.3.3 (f)(3) Para 5.3.3 (g)(3)

1)

Test frequency shall be as indicated in this table and the paragraphs of the specific are not applicable.

frequency indicated in the applicable

2)

Two tests each on the selected pipes i.e 30 days and 48 hours test shall be carried out on each test pipe.

3)

Previously carried out tests in an independent laboratory of national / international recognition on PE top coat are also acceptable.

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Page 35 of 35

PROCESS & PIPING DESIGN SECTION MECON LIMITED,DELHI

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

SPECIFICATION NO. :MEC/S/05/21/014B, Rev-0

D:\old data\Vijyant\GSPL\Tender\Const\vol II of V\spec\pdf\PDF Final\014B-3-LPP-Coating of Linepipes-TS-Rev..doc

MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

REV-0

Page 1of 42

CONTENTS

1.0

SCOPE

2.0

DOCUMENTS

2.1

REFERENCE DOCUMENTS

3.0

PLANT SCALE AND INSTALLATION

4.0

MATERIALS

5.0

FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING

6.0

MEASUREMENT AND LOGGING

7.0

COATING PROCEDURE AND QUALIFICATION

8.0

PIPE SURFACE PREPARATION

9.0

COATING APPLICATION

10.0

INSPECTION AND TESTING

11.0

HANDLING, TRANSPORTATION AND STORAGE

12.0

REPAIR OF COATING

13.0

MARKING

14.0

QUALITY ASSURANCE

15.0

C0ATING SYSTEM

Revision No.

Date

Revised by

Checked by

Approved by

PREPARED BY :

CHECKED BY :

APPROVED BY :

ANIL KUMAR

TAPAS ROY

A.K. JOHRI

MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

1.0

1

REV-0

Page 2of 42

SCOPE This specification covers the minimum requirements for supply/ arrangement of all materials, plant, equipment, plant sites, consumables, utilities and application including all labour, supervision, inspection and tests etc. for application of external anti-corrosion coating of pipes by using 3 Layer Side Extruded Polypropylene Coating conforming to DIN-30678, 1992, `Polypropylene Coating of Steel Pipes and the requirements of this specification. This specification covers the external anticorrosion of pipes used as pipeline elements for onshore or offshore oil or gas. The coating shall be plant applied three coat polypropylene suitable for service temperature from – 200 to + 600 C. Its purpose is to define the following :¾ Applicators obligations. ¾ Raw Material Composition of coating and characteristics of the epoxy undercoat, the binder and the polypropylene. ¾ Application of the epoxy undercoat, the binder and the extruded polypropylene and repairing. ¾ Characteristics of the coating ¾ Inspection ¾ Handing, transport and storage rules ¾ Field joint coating

2.0

DOCUMENTS SUBMISSION BY CONTRACTOR At the time of bidding, following documents shall be furnished as a minimum by the contractor. a) Reference list of the previous 3-Layer side extruded polypropylene coating projects carried out in the last five\ years giving following minimum information : Name of project including year, client, location, pipe size, length, material, scope of work performed, client’s contact person, contract value, coating material and coating yard.

D:\old data\Vijyant\GSPL\Tender\Const\vol II of V\spec\pdf\PDF Final\014B-3-LPP-Coating of Linepipes-TS-Rev..doc

MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

REV-0

Page 3of 42

b) Details of proposed raw materials i.e. epoxy, adhesive & polypropylene compound along with following information. Name of the proposed manufacturer, product trade name, place/ source of supply of the product, authorization letter from manufacturer together with undertaking that the product conforms to all properties as per specification, a commitment letter from manufacturers to supply the material and list of similar previous supplies for at least a period of five years from the date of bid submission indicating name of the project, client and contact person. c) Compatibility certificate for the proposed combination of epoxy, adhesive and polypropylene compound from their respective manufacturers. d) A detailed activity wise time schedule for the entire works, clearly indicating all critical activities, viz. procurement of coating materials, consumables, setting up of plant and making it ready for production, application of coating on bare pipes and making coated pipes ready for delivery, schedule of pipe transportation, handling, clearance etc. as applicable. e) Manpower, and bio-data of key personnel to be deployed along with their related experience in such field. f) The guarantee that the epoxy undercoat material, the binder material, the ply and the repair products delivered shall meet the required coating characteristics as set forth in Chapter – 5 according to the specified methods. 2.1

REFERENCE DOCUMENTS Reference has also been made to the latest edition of the following standards, codes and specifications. The edition enforce at the time of floating the enquiry shall be termed as latest edition. ASTM B 117 – 73 (1979) ASTM D 149 – 81

: :

ASTM D 257 – 78

:

ASTM D 543 – 84

:

ASTMD 570 – 81

:

ASTMD 638 – 84

:

ASTM D 746 – 79

:

SALT SPRAY (FOG) TESTING Test methods for dielectric breakdown voltage and dielectric strength of solid electrical insulating material. Test methods for D.C. resistance or conductance or insulating materials. Test method for resistance of plastics to chemical reagents. Test method for water absorption of plastics. Test method for tensile properties of plastics. Test method for brittleness temperature of plastics and elastomers by impact.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

REV-0

ASTM D 785 – 65

:

ASTM D 792 – 66 (1970)

:

ASTM D 1002 – 72 (1983)

:

ASTM D 1076 – 80

:

ASTM D 1238 – 82

:

ASTM D 1505 –68 (1979)

:

ASTM D 1525 – 76

:

ASTM D 2117 – 82

:

ASTM D 2240 – 84

:

ASTM D 2370 – 82 ASTM E 28 – 67 (1982)

: :

ASTM E 96 – 80

:

ASTM G 8 – 85

:

ASTM G 14 – 83

:

ASTM G 17 – 83

:

CARL FISHER Method DIN 30678

: :

DIN 53 151 – 1981

:

DIN 53 153 – 1977

:

NF –A – 49 – 711

:

BS 3900 – E1 (70) BS 3900 – e 10 (79) SIS 0559 00 – 1967

: : :

ASTM D-1603

:

ASTM D-3895

:

Page 4of 42

Test method for Rockwell hardness of plastic and electrical insulating materials. Test methods for specific gravity and density of plastics by displacement. Test method for strength properties of adhesives in shear by tension loading. Standard specification for rubber, concentrated, ammonia preserved, creamed and centrifuged natural latex. Test method for flow rates of thermoplastics by extrusion plastomer. Test method for density of plastics by the density – gradient technique. Test method for vecat softening temperature of plastics. Test method for melting point of semicrystalline polymers. Test method for rubber property, Durometer hardness. Test for tensile properties or organic. Test method for softening point by ring and ball apparatus. Test methods for water vapour transmission of materials. Test methods for cathodic disbanding of pipeline. Test method for impact resistance of pipeline coatings (falling weight test). Test method for penetration resistance of pipeline coatings (blunt rod). Moisture content. Polypropylene coatings of steel pipes and fittings – requirements and testing. Testing of paints, vamishes and similar coating materials, cross-cut test on paint coatings and similar coatings. Testing of paints, vamishes and similar coating materials, Buchholz indentation test on paint coatings and similar coating. Three layer external coating based on Polypropylene. Bend test (Cylindrical Mandrel) Pull of test for adhesion. Pictorial surface preparation standards for painting steel surfaces. Test Method for Carbon Black in Olefin Plastics Test Method for Oxidative – Induction Time

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 5of 42

of Polyolefins by Differential Scanning Calorimetry ASTM G-42 : Tentative Methods for Cathodic disbonding of Pipeline Coatings Subjected to Elevated or Cyclic Temperatures. API RP 5L1 : Recommended Practice for Railroad Transportation of Linepipe. DIN EN 10204 : Metallic Products – Types of Inspection Documents ISO 8502-3 : Preparation of Steel Stubstrates before Application of Paints and Related Products – Part-3 – Assessment of Dust on Steel Surfaces Prepared for Painting (Pressure Sensitive Tape Method) ISO 9002 : Quality Systems : Specification of Production and Installation ISO 11124 : Preparation of Steel Substrates Before Application of Paints and Related Products APL 5L : Specification for Line Pipe ASME B 31.8 : Gas Transmission and Distribution Piping Systems ASME B 31.4 : Liquid Transportation systems for Hydrocarbons, Liquid petroleum Gas Anhydrous ammonia, and Alcohols CSA Z245.20-02 : External Fusion Bond Epoxy Coating for Steel Pipe The CONTRACTOR shall be familiar with the requirements of these documents and shall make them readily available at the coating plant to all persons concerned with carrying out the works specified in this specification. 3.0

PLANT SCALE AND INSTALLATION

3.1

CONTRACTOR shall size coating plant(s) after evaluating the scale of work and the time schedule required for the works. Coating plant(s), shall be installed into a yard whose geometry and dimensions are such as to allow the execution of a continuous work schedule. For this purpose the CONTRACTOR shall ensure non stop work execution owing to prohibitive adverse weather conditions and when required CONTRACTOR shall install requisite equipment and plant in roofed and adequately weather protected areas.

3.2

Plant equipment, machinery and other facilities shall be in first class operating condition to atleast meet the job requirements of quality and production. Worn out and improvised plants are not acceptable.

