SITE COATINGS INSPECTOR (ATC90) TWI Cia ‘Training & Examination Services Granta Park, Great Abington Cambridge CB1 GAL, UK Copyright © TWILidSITE COATINGS CONTENTS Section Subject 1 CORROSION 2 SURFACE PREPARATION METHODS & STANDARDS 3. SURFACE CONTAMINANTS AND TESTS FOR DETECTION 4. SOLUTIONS AND DISPERSIONS 5 APPRECIATION OF PAINT TECHNOLOGY 6. STAGES OF PIPELINE CONSTRUCTION 7. COAL TAR AND BITUMEN COATINGS TO BGC PS CWI AND BGC PS CW3 HOT APPLIED TAP! COLD APPLIED LAMINATE TAPE GREASE BASED TAPES COLD APPLIED SELF ADHESIVE OVERWRAP TAPE! POLYETHYLENE CLADDING ENDIX A FILLERS, MASTICS AND PUTTIES HEAT SHRINKABLE PLASTICS BRUSHING MASTICS FUSION BONDED EPOXY MCLs URETHANES SPECIAL SITUATIONS. INTERNAL COATINGS FOR FITTINGS AND HOLIDAY DETECTION TRANSPORT AND STORAGE, EPIPE, LING M THICKNESS SPECIFIED COATING CONDITION CATHODIC PROTECTION HEALTH AND SAFETY DUTIES OF AN INSPE LIST OF SPECIFICATIONS AND BS QUALITY REVISION QUE ONSCORROSION Corrosion can be generally defined ay “Degradation of a metal by chemical or Electro- chemical means”. From this definition it is obvious that two mechanisms are involved, firstly an electrical circuit and secondly a chemical reaction Electrical Circuit In a corrosion circuit the current is always D.C. (Direct Current), It is conventionally tho that a current passes from positive + 10 negative -, ie. from anode to cathode. In fact electrons are flowing in exactly the opposite direction, from cathode to anode. For corrosion Circuit to exist three things are needed: a) Anode An anode is a positively charged area. It becomes positively charged because the atoms release two electrons each, thus causing an imbalance between protons and electrons, positive and negatively charged units, In it's passive state, the iron atom has 26 of each, protons and electrons. when the 1wo electrons are released the atom still has it’s 26 protons. but now only 24 electrons. In this state the atom is now an ion, overall positively charged by two units and written as Fe“*, (An ion is a charged particle, and can be positive or negative. a single atom or a group of atoms. known as a molecule.) This losing of electrons ean be shown as: - Fe > Fe"’ + 2c, The Fe™ is called a positive iron ion. An ion ean be positive or negative and is a charged particle, an atom or a group of atoms. A passive iron atom Fe 26 protons and An iron jon Fe’. 26 protons and only 26 electrons 24 electrons @ @ Nocteus Figure 1.1 iron atoms Comnion Rev PAPI a ‘emacs a 2004 TWH Lid M WT itis donrt az Sie Gv Copstibj) Cathode A cathode is a negatively charged area where there are more electrons than needed in its passive state. These are electrons released from the anode. At the cathode the electrons enter into the electrolyte to pass back to the anode, ©) Electrolyte An electrolyte is @ substance. which will conduct a current and be broken down by it (dissociate into ions). Water is the most abundant elecirolyte and also very efficient. Acids, alkalis and salts in solution are also very efficient electrolytes. As the electrons pass into the electrolyte it is dissociated into positive and negative ions, as shown by the formula: - 2H:032H" + 20H. Simultaneously the electrons couple back with the Hydrogen ions 10 form two full Hydrogen atoms, which join together diatomically to form Hydrogen gas. This is termed as being evolved. or given off from the cathode, The hydroxyl jons return to the anode through the electrolyte carrying the electrons. The corrosion triangle, as shown below, can illustrate the electrical circuit, The electron circuit can be seen 10 be from anode A, to cathode C. through the electrolyte E, back to A. E A c jgure 1.2 The corrosion triai ‘he Chemical Reaction From the above we can see that no chemicill rection, (combination of elements) has occurred at the cathode, or in the electrolyte. The chemical reaction. the formation of corrosion products. only occurs at the anode. The positive iron ions. Fe++. receive the returning hydroxyl ions and ionicatly bond together to form iron hydroxide. which is hydrous iron oxide, rust, and is shown by the formula: Fe"? + 20H Fe (OH): It is now apparent that corrosion only occurs at the unode. never at the cathode. Hence the term cuthodie protection. Ifa structure can be made 1o be the eathode in a circuit it will not corrode. The corrosion triangle shows the three elements needed for corrosion 1 occur. anode. cathode und electrolyte. If any one of these three is removed from the triangle, corrosion cannot occur. The one most commonly eliminated is the electrolyte. Placing a barrier Site Coa Toms Consebetween the electrolyte and the anodic and cathodic areas. in the form of a coating or paint system does this. If electrolyte is not in direct contact with anode and cathode, there can be no circuit, and so no corrosion. The basic corrosion reaction, as explained above, occurs fairly slowly at ambient temperatures. In common with all chemical reactions certain factors can increase the reaction rate, listed below are some of these. 1 Temperature. Steel, in common with most metals, is thermodynamically unstable. The hotter the steel is the faster the corrosion will occur. Hygroscopic Salts. A hygroscopic salt is one, which will attract water and dissolve in it, When salty are present on a substrate and a coating is applied over them, water will be drawn through the film and the resulting solution builds up a pressure under the film, Eventually the film is forced up to form blisters. “These blisters are called osmotic or hygroscopic blisters, and are defined as “pinhead sized water filled blisters’. Sulphates and Chlorides are the two most common salts, chlorides predominant in marine environments. and sulphates in industrial areas and sometimes agricultural 3 Aerobic conditions, (presence of oxygen). By introducing oxygen into the cathodic reaction the number of Hydroxyl ions doubles. This means that double the number of jron ions will be passivated and therefore double the corrosion rate. Shown by = 2H;0 + O; + 4e > 40H: 4 Presence of some types of bacteria on the metal surface, for example Sulphur Reducing Bacteria. better known as SRBs, or MEMs, Metal Eating Microbes. Bi-metallic contact. Otherwise known as Bi-Metallie Corrosion. Meuals can be listed in order of nobility. A noble metal is one, which will not corrode. In descending order. the further down the list the metal is. the more reactive it is. and so, the ‘more anodic itis. the metal loses its electrons to become reactive ions. The degree of activity can be expressed as potential, in volts. The list can be called a Galvanic List. but when the free potentials of the metals are known it can also be called the Electro Motive forces series fr the Electro-Chemical series. Below is a lit of some metals in order of nobility with potentials as measured using a copperlcopper sulphate haif-cell reference electrode, in seawater at 250¢ Tie Casings > Const ROT Ap coononntes Copyright ©2004 TWH Lad : By skisMATERIAL, KNOWN POTENTIAL AV. VALUES Graphite $0.35 v Titanium 0.0% Silver “ON Nickel 200 =O.15 Lead ~02¥ ‘Admiralty Brass =O.av Copper = 0.35% Tin _ = 0.35 Mill Scale =. v Low Alloy Steel 076 Mild Steel O78 ‘Aluminium Alloys 09 Zine = 1.0 Magnesium = Ley From the list above it can be seen that millscale is immediately above steel on the galvanic list. ‘This means that millseale is cathodic to steel. and if lefi on the surface of steel will accelerate the corrosion of the steel substrate. Millscale is formed during the roiling operation of steel sections e.g. RSC. RSA. RSJ. The oxides of iron form very quickly at temperatures in excess of $80c. The first oxide formed is FeO, iron oxide. the next is FexOx and last of all Fe:Os. Common names in order are Wustite, Magnetite and Haematite. These oxides are compressed during the rolling operation to produce blue millscale. The thickness of millscale varies from 25 to 100 um. Because millscale is only produced during rolling, when it has been removed by any surface preparation method, it can never re-cur. Site Gna ‘Convsion Rov P Apel Od PW] seer siie tone Cis " ty 4 TWH Ld Ma La ine aeSURFACE PREPARATION METHODS & STANDARDS Ii the products of the corrosion reactions. and other contaminants, were Jeft on a substrate and paint applied over them. the adhesion of the coating and thus the coatings life would be far from satisfactory. Surface preparation involves removing these contaminants, and in some instances increasing the area available for adhesion by roughening up the substrate. A good Surface preparation grade (degree of cleanliness) along with a suitable surface profile can give 10 years life from a typical four coat paint system. The same system applied over a Substrate with little or no profile and contaminant remaining might give four to six years, or even less Therefore wo factors need to be considered when inspecting a surface preparation, 1. Degree of cleanliness 2. Surfuce Profile (degree of roughness) Ifa speci criteria are satistied. ion gives criteria for both of these factors. then quality is not achieved until both Surfaces can be prepared for paint application in several different ways, each one varies in cost. efficiency. ease and suitability. a) Dry Abrasive Blast Cleaning b) Water Blasting ¢) Hand and Power Too! Cleaning 4) Flame Cleaning ©) Pickling i) Vapour Degreasing g) Weathering Dry abrasive blast cleaning, Dry abrasive blast cleaning involves compressing air and forcing it along a hose and out of a small aperture called a nozzle. A pressure of 100 PSI results in the air exiting the nozzle at approximately 450 mph. 1f abrasive particles are mixed in with the air und travel at the same speed. they will carry a lot of work energy. This energy is used in chipping away millseale ‘and other detritus trom the substrate. With some abrasives part of the energy is used in Shattering into small pieces and with others all the energy is used in impinging into the see! surface, roughening the surface and increasing the surface area to increase adhesion properties. Because all standards sefer to the amount of contamination remaining on the surface, the her the degree of cleanliness longer the time spent on this operation. the bi Sori Prpaaina Rev PAPI . Cipsrs hv © 2008 781i 2 BY SassonAbrasives Abrasives come in many forms and can be classified in several different ways. as shown below. None metallic (Mineral) | Metallic (Recyclable) Agricultural by-product expendable | Copper Slag ‘ACI (Angular Chilled Iron)_) Walnut Shell | Nickel Slag Steel Grit Coconut Shell Boiler Slag Steel Shot Fggshell Glass Bead Grit and Shot Mix Corn Cob Husk Aquamarine (Olivine) Garnet Peach Husk Garnet Sand It can be seen that the recyclable abrasives are the more costly, and therefore justify a 1g operation before re-use. In the context of this course we are considering the following: - a) Sand It is not permitted to use sand. $1 1657 states that any mineral used as an abrasive must release less than 1% free silicw on impact. (Silica causes preumonicosis or silicosis). COSHH REGS does not allow the use of sand containing silica for dry blasting. Sand itself is perfectly safe. but shattering on impact releases silica. which can be inhaled. b} Copper Slag Although the name implies metallic content, the amount of copper in the structure is extremely minute. Minerals smelted with the copper. liquefy and form a protective cover over the molten copper to prevent reaction with the atmosphere like slug on a weld, When the copper metal is run off the slag is rapidly cooled in cold running water which eauses it to shatier The material is supplied in grit form (random, sharp edges, amorphous) and is very brittle shatters into smaller pieces on impact, and should be used only once and then discarded. and so classed as expendable. Site Coatings ~ Surface Preparation Res F Apa Od Copyright © 2004 TWH Ld 2cc) Garnet A natural mineral classed as being “of a diamond type hardness”, can be either expendable or recyclable. Ifthe situation justifies, cleansing units are available to extract contamination so that the material can be re-used, usually up 0 three times. Doesn't shatter on impact but does suffer some “wear”. Supplied in Grit form, d) Metallic Grit In this context, steel! and iron are both metallic. Cast steel grit being the softer of the 1wo tends to round off on impuct and loses its sharp edges. Angular Chilled Iron chips off small slivers on impact to produce sharp cutting surfaces on its next cycle. The finings so produced are extremely abrasive and cause extreme wear on moving parts of the recovery systems Metallic abrasives are recyclable because the particles reduce in size slowly, Hence it can be re-used many times and sill perform a useful function in a “working mix’. A working mix is an accepted ratio of large and small particles, where the large particles cut the profile and the smaller particles clean out the troughs. ©) Metallic Shot Shot is spherical and doesn’t shatter (otherwise it would form grit). When supplied the particles are virlually uniform in size and shape, (not working mix) but like the grit they wear down slowly in size. Regular addition of new abrasive, as with grit, will then maintain a working mix. The particles are worn down eventually 10 finings, and are drawn out of the system during cleansing. f) Metallic Shot and Grit Mixed A mix of shot and grit results in a more uniform profile. The grit cuts the profile and the shot. being unable to enter the troughs produced. controls the peak height and so greatly reduces the number of *rogue peaks’. A rogue peak is one, which is well proud of the acceptable profile range. and if painted over due to contraction of the paint. will leave bare metal in contact with the almosphere, thus allowing corrosion to occur. When rogue peaks are in concentrated area the effect is of a rash. hence rust rashing or rust spotting A typical mix ratio of Shot to Grit as used in pipe coating mill would be 70 ~ 80 % shot to 20-30% grit Sie Changs = Sores Paporaow Rew VAST Wy] wane Consright © 200 TWH Lid 23 Dy SSSOther properties of an abrasive have an effect on the resulting substrate also. these being. Size of the particles Hardness of the material Density of the material Shape of the particle For example steel has a density of approximately 7.6 gmvcc and copper slag. depending on composition, approximately 4.2 gmvec. Ione particle of each material, of identical size, hit a stee] substrate, then it would be logical to say that the steel would impinge further into the substrate. resulting in a deeper trough. A spherical particle would not impinge as deeply because the large smooth surface area would use its energy up in peening or work hardening the surface rather than cutting into it. So a shot blasted surface is different in appearance and texture to that of a grit blasted surface. Sizing of abrasives G Prefi S Prefix Grit amorphous. points and cutting edges. irregular profile, hot spherical, smoother profile. The G oF S notation is followed by a number. which denotes the particle size. E.g. G24 or S330. From system to system the number can represent vastly different values. e.g. with the now defunct BS 2451 the 24 means nominally 24 thousandths of an inch where as in the SAE system it represents '/ss = approximately 40 thou. The new BS ref. 7079 pt E uses a different method again, in metric units, G140 would mean a nominal particle size of 1.4mm, Adhesion and Profile A commonly used definition of adhesion is: - The force required to separate wo surfaces in touch, A newly rolled plate, perfectly smooth, 1m x Im has an apparent surface area of Im? and an actual area of Im*. Abrasive blasting roughens the surface and increases the actual ares. (the apparent area is still 1m"). thus increasing the adhesion. Two theories of adhesion are: J Molecular Interference. Because the surface is rough and uneven the paint wets. and Jocks into the profile. analogy Velcro, Physical 2 Molecular Attraction, Negatively charged particles attracted to positive areas, and vice versa, Analogy. Magnet (sometimes called lonic Bonding), Chemical. Soriace Preparation Rev Ppa TWI wenn Clpanah@ 50nt TIT a TWD eneThe original rust grade is then given a degree of cleanliness. ie. a grading relating 1 how much contaminant is left on the surface after preparation. The degree of cleanliness is mainly dependent on the time spent on the area and the velocity of the particles. Abrasive Blasting Grades Before surface preparation commences any oil or grease should be removed (by specified solvent or proprietary degreaser) and heavy rust and scale removed by chipping. After preparation the surface should be free from dust and debris. Sal ~ Light Blast Cleaning. When viewed without magnification, the surface shall be free from visible oil grease and dirt and from poorly adhering mill scale, rust, paint coatings and foreign matter. Sa2- Thorough Blast Cleaning. When viewed without magnification, the surface shall be free from visible oil grease and dirt and most of the millscale. rust. paint coatings and foreign matter. Any residual contamination shall be firmly adhering. Su2' —- Very Thorough Blast Cleaning. When viewed without magnification, the surface shall be free from visible oil grease and dirt and from millscale. rust paint coatings and foreign matter, Any remaining traces of contamination shall show only as slight stains in the form of spots or stripes. Sa3- Blast Cleaning to. Visually Clean Steel. When viewed without magnification the surface shall be free from visible oil grease and dirt, and shall be free from millscale. rust, paint coatings and foreign matter. It shail have a uniform metallic colour, From the above definitions it ean be seen that Sa 1 and Sa 2 are not achievable on rust grade ‘A and consequently there are no photographs for the grades. ‘The American SSPC and NACE (Steel Structures Painting Council and National Association of Corrosion Engineers) have their own systems and compare as below. BS 7079 A] SSPC NACE Sud White Metal SP5 Grade 1 Su27 Near White Metal SPIO Grade 2 ‘Sa2 ‘Commercial Finish SA6 Grade 3 Sel Light Blast and Brush of SP7_[ Grade 4 Sie Coatings ~ Suave Preparation Rew T April wav Copsright © 200 TWH Lat ee TW ren SaEquipment 1 Wheel abrators Wheel ubrators, sometimes known as centrifugal blast units are a mechanised way of preparing components for coating. They are ideal for long production runs on similar section components such as pipes in a pipe coating mill, or bridge steelwork. They are usually referred to by the number of “wheels” which they operate e.g. 6 wheel. Special machines are designed for special circumstances €.g. Mat steel plated for fabrication yards or ship yards, pneumatically driven operator controlled machines for blasting decks or internal tanks magnetic crawlers for tank externals. ‘The operators of these machines prefer shot as an abrasive. grit cuts the impellers and entails large amounts of downtime, but when the specification demands, it must be used, ‘The abrasive is gravity fed into the centre of the wheel. Centrifugal forces carry it to the end of the impeller where it is impelled at the component to be cleaned at a speed of 220 mph app. in a fan patiern. The fast moving metallic abrasive shatters millscale, cuts a profile etc.. rivochets and eventually. its kinetic energy spent, drops. The floor of the unit is open gratin: over a °V" shaped pit, in the bottom of which is a rotating screw which carries the spent abrasive plus detritus into a hopper. A conveyer system then carries the abrasives 10 the top Of the machine. dispenses it, to start a gravity fed path back to be re-used. As an integral part of the system the abrasive passes aver a tilted plated. known as & weir plate, As the abrasive and detritus cascades over the edge of the weir plate. a current of air is drawn through it This draws out low density materials such as rust, millscale. flakes of paint ete.,. and finings. abrasive worn so small that it is no longer useful. This is known as an Air Wash Separator. the same principle is used in enclosed grit blasting pens, Meanwhile the cleansed abrasive is fed back into 2 common hopper with feed fined to all the wheels, to be re-used. As mentioned previously new abrasives need 10 be added periodically 10 maintain an adequate working mix, Considerations ‘The quality can he controlled by adjusting the feed roller speeds and therefore is more consistent. Because the system is totally enclosed there is efficient use of abrasives, More operator safety because the operator is not involved. The systems can be far more productive (dependent on supply of components) than open blasting ‘Site Coarings — Surtave Preparation Rev | Apia FW meses nr 2004 TWH Lad MR Cat Sie CopyOne mujor problem is access to bolt pockets, gussets and stiffeners etc. Because the wheels are fixed. there is no manoeuvrability, and thus shadow areas arise, One way to avoid this is, ‘manually blast difficult areas prior to machine blasting. Air Blasting Site blasting is normally carried out using expendable abrasives and open blasting systems, Open blasting systems operate using. 2) compressor b) A pot containing the abrasives. ©) Vapour Traps for oil and water (knock out pots) 4) Arhose. usually carbon impregnated. ®) Anozzle 1) A dead mans handle for operator safety a) Compressor Compressors are rated by two factors. i Air pressure ~ measured in Psi, pounds per square inch. ii Capacity, the amount of air it can deliver at the pressure required. in cubic feet per min cfm, or litrevmin, I is normal in the UK for portable compressors to be set at 100 psi. which is considered 10 be the ultimate pressure for open blasting. Air abrasive mix and stand off being constant it is considered that blasting at 100 psi gives 100% efficiency. Using pressures over the 100 psi uses more abrasives, more fuel, more effort from the operator, more work by the compressor. without a proportionate increase in area blasted. where us every I psi drop in pressure results in an efficiency drop of 1'/2%. 80 psi blasting pressure results in 70% efficiency. Although this is not a responsibility of the inypector itis required information, It is far better to have a large capacity compressor working below its capacity than to have & smaller rated compressor working to full capacity b) Blast Pot For site work the most common is the pressurised blasting pot, These are supplied in various sizes and are selected according to purpose. E.g. it would not be economical to recharge the pot every 5 minutes when blasting a large crude oil tank. ‘The pots are charged with abrasives and when pressurised, seal, rubber to rubber. by means of a mushroom shaped cap. The abrasive is blown by air pressure into the air stream feeding the nozzle. ‘The abrasive flow can he adjusted by means of a metering valve on the conical base of the pot, This is sometimes culled a ‘miser’ valve. Sie Gores Surfs Papaavion Rov Tape ——F cnn Copyright © 2008 TWH Lid om By aterm©) Vapour Traps ‘Air contains water vapour and when air is compressed the water vapour in the air is compressed, Compression produces heat and as the air heuts up its capacity 10 hold water increases, every 11° rise in temperature the airs capacity 10 hold water doubles. Conversely when the air cools rapidly on expansion, exiting the nozzle, water droplets are formed. Should this water contact the substrate. corrosion would result. Also atomised oil (f#om the cylinder lubricants) needs to be extracted, otherwise low surface energy material, oil. on the substrate will adversely affect adhesion. The knockout pots are on the main airline and are inverted transparent glass domes. A small cock on the bottom allows them to be emptied, and usually are kept slightly open. In the UK climate it is not unustsl to blow downstream 20 gallons of ‘water in an eight-hour working day 4) Carbon impregnated Hose Because pressure drops along the length of the hose, line lengths are better restricted 10 around seven 10 eight metres. Internal couplings reduce the hove diameter and uct as pressure reducers. cause turbulence and wear. so external couptings should be used, Hose diameter is related to nozzle size and should have an internal diameter al Jeast three to four times the nozzle diameter. Any specified blasting pressure refers 10 pressure as taken at the nozzle. This can be measured using a hypodermic needle gauge. The needle is placed through the hose near the nozzle with the needle fucing towards the nozzle. ©) Nozzles ‘The air consumption and air speed are directly related to the nozzle aperture size. ‘The larger the nozzle size the more air will be needed 10 maintain pressure. Typically a /4" nozzle will need 103 cfm to maintain 100 psi. where as a ¥%” nozzle needs 413 clm. Therefore big nozzle. large bore hose. needs high capacity compressor, Sometimes the nozzles are lined with tungsten carbide or ceramics to reduce weer, Various types of nozzles exist including angled nozzles straight bore and venturi, The venturi Shaped nozzle give a larger blast pattern with a more even spread of abrasives and higher velocity of the particles at approximately 450 mph, The straight bore nozzle gives small concentrated area of abrasive contact with a fringe area of lower concentration and particle speed of around 200 mph. The stand off distance for both types varies according 10 hose size and nozzle aperture size, but an average figure is around 450mm. Site Cvatings = Soave Preparation R&D April Dd eat erin vee TW) Copyright € 2004 TWT Lid DIS Cea seisf) Safety 10 IGE SR 21 With enclosed systems like wheel abrators, personnel passing the equipment are far safer than in site situations. abrasives are confined in a small area. When abrasive blasting is taking place on a construction site or pipeline. access is not restricted and vehicles and personnel can be within close proximity of the equipment. I is therefore necessary to have warning sig advising that abrasive blasting is in progress. along with warning buntings segregati area Other safety considerations are. i The hose should be carbon impregnated to reduce the chance of the operator getting electric shock from static. iA dead mans handle should be under direct operator control for his/her own safety. iii Hoves should be kept ay straight and ay short as possible to avoid kinks, and blowouts and to maintain pressure at the nozzle. iv Use reinforced hoses if possible. v__Use external bayonet type couplings. continually bonded. vi Maintain operating pressure at 100 psi vii Correet protective clothing should he wor by the operator. including direct air fed helmet, with adequate visors. leather aprons and gloves, boots und ear protectors. Water Blas ing Surface preparation methods using water are more environmentally friendly than open blasting and also. from the safety aypect. spark free. ‘They are ideal for removal of soluble salts. sulphates and chlorides, (the hygroscopies) although complete removal needs high pressure ranges. Wet blasting methods are also ideal for removing layers of toxie materials. e.g. read lead. calcium plumbate, and zine chromate primers. These materials are safe during application but removal by abrasion results in fine particulate matter passing into the air which can then be inhstled and passed into the bloodstream. There are certain disadvantas ted to wet blasting e.g. supply of large amounts of water and disposal of the resulting shurry (water and detritus as an entity) nd also mixing substrate inhibitors if the specification demands it. (Substrate inhibitors are substances usually sodium compounds. added 10 the water. to retard the formation of corrosion products) Some organisations, including B G do not allow the use of inhibitors. in which case wet blasting is followed by dry blasting. 