D.P.JINDAL GROUP OF INDUSTRIES DOCUMENT No.

:
MAHARASHTRA SEAMLESS LIMITED, MSL/RPROC/CPCL-CBR/PE/23-06
DATE : 14.03.2023, Rev.00
PIPE NAGAR, COATING PLANT
REPAIR PROCEDURE FOR 3LPE COATING ON LINE PIPES
CUSTOMER / CLIENT : M/s CHENNAI PETROLEUM CORPORATION LIMITED (CPCL)
PROJECT NAME : PIPELINE REROUTING WORKS FOR CAUVERY BASIN REFINERY (CBR) PROJECT AT Nagapattinam, Tamilnadu
CONSULTANT : M/s Engineers India Pvt. Limited (EIL) EIL Job No.: B416 INSPECTION CATEGORY: ‘’B’’
WO No/FOA No : 28235763/ (1046/SC0262/W/111) Dated 13.10.2022
CONTRACTOR : M/s Mastek Engineering Pvt. Limited (MEPL)
: EIL SPECIFICATION NO.6-71-0041 REV.4, DATED 05.01.2018, AND REPAIR MATERIAL MANUFACTUERER
REFERENCE SPEC./STD.
RECOMMENDATION
OD WT QUANTITY
SR. NO.
PIPE SIZE & QUANTITY (MM) (MM) (METERS)
1 219.1 7.92 2163

Purpose:
This procedure covers the repair of 3LPE Coated pipes damage during the Coating process (testing & process damage),
Handling, Shifting to Coating yard & Transportation from Coating yard to the Dumpsite.
Details:
The required Repair Materials are as under -
Material Manufacturer – SEAL FOR LIFE (Covalence)
 Melt Stick
 Heat Shrink Patch Roll – PERP -80
 Filler – FILLER MATERIAL – S-1137
 Heat Shrink Sleeve Roll HTLP-80 or Equivalent
 Primer Part- A & Part– B (S1301/S1401– Make seal for life or 323i – Make 3M)
Defects type, Procedure & Acceptance Criteria:
Repair of scratch on PE coating layer (HE 3450 H) of 3LPE coating:
As per HDPE manufacturer recommendation the Repair of scratch on PE coating layer as per below instructions:

 Inspect and ensure the scratch on PE coating is not though PE layer.

 Ensure no contamination observe, clean with dry brush/cloth.
 Heat the scratch area using LPG flame or electric hot blower; ensure temperature 10 deg.C below Vicat softening
point say below 120°C. Do not heat for long time at one place to avoid degradation of material.
 Gently apply repair roller and spatula to cover the damaged area and smoothen to match with surrounding 3LPE
coating.
 Once the repair area is below 40°C or at ambient temperature, inspect the repair area for thickness and holiday.
 Repair area must meet the minimum thickness requirement and free from holiday.
Repair area must meet the minimum thickness requirement and free from holiday.

Repair by Heat Shrink Patch Roll, Filler – Filler Materials:-

Damages caused to coating by handling such as scratches, cuts, dents, gouges, when Steel / FBE not exposed, having a total
2
reduced thickness on damaged portion shall be not less than 2 mm and an area not Exceeding 20 cm shall be rebuilt by heat
shrink patch only and without exposing to bare metal.

Defects exceeding the sizes as indicated above or any holidays of size less than 300 mm shall be repaired using heat shrink
patch. Defects to be repaired by Heat Shrink patch/Sleeve shall be maximum 2 per pipe.
Irrespective of type of repair, the maximum numbers of repair of coating shall be as follows:-
2
- Holiday repairs of size ≤ 100 cm attributable to coating application process shall be Maximum 1 number per pipe.
- In addition to the above, defects to be repaired by heat shrink patch/sleeve shall be maximum 2 (two) per pipe.
Cutting repair patch to appropriate size so as to provide minimum 50 mm overlap with the parent coating. It shall be positioned
correctly over the filler filled area and the patch shall be heated until there is a perfect bonding between patch with line coating
and mastic filler.