3.3

CONTRACTOR shall, at his own responsibility and cost, provide and prepare all necessary area for the storage of bare and coated pipe and all other materials, for coating yard, stock-piling and other temporary installation. For each area, CONTRACTOR shall provide to stipulate servitude agreements as required with

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 6of 42

the relevant Authorities, and, on work completion, to clean, restore and pay servitude and claims for damages, as applicable. 3.4

CONTRACTOR shall at its own responsibility and cost, provide for water and power supply and other utilities and consumables and obtain authorisation regarding access roads and other permits required for the execution of works conforming to all the requirements of the governing authorities.

3.5

CONTRACTOR shall at its own expense provide a fully equipped laboratory and test facilities with adequate inventory to carry out tests required for the procedure qualification and during regular production. Outside testing for qualification and regular production is not acceptable to COMPANY.

3.6

The CONTRACTOR shall be fully responsible for adherence to all statutory regulations applicable for handling and disposal of the hazardous chemicals during the coating works.

3.7

The CONTRACTOR shall be responsible for obtaining all statutory approvals/ clearances from relevant Authorities including Pollution Control Board, as applicable for the coating plant(s).

4.0

MATERIALS

4.1

The three layer coating system shall comprise of a powder epoxy primer, polypropylene adhesive and a polypropylene top coat. Coating materials shall be suitable for the service conditions and the pipe sizes involved. The coating materials i.e. epoxy powder, adhesive and polypropylene compound shall have proven compatibility. The coating system and materials shall be pre-qualified and approved by COMPANY in accordance with provision indicated in this specification. CONTRACTOR shall obtain prior approval from COMPANY for the coating system and coating of all materials.

4.2

The coating materials Manufacturer shall carry out tests for all properties specified in para 5.3.2, 5.3.3 & 5.3.4 for each batch of epoxy, adhesive and polypropylene compound. In addition, the Manufacturer shall also furnish Infrared Scan for each batch of epoxy powder. The coating materials manufacturer shall issue test certificates as per DIN EN 10204, 3.1B for each batch of materials supplied to CONTRACTOR and the same shall be submitted to COMPANY for approval prior to their use.

4.3

In addition to Manufacturer’s certificate, the CONTRACTOR shall draw samples from each batch of epoxy, adhesive and polypropylene in the presence of COMPANY representative and test for the following properties at the coating yard at least one week prior to its use, to establish compliance with the Manufacturer’s certificates. a) Epoxy Powder i. Gel Time ii. Cure Time

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

b)

Page 7of 42

iii. Moisture Content iv. Thermal Characteristics (Tgl, Tg2, ∆H) Adhesive i. ii. iii.

c)

REV-0

Specific Gravity Melt Flow Rate Vicat Softening Point

Polypropylene i. ii. iii. iv. v.

Melt Flow Rate Specific Gravity Vicat Softening Point Moisture Content Oxidative Induction Time

In case of failure of any of the above tests in a batch, that batch of material shall be tested for all other tests required as per para 5.3.2, 5.3.3 & 5.3.4 including the tests which failed. If all tests pass, the batch shall be accepted for coating. If any of the tests fail, entire batch of material shall be rejected and shall not be used for the coating. 4.4

All materials to be used shall be supplied in sealed, damage free containers and shall be suitably marked and identifiable with the following minimum information: a. b. c. d. e. f.

Name of the manufacturer Type of material Batch Number Place and Date of Manufacture Shelf Life/ Expiry Date (if applicable) Quantity

All materials noted to be without above identification shall be deemed/ suspect and shall be rejected by COMPANY. Such materials shall not be used for coating and shall be removed from site and replaced by CONTRACTOR at its expense. 4.6

CONTRACTOR shall ensure that all coating materials properly stored in accordance with the Manufacturer’s recommendation at all times, to prevent damage and deterioration in quality prior to use.

4.7

CONTRACTOR shall be required to use all materials on a date received rotation basis, i.e. first in-first used basis.

5.0

FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING

5.1

The coating must be suitable for service temperature from – 200 C to + 1000 C and shall conform coating as per DIN 30678. In addition, in open storage the

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

5.2

5.3

REV-0

Page 8of 42

coating must be able to withstand a temperature of atleast +80°C, without impairing its serviceability and properties specified. The top coat polypropylene used shall be black readymade compound, fully stabilized against influence of ultraviolet radiation (.e. sunlight), oxygen in air and heat (due to environmental temperature as specified above). No appreciable changes shall occur during exposure to such environments up to at least a period of 6000 hours. The CONTRACTOR shall submit certificate from Manufacturer in this regard. Properties Properties of coating system and coating material shall comply the requirements indicated in subsequent paragraph. In case the coating/ material properties are tested as per test methods/ standards other than specified herein below, the same may be accepted provided the test procedures and test conditions are same or more stringent than the specified. CONTRACTOR shall choose such a brand of epoxy powder and adhesive that will achieve the functional requirements and properties of coating system as specified in para 5.3.1, and 5.3.2 of this specification respectively. Epoxy powder properties shall be as per CSA Z245.20.98. The colour of epoxy powder shall be either green or dark red or any other colour approved by COMPANY except grey colour.

5.3.1

Properties of Epoxy Powder

The epoxy powder shall be a solid matter divided into very small particles obtained by crushing of an artificial stable mixture made up of ethoxyl resin(s), hardener(s), coloring agent(s), filler(s) and possibly other additives. The selected epoxy powder shall meet the characteristics as specified below before or after conditioning at 300 C for one month. CHARACTERISTICS Sieve analysis - below 120 microns - - below 32 microns Gel time at 2000 C Specific gravity Moisture content

Glass Transition temperature . 1st cure . 2nd cure Residual enthalpy Adhesion Impact strength

METHODS COULTER COUNTER TA Articles analyzer Orifice tube : 280 mu O.D. Heating plate Standard method CARL FISHER Powder : 20g Temperature : 1050 C Time : 30 minutes Differential heat analysis Powder : 10 mg Tempperature rise :10 °C/mn From 25 to 250 °C- gas = helium DIN 53 151 – 1981 Crosshatch : 1 mm ASTM G 14 – 83

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UNITS

ACCEPTABLE VALUES

% WT % Part Sec %

95 30 20 – 45 1.20 – 1.50 0.5 (max.)

0

40 – 60

0

90-105 10-13 Gto

C C

GUTTER SCHNIT Degree

MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

CHARACTERISTICS

REV-0

METHODS Steel Plate : 7.6 x 7.6 x 3.2 mm Coateing : 100 microns

5.3.2

UNITS J

Page 9of 42

ACCEPTABLE VALUES 1.8(min)

Properties of binder (Adhesive) Its main characteristics are given in the following table below:CHARACTERISTICS

UNITS g/10m

ACCEPTABLE VALUES 5 to 12 0.90 to 0.92 > 20

Melt flow rate Density Breaking strength

ASTM D 1238 ASTM D 1505 ASTM D 638

Elongation at break Rockwell hardness Brittle point

ASTM D 785 ASTM D 746

0

ASTM D 1525

0

125

ASTM D 2117

0

140

Mpa %

VICAT Softening Point(9.8 N) Melting Point

5.3.3

METHODS

C C C

> 200 > 60 - 30

Note - 1 :

Raw Material shall be proposed by bidder stage only, no changes afterwards will be allowed.

Note – 2 :

Material to conform to 800 C at open storage.

Properties of Polypropylene Its main characteristics are given in the following table below:CHARACTERISTICS Melt flow rate Density Carbon black content Strength at yield point at 230 C Breaking strength Elongation at break at 230 C Rockwell hardness Water absorption VICAT Softening point (9.8 N) Melting point Brittle point

METHODS ASTM D 1238 ASTM D 1505 ASTM D 603 ASTM D 638 ASTM D 638 ASTM D 638 ASTM D 785 ASTM D 570 ASTM D 1525 ASTM D 2117 ASTM D 746

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UNITS g/10mm % Mpa Mpa % %24 H 0 C 0 C 0 C

ACCEPTABLE VALUES 0.7 to 1.0 0.91 to 0.92 0 > 20 > 20 > 200 > 60 > 0.005 > 135 >150 <-30

MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

5.3.4 Sl. No. a.

Page 10of 42

Properties of Polypropylene Coating System Properties

b.

Bond Strength (Resistance to puling a) at a test temperature of 50 +50 C b) at test temp 90 +50 C Impact Strength at 00 C

c.

Indentation Hardness

d.

REV-0

Unit

Requirement

N/50mm

Nm/mm of coating thickness mm

>500 >400 >15

@ 25°C

0.10 max

@ 100°C

0.3 max

Elongation at Failure

%

300 min.

Test Method DIN 30678 NF A 49-711

DIN 30678 NF A49-711 DIN 30678 NF A 49-711 DIN 30678 NF A49-711

e.

Coating Resistivity (*)

f.

2

8

Ohm-m

10 min.

NF A49-711

Heat Ageing (*)

%

Melt flow rate shall not deviate by more than 35% of original value

DIN 30678

g.

Light Ageing (*)

%

Melt flow rate shall not deviate by more than 35% of original value

NF A49-711 Variation of electric at (ASTM D 638)

h.

Cathodic Disbondment After 30 days After 48 hrs.

i. j.

mm radius of disbondment (**)

ASTM G 8 15 max. 7 max.

Degree of Cure of Epoxy

%

95

Percentage Cure, ∆H ∆Tg

°C

+3/ -2

Bendability

No Holiday

CSA Z245.2098(*) Bending the coated pipe to a radius equivalent to 20 times the pipe O.D. Tests after bending : -Holiday detection

Resistance to peeling -

on compression side

-

on tension side

N/50mm

>500

No crack

N/50mm

>500

No wrinkle

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No surface defect

MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

Sl. No. k.