1o remove light oxidation. Site Coatings ~ Surface Preparation Rew 1 April TWH 8 ina sia ion Copyright © 2004 TWH Lid 26 Cow sissonHigh pressure water blasting up to 30 000 psi (water jetting) Using pure water, usually out of a rotating head giving alternating pencil and fan jets. Water usage is about 60 litres per minute. To work efficiently the head must be near to the surface. within 25 10 35 mm, and as the distance increases the elficiency reduces, until at “approximately 250 mm only loose and flaking material will be removed... ‘The principle of operation is simple and flexible. but operator fatigue is a problem, This system will remove soluble contamination and millscale at the higher pressure ranges but will not cut a profile, It vill only clean up the original profile on rework areas High pressure water plus abrasive injection This system operates at about 20.000 psi and uses abrasives. either gravity fed into the system, suction fed or mixed as a slurry. Marine growths e.g. bamnacles. are easily removed with this system and it us often used in dry-docks on ship hulls. Because of the abrasives a profile is cut using this method. Low pressure water plus abrasive injection Uses normal blasting pressures of 100 psi. but with water as a propellant rather than air, The abrasive content is semi-soluble e.g. Sodium Bicarbonate crystals. tale, chalk, and ideal for use on non-ferrous metals and G, R. P. Sodium Bicarbonate is excellent for acidic or greasy situations. This method is very slow and controllable and can if needed, remove one cout of paint. The abrasives have a very gentle action but leave masses of problematic slurry Steam Cleaning Ideal for oily und greasy situations. but steam production requires a heat source, which is not conducive with the oil and gas industry Air blasting with wate Water is injected. with or without an inhibitor into the air/abrasive stream. either immediately afler it exits the nozzle or immediately before it enters the nozzic. Water usage with this method is approximately one to one and a half litres per minute. which is sufficient to control dust Hand and power tool cleaning. 7079 Pt A. ISO 8501, SS 05 59 00 Any hand operated or power tools. including needle guns, wire brushes. emery cloth and grinders can be used to achieve these standards, Sie Comings ~ Sorte Para RST ApH TW] concn © 204 TWH Ld 2 Fwy sistasHand and power tool cleaning methods are tried and tested over many years, but are now considered to be far less efficient than other modern methods, Limited access or environmental considerations may be factors which influence the choice of methods. Hand and power tool cleaning is often specified for short term maintenance programmes. One major disadvantage of this method is the lack of surface profile. Wire brushing will not produce a profile and in most cases will actually reduce an existing profile. sometimes resulting in burnishing. which is polishing. and a smooth shiny area does not provide good adhesion, Burnishing needs to be treated by abrading with coarse emery As with abrasive blasting heavy rust, oil und grease need to be removed prior to preparation of the substrate S12 - Thorough hand and power tool cleaning. When viewed without magnification the surface shall be free from visible oil, grease and dirt and from poorly adhering millscale rust. paint coating and foreign matter S13 ~ Very thorough hand and power tool cleaning. As for St2 but the surface shall be treated much more thoroughly to give a metallic sheen arising from the metallic substrate. There are no wire brushing grades for Rust Grade A as the millscale iy much harder than the bristles on the brushes. which are of non sparking alloys such as phosphor bronze and beryllium bronze. If needle guns, jasons hammers, are used they tend to leave a very coarse profile which invariably needs to be reduced by abrading with emery. or grinding. Flame cleaning Not likely 10 be used on oil and gas plants, but it is an approved method of surface preparation, with photographic standards, The BS 7079. ISO 8501 (SS 05 5900) contains Jour photographs showing flame cleaning standards from the original rust grades A, B. C. D. The designation given is AFL. BFL. CFL. and DFL. There is only one flame cleaning standard for each rust grade. ‘Three factors contribute to how flame cleaning works 1. Expansion All materials have different co-efficient of expansion, ic. all expand and contract at different rates per degree centigrade rise or fall in temperature. Millscale is chemically bonded 10 the ed heat causes the materials 10 expand at different rates. thus breaking the steel and appl chemical bond Sis Crating > Burka Propaion Rov TAT PWT warn ioe Copyright © 2008 TWH La has ” WasaDehydration Water in the corrosion products and in the fissures ete. is evaporated away, facilitating the semoval of the corrosion products. 3. Heat penetration ‘The heat is conducted efficiently into the substrate aiding the drying of the stee! and removal of penetrated oil or grease, It is not wise 0 use this method of surface preparation on any fasteners relying on tension, e.g. rivets. screws, nuts and bolts. Method ‘The operator slowly passes an oxygen/HC gas flame (Butane. Propane. Acetylene) over the area to be cleaned, (weld preheat torches oF specially adapted lances) 10 burn and de oxidise the corrosion products and other contaminants. This leaves a grey coloured ash deposit ‘A second operator follows on with a power brush to remove the now loose, ash deposits. ‘The primer can now be applied over the warm steel, reducing the need for addition of thinners. Other benefits are that the heat reduces the viscosity of the paint and gives betier flow properties. The paint can then ‘wet out’ better and pass into tiny cavities and irregularities on the surface. The heat also accelerates the drying process and keeps the stee! above dew point temperature. Pickling Pickling is a general term relating to the chemical removal of oxides (rust), from & metal substrate. The metals can be either dipped (totally immersed) in the pickling fluid or sprayed with it. Usually aqueous solutions of acids are used for steel. they convert the oxides into soluble sults e.g, Sulphuric Acid produces Iron Sulphate salts. Sulphuric is the most common acid used for economic and safety reasons. Footners Duplex System involves the pickling process followed hy a passivation process using Phosphoric or Chromic acid along with a small percentage of iron filings, which produces Iron Chromate or Iron Phosphate salts. which are not soluble ‘These form a rust inhibitive layer, which passivates the surface and increases the adhesion properties. They are also extremely resistant 10 cathodic disbondment Te Coane Swi Pepa Re TARO Copyright © 2008 TWH Lid ny WY coneA typical process would be: ~ 1. Any oil or grease needs to be removed by using a suitable solvent e.g. xylene or as specified. Oil and grease show up as fluorescent yellow/green under an ultra violet light 2. Totally immerse in a bath of Sulphuric Acid. 5 ~ 10% concentration at a temperature of 65~ 70". Time can vary from 5 10 25 minutes depending on degree of contamination but is invariably at the lower end, 3. Rinse using clean warm water to remove the layer of soluble salts formed. If required the component could be coated after pickling. Likewise components can be blast cleaned and sent on for phosphating/chromating, but the patented process is only called “Footners” when pickled then phosphated/chromaied. 4, Immerse in a bath of phosphorie/chromic acid, 2% solution at 80™ for approximately ‘one 10 tWo minutes with iron filing (0.5%) (and an inhibitor to prevent embrittlement} This leaves a very thin layer of iron phoyphate/chromate, which acts as a rust preventative for a fimited time. 5. Rinse in clean water. and check for pH values, pH is a measure of ucidity or alkalinity of a substance and is measured using pH indicator strips. An indicator such as litmus will only tell if a substance is an acid or an alkali Indicator strips give a measure of acidity or alkalinity, based upon the scale below 9 10 1 12:13 14 Acid Alkaline ey Figure 2.8 pH scale This is a logarithmic seale and seven is neutral. the pH value of distilled water. From 7 10 0 the acidity increases. and from 7 10 14 the alkalinity increases. A typical requirement alter rinsing will be in the region of pH 4.5 10 7.0, slightly ess acidic than household vini Vapour degreasing Fumes from a solvent bath condense on component suspended over the bath and dissolve any oil or grease, which then drips back into the bath. Very rarely used because of modern regulations regarding strong hydrocarbon solvents “Site Coatings = Surface Prepara Copgright © 2008 TWH Lid TW Sones om CLM isonsWeathering Weathering relies on co-efficient of expansion properties as mentioned in Flame Cleaning. When lefi in a stockyard, open to temperature changes, day and night, she millscale sheds. This can now leave the steel open 10 aimospherie corrosion, which produces such as Sulphate salts Sie Gouinges Suri Papuan Ra Tap WYP Sow nese Congr © 2008 TWH Li 221 NeSURFACE CONTAMINANTS AND TESTS FOR DETECTION Any contaminants left on a prepared substrate will effect the adhesion of a coating 10 that Substrate, and therefore specifications often request that certain tests are done 10 ensure that contamination is within set criteria, Some tests are qualitative and some are quantitative. A qualitative test is one, which give a result as accepUreject, pasvfail. go/ng go, whereas a Quantitative test is one, which gives a result in known units e.g. milligrams” Test for soluble iron salts This is a qualitative test, it will not even differentiate between the salts. It will detect the presence of either Sulphates or Chlorides. This test is known as the Potassium Ferricyanide test, although it is now under a new universal naming system, known as Potassium Hexa-cyanoferrate. a name more descriptive of its formula. Test papers. usually Whatman N°3 laboratory filter papers are soaked in 2 S~ 10% solution of potassium ferricyanide and distilled water. and left 10 dry. ‘The result is a lime green paper, fringed with an orange brim The area of blast to be tested is sprayed with a fine mist of distilled water, (any other water is likely to contain dissolved salts). and left a few seconds to allow the salts, if present, to dissolve and form a solution, A potassium ferricyanide test paper is then applied to the area and by capillary action draws up the solution like blotting paper. Iv there are any dissolved salts they react with the potassium ferricyanide to form potassium ferrocyanide, The ferrocyanide is prussian blue and shows as blue spots on a lime green background. Test to detect soluble chlorides The test for detecting chloride salts is known as the Silver Nitrate Test |As with the previous test a solution of silver nitrate. 2% with distilled water. is made and the Whatman papers cut into strips. The strips are then soaked in the solution and pressed onto the area under test for about 20 seconds, then washed in distilled water. ‘Sie Contings Salutions & Dispersions Rev 1 April DE PW sone sin ten Copyright © 2004 TWH Lis st By wisThe reaction between silver nitrate and any chloride salty present produces silver chloride, which remains on the strip after washing. 1 the sivip is then dipped into photographic developer the chlorides show up as black/brown, Other tests for salts 1 Merkoquant A saltsfwater solution is made by swabbing an area of 150 mm x 150 mm with distilled water. 22.5 ml, Merkoquant strips are then dipped into the solution and the resulting colour change is compared to a master chart on the container. The concentration is read off Irom the chart. 2 Bresle sample patch Reported as being 95% accurate. An adhesive patch with & rubber diaphragm is stuck onto the surface and distilled water injected and extracted several times to produce a solution of any sults present, By a process of Mercurie Nitrate Titration concentrations of 15 mg/m? can be detected. A quantitative test. 3. Salt contamination meters Salt contamination meters measure the resistivity or conductivity of a given sample and convert this value into a concentration (mg/m). With any of the above tests. if the amount of sults present is greater than specified. the area should be washed down with copious amounts of clean water, reblasted and retested ‘Test to detect the presence of millscale Millscale being cathodic in relation to steel can cause corrosion cells under a paint film and Subsequent early disbondment, Millscale in small quantities is permitted on a SA 2! blast sandard, but not on an SA3. Therefore the test needs to be carried out only if the specification requires an SA3. Blasted steel is dark grey in colour and millscale is dark blue. so by naked eye the contrast is difficult, However. if the surface is sprayed with a fine mist of slightly acidic copper sulphate solution. the solution ionises and tints the steel copper colour and blackens the millscale. if present, thus providing a better contrast sted. IF this test indicates millscale presence then it should be reblasted and then ret Si Comings Solan & Binion RS PARI arg wenn Copyright © 2004 TWH Lid a2 Cm sen‘Test to detect the presence of dust on a substrate ‘Any dust on a blasted substrate will adversely effect the adhesion of a paint film. In conditions of low relative humidity. dust and finings passing down a blast hose become electro statically charged and stick onto the substrate. Brushing or air blowing the surface ‘will not remove them. self adhesive tape however. will Ifa piece of self adhesive tape is stuck onto the surface and snatched off, the dust/finings sticks to the tape. By then sticking the tape onto white paper the dust can easily be seen. ‘Test to detect the presence of moisture on a substrate Presence of moisture, even in the teeniest amount, can affect the choice of paints and if work can be done or otherwise. A very simple test for the presence of moisture is to sprinkle with tale or powdered chalk and then lightly blow away, The powder will stick to areas where moisture is. ‘Test to detect the presence of oil or grease Other than ultra violet light, oil and grease can be detected by dropping solvent onto the suspect area, and absorbing the solution on Whatman or blotting paper. ‘The solvent will evaporate and oil or grease will give a darker appearance Sine Coat Copy Satutions & Dispersions RAP ApH DE TWI Sern ee bn © 200 TWH Lid RB BI saeSOLUTIONS AND DISPERSIONS Solutions A solvent is a liquid, which will dissolve another material. liquid or solid. ‘A solute is the material dissolved by the solvent. A solution is the resulting liquid. Salt and water, sugar and water are solutions, a binder and solvent are also a solution, Dispersions 'A paint consists of solid particles suspended in the vehicle. where there is no solubility, so @ paint is a dispersion. A dispersion can be either a solid or liquid dispersed within another Tiquid, where there is no solubility A suspension A suspension is when fine particulate solids, e.g. pigment and extenders are dispersed within ‘a liguid, the vehicle. Ideally: afier the manufacturing process. each particle should be completely wetted by the vehicle. However because the pigment particles are so small, they Cluster together to form agglomerates or aggregates. In some paints, expecially gloss. the size of these aggregates is a very important factor and so has to he checked. The aggregate size is known as Degree of Dispersion of Fineness of Grind An emulsion An emulsion is a liquid dispersed in another liquid when there is no solubility. In vinyl or ‘acrylic emulsion. very tiny droplets of resin are suspended within water. which can now be scen to be anon solvent. In an emulsion water is a carrier, not a solvent. Water is called the continuous phase, and oil/resin is called the dispersed phase ‘Sire Coatings Paint Teehnok Coporitt © 2M TW Ld mn ByAPPRECIATION OF PAINT TECHNOLOGY ‘Some aspects of paint technology apply equally to pipeline coatings and site painting. Some coatings commonly used on pipelines specify primers. Some repair systems are based on two pack epoxies and urethanes. Some materials are not suitable for use over others. solvents in & ‘material may have adverse effects on an underlying coating. It is important, therefore. to have an understanding of the basic concepts of paint technology Paints can be divided into three categories 1 Liquid paints containing solvents Primers for enamels and tapes fall under this category. By definition a soivent is a liquid that will dissolve another substance. und so water borne materials afso fall under this category, but in the context of pipeline coatings the solvents referred to are Hydrocarbon. 2 Solvent free liquid paints Generally referred to as MCLs. (Multi-Component Liquids). Used widely on pipelines for repairs and. in special circumstances. as a primary system, 3 Powder paints First used in 1976 and since that. sdopied the main coating system for BG Lines. Principally the same concept as solvent free paints, but at room temperatures are particles of solid materials. Powdered materials can be either thermoplastic or thermosetting. Thermoplastic means the material will soften when heat is applied and thermosetting means it will cure when heat is applied Paints are formulated to suit various situations and environments, but consist of three main components with minor additives to control or enhance certain properties. The three main constituents are Binder. Pigment and Solvent 1 Binder The main constituent of the paint or coating. usually chosen for its suitabitity to resist degradation in certain environments, and its ability to resist the permeation of water especially for pipeline comings. Other considerations are ease of application. its ability 10 provide adhesion to the substrate. 1o hold the other constituents together in a cohesive film for fas Jong as the system is designed to last. (To provide adhesion the binder must wei out Site Coatings Paint Technology Rev | Apa oe TWI omnes ies © 0s TIL 5 emp Seimei Copythoroughly over the complete prepared surfuce, not a problem for liquid paints, but powder paints need to be melted to perform this function), To satisfy the other requirements the material must be able to change from a liquid into a solid coating. Some such materials ase Epoxies. Lrethanes, Vinyls, Acrylics. Alkyds, Phenolics. Silicones, Natural Oils and Natural Resins and many more, The binder often lends its name to the paint type e.g. Oil paint epoxy paint etc. All the binder types above are either oils or resins. Oils Oils come from the seeds of planis. e.g. linseed. rape seed, olive oil, and because of the mechanism used to change from a liquid into a solid, are totally unsuitable for subterranean for subsew use, These use oxygen from the environment in order 10 undergo a chemical change and have a relatively short fife. Natural oils are slow drying and flexible and are used 10 modify properties of natural resins Resins Resins ean be subdivided into two categories. Natural Resins Resins derived from trees and plants. e.g. copals. dammars, und coumarones, luc and amber, These materials are fast drying and very brittle and are modified using oils 10 make oleoresinous paints (a mixture of oil and resin). Natural resins cure by combination with oxygen from the environment, und are not suitable for pipeline work. 2 Synthetic Resins Some synthetic resins, e.g. Phenolics and Alkyds are made 10 mimie the properties of natural resins in paint, and by the same token are just as unsuitable Tor pipeline coatings Epoxies and Urethanes however are synthetic resins which will only cure by chemical meuns. not by Oxygen in the atmoxphere. These two materials are ideally suited to a pipeline environment because they provide all the qualities required. especially impermeability All binders which change from a liquid to a solid do so by polymerisation. Le. they form polymers. A polymer can be described as “a string or struciure of repeated units”. The units being mers or monomers. which can be single atoms or groups of atoms called molecules. ve is the joining together of the string or structure of repeated units. Carbon, Hydrogen, Nitrogen, Chlorine Poly merisation there The main elements involved in organic polymers a and Oxy en, In coating terms there are three main types of polymer. Linear. Branched and Crosslinked, She Caiinps> Pane Technaagy ROT Ap TWI orcas Copyright © 2008 TW Lad 82 aLinear Polymer O-0-0-0-0-0-0 Figure 5.1 Linear polymer Where each circle is a monomer joined to the next by a single line to form a fine ¢in actual fact many thousands long) of monomers. ‘The line joining each monomer represents an electron bond. Only one line joining the mers together depicts a “saturated bond”. More than one line depicts a double, a riple or unsaturated bond. which incidentally does not occur in a Jinear polymer when formed. but is essential in the formation of the polymer. H HOH HOH | Lol Lo H-C-H H-C-~C-H cece I Io tot H HOH HOH CHe CoHo OHs METHANE ETHANE ETHYLENE SATURATED SATURATED UNSATURATED SINGLEBOND SINGLEBOND DOUBLEBOND Figure 5.2 Saturated and unsaturated bonds When the unsaturated molecules are together in correct conditions of temperature and pressure etc, the secondary valency bond (the weaker of the two) releases and joins to another molecule. This reaction repeats until the chain is many thousands of molecules long. re 5,3 Ethylene molecules polymerise When each end closes of with a Hyd further che n atom the polymer then has no activity points for ical reaction, and so retains this form until destroyed. She Coanings Pav Techningy Rev | April Copyright © 2004 TWH Lid 83Linear polymers in liquid form e.g. primers for enamels and tapes are reversible or non- convertible, which means that when dry. if the solvent is re-udded the film will return to its original liquid form, Linear polymers in materials, which are solid at ambient temperature, are thermoplastic, ie. they soften when heat is applied. Materials in this category are vinyl tapes and polyethylene tapes. polyethylene and polypropylene cladding and neoprene and many more. Branched polymers Materials using the polymerisation mechanism are not used in pipeline coating systems but the principle is the same. A linear molecule has two or three double bonds situated near the cenite of the line of carbons, so when joining (this time to Oxygen in the almosphere) the reaction forms a “branch” Crosslinked polymers A crosslinked polymer is formed as the result of a chemical reaction and is a three dimensional polymer formation resulting in a strong resilient couting, Chemically cusing materials are Epoxies and Urethanes. widely used as repair systems and as principal systems. Figure 5.4 Crosslinked polymer 2 Pigments Pigments are added into coating materials for several reasons. They can contribute to film properties in various ways. €.g. aid cohesion, and the durability of the film, Pigments are solid particles, which must be inert and insoluble in the binder and solvent. if a solvent is present. A typical particle size for a pigment is less than | um, ‘There are several pigment classifications but not all are relevant to pipeline materials. a) Pigments which provide colour only ise, Opaque Pigments are employed on pipeline coatings e.g. carbon (black), titanium dioxide (white), by) Extender Pigments. filler materials such chalk kuolin and slate dust. Used in binders to aid with inter-coat adhesion and cohesion Site Coatings Paint Technology Rov) Apa Os TWI weve Copyright © 2004 TWH Lid ss Eee See©) Metallic pigments in coatings e.g. zine and aluminium provide eathodie protection. 