Cochin LPG Import Terminal

Project, Puthu Vypeen

JOB PROCEDURE FOR INSTALLATION AND LPGTK-PVP-PRJ-

TITLE: TESTING OF HBPE80 WRAPPING GEN- JP-01 R.00
DATE:31-12-2020

CONTENTS
1. PURPOSE………………………………………………………………………………………………………………………..2
2. SCOPE…………………………………………………………………………………………………………………………….2
3. REFERENCES…………………………………………………………………………………………………………………..2
4. GENERAL REQUIREMENTS……………………………………………………………………………………………..2
5. RESPONSIBILITIES…………………………………………………………………………………………………………..3
6. TRANSPORTATION, DELIVERY, STORAGE AND HANDLING…………………………………………..…3
7. PRODUCT……………………………………………………………………………………………………………………….4
7.1. COATING MATERIAL……………………………………………………………………………………………………....4
7.2. TEMPERATURE RANGES……………………………………………………………………………………………….…5
8. APPLICATION PROCEDURE………………………………………………………………………………………..……5
8.1. SURFACE PREPARATION………………………………………………………………………………..……5
8.2. APPLICATION CONDITION………………………………………………………………………………..…6
8.3. APPLICATION OF HBPE80 WRAPPING BAND……………………………………………………..…
7
8.4. APPLICATION OF HBPE80 COVERING TAPE…………………………………………………….……8
8.5. QUALITY CONTROL- HIGH VOLTAGE PORE TEST………………………………………….………9
9. POST COATING OPERATION……………………………………………………………………………………………9
9.1. HANDLING AND BURYING OF HBPE80 PROTECTED PIPE SECTONS…………………….…
9
9.2. HBPE80 COATING DAMAGES…………………………………………………………………………..…
10
10. SPECIAL APPLICATION…………………………………………………………………………………………………..11
10.1. COATING OF PIPELINE REPAIR SLEEVES…………………………………………………………..…
11
10.2. CLEAN-UP…………………………………………………………………………………………………………11

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 Cochin LPG Import Terminal
Project, Puthu Vypeen

JOB PROCEDURE FOR INSTALLATION AND LPGTK-PVP-PRJ-

TITLE: TESTING OF HBPE80 WRAPPING GEN- JP-01 R.00
DATE:31-12-2020

1. PURPOSE
To provide guideline to all concerned personnel regarding minimum requirements for
the application of HBPE80 on pipelines.

2. SCOPE
This procedure sets guidelines for CEL personnel in the application of HBPE80specialized
coating products into underground piping and pipelines for IOCL operations.

The scope also include the minimum requirements for surface preparation prior to application,
quality inspection, workmanship, material handling and storage.

The application of HBPE80 includes procedure regarding the application on straight, shaped
pipeline section as well as pipeline field joints in protecting the steel substrate thus
creating a tight and flexible seal to the underground piping surface.

Application of the HBPE80 product is possible with ambient temperature between minus
45 C to plus 50 C.

3. REFERENCES

IOCL Vendor List

Technical Data Sheet
Safety Data Sheet
NACE

4. GENERAL REQUIREMENTS

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 Cochin LPG Import Terminal
Project, Puthu Vypeen

JOB PROCEDURE FOR INSTALLATION AND LPGTK-PVP-PRJ-

TITLE: TESTING OF HBPE80 WRAPPING GEN- JP-01 R.00
DATE:31-12-2020

 No HBPE80 application shall be carried out until there is prior schedule and all authorities in
IOCL are informed.
 All relevant supervision, manpower, materials, tools and consumable items, equipment
necessary for the surface preparation and application of the corrosion protection HBPE80
products shall be available at site during the first day of activities.

5. RESPONSIBILITIES
5.1. The HBPE80 APPLICATOR FOREMAN shall be responsible for the following :
 Ensure PTW validation prior to site activities.
 Conduct relevant toolbox talk daily prior to the day’s activities.
 Applicator shall be approved by IOCL and certified by HBPE80.
 Ensure only qualified personnel are deployed for the application.

 Ensure required excavation is carried out prior to any work in the trench

 Supervision of all site activities and ensure compliance

to the manufacturer’s procedure.

 Check the climate condition.

 Check the material matches to the available material test certificates.
 Prepare Daily reports.