Properties Water absorption

REV-0

Page 11of 42

Unit

Requirement

Test Method

% 24 h

<0.005

ASTM D 570

(*)

6.0

7.0 7.1

Test carried out in an independent laboratory of national/ international recognition on PP top coat is also acceptable. (**) Disbondment shall be equivalent circle radius of total unsealed area as per ASTM G8. (***) Temperature to which the test specimens are to be heated during cyclic heating shall however be as per the recommendations of epoxy powder manufacturer. MEASUREMENT AND LOGGING

CONTRACTOR shall maintain records in computer using MS ACCESS database Software containing all the relevant data of individual pipe and pipe coating including heat number, diameter, length, wall thickness, defects, pipe number, batches of materials, materials balance, sampling, testing, damages, repairs, rejects and any other information that COMPANY considers to be relevant and required for all incoming bare pipes and COMPANY approved outgoing coated pipes as applicable. CONTRACTOR shall submit this information in the form of a report at the agreed intervals. The above data shall also be provided in MS EXCEL/MS ACCESS formant in Compact Disc (CD). CONTRACTOR shall provide a Computer Terminal to COMPANY Representative for monitoring/tracking of the above. The CONTRACTOR shall also submit the material balance details to COMPANY for information at the end of shift. COATING PROCEDURE AND QUALIFICATION Upon the award of the CONTRACT, the CONTRACTOR shall submit within two(2) weeks for COMPANY approval, a detailed report in the form of bound manual outlining, but not limited to the following: a. Details of plant(s), locations, layout, capacity and production rate(s). b. Details of the equipment available to carry out the coating works including surface preparation, epoxy powder application and its recycling system, adhesive & polypropylene extrusion, moisture control facilities available for coating materials. c. Details of process control and inspection equipment required for the coating process such as temperature control, thickness control, holiday testers, etc. d. Details of chemicals pre-treatment facilities including process control and inspection equipment for phosphoric acid wash, de-ionised water wash and chromate wash. e. Facilities in the yard for unloading, handling, transport, production, storage, stockpiling, loading of bare and coated pipes and warehouses for storage of other coating materials. f Plant Organogram Chart and availability of manpower including coating specialist.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 12of 42

g

Details of utilities/facilities such as water, power, fuel, access roads and communication etc. After approval has been given by COMPANY, no change in plant set-up shall be made. However, unavoidable changes shall be executed only after obtaining written approval from COMPANY. 7.2

At least four(4) weeks prior to the commencement of production coating, a detailed procedure of CONTRACTOR's methods, material proposed, etc., shall be formulated by CONTRACTOR and submitted for COMPANY's approval in the form of a bound manual. The procedure shall include, but not limited to the following information and proposals: a. b. c.

d. e. f. g. h. i. j. k. l. m. n. o. p. q.

Pipe inspection at the time of bare pipe receipt. Steel surface preparation, including preheating, removal of steel defects, method of pipe cleaning, dust removal, abrasive blast cleaning and surface profile, methods of measurements and consumables. Complete details of chemical pre-treatment viz phosphoric acid wash, de-ionised water wash, and chromate wash including product data sheets, health and safety sheets and manufacturer’s recommended application procedure. Pipe heating, temperatures and control prior to epoxy application. Complete details of raw materials including current data sheets showing values for all the properties specified together with quality control and application procedure recommendation from manufacturer(s). Application of FBE powder, adhesive and polypropylene, including characteristics, temperature, line speed, application window, curing time, etc. Quenching and cooling, including time and temperature. Quality assurance system, Inspection and testing methods and reporting formats, including instrument and equipment types, makes and uses etc. Detailed method of repair of coating defects duly classified depending upon nature and magnitude of defects and repairs thereof including coating stripping technique. Details of instrument and equipment calibration methods including relevant standards and examples of calibration certificates. Complete details and inventory of laboratory and equipment for procedure qualification and regular production. Pipe handling and stock piling procedures. Sample of recording and reporting formats, including laboratory reports, certificates and requirement as per clause 6.0 of this specification. Complete details of test certificates for raw materials including test methods standards used. Test certificates from PP compound manufacturer for tests for thermal aging coating resistivity and aging under exposure to light. These test certificates shall not be older than three years. Health, safety and environment plans. Storage details of coating materials and chemicals.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 13of 42

r. Continuous temperature monitoring at various stages of coating. Procedure Qualification Tests (PQT) shall be carried out only after obtaining written approval of the above procedure from COMPANY. No change in the procedure shall be made after approval has been given by the COMPANY. However, unavoidable changes shall be executed only after obtaining written approval from COMPANY. 7.3

Prior to start of production, CONTRACTOR shall, at his expense, carry out a coating procedure qualification trial for each pipe diameter, and for each plant, to prove that his plant, materials, and coating procedures result in a quality of end product conforming to the properties stated in clause 5.3, relevant standards, specifications and material manufacturer’s recommendations. CONTRACTOR shall give seven(7) working days notice to witness procedures and tests. A batch representing a normal production run, typically 15 pipes, shall be coated in accordance with the approval coating procedure and the coating operations witnessed by COMPANY Representative. Out of these pipes, at least one pipe shall be coated partly with epoxy and partly with both epoxy and adhesive layers. Atleast 5 (five) test pipes shall be selected by Company Representative for coating procedure approval tests and shall be subjected to procedure qualification testing as described hereinafter. All tests shall be witnessed by COMPANY’s representative. Out of 5(five) test pipes 1(one) pipe shall be coated partly with epoxy and partly with both epoxy and adhesive layers. Remaining 4(four) test pipes shall be coated with all three layers. During PQT, the CONTRACTOR shall qualify various procedures forming a part of coating operations as detailed subsequently.

7.4

Qualification of Procedures

7.4.1

Epoxy Powder Application & Recycling During pre-qualification, air pressure in the epoxy spray guns, satisfactory functioning of monitoring system, line speed vs coating thickness, etc. shall be established. Dew point of air used to supply the fluidised bed, epoxy spray system and epoxy recycling system shall be recorded during the PQT. Also, the CONTRACTOR shall remove samples of reclaimed powder from the reclamation system. These of reclaimed powder shall be subject to a detailed visual examination, thermal analysis and moisture content tests. The properties of the reclaimed powder shall be within the range specified by the Manufacturer of epoxy powder. In case the properties of the reclaimed powder are out of the range specified by the Manufacturer, CONTRACTOR shall not the use the reclaimed powder during the regular production.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

7.4.2

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 14of 42

Pipe Pre-Heating The CONTRACTOR shall establish the temperature variation due to in-coming pipe temperature, line speed variation, wall thickness variation, emissivity, interruptions, etc. and document the same during the PQT stage. During PQT, proper functioning of pipe temperature monitoring and recording system including alarm/ hooter shall be demonstrated to the COMPANY Representative.

7.4.3

Surface Preparation The procedure to clean and prepare the pipe surface shall be in accordance with the requirements of this specification. The ratio to shots to grits shall be established during procedure qualification testing, such that the resultant surface profile is not dished and rounded. The qualification shall be performed through a visual inspection, measurement of roughness and check of the presence of dust in the abrasive blast cleaned pipe surface.

7.4.4

Coating Application The COMPANY Representative will check the correctness of each coating application operation, values of the main parameters of each operation, preheating pipe surface temperature prior to epoxy powder application temperature, line speed, fusion bonded epoxy curing time, temperature and flow rate of co-polymer adhesive and polypropylene etc. and the same shall be recorded. These values shall be complied with during regular production.

7.5

Qualification of Applied Coating

7.5.1

Tests on pipe coated partly with epoxy and partly with epoxy & adhesive Layers a.

Degree of Cure Epoxy film samples (min 4 Nos.) shall be scrapped from the coated pipe using hammer and cold chisel and the samples shall be taken for cure test using Differential Scanning Calorimatry (DSC) procedure. Care shall be taken to remove the samples of full film thickness avoiding inclusion of steel debris. Glass transition temperature differential (∆Tg) and % cure (∆H) shall comply the specified requirements.

b.

Epoxy Layer Thickness Epoxy layer thickness shall be checked at every one meter spacing at 3, 6, 9 and 12 o’clock positions. The thickness shall comply the specified thickness requirements.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

c.

REV-0

Page 15of 42

Adhesive Layer Thickness Adhesive layer thickness shall be checked at every one meter spacing at 3, 6, 9 and 12 o’clock positions. The thickness shall comply the specified thickness requirements.

d.

Holiday Inspection Entire pipe shall be subject to holiday inspection and the test voltage shall be set to exceed 5 v/micron of epoxy thickness specified for the portion coated only with epoxy layer.

e.

Adhesion Test i) ii)

f.

Adhesion Test (24 hrs or 48 hrs) shall be carried out on the epoxy coated pipe. Test method, no. of test specimen and acceptance criteria shall comply CSA Z.245,20-98, Table 4. Adhesion of FBE shall also be separately determined at ambient temperature at two locations by the “St Andrews Cross” method and the test shall comply with the specified requirements.

2.5° Flexibility Test 2.5° Flexibility test shall be carried out on the epoxy coated pipe at test temperature of 0°C. Test method, no. of test specimen and acceptance criteria shall comply CSA Z.245,20-98, Table-4.

g.

