LARSEN & TOUBRO STANDARD OPERATING PROCEDURE

PROCEDURE FOR COATING & WRAPPING

PROCEDURE NO: LT-STD-SOP-CP-MEC-094

Rev. No.: 00

Date: 13.03.2020

Prepared by: HCI QAQC

Reviewed by: PSI

Approved by: DKS

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No part of this publication may be reproduced, distributed, or transmitted in any form or by any means, including photocopying, recording, or other electronic or mechanical methods, without prior written permission from
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 LARSEN & TOUBRO STANDARD OPERATING PROCEDURE

REVISION RECORD

REV.NO CLAUSE NO. DETAILS OF REVISION

00 - -

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CONTENTS

1. SCOPE....................................................................................................................................4

2. PURPOSE..............................................................................................................................4

3. ABBREVIATIONS..................................................................................................................4

4. REFERENCES.......................................................................................................................5

5. RESPONSIBILITY.................................................................................................................5

6. RESOURCES.........................................................................................................................7

6.1. EQUIPMENT & Accessories............................................................................................................... 7

6.2. Personnel Qualification................................................................................................................... 7

7. MATERIALS..........................................................................................................................8

8. APPLICATIONS TO EXTERIOR SURFACES:.....................................................................8

8.1. Types & methods of applications................................................................................................... 8

8.2. Surface Preparation:........................................................................................................................ 9

8.3. Primer Application:........................................................................................................................ 10

8.4. Hot Melt Coating application (As per IS 10221):........................................................................10

8.5. Cold Tape Application (As per EN 12068)...................................................................................10

9. INSPECTION REQUIREMENTS:........................................................................................11

10. SAFETY REQUIREMENTS:................................................................................................12

11. TEST REPORT FORMAT...................................................................................................13

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1. SCOPE
This procedure details the coating & wrapping of the external surfaces of
underground piping / equipment in line with contractual requirements /
relevant technical specifications / applicable National or International standard.

2. PURPOSE
Selection of Coatings depends primarily on the environment to which the piping
surface would be exposed. Most of the Underground terrains consist of dissolved
salts, moisture resulting in severe corrosive atmosphere compared to above
ground conditions. The relatively higher corrosive environment demands for
better corrosion protection mechanisms. Coating materials are diversified, it
includes coal tar enamels and epoxy, polyolefins (extruded, cross-linked, and
fused), PU, petrolatum wax and tape, and nylon polyamides. Each requires
different methods of application and inspection. This procedure details the
common processes.

3. ABBREVIATIONS
FBE Fusion Bond Epoxy Coating
UG Under Ground
CP Cathodic Protection
UV Ultra Violet
DFT Dry Film Thickness
PPE Personnel Protective Equipment
AWWA American Water Works Association
ASTM American Society for Testing & Materials
3LPE 3 Layer Polyethylene
3LPP 3 Layer Polypropylene
PU Polyurethane
SOP Standard Operating Procedure
LTI Loss Time Injury
NDT Non-Destructive Testing
AG Above Ground
WFT Wet Film Thickness
EXT External
INT Internal

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4. REFERENCES
a) Relevant standards (AWWA C203, C210, C213, C214, C215, C216, C217, C218,
C222, C224, C225, IS 10221, IS 15337, DIN 30672, EN 12068 & other applicable
Standards
b) Contract Technical specification.
c) Material specification.
d) Inspection & test plans.
e) Approved Drawings

Note: Refer as per latest revisions / as mentioned in the contractual specification.

5. RESPONSIBILITY
ROLES RESPONSIBILITIES
 Facilitate the activity by liaising with client, sub-contractor,
workmen & Quality Control Engineer.
 Ensure the proper shop arrangements which includes earmarked area
for the activity, availability of adequate material handling facilities,
availability of stools / stands, wrapping machines, storage of
materials & finished.
 Facilitate the above for field applications.
Coating
Engineer /  Possess thorough understanding of fabrication drawings, knowledge
Applicator
of materials, SOP & testing.
 Ensure the usage of calibrated equipment & relevant instruments.
 Responsible for the safe execution of testing by ensuring the fullest
compliance to the safety standards {PPE’s, understanding the
relevant hazards, possess thorough knowledge on MSDS}, obtain
relevant safe work permits as demanded.
 Prepare & maintain the relevant testing records.
QC Engineer  Possess thorough understanding of fabrication drawings, knowledge
of testing procedures with acceptance norms.
 Witness the activities in line with SOP and record the observations.
 Possess adequate knowledge, experience & demanded qualifications

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(if any for holiday & other electric tests) for witnessing & accepting
the tests.
 Execution of works as per specification / Method statement /
agreement.
Sub
 Daily reporting to site engineer regarding daily progress.
Contractor
 Mobilization and maintaining of adequate inventory.
 Maintaining good housekeeping of work location.
Project  Overall responsible for the project operations and activities in a
manager manner to ensure attaining the project objectives.
 Carry out HSE inspection of Work Area, Work Method, Men, Machine
& Materials, P&M and other tools and tackles.
 Co-ordinate in preparation of Group Risk Assessment.
 Conduct investigation of all near miss cases / LTI / Fatal / dangerous
occurrences & recommend appropriate corrective measures.
 Convene HSE Committee meeting & minute the proceedings for
circulation & follow-up action.
 Advice & co-ordinate for implementation of Work Permit Systems.