5.2. The Supervisor shall be responsible for the following :

 Plan and arrange resources for the HBPE80 application.
 Ensure that instrument used at site are calibrated.

5.3. The QC Inspector shall be responslble for the following :

 Check surface preparation prior to any HBPE80 application.
 Arrange Holiday Testing by the coating inspector.
 Give clearance for backfilling the trench.

6. TRANSPORTAT1ON, DELIVERY, STORAGE AND HANDLING

6.1. The HBPE80 Corrosion Preventive System does not require special transportation. During

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 Cochin LPG Import Terminal
Project, Puthu Vypeen

JOB PROCEDURE FOR INSTALLATION AND LPGTK-PVP-PRJ-

TITLE: TESTING OF HBPE80 WRAPPING GEN- JP-01 R.00
DATE:31-12-2020

adverse weather condition like extreme heat, transportation time should be kept to
minimum.

6.2. The HBPE80 material to be delivered to the Project site shall be labeled, indicating the
quantity, type, code and batch number.

6.3. Material receiving inspection shall be conducted as per Standard.

6.4. Storage of HBPE80 product shall be in a dry area, protected from weather related exposures.
Recommended storage temperature and humidity shall be between minus 200C and plus 40OC
at maximum 85% humidity.

6.4.1. Due to visco-elastic properties of the HBPE80 WRAPPINGBAND, storage of this material
for longer time at higher temperatures may cause a slight material “flow” over the edge of
it’s disposable backing film. This will not affect the material properties, but can cause
some inconvenience during the application. Consequently, the maximum storage
temperature must be kept below 400C (1040F).

6.5. The HBPE80 Corrosion Preventive System is extremely durable in the broad range of
applications in the field. It must be handled and stored with care prior to application. The
system’s unique durability, toughness and adaptability in the field must not be mistaken for
reason to mishandle it during transportation, handling and storage. The boxes containing the
HBPE80 Wrapping band should be handle with care, ensuring that the rolls, their inner
cartoon cores and protective outer packing will remain without damage.

7. PRODUCT

7.1 Coating Material

All HBPE80 Corrosion Preventive Systems consists of 2 layers;

• Protective layer
• Mechanical Protective layer

The material types and properties of each layer can vary, depending of the
substrate, pipeline operation temperature, the application as well as the type of
soil and backfill.

7.1.1. The HBPE80 consist of 1.8 — 2 mm thick, visco-elastic polymer CORROSION

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 Cochin LPG Import Terminal
Project, Puthu Vypeen

JOB PROCEDURE FOR INSTALLATION AND LPGTK-PVP-PRJ-

TITLE: TESTING OF HBPE80 WRAPPING GEN- JP-01 R.00
DATE:31-12-2020

PROTECTIVE LAYER of HBPE80 WRAPPINGBAND, covered with a 2x 0.5 mm

thick PVC- based, MECHANICAL PROTECTIVE LAYER of HBPE80 COVERING TAPE.

7.1.2. The high performance of this coating system: Immediate adhesion, permanent
flexibility and no curing, makes it possible to withstand burial and backfilling
short time after application.

7.1.3. The system is used on buried or submerged pipeline where severe soil or water
condition and corrosion factors are the main design considerations. HBPE80 is
resistant to pH values between 2 to 12. Its chemical resistance is depending on
the exposure time, temperature and concentration of the chemical substances.

7.2 Temperature Ranges

The HBPE80 WRAPPING BAND and HBPE80 COVERING TAPE material withstand storage
temperatures from minus 450C to plus 400C.

7.2.1. The shelf life of the HBPE80 WRAPPINGBAND and HBPE80 COVERING TAPE is not critical.
7.2.2. The maximum continuous service temperature for HBPE80 is 70”C and
short terns service temperature is allowed to maximum 85”C (under
non-immersed conditions).
7.2.3. Application temperatures advised for ambient, substrate and HBPE80 material:
The ambient temperature between minus 450 C and plus 600 C at maximum 85% relativehumidity
Material temperature of HBPE80 WRAPPINGBAND prior to application between + 20 C and +40 0 C
substrate temperature for application of HBPE80 WRAPPING between -40 0 C and +650 C, (always
+3°C above dew point).
Material temperature of HBPE80 COVERING TAPE prior to application between +15 C and plus
+40 C substrate temperature for application of HBPE80 Covering Tape between +10 C and +65”C,
(always +3°c above dew point).

