PROCEDURE FOR FIELD JOINT

COATING
MAS
CONSTRUCTIONS Doc No.: MAS-BGRL-TE-JP-A4- 1 3,
Rev - 00

LAYING OF 3 LPE COATED STEEL PIPELINE IN BALLARI-GADAG

tlPROJECT
crmrvr
I CLIENT wr BHARAT
I M/s eHanar GAS RESOT]RCES
RESouRCES LIMITED

coNsr-nrnxr I M/s
I CONSULTANT luv* rnacrEBEL ENGINEERINc
TRACTEBEL ENGINEERING

conrnacroR I M/s
I CONTRACTOR
ll
ws MAS
nms coNSTRUCTIoNS
CONSTRUCTIONS

| JOB p*o"EDURE I ruras-ecRt.-TE-Jp-

,o* PROCEDURE A4-13, Rev - 00
MAS-BGRL-TE-JP-A4-13,
l--l

PROCEDURE FORFIELI} JOINT COATING

1 MAS CONSTRUCTIONS r,
BGRL/TRACTEBEL
PRE,PARED CHECKED
CHECKED I APPROVED
APPROVEI)

NAME: r,pffi*knna
lNai*m, 1GGDA*a^/@/il RA*.wkaw
SIGNATURE: \1>vd tg6,rUf,, ,'^$S s+=
DATE: ,olrXr] % lo>lzrro
 TROCEI}URS FOR FIELD JOINT 14
COATING Ep
{it.E#
r.-*r6u1q/&*I:
gGssGy*Gs
MAS
CONSTRUCTIONS Doc No.: MAS-BGRL-TE-JP-A4- 1 3,
Rev - 00
!a3toir:i,"f

INDEX

Topic No. Items Page No.

1.0 Purpose -J

a
2.0 Reference J

3.0 Coating Material -1

4.0 Material Requirements 4

5.0 Method For Joint Coating 4

6.0 Surface Preparation For Coating Application 4

7.4 Application of Heat Shrink Sleeves 5

8.0 Coating Repairs 5

9.0 Inspection & Holiday Testing 6

10.0 Acceptance Criteria 7

11.0 Documentation

12.0 Note 7

iff!-.-,*u**t
,'r{'i#,li;l*:i;,r}
*
it- t"-... ..*l't'"ii
""D",ii
nro. MAS-BGRL-TE-Jp-A4- 1 3,Rev -00 Page 2 of8
 PROCEDURE FOR T'IELD JOINT 6,fu_
MAS
COATING @
CONSTRI}CTIONS Doc No. : MAS-BGRL-TE-JP-A4- I 3,
Rev - 00

1.0 PIJRPOSE:

This procodure covers the method for joint coating of field weld joints, coating repair of Field
weld joints and pre-coated pipe sections.

2.0 REFERENCE:

r BGRL/TRACTEBEL specification-
r L
ASTM D-149: Standard Test Methods of Dielectric Breakdown voltage and Dielectric strength of
-; solid electrical insulating materials at commercial frequencies.

1 . ASTM D-257: Standard Test Methods for D-C Resistance or conductance of insulating materials.

o DIN EN12068 Class C: Cathodic Protection-External Organic Coatings for the Corrosion
;-
Protection of Buried Steel Pipelines.
r Manufactures Test certificates/result for each batch ofjoint lrepair coating material.
r Date of manufacture & expuy for each batch ofjoint lrcpar coating material-
o Specific application inskuctions forpipelinejoint / repair coating.
o Specific storage & handling instruction for coating materials.

3.0 cOATHG,MATERTAIS:
r Joint coating material shall be Heat Shrink Wrap around sleeves "HTLP 80'and coating repair L
shall be "PERP" of NOs RAYCIffiM or equivalent.
c Raychem heat shrink sleeve HTLP-8O suitable for the following pipe diameters:

o Raychem Epoxy Pump - S1301M Part A I S1301M Part B

. Raychem applicator pad with mixing cup and stick (1 per joint)
. Raychem repair patch (PERP)
c Raychem filler adhesive (S1137 )
o These materials shall be stored as long as possible in the manufacture's original packaging and
away from direct sunlight and in accordance with the instructions ofthe manufacturer.
r Material shall not be older than the period of validity at the time of application.
ufactures batch test reports/certificates indicating all the properties listed in BGRLITRACTEBEL
ions shall be submitted to BGRLITRACTEBEL for each batch of materials supplied at site.