Cross-section & Interface Porosity Test Cross section porosity and interface porosity tests shall be carried out on the epoxy coated pipe. Test method, no. of test specimen and acceptance criteria shall comply CSA Z.245,20-98, Table-4.

7.5.2

Tests on pipes coated only with all three layers a.

Bond Strength Three test pipes shall be selected for bond strength tests. On each of the selected pipes, three bond strength test shall be performed for each specified temperature i.e. one at each end and one in the middle of the pipe and specified requirements shall be complied with, i.e. bond strength as well as mode of separation. Length of peel shall be minimum 65mm. None of these samples shall fail.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

b.

REV-0

Page 16of 42

Impact Strength Three test pipes shall be selected for impact strength test and the test shall meet the requirement.

c.

Indentation Hardness Two samples for both the temperatures from all pipes shall be taken. If any one of these samples fail to satisfy the requirements, then the test shall be repeated on four more samples. In this case, none of the samples must fail.

d.

Elongation at Failure Six samples each from two coated pipes i.e. 18 samples in all shall be tested and the test shall comply the specified requirement. Only one sample per pipe may fail.

e)

Cathodic Disbondment Test Two CD test shall be carried out for the total lot of test pipes having all three layers. Accelerated test shall be carried out after 48 hrs duration and other test shall be carried out for 30 days. Two sample shall be collected for 30 days. One sample shall be tested at coating applicators in-house lab. and other sample shall be tested in an independent laboratory of national / international recognition.The tests shall comply the specified requirment.

f.

Holiday Inspection All the pipes shall be subject to holiday inspection. The test voltage shall be as specified in para 10.4(b)

g.

Coating Thickness Measurement All pipes shall be subject to coating thickness measurement. Acceptance criteria shall be as per para 10.3

h.

Air Entrapment One sample each from pipe body and on weld (if applicable) shall be taken from all four coated pipes and the specified requirements shall be complied with.

i.

Degree of Cure Epoxy film samples (minimum 4 no., equally spaced) shall be scrapped from one coated pipe and the samples shall be taken for cure test using Differential Scanning Calorimetry (DSC) procedure.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

7.5.3

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

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Care shall be taken to remove the samples of full film thickness avoiding inclusion of steel debris. Glass transition temperature differential (∆Tg) and % cure (∆H) shall comply with the specified requirements. Inspection of all test pipes All pipes shall be subject to the following inspections: a. b. c. d.

surface cleanliness, surface roughness measurements and dust control immediately after second abrasive blast cleaning and salt test immediately after De-ionised water wash. pH of pipe surface before and after phosphoric acid wash. visual inspection of chromate coating. visual inspection of finished coating, cut back dimension, internal/ external cleanliness, end sealing and bevel inspection.

Acceptance criteria for all inspection and testing shall be as specified in this specification. 7.6

After completion of the qualification tests and inspection as per para 7.4 and 7.5 above, the CONTRACTOR shall prepare and issue to COMPANY for approval a detailed report of the above tests and inspection including test reports/ certificates of all materials and coatings tested. Only upon written approval from COMPANY, CONTRACTOR shall commence production coating.

7.7

On successful completion of PQT, coating of all five(5) test pipes shall be removed and completely recycled as per the approval coating procedure specification, at CONTRACTOR’s expense. Remaining pipes will be accepted by COMPANY provided they meet the requirements of this specification and need not be stripped and re-cycled.

7.8

The CONTRACTOR shall re-establish the requirements of qualification and in a manner as stated before or to the extent considered necessary by COMPANY, in the event of, but not limited to, the following : •

Every time there is a change in the previously qualified procedure.

•

Every time there is a change in the manufacturer and change in formulation of any of the raw materials and change in location of raw material manufacture.

•

Every time the coating yard is shifted from one location to the other or every time the critical coating equipments (induction heater, epoxy spray system, extruder, etc) are shifted.

•

Any change in line speed during coating application.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

•

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 18of 42

Any time when in COMPANY’s opinion the properties are deemed to be suspect during regular production tests.

7.9

COMPANY reserves the right to conduct any or all the test required for qualification through an independent laboratory or agency at the cost of CONTRACTOR when in COMPANY’s opinion, the results are deemed suspect. COMPANY’s decision shall be final.

8.0

PIPE SURFACE PREPARATION

8.1

Unless specified otherwise, the pipes shall be supplied free from mill applied oils but may be subject to contamination occurring during transit.

8.2

Prior to cleaning operation, CONTRACTOR shall visually examine the pipes and shall ensure that all defects, flats and other damages have been repaired or removed. The CONTRACTOR shall also remove marking stickers, if any, present within the pipe. Record shall be kept of such marking on the stickers of ensure traceability of pipe after coating.

8.3

Any oil, grease, salt or other contaminants detrimental to the formation of a good coating bond or coating quality shall be removed prior to coating application. Contaminants may be removed by the use of non-oily solvents. Gasoline or kerosene shall not be used for this purpose. Visible oil and grease spots shall be removed by solvent wiping. Solvents cleaning shall be in accordance with SSPC-SP1. Steel surface shall be allowed to dry before abrasive cleaning.

8.4

All pipes shall be preheated to a temperature 65°C to 85°C prior to abrasive blast cleaning. The external surface of the pipe shall be cleaned using 2 no. dry abrasive blasting cleaning units to achieve the specified surface cleanliness and profile. After first abrasive blast cleaning, chemical pretreatment with phosphoric acid solution as per para 8.6 shall be carried out prior to second abrasive blast cleaning. However at the option of CONTRACTOR, chemical pre-treatment with phosphoric acid solution as per para 8.6 may be carried out after the second abrasive blaster. The abrasive blast cleaning units shall have an effective dust collection system to ensure total removal of dust generated during blast cleaning from the pipe surface. The equipment used for abrasive blast cleaning shall meet the specified requirements and shall be free from oil, water soluble salts and other forms of contamination to ensure that the cleaning process is not impaired. Traps, separators and filters shall be checked for condensed water and oil at the start of each shift and emptied and cleaned regularly. During abrasive blast cleaning the metallic abrasive shall be continuously sieved to remove “fines” and “contaminates” and the quality checked at every four hours. Abrasive used for blast cleaning shall comply ISO- 11124.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 19of 42

8.5

Suitable plugs shall be provided at both pipe ends to prevent entry of any shot/grit into pipe during blast cleaning operations. These plugs shall be removed after blast cleaning. Alternatively the CONTRACTOR may link pipes suitably together to prevent the entry of any short/grit into the pipe.

8.6

Abrasive cleaning carried out shall be such that the resultant surface profile is not dished and rounded when viewed with 30X magnification. The standard of finish for cleaned pipe shall conform to near white metal finish to Sa 2½ of Swedish Standard SIS 055900 latest edition. Surface of pipe after abrasive blast cleaning shall have an anchor pattern of 50 to 70 microns(Rz). This shall be measured for each pipe by a suitable instrument such as surface profile depth gauge. In addition the pipe surface after blast cleaning shall be checked for the degree of cleanliness (Sa 2½), degree of dust and shape of profile. Degree of dust shall comply the requirements of ISO:8502 – 3. Acceptance limit shall be either quality rating 2 or Class 2.

8.7

All pipes shall be visually examined for presence of any shot/ grit/ loose material left inside the pipe during blast cleaning. Suitable mechanical means (stiff brush) shall be employed to remove the same before the pipes are processed further. In addition, inside surface of the pipe shall also be visually inspected for presence of any foreign material or shots and grit (free or embedded/ sticking to pipe inside surface). The pipe inside surface shall be examined using sharp floodlight focused at the middle of the pipe at one end while inspection is carried out visually from other end. Any foreign material or shots/ grit present in the pipe shall be completely removed by mechanical/ brush, high pressure air jets, by tilting of pipe etc.

8.8

At no time shall the blast cleaning be performed when the relative humidity exceeds 85%. The CONTRACTOR shall measure the ambient conditions at regular intervals during blast cleaning and coating operations and keep records of prevailing temperature, humidity and dew point.