8. APPLICATION PROCEDURE

5
 Cochin LPG Import Terminal
Project, Puthu Vypeen

JOB PROCEDURE FOR INSTALLATION AND LPGTK-PVP-PRJ-

TITLE: TESTING OF HBPE80 WRAPPING GEN- JP-01 R.00
DATE:31-12-2020

8.1 Surface preparation

8.1.1. Clean all surfaces for eventual grease, oil and dirt.

HBPE80 Corrosion Protective Systems are not sensitive to soluble salts, therefore no
procedures are needed for detection of salt contamination of substrate and blast
abrasives (if used).

8.1.2. Remove loose corrosion, loose mill scale, dust or other loosely adherent
contaminates to cleanliness St-2 / St-3 (hand toll / machine tool cleaning) or
by means of abrasive blasting to cleanliness Sa-1 (brush off blasting) in
accordance with ISO 8501-01.

A specific surface profile is not needed for HBPE80 Corrosion Protective

Systems

8.1.3. Mechanically remove all weld spatters, lamination, slivers, sharp edges, high
points and other visual roughness, which might penetrate into the corrosion
protective coating layer.

8.1.4. Approximately 150mm wide zones of the main pipe-coating, adjacent to the
bare steel area should be cleaned and slightly abraded by hand tool or
abrasive sweep-blasting.

8.2 Application condition

8.2.1. The pipe to be coated must be accessible from all sides with a minimum of
300mm free space under the pipe. The work area should be kept dry and the
pipe surface to be coated should be protected against rain or snow during
the application operation. Allow sufficient ventilation in the work area,
preventing dew point changes.

8.2.2. Do not apply on the surface with visual moisture. Always control the
coldest surface zone (shadow side) and areas near soil with high humidity.
The Steel temperature shall be at least 3O 0 C above Dew Point.

HBPE80 WRAPPINGBAND application conditions:

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 Cochin LPG Import Terminal
Project, Puthu Vypeen

JOB PROCEDURE FOR INSTALLATION AND LPGTK-PVP-PRJ-

TITLE: TESTING OF HBPE80 WRAPPING GEN- JP-01 R.00
DATE:31-12-2020

Condition Humidity Ambient Temp. Substrate temp. HBPE80temp.

Maximum <85% +500C +600C* +400C
Normal 20-80% 00C-300C 100C-300C* 200C-250C
Minimum 0% -450C -400C* +150C
*The substrate temperature should always be kept >3 0C above dew point.

HBPE80 COVERING TAPE application conditions:

Condition Humidity Ambient Temp. Substrate temp. HBPE80temp.

Maximum +/<85% +500C +600C* +400C
Normal 20-80% 00C-300C 100C-300C* 200C-250C
Minimum 0% -450C +100C* +150C

8.2.3. Application of HBPE80 CORROSION PREVENTIVE Systems should always he carried out
by persons in possession of valid HBPE80 APPLICATION. CERTIFICATE including ID-
card, received after having fulfilled a HBPE80 APPLICATON COUftSE and passed the
connected theoretical and practical tests for this specific type of application .

8.3 Application of HBPE80 WRAPPING BAND

8.3.1. The corrosion protecting HBPE80 WRAPPINGBAND adheres immediately to

almost any dry and clean substrate. A surface profile is not required. Due to
the visco-elastic cold-flow properties of the HBPE80 compound, it will, during
time, continue penetrating into the pores of the substrate until total surface
coverage has been achieved.

8.3.2. APPLICATION OF HBPE80 WRAPPING BAND CORROSON PROTECTIVE LAYER is

to be done without tension.

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 Cochin LPG Import Terminal
Project, Puthu Vypeen

JOB PROCEDURE FOR INSTALLATION AND LPGTK-PVP-PRJ-

TITLE: TESTING OF HBPE80 WRAPPING GEN- JP-01 R.00
DATE:31-12-2020

Never tension but LAY the Wrapping band on the surface. Avoid air
enclosures and equally press and smoothen the Wrapping band tight on the
substrate surface.
Start wrapping minimum 50mm overlapping the existing original factory-pipe
coating, near the top of the pipe, by fastening the end of the Wrapping band
in 10 ‘o’clock to 2 ‘o’clock position and apply downwards.