4) Rust inhibitive pigments. added into primers to provide anticorrosion properties. e) Laminar Pigmentation. leafing pigments, platelets which lie parallel to the substrate and provide a degree of impermeability Solvents, Solvent in a coating material improves its application and levelling properties. reduces the viscosity and allows better weiting of the substrate, which in tum will improve adhesion. However, low viscosity materials will not provide high build films. Other properties of a solvent are rate of evaporation, toxicity. solvent power and flash point. Other additives To modify or enhance certain properties of a coating material, other constituents can be added. Among these are driers and anti-skinning agents, used in oils and resins. thixotropes as an aid to storage. antifoaming agents and flow control agents used in powders. and many more. Drying and curing of paint films During the drying/curing process a paint changes from a liquid into a solid. 1 does this by Various mechanisms and combinations of mechanisms. The time it takes 10 undergo this physical change is governed by several factors including temperature. Generally three terms are used to refer 1o drying/curing temperatures. a) Air Drying This refers to normal ambient temperatures. b) Forced Drying When heat is needed to effect a cure or accelerate the reaction it is called forced drying. but the temperature range for forced drying is ambient 10 65 ©) Stoving When temperatures above 65° ate used, using ovens or infra red. the term used is stoving intumescents. are generally in the air drying Industrial paints, with a few exceptions e. category. and the liquid to solid transition is dependant on one of the four drying mechanisms as follows. Site Co Copsrie in Tachaniogy ROOT pa TWI ces © 204 TWH Lid ss 7 cee1 Solvent Evaporation Paints employing this drying mechanism are linear polymer materials. sometimes referred to as solution polymers. Solution polymers dissolve in the solvent. when the paint is applied the solvent evaporates away allowing the fully formed linear polymers, saturated. with no activity points. 10 come out of solution and form a film on the substrate, The polymers lie in & random interlocking pattern, similar 10 cooked spagheiti or noodles and loosely bond together by ~ secondary Hydrogen bonds”. The solvents used by these materials are strong solvents and. when reapplied onto the paints, easily penetrate between the polymers and split the secondary bond, allowing the polymer to go back into solution. Materials. which can do this are, called reversible or non-convertible. Chlorinated rubber. vinyl's. acrylics. cellulosic materials and lacquers fall into this category. 2 Oxidation Paints using this mechanism form a film by “oxidative cross linking” (polymerisation) using atmospheric oxygen, and in some cases. the oxygen contained in the driers. First of all if a solvent is present. the solvent evaporates away. allowing the oxidation to begin, Oxygen then combines with the unsaturated bonds on the fatty acid esters. progressively linking them together. to form the film, Once the oxygen has reacted with the binder. it has changed the chemical structure of the binder and cannot be removed, These materials ure therefore convertible or non-reversible. Because oxygen is in abundance in the atmosphere the reactions continue, ad infinitum, until the materials crack and peel, having formed a very complex cross-linked matrix. Alkyds. Phenolics, natural oils and resins are materials from this category 3 Chemical Curing Chemical curing paints need addition of a second material. (in some cases as in moisture curing. water from the atmosphere) but generally the second material, the activator. is supplied in a can. hence the term 2 pack or Multi Component Liquid. In order to obtain the desired film the whole of the contents of both cans should he thoroughly mixed together and instructions on the materials data sheet should be strictly observed. Some materials will reguire an induction period and most data Sheets will state the ‘pot life An induction period is “The length of time after mixing which the paint should stand before use”. Induction time is also called stand time or lead time. and is recommended to allow thorough wetting of the solids. During the induction period the chemical reaction will commence und will be either a) An exothermic reaction. Giving off heat. the container will warm up b) Anendothermic reaction, Taking in heat. the container will cool forming condensation, TW eens CH ee Paar Tathaohey RT Apa M TW Lal Site Coa Copyright © 2A typical induction period is 20 ~ 30 minutes. ot life is the period of time after mixing in which the paint must be used, and with industrial paints. dependant on temperature is usually 6 ~ 8 hours. After the recommended pot life the material becomes very user unfriendly and if in bulk, is quite often subject to spontaneous combustion Amides ~ Epoxy curing agents, usually quote seven days to full cross linking at 20". Amines ~ Epoxy curing agents. three days to full cross linking at 20™ Tsocyanates — Mainly used for urethanes but also for some epoxies where low temperature application is unavoidable, -10™ heing typical. Ambient temperature urethanes. especially for pipeline use, quote 16 hours to full eure. NB. Isocyanates are very toxic and need great care during use. Chemically curing materials are convertible or non-reversible. 4 Coalescence Coulescence means to physically join together. In an emulsion the resin droplets are dispersed in the continuous phase, water. Upon application the water evaporates away allowing the resin droplets to come close together until they are touching. AL this stage small amounts of high boiling point solvents are concentrated in the voids between the spheres. from where they migrate into the spheres. plasticise them and ullow them to fuse together. In so doing they also reduce the Tg of the material (Tg = Glass Transition and is the temperature at which the material changes from rubbery to a glassy solid, and vice versa). If the Te ‘wasn't changed. the resulting film would stay a a Tiguid and be easily wiped away These materials e.g. acrylics and vinyl's are reversible, It is important to remember in this case that water is not a solvent, but if the true hydrocarbon solvent was used the material ‘would form a solution: Methods used to protect against corrosion Ast employi cl substrate needs 10 be protected against corrosion. Protection can be provided by one or more of the systems listed below | Barrier principle, Ideally a thick. impermeable layer of w high electrical resistance. 2 The Passivation principle, The surface is passivated by chemical means e.g. by the use of rust inhibitive pigmentation, Site Cost Copy <7 Paint Techavingy Rev TApAlOd TW nannies ve TW Lid 5 a A3 Cathodic protection, ‘The use of less noble metals as pigmentation in a coating. any electrolyte permeation. e.g. walter. allows a circuit 10 join so that the pigmentation corrodes preferentially to the substrate. Sie Cais = Pant Technology ROT ApH ‘mean Copyright © 2004 11 Lid ss A Sia nnSTAGES OF PIPELINE CONSTRUCTION Planning During the planning stage the route of the pipeline is determined. and access rights are purchased. linepipe ordered und other contractual details dealt with, Pre construction drainage Pre construction drainage is often required to keep the area of the right of way reasonably dry and help to prevent the pipeline from becoming in itself, a drain, The engineer and farmer, land owner/agent meet and prepare a pre eniry record, with photographs of condition of the land. fences, hedges, walls etc. and if possible a plan of any existing drainage (aslaids). The pre construction drainage is installed on the upside of the planned line. (sometimes both) with the drain three metres inside the demarcation fence line on the subsoil side of the ROW or under the topsoil area on the topsoil side of the ROW. ROW clearance ‘Any existing field boundaries are noted and photographed. dry stone walls are manually Stripped and stacked 10 one side. hedges uprooted and flumes laid in ditches, any existin crops ate cut and disposed of and suitable stock proof fencing erected. with appropriate gates for access. Typical ROW 50 m wide. Topsoil strip The topsoil is bulldozed into piles on the East side, (North is always the direction to the end of the proposed line, South is the beginning), leaving a running track for men and vehicles. and room for the trench. Pipe storage AAs the coated pipes are delivered, ready for the construction stage. to the pipe dump. we have the first input from a site coatings inspector. A full record of pipe numbers. lengths. heat numbers and existing damages is taken and the pipes stacked in accordance with the specifications, Site Coatings — Pipwtine Consiraction Rey | ApAI OE eer He Copyright © 2004 TWH Lad ol Cee eaeStringing The linepipe is loaded out from the pipe dump and taken out to the spread. easement or of way are alternative expressions, where the pipes are laid out in readiness for welding together. ‘The inspector should again record all possible information and note where each linepipe is positioned for full traceability. Specification requirements regarding handling and stacking should be rigidly enforced 10 avoid damage to coating and weld preparation areas. ‘The pipes are placed on skids (stacks of wooden blocks) and padded and chocked to avoid contact damage and possible rolling off. Longitudinal submerged arc welds should be placed (on the top position. slternating between 10 and 2 o'clock. Each linepipe is strung at an angle of approximately 30" to the intended pipeline to enable access between them. Linepipe would not he placed across furm access track but instead laid parallel 10 the linepipe on either side. Figure 6.1 Stingi Bending c raphical factors, e.g. hills and valleys may necessitate the bending of a linepipe. An inypector should he present to ensure minimum damage to the coating is incurred. A bending machine is used to perform this operation, This entails a hydraulic ram being used 10 apply pressure 1o slightly hend the pipe. The pipe is then moved along and the ram e to extend the hend, An internal mandrel can he used 10 check the degree of bend. To minimise coating damage. all pipe to shoe contact point should be padded with at least 12 mm of rubber. An aluminium pull through plate can be used to check for ovality. ‘The plate should be 95% of the nominal internal diameter of the pipe. No bending should take place within two metes of the ends of the pipe. S—Piptin Comraon Rev TART TW Swncn nn ©2008 TWH Ld 62 Clap Seis Copsti‘The pipes are then appropriately marked ay Sag bends. Over bends. Left or right bends according 10 in line position. Pipes can be bent up to about 22.5". Front end welding This operation is covered by a welding inspector. not a coatings inspector. The pipes are lified from the skids by side booms. checked for alignment and a root puss deposited. followed by a hot pass and a first filler, if MMA is being employed. If mechanised MAG process is used then two weld passes are deposited. This procedure is repeated until many pipes are welded together, called a string. Each weld iy allocated w number in sequence of welding by the front end inspector. Everyone then uses that number for reference. Back end welding inspectors duty. The back end welders fill in the remaining weld prep cap. Again, not the coati area and apply the fi NDT After the welding operation is completed all butts are subjected 100% to Non Destructive Testing in the form of X-Radiography. Pipes of 750. mm diameter and above are also subjected to MPI on internal roots 11 o°clock 10 1 and 5 o°clock to 7. top and bottom, ating and wrapping. All welds are coated with specified systems afier aeceptance of welds/repairs by NDT. under inspection by the site coating inspector. Ditching ‘The pipe strings are lowered into the trench by’ side booms. When iwo strings need welding together. it may’ be that there is overlap of the 1Wo. in which case the excess is cut off. re bevelled and welded. If there is a gap between the two string ends then a PUP (Pick-up- piece) is inserted to specified requirements and two welds performed. In both cases the welding would be facilitated by digging a “bell hole”, These welds are called “tie in welds in the case of the latter situation the second weld would be the “final tie in weld”, Tie in welds would also be found at RDXs. RVXs and RLXs (Road, River und Rail crossings). as well as in the middle of long sections. typically were two front end crews have been workit A section is the area between two RDXs “Sie Coatings Piping Comsitocton Rev T ApH TW wens Copyiighi © 2004 TWH Lad ‘6 Bg setsBackfill The areas above and around the pipe are filled and compacted with selected material from the spoil. An inspector should be present at ail times, Reinstatement After ripping and subsoiling, the breaking up of the compacted “panning” caused by heavy traffic along the running track, the topsoil is replaced. lll hedges and walls, gates and fences are replaced or replanted so that the Jand is, or soon will be, back to its original condition. This is part of the duties of the Agricultural Inspector Numbering system for pipeline welds Two methods of allocating section numbers can be employed. 1 The section from the start AGI 10 the first RDX is Section 0 2 The section from the start AG1 to the first RDX is Section J In either situation the welds are numbered in sequence of welding the front end butts, starting at WI If crossing a railway’ or river the first number allocated afer the crossing follows in sequence to the last number allocated before the crossing. The fabrication used to go over or under at the crossing is then numbered as RLX no WI or RVX no WI. A special fabrication (SF) normally has fittings e.g. forged bends or block valves incorporated and will include more than iwo welds. These welds are numbered SF] etc. Repairs are allocated a suffix R e.g. WIR. Re welds are allocated a prefix RW e.g. RWI. A repair on a reweld would then become RWI R. Only a road crossing will alter the section number. then the weld numbers will start again at WI ‘The welding inspector records which pipe numbers are welded to which others and the weld number allocated. ll pipeline personnel then use that allocated number as a reference. Site Coatings ~ Pipeline Construction Rev | April Od ‘wenn 1 SH 1 Copyright © 2004 TW Lat oa TWD init CEM seisinnsCOAL TAR AND BITUMEN COATINGS TO BGC PS CWI AND BGC PS CW3 Coal tar, as a barrier coating, has been in use since before 1680. The first patent on the material was taken out in 1681], re the use of coal tarre and pitch, N" 214,by John Becket and Henry Searle. Originally the materials used were unplaticised. brite, and cracked and disbonded at temperatures below 0”. Luter, additions of plasticisers meant that better temperature flexibility could be achieved and softening points and penetration resistance could be controlled. When synthetic primers were introduced. adhesion and overcoating properties were greatly improved (original coal tar primers oxidised, went dead and provided no adhesion) ‘Around the same period of time nearly a century ago the Americans discovered that naturally occurring Bitumen in Trinidad had equally good anticorrosion properties and started using it for coating iron and sicel pipes, becoming widely used for transporting oil gas and water subterranean and subsea. Further advancement in technology resulted in the materials further development and subsequently a major coating system for pipelines, and were only superseded us the major system in the mid seventies. B Gay Transco no longer use the systems but there are many many miles of pipeline, still in service coated with these systems, and an inspector will need to be aware of compatibility aspects if ever they are encountered in tie-in operations etc Coal Tar Enamel and Bitumen enamel are covered in different B Gas Specifications and have different BS reference numbers because they are utterly and completely incompatible, and come from completely different sources. Any one will not stick to the other and if mixed when molten. will curdle Se Coatings = Coal Tar & Bitumen Coatings RET Apel OF FW Sn esin vo © 2004 TWHLid n Cn Isis CopyCoal Tar, enamel source BS 4164. BGC PS CW1 ‘The source of coal tar is coal, a ve; tar the result is coal tar enamel. ible product. If coal oil (plasticiser) is re-added to coal Town gas Sulphur Phenols a Heat —» | Coal | +» Coke _¥ Coal Coal oil i Benzene 5 Toluene Xylene Coal Tar Enamel Figure 7.1 Coal Tar. enamel source BS 4164, BGC PS CWI Bitumen enamel source. BS4147 BGC PS CW3 Bitumen is the end of the distillation chain in crude oil, an animal source, Gases Chemical feed stock Gasolines H Fo Kerosene Het Guo > Diesels & Oils Lube oils Paraffin waxes Heavy fuel oils > Bitumen‘ Asnhalty Figure 7.2 Distillation chain in crude oil Coat Tar & Bitumen Cos April FW worcsininn © 24 TWH Lid CleThe bitumen is oxidised (air blown), paraffin waxes added as plasticisers, result is bitumen enamel Extenders in the form of slate flour are added 10 give bulk to both products. Pulverised coal is sometimes digested into coal tar to give the same effect as “blowing” the bitumen. Because both materials are incompatible it is necessary to have a test to differentiate between the two, as they are identical in appearance, ‘Test for bitumen and coal tar Allow a few drops of strong solvent, preferably Xylene, but toluene or acetone will work equally well. to fall onto a sliver or ball of the enamel placed on white blotting paper or Whatman filter paper or similar. The solvent will dissolve some of the enamel and carry it onto the paper. Bitumen will Ieave a heavy brown stain, Coat tar will leave # lightly stained Yellow area. Using enamels Brief synopsis of factory coating Larger pipe coating milly would use a production line yystem whereas smaller unis would coat linepipe ws individual items. Specifications and dimensions are the sume in either case. 1 Prepare the surface by grit blasting 10 Su 2%, remove dust ete. by vacuum, clean compressed air or brush. Profile $0.75 um, Apply synthetic, type B. fast drying primer for coal tar enamels und synthetic or bitumen hased primer for bitumen enamels. When the primer is dry apply hot enamel at approximately 200 - 208 ™ through a flood box onto the 12 o'clock position on the pipe. (The pipe would be slowly rotating and moving forward with plastic spacers separating and protecting the weld preparation area, overwrapped with wax or Silicone paper) 4 Simultaneously as the enamel wels the whole of the pipe diameter a reinforcement of fibre glass bandage is fed in at the 6 o'clock position from a creel. tensioned so that the reinforcement embeds approximately halt way into the total enamel thickness. As the fibreglass bandage approaches the 12 o'clock position again. further enamel is poured on which fuses with the first layer through the wetted reinforcing bandage 5 Just outside the flood box area the final wrap of thesmoglass is applied (a mineral impregnated outer wrap bandage of the same base material as the enamel, Thermoglass ix a trade name but is widely used for this generic material). The base material of the outer wrap fuses with the molten enamel to Form a complete homogenous layer Site Comings ~ Coal Tar & Bitun Copyright © 2004 TWH Lid eB 4 sinensisNote. All reinforcements and outer wraps our applied in a spiral fashion with a minimum of 25 mm overlap, 6 The spacers and silicone paper is removed and the enamel coating is bevelled back by al least 25 mm, leaving 150 mm at both ends of the pipe uncoated, 7A colour coded solar protective coating is applied, white for coal tar enamel and blue for bitumen. 300 mm of enamel at each end should be left uncoated. ig 300 —__pig. 25 4g 150 —) Enainel Primer | Weld Pipe ‘prep Reinforcing bandage Figure 7.3 Cross section of coated end Primer DFT 19° 6um mel DFT. 4107 mm, 2.4 mm over welds Inner reinforcing to be not within 1 mm of pipe surface Co: ing with enamels on site Afier the pipes have been welded together on site there will be a certain amount of damage from heat transfer from the weld, and the pipe cannot be rotated. ‘The enamel is melted in a melting pot with a thermocouple build into it for temperature control. ‘The enamel is melted by flame from butane/propane bottled gas and transported by bucket to the butt 10 be couted Site Coatings — Coal Tar & Bitumen Coatings Rew TApHION TWI Copyright © 2004 TWH Lid 7 } “ CM sieProcedure for wrapping a butt 1 Blast clean to Sa 2! removing any damaged or extraneous material over the entire butt Blast onto sound existing coating 100 mm on either side to provide a key. Profile over the blust cleaned are to be 50 — 75 um. Remove dust and detritus by blowing with clean dry compressed air or by vacuum or brushing 3. Apply appropriate primer by brush to give a DFT of 19° 6 um overlappi coating by 100 mm. 4 As soon as the primer is dry apply one flood coat of hot enamel at the 12 o’clock position overlapping onto primed area by at least 75mm. 5 Apply inner reinforcing in a spiral fashion 25mm overlap, overlapping 75 um minimum onto existing coating. 6 Apply further flood coats, Apply outer wrap ina spiral fashion 25mm overlap, overlapping onto existing coating to provide a neat seal nto existing Considerations for materials Primers, enamel and substrate should be compatible, Enamels will not stick to any plastic e.g. vinyl or polyethylene. Temperature of material is critical. Coal tar should not exceed 260" and bitumen 240!", If these temperatures are exceeded the material should be discarded. Ideal application temperature range 240 ~ 255" for coal tar and 230 for bitumen. In any situation requiring stoppage of work. the heat should be reduced and the material maintained at approximately 200". 6 The enamel should be agitated at intervals of less than one hour. Coal tar is now known 10 be carcinogenic. Every conceivable precaution should be taken 10 avoid skin contact. Barrier creams. masks and goggles should be worn at all times. Iv is not practical to erect shelters in the event of inclement weather Herbicides should be incorporated into bitumen enamels. 