8.9

The blast cleaned surface shall not be contaminated with dirt, dust, metal particles, oil, water or any other foreign material, nor shall be surface or its anchor pattern be scarred or burnished. All blast cleaned pipe surface shall be kept in dust free enclosure prior to coating. After blast cleaning, all surfaces shall be thoroughly inspected under adequate lighting to determine anchor pattern, quality of blasting and identify any surface defects prior to coating application. All surface defects such as slivers, scab, burns, laminations, welds spatters, gouges, scores, indentations, slugs or any other defects considered injurious to the coating integrity made visible during blast cleaning shall be reported to the COMPANY Representative and on permission from COMPANY Representative, such defects shall be removed by filing or grinding. After any grinding or mechanical repairs, the remaining wall thickness shall be checked and compared with specified thickness. Any pipes having thickness less than 95% of specified thickness shall be kept aside and disposed off as per the instructions of COMPANY Representative. The method employed to remove surface defects shall not burnish or destroy the anchor

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 20of 42

pattern or contaminate the surface. Pneumatic tools shall not be used unless they are fitted with effective air/ oil and water traps. Where burnishing results in destruction of anchor pattern, the anchor patter shall be restored by suitable means. Pipes which have damages repaired by grinding and have ground areas more than 50mm in diameter shall be recycling-blasted. Any dust or loose residues that have been accumulated during blasting and/ or during filing/ grinding operations shall be removed by vacuum cleaning. If contamination of surface occurs, the quality of blast cleaning method and process shall be examined. If the surface roughness is outside the specified limit, the blast cleaning material shall be checked and replaced. 8.10

8.11 9.0

Upon Completion of the blasting operations, the quality control supervisor shall accept the pipe for further processing or return for re-blasting after removal of defects/ imperfections. In case imperfections are considered detrimental to the coating quality, the same shall be reported to COMPANY’s Representative for final decision on rejection or re-blasting/ removal of defects. Re-blasting/ removal of defects or returning pipe to the yard shall be at the CONTRACTOR’s cost. COMPANY’s Representative, in additions, reserves the right to initiate any of the above actions during periodic inspections for oil, dust, salt, imperfections, surface defects, lack of white metal finish etc. In order to ensure that pipe with defects are not processed further, provisions shall be available to lift the pipes from inspection stand. COATING APPLICATION The external surface of the cleaned pipe conforming to clause 8.0 of this specification shall be immediately coated with 3-layer extruded polypropylene coating in accordance with the procedures approved by COMPANY, relevant standards and this specification. In general, the procedure shall be as follows:

9.1 9.1.1

9.1.2

9.1.3

Pipe Heating Immediately prior to heating of pipe, all dust and grit shall be removed from both inside and outside of the pipe by a combination of air blast, brushing and vacuum cleaning. Suitable arrangement shall be made to protect the bevel ends from getting damaged during the coating operation. Induction heater or gas furnace shall be used for heating the pipe. The method shall be capable of maintaining uniform temperature along the total length of the pipe, and shall be such that it shall not contaminate the surface to be coated. In case of induction heating, appropriate frequency shall be used to ensure `deep heating’ and intense skin heating is avoided. Gas fired heating system shall be well adjusted so that no combustion products are deposited on the steel surface. This shall be demonstrated on bare pipes prior to start of PQT. Oxidation of the cleaned pipe surfaces prior to coating (in the form of bluing or other apparent oxide formation) is not acceptable. External surface of the pipe shall be heated to about 190°C or within a temperature range (min. to max.) as recommended by the powder

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

9.1.4

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

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manufacturer. Required pipe temperature shall be maintained as it enters the coating chamber. Temperature of the pipe surface shall be continuously monitored & recorded by using suitable instruments such as infrared sensors, contact thermometers, thermocouples etc. The recording method shall allow to correlate each line pipe. The monitoring instrument shall be able to raise an alarm/ activate audio system (hooter) in the event of tripping of induction heater/ gas fired heater or in the event of pipe temperature being outside the range recommended by the manufacturer. Any deviation from the application temperature range recommended by manufacturer shall be rectified. If immediate rectification is not feasible, the production shall be stopped until cause of deviation has been removed. Any pipe coated during the duration of temperature deviation shall be identified by marking and rejected. Such rejected pipes shall be stripped and recoated.

9.1.5

Temperature measuring & monitoring equipment shall be calibrated twice every shift and/ or as per COMPANY representative’s instruction.

9.1.6

Contractor shall ensure that pipe surface emissivity variations are minimised during pipe heating. To avoid significant variance, more than once blasted joints should be coated at the same time and not mixed with joints blasted only once.

9.2

Pipe Coating

9.2 .1

Subsequent to pipe heating, coating consisting of following layers shall be applied onto the pipe. i.

Electrostatic application of epoxy powder of minimum dry film thickness 180 micron, unless otherwise specified. The maximum thickness shall not exceed the epoxy thickness specified by epoxy powder manufacturer. ii. Grafted co-polymer adhesive applied by extrusion, minimum thickness 200 microns. iii. Polypropylene coating by extrusion. The coated pipe shall be subsequently quenched and cooled in water for a period which shall sufficiently lower the temperature of pipe coating to permit handling and inspection. 9.2.2

Minimum total thickness of finished coating shall be as under : Nominal Size (DN) Min. Coating Thickness (mm)(*) 300 mm 3.2 on body & weld seam

9.2.3

Coating materials shall be inspected in accordance with the manufacturer’s recommendation prior to coating application and it shall be ensured that the materials are moisture free. In case the relative humidity exceeds 80%, the

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 22of 42

adhesive and polypropylene material shall be dried using hot air as per the directions of COMPANY representative. 9.2.4

Prior to starting the application of fusion bonded epoxy powder, the recovery system shall be thoroughly cleaned to remove any unused powder remaining from a previous line pipe coating application. The use of recycled powder shall be permitted subjected to: a)

satisfactory qualification of the reclaimed system during PQT stage

b)

the proportion of the reclaimed powder in the working mix does not exceed 20% at any one time.

c)

the quality of the recycled powder being routinely checked during production, at a minimum frequency of once per shift and consistently meets the requirements stated at para 5.3.1.

9.2.5

Dry air, free of oil and moisture shall be used in the coating chamber and spraying system and for this purpose filters, dehumidifier/ heater as required alongwith control & monitoring system shall be provided for this purpose. Dew point of air used to supply the fluidized bed, epoxy spray system and epoxy recycling system shall be at least (-) 40°C and this shall be shall monitored during the regular production.

9.2.6

Air pressure in the epoxy spray guns shall be controlled, continuously monitored and recorded by using suitable instruments. The air pressure shall be controlled within the limits established during coating procedure qualification. The monitoring system shall be able capable of raising an alarm/ activate audio system (hooter) in the event of change in air pressure beyond the set limits. Any deviation from the pre-set limits shall be rectified. If immediate rectification is not feasible, the production shall be stopped until cause of deviation has been removed. Any pipe coated during the duration of air pressure deviation shall be identified by suitable marking and rejected. Such rejected pipes shall be stripped and recoated.

9.2.7

Extruded adhesive layer shall be applied before gel time of the epoxy coating has elapsed. The application of the adhesive layer shall not be permitted after epoxy is fully cured. The CONTRACTOR shall establish, to the satisfaction of the COMPANY representative, that the adhesive is applied within the gel time window of epoxy and at the temperature recommended by the adhesive manufacturer. The CONTRACTOR shall state the minimum and maximum time interval between epoxy and adhesive application at the proposed pre-heat temperature and line speed. Extruded polypropylene layer shall be applied over the adhesive layer within the time limit established during PQT stage and within the time/ temperature range recommended by the manufacturer. The extrusion temperatures of the adhesive and polypropylene shall be continuously recorded. The monitoring instruments shall be independent of the temperature control equipment. The instruments shall be calibrated prior to start of each shift.

9.2.8

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 23of 42

9.2.9

CONTRACTOR shall ensure that there is no entrapment of air or void formation along the seam weld (where applicable) during application of coating. Air entrapment below the coating and also along the coating overlap shall be prevented by forcing the coating on to the pipe using high pressure roller of suitable design during coating application. In case it is not adequately achieved, CONTRACTOR shall supplement by other method to avoid air entrapment. The methods used shall be witnessed and approved by COMPANY.

9.2.10

Resultant coating shall have a uniform gloss and appearance and shall be free from air bubbles, wrinkles, holidays, irregularities, discontinuities, separation between layers of polypropylene & adhesive, etc.

9.2.11

Coating and/ or adhesive shall terminate 120mm (+)20/(-)0 mm from pipe ends. The adhesive shall seal the end of applied coating. CONTRACTOR shall adopt mechanical brushing for termination of the coating at pipe ends. Edge of the coating shall be shaped to form a bevel angle of 30° to 45°.

9.2.12

Failure to comply with any of the above applicable requirement and of the approved procedure shall be cause for the rejection of the coating and such coating shall be removed in a manner approved by COMPANY at CONTRACTOR’s expense.

10.0

INSPECTION AND TESTING

10.1

General CONTRACTOR shall establish and maintain such quality assurance system as are necessary to ensure that goods or services supplied comply in all respects with the requirements of this specification. The minimum inspection and testing to be performed shall be as indicated subsequently herein. The Inspector shall have free access to all departments of the plants where the powder is produced and where it is applied. An office and all necessary means to the perfect completion of his work shall be made available for him as well by the Manufacturer as by the Applicator. Coating Inspection shall be carried out by the Applicator in the presence of the Inspector it shall include the following five operations: -

Inspection of the epoxy powder or liquid epoxy, binder material and Polypropylene deliveries, Inspection of the epoxy powder of liquid epoxy, binder material and Polypropylene quality, Inspection of the various application parameter of the epoxy undercoat, the binder coat and the Polypropylene coat,

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

-

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 24of 42

Systematic inspection of pipe coating or test samples taken from pipe end, Systematic inspection of each coated pipe.

The Inspector may check by himself the conformity of nay characteristic mentioned in the Chapter 5. The Inspector may take sample of the coating materials or repair product and test specimens of coated pipes(s) for testing in laboratories selected by the Company in order to check the quality of the tested products. 10.2

Inspection of Coating Materials and Repair Product Delivery This inspection shall be performed upon delivery of the coating materials and repair product for packaging and marking checking. Packaging shall be in accordance with the manufacturer’s instructions and marking shall be Non-conformity with any of the specified requirements shall cause the immediate rejection of the delivery concerned. In order to face any dispute arising at a later stage, three 50g samples of each of raw coating materials shall be taken from the production batches. One shall be reserved for the Applicator, one shall be transmitted to the Company and one shall be kept as check sample in the Applicator’s laboratory for six months, away from humidity at a temperature below and close to 200C.