The first wrap, one complete wrap circumferentially around the pipe is made
before starting the subsequent spiral-type overlapping wraps.
8.3.3. The following wrap should be done under such an angle that it should end
overlapping the previous wrap by 10 — 15 mm at the starting point.
Subsequent spiral-wraps can now be done, side-overlapping each other by
minimum 1Omm. A line printed on the outside the film on the Wrapping
band, indicates the 10mm overlap.

Note: Overlaps of less than 10mm in any portion of the Wrapping band,
coated surface will invalidate the HBPE80 30 year guarantee.

8.3.4. Continue the wrapping. Subsequent rolls may be initiated where the previous
roll expired. The end-overlap on the previous HBPE80wrap should be
minimum 100mm.

8.3.5. During the entire wrapping process, any area where small air enclosures or
portions of slack are observed, along overlap and weld seam should be
additionally smoothened by hand in order to achieve maximum contact
between the HBPE80 compound and the substrate surface.

8.3.6. Once the enFire steel pipe surface has been wrapped, the last final wrap,
overlapping the adjacent factory coating with minimum 50mm should be
made similar to the first wrap: One complete circumferential wrap around
the pipe.
8.4. Application of HBPE80 COVERING TAPE

8.4.1. Prior to Start of application, control that cleanliness and temperature of the
surface to be coated in accordance to specification.

8.4.2. Application of HBPE80 Covering Tape is to be done with tension .

8
 Cochin LPG Import Terminal
Project, Puthu Vypeen

JOB PROCEDURE FOR INSTALLATION AND LPGTK-PVP-PRJ-

TITLE: TESTING OF HBPE80 WRAPPING GEN- JP-01 R.00
DATE:31-12-2020

The first wraps of the HBPE80 Covering Tape mechanical protective layer are
done without advancing the roll.

Always start the wrapping three to five millimeters inside the end of the
green, HBPE80corrosion protective wrapping. Start wiFh two circumferential
wraps around the pipe.

8.4.3. Applying the subsequent TENSIONED spiral wrapping by advancing the roll,
an overlap should maintained of minimum 50%. In this way a double layer of
HBPE80 Covering Tape will be created. Subsequent rolls should overlap the
previous tape-end with minimum 25 cm.

8.4.4. During the entire wrapping process, the applicator should apply the Covering
Tape as smooth as possible, avoiding air enclosures. It is important that
optimal adhesion is achieved between the overlapping Covering Tape layers
as well as the adhesion t the corrosion protective layer. This will ensure
optional performance of the mechanical protective layer.

8.4.5. The wrapping should end 3 — 5 mm inside the green HBPE80 Wrapping band,
with two, NON- TENSIONED, circumferential craps around the pipe.

8.4.6. The final visual control should be carried out by the certified
HBPE80supervisor, approving and reporting the quality application. No
further tesFs are needed and the coated section can be released.

8.5 Quality Control — High Voltage Pore Test

8.5.1. Quality Control — A high voltage Pore Test shall be carried out on HBPE80
CORROSION PROTECTIVE system direct after application.

8.5.2. A High voltage pore testing should be done with 5 kV per mm coating
thickness plus 5 kv.

The final holiday detection can be carried out before lowering the ready pipe
into the trench. The total thickness of the HBPE80CPS 1 is minimum 3 mm

9
 Cochin LPG Import Terminal
Project, Puthu Vypeen

JOB PROCEDURE FOR INSTALLATION AND LPGTK-PVP-PRJ-

TITLE: TESTING OF HBPE80 WRAPPING GEN- JP-01 R.00
DATE:31-12-2020

and the pore-testing should therefore be carried out with (3 x 5 kV) + 5kV =
20 kV

A clean, copper-brush probe/ a ring probe us recommended for the testing.

there shall be zero holidays.

9. POST COATING OPERATION

9.1. Handling and burying of HBPE80 protected pipe sections

9.1.1. Due to the visco-elastic behaviour of the HBPE80corrosion protective

layer,any local load on HBPE80 coated areas should always be avoided.
When support or lifting is needed it should always be carried out on the
less load-sensitive, factory-coated part of the pipe section.

9.1.2. The pipeline sand-bed under a HBPE80 protected pipe section should
consist of clean sand, free of rocks, brush or other material which might
damage the coating.