VIJAY PANDEY VED PRAKASH MISHRA RAGHVENDRA SINGH TPI CPCL/EIL

ENGINEER -QA SR.MANAGER - QA/QC GM - COATING PLANT APPROVAL APPROVAL
PREPARED BY REVIEWED BY APPROVED BY

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 D.P.JINDAL GROUP OF INDUSTRIES DOCUMENT No.:
MAHARASHTRA SEAMLESS LIMITED, MSL/RPROC/CPCL-CBR/PE/23-06
DATE : 14.03.2023, Rev.00
PIPE NAGAR, COATING PLANT
REPAIR PROCEDURE FOR 3LPE COATING ON LINE PIPES
CUSTOMER / CLIENT : M/s CHENNAI PETROLEUM CORPORATION LIMITED (CPCL)
PROJECT NAME : PIPELINE REROUTING WORKS FOR CAUVERY BASIN REFINERY (CBR) PROJECT AT Nagapattinam, Tamilnadu
CONSULTANT : M/s Engineers India Pvt. Limited (EIL) EIL Job No.: B416 INSPECTION CATEGORY: ‘’B’’
WO No/FOA No : 28235763/ (1046/SC0262/W/111) Dated 13.10.2022
CONTRACTOR : M/s Mastek Engineering Pvt. Limited (MEPL)
: EIL SPECIFICATION NO.6-71-0041 REV.4, DATED 05.01.2018, AND REPAIR MATERIAL MANUFACTUERER
REFERENCE SPEC./STD.
RECOMMENDATION
OD WT QUANTITY
SR. NO.
PIPE SIZE & QUANTITY (MM) (MM) (METERS)
1 219.1 7.92 2163

 Procedure for repair by Heat Shrink Patch:-

By using Knife, Emery Disc/Paper, and Sander disc (Flap Disc), Grinding or any other suitable modes remove all loose coating
and sharp edges from all around the damaged area. Also remove all foreign material such as dirt, oil, grease and moisture.
Coating around the repair area shall be cleaned up to 100 mm distance.

A) Damage area is not exposing the bare metal

If damage area is not exposing the bare metal, we will be repaired by using heat shrink Patch (PERP-80) and Filler material
(S1137). If Damage to coating caused during handling such as scratches, cuts, dents, gouges, not detected during holiday test,
2
having a total reduced thickness on the damaged portion of not less than 2.0 mm and an area not exceeding 20 cm shall be
repaired by applying a heat shrink patch without exposing bare metal surface as follows:
Cut the PERP 80 Patch according to size of damage considering 50mm overlap all around. Abrade the surrounding of the
damaged area. Clean the prepared area properly. Heat the area Minimum 90°C and ensure the correct temperature has been
reached. Apply S1137 mastic filler to profile the damaged area before using PERP 80 repair patch. Heat the underside of the
patch to soften it, and heat the repair area at the same time. Gradually place the PERP-80 patch on the repair area. Uniformly
heat the entire PERP-80 patch. Carefully roll the patch from the middle to the edges. Repeat the heating and rolling steps until
entrapped air has been removed. If required, reheat with the torch and roll the patch again till adhesive comes out from edges.
After the process all repaired area shall be offered for inspection. Holiday test shall be conducted at 25 kV on the repaired area.
B) Damage area is Exposing bare metal:
If damage area is exposing bare metal, the exposed steel and/or 3LPE shall be cleaned and abraded. All rust must be removed.
Clean the prepared area properly. Pre-heat the area Minimum 90°C and ensure the correct temperature has been reached.
Cut the PERP-80 Patch according to size of damage considering 50 mm overlap all around. Abrade the surroundings of the
damaged area & chamfer the edges of the damaged area.
Dispense an adequate amount of part B in to part A of primer in ratio recommended by primer manufacture, mix homogeneously
and then apply primer on prepared steel surface and apply properly. Apply S1137 mastic filler to profile the damaged area before
using PERP 80 repair patch. Heat the underside of the patch to soften it, and heat the repair area at the same time. Gradually
place the PERP-80 patch on the repair area. Uniformly heat the entire PERP-80 patch to 80 – 90°C. Carefully roll the patch from
the middle to the edges. Repeat the heating and rolling steps until entrapped air has been removed. If required, reheat with the
LPG torch and roll the patch again till adhesive comes out from edges. Visual inspection shall be performed on repaired area.
After the process all repaired area shall be offered for inspection. Holiday test shall be conducted at 25 kV on the repaired area.
In case the damage is restricted to the PE only and bare metal shall not expose, application of primer is not required. Mastic filler
shall be applied directly on the damage PE or adhesive surface and filled to the level of line coating. Defects exceeding the sizes
as indicated above or any holiday’s size less than 300 mm shall be repaired using heat shrink patch. The defect area shall be
exposed up to bare metal prior to application of heat shrink patch.
Circumferentially large damaged areas by Heat Shrink Sleeves:-
If the coating defect is close to cutback of coating then it shall be repaired using heat shrinkable sleeves of HTLP 80 or
equivalent.
In case of coating defect close to coating cut back, Applicator shall remove the coating throughout the entire circumference of
the pipe down to the steel surface and increase the coating cut back length. Now if the coating cut back exceeds 140 mm of
linear length of pipe then the coating shall be repaired by the use of heat shrink sleeves thereby making up the coating cut back
length of 120 mm.
If any defect exceeds 70 mm from the original coating cut back length, the entire coating shall be removed and the pipe shall be
recycled through the entire coating procedure.
For damages greater than Coating defects exceeding above but not exceeding two in number and linear length of 500 mm shall
be repaired by using heat shrink sleeves HTLP-80 or equivalent.
Primer applied on the steel/FBE expose surface shall be used. The width of the sleeve shall be such that it extends minimum
100 mm from the damaged ends before shrinkage and 50 mm after shrinkage.
If the damage area is circumferential, than all defective coating (loose) shall be uniformly removed using knife, scrapper or power
brush. Brush off all foreign material around defective area and adjacent coating according to sleeve width.