Safety  Plan procurement of PPE & safety devices and inspect before use as
Engineer per laid down norms.
 Report to Cluster HSE head on all matters pertaining to status of HSE
and promotional program’s at site level.
 Facilitate screening of workers and conduct HSE induction.
 Monitor administration of First Aid.
 Conduct Fire Drill, Procure, inspect and arrange to maintain Fire
Extinguishers.
Organize campaigns, competitions & other special emphasis program has
to promote HSE in the workplace

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6. RESOURCES
6.1. EQUIPMENT & Accessories
a) Wrapping machine

b) Heating torches with gas source

c) Pneumatic compressor set-up for blasting

d) Mechanical cleaning tools

e) Material handing equipment – Cranes with adequate capacities, D-

shackle, lifting belts / ropes and other relevant accessories
f) Pipe supports (Stools & saddles)

g) Tarpaulins and covers for preserving finished pipes

h) Peel Gauge tester

i) Holiday detector

j) Dry Film Thickness Gauge

k) Pyrometer / Digital Thermometer

l) Relevant PPE’s

Other project specific / suit to site arrangement may necessitate additional

equipment / accessories.

6.2. Personnel Qualification

The entire operation of coating & wrapping shall be performed by personnel
skilled in the application of protective coating & possess sufficient knowledge on
the materials. Personnel conducting the test and recording test results shall be

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suitably qualified in terms of experience and training to properly conduct the

test & record results.

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7. MATERIALS
 Coating materials includes Coating Primer, Coating Enamel & wrapping
materials.
 All coating material shall be stored, handled, and transported in such a
manner as to prevent damage to individual carton containers. Cartons,
tapes rolls or individual repair rolls removed from the storage pallets not
be dropped, rolled, or thrown in any manner as to damage the coating
material. Cartons or tape rolls shall not be handled with hooks, ropes,
cables, or any other mechanical devices to damage the coating materials.
 The coating materials shall be stored and/or transported in a dry,
ventilated location. Storage temperature shall be a minimum of 15.5˚ C
and not to exceed 50˚ C. The primer shall be stored in a dry ventilated
location and the lid will be kept tightly shut and shall be kept away from
flames or any other heat source.
 Individual cartons or rolls of coating material shall not contact bare
ground or bare warehouse floor. Tools or equipment shall not be stacked
on top of the rolls.
 Ensure the availability of suitable / adequate fire extinguishers in case
any mishaps.
 Prior to use, samples of all materials proposed to be used under the
applicable specifications shall be verified & all the relevant test
certificates shall be duly reviewed & cleared for further process.

8. Applications to exterior surfaces:

8.1. Types & methods of applications
 Based on the coating thickness, application is broadly classified as Single
coat / Double wrap & Double Coat / Double wrap.
 For pipelines, wrapping methods includes: Mill/ yard wrapping, Site
wrapping & line wrapping.
 Mill wrapping is performed at pipe manufacturer premises, however for
larger diameter pipes it is required to be performed in yard.

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 Special surfacing of sides, trenches shall be needed for performing the

activity at sites.
Following table details the standards describes various methods of coating w.r.t the
diversified basic type of coating materials & application. Diversified coating materials
includes petrolatum tapes, bituminous tape, polymeric tapes & other shrinkable
materials:
Specification & Description Thickness Adhesio Adsorption Holiday
n Test
AWWA C-203-Coal Tar coating 2.38mm Pull Test N/A Y
AWWA C-210- Liquid Epoxy coating 0.41mm Y Y Y
AWWA C-213- FBE Coating 0.3mm X- Cut N/A Y
AWWA C-214- Tape Coating 1.3-2mm Y Y Y
AWWA C-215- Polyolefin coating 1.2-1.8mm N/A Y Y
AWWA C-216- Heat shrink tape 1-1.5mm Y Y Y
AWWA C-217- Petrolatum coating 40mils N/A Y N/A
AWWA C-218- Liquid AG coating 0.09-0.36mm Y N/A N/A
AWWA C-222-PU Coating 0.51-0.63mm Y Y Y
AWWA C-224-Polyamide coating 0.6-1mm Y Y Y
AWWA C-225-Fused polyolefin 1.3-1.9mm Y Y Y
IS-10221-Hot melt coating 3-4mm (Ext) Y N/A Y
2.4mm (Int)
DIN 30670 / EN12068- Cold Tape 2.5mm to Y N/A Y
application 3.5mm

8.2. Surface Preparation:

 The steel surface shall be free of mud, oil, grease, or any other foreign
material that will prevent the cold applied tape coating system from
bonding to the pipe surface.
 Visible oil and grease shall be removed with suitable solvent like Xylene.
The surface shall be dry prior to the application of the wrap tapes.
Kerosene shall not be used for cleaning the piping spools.
 All bare metal surfaces shall be blasted according to the specified SSPC –
SP standards. Surface shall be either prepared thru solvent cleaning /
blasting with suitable abrasives or thru power tool cleaning or with power
wire brush to create appropriate surface finish for application., (use
appropriate sand disc for the type of material to be coated).