7 Inspection criteria for attached coatings DFT To be checked using a correctly calibrated “banana (Magnetic Thickness Gauge). The DFT should be a minimum of 2.4mm over welds. a nominal of 4mm over general plate areas, and should not exceed 7mm at any position. Site Coatings — Coal Tar & Bitumen Coatings Rev April TW ens or © 204 TWH Lad 5 DG ceeAdhesion Bond test The bond test should not be conducted within 24 hours of application of the enamel and is done “at a frequency specified by the engineer”. or when the inspector, having done a tapping test, suspects inherent adhesion faults Procedure Ensure that the enamel temperature is within the range of 5 to 25, Circumferentially. cut two parallel lines through to the substrate 100mm Jong and 30mm apart, heating the knife blade if necessary Make a longitudinal cut ut the lower end to join the two circumferential. Insert a flat blade into the longitudinal cut and apply a levering motion downwards. The enamel should chip cohesively at the edge and not lift from the substrate or split slong any layer. Holiday detection All arews are subject to 100% holiday detection, The holiday detection should he carried out using DC holiday detector set at 1Skv. The maximum voltage setting permitted is ISkv. and BGC PS CWS recommends Sv per micron, but enamels are an exception Visual checks Blisters. Dome shaped projections in the enamel Holes. Caused by escaping vapours, or by impact. Bleed through, Bleed through is not a fault. it is an indication that fusion has occurred between the enamel and the outer wrap. It manifests as small shiny areas where the enamel in the outer wrap has melted 4 Teicles. Occurs at the six o’clock position on a pipe. It is where excess enamel runs off Grips. which solidify. Icicles can be incorporated back into hot enamel by operating a canvas or leather sling back and forth on the enamel 5 Carbonising (coking). Carbonising or coking occurs when enamel is over heated. appears as a protrusion from the film and when firmly scratched reveals tiny bubbles in a closed cell structure Site Coaiings ~ Coal Tar & Bitumen Coatings Rev 1 April TW Siro inn Copyright © 2004 TWH Lad 16 Ce ieee6 Cracks. Usually on aged coatings and mainly due 10 soil stressing. Soil stressing ‘occurs due 10 Variation in temperature and backfill compression ete. leaving a pipe room to expand, Enamels and hot applied tapes (discussed later) are brittle at Jow temperatures and form a random zig zag crack. usually along the top of the pipe. A typical situation where soil stressing would be expected is the outlet side of a compressor station Repairs ‘Small holes and pinholes can be repaired by moulding in a small plug of enamel. using a heuted blade. or by softening adjacent areas and mould to fill the hole. Larger areas would now he repaired using more modern technology. such as urethane pitch, to be discussed later Safety Naked flames and other sources of ignition including smoking. should not be permitted near hot material. especially in enclosed areas. Toxicity Bitumen and coal tar enamels. when heated. give of fumes. which are now known (especially coal tar) 10 be carcinogenic. It is therefore necessary 10 observe recommended safety precautions which may include. i) Avoid skin contact. ji) Wear protective clothing. iii) Use barrier creams on exposed areas of skin. ix) Maintain good personal hygiene (wash hands. before and after toile). ¥) Seek medical advice if warts are found. vi) Avoid. if possible, inhaling fumes. sings Chal Tar & Bitumen Coalings Rev | April OF SowersHOT APPLIED TAPES Hot applied tapes consist of a plasticised coal tar or bitumen enveloping a carrier tape of ‘woven nylon or similar synthetic material with an open mesh of approximately 20 x 20. The tapes are approximately 2mm thick. shiny black and flexible enough to form a roll. One side of the tape usually has # thicker deposit of plasticised enamel. This thicker side is pliced against the pipe surface 10 be coated. Hot applied tapes are covered in two BGC specifications. BGC PS CW2 - cold applied wrapping tapes and tape systems, which covers the technical requirements. BGC PS CWS — code of practice for selection and application of field applied external pipework coatings. Like enamels, these materials are no longer used by BG but they are likely to be encountered on tie ins and maintenance work on existing lines. Use of hot applied tapes, Factory application These materials are not used for coating full pipe lengths as « principle system. Site appli Hot applied tapes can be used in two situations on site. 1 Wrapping a butt when two adjoining pipes are coated with the same enamel system, 2 Overwrapping an existing enamel coated pipe for extra resistance 10 mechanical damage. for example. thrust boring. or at the interface ‘of above/below ground on a Procedure for wrapping a butt 1 Blast clean the area to Sa 2%, profile $0.75 um using an expendable abrasive. ‘The existing coating should he bevelled back SOmm with the blast pattern overlapping the coating 10 provide a key Apply appropriate primer. synthetic type B for coal tar enamel or a synthetic or bitumen used primer for bitumen enamel. w a DFT of 19° 6 um, overlapping onto sound existing coating by 100mm, 3 When the primer is dry apply the tape in a spiral fashion with 55% overlap 0 give double tape thickness over the area. Site Coatings Hor Applicd Tapes Rev 1 Apel 04 WORT CYS HE Tn Copyright © 2004 TWH Ld sa CM See4 Overlap the existing coating by at least 75mm ensuring that both the start and finish of the tape is facing in a downward direction (o avoid water traps, Procedure for wrapping full pipe lengths (mechanical damage) 1 Remove any solar protective coating by power wire brushing Remove any oil or grease contamination by swabbing with a solvent. (Care needs to be exercised during this operation. as the enamels are reversible and extremely sensitive 10 solvents), 3) Apply the appropriate primer to the full pipe length. 4 When the primer iy dry apply the tape in a spiral fashion with a 55% overlap to give @ minimum of two tape thicknesses for the length of the pipe. 5 Ona riser the wrapping should commence at the lower end of the pipe so that the overlap is facing in a downward direction (like roof tiles) Inall cases the tape is applied by using a blow torch or hot air torch, or any device which will melt the enamel. This is a two man job, one man maintaining tension and the spiral of the wrapping. the other operating the heat source. The tape is maintained at a tangent to the pipe and the heat applied into the interface ang! As the tape melts it is fused onto the pipe enamel by’ the spiralling motion applied by the wrapper Considerations for materials | Primers. enamels and substrates should all be compatible 2 Neither hot applied tape material will stick to any plastic. 3. Lack of attention by the operator can result in the material catching fire or alternatively not being melted to allow fusion, The main area for this being 6 o'clock and 12o'clock. Flames are easily extinguished by dousing with water. Under heating iedied by reupplication of heat externally. Fully 1reated tapes are hard and brite like enamels. Under treated tapes retain the plasticisers and remain soft and flexible 4 Becaune of its brittle nature. like enamels. hot applied tapes are susceptible 10 soil stressing. 5 The tapes when heated produce irritant and acrid fumes and every conceivable precaution taken to avoid skin contact, Barrier creams, masks and goggles should be ‘worn at all times, It is not practical to erect shelters in the event of inclement weather 6 Herbicides should be incorporated into bitumen enamels. “Siw Ghavinge > How Applied Taps Rev T Api Sar CET veinccinsInspection criteria for attached coatings DFT No specified DFT requirement Adhes Usually *V" cut test on butts, at a frequency agreed by the engineer, «wo per day. or if the inspector has reason to believe that there isa fault Holiday detection Fixed voltage requirement of 1Skv as per enamels. 15kw is maximum permived voltage on site. Visual checks Blisters, Dome shaped projections in the wrapping. 1 2 Holes. Caused by escaping vapours or impact damage. 3 Curhonising. Overheating and burning of the enamel tapes. 4 Creases. Caused by incorrect tensioning or wrong angle of spiral. or tape too wide for pipe diameter 5S Cracks. Usually on aged coatings due 10 soil stressing 6 55% overlap. Check for correct overlap to ensure two thicknesses. 7 Siar and finish, Check star and finish to ensure downward facing direction (where applicable) Checks on detached film None specitied Repairs ‘Small holes and pinholes can be repaired by moulding in with a hot knife. areas, overwrap with further layer of tape. Safety Naked flames and other sources of ignition. including smoking should not be permined. especially in enclosed ares. “Sie Cong Fav Sp Tapes Ros Apa Twi Copyright © 2004 TW Lid 3 Cee soBitumen and coal tar enamels when heated. give off fumes. which are now known (especially coal tar) 10 be carcinogenic. It is therefore necessary to observe recommended safely precautions, which may include. i) Avoid skin contact ) Wear protective clothing. iii) Use barrier creams on exposed areas of skin iv) Maintain good personal hygiene (wash hands, before and after toilet). ¥) Seek medical advice if warts are found. vi) Avoid. if possible, inhaling fumes. Site Cnaiings Hot Applied Tapes Rov April enc Copyright © 2004 TW Lid Na Clap seisCOLD APPLIED LAMINATE TAPE Cold upplied laminate tapes, CALT. consist of a plastic carrier tape of PE (polyethylene) or PVC (poly’ vinyl chloride) one side of which is coated with a layer of sticky mastic. The mastic can be either synthetic rubber or rubber modified bitumen. The superb adhesive properties of the mastics provide an excellent bond to the carrier tape, and t0 enable it 10 be Tolled it is essential 10 incorporate a layer of waxed or silicone paper on top of the mastic, 10 avoid adhesion to the next layer Cold applied laminate tapes can be subdivided into wo categories. light and heavy duty tapes. There is no set criteria for light or heavy duty and tape manufacturers have freedom of choice. Tape thickness can vary immensely from 0.2mm to 1.0mm with subsequent effect on the performance properties of the tape. Both the mastics and the cartier tape material are thermoplastic in mature and low temperature application renders the tape systems user unfriendly. The minimum application temperature is specified at S*, and maximum handling temperatures 27, because the materials are 100 soft over this temperature. It is common practice to heat up the tapes prior to application in cooler weather. ‘The BGC Specification numbers which apply to this wrapping system are: - BGC PS CW2 - cold applied wrapping tapes and tape systems. covering technical requirements. BGC PS CWS — code of practice for selection and application of field applied external pipework coatings. Cold applied laminate tapes currently approved for use on a BG Transco pipeline are: - Light duty tapes Maflowrap 40/15, Serviwrap -R 154 and Densopol 60 Heavy duty tapes Maflowrap 50/40 Serviwrap 50/40 Maflowrup 65/75 Denxopol 80 Tai Appel Taps Ap TWI on TWH Ld va arUse of cold applied laminate tapes Factory application Not a specified system for BG but can be applied by rolling rig. Extra large rolls are supplied, approximately 12m, are correctly’ tensioned on a creel and geared to traverse along the slowly rotating pipe. to achieve a neat even overlap and constant tensioning. Site application Cold applied laminate tapes can be used in most situations on a pipeline. The only limitation is coal lar/bitumen compatibility factors with the rubberised bitumen mastic types. CALT are commonly specified for repairing damaged areas on Polyethylene Clad lines. FBE coated lines and lines previously wrapped with CALT and also on CTE coated lines. (compatibility considered). Cold applied laminate tapes ure specified as a preferred system for coating butts on many pipe 10 pipe coating systems. Ref, table four CWS. Eg Polyethylene to PBE. MCL. CTE. Polyethylene. CALT to FBE, MCL. CALT, Polyethylene. Also specified as a second option on the following systems MCL. to FBE, MCL CTE to FBE. MCL. CTE The materials suitability for uve in thiy wide range of situations stems partially from its tolerance of substrate surface preparation standards. BGC PS CWS supplement CA/13 states Surface preparation to either Sa 2!2 grit blast. or wire brush 0 S12 oF $13, according 10 the preference of the enginecr ‘Typical procedure for wrapping a butt 1 Prepare the area (according 10 specified method and standard). overlapping onto existing sound coatings to provide a key Remove dust and detritus by brushing or blowing with clean dry compressed air Apply primer tas supplied by the tape manufacturer) by brush to recommended thickness. overlapping onto existing coatings by 100mm: 4 Apply the tape in a spiral fashion with $5% overlap to ensure two tape thicknesses over the area. stunting and finishing in a downwards facing dizection, overlapping onto existing coating by 75mm minimum, Site CopyriNote, When wrapping a butt where polyethylene cladding is involved, due regard should be paid 10 the following. When the hutt is welded, heat conducts through the pipe steel and mnells the end of the polyethylene. causing the tensioned polymers to pull in and “pucker” ‘This forms a raised, hard ring around the pipe diameter. Before any surface preparation commences the “puckering” should be removed by cutting with a sharp knife, The cut should be done neatly. evenly, circumferentially. leaving an even chamfer Repairs to existing coating using CALT Surface preparation as specified. prime using material supplied by the tape manufactur When the primer is dry apply the CALT in a spiral fashion with $5% overlap. According to the size of the repair. a minimum of one and a half turns is required to ensure starting and finishing ins downward facing direction. Note. Patches of CALT are not recommended for repairs Considerations for materials 1 There are no incompatibility problems other than bitumen gnamel. 2 Because of their thermoplasticity they are prone to damage in warmer temperatures, 3 They have litte resistance to mechanical damage (thrust boring). 4 — Rubberised bitumen mustics are susceptible 10 microbiological attack and should incorporate appropriate biocides, 5 The materials should preferably be stored in cool conditions 10 avoid flow of mastic. but may benefit from warming prior to application. Inspection criteria for attached coatings DFT No specified DFT but will be required in order to set correct voltage for hotiday detection. Adhesion Not before 24 hours have elapsed. Done by V cut test. Two per day specified by the engineer. one a.m., one p.m, Random or “if the inspector has reason to believe”, Jay detection fo thickness. using the formula Sv per mieron. to a maximum of 15kv set according Tis Coan CORT Apped Tapes Apa Tonner Copsnighr © 2004 TWIT vs By essVisual checks Blisters. Dome shaped projections in the film. Creases and folds. Bad application techniques or incorrect tape width. Over tensioning. Will result in “necking” a narrowing of the tape. usually accompanied by blue or grey longitudinal streaks and excess mastic squeezed from the tape ed Surface preparation, Light abrasion should be visible at primer edge. Primer. Primer should be visible at tape edges, 55% overlap. Should show as a regular slightly raised ridge at the edge of the tape Checks on detached film None specified, Repair of CALT Overwrap (sometimes contra wrap) with further layer of CALT. $5% overlap with a minimum of one and a half turns, starting and finishing in a downward facing direction Safety Operators should wear gloves and other precautions as per Site requirements To} No known significant hazards, Site Coatings = Cold Applied Tapes 1 Apel OF Copyright © 2004 TWH Lid oyGREASE BASED TAPES Application to BGC PS CWS. technical requirements to BGC PS CW2 Grease based tapes consist of a woven synthetic bandage couted with petrolatum grease, with other minor additives e.g. inhibitors and some times moisture displacing additives, Grease hased tapes are chemically compatible with al] coatings in current use and are tolerant of very low standards of surface preparation. Unfortunately grease based tapes do not provide u stand alone system of pipeline protection, and need to be used in conjunction with self adhesive overwrap tapes. Grease based tapes. because of their mouldability, are often Used to cout areas of difficult access. e.g. on small service pipes. but still give better performance if overwrapped. Because this type of material is compatible with all known pipe coating it is one of a few which is suitable for coating a butt when the 1wo adjoining pipes are. one bitumen and the other coal tar enamel Grease based tapes currently approved for use are: ~ Denso tape. PAM 105 and Serviwrap G4SA Factory application Not applied in a factory table four refers to grease hased tapes. as an option (not preferred method) for Polyethylene to FBE, MCL, CTE and Polyethylene. ‘The tape can be folded and moulded to give a chamfer on polyethylene cladding und likewise on old enamels. Other uses include Valves. flanges and items of complex shape where advantage can be taken of the mouldability of the material A typical procedure would be 1 Remove any loose rust and dirt by specified method 10 the required standard (any firmly adhering paint in good condition is not a problem). 2 Remove dus und any moisture by compressed air or swabbing. 3 Apply by brush, paste type primer. ov eslapping existing coating by 100mm. Sin Goaiings Grave Banal Tips Rev PATO SPW con Copyright © 2004 TWH Lid 1. BY Sie4 Apply grease bused tape in a spiral fashion with 55% overlap. overlapping onto existing coating by 75mm minimum. (Assuming easy access. in other situations the tape would be moulded from small patches), If a coating of pipetine quality was required e.g. Bitumen 10 Coat Tar Enamel coated pipe butt. then a further clause would be added 5 Apply an overwrap of PE or PVC self adhesive tape overlapping onto sound existing coating by a further SOmm, in a spiral fashion with an overlap of 25mm or $5%. at the discretion of the engineer. The overwrap to be terminated by one full twin back on itsel. Note. When the last clause is applicable. using the grease based primer would leave only 25mm of the original coating at each end for the overwrap tape to adhere to, Considerations for materials 1 At normal temperatures the grease is non drying, but al elevated temperatures will form a crust due to slow distillation, It hay no mechanical strength and needs overwrapping to stop migration. High standards of surfuce preparation are unnecessary ‘The material is tolerant of damp or moist surfaces, Very simple to apply Inspection criteria for attached coating DFT No specified requirements Adhesion No specified requirements Not done unless the tape is overwrapped. Visual cheeks Check for adequate. even coverage. Givin Bona Taps PAPE yp enChecks on detached film None specified. Repairs Easily affected by addition of further material Safety No hazards known Toxicity No hazards known. ‘Site Ghatings — Grease Based Tapes Rev | April 4 1 © 2004 TW Lad w3 CopsrigCOLD APPLIED SELF ADHESIVE OVERWRAP TAPES Application to BGC PS CWS. technical requirements 10 BGC PS CWS This classification of tapes is supplied in a wide variety of tape widths and colours, The main tape is of PE or PVC coated with a very thin layer of pressure sensitive adhesive. (Pressure sensitive means the tighter the tension, the hetier the adhesion). ‘These tupes have the ippearance of insulating tapes, nothing like cold applied laminate tapes, which have the jnterleafing wax paper. They are not a stand alone system and are used to stop migration of, for example, fillers mastics. putties and grease haved tapes, Materials currently having approval for use include: - Scotchwrap N’ 50 Sellotape 1408 Rotunda Allweather 2901 Denso PVC Sellotape 1408 Maflowrap 20/10 Factory application Not applicable application. Surface preparation ix not required because the tapes are used for overwrapping other Systems. Primers ate usually recommended except when applying over grease based tapes The tapes are applied neatly. spirally 55% or 25mm overlap (at the discretion of the engineer) terminating the wrap with one full turn back on itself Considerations for mate jals 1 No problems of compatibility with any coating used, Best suited for use on smooth surfaces such as FBE, Polyethylene and MCLs. Will not bond efficiently to roughened surfaces with pits und imperfections e.g. enamels. In this case for the overs rapping of a grease based tape wrapped joint it is far better 10 use it than not 3 The tapes are sufficiently flexible for easy application and are Jess likely than other tape types to be affected by soil stressing. Site Coa Copy rig Torarerap Tans Rv FATE pee 16 2004 TWIT ma Bp SassInspection criteria for attached coating DFT No specified requirements. Done for Holiday detection setting. Adhesion No requirement, (No adhesion over greased based tapes) Holiday detection Voltage set at Sky per mm of coating thickness to a maximum of 1Skw Visual checks Check for neat business-like appearance of completed job. Checks on detached film None specified. Repairs Apply further layer of self adhesive tape. Safety No hazards known Toxicity No hazards known, eS TOIL ne BY © Sie Costing. = Ovensrap Tape CopsPOLYETHYLENE CLADDING Factory application 10 PS CW ~ Polyethylene cladding on steel pipe. dealing with steel pipes up to 450mm nominal bore, Polyethylene cladding cannot be applied on site to butt joints. A medium to high density yellow polyethylene (dependant on polymer length) is upplied over a mastic by extrusion. Nominal thickness for the polyethylene is 1.3mm and for the mastic 0.15mm, the solerances allow an absolute minimum dimension of 122% below this nominal figure Factory application 1 blasting and flood coated with hot mastic 200. Immediately following this operation the pipe is passed through a circular die (a cross head extrusion die) which is extruding @ continual sheath of polyethylene. ‘The pipe is not rotating as in enamel coating. Immediately after the die cold ‘water is sprayed onto the polyethylene. which contracts and tightly envelopes the mastic. Profiled rollers push back any entrapped air pockets. Pipes are prepared hy specified method, usual ‘at_approximatel Site application Not applicable 1 The material is thermoplastic and ‘puckers” when heated to near melting point. 2 The linear polymers are stretched during application and tend 10 fine up in one DFT Not applicable, done at factory Adhesion Having the mastic undercoat adhesion is not a problem. Sie Cong Poh Cag RT Apa TW wanes WI Copyright © 2004 TWH Lid a Fg nies emHoliday detection Special voltage of 10kv Visual checks 1 Blisters. Dome shaped projections usually air filled 2 Damages. Usually seen as areas of exposed black mastic. Checks on detached film Not applicable. Repairs BGC PS CWS, table seven recommends in order of preference. 1 Cold applied laminate tape. 2 Heat shrinkable plasties. 3 Grease based tapes (overwrapped with self adhesive overwrap tapes). Safety No hazards (in its solid form). Toxicity No hazards, ings — Polyethylene Cladding Rev U ApH TW borne 1 2004 TW Lad 2 CM neFILLERS, MASTICS AND PUTTIES Field application procedures to BGC PS CWS Technical requirements to BGC PS CW2 Fillers, mastics and putiies are used for modifying contours to facilitate the use of wrapping tapes. typically on valves and flanges and “T" pieces. Usually supplied in a variation of mediums e.g. cans, bags and specially designed extrusion devices they can be easily: matched for compatibility with existing coating and tapes to be applied over them: Materials currently approve are: - Denso Mastic Servicised Moulding Putty Densyl Mastic Servicised GASA Mastic Factory application Not applicable Site application Surface preparation carried out as specified. apply primer. when primer is dry. apply mastic/putty by gloved hand. moulding to the required contour. Knives and troweis can be used but the material is better moulded by hand. ‘The whole is then overwrapped with the specified tape system, Considerations for materials Compatibility with existing coating and overwrapping tape 10 be used to be considered. Where bitumen is involved the materials should contain biocides. Working temperature of the component should be considered, Inspection criteria for attached coating DFT Only for Holiday detection setting Sic NTT Mn Panis Rs PARE we Cision © 28 THT Lad 1 FY sansAdhesion No requirements, materials will migrate under pressure, Holiday detect Voltage settings according 10 formula specified in CWS. 5v per micron up to a maximum of 15k Visual checks Check for smooth contour to facilitate overwrapping Checks on detached film Not applicable, Repairs Repair using same material Safety No hazards known, usual precautions e.g. gloves. ‘Toxicity No hazards known Site Coatings ~ Filer Mastioe & Patties Rev Copyright © 2004 TWI Lad TWH von CM esHEAT SHRINKABLE PLASTICS Applicution as per BGC PS CWS Heat shrinkable plastics have worldwide applications both onshore and offshore. In terms of BG Transco, heat shrinkables are mentioned in only one context. for the repair of polyethylene cladding and even then. only as a first option, not the preferred method. Ref. CWS, table seven. Heat shrinkable materials can be supplied in many forms. as wraparounds or tapes and pre expanded sleeves, Pre formed sections are supplied for flanges, bends. weld on tees and many more. Other Variations include solt mastic lining with interleaving polythene and ‘grafted co polymer adhesive. which melts when heat is applied. Approved currently as suppliers are: ~ 1 Raychem 2 Canusa Factory application Not applicable te application Because of the wide ranging materials and variations available. a single procedure would not Suffice but typically assuming a wraparound sleeve with a closure sti 1 Clean the area to he coated as specified. 2 Remove uny dusv/detritus as specified 3 Preheat the area using e.g. a propane torch. until above the dew: point or warm to the touch, 4 Remove the plastic cover and wrap the sleeve loovely around the pipe. (Printed arrows 6 logo line will indicate direction of shrink). Position the overlap to facilitate easy access for the closure stip. E.g. 12 o'clock. 5 Use the yellow flame to heat the closure strip evenly and apply to the overlap neatly No bubbles or creases. 6 Beginning from the centre of the sleeve apply heat circumferentially using a constant uniform motion, Site Cowtings ~ Heat Shrinkable Plastics Rec 1 Apal 0 Copyright 2008 TWH Lid WwConsiderations for materials 1 fusing tapes ensure correct ditection of shrink 2 Apply primers only if recommended. Inspection criteria for attached coati DFT Not specified Adhesion V cut in the event of suspicion. Holiday detection Speciall voltage setting of 1Skv Visual cheeks 1 Blisters. 2 Burnt or puckered areas. 3 Ensure firm edges with overlap onto sound coating, Checks on detached film Not specified. Repairs No method spec Banting MSR 1 NPT Twi Copyright © 2004 TWILL Is GapInspection criteria for attached coating DFT Use correctly calibrated magnetic gauge to check for minimum DFT, no area to be below specified minimum Adhesion No specified requirements but if necessary. V cut test Holiday dete Set 10 minimum specified DFT using the formula Sv per micron. 