The backfilling material should as well be fine material, free if rocks,

lumps of clay or frozen soil. The free fall of the backfill should be as
limited as possible.

9.1.3. In case of coarse and less quality backfill HBPE80recommends to

additional protect the HBPE80 coated area by means of an outer shield
of impact absorbing geo-textile

9.2 HBPE80 Coating damages

9.2.1. The HBPE80corrosion protective layer 1 is able to absorb minor

damages such as needle-like penetration or cuts shorter than 10 mm.
The self-healing properties of the HBPE80 permanent visco-elastic
compound will create a flow of material, closing the defect within
minute or few hours. Patching can easily repair larger damages, like
long cuts.

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 Cochin LPG Import Terminal
Project, Puthu Vypeen

JOB PROCEDURE FOR INSTALLATION AND LPGTK-PVP-PRJ-

TITLE: TESTING OF HBPE80 WRAPPING GEN- JP-01 R.00
DATE:31-12-2020

9.2.2. Create access to the full circumference of the pipe, in a width of

minimum 100 mm on each side of damaged area. Clean the coating
around the pipe and cut-out the damaged, contaminated or non-
adhering coating down to the substrate and create a square or
rectangular shaped ‘window” with 600 chamfered sides, easy to patch
with pre-cut pieces of HBPE80 Wrapping band. Clean and dry the
substrate surface.

The HBPE80 supervisor must inspect eventual damages of the pipe

substrate and action should be undertaken according Fo project
specifications.

9.2.3 The "Window” should be filled-up with one or more layers of well-
fitting,
pre-cut patches of HBPE80 Wrapping band until the surface is flush (or
slightly above) with the adjacent coating. Apply each thoroughly.
Smoothen and shape the patches into the corners and side seams.

9.2.4 Carry out High voltage pore detection, using a copper bush probe/ a
ring
probe. Test voltage should be 5 kV per mm coating thickness plus 5 kV.
In
case the damage is filled-up with two layers of HBPE80CZ H Wrapping
band, the test voltage will be (2x2x5kV) + 5 kV = 25 kV.

9.2.5 When the patch application has been approved by the HBPE80
supervisor, the application of the outer mechanical protective
wrapping with HBPE80 Covering Tape can be carried out. The wrapping
should be fully circumferential, starting and finishing minimum 50 mm
on each side of the patch-repaired area.

9.2.6 After approval by the HBPE80 supervisor this patch repair is ready for
eventual backfilling. Due to the visco-elastic behaviour, the HBPE80
material will flow together with adjacent material and form a seamless
corrosion protective barrier.

10. SPECIAL APPLICATION

11
 Cochin LPG Import Terminal
Project, Puthu Vypeen

JOB PROCEDURE FOR INSTALLATION AND LPGTK-PVP-PRJ-

TITLE: TESTING OF HBPE80 WRAPPING GEN- JP-01 R.00
DATE:31-12-2020

10.1 Coating of pipeline repair sleeves

10.1.1 On pipelines, repair with welded-on steel repair sleeves, the

longitudinal butt-weld seam joints, the circumferential fillet weld and
butt weld seams should be filled-up with HBPE80 paste material
and chamfered to an angle of minimum 60

By using this filler compound, a gradual transition is created from the

sleeve to the pipe surface. This transition allows an adequate
application of the HBPE80 system without “denting” effects and with
minimal wrinkles.
10.1.2 Due to visco-elastic behaviour and cold-flow properties of the
HBPE80 paste, the filled areas should as soon as possible be
covered with the HBPE80 Wrapping band.
10.2. Clean-up

10.2.1. Cleaning operation after application of HBPE80 system is very

limited. Disposable papers, backing and cardboard roll-cores should
be collected and treated as non-chemical waste. Every cm of the
green HBPE80materials can be used and re-usecl, provided not
contaminated. Eventual small bits of contaminated HBPE80
Wrapping band should be collected and treated like waste of PP or
PE.
The HBPE80 Covering Tape is PVC-based and eventual bits of waste
should be treated according to the rules for PVC containing
materials.

12
 Cochin LPG Import Terminal
Project, Puthu Vypeen

JOB PROCEDURE FOR INSTALLATION AND LPGTK-PVP-PRJ-

TITLE: TESTING OF HBPE80 WRAPPING GEN- JP-01 R.00
DATE:31-12-2020

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