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 All burrs and weld slag shall be removed from the pipe surface / bends.
8.3. Primer Application:
 The primer will be brush applied on the roughened steel surface. Prior to
application of the primer, vigorously stir the primer in the original
container. Care to be taken that there will be no visible steel surface.
Allow the primer to dry. The drying time will be 5-10 minutes. The
thickness of the primer will be 50-100 micron and can be measured using
WFT gauge. However specified values of DFT/WFT shall be maintained
inline with the reference coating specification
 Primer coverage shall be such as to ensure maximum bond between the
steel surface & the enamel coating.
 Atmospheric conditions, type & coverage of primer determine the drying
time. If the primer coat is found to be unsatisfactory due to rain and
excessive humidity, the pipe shall be re-primed.
8.4. Hot Melt Coating application (As per IS 10221):
 All enamel coating shall be broken into lumps suitable for the heating
equipment employed and shall be free of any foreign material.
 Application temperature of enamel is normally 230˚C to 250˚C, through a
standard flood box.
 Simultaneously with the flood, the glass fibre inner wrap and outer wrap
should be applied under tension, the wrapping having a minimum overlap
of 12 mm. There should be approximately 0.8 mm of enamel between the
pipe surface and the inner wrap.
 Enamel should not be applied to the primed pipe when the pipe metal
temperature is below 7˚C.
 Glass fibre tissue for inner wrapping. The glass fibre tissue shall be with a
minimum thickness of 0.3 mm.
 Final coat of coal tar enamel shall be applied with 2 mm thickness.
 Outer wrap coal tar impregnated glass fibre. The outer wrapping
thickness shall be 0.75 mm minimum.
8.5. Cold Tape Application (As per EN 12068 / DIN 30670 / DIN 30672)

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 The cold applied tape (inner anti corrosive layer) shall be applied with
tension by using the wrapping machine while maintaining even and
constant tension across the width of the tape with a 50% overlap.
 The cold applied tape coating will be started 150 mm away from the edge
and shall terminate also 150 mm from the end.
 Coating cut back of 150 mm is to facilitate field welding. At the finish of
the roll, the next roll application will start with a minimum overlap of
150 mm to the previous completed coating.
 For Tee sections, wrap the tape in perpendicular (on stem- in U shape) as
well as diagonally (cross way) across the T joint with min 50% overlap in
such way that no bare metal is visible prior to the straight pipe wrapping
coating. Please maintain more tension in such cases.
 The Outer tape shall be applied with tension by using wrapping machine
as explained above for inner tape.
9. Inspection requirements:
 Visual inspection shall ensure that the coating is continuous, the overlap
is correctly maintained, that there is no wrinkle in the tape, confirms the
required total DFT, adequacy of overlaps, termination from ends etc.
 The coating shall be checked for any holidays of mentioned “KV” values
through holiday detectors. All holidays and all damages coating shall be
clearly marked and repaired immediately. The repair shall be carried out
by filling the damaged area with patch of inner tape and then wrapping
the outer tape around the circumference to extend 50 mm beyond the
damage.
 During the procedure qualification, peel test shall be carried out using
hand peel test gauge. The peel test shall be conducted on a strip 25 X
100mm long. The minimum peel value to be recorded shall be 3.8 Kg at
temperature of 23˚C. The frequency of peel test will be done at every 50
SQM of coating. It shall be done after 24 hours of coating.
 In case of severe coating repairs where steel is exposed, apply the Primer
on the steel after surface preparation and then to follow the repair
procedure.

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10. Safety Requirements:

 Avoid contact with skin / eyes and avoid swallowing.
 Ensure adequate ventilation and avoid inhalation of vapor.
 Wear suitable protective clothing, gloves and eye protection.
 In case of skin contact, rinse with plenty of clean water, then cleanse
with soap and water. Do not use solvent to clean the contacted area.
 In case of eye contact, wash with plenty of clean water and seek medical
advice.
 If swallowed, seek medical attention immediately. Do not induce
vomiting.
 Should aware of safety data sheets from manufacturer, which includes
hazard(s) identification, firefighting measures, accidental release
measures, exposure controls / personal protection, disposal information,
handling and storage, regulatory information etc.
 Emergency contact information / telephone numbers established /
provided.

11. TEST REPORT FORMAT (MODEL)

S.No Equipment details Coating Visual Holiday Remarks

Thickness Test

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Observations

Certified by
Coating Engineer QC Engineer Client

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