Page 2 of 3
 D.P.JINDAL GROUP OF INDUSTRIES DOCUMENT No.:
MAHARASHTRA SEAMLESS LIMITED, MSL/RPROC/CPCL-CBR/PE/23-06
DATE : 14.03.2023, Rev.00
PIPE NAGAR, COATING PLANT
REPAIR PROCEDURE FOR 3LPE COATING ON LINE PIPES
CUSTOMER / CLIENT : M/s CHENNAI PETROLEUM CORPORATION LIMITED (CPCL)
PROJECT NAME : PIPELINE REROUTING WORKS FOR CAUVERY BASIN REFINERY (CBR) PROJECT AT Nagapattinam, Tamilnadu
CONSULTANT : M/s Engineers India Pvt. Limited (EIL) EIL Job No.: B416 INSPECTION CATEGORY: ‘’B’’
WO No/FOA No : 28235763/ (1046/SC0262/W/111) Dated 13.10.2022
CONTRACTOR : M/s Mastek Engineering Pvt. Limited (MEPL)
: EIL SPECIFICATION NO.6-71-0041 REV.4, DATED 05.01.2018, AND REPAIR MATERIAL MANUFACTUERER
REFERENCE SPEC./STD.
RECOMMENDATION
OD WT QUANTITY
SR. NO.
PIPE SIZE & QUANTITY (MM) (MM) (METERS)
1 219.1 7.92 2163

Remove damage coating all around (circumferential of the pipe) the pipe surface. After removing the PE coating, chamfered the
edge of the PE coating at the angle of 15 to 30°. All loose coating from the damaged area is to be removed with a knife;
scraper/sander disc (Flap discs) or emery paper. Eliminate all sharp edges and clean the damaged area to remove all foreign
materials rust, dirt oil & grease and moisture. All exposed steel/FBE surface shall be abraded to finish of Sa½ or if no steel
exposed than FBE has to be roughen with scraper/ sander disc (Flap discs) or emery paper.
Adjacent 3LPE coating over which the HTLP80 sleeve shall be installed shall be sweep roughen with scraper/ sander disc (Flap
discs) or emery paper. Steel / FBE surface of the damaged area will be heated using LPG gas torches to a temperature of
minimum 80˚C. The pre-heat temperature will be measured using digital thermometer/ IR gun while pre-heating is in progress,
epoxy part A & part B will be dispensed in the mixing cup in ratio recommended by primer manufacturer. The epoxy will be
thoroughly mixed and immediately applied only on the steel portion using applicator pad. Primer epoxy shall not be applied on
the adjacent PE line coating. HTLP-80/HP shrink sleeve shall be applied immediately after the primer application without waiting.
Check the adjacent PE line coating temperature after application of epoxy. In case the temperature has dropped below 70°C,
during the application of the primer, reheat the PE coating to 70°C.

Wrap the HTLP sleeve centrally around the damage. Sleeve should overlap the adjacent 3LPE coating on both sides by 100mm.
Preheat the underside of the leading edge of the sleeve with the flame and press firmly down onto the top of the joint area.
The sleeve should be wrapped loosely around the joint leaving 60 to 90mm gap between the bottom of the joint and the sleeve.
Sleeve overlap onto itself should be approximately 50mm.
Apply closure patch centrally over sleeve overlap area. While heating press down and smooth the closure patch with a gloved
hand to ensure good bonding and eliminate air entrapment.
Complete cool down, repair shall be checked for thickness and holiday at voltage setting of 25 kV.
For testing area repair, by using Heat Shrink Patch and mastic Filler.
If FBE Toe damage, then repair the damage area by using repair material 323i (Part –A & Part- B)-3M Make. Before using mix
repair material as per ratio given by repair material manufacturer recommendation. Repair material 323i (Part –A & Part- B)-3M
Make, can be using during the repair of Heat Shrink Patch and Heat Shrink Sleeve repair.
Repair of FBE toe and Heat Shrink Patch and Heat Shrink Sleeve repair (If Steel/ FBE surface of the damage) with Repair
material 323i (Part –A & Part- B)-3M Make, as per Repair Materials recommended procedure.

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