500 um = 2.Skv Visual checks Check for misses. voids. correct overlap ete Checks on detached film None specified. Repairs Apply further material after abrasion Safety Site regulations apply Toxicity No known hazards. Brushing Masties Rev 1 April Os Copyright © 8 TT La 152 yy seta aFUSION BONDED EPOXY Fusion bonded epoxy (FBE) sometimes called RPC. resin powder coatings, are used in the field on butts, when both adjoining pipes are coated with FBE Fusion bonded epoxy powder is virally a premixed two pack epoxy which is solid at room temperature, in powder form. Each particle in theory contains all components necessary to effect a full cure when the powder is melted into a liquid. The constituents will now be binder, pigment and extenders with additives such as flow control agents. anti-foaming agents. welting agents, deodorisers and others. The particle sizes will be in the range of 25 ~ 75 microns. Two B, Gas Transco specifications deal with powder coatings. BGC PS CW6. specification for the external protection of steel pipelines and fittings, using resin powder and associated coating systems PUI ~ Requirements for materials and methods of test Pc 2 ~ Fuctory applied coatings. BGC PS CWS. code of pructice for the selection and application of field applied external pipework coatings. One material which is approved for use on all parts of a pipeline is Scotchkote 206 N. made by 3M (Minnesota Mining & Manufacturing) and an applicator of the materials approved by BG Transco is PIH, Pipeline Induction Heat Factory application of FBEs Linepipe and fittings are coated in the factory prior to despatch to site, Different application techniques are used dependant upon the steel thickness variations. Linepipe is even wall thickness for the 12m length, whilst a blockvalve will have several areas of the casting with a quite substantial thickness of steel which will result in irregular temperatures if the same ‘method of heating is employed. Fittings. e.g. valves and bends and *T” pieces are therefore heated in an oven over a longer period of time before coating. Any oil or grease present is removed by swabbing with a solvent, usually xylene. or as otherwise specified, e.g. proprietary degreasers. The components are then blast cleaned 1o Sa 2% with a profile of $0 ~ 100 um using grit shot mix of metallic abrasives (factory). The surfuce is inypected for slivers and any found are reported 10 the engineer for Ultrasonic Testing. IF sufficient wall thickness remains the engineer will give permission to remoxe the sliver by grinding and the area is then reblasted, Sie Cinnge Fos Bond pny RT AT TWI conn Copyright © 2001 TW a Ie seaLinepipe sections will then progress through a series of induction coils (very rare occasions gas flames) 10 heat_up the steel. Any weld preparation areas are masked off to leave an uncoated are of 40 * 15 um hack from the root fuce at each end of the pipe. The pipe then passes into the coating area where it is coated electrostatically. The powder is sprayed through an arew of ionised air. which charges the powder positively. ‘The pipe is earthed into the circuit by means of a wheel on the internal surface of the pipe. ‘The pipe then becomes. atively charged and attracts the positively charge powder particles onto its surface. The powder melts instantaneously and starts ity cure reaction, As the thickness builds it insulates against the attraction of further particles. which are then attracted to other areas. ‘The epoxy thickness can be controlled by the voltage potential of the system. and the speed of the pipe passing through the coating area. Components such as bends etc. can be coated in various ways afier removal from the ovens. Some components are suspended from a rotating hook and manually sprayed with powder giving extremely irregular thicknesses, 1500 um being not uncommon, Another method for coating these components is called the Fluidised bed. By passing ait through powder in a container. the particles separate and sichieve freedom similar 10 the molecules in a liquid. giving the appearance of a liquid. hence fluidised. The components are then immersed into this container. sometimes elecirostatically. charged and coated ‘The specified DFT should be 350 ~ S00 um with a nominal thickness of 400 um. for Factory’ application Site application FBE application on site is only done on the welded joint between wo pipes when both of the pipes ure factory coated with epoxy powder. The process is done in three stages. one immediately following on from the previous stage, i.e. preparation by blast cleaning. followed immediately by heating with an induction coil, and finally the powder application, is customary for the equipment needed for all three operations to be carried on one vehicle. this enables immediate access to the previously treated butt in its ideal condition. E.g. the induction coil can move onto x grit blasted butt within minutes of completion. As soon as the butt reaches the required temperature the rig moves on a further hutt allowing access for the coating equipment Each individual operation is carried out as follows. 1 Preparation of the butt If necessary the area is degreased hy using a suitable solvent. typically xylene. An area of 250mm on either side of the weld, should he degreased in this way. Any hurnt and damaged epoxy from the welding process should be removed and the are steel area of the butt should Se Coaings~ Fusion Boned Eng Rv T April TWH cm Copyright © 2004 TW Lid lod at 1 AISITREM Sans CM wreisnesbe hlusted 10 Sa 2% with a profile of $0 to 400 um, using an expendable abrasive. The blast pattern should encroach onto 30mm of sound coating on either side of the butt, 10 provide a key. and the edge of the existing coating should be chamfered. ‘The area should be inspected for slivers and loose and disbonded areas of coating. Slivers to be ground and reblasted (with the engineers approval). Loose and jagged areas removed. reblasted and re chamfered by approximately 1Smm. 2 Heating the but The blast cleaned area of the but must be at Sa 2% quality with no rust blooming ot degradation when the induction coil is started. The induction coil is clipped in place and started. Operating at site voltage of | }0v the induction coil runs on AC supply. The copper Sirips which constitute the coil do not heat up and radiate heat onto the butt, they conduct the AC current which sets up a field causing the molecules in the pipe stee] to agitate, and their friction causes the heat, The time taken depends upon factors stich as the starting temperature of the steel. the pipe wall thickness. and the pipe diameter. and can resuit in times of one to eight minutes. but would typically be four to five minutes, The butt will be heated to x temperature above the powder application temperature 10 allow for a “heat decay”. the temperature drop before the powder application starts. A typical temperature. as specified by the engineer would be 253", measured by tempil stick or contact thermometer. Tempil sticks would be the preferred method. (Tempil sticks are temperature indicating crayons which melt when a specified temperature is reached, guaranteed 10 be within = 1% of temperature indicated on the crayon) Prior to heating a small mark is made on the steel with the tempil stick approximately 10mm. When the wax mark melts the temperature required hay been reached and the coil should be stopped. The operator should then ensure that the molten mark is removed (by wire brushing) before the coating operation commences. The butt temperature should never be allowed 10 reach the blue temper stage. 300". when the mechanical properties of the steel ean be affected. Exceeding the 300" would result in a “cut out”. Therefore the inspector should also be in possession of a tempil stick which should not melt at a temperature below 300" tices should he displayed to warn personnel that the pipes are hot Ideally warnii 3 Powder Application When the bult temperature drops 10 the specified powder application temperature range. the powder application can commence hy using either & manual ar semi automatic method. The specilied temperatures will he stated on the materials data sheet and would be in the region of 218" 10 246", The steel temperature. would be taken at 12 o°elock and 6 o'clock positions the Jatter being the coolest place on the Hine ‘ating. ~ Fusion Bonded Epoxy Rev 1 Apa TW woe sier Sie Copyright © 2004 TWH Lid 63 Cp‘Semi automatic systems usually consist of two application heads. manually operated through just over 180” on either side of the pipe. with the application positions being diametrically opposed. ‘The powder is fed through flexible lines and ejected onto the hot pipe. where it melts and cures in approximately three minutes. Because the pipe is continually cooling and chemical cure rates are temperature dependent the powder needs 10 be applied in as few passes as is possible to avoid differential curing. A typical number of passes would be six and a typical butt coating time approximately two to three minutes. The operators should check that sufficient powder is available to coat a butt before the operation commences, and some equipment has a suction reclaim facility. The reclaimed material should not exceed 25% of material in the application container ‘The CWS supplement, CA8 gives a minimum specified DFT requirement of 400 um, over the entire blast cleaned area of the buti, No maximum is given but economics will dictate Considerations for materials | FBE cannot be applied over any other coating material. nothing else can stand the temperature. If the finished product is to be exposed to UV it will require solar protective coating. Raw Material Storage. The powder needs to be stored in dry conditions. Containers should not be damaged and material exposed 10 sunlight or water. The material has a Matted shelf Jife which should not he exceeded so batches should be used in date onder or first in first out (FIFO). ‘The powder is also susceptible to compaction sintering so boxes should not he damaged. 11 is also advisable to have a quarantine area. Inspection criteria for attached coating DI Minimum DFT requirements are specified on both pipe lengths and butts, DFTs on buts should be done at ambient temperatures using correctly calibrated magnetic thickness gauges Six readings to be taken spaced equidistantly around the butt, Any areas found 10 be under thick are repaired by approved methods or by recoating. Adhesion Ata frequency agreed by the engineer. usually two per day. one on a morning and one in the afiernoon. *V" cut test allowing no peeling. Holiday detection Done 100% si ambient temperature using the formula. Sv per micron, Holiday detector needs only 10 be set a minimum DFT stated = 400 um = 2kv Site Coutings — Fusion Bonded Epoxy Rev | April 0d Copyright © 2004 TWH Ld lod‘Tests on raw materials (powders) FBEs are thermosetting materials and in common with all thermosetting materials the cure rate is temperature dependent, the higher the temperature the faster the cure 10 final crosslinking ‘The curing graph follows an exponential curve, i.e. every 10" rise in temperature. the chemical cure rate doubles from the previous 10, hence the “differential cure” in powder application. During its transition from powder to solid film the material passes through four stages. Flow time, from powder to semi liguid. less than one second. Wetting time, from powder to liquid, approximately one second. Gel time. from powder to start of solidification. approximately 46 seconds, Cure time. from powder to completion of crosslinking, approximately three minutes. From these four stages. the gel time is u very important property of a powder paint. After the stated gel time the material can no longer wet out over the surfuce to provide adhesion. so if a material deteriorates in any way and the gel time shortens then the performance can be severely adversely affected. If a gel time test indicates that the gel time is below the time specified on the data sheet, then the material should not be used on the pipe. The test is conducted as follows: « ‘The gel time test, Heat up a hotplate to stated temperature, usually 204" Apply ¥2 to 1am of powder to cover an area 3 = S em’ Simultaneously start a stopwatch when powder strikes the plate Stir the epoxy (which should now be liquid) with the spatula and keep lifting trom the Wet film, After a few lifts the liquid will retain its peak. at this point stop the watch, This is the gel time, Visual checks 1 Pinholes. could be escaping gas or water vapour Contamination. Specks of foreign matter in the film, Orange peeling, Usually under thick. viscosity problem. Over cure, Brown cast to material TFasion Bondod Epoxy Rev 1 Apa Ot TWI cence 204 TWH Ld a Ly meses ‘Site Coating CopstiUnder cure. Sickly green appearance. Staining. Could be non-removal of tempil stick mark, Detachment. Lack of surface preparation, Lack of chamfer, Original coating should be adequately feathered. Weld toes, Undercut and cold lap will have uncoated areas. 10 Excess weld cup height. The vertical face will have little oF no cover Note, Weld defects (the last 1Wo) cannot he dealt with by the coatings inspector and should be reported to senior personnel Checks on detached film Cure checks Checks to ascertain the degree of cure of the epoxy coating are carried out on all procedure butts, (first ten on a pipeline), and then one per day. or one per 100 butts. whichever is the most frequent. The quantitative test used by BG Transco is the DSC, the Differential Scanning Calorimeter, a laboratory text used 10 determine the degree of cure of a coating applied onto a but ‘The test determines the Tg, the glass transition temperature which can be defined as “the temperature at which the material changes from a glassy solid 1 a rubbery solid”. Tg is a “therm characteristic” of the cured epoxy Sampling ‘The inspector or engineer selects a butt and takes a sample from the 6 o°clock position, on the parent plate area of the coated butt, The sample size should be no more than 1Omm x }0mm = Jem’. and should be taken by use of a small hammer and chisel. ensuring no damage is Gone to the pipe steel. Any’ indentation is a possible crack propagation point. Ideally colleague should hold « clean tissue or linen handkerchief under the sample area to collect the slivers of epoxy (material falling onto the spread will be contaminated). The sample should then be put into a small sealable polythene bag and labelled with the Following information, Epoxy batch number ection number Correct butt number, Pipe number Position of sample. Date of sample. The sample area should then be repaired (see repairs luter) as specified, and holiday detected after Ihe time lapse recommended by the manufacturer of the repair material ‘nating ~ Fusion Bonded Epoxy Rev T Apel eh © 2004 TW Lid Isepsc The manufacturer of the powder provides trace of the DSCs done under ideal conditions, ‘The DSCs traces obtained from the samples from the pipe butts are then compared to the manufacturers Under ideal laboratory conditions the Tg of the cured powder should he at 100% cure. if the Tg of the raw. uncured powder is known then the temperature difference between the two can be apportioned into a percentage value, E.g. raw powder Tg = 100™. cured epoxy Tg = 108" sample from pipe Tg = 104" would represent 80% cure, ‘The sample taken from the pipe is micronised and a sample size of 10-15 milligrams is placed into a reference cup and heated prior to the test, 10 dispel any moisture present, The heat source is then activated giving a known heat input to raise the temperature by 20” per minute, and a trace is activated to record the reaction temperature in the cup. A line passing in an upward direction represents an exothermic reaction and a downward line represents an endothermic reaction. (Exothermic = giving off heat, Endothermie = taking in heat). ‘A trace from a sample taken from a pipe should not show an exothermic reaction, this would represent un uncured coating. Two runs are done on each sample. Run 1 and Run 2, providing two Tg values. ie. Tg) and Te2. On each run the material is given the chance to cure further and so theoretically the Tg2 should be on. oF nearer 10, the ideal laboratory Tg. than is Tel. So the criteria is given as Tp? should be within -2 and +5" of Tg1 Original powder trace raw 4 powder Post cure — Te post cure Temperature heating rate 20"/minure Figure 16.1 Typical powder manufacturers graph ‘Tgs shown as shilt in baseline due 10 temperature density changes. Sie Copy <= Fusion Bonded Epoxy Rev PApAT OL TWI © TWH Lid loo UmRunt Tel An ny | Ren? > «—Te? Residual exothesm Temperature Temperature Figure 16.2 Powder sample not cured Quick methods of cure check 1 MIBK swab test Soak a lint free swab in MIBK (Methyl-iso-butyl-ketone) and rub for 30 seconds on material to be assessed for cure, If there is no colour transfer from the epoxy onto the swab the epory iy deemed to be cured. 2 Buchholz indentor and microscope ‘The buchholz indentor is a block of steel weighing one kilogram. Approximately 25mm thick x 100mm x 50mm. A slot cut into the front houses a “glass cutter” shaped whee! 30mm diameter, Two small feet are on the underside of the block spaced so that when the block is placed in position there is S00gm point load on the wheel contact. Side elevation Front elevation Figure 16.3 Buchholz indentor Grain Tasin Bond pny Rw Ap TWI wen Copyright © 2004 TW1 Lit os anMethod i) Apply the buchholz onto the surface and leave for 30 seconds. ii) Remove and measure the indent length using the microscope (in the kit) iii) Convert indent Jength to hardness figure from tables in BS 3900 E6, iv) Apply an MIBK swab to immediately adjacent area. Leave for one hour. ¥) Apply buchholz to the swabbed area and leave for 30 seconds. vi) Remove the buchholz and measure the second indent length vii) Oblain a second hardness value from E6. Criteria If hardness value two is 85% oF more of hardness value one then the material is deemed to be sufficiently cured. Repairs Repairs on resin powder coatings (for dry surfaces) can be done in several ways, Table seven from CWS gives. in order of preference. } Brush or trowel applied MCLs. 2 Light or heavy duty CALTs Brush or trowel applied MCLs MCLs can be either epoxy or urethane. Both products come supplied in a variety of forms. ans. tubes and blister packs. but always involve mixing the components together in correct ratios. Some of the materials are designed to cure quicker than others and so have very short pot lives with very exothermic reactions. and so re only used on small areas, Repairs on areas up to lem? (10mm x 10mm) Abrade using course grade emery or wire brash. Remove dust and detritus by wiping or blowing (clean dry air), Repair using quickset materials. Holiday detect alter recommended time lapse. ‘A typical quickset material for this category of repair would be a blister pack urethane oF interpon quickset epory Cubes). Blisier packs are wo components separated by a plastic sealing strip. ‘The strip is removed and the components worked together hy squeezing. When thoroughly. mixed (no colour streaks) a corner is cut from the puck leaving a very small aperture through which the urethane can he dispensed by squeezing onto the repair are. Site Coatings ~ Fusion Bonded Epoxy Re. 1 April Copyright © 2004 TWH Lad 169Interpon quickset is supplied in tubes the contents of one being white and the other yellow. Equal amounts from euch tube are mixed thoroughly’ until no streaking is evident and the material is of a uniform consistency. and then applied onto the repair ares using a scraper of filing knife or similar to give a smooth raised ares of approximately 600 um DFT The manufacturer of this material quotes: - Base resin puck A Yellow contents Activator resin pack B-—— White contents Mixing ratio 1:1 V:V Pot life Sminutes @ 20% Hard dry Thour = @ 20 Full crosslinking 7 days @~—20 Repairs on areas over Jem? Blast clean to Sa2¥2 removing a further 10mm of sound coating from around the area. Clean the area by blowing with clean dry compressed ait Repair by using two pack repair material Holiday detect This type of repair is done using either epoxy or urethane, as specified, supplied in cans. Pack A, base resin and pack B activator resin are mixed together thoroughly. by emptying the total contents (serape out using a spatula or similar) of pack B into the space left in pack A. The total comtenty are then thoroughly mixed, mechanically preferably. or by a flat. square ended stirrer until a homogenous liquid (no streaks} is achieved. It is'then applied by brush or trowel onto the repair area. A typical material in this category is Interpon Repair Compound and the manufacturer quoies: Baye resin pack A. = 500m! can containing 200ml yellow Activator resin pack B-— -—-250mi can containing 200ml white Mixing ratio 1:1 V-V Pot life Thour @ 20% Hard dry Zhours @ 20% Full crosslinking 7days — @ =~ 20 All the repair material MCLs are solvent free. and solvent should never be added 1 them. Solvents are permitted for cleaning tools and equipment only Tie Goong Fann Bond wy RN TARE TWH osm hi © 2008 TW Lit oto CEM onsCold applied laminate tape Repairs on FBE Lines can be done using CALT. but only, by specification, of full circumferential repairs. (lt may be worthy of note that CALT cun be used on the butts of an FBE coated line when grit blasting cannot be done, and wire brushing is the alternative) Repairs using CALT are performed in the standard way. by abrasion (onto existing coa and primer application. the tape is applied in a spiral fashion with a 55% overlap. start finishing in a downward facing direction, Repairs using melistick Melisticks are not specified and not used for repairs now, but it is considered that an inspector should be aware of them. Melisticks are in the form of an oval cross section approximately 10x 6mm of varying lengihs, quite flexible and of thermoplastic type material. By applying lighted match. cigarette lighter to the end of the stick, it melts and then can be rubbed onto the repair area. Some other specifications allow their use on polyethylene and polypropylene and other polyols Safety When working with the powder form it is advisable to avoid inhalation, (wear masks). and refrain from smoking. When mixed with area the powder iy inflammable. Site safety regulations would apply Tonicity No known hazards in its solid form, ‘She Coatings ~ Fusion Bonded! Epoxy Rev T Apa 0 ‘Sea tot Copyright © 2004 TWH Lid et warMCLs URETHANE: Urethane MCLs have 1wo specified uses on a pipeline. Firstly for coating tie in welds on a pipeline when the powder coating machinery may have difficulty accessing. and secondly for patch repairing of damaged areas on coal tar enamel, CWS T7. repair for dry surfaces. gives MCLs as the preferred method with grease based tapes as first option, Urethane MCLs are two pack componenis consisting of a base material of urethane or polyurethane, and coal tar or pitch, and a curing agent of isocyanates modified in various ways. The modification give different properties e.g. some materials can cure at very low temperatures ~20" slowly but effectively. some will cure underwater with no adverse effect, some cure by using moisture from the atmosphere. However the ones used on BG Transco pipelines are extremely moisture sensitive. These two pack urethanes have a very high viscosity base material and very low viscosity isocyanate curing agent, and should be mixed mechanically, sometimes preheating may be required 10 slightly lower the viscosity, It is advisable with some materials to mix at approximately 400 rpm 10 avoid air entrapment and mixing should be done as quickly as possible as the material has a very shor pot life, about 10 minutes at 20". Both components are blackish in colour and therefore homogeneity is the only sign of adequate mixing. Because isocyanates are extremely toxic, urethanes are supplied in two grades. brushing and spraying. Protegol 32-10 is a common spray grade urethane and Protegol 32-401, designed for brush trowel application. All these materials are solvent free and solvent should never be added. for any reason. without written consent from the manufacturer. They should comply with BGC PS CW6 Pil, Some materials currently approved for use by BG Transco are: - Protego! 