JPKENNY TRIUNE

STANDARD SPECIFICATION

No OF SHEETS 11 DOCUMENT No 110000-JPKT-00-P-1-012

STANDARD SPECIFICATION FOR FIELD JOINT COATING

0 A REV.

.08.06 .08.06 DATE

ISSUED FOR REVIEW ISSUED FOR IDC APPROVAL

AKS AKS

SB SB

AKG AKG

JKB JKB

REVISION DESCRIPTION

PREPD.

CHKD.

REVD.

APPD.

JPKENNYTRIUNE

GSPC CITY GAS DISTRIBUTION PROJECT

SPECIFICATION FOR FIELD JOINT COATING
110000-JPKT-00-P-1-012

TABLE OF CONTENT 1.0 SCOPE.......................................................................................................................... 3 2.0 DEFINITIONS................................................................................................................ 3 3.0 REFERENCE DOCUMENTS......................................................................................... 3 4.0 COATING MATERIAL AND EQUIPMENT .................................................................... 4 5.0 APPLICATION PROCEDURE....................................................................................... 8 6.0 INSPECTION................................................................................................................. 9 7.0 TESTING ..................................................................................................................... 10 8.0 REPAIRS .................................................................................................................... 10 9.0 DOCUMENTATION..................................................................................................... 11

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JPKENNYTRIUNE

GSPC CITY GAS DISTRIBUTION PROJECT

SPECIFICATION FOR FIELD JOINT COATING
110000-JPKT-00-P-1-012

1.0

SCOPE
This specification defines the minimum technical requirements of materials, manpower, equipment, application, inspection and testing of field joint corrosion coating of onshore pipeline.

2.0

DEFINITIONS
For this specification the following definitions shall apply: OWNER CONSULTANT CONTRACTOR SHALL/MUST/IS TO BE SHOULD : : : GSPC GAS COMPANY LIMITED J.P KENNY TRIUNE ENGG. PVT. LTD The company named as such in the deed. A mandatory requirement A non-mandatory requirement, advisory or recommendation.

3.0

REFERENCE DOCUMENTS

3.1.1 Reference has been made in this specification to the latest edition of the following standards and specifications:
i) ii) DIN-30672 DIN-EN-12068 : : Corrosion Protection Tapes and Heat Shrinkable Sleeves Cathodic Protection External Organic Coatings for the corrosion protection of buried or immersed steel pipelines used in conjunction with Cathodic Protection Tapes and Shrinkable Materials. Standard Method of Test for Tensile properties of Plastics. Standard Test method for D.C Resistance or Conductance of Insulating Materials. Standard Test Methods of Dielectric Strength of Solid Electrical Insulating Materials at Commercial frequencies. Standard method of test for water absorption of plastics Water Vapour Transmission of Materials in Sheet Form.
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ii) iii) iv)

ASTM D-638 ASTM D-257 ASTM-D-149

: : :

v) vi)

ASTM-D-570 ASTM-E-96

: :

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GSPC CITY GAS DISTRIBUTION PROJECT

SPECIFICATION FOR FIELD JOINT COATING
110000-JPKT-00-P-1-012

vii) viii)

ASTM-D-1002 ASTM-D-2671 ASTM-G-42 SIS-055900 SSPC-SP-1

: : : : :

Standard Method of Test for Strength Properties of Adhesives in Shear by Tension Loading. Heat Shrinkable Tubing for Electrical use. Cathodic disbonding of pipeline coating subjected to elevated or cyclic temperatures. Pictorial surface preparation standard for painting steel surfaces. Solvent cleaning, steel structure painting council.