No. MAE-BGRL-TE-JP-A4- 1 3,Rev -00 Page 3 ofB

 - \

PROCEDURS T'OR FIELD JOINT

COATING
MAS
CONSTRUCTIONS Doc No. : MAS-BGFI-TE-JP-A4- 13
"
. Rev-00

4.O MATSRTAL RE OUIREId4NTS :

1 HTLP 80 2 PERP
-l Epoxy - Part A and Part B 4 Mixing sticks, cups etc.
5 Applicator pads 6 EPOXYhandpump
7 LPG Torch, Regglators, Hose pipes I LPG cylinder
9 Wet film thickness gauge. 10 Contact pyrometer
11 Silicon hand roller (curved) 12 Silicon hand roller (straighQ
Standard safety wears such as gloves, goggles,
13 t4 Portable peel tester.
helmets, apron, asbestos leg guards etc.
l5 Mobile blasting equipment. t6 Coating thickness gauge.
t7 Holiday detector. 18 Digital thennometer
t9 Hygrometer.

5.0 METIIOD FOR J-OINT COATING:

r Prior to use ofjoint coating materiqls, following documents need to be verified & referred.
a. Manufacfurer's test certificates / result of each batch of materials.
b. Date of manufacture and expiry.
o. Specifrc applioation instructions.
d. Specific storage & handling instructions.

SURFACEP-RDPAR TIONFORCOA,TINGAPPLICATION:
The ends of existing coating on both sides of weld joint shall be inspected, un-bounded coating, if
any, shall be removed and ends shall be chamfered at an angle of 15o from pipe line surface.
Before application of coating material, pipe surface shall be thoroughly cleaned of oil, gre:me or
any foreign rnaters by wiping with rags soaked with non-naphtha based suitable solvents such as
benzene and dried followed by compressed air blasting using mineral abrasive / coarse sand in
accordance with SSPC - SPl code.
The abrasive blast materials / coarse sand should be dry and free from any impurities, inclusions or
oil and shall be rernoved after blasting usiag btush or compressed air before application of coating.
Blast cleaning operation should not be carried out if relative humidity exceeds 80Yo.

The comprcssed air used for blasting operation should be dry & free &om oiletc... it should be
6q*ffir checked at the time of start of blast cleaning and thereafter, every 4 }ks. By checking separators &
trap installed on compressors.

Doc No. MAS-BGRL-TE-JP-A4-1 3,Rev -00 Page 4 of8

 PROCEDUR TOR FIELD JSINT
COATING
IHHr&.rc"rfrn.:E.
E.as FrGs#urcs*
MAS
CONSTRUCTIONS Doc No.: MAS-BGRL-TE-JP-A4-1 3,
Rev - 00

. After blast cleaning, the cleaned pipe surface shall be inspected for defects such as silvets,
laminations, leafrnf,-scores and indentation slugs etc... & repaired by grinding as directed
by
BGRL/TRACTEBEL fi eld Engineer.

o The standard finish for cleaned pipe surface should conform to SA 2 % Swedish Standard SIS
055900. The pipe after blasting should have an anchor pattem of 50 to 70 p. This
shall be
measured using iy Electrometerl press 'o' Film / comparator. AII required rnaterial / equipments
shall be made available at site for carry out inspection'

7.0 APPLICATION OF HEAT SHRINK SLEEYES:

amount
Using multiple of the full stroke of the calibrated pumps supplied by Raychem, l{equate
of pirt-e *itl b" poured into the part-A in the plastic cup and mked. Mixing will be for about 30
seconds thoroughly until a homogenous mass is obtained'

The surface to be pre-heated to 70o C + 10" C with LPG burners prior to application of
primer. The
temperature should be checked using digital temperature indicator.