10.3

10.4

Inspection of Coating Materials and Repair Product Quality Such inspection is carried out before coating application to ascertain the quality of the coating materials and repair products by checking that all the documents to be supplied by the Contractor have been requested from the Manufacturer and are available in the required from as per 2.0 (Documents). Any missing document and/ or non-conformity of the production test certificates with the specification will cause the rejection of the concerned coated material and repair product. For example, infa-red scans shall in no case be supplied in reduced copy. Strip test of one pipe for every 1000 pipes (for checking air entrapments, bonding etc.). Inspection of the various Application Parameters of the Coating Materials This inspection shall be performed during coating application in order to check the following parameters : - Finish of prepared surface, - Dust degree of prepared surface, - Total roughness of prepared surface, - Pipe temperature when entering spraying machine - Pipe travel sped.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

10.4.1

10.4.2

10.4.3

REV-0

Page 25of 42

Finish of Prepared Surface Material

:

as per SIS 05 99 00

Method

:

comparison of prepared surface finish with the illustration corresponding to SA 2 ½ surface finish according to the initial metal rust degree (A, B, C or D) or pipe metal.

Inspection

:

100% of the prepared surface of each pipe.

Dust Degree of Prepared Surface Material:

Adhesive tape.

Method:

application of the adhesive tape on prepared surface and removal for visual inspection.

Inspection:

4 per shift on each of the first 25 pipes.

Specification requirements:

the inspection of the dust degree of each pipe shall be considered as acceptable when the proportion of adhesive surface – magnified 40 times – showing dust particles is less than 25%. Failing this, the pipe shall be de-dusted again.

Total roughness of Prepared Surface Material:

tape made of thermoplastic measuring patches such as “Press-O-Film” of TESTEX.

Method:

take the impression of the prepared surface by pressing a patch on the prepared surface. The total roughness value is then measured using an appropriate comparator and taking into account the thickness of the support. 4 per shift on each of the first 25 pipes.

Inspection: Specification requirements:

the inspection of each pipe shall be considered as acceptable when the 4 total roughness values are within the range of 50-75 microns. In the case of value(s) out of range, 4 additional measurements shall be made around the critical point.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 26of 42

If the roughness obtained from one of the 4 new measurements is:- below 50 microns, the pipe shall be re-blasted, - above 80 microns, the pipe shall be examined by the Inspector. If the Inspector deems the more than 10% of the surface shows a total roughness value exceeding 80 microns, the pipe shall be rejected and reblasted. 10.4.4

Pipe Temperature when Entering Spraying Machine Material

:

Optical pyrometer, temperature manometer or monitor.

Method

:

Specific to the equipment used which shall be calibrated at least twice per shift by means of heat indicating sticks.

Inspection

:

continuous over total pipe length.

Specification requirements:

10.4.5

recorder

the inspection of pipe temperature when entering spraying machine shall be considered as acceptable when the temperature recorded does not deviate more than + 100C from the Manufacture specified temperature. Failing this, the pipe shall be re-blasted. Any pipe heated above 2800C shall be rejected and company will decide for further action to be taken on such pipes.

Pipe travel Speed Material

:

at the applicator’s option.

Method

:

specific to the equipment used which shall be calibrated at least twice per shift using a tachometer.

Inspection

:

continuous during pipe travel along the coating line. The Inspection of pipe travel speed shall be considered as acceptable when the measured speed does not deviate by more than + 0.5 m/mn from the calculated speed Vc.

Specification requirements:

Vc =

Distance (from last spray gun to first roller support) ---------------------------------------------------------------------Pick-up time (specified by Manufacturer)

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

REV-0

Page 27of 42

Failing this the manufacturing process shall be adjusted until conformity with specified requirements is obtained. The pipes already coated with unaccepted speed shall be put apart and recoated as per __ 6.6. 10.4.6

Systematic Inspection of each Coated Pipe This inspection shall be performed after coating application on each dry coated pipe cooled down at ambient temperature, which shall be less than 350C and more then 100C in order to check the following :-

10.4.7

aspect, thickness, cut-backs, electrical porosity,

Aspect Method

:

visual

Inspection Specification

: :

100% of the pipe coated surface. the inspection of each pipe shall be considered as acceptable when the aspect is in conformity with the requirement of 5.1.

Failing this, the Inspector shall be alone entitled to decide of any further action. 10.4.8

Thickness Material

:

magnetic or electromagnetic type overlap measuring instruments.

Method

:

specific to the instrument used which shall be suitably calibrated.

Inspection

:

10 thickness readings made on each pipe at equial intervals along any pipe axis taken at random.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

Specification requirements:

REV-0

Page 28of 42

the inspection of each pipe shall be considered as acceptable is the thickness readings are within the range : specified thickness 3.2mm plus 20%.

If more than 2% of the pipes are found with any coating thickness reading out of the above mentioned range the manufacturing process shall be modified until conformity with the specified requirements is obtained. Only two percent of pipes will be accepted per shift with coating thickness between specified thickness and specified thickness minus 10%. All pipes with thickness below specified thickness minus 10% shall be rejected and recoated as per paragraph 6.6. Thickness of epoxy and adhesive shall be measured at the beginning of each shift and whenever the plant re-starts after any stoppage for compliance. Coating of epoxy and adhesive on portion of pipe required for this purpose , stripping and recoating of such partly coated pipe shall be at contractor’s expence. 10.4.9

Cutback Material

:

rule or template.

Method

:

specified to the material used

Inspection

:

at both ends (110mm,+20mm).

Specification requirements:

of

each

coated

pipe

the inspection of each pipe shall be considered as acceptable when the cut-back length is in conformity with the requirement of 5.3.

Falling this, the inspection shall be alone entitled to decide of any further action. 10.4.10

Electrical Porosity Material

:

adjustable DC holiday detector with voltage indicator – maximum voltage 40,000 volts – and electrode consisting of :- one circular metal searching coil, - one elastomer element for possible defect location.

Method

:

setting of supply voltage to 25000 volts. Total contact of electrode with coating. Pipe travel speed below or equal to 0.2 meter per second. The hliday detector shall be calibrated once per shift.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

Inspection

:

Specification requirements:

REV-0

Page 29of 42

continuous over the entire coated surfaces. the inspection of each pipe shall be considered as acceptable when the number of holidays such as bubbles, scratches and other minor defects does not exceed 3 per tube. Defects shall be repaired as per 4.2. If two successive pipes show respectively a number of defects equal or superior to three (3) the Applicator shall stop the coating line immediately to find the cause and remedy it. Any pipe showing a number of pinholes and/or defects exceeding three(3) shall be rejected and recoated as per paragraph 6.6.

10.5

Systematic Inspection of Pipe coating or Test Samples Taken from coated pipe The inspection shall be performed upon completion of coating application on dry coated pipes cooled down at ambient temperature which shall be less than 350C and more than 100C in order to check the following characteristics:-

10.5.1

Impact resistance, Resistance to peeling, Indentation, Bendability, Coating specific resistivity.

Impact Resistance Material

:

as per DIN 30678.

Inspection

:

work shall be more than 15 Nm per mm of coating thickness.

Specification requirements:

to determine resistance to shock a pile hammer shall be used. The coated pipe is placed on a steel block with a V-notch (1200 angel). The pile hammer surface is a section of a sphere with a size diameter of 25mm. Test drop height shall be 1m, work generated by impact shall be measured within an accuracy of 1%. Spacing between two points of impact shall be at least 30mm.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

REV-0

Page 30of 42

During the testing, check that the impact force is constant. The coating shall be examined with a holiday detector, over the points of impact, at a voltage of 25 kV. For 100 impact points, the detector should not detect more than 2 defects. Method 10.5.2

10.5.3

:

per shift, one test every 50 pipes starting from the first pipe.

Rockwell Hardness R Scale Material

:

as per ASTM D 785.

Inspection

:

equal or more than 60.

Specification requirements:

test shall be carried at 23 + 20C. A type D indentation shall be used with a weight of 5 kg.

Method

one test per shift.

:

Resistance to Peeling Material

:

as per DIN 30678 or NF A 49 711.

Inspection

:

one test per shift starting from the first pipe but not less than 5 test. If one test does not satisfy the requirements given hereafter, measurements shall be taken from 10 new specimens, none of them shall be defective.

Specification requirements:

> 500 N/50 mm at 50 + 5° C > 400 N/50 mm at 90 + 5° C

Method

The Polypropylene coat shall be cut down to the steel surface using a double saw with blades spaced 50mm apart. This band shall be cut along a feneratrix. The free end of the band shall be held in the jaws of a traction machine. The traction shall be made at a constant speed of 10mm per minute.

:

Record the peeling force over the entire circumference. Discard the last 20mm. The average peeling force shall be determined and reported.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

10.5.4

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 31of 42

Indentation Material

:

as per DIN 30678 or NF A 49-711.

Inspection

:

one test per shift, but 5 tests minimum. If one fails, 10 new samples shall be tested, none of the 10 shall be defective.