32-10 Acothane Debrathane Protegol 32-10L Durathane Versathane Factory application In a factory the urethanes would normally be spray’ applied using typically Protegol 32-40 Spraying grade. The application conditions applicable to this. material are very strict, regarding both its sensitivity 1 moisture and the toxicity’ of the urethanes curing agent. isocyanates. (spraying is not allowed in the open due to atomised isocyanates parsing into the atmosphere). Application constraints will require that urethanes cannot by applied (ihis applies to factory and site with brushing grades) during fog. mist, rain or snow or when the surface is wet, The Sie Gongs METS Ethan RT ApH TW conn eas TW La mn BAZ Sse Copyair oF metal temperature must not be within 3® of the calculated dew point temperature, and the air or metal temperature must not be below 10". w typical RH constraint would be not more than 80% although some manufacturers say 70% I is permissible to erect shelters and use dehumidifiers and heaters 1o ensure these constraints. can be met, and maintained for the required period, Method Grit blast 10 Sa 2% with a surface profile of 75 — 100 um (no primers are used so a coarser profile is needed for adhesion), Apply urethane tar using plural pump system to a minimum thickness of Imm, unless BG Transco specify otherwise. Chemical cure time is temperature ependant but will be around eight hours at 20". cheating the pipe would accelerate this time hut must not be done without engineers permission). The newly coated piece should not he handled if damage is likely 10 occur and the coating must not be allowed to be in contact with water within this cure period. which, regardless of the manufacturers recommendations is, 24 hours for BG Transco. Plural spray pumps Two or more aitless spray pumps are metered to pump fixed ratios of base and activator into a mixing bafMle. The containers are heated (in jackets) to facilitate the flow and uecelerate the cure. In the mixing baffle the components thoroughly mix and pass along a short line 10 the spray’ gun, for application, Before the baffle the components are stable. but upon mixing the cure starts. If for any reason spraying has t0 stop. the pumps are stopped and a solvent pumped into the baffle to clear the system from the baffle onwards. If this is not done and the material starts to gel. the baffle. line and spray gun are rendered useless. Before spraying can recommence the solvent supply must be shut off and the system flushed through to remove all traces of solvent. Site application 11 iy normal to use the brush/trowel grade for site work Protegol 32 10L. although spraying can he carried out subject to constraints of the previous paragraph Tie-ins on FBE coated lines Blast clean to Sa 2% using expendable abrasives, with a surface profile of 75 - 100 um, providing a key on existing coating either side, Remove dust and detritus by blowing with clean dry compressed air or brushing. TRC Gitano Pape TWH Ld 7 sn Site Gna CopyrightApply a first coat by brush/trowel commencing at the underside of the pipe and spreading circumferentially, with excess material directed towards the weld. Overlap 75mm minimum onto sound existing coating on each side of the weld. Allow the recommended drying time. typically one hour, before the application of a further coat ial Apply a second coat of the urethane in a longitudinal direction with excess mat conducted towards the weld area overlapping 75mm minimum onto existing coating either side of the weld. Apply any further coats as above. at 90" to the application direction of the previous coat. until the required thickness of Imm is achieved. Ensure that the final application is smooth and professional looking Coal tar enamel Urethane tar materials are specified on CWS T7 for coating CTE to CTE pipe butts and for repairs to CTE. dry damaged areas. ‘They are not compatible with bitumen enamel ‘The specification for the couting of butts using UT requires that the existing enamel be bevelled back by 100mm, The area should be grit lasted to Sa 2%, profile 75 — 100 um blown down and cleaned us previous. The urethane tar should then he applied circumferentially’ then longitudinally t0 build to the required Imm DFT. overlapping onto sound existing coating by not less than 150mm. The specification requires that the wo interface areas be then overwrapped with heavy duty’ CALT Nowadays however it is not considered to be necessary as the manufacturers of Protegol guarantee the bond. Considerations for mate Urethane tars are not suitable for use over plastics Urethane tars are not compatible with any bitumen based material The materials are only toxic in liquid form. They are extremely moisture sensitive and due regard should be given to application constraints $ The materials should not be exposed to temperatures above 145° as they release various cyanide Sie Cogs MCLs Crime ROT A TW] wns i Copyright © 2008 TWH Lid ma Clap eesInspection criteria for attached coating DFT Six reading 10 be taken on butts, equidistant on random areas using a correctly calibrated banana gauge, minimum thickness Imm, Any areas under thick to be recoaled, Adhesion “V" cut test. It may be found necessary to use a mini-hacksuw rather than a Holiday detection 100% of area to be holiday detected using vol formula Sv per micron = Skv e setlings 10 minimum DFT requirements, Visual checks Check for blisters, pinholes ete. usual defects, Checks on detached film None specified. Repairs For areas of Jess than Tem*, surface preparation by abrading with coarse emery. Areas greater than lem by blast cleaning. The prepared areas are then coated using the same material as the existing parent coating. Safety Recommended safety precautions must be observed. and the liguid material should not be allowed to contact any bare areas of skin. If this occurs then the affected area must be washed immediately with soap and water, In the event of UT having 10 be removed from a Surface, it must be done using prolonged blasting (CWS table 1), with no heat application ‘Site Coatings — MCLs Urethanes Rev LApring Copyright © 2004 TW Lid TWH wn Cm seeToxicit The isocyanate curing agents employed in curing urethanes are very toxic and have an MEL, of 0.02 milligrams per cubic metre (see health and safety unit), During spray application of these materials the applicators should wear as a minimum. a positive air supply mask. total body coverage sealed at the wrists and ankles, over gloves and adequate footwear. Extraction units should be operating. Siw € Cops TW vnc CEM icin Cistha TWH LadSPECIAL SITUATIONS A situation may arise when it is not possible 10 use the specified material. One such instance would be for the repair of coal tar enamel subjected to soil stressing on a live line. In a situation such as this. the line would have been exposed by excavation, and in all probability the base of the trench would be in standing water. The operating temperature of the gas in the line would be below dew point temperature and so the enamel would be wet with condensation, Therefore repairs using urethane tar would be out of the question. as would repairs on bitumen enamel with urethane tar, Laminate tapes would also be out of the question. firstly the damp surfaces and secondly because of the room under the pipe. (full circumferential repairs). Jn situations such as these # material called Playgard 410 would be used. Plasgard 410 is a solvent free. 1wo pack epoxy. which is moisture tolerant and compatible with ai] coating materials (being solvent free). The soil stressing would be wire brushed along the length using a dise brush to clean all debris out of the zig-zag longitudinal crack, and solar protective materials and other debris from a band approximately 300 ~ 400mm wide centred on the crack. The area would then be swabbed 10 remove as much moisture as possible and progressively swabbed and brush coated with Plasgard along the length of the damage. Any’ condensation will then form on the outer surface of the Plasgard. and can be easily swabbed away prior to subsequent coats Specified minimum DFT would be $00 um but ideally the damage would be filled to be flush with the surface. After an appropriate time lapse the pipe would be subjected to holiday detection. and if satisfactory. the trench refilled. ae Counings > Spastal Siuations Rev 1 April yeINTERNAL COATINGS FOR FITTINGS AND LINEPIPE Coatings applied to the internal surfaces of linepipe and fittings are not a consideration for the site coatings inspector. in fact once the linepipe has left the coating plant there is no procedure for repairing damages to internal coatings. It is however considered to be essential for the inspector to understand the reasons for applying internal coatings. which are: To help to reduce noise. To ease the gas flow by reducing Iriction. ‘To reduce turbulence and thus vibration, To prevent corrosion during pipe sto To reduce fatigue stress “The materials used ure usually two pack polyamide cured epoxy applied over an Sa 242 blast to a DFT of approximately 50 um. The BG specifications dealing with internal coatings are: - BGC PS. CMI - Procedure for internal coating operations for steel linepipe and fittings, BGC PS.CM2.- Specification for internal coating materials for ste! linepipe and Fittings. BGC PS PAS - Specification for internal coatings for stee! small bore pipes (below 100mm nominal size) Tie Changs Fangs & Hinpipe ROT ATO Sowa Capi © 2004 707 Lad wt Bp SessHOLIDAY DETECTION Holiday detection is an operation carried out by a coatings inspector in order to find any Voids, misses or uncoated arews, which may be present on a pipeline. This operation can also detect areas of low film build, but is not a substitute for any other inspection function. i is done in conjunction with all other inspection functions. High voltage holiday detectors, sometimes called “spark detectors” all work on the same principle. All coating materials used on pipelines (polymer based) have a known resistance to the passage of a current, measured in ohms per cm, ranging from 10° to 10" Qiem. Air and water have extremely low resistances compared to this. I a substrate is made into a cathode © in a circuit and the anode @ is passed over the coating. where there is sufficient resistance in the coating it will not allow the passage of the current. If however the anode is passed over a pinhole in the coating. the resistance of the air in the pinhole is far far less and ‘will allow the passage of the current. Where a coating is under thick the resistance will be reduced and the current will pass. It should be noted however that there will be no indication as to why the cireuit has been joined. but only a signal that it has been joined. DFTs and visual inspection are therefore still very important. There are several types of holiday detector, AC, DC and high frequency and pulsed, but for pipeline work the most common is the DC detector, powered by a 6v rechargeable battery For FBE coated lines a Skv model is quite adequate and the scales are usually set in 25v increments for accuracy. For CTE and polyethylene a much larger model capable of providing I5kv would be required, calibrated and For using within the auspices of a quality system the machines should be checked, For obvious reasons this type of equipment should not be used on wet surfaces. or in the rain. Use of the holiday detector Prior to actual use it is necessary 10 Set the voltage to a predetermined value, as specification for 1 u formula, BG Transco use the formula Sv per micron = Skv per mm. Special voltage selling are specified for some coutings e.g. CTE at 1Skv, others such ay CALT require a DFT and then setting as per the formula. Itis essential 10 have the voltage setting correct as too low a voltage setting will result in holiday not being detected und 100 high a voliage setting will cause holidays. Sie Chatngs = Wally Dasowion Rex ANT ‘mera Copyrigin © 2004 TOT Lid 201 Bp SissiThe structure 10 be holiday detected must be earthed into the circuit by means of a crocodile clip onto the structure (bare steel) wired up to a spike driven into electrolyte level in the ground, or wired direct to the holiday detector. If using the spike method (advantageous for working some distance away, above the Jength of the earth wire provided), a spike with a connection to the holiday detector must be used similarly at the station of work. The holiday detector is then switched on and the circuit tested by contacting a known pinhole with the anode. or striking the earth clip. If the circuit is OK then the operation can commence. The anode, which is now preferably a wire or copper bristled brush. (spring and carbon impregnated neoprene are not now permitted by BG Transco) is passed over the coating at a speed of not more than 300 mm/sec. ‘The brushes ean be of the drum brush type of in some cases over 15" long copper bristled brushes. sometimes curved to suit the pipe contour. Flat brushes should be traversed circumferentially and “T” pieces should be done by circumferential action on both the carrier pipe and the branch. with the weld done as an entity using the comer of the brush, on both sides of the pipe. On contacting a holiday the follow 1g will indicate its presence Needle on the kv dial will drop to zero. A bleeper will sound. Lights will flash on the control box or anode handle. Blue sparks will crackle from anode to cathode. When dismantling the holiday detector the earth should be the last disconnection. Holidays should be marked by circling with a waterproof marker. with the holiday in the centre of the circle, so as not to interfere with the adhesion of the repair. Site Coatings — Holiday Detection Rev | April 04 wok DEN toHANDLING TRANSPORT AND STORAGE It is an inspector's duty to ensure that all handling, transport and storage is conducted according to IGE TD 6. Materials control requirements are that an inspector should report and record the following during receiving. loading and stringing. 4) Location/section number (loading out) bb) Operation type. ©) Pipe number. heat number and pipe length, 4) Coating type. €) Any coating damage and repair details f) Any damages or dents to weld preparation area. Destination (on load out operations), h) Wf stringing the direction of travel. normal for low to high section number reverse when stringing to next low number section Handling of pipes In oxder 10 minimise couting damage. certain precautions are specified for handling transport and storage: When pipes ate 10 be lifted the preferred method is a spreader beam with slings. When a spreader beam is not practicable then brothers shall be used. (Iwo leg chains fitted with profiled hooks, fined with material which will not damage the weld preparation area e.g nylon). A guide rope is fited 10 each leg for operator safety. It is mot permitted t0 uve chains. padded or otherwise around a pipe When transporting pipes from mill 10 pipe store or out to the spread they can be stacked either pyramidal or on specially profiled cradles. dependant on size. It is essential that every contact paint be padded with at least 12mm of rubber. pipe to pipe. pipe to cradle or batten. pipe to stanchion and pipe to straps. Stacking of pipes Pipes shall he stacked, according to specification. in. pyramid fashion on hard or soft standings. Tables in the specification give details. according 10 pipe diameter and coating type. aso how muany tiers may be wsed, Sie Guang Aoming W Swe Rs Te Tun Copyright © 200 TW1 Lid M4 yy hvniusuiane‘On soft standing 1wo parallel rows of sand (berms) approximately three metres apart are deposited. covered with polyethylene. and the pipes lain across the sand rows, allowing a [all of approximately 10mm for drainage of water from the inside of the pipe. Hard standings consist of the specified number of bearers (skids or sleepers). in rows. padded Further tiers can be laid with wood wool pads underneath the bottom layer of pipes. according to conditions specified. ‘Table 21.1 Stacking details for 12 m random length resin coated pipe Tie Tngand Tne Wises | dana moma! aT umber | wall | Nuk Wo] Nompr | Wal arches | ort | aks | tn | ches | att | eknes | maxi tmani- tani mm mm m) | mm mum) mm soum) | im 80, 5.49 x») - | : 5.49) to) pass [aes] ae nae isd) seg iat 5 a0 Pas | ie asf 300 714 4 [12.70 i 12.70 ul 9.52 ri 400, R74 2 14.27 8] 1427 8 1031 no 450) 952} 9 1S.88 7 [sss z es y jose} ax fsa se 501 is) s | was] oo isae Po) 0 ia | sos asa se ios | 14 4 19.05 3 2871 2 | a8 4 aw) : — | | W400 14.27 4 t Note ~ Numbers ot Hers based on the Following conditions hard standings Coating sess limited 10 20% of manulacturers published compressive srength Maximum rubher compression of 40% Three equally spaced separators tited 1 each linepipe section, ‘Separator wih of 100mm and thickness of Sm, Separators mnutactured from rubber with 6010 70 RMD. “Three additional supporter. ofthe same dimensions and material being placed he Uh the bottom ro on Sie Coy Cony 1 20 TW) Lad inge = Handling & Son oT m2 TW SyncTable 21.2 Stacking details for 12m random length coal tar coated pipe [Pipe win sve Sona | Tapani | om Walivins | Nmroies | Wacken] Nomberon a mst ro ‘cnimumy I 80 say Ea - - | va 19) zl ai a 1% 3% n 19 1 200 os n 1279 a 250 om i TB i ra) om ; a 7 0 oH n 13 3 450 | 9s2 5 1S88 5 con 789 3 Tas : 750 vist 2 1308 2 0 | 12.70 2 19.05 2 7089 1327 2 72a 130 B50 : : : 130 at > I ‘he nonheroti gon isha on dql spaced Spo hos ish and ear a ‘pads heneath the bottom layer “The number of ers given is hased on 6 equally spaved separations between pipe layers and HT hearers and pads bon the bovtom layer. In is also a requirement that the weld preparation areas are not damaged during transport and Morage, There are three specified methods of protection. Plastic end caps (night caps) taped in position over the ends of the pipe. I 2 Specially profiled metal caps which bolt in position 3 Wax-oil. a preparation which is painted on or dipped. This is regarded as a temporary measure and would preferably’ be covered with an end cup. Site Coa WP Storage Re P Apa FT sins si Copyright © 2004 TWH Lid Ds wa eeeCONCRETE COATINGS Concrete is applied 10 the external surfaces of pipes in certain, situations. The specification BGC PS CW9. concrete coating of pipes is a three part specification. Part 1 Negative Buoyancy Coatings (plus supplement notes for guidance) Part2- Security Coatings Part3- Thrust Bore Coatings During the planning stage of the pipeline it can be determined how muny linepipe sections will be needed for each eventuality. and so, much of the coating is done as a factory. There are oceasions however when conerete may have to be applied at site nsiderations for Materials 1 The cement used can be either Portland, Blast Furnace, or Sulphate resisting cement 2 The aggregates and sand used should be clean (potable). 3 The reinforcements used should be concentric and rigid. 4 Plastic (non conductive) spacers should be used to hold the reinforcement from contact with the pipe. Application Applicution of the concrete can be by any of three methods a) Moulding b) Impingement ©) Guniting Moulding Female moulds are made from timber or similar. filled with concrete and allowed to set. Impingement The conerete is passed under a roller with rubber blades, rotatit onto the pipe. The pipe generally traverses across the application area giving a corrugi appearance. Be Gaatnes conve rang RT ATTN TWI concn Copsisht © 206 TST 2 Ay sites ’ aGuniting Spray application of conerete. The mixed concrete is compressed by means of a rotating sctew und forced along a hose. Upon exiting the hose the concrete is carried by high pressure water, and/or compressed air onto the substrate. In all cases, concrete is applied over existing anti-corrosion coatings. Because FBE is relatively thin, there is a strong likelihood that during impingement or guniting. the coating could suffer impact damage. In order to avoid this the mill coating will be applied (0 an extra thickness of 650 ~ 700 um. Inspection considerations The concrete thickness should be 75mm + 10% The concrete should he applied to within 400 + 2Smm from the pipe ends. The anti-corrosion coating should be inspected and holiday detected. (on the uncoated area) and any damages repaired 4 There should be no continuity between pipe and reinforcing. This is tested using a 6 oF 12y batlery circuit with 4 bulb wired in, One end connected 10 the reinforcing, the other to the pipe end. For acceptance the bulb should not light Ambient conditions should be recorded Visual checks cracks. voids. spalling, and compaction, Ringing test using a 21b hammer, similar to enamels. Cheek for ovality Note. Security coating can be done by using concurrent sleeving. with thinsulators to hold the carrier pipe dead centre of the sleeving. sealing off the ends with forged steel caps, The internal pipe space hetween the security pipe and the carrier pipe is called the annular space. This space can be filled with grout (concrete) or alternatively by using nitrogen gas 10 a pressure of 12 bar Site Coatings ~ Conereis Coatings Rev | April OF ‘OR DET I Fo Copyright © 2004 TW1 Lil 22 by we neDITCHING AND BACKFILLING Ditching the pipe When the pipe has been successfully coated, holiday detected, and repairs completed. the ext operation is the ditching of the pipe. This is done to the general pipeline specification BGC PS P10. This specification deals with the civil engineering requirements on a pipeline such as trench depth and width, fencing requirements etc, Ditching means the placing of the completed sections of pipe into the ditch. and is done by means of a number of side booms progressively lifting the pipe from the skids. moving it over the ditch and lowering into the ditch. Ideally the jibs should be padded with old cat {yres to prevent damage if the suspended pipe should swing back and strike the jib. The inspector should walk the length of ditch and inspect for electrodes oF protruding rocks etc. which might damage the pipe coating during ditching operations. If the trench is excavated in rocky ground it may be required to line the ditch with 150mm layer of imported sand/eravel to provide a level surface and avoid unnecessarily stressing the pipe. As the pipe is lifted from the skids, the contact area, previously inaccessible, should be holiday detected (and repaired if needed). Note. Where thermoplastic coatings are used. handling must not take place if the temperature exceeds 27°. as migration of the material may oceur Backfilling of the trench When the pipe is laid in the bottom of the trench. sometimes it may be deemed necessary to pad around the pipe with further imported backfill. but otherwise stone free layers of S00mm Geep. from the best of the excavated material would be used. and compacted with hand rammers or mechanical devices. The layers should be of the same material as the layers evident on the sides of the excavation, e.g. yellow clay’ to yellow clay. The stone free layers. 300mm deep should be deposited until there is 300mm of cover over the pipe. The remaining uckfill may then be replaced. in 300mm layers. providing stones and lumps of vegetation over 200mm are discarded, up to the top of the subsoil level. The total cover over the top of the pipe to the top of the topsoil (when replaced) should be 1.2m, minimum. The bac! penetrometer, compaction can be checked by either CBR. Californian Bearing Ratio, or a jard. « plastic mesh. cun be minimised by using Roc! Impact dumage on the pipe coat which is strapped around the pipe. ‘Site Coatings Ditching & Bavkiing Re Apal 04 Copy 2004 TWH La x TVA RSPEARSON’S SURVEY ‘After backfill, when the electrolyte has been ullowed sufficient time t permeate through to the pipe coating, a Pearson's survey can be done. From the Pearson's survey the following can be detected. i) The presence of coating damage. ji) Metallic objects near the pipe. fii) By triangulation, the depth of the pipe. ix) The pipe position and direction. ‘Two operators walk along the line of the buried pipe. Both are wearing clampon type fittings con their boots. The spiked boots are connected by wire to their belts. which in turn are connected together by an cight metre long conductive cable. At any time a circuit can be joined between the two men, to earth. |A battery is coupled to a CP test point and a current passed into the pipe. The battery is earthed by driving a pin into the ground, wired to the negative pole. Wherever bare steel on the pipe is in direct contact with electrolyte in the soil. (damaged areas). current will be released into the electrolyte. The Jead man of the 1wo carries an instrument. which amplifies the signal of the current release, As he passes directly over the top of a damage he will receive his strongest signal. The signal will diminish ay he gets further away. Through his earphones the second man will know when he is approaching. when the signal is equal for both men, the damage is half way eiween them, When the second man receives peak signsl, he stops and marks the spot by hammering a small peg into the ground. The repair team then investigates by excavating manually 1o find the problem. Sa Coatings Pearson's Survey Rev P ApH FWI wens Copyright © 2008 TWH Lid 1 tar seeTESTING OF PAINT FOR PROPERTIES AND PERFORMANCE Viscosity Viscosity is a very important property for paint. it affects the manufucturing process and pplication and levelling properties. Viscosity is defined as being a fluid resistance to flow, Therefore a liquid described as being of a high viscosity is one which as a high resistance to flow, it will not run easily. and conversely. a low viscosity fluid runs very easily, [An increase in temperature (or decrease) can have a severe effect on a fluids viscosity and therefore comparative tests should be done at the same temperature. As the temperature increases the molecules within the paint gain more molecular freedom, move more easily and thus reduce viscosity. A typical recommended temperature is standard laboratory temperature of 20 + 0.5% There are several types of equipment available for measuring viscosity but they mainly fall into two categories. 1 Rotational Viscometers Flow Viscometers 1 Rotational viscometers Rotational viscometets rely on a paddle, disc or hall rotating in a liquid to measure the viscosity. The rotation can be driven by an electric motor. which gives Dynamic Viscosity measurements. oF by falling weights which gives Kinematic Viscosity measurements a) Dynamie viscosity For dynamic viscosity measurements a rotothinner can be used Figure 25.1 Rotothinner Sis Changs” Pees W Pearse Rev PAT Capi © 204 TH Lad BeThe rotothinner, a flat circular dise with four holes drilled transversely through it. is fixed into the chuck of the rotational viscometer (not unlike a pillar drill) and lowered into a 250 millilitre can containing the fluid under test. The can is magnetically attached to a spring oaded conical shaped base. When the dise enters the can, a micro-switch engages the motor and starts the dise rotating. When the rotating disc enters into the paint the frictional forces between the disc and the paint molecules and the can cause the can to rotate, which in turn tensions a spring in the base, When the two equalise the can will stop rotating and a reading can be taken from the pointer on the scale on the conical base. The systems international (S1) units for dynamic viscosity are. newton-second per square mete (N.v/m") although on many machines the poise is still used (egs. unit). A poise has ten subdivision called centi-poise. Water has a viscosity of approximately one centi-poise. One poise is equal to one dyne second per em’ b) Kinematic viscosity — re) Weight —ly Figure 25.2 Krebs stormer viscometer Kinematic viscosity is measured using a Krebs Stormer Viscometer. The weight is allowed to fall. which in turn causes the paddle to rotate in the paint, More weight added results in a higher rotation speed, Weights are added umtil the rotation speed is 200 rpm as measured either with a stroboscope or digital display counter. A viscosity unit frequently’ used for kinematic viscosity is the stoke and centi Moke, A fluid having a viscosity of one poise and a density of 1 gmfce has a viscosity density ratio of one stoke. (Krebs units or poise can also be used.) Site Gratings ~ Properies & Pevlormancy Rew 1 April TWI vmnnse Copyright © 2004 TWH Ld 282 Ce ieFlow viscometers (Flow cups) There are various types of How cups e.g. Zahn and Frikmar, used for hot fluids. Ford, ISO and DIN used for ambient temperature materials. The ford cup being the most widely used for industrial paints. The flow cup is machined from Aluminium, has a capacity of 100ce, and is fitted with a Stainless steel nozzle at the bottom with various orifice sizes, in millimetres. For use with industrial paints. a 4mm hole size is standard, and known as A Ford Flow Cup N's. The cup is mounted on a special stand, and has a lid with a bubble spirit level. The triangular base of the stand has one fixed foot and two screw adjustable fect. 10 facilitate the levelling of the stand and cup. A ypical procedure for use would be: Ensure that the equipment and paint temperatures are at 20% + 0.5% Level off the equipment using the bubble level and adjustable serew legs. Put the lid 10 one side when levelling is complete Place a suitably sized receptacle under the orifice (greater than 100cc). Place a finger over the nozzle orifice and fill with the paint 10 be tested, up 10 the brim, leaving a convex meniscus. 6 Using a straight edge (a ruler) quickly scrape excess material into the overflow rim on the top of the cup. 7 Simultaneously start a stopwatch (or use sweep second hand) and remove Finger from the nozzle. 8 The paint will run from the orifice in a continual stream, At the first distinctive break in the stream i.e. when it drips. stop the watch. The time in seconds is recorded as the Viscosity. at the measured temperature, Thinners added to paint over and above recommended quantities could also be determined by viscosity, To do this a sample containing maximum amount permitted (by: manufacturers TDS) is prepared, and compared 10 samples taken from the operators at the point of application. Using the flow cup. if the operators sample runs through the cup faster than the reference sample. then more thinners than allowed has been added. To find the exact percentage added, small amounts can be added to the reference sample until operator’s sample and reference sample run through in the same time. Should the operator's sample take longer than the reference sample. then there is no problem. Thixotropic paints cannot be ‘measured using a flow cup. eRe | Apa De 7 peererrentt oa TWH 284 My nein Se € CopyFILM THICKNES Wet film thickness measurement From information given on a specification and the technical data sheets (TDS) correct application thickness can be calculated. If regular checks of wet film thickness (WFT) are cartied out. and found 10 be adequate, it gives added confidence that upon checking the following day, the dry film thickness (DFT) should meet specification requirements and hopefully eliminate major rectifieution: Wet film readings should be taken immediately after application, in order to obtain trve readings (solvent starts {0 evaporate away as it exits the spray’ tip), WFTs ean be measured by using either an eccentric wheel. or comb gauges. 1 Eccentric wheel An eccentric wheel is a steel disc, machined to cut two grooves Jeaving three rims. The centre rim is machined smaller than and eccentric to the two outer rims, The inner rim is called the Eccentric Rim and the two outer, the Concentric Rims. Degree of eccentricity 250.um, normal A scale is engraved on the outer surfuce of one side of the wheel giving degree of eccentricity at any point Sie Cong Fn Talos Rev 1 TE Tw oe Copy ed TW La dot rants osTo uve the whee! it should be placed on the surface with the zer0 at the six o°clock position. rolled through 180° in one direction. back to the zero and then 180” in the opposite direction. back to zero. The concentric outer rims will he wet for the full circumference. but the inner Fim, the eccentric rim. will only be wet for part of the circumference. having left and re- entered the film on two occasions. The wet film thickness value is taken by transfer (mentally) the interface between wet and dry on both sides of the eccentric rim into a value from the scale. The average of the two values is the WET of the paint film. It should be noted that the eccentric wheel can only be used on fat plate, On a pipe. for example it would be used circumferemtially ‘Comb gauges Comb gauges are supplied in many forms. square. rectangular. and triangular, in metal and in plastic. Disposable plastic gauges will be supplied in small boxes containing several hundred. Stainless Steel gauges are supplied in sets of four in a Jeather wallet. However all comb gauges ate used in a similar manner. Assuming use of the SS gauges, four gauges will each have two working ends covering eight different WFT ranges. “Above each tooth is engraved a value “thou” on one side and its ‘equivalent in microns on the other side. This represents the value of the gap from tooth end to substrate when the gauge is place firmly. perpendicularly onto the substrate. When the wet the tooth, ip under the tooth is full of paint it will wet the tooth, When not full it will not A procedure for this operation would be: - a) Select the appropriate gauge with the smallest increment rise tooth to tooth b) Apply the gauge firmly. perpendicular to the substrate into the paint film ensuring that the two end lands are firmly on the substrate. ©) Withdraw the comb gauge and look at the teeth. d) Two values should be recorded. The number above the last tooth weited by the paint and the value of the next highest not wetted. ‘The WET is not an absolute value but “in between’ NB Comb gauges should be used longitudinally on curved surfaces e.g. pipes. Sie Goong Fin Tasks ROOT Apa Fwi Copyright © 2004 TWH Ld Ca SitesWet — 2s \so Recorded as 50/75 wet ae [ aS Wet > Paint Subsrate Figure 26.2Comb gauge WETS can be calculated by using the following formulae, according to information given WRT = 100 x DFT VS WRT = Y= Volume A ‘Area Binder Solvent % Volume —=> Solids % F Figure 26.3 Contraction from evaporation Sing Hin Takes RV TAN ight © 2004 TWH Lad 28 Ce SitesiTests done on dry paint films Dry film thickness The specification for a painting contract will state a DFT criteria for each coat of paint applied. As it is the inspector's main function to ensure that Work is carried out to specification, he/she should perform as many checks as needed to ensure that the specification criteria is met. The DFT value can be determined by one of four methods. 1 Test panels 2 Caleulations 3 Destructive test ga 4 Non destructive test gauges Test panels Test panels are usually 150mm square plates of the same material as the component being processed. The plates undergo the same operations a the same time as the main components. Mainly used for destructive tests e.g. adhesion. they can also be used for DFT checks. Calculations Using certain formulae and information given on a materials data sheet, in conjunction with values deiermined from WFTS for example, calculations can give us the “unknown” values. Four formulae can be used according to information provided, 1 WRT = 3. DFT = WET x YS A 1 100 2 wer = lo x DI 4 VS% x 100 vs 1 1 Destructive test gauges As the name implies these types of gauges cause damage to the film whieh then needs 10 be repaired. If a specification required a magnetic gauge 10 be used 10 measure a coating including MIO (Micaceous Iron Oxide). in theory it can't he done. MIO is magnetic and would cause error in the reading. In this instance a destructive test gauge might be specitied or it may be required to monitor closely the WFT and calculate (as above) the DFT, A PIG. paint inspectors gauge is a type of destructive gauge. A reference line of a contrasting colour is drawn on the painted surface 10 be tested. A blude is tightened into a special slot in the PIG. pressure applied 10 force the blade through the paint to the substrate ‘She Goaings— Fn Thane Rev VAR Soupevin von Copyright © 2004 TW Lad cot By iesand then cut across the reference line. leaving a damage about %" it is then possible to examine the damage through a focusable microscope. Measurements ean be taken by means of a graticule scale engraved on one of the lenses Reference | View fine Blade Damage View through lens with graticule scale Figure 26.4 Tinsley Pencil, pull off gauge ‘The dimensions taken from the graticule scale at this point ate not in any units, as the angle of the cutter used alters, so will the representations of the graticule, A chart is supplied with each gauge. and blades of different angles. If for example the chart indicates Blade N"3 will be ground to x angle, can be used on thickness less than 500 um. multiply graticule reading by 1.8. 20 unit of graticule scale would then convert to 20 x 1.8 36 um Other commonly used destructive gauges are the Erieson Test Dritl and Saber Thickness Drill. The damage caused with this is circular. Non destructive test gauges This category of gauges is the most widely used and can be subdivided into Electronic and Magnetic. a) Electronic The electronic gauges work mainly on two principles. Electro Magnetic Induction and Eddy Current. The Electro Magnetic Induction is suitable for ferro-magnetic substrates and the Eddy Current is suitable for non ferro-magnetie substrates. Site Comings Film Thickness Rov 1 ApH OF Copyright © 2001 TWH LaModern electronic gauges are sometimes supplied with probes suitable for both situations and the gauges automatically change function according to the fitted probe. Both types are for measuring non-ferro magnetic coatings. Accuracy + %4% b) Magnetic This classification of gauges works with permanent magnets. no batteries. The simplest of these is: - The Tinsley Pencil or Pull of Gauge, Sometimes called a foreman's gauge is suitable for spot checks and iy not very accurate. even on modem gauges of this type +15 % accuracy is quoted. It looks very much like & pen and indeed is sometimes fitted with a pocket clip. It has a permanent mugnet attached 10 a spring. ‘The tension of the spring can be adjusted so that the gauge can be calibrated to work over a variety of thicknesses CA 1¢ Screw 10 adjust tension a> 4 A Spring Scale —___5f Cursor line \ Se nae " Permanent magnet Figure 26.5Cross section of Tinsley pencil Site Coatings — Film Thickness Rev) April 0 wom per Ste 108Lock/unlock Knurled wheel for calibration re 26.6 Magnetic horseshoe gauge The Magnetic Horseshoe gauge is a very old type of gauge still favoured for measuring hot surfaces such as metal spray. Accuracy often quoted as beiter than + 10% and as for all magnetic gauges. it is suitable for use in hazardous areas. This gauge works by measuring the change in magnetic flux between two magnetic poles at the bottom of the gauge. The flux change is brought about by the thickness of the non-magnetic coating. ‘The gauges are supplied in a wide variety of scales and are calibrated like all magnetic gauges The Magnetic Coating Thickness gauge, known colloquially as the ‘banana gauge’. measures non-ferromagnetic coalings over ferromagnetic substrates and can, according 10 the manufacturer even be used under water. This type of gauge relies on spring tension to break the magnetic uttraction of a permanent magnet to a ferromagnetic substrate. Because spring tension doesn't have a linear function the scales on the gauges are in logarithmic increments When calibrating for use it is therefore of paramount importance 10 calibrate using a shim as near as possible 10 the paint thickness. Modern gauges of this type often quote #5 % accuracy Procedure for calibration to BS 3900 PT C5 (now ISO 2808) (BG Transco specify calibration on « prepared surface. therefore a plate with the sume substrate surface finish as that to which the paint is applied. should he used). Spas TWI concn Film Thickness Row 200 TW Lad aa Cea Seite Site Cvain CopyrightI is extremely important to remember that should the gauge be calibrated on a flat plate. the reading on a blasted surface would take from approximately % of the depth of the profile. giving Valuey of up to 50 um more than the actual ‘over the peak’ value. 1. Select a plastic shim (magnetically insulated) as near as possible in thickness to that of the paint to be measured. Place the shim centrally on the calibration plate. as detailed above. Locate the magnet in th ‘onto the shim, apply a light pressure to ensure that the heel doesn't wobble or rock. and wind the scale wheel on the gauge fully forward 10 release all tension on the spring allowing the magnet to attach 10 the substrate. 4. Wind the wheel slowly back. clockwise. tensioning the spring until the magnet detaches. At this point the movable cursor on the gauge is adjusted so that the red line on top of the cursor is in line with the thickness value of the shim as shown on the scale wheel ‘The gauge is now ready 10 use. Some ‘banana’ gauges do not have a movable cursor. Instead these have a fixed cursor. moulded into the case, and a movable scale. and to calibrate these gauges. the value of the shim on the scale whee! has 10 be moved to the cursor Adhesion Inspection is defined as “Examining. testing. gauging, one or more characteristies etc.” One Of the properties required of a paint film is to “provide adhesion to the substrate’, therefore an inspector is expected 10 test 10 ensure the paint is performing this function. There are three main areas for adhesive failure within a paint system, a) Primerto substrate failure b)—Inter-coat adhesion (between films) €) Cohesive failure (within a paint film) a) Primer to substrate failure Primer to substrate failure is the most serious. Failure here means no protection at all. This is surface contamination problem mainly. Lack of adequate surface preparation, grease. oil dirt, dust are the usual causes. b) —Imter-cout adhesion Caused by the problems above and others. Lack af observance of recommended over-coating limits and expansion/contraction differences between materials. She Coatings - Film Thivkness Rev | Apa 4 a Copan © 5004 TT 1a aos TW inion " ue WHALES©) Cohesive failure Over thickness of a layer can entrap solvent during the drying process and thus stop polymerisation and the correct formation of the film, reducing Cohesive strength. The main reason for cohesive failure is solvent entrapment but incorrect ratio mix of a two pack can have exactly the same effect. These failure points can be detected in several ways, some costly, requiring equipment costing several hundred pounds and some requiring un outlay of a few pounds only. “V? cut test A craft knife i all that is required to perform this test. Cut through the paint, to the steel with two cuts forming an inclusive angle of approximately 30°. with leg length of approximately 13 mm, Insert the tip of the blade into the tip of the °V" and try 10 lever off. The paint should chip across the tip of the *V” clearly and cohesive without following the line of any of the faults described. It should not expose any of the substrate. substrate, ‘Cross cut (cross hatch test) Cut through the paint using six horizontal and six vertical cuts approximately 2 mm spaces giving a 25 squared grid. Special profile cutters can be purchased for this. of a craft knil be used. Apply an agreed tupe to the area (different tapes have different d and would give different results). rub smoothly onto the hatched area and then snatch off. The resulting areas of disbondment are then compared to diagrams shown in BS 3900 Pt E6 and classified according to percentage ares of disbondment Dolly test The dolly test is more expensive to use, but unlike the above gives an answer in units of psi or newtons/um square, etc and so is classed as a quantitative test. A typical procedure for the test would be: - Ensure the test area is clean and oil/grease free. lightly abrade the area and apply mixed two pack heavy duty adhesive, Firmly place the aluminium alloy dolly in position onto the adhesive ensuring that the skirted flange is to the adhesive. Leave for manufacturers recommended cure time, Place the core drill supplied around the dolly and cut through the coating to the substrate (this ensures that only the area of the dolly flange receives the pull off forces). Apply the pull off gauge and apply pull off force. some models use a ratcheted lever. others a knurled wheel) until failure occurs. This will usually involve a loud bang and the instrument will “jump” from the substrate. Examine the face of the dolly and apportion adhesive failure according to areas exposed. at the pull off force indicated on the scale. Site Coatings Film Thickness Rew T Apa Ot baw Consign © 200081 Ld zy BY SwFor example with an aluminium metal spray. single coat, there could be: - 1, Adhesive to dolly failure, 2. Adhesive to aluminium failure, 3. Cohesive failure within the aluminium. 4. Aluminium to substrate failure. Hydraulic adhesion test equipment This is a much quicker test with a hig! ier deg ¢ of accuracy. The HATE use cyano-acrylic impact adhesives and can usually be done approximately two hours after dolly/adhesive application, the dolly’s are mild steel and reusable because they are heated up 10 destroy the adhesive after use, Big downside for this test is initial cost and usually high maintenance. © Cong Fils ska Rs ATO ri © 2 TWD Sitios Consrghy © 2004 TWH LA By essSPECIFIED COATING CONDITIONS ‘A. manufacturers product data sheet will indicate under which ambient conditions a ‘an or cannot be applied. The clients specification may sometimes be a fttle However, in all cases, it is the specification which takes precedence. (it is common practice nowadays 10 include a phrase such ax “when these conditions do not prevail” or similar, 0 allow coating to continue using special products), A typical specification used to be: - “Is not permissible to apply paints 1. During rain, snow, or high winds”. This clause would be sensible even in modern specifications, 2. When the air or metal temperature ix down to within 3" above the dew point emperature”. Still common in specification now. but can be overridden by giving alternate systems. 3. When the air or metal temperature is below 5°". Solvent evaporates very slowly at low temperatures and chemical cure rates used to be static. 4, When the relative humidity is more than 90%". Still a very common restraint, and sometimes the benchmark for using moisture curing polyurethane’s. ind Dew Point From the above, 1wo very important phrases arise. Relative Humidi Relative Humidity Defined as being “The amount of water vapour in the air expressed as a percentage of the amount of water vapour which could be in the air at that same temperature”. 100% humidity. ken within 1” of the surface of a fast flowing river, saturation, is measured as bein; Dew Point This is the temperature at which water vapour in the air will condense. Condensation cannot occur unless the relative humidity is 100%. Recalling that every 11° drop in temperature results in the airs capacity to hold water halving. even the smallest drop in temperature results, in water being released from the air. in the form of condensation. So at 100% humidity the air temperature and dew point temperature. and wet bulb temperature on the whirling hygrometer are all the same value. Tie Cran SNTTRT Coating Cons Rev AW Som Copovigh © 2998 TW Lt sh TO sors‘The Whirling Hygrometer, Aspirated Hygrometer or Psychrometer Commonly called the whirling hygrometer, this piece of equipment is widely used by coxting inypectors to determine wet and dry bulb temperature readings, from which, using calculators or hygrometric tables. relative humidities and dew points can be calculated, Two thermometers are mounted in a plastic frame, fitted with a handle so that the frame can be rotated through the air. One of the thermometers is fitted with a wick around the bulb, The wick passes through a hole in the end of the frame and into @ small container with a screw lid. into which is put distilled water or clean rainwater i.e. de-ionised water. The water is drawn by capillary xction all along the wick out the area enveloping the thermometer bulb, This is referred to as the wei bulb and the second thermometer is the dry bulb. The frame with the thermometers mounted should be rotated quickly about a horizontal axis. (The BS 4872 states in front of and 10 windward of the operator) so that the bulbs pass through the air at 4m/sec, If there is a wind the operator should face into the wind. if no wind then walk slowly into a clean air current The frame should be rotated for 30 ~ 40 seconds. or as otherwise specified. as fast as possible (10 meet requirement as above) and then read the values on the thermometer. always the wet bulb first, immediately on ceasing rotation. The water on the wet bulb uses heat energy from the air to change into water vapour, so the wet bulb will give a lower temperature reading than the dry bulb. When rotation stops. the aspiration rate slows and so the wet bulb temperature will slowly start to rise towards that of the dry bull This operation should be repeated as many times as is necessary until the following criteria is, met, On two consecutive spins the readings should be within 0.2%, wet bulb to wet bulb and dry bulb to dry bulb, The wet bulb and dry bulb temperatures recorded can then be used to determine the RH and DP from scales or tables. This operation should be carried out as near as possible to where the work is being done. Big difference in temperature can occur from N side {0 S side of a tank or down a trench and lopside. Steel temperature measurement The air temperature (ambient) is the temperature recorded from the dry bulb thermometer ‘To meusure the steel substrate temperature a magnetic gauge. known commonly as a limpet auge is used. or a digital thermometer. thermocouple. sometimes called a touch pyrometer ‘ite Coatings ~ Spwciticd Coating Conditions Rew 1 April Copyright © 2004 TW Lid m2CATHODIC PROTECTION Cathodic protection is a secondary line of defence against corrosion, the primary defence being the coating. When damage to the coating occurs e.g. through impact on the coating during back filling on a pipeline, sling damage during the lowering in operation, or flotsam impact on an offshore platform Jeg. the underlying steel can then be in contact with electrolyte and corrosion can occur. But if these areas can become cathodic i.e. receive current, corrosion can be avoided. In order for cathodic protection 10 be applied, an electrolyte must be present. For example the external surface of a tank cannot have cathodic protection. but internal surfaces can if the tank is holding an electrolytic medium, but only up to the level of medium. not above. Underground and subsea pipelines can be protected. but steelwork above ground in an AGI needs painting. Cathodic protection can be applied in one of two ways, a) Sacrificial Anodes Systems. b) Impressed Current Systems. Sacrificial anode systems This system sometimes called, Galvanic Anode corrosion, the natural potential between metals. Any metal which is more electroneg less noble) or below steel on the galvanic list ean be used as an anode. The choice of metal used would depend upon the potential required to protect the prescribed area. Sacrificial systems only protect small areas and the anodes need changing regularly as they corrode x ° ystem, works on the principle of bimetatlic ive Approximately 50 m maximum Connecting wire of copper, Minimum, resistance Aluminium zine or G__illovsof these Figure 28.1 Sacri ail system Site Coatings ~ Cathodic Protwetion Rev F April OF Copyright © 2004 TWH Lad ca)Impressed current system The impressed current system is used 10 protect long lengths of pipeline from one installation, a distance of approximately 10 miles. The current needed to run the system comes from the national grid and is connected through a transformer rectifier (TR). The national grid is very high vollage and very high amperage and also AC, Anti-corrosion currents need to be DC. The TR rectifies the current to DC and transforms it to low voltage and amperage. The positive side of the TR is connected to a ground bed (anode system) and the negative to the pipe, making the pipe the cathode. ‘The current is released into the electrolyte at the ground bed. passes through the electrolyte and is received at areas of coating damage on the pipe. Atypical ground bed will be approximately SO m in length. at the same depth as. and running parallel to the pipe. The cables carrying the current are of a substantial diameter and pure copper to produce a circuit of little or no resistance at the anode. The resistance encountered comes in the soil/clay/rock bearing the electrolyte and this will govern the driving voltage required, and the number of anodes required to maintain negative potential on the buried pipe. ‘The voltage required varies but is usually within the range of 1Ov to SOv at an amperage of around 0.15 amps. A CP system does not eliminate corrosion, it controls where corrosion curs, To national rid sunny TR Transformer eetifior Current received at cathode, Protected. Ground bed iS. releases current intr etectrotvne <—> Figure 28.2 Impressed current system Sic Goaings Cas Poastnn Rev PAO yyy a Copyright © 2004 TWH Lit TwI IP REAES ASIN MD inceInterference When a buried steel structure is near to, or in the case of another pipeline, passes over or below a pipeline which is cathodically protected. problems can occur. This is “interference” but the term can be misleading. The offending structure does not adversely affect the CP system. but instead is affected by it ‘The “interference” siructure picks up current released from the anode bed and conducts the current through a circuit of minimal resistance and releases the current again into the electrolyte near to the protected line, The interference therefore becomes a secondary anode and can suffer severe corrosion If there is a possibility of a structure becoming interference then precautions need to be taken to avoid this eventuality. With the permission of the owner of the offending structure, three main methods can be employed. 