The heat shrink sleeve shall be wrapped around the joint after applying mixed primer,
overlapping
the existing pipe coating by 100 mm on each side.
patch off to
The wraparotrnd sle€ve should be wrapped around the prpe by positioning the closer
one side of the pipe in one side l0'Oclock or 2'O clock position having the edge of the under
laying layer facing upward with the upper layer overlapping minimum by 100 mm-
by
The sleeve shall be"tightly around the pipe joint by heating with LPG torch and forth followed
have
*11*, pr*r*ing-over t[e surface when heated above 125o C. The frnished coating should no
entrapped air"bubbles. The coating should not be disturbed until the adhesive has solidified
and
shall have a finished overlap afteishrinking to the pipe coating by 100mm on both sides of CTE
coated pipe and 5Qmm on both side of 3LPE coated pipes'
seam, extra
For maintaining the required coating thickness, removal of entrapped air from the weld
hot melt adhesive shail be appliel on both side of the weld seam as per requirement before
wrapping around the sleeve.

8.0 COATING REPAIRS:

For field repair of coating defects, which have been caused during transportatiol fro.* stockpile
to
ROW or during handlinf / stringing operations, the following repair procedure should be adopted'
Al1 coated pipes with damages to coating should be repaired by using PERP I Sleeve system
or
alternatively Ly using the saLe material of the pipe coating subject to procedure qualification of
same at site as per details given below.
Full girth repair on the coated pipes shall be carried out with heat shrinkable sleeves type HTLP-80
if th; defed area is more tha:r 100 CM? and patch repair shall be carried out with Repair patch if
the defective area is less than 100 CM2.

Doc No. MAS-BGRL-TE-JP-A4- 1 3,Rev -00 Page 5 of8

 PROCEDURE TOR FIELI} JOINT
COATING
MAS
Doc No. : MAS-BGRL-TE-JP-A4- 1 3,
CONSTRUCTIONS
Rev - 00

on the prepared
pre-heating a coat'of 100% solvent free liquid epoxy primer shall be applied
surface. ffffp-gO sleeves shall be applied uu p*t the joint coating procedure mBntioned above'
a
ar}a, pinholes
a For repair of defective areas less than 100 CM', the coating around the defective
shall be proper$
etc... shall be removed to give a shape similar to the truncated cone. The area
metted with gas torch and
brush cleaned. The truncatJ cone shall be filled with mastic compound,
adjoining pipe coating. A heat
smoothened so thalit is finished to the sarne thickness as that of the
pipe coating' The patch
.irriot patch shall be positioned extending at least 50mm on the adjoining
shall be heat shrunk with the help of LPG torch and roller'

9.0 INSPECTION & HOTIDAY TESTING:

a Visual inspection shali be carried out as follows'
a Mastic exkusioa on the either ends of the sleeves shall be examined'
sleeve I PERP shall be
a There shall be no sign ofpunchers or pinholes. External appearanoe ofthe
smooth, free of dimples, air entrapment or void formation and cold spot' All entrapped sha1l be
removed without undue heating.
a Weld bead profile shall be visible through the sleeve'
and2'2mm minimum
a The completed field joint coating'shall have an average thickness of 2'5mm
on pipe body. Permissible thickness at the weld seam shal1 be 2.0mm.
Dimples' Wrinkles etc"'
Full circle holiday detection for Puachers, Pinholes, External appearance,
daily with an accurate DC
shall be carried oot. UotiOuy detector used shall be checked & calibrated
have full contact wi& the
voltmeter. The tes! voltage shall be 15 KV. The detector electrode shall
entire circumference of the coating to be inspected-
r Inspection shall be conducted only after the joint has cooled below
Mecon/Gail'
a No field joints shall be lowered or backfilled until it has been approved by
out of every 50 finished joint coating or per day's production whichever is less should
be
a
subiected to peel test by peeling - offa strip of 25 mm X 200 mm'
chart is
generally be carried out early in the moming' Temperature vs' peel value
as
The peel test
follows:

Requirement for Mech- Resistance Test Method as Per

Class C (minimum DIN EN 12068

i;r;n,,,,.c1,l

Page 6 of 8
Doc No. MAS-BGRL-TE-JP-A4-1 3,Rev -00
 PROCEDURE B'OR FIELD JOINT
COATING
MAS
CONSTRUCTIONS Doc No. : MAS-BGRL-TE-JP-A4- I 3,
Rev - 00

@23',C N/mm 3.5

To Pipe Surface
@,T max N/mm 0.5
To Factory @23',C N/mm 3.5
Coating @T max N/mm 0.5

Temperature Feel value

{in cC} {in N/cm}
23 >35
30 30
35 25
4A 2A
45 15
50 10
55 7,5
60 5

r No failure either adhesion to steel, adhesion to backing or adhesion to pipe coating is perrnitted,
The test is accepted only when peeled strip comes out only from the adhesive layer of the joint
coating. The required peel strength shall be as per DIN - 306i2.
r In case joint fails in the peel test, following methodology is to be adopted.
t Stop flrrther joint coating until remedial measures are taken against the cause of failure.
I Two more coated joints (randomly setrected) of that day productions are subjected to peetr testing
and if any of these fails, the entire production of the day is to be rejected.
r Determine the cause of failure of coating.
r The coating operation should recommence only after remedial measures are taken and accepted by
MECON /GArL (I) LTD.

10, ACCEPTANCE CRITERIA:

Acceptance criteria shall be as per the above procedure & BGRL/TRACTEBEL specification

11. DOCUMENTATION:

Inspection Report : MAS-BGRL-TE-IR-A4-13, Rev - 00

Inspection TestPlan : MAS-BGRL-TE-ITP-A4-I3,Rev - 00

12.0 NOTE:

-o9r$N Any other procedure not covered here but as per contractual terms shall also form a part of work

w&,
S-."t*\
\U \\
case of any conflicts between this procedure and contract specification, then later shall govem.

Doc No. MAS-BGRL-TE-JP-A4- 1 3,Rev -00

 PROCEDURE FOR FTELD JOINT
COA:ilNG
MAS
CONSTRUCTIONS Doc No.: MAS-BGRL-TE-JP-A4-1 3,
Rev - 00

MAS CONSTRUCTIONS

APPROYED

oqloJ*zo oe f ozlwza

Doc No. MAS-BGRL-TE-JP-A4-1 3,Rev -00 Page B of I

 PROJECT : I"AYING OF3 LPE COATED STEELPIPELINE IN BALLARI-GAI)AG
CLIENT : M/s BEARAT GAS RESOURCES LIMITII}
h,IAO MAS
CONSULTANT : ITIls TRACTEBEL ENGINEERING

CONTRACTOR : M/s MAS CONSTRUCTIONS TII.&CTEB€L,ilrG

rc
CONSTRUCTIONS :
Doe No. MAS-BGRI-TE-ITP-A4-13 , Rev - fi)
INSPECTION TEST PLAI\I FOR FIELD JOINT COATING

Heating of Pipe Surface, Mixing andprimer application.

Applic*ionof sleeve and closrre patch

Holiday Check duriag lowerin In

Iloilday Check after repair

'HP':HOLDPOINT

: 100% EXAMINATION BY CONTRACTOR "RM': RANDOM

: REVIEW OF CONTRACTOR'S DOCUMENTAION ,AP,:APPROYAL

BGRI-ITRACTEBEL
 PROJECT : LAYINGOF3 LPE COATED STEEL PIPELINE INBIDAR

CLIENT : BILdRAT GAs RESOURCES LIMITED

M1s
eL,
;i,W.ffigHj,;
,

CONSULT-A.NT : L{/s TRACTEBEL ENGINEERJNG

MAS CONTTRACTOR : M/s NIAS CONSTRUCTTONS
CONSTRUCTIONS TSrAf"r€EI€L
Doc No. : MAS-EGRL-TE-IR-A+13 , Rcv _ 00 €s.re
INSPECTION REPORT : FIELD JOINT COATING

ON SEAM

No. ofJoints

CHECKED & \,ERIFIED BY