Specification requirements: penetration shall be less than :- 0.10mm at 250C - 0.30mm at 1000C Method

:

test shall be carried out at a stable temperature comprised between 15 and 250C but controlled within 20C. Testing device consists of a metal rod mounted at the end with a metal punch with a frontal plane surface area of 2.5mm2 ( Dia. 1.8mm). the total weight of the rod and punch shall be 2.5 kg. The pressure excited on the coating shall be 10 N per mm2. The assembly shall be relayed to a penetrometer, whose dial allows a reading to within an accuracy of 1/100 of a mm. The depth of penetration shall be read to within an accuracy of 1/100 of a mm.

10.5.5

Bendability Material

:

adapted bending machine

Inspection

:

2 test among the coated pipes. If one test does not satisfy the requirements 2 other tests shall be made, none of them shall be defective.

Specification requirements:

no holiday, no crack, no wrinkle, no surface defect at resistance to peeling > 500 N/50 mm

Method

Bending shall be carried out at 15 to 250C. Bending radius shall be 20 times the pipe O.D.

:

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

10.5.6

REV-0

Page 32of 42

Cathodic Disbonding Material

:

as per ASTM G 8.

Inspection

:

CD test for 48 hrs. – One test shall be conducted at manufacturer’s in-house laboratory CD test for 30 days – Two numbers test shall be conducted, one test at manufacture’s in-house laboratory and another test in an independent laboratory of national / international recognition

10.5.7

Specification requirement:

As per Clause No. 5.3.4

Method

the test shall be performed at room temperature. A 7mm hole shall be drilled through the coating sample. The hole and the surrounding coating shall be immersed in a 3% Na CI solution and polarized at 1.5 volt by impressed current our with a magnesium anode.

:

Coating Specific Resistivity Material

:

as per NF A 49-711.

Inspection

:

5 tests for the coating, system performed in an independent laboratory. These tests may have been performed previously. The results shall be given to the Inspector.

Specification requirements:

more than 108 ohmx m2 .

Method

the test shall be performed in 0.1 M NaCI solution.

:

Materials needed -

-

a back electrode, e.g. copper cloth, direct current power source supplying a voltage U adjustable from 0 to 50 volts minimum, a voltmeter and an amperometer. One end of the pipe shall be made waterproof so that noe of the uncoated metallic surface is in contact with the electrolyte. The other end out of the electrolyte shall be fitted with an electrical connection. Before insertion into

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

REV-0

Page 33of 42

the electrolyte, absence of pores shall be verified with the holiday detector and the insulation quality at the submersible end checked. To measure resistivity the coated sample shallbe connected to the “+” pole and the back electrode to the “-“ pole of the direct current source. Coating resistivity RS is computed from the values of U, S and I according to the formula. U.S RS= ----------- in ohms x m2 Where: U = Voltage in volts from the direct current source. S = Surface area in m2 of the sample in contact surface with electrolyte. It must be equal to 0.3 m2 minimum. I = Current in A, flowing through coating. If the insulation on the submerged end is correct, the I read is the current passing through the coating. Electric voltage shall only applied during reading. The test shall be continued for 100 days with daily readings. 10.5.8

U.V. Ageing Material

:

as per NF A 49-711 and ASTM D 638.

Inspection

:

5 tests on the same exposed sample of the Polypropylene. These tests may have been performed previously in an independent laboratory. The results shall be given to the inspector.

Specification requirements:

the elongation at break according to ASTM D 638 shall be larger than 390%.

Method

a piece Polypropylene wrap shall be stripped off. The binder coat shall be removed from it.

:

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

REV-0

Page 34of 42

The sample is exposed to the light of a 400 W xenon bulb for 800 hours. The elongation at break shall be measured before and after exposure. Material

:

as per SIS 05 99 00

Method

:

comparison of prepared surface finish with the illustration corresponding to SA 2 ½ surface finish according to the initial metal rust degree (A, B, C or D) or pipe metal.

Inspection

:

100% of the prepared surface of each pipe.

Specification requirements:

10.5.9

the inspection of each pipe shall be considered as acceptable when the whole prepared surface shows the same aspect as the relevant illustration.

Air Entrapment Test a.

Strips from bond strength tests or coated pipe may be used to help determine the porosity of the finished coating. Strip shall be also cut from longitudinal weld (if applicable) at cut back portion and examined for the presence of voids.

b.

Bond strength strip shall be viewed from the side and at the failure interface. At the pipe bond strength test location, utility knife shall be used to cut the edge of the coating to a 45° angle and view with a microscope. Similar examination shall be done in the coating cut back area.

c.

One sample each either on the bond strength strip or coated pipe and strip cut from the longitudinal weld (if applicable) shall be examined for air entrapment per shift. Strips shall be viewed from the side.

d.

All examination shall done using a 30X magnification hand-held microscope. The polypropylene and adhesive layers shall have no more than 10% of the observed area taken up with air entrapment (porosity or bubbles). Air entrapment shall not occupy more than 10% of the thickness in each case. Bubbles shall not link together to provide a moisture path to the epoxy layer.

e.

In case of test failure, retesting and disposal of coated pipe shall be as per 10.5(c) above.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

10.5.10

10.5.11

REV-0

Page 35of 42

Degree of Cure a.

Epoxy film samples shall be removed from cut back portion of the coated pipe using hammer and cold chisel and the samples shall be taken for cure test using DSC procedure. Care shall be taken to remove the samples of full film thickness avoiding inclusion of steel debris. Glass transition temperature differential (∆Tg) and % cure (∆H) shall comply the specified requirements.

b.

Frequency of this test shall be once per shift. Pipe shall be selected randomly by COMPANY Representative during the middle of a shift. Suitable provisions/ arrangements as per the instructions of COMPANY Representative shall be made by the CONTRACTOR for this purpose.

c.

In case of test failure, production carried out during the entire shift shall be rejected, unless the CONTRACTOR proposes a method to establish the compliance with the degree of cure requirements of all pipes coated during that shift.

Epoxy Layer Adhesive Test a.

Adhesion of epoxy layer shall be determined at ambient temperature by the “St Andrews Cross” method i.e. by cutting two straight lines through the epoxy layer with a sharp knife. The incisions shall intersect at an angle of 30°/ 150°. The epoxy coating shall resist disbondment from the steel when attempts are made to flick/ lift the coating from the 30° angle with a sharp knife.

b.

Frequency of this test shall be once per shift. The test shall be carried out at the cut back portion of the pipe from which the Degree of Cure test has been carried out as per para 10.9 above.

c.

In case of test failure, retesting and disposal of coated pipe shall be as per 10.9(c) above.

11.0

HANDLING, TRANSPORTATION AND STORAGE

11.1

The CONTRACTOR shall be fully responsible for the pipe and for the pipe identification marking from the time of “taking over” of bare pipe from COMPANY until such time that the coated line pipes are `handed over’ and/ or installed in the permanent installation as the case may be according to the provisions of the Contract. At the time of “taking over” of bare pipes CONTRACTOR shall inspect and record all the relevant details referred above including pipe defects in the presence of COMPANY. All pipes shall be checked for bevel damages, weld seam height, dents, gouges, corrosion and other damages. COMPANY

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 36of 42

Representative shall decide whether pipe defects/ damages are suitable for repair. Damage to the pipes which occur after the CONTRACTOR has taken delivery such as dents, flats, or damage to the weld ends shall be cut off or removed and pipes rebevelled and repaired again as necessary. The cost of this work, as well as that of the pipe lost in cutting and repair shall be to the CONTRACTOR’s account. All such works shall be carried out after written approval of the COMPANY. Any reduction in length shall be indicated in the CONTRACTOR’s pipe tracking system. 11.2

The CONTRACTOR shall unload, load, stockpile and transport the bare pipes within the coating plant(s) using suitable means and in a manner to avoid damage to pipes. The CONTRACTOR shall stockpile the bare pipes at the storage area of the coating plant. The CONTRACTOR shall prepare and furnish to COMPANY a procedure/ calculation generally in compliance with API RP-5L1 for pipe stacking, which shall be approved by COMPANY prior to commencement.

11.3

The CONTRACTOR shall load, unload, transport and stockpile the coated pipes within the coating plant using approved suitable means and in a manner to avoid damage to the pipe and coating. The procedure shall be approved by COMPANY prior to commencement of work.

11.4

Coated pipes may be handled by means of slings and belts of proper width (minimum 60mm) made of non-abrasive/ non-metallic materials. In this case, pipes to be stacked shall be separated row by row to avoid damages by rubbing the coated surface in the process of taking off the slings. Use of round sectional slings are prohibited. Fork lifts may be used provided that the arms of the fork lift are covered with suitable pads preferably rubber.

11.5

Bare/ coated pipes at all times shall be stacked completely clear from the ground so that the bottom row of pipes remain free from any surface water. The pipes shall be stacked at a slope so that driving rain does not collect inside the pipe. Bare/ coated pipes may be stacked by placing them on ridges of sand free from stones and covered with a plastic film or on wooden supports provided with suitable cover. This cover can, for example, consist of dry, germ free straw with a plastic film, otherwise foam rubber may be used. The supports shall be spaced in such a manner as to avoid permanent bending of the pipes. Stacks shall consist of limited number of layers such that the pressure exercised by the pipe’s own weight does not cause damages to the coating. CONTRACTOR shall submit calculations for COMPANY approval in this regard. Each pipe section shall be separated by means of spacers suitably spaced for this purpose. Stacks shall be suitably secured against falling down and shall consist of pipe sections having the same diameter and wall thickness. The weld seam of pipes shall be positioned always in a manner so as not to touch the adjacent pipes.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 37of 42

The ends of the pipes during handling and stacking shall always be protected with bevel protectors. 11.6

The lorries used for transportation shall be equipped with adequate pipe supports having as many round hollow beds as there as pipes to be placed on the bottom of the lorry bed. Total width of the supports shall be at least 5% of the pipe length and min. 3 Nos. support shall be provided. These supports shall be lined with a rubber protection and shall be spaced in a manner as to support equal load from the pipes. The rubber protection must be free from all nails and staples where pipes are in contact. The second layer and all following layers shall be separated from the other with adequate number of separating layers of protective material such as straw in plastic covers or mineral wool strips or equivalent, to avoid direct touch between the coated pipes. All stanchions of lorries used for transportation shall be covered by nonabrasive material like rubber belts or equivalent. Care shall be exercised to properly cover the top of the stanchions and other positions such as reinforcement of the truck body, rivets, etc. to prevent damage to the coated surface. Slings or non-metallic straps shall be used for securing loads during transportation. They shall be suitable padded at the contact points with the pipe.

11.7

11.8

Materials other than pipes and which are susceptible of deteriorating or suffering from damages especially due to humidity, exposure to high thermal excursions or other advers weather conditions, shall be suitably stored and protected. Deteriorated materials shall not be used and shall be replaced at CONTRACTOR’s expenses. These materials, shall always be handled during loading, unloading and storage in a manner so as to prevent any damage, alteration and dispersion. When supplied in containers and envelopes, they shall bot be dropped or thrown, or removed by means of hooks, both during the handling operations till their complete use. During unloading transport and utilization, any contact with water earth, crushed stone and any other foreign material shall be carefully avoided. CONTRACTOR shall strictly follow Manufacturer’s instructions regarding storage temperature and methods for volatile materials which are susceptible to change in properties and characteristics due to unsuitable storage. If necessary the CONTRACTOR shall provide for a proper conditioning. In case of any marine transportation of bare/ coated line pipes involved, the same shall be carried out in compliance with API RP 5LW. CONTRACTOR shall furnish all details pertaining to marine transportation including necessary drawings of cargo barges, storing/ stacking, sea fastening of pipes on the barges/ marine vessels to the COMPANY for approval prior to undertaking such transportation works. In addition CONTRACTOR shall also carry out requisite analyses considering the proposed transportation scheme and establish the same is safe and stable. On-deck overseas shipment shall not be allowed.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

D:\old data\Vijyant\GSPL\Tender\Const\vol II of V\spec\pdf\PDF Final\014B-3-LPP-Coating of Linepipes-TS-Rev..doc

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 38of 42

MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

12.0

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 39of 42

REPAIR OF COATING CONTRACTOR shall submit to COMPANY, its methods and materials proposed to be used for executing a coating repair and shall receive approval from COMPANY prior to use. In open storage the repair coating materials must be able to withstand a temperature of atleast +80°C, without impairing its serviceability and properties. CONTRACTOR shall furnish manufacturer’s test certificates for the repair materials clearly establishing the compliance of the repair materials with the applicable coating requirements indicated in this specification. All pipe leaving coating plant, shall have sound external coating with no holiday porosity on 100% of the surface. Defects, repairs and acceptability criteria shall be as follows : •

Pipes showing porosities or very small damage not picked up during holiday test and having a surface less than 0.5 cm2 or linear damage (cut) of less than 3 cm shall be repaired by stick welding using material of same quality.

•

Damages caused to coating by handling such as scratches, cuts, dents, gouges, not picked up during holiday test, having a total reduced thickness on damaged portion not less than 2.0mm and an area not exceeding 20 cm2 shall be rebuild by heat shrink patch only and without exposing to bare metal.

•

Defects or size exceeding above mentioned area or holidays of width less than 300 mm shall be repaired with heat shrinks repair patch by exposing the bare metal surface.

•

Defects exceeding the above and in number not exceeding 2 per pipe and linear length not exceeding 500mm shall be repaired with Direx or Cansua Sleeve.

•

Pipes with bigger damage shall be stripped and recoated.

•

In case of coating defect close to coating cut back, CONTRACTOR shall remove the coating throughout the entire circumference of the pipe down to the steel surface and increase the coating cut back length. Now if the coating cut back exceeds 140mm of linear length of pipe then the coating shall be repaired by the use of heat shrinkable sleeves thereby making up the coating cut back length of 120mm.

Not withstanding the above, under no circumstances, if the defects exceeds 70mm from the original coating cut back length, the entire coating shall be removed and the pipe shall be recycled through the entire coating procedure.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 40of 42

Irrespective of type of repair, the maximum nos of repair of coating shall be as follows : •

Holiday repair of size ≤ 100 cm2 attributable to process of coating application shall be maximum of one per pipe.

•

In addition to the above, defects to be repaired by heat shrink patch/ sleeve shall be maximum 2(two) per pipe.

Defects exceeding the above limits shall cause pipe coating rejection, stripping and recoating. The above is exclusive of the repairs warranted due to testing as per this specification. All repairs carried out to coating for whatever reason shall be to the account of CONTRACTOR. Cosmetic damages occurring only in the Polypropylene layer only need not be repaired by exposing upto steel surface, as deemed fit by the COMPANY representative. In any case the CONTRACTOR shall establish his material, methods and procedure of repair that results in acceptable quality of product by testing and shall receive approval from COMPANY prior to use. Testing of repairs shall be in the same form as testing coating. All repairs shall result in a coating thickness no less than the parent coating thickness. CONTRACTOR shall test repairs to coating as and when required by COMPANY. 13.0

MARKING CONTRACTOR shall place marking on the outside surface of the coating at one end of the coated pipe, and marking shall indicate, but not limited to the following information: a. b. c. d. e. f. g.

Pipe number, Heat number Diameter & Wall Thickness Coated Pipe Number Colour band Any other information considered relevant by COMPANY. Pipe Manufacturer Name Inspection Mark/ Punch

CONTRACTOR shall obtain prior approval on making procedure to be adopted from the COMPANY.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING) REV-0

Page 41of 42

14.0

QUALITY ASSURANCE

14.1

The CONTRACTOR shall have established within the organisation and, shall operate for the contract, a documented Quality System that ensures that the requirements of this specification are met in all aspects. The Quality System shall be based upon ISO 9001/2 or equivalent.

14.2

The CONTRACTOR shall have established a Quality Assurance Group within its organisation that shall be responsible for reviewing the Quality System and ensuring that it is implemented.

14.3

The CONTRACTOR shall submit the procedures that comprise the Quality System to the COMPANY for agreement.

14.4

The CONTRACTOR’s Quality System shall pay particular attention to the control of Suppliers and sub-contractors and shall ensure that the requirements of this specification are satisfied by the Suppliers and Subcontractors operating Quality system in their organisation.

14.5

The CONTRACTOR shall, prior to the commencement of work, prepare and issue a Quality plan for all of the activities required to satisfy the requirements of this specification. The plan shall include any sub-contracted work, for which the sub-contractors Quality plans shall be submitted. The plan shall be sufficiently detailed to indicate sequentially for each discipline the requisite quality control, inspection , testing and certification activities with reference to the relevant procedures and the acceptance standards.

14.6

The CONTRACTOR’s Quality system and associated procedures may, with due notice, be subject to formal audits. The application of quality control by the CONTRACTOR will be monitored by the COMPANY Representatives who will witness and accept the inspection testing and associated work required by this specification.

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MECON LIMITED Delhi

PROCESS & PIPING DESIGN SECTION

SPECIFICATION FOR 3-LAYER POLYPROPYLENE COATING OF LINEPIPES (EXTERNAL COATING)

TECHNICAL SPECIFICATION NO. : MEC/S/05/21/014B

REV-0

Page 42of 42

COATING SYSTEM Coating material Manufacturers acceptable to Company are as follows : Epoxy

:

BASF/Basepox Jotun 3M Dupont Bitumese Speciaux, France

Adhesive

:

BASF/Basell Boresalis Dupont SK Corporation\

Polypropylene :

Novacorp BASF/Basell Boresalis/Borouge SK Corporation Malaysian Polypropylene Malaysia (ETILINAS) ELF ATOCHEM, FRANCE

Contractor shall propose coating system(s) indicating specific grade of epoxy, adhesive and polypropylene manufactured by any of the above mentioned material Manufactures and submit the details as per Table 1. Table – 1 Manufacturers Data on Coating System and Materials Coating System data

Epoxy

Adhesive

Polypropylene Compound

Coating System Designation Coating Material combination (s) Technical Data Sheet covering all properties as per specifications Laboratory Test Reports in support of technical data

Manufacturer’s Name

Manufacturer’s Name

Manufacturer’s Name

Product Trade Name

Product Trade Name

Product Trade Name

Technical Data sheet covering all properties as per specification Laboratory Test Reports in support of technical data Certificate of Compatibility with Adhesive Storage Instructions Shelf Life Safety Data Sheets and HSE instructions

Technical Data sheet covering all properties as per specification Laboratory Test Reports in support of technical data Certificate of Compatibility with epoxy and polypropylene Storage Instructions Shelf Life Safety Data Sheets and HSE instructions

Technical Data sheet covering all properties as per specification Laboratory Test Reports in support of technical data Certificate of Compatibility with Adhesive Storage Instructions Shelf Life Safety Data Sheets and HSE instructions

Certificate of Compatibility of proposed materials Application Procedure

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