1 Attach isolation joints one pipe length either side of the nearest point of the offending line to the protected line, Join the two pipe lengths to the protected line with insulated wire and doubler plates, thus making them the same potential 2 Attach isolation joints to both lines. one pipe length either side of the neurest point Join the wo isolated sections together and install a sacrificial anode to protect both sections. 3. Double wrap and contra-wrap the protected line giving four tape thicknesses with Cold Applied Laminate Tape for one pipe length either side of the nearest point The method chosen would be at the discretion of the engineer. Monitoring CP It is considered that -850 my will maintain a pipeline in a passive state but most CP engineers will require more negative value. -] to ~2v heing typical. To ensure that the required potential is being maintained. checks need to be carried out at regular intervals. One method of monitoring is known as hall-cell reference electrode, The most commonly used hali-cell electrode is the copper/copper sulphate half-cell electrode. Wt iy used for measuring the pipe to earth potential. i.c. cathode 10 earth, the other half of the circuit being anode 10 earth, Sie Coninge = Calas Precio RN PARADA wi Copyrist© 2008 781 La ms By Sins:Periodically along the line. CP monitoring poss are installed, with a direct wire connection 10 the pipe. accessed from a Siud on the CP post panel. A voltmeter is connected to the stud and to the copper/copper sulphate half-cell. which is then pushed into the earth directly above the pipe. This provides a circuit for electrons trom the pipe. into the electrolyte. back to the anode bed. U [ oo \ — Halve reference of Se a with copper ] Voltmeter yh cope sulphate solution CP post —pl] ¢ Ground level VRE Porous plug Pipe Figure 28.3 Monitoring CP Cathodic disbondment Part of the electrical circuit of the corrosion reaction is the evolvement of Hydrogen gas from the cathode. Hydrogen is a very powerful gas and can cause cracking in steel. (HICC). I Hydrogen gas can penetrate underneath a coating it can easily disbond it. This is known as Cathodic or Hydrogen Disbondment. Over protection of damaged areas on a pipe. results in over production of Hydrogen and subsequent disbondment of more of the couting. resulting in a bigger area to protect. needing more current All material used on a pipeline have to undergo tests to determine their resistance to cathodic disbondment, ‘The test is done in the following manner A6 mm diameter hole is drilled into a plate coated with the material 1o be tested. through the coating and into but not through the underlying steel, A short Jength, approximately SO mm of plastic the approximately $0 mm diameter is fixed in position, using typically: araldite epoxy ar elastomeric sealant with the drilled hole central to the tube. This is then part filled with 3% solution of common salt, sodium chloride. und x lid fined, The lid can be machined from u block of polyethylene with a suitable diameter hole drilled through. ‘The plate is = Gaile Pretion REX 1 Apa TWI ecw © 2H THI LW! 24 WU Sse sas CEM Seisns Sine Coating Copsriconnected 10 the negative pole of a battery, an anode is connected to the positive pole and inserted through the hole in the lid into the salt solution, When the circuit is switched on the plate is the cathode and Hydrogen (and Chlorine) will be evolved from the steel, und also at the interface of teel/coating. This enables Hydrogen to penetrate under the coating. simulating areas of coating dumage. The circuit is stopped aller 28 day’ stripped down, dried off, and using a craft knife, two cuis ‘are made at an inclusive angle of approximately 30° radiating from the centre of the hole, through the coating to the substrate. Where disbondment has occurred the coating will chip fof as the cuts are being made. The distance from the edge of the hole to the extent of the disbondment is measured and should not exceed the stated requirements, For example FBE maximum Smm after 28 days. Plastic ring Lid | Elastomeric os ® © Battery Coating Plate 6 mm diameter Salt hte solution re 28.4 Cathodic disbondment Fis Coangs> Gaal Pawan Ro PARTE WT wesc Copy eh © 24 TW Lid Oxs DG istoStr: polarisation In certain situations on site, coated pipes have to undergo cold bending, and jt is important that the coating can withstand the stresses imposed. When the pipe is bent the steel and coating is stressed. After bending the result of the stress is strain, In operation the pipe will be polarised negative (cathodically protected) hence the strain polarisation test to ensure that the coating will work under those conditions. A coated strip is bent by means of a mandrel, with the coating on the outside of the bend. A cup is placed in position on the minimum radius of the bend (the area most strained) and a test done as per Cathodie Dishondment Test as above. except that no holes are drilled. It is run for twenty-eight days. The area. after (wenty-eight days. should not show any cracks or pinholes and should undergo a pinhole detection test Sie Ching = Cathe Ponston Rov ATO : Conssigh © 2m TWIT xo 7 nseHEALTH AND SAFETY Control of substance hazardous to health regulations 1988 generally abbreviated to COSHH regulations. ‘These regulations provide a framework to help to protect personnel at the workplace against health risks from substances. which are hazardous. For the purpose of COSHH regulations. substances hazardous to health include, a) Substances or preparations listed as being toxic, very toxic, harmful. corrosive or irvitamt in part LA of Chemicals (Hazard Information for Packaging) Supply b) Substances with MEL or OES as detailed in schedule one of COSHH or if Health and Safety Commission has approved an OEL. ©) Harmful micro-organisms. dd) Dustof any kind in substantial concentrations, €) Any other substance creating comparable hazards to peoples health such as pesticides tand other chemicals used on farms. Hazard warning symbols = Black symbol of skull and crossbones on an orange square @ ‘withthe words Toxic or Very Toxic printed below ~~ Toxic or Very Toxie Black diagonal cross on an orange square with the words Harmful or Irritant printed below. Harmful or Uitant ea Black symbol showing a tilted test-tube dripping onto a ax hand wa chink om acento ae ube ppg om ase fg. Orange hahgiond withthe wont come CHER printed eos Comunive Ticalth & Sally Rov | Apatog _ aa 1 END snesIt iy the employer's duty 10 assess the risk (0 employees on hissher premises and any other premises. which might be visited during the execution of duties. Training establishments are responsible for trainees. 11 is an employers duty to prevent. where ever possible, exposure to hazardous substances. but if itis not reasonably practical 10 totally prevent exposure then protective clothing. masks etc, should be issued 10 minimise exposure. COSHH regulations require that regular monitoring should be carried out and records kept particularly’ in situations where there could be serious risk 10 health if control measures were to fuil or deteriorate, Guidance note EH 40 (occupational exposure limits). is a document published by the HS which lists all substances known to be hazardous to mankind. I gives details in table form of formulue and chemical names of hazardous substances. common names, chemic ‘The Hydrocarbon solvents used in modern paint formulations are hazardous to health and are listed in EH 40. Xylene is one such solvent and has an Occupational Exposure Limit (EL) of 100 ppm (pats, per million). This means that air containing more than J00 ppm would be considered 10 be a hazard to the health of personnel exposed 10 it, There are two categories of OEL 1 Maximum Exposure Limit (MEL). ‘The maximum concentration of an airborne substance, averaged over a reference period. 10, which employees may be exposed by inhalation under any circumstances and is specified. together with the appropriate reference period, in Schedule one of COSHH.” 2 Occupations Exposure Standard (OES). “The concentration of an airborne substance. averaged over a reference period, at which. according to current knowledge, there is no evidence that it is likely 1 be injurious to employees if they are exposed to inhalation. day after day. to that concentration, and which is specified in a list approved by HSE When referring to reference periods above. long term exposure Jimils are averaged over an eight hour reference period and short term exposures over ten minute relerence periods. If the EH 40 specifies that a substance has an MEL then the quoted figure must not be exceeded at any time. but kept as low as 3s reasonably practical Site Gna Copyright Tisai & Saag Rev PAO Toma oneTwI La my BA SessWith an OES it is permissible 10 exceed the stated figure provided that the average over a reference period is below the stated figure. Exposures above should result in measures being taken to reduce the value to below the stated OES. EL examples of some solvents Solvent ‘Name ‘OEL in ppm ‘Alcohols Methanol 200 Ethanol 1000 Ethers Ethyl Ether 400 Isopropyl Ether 250 Exes Methyl Acetate 200 Ethyl Acetate 400 Ketones ‘Acetone 750 Methyl Ethyl Ketone 200 ‘Aromatics Xylene 100 Toluene 50 Aliphaties White Spint 100 Hexane 500, Chlorinated Hydrocarbons | 1.1.1 Trichloroethane 350 ab Trichloroethylene 300_ac a= MEL, b= Maximum short term exposure 450, = Maximum short term exposure 150. Driiger tube and Driiger bellows = Figure 29.1 Driiger tube One way of monitoring the toxicity of the air is by driiger tube and driiger bellows, The driger the is a glass tuhe ahout 110 mm Jong with moulded nipples at each end. One half of the tuhe is filled with chemical crystals (senvitive 10 the material testing for) and are held in position by fine wire mesh plugs. A cellophane Sleeve. incorporating a scale in ppm js wrapped around the tube, There is also an arrow on the sleeve indicating the way in which, the tuhe is to he inserted into the bellows. Fie Cauinps Hoan & Saag Reap yyp ween Copyright € 2000 DWT Lid a ry wna cnwnThe bellows are hand operated and are a one way air system, as the bellows are depressed. air is expelled from a slot at the back. when released, air is drawn in through a small rubber grommet like aperture at the front, The bellows incorporate two compression springs and Stops, and two retaining chains. so that every depression and release exchanges an air volume of 100 ce exactly. | Break-off husk _»/~ Is} cdooass Limiting chain Pump head Sieve Front plate)» “+ Discharge valve Figure 29.2 Cross-section of driger bellows Using the tubes and bellows Using a special fitting situated on the bellows. the nipples are snapped off both ends of the tube, which is then inserted into the aperture on the bellows in the direction indicated by the arrow. The erystals should be adjacent to the bellows. The bellows are then depressed and released uecording 10 the number expressed as n =. ais written circumierentally around the centre of the tube. Each depression and release slowly draws 100 ce of air through the open end of the tube. through the crystals and into the bellows. As the air containing the hazardous imaterial passes into the crystals. x chemical reaction takes phice. resulting in a colour change im the crystals. The extent of the colour change along the scale is recorded in ppm. NB. Many variation of crystal combinations exist for monitoring a variety of different toxicants, all have a different requirement for number of depressions and different colour changes. The tube for monitoring the concentrations of Xylene needs five depressions and the colour change is from white to reddish brown ‘Site Coatings Health & Sateiy Rev | April od WORDEN Consign © 2004 TW La Da BAY SiseisecSome materials in common use in the coatings industry do not evaporate into gas or fumes, they remain instead as tiny particles of solids suspended in the atmosphere. Materials of this nature cannot therefore be detected by Driiger Tube. They are quantitied by the units milligrams per cubic metre rather than ppm. ‘Three materials. which fall into this category, are Asphalt, Coal Tar and Isocyanates. Asphalt is considered 10 be fairly safe with an OBL of 5 m/gm per m*, Isocyanates are very toxic with an MEL of 0.02 m gm/m’. ‘Sie Coatings Health & Saleyy Rev) Apalag TWIT cones MTWI Ld ms Clap Sisson Copyright ©DUTIES OF AN INSPECTOR BS 4778 Pil (EN 28402, ISO 8402) Quality Vocabulary ~ International Terms, defines inspection as “Activities such as measuring, examining, testing, gauging, one or more characteristics of a product or service and comparing these with specified requirements, to determine conformity”. Documents available to an inspector could include, but not be fimited to. a) Job Specification b) Data Sheets for the paints/coatings. ©) Procedures. 4) Quality Plans. e) Plant Draw f) Site Plans, 2) BS'seg. 7079 PLA. h) Waste Management, Duty of Care Document. i) Relevant Local Regulations. The job specification is the main tool of the inspector and should be observed at all times. It is not the inspector's responsibility to rewrite the specification and permission for any deviation should be given in writing and retained by the inspector ‘An inspector should keep adequate and accurate records of all stages of the work being carried out. materials used, ambient conditions etc. so that in the event of illness or any other situation requiring a replacement. the new inspector will be in full possession of all relevant information, Pain/Coatings Inspectors Daily Report Sheets need to he completed. and passed on 40 the engineer. containing all information requested, and a copy retained by the inypector. The format of Daily Report Sheets varies but in general will require the following information. 1 Details about the contract and contractor. including plant on site and number of personnel 2 Ambient conditions applicable during the work period. 10 he monitored as near as possible to the task location, 3. For surfuce preparation activities the information required will include. method ased original substrate condition, abrasive iype. degree of cleunliness achieved. profile achieved. identity of plant and times of starting and completion. Sie Copyright
Revhion Oasis Rev TARE nc Copyright © 2008 TTL Ma ty Sines40 4y a2 B 44 45 46 47 48 49 50 Sie Coatings” Revision Quvstions Rev T Apo What would be the typical temperature and concer pickling process? Describe the ‘Duplex Process” What would be a maximum pressure for high pressure water jetting? What are the disadvantages of wet blasting over dry blasting? Describe the phosphating process What would be considered 10 be advantages of wet blasting over dry blasting? Why is the phoyphating or chromating of steel done? What would be an acceptable remedy for burnished areas? Would burnishing be expected on areas of St2 preparation? How many photographs of blast cleaning standards are shown in BS 7079 Pt A? Do the plates shown in Bs 7079 Pt A relate to grit blasting or shot blasting? ‘ion of Sulphuric Acid in the Capgnig © 2004 FT Lal Ma TW] vioas en , CEM WeivenesRH and DP exercise WB 10 9 “Se Goaings = Rovio Qastons Rev Apa hve oon Twi tid us Steel Tem i 1 6 65 12 16 HW 7 13 14 Twi cmtAppendix A Tables Table 1 - Preferred methods for the removal of anti-corrosion coatings Method of removal (see Note 1) (method “a” is preferred to method *b* Type of coating | Prolonged | Power wire Heating blast cleaning | brushing Resin powder a (see Note2) b a | NIA Multicomponent | x74 (see Note 3) | N/A (see Note 3) a NA iquid | Coal tar enamel NIA a b b Polyethylene (see Note 3) a | NIA NA Wrapping tape bisce Note 3) | a NA) NIA Notes 1. Any method that risks damaging the pipe is unacceptable. 2. The metal temperature shall not 3 particles or fumes exceed 300°C, ‘The use of heat should be limited since some of these materials may release toxic Twl a‘Table 2 - Surface preparation qual cld applied coating group Minimum preparation standard ket | Description SIS 05 59.00 BS 42 1 | Cold applied self adhesive tapes ‘Oxerwrap only Overwrap only 2 | Cold applied laminate tapes St /Sa 14 NA 4 Heavy: duty cold applied laminate NA tapes 4 | Grease based tapes S| Fillers 6 | Masties Si2/Sa 1 7 | Heat shrink materials Si 2/Sa 1 NA 8 Resin powders Save 2" quality Spray applied multi-component » | > Quality 9 | Tutte sud | 2" quality Brushitrowel applied multi- > | 0 | component igs Sah \ guality 11 Mul-component uid reps 2” quality [17 materials | | | Moisture tolerant multi-component | 7 2 | a 9 2" quality |! | guide | sar 2™ quality © This surface will Mash rust due to the continued presence of surtuce moisture # Better than S12 with loose millscale, rust and foreign matter removed and dust finally: removed with a clean brush, Tis Conn Apu ART apa Capgrp& 2008 11 TW oseTable 3 — Recommended field apy fittings coatings for the protection of Description of Preferred coating T option 7" option component Product group Product group Product group | Long pipe lengths. | Spray or brush/trowel | Light duty orheayy | #Grease based tapes | | | | upplied mul duty cold applied | i | Jaminate tapes Valves, flanges. cast | Spray or brush/trowel | #°Grease based tapes | Light and heavy duty iron couplings and | applied molti- cold applied laminate Similar components | component liquids | tapes Service pipe and #Grease based tapes | Spray or brush/trowel | Light and heavy duty fittings (up to 50mm) applied mutti- | cold applied laminate including non-ferrous component liquids | lapes. metals ' | ‘complicated shupes must be evenly contoured by the use of the mastic fillers oF puities prior to wrapping. # Grease based lapes to be over wrapped with group | cold applied self adhesive overwrap tape. Site Coatings Appendin A Rev P Apri TW ena sioion 1G OM TWH La a Be reeete‘Table 4 - Preferred materials for protection of weld joints r Choice of weld joint coating Possible components of difleving types of S ‘coating on each side of a weld Preferred Option Product group Product group Resin powder | Resin powder | #Spray or Resin powder | DNb/vowel applied ‘multiscomponent | Figuid Multi-component | Resin powder | tiga | p Spray or brush/trowel L applic mut | Multicomponent” | component liquid liquid Light or heavy duty 5 xin pow cold applied laminate Coal tarenamel__|__Resin powder ‘Spray or tape Coal tarenamel | Multiscomponem | brushitrowel applied liguid ‘ulti component Coal tar enamel Coal tar enamel Hquid | Polyethylene Resin powder [_—onetiytene _|_ Kenn power _| Grease based tape Polyethylene Multicomponent. | Light orheavy duty | overwrapped with | _ Jiguid cold applied laminate | Group | cold applied Polyethylene Coal tar enamel pe self adhesive ——— ee overwrap tape Polyethylene Polyethylene | | Cold laminate tape | _ Resin powder | | Cold laminate tape | Muhiscomponent | Light or heavy duty liquid cold applied laminate jaminate tape Polyethylene tape component liquid coal tar enamel and multi Shall pped with | tight or heavy cold applied laminate tape. LAA second option is the use of light or heavy duty cold applied laminate tape. Sie Coatings” Append AR TAT PWT mc cin Copgrigh' 2008 TWH Lad a a CM Wns‘Table 5 — Systems for overwrapping existing pipe coatings | Recommended overwrap systems, Existing factory/field applied Prefenred Option coating Product group Product group Resin powder Spray or brush/trowel applied | Light or heuxy duty cold multi-component liquids applied laminate tapes Polyethylene W yl Light or heavy duty cold “Grease bared tapes ‘Coal tar enamel | applied laminate tapes | Spray or bruyh/rowel applied | Light or heavy duty cold Molti-component liquid multi-component liguids | _apptied laminate tapes °Grease based tapes shall be overwrapped with Group 1 cold applied sell adhesive overwrap tape at the discretion of the engineer Table 6 - Systems for 0: 1g exposed pipe | [ Recommended overwrap systems, | *Existing factoryitield | wpplied costing | Preferred Option | Product group Product group Resin powder Spray or brush/rowel applied Brushing mastic Multi-component liquid multi-component liquid ing mastic Polyethylene Light or heavy duty cold . Cold laminate tape applied laminate tape Coal tar enamel | Light or heavy duty cold | Ling mast |__applied laminate tape | Brushing mastic | Light or heavy duty cold applied laminate tapes Brushing mastic | Brushing mastic “For paint coatings refer to BG/PSIPA10 Site Coa Copy <= Append 8 Rov | April TW seis ©2001 TWH La is Car i‘Table 7 - Repair systems for dry surfaces Repair systems Existing factory/tield upplied coatings Preferred Option! Option 2 Product group Product group Product group Brush/trowel Light or heavy Resin powder applied multi- | duty cold applied NA component liquids | laminate tapes Light or heavy | Polyethylene | duty cold applied | Hest shrinkable | "Greaxe haved laminate tapes materials tapes Coal tar enamel Spray or brush/trowel "Grease hased s NIA Mulii-component liquids applied multi- tapes: component liguids Light or heavy | Cold laminate tapes duty cold applied | NIA | NIA |_laminate tapes Brush mastic Brush mastic | NIA NA » Grease based tapes shall be overwrapped with group | cold applied self adhesive overwrap tape at the discretion of the Engineer. # Mulli-component liquid repairs shall be overwrapped with a light or heavy cold applied Jaminate tape. ‘Shue Coatings - Appondiy A Rw | April ~ ont Copsrighv © 2000 TI 1a be BY os‘Table 8 - Repair systems for damp surfaces Repair systems Existing factory/field applied coatings L Preferred Option i Product group Product group Moisture tolerant mul x . Resin powder Peponesn je Grease based tapes Polyethylene Grease baxed tapes Moisture tolerant multi- component liquid Grease baved tapes Coal tar enamel Cold laminate tapes | __*Grease based tapes - Moisture tolerant multi- component liquid ‘Grease based tapes Multi-component liquids Brush mastic L___8Greave based tapes - Grease based tapes shall be overwrapped with group | cold applied self adhesive overwrap tape at the discretion of the Engineer. Site Co Copy i Appendis A Rev Ap TWI vein 1 © 2000 TWH Lad 7 CEA seisContact us for information on our wide range of courses at: Training & Examination Services TWILid Granta Park Great Abington Cambridge CBI 6AL. UK Tel: +44 (0)1223 899000 Fax: +44 (0)1223 891630 E-mail: wainexam@1wi.co.uk TWI Technology Centre (North East) Aurora Court Barton Road Riverside Park Middlesbrough TS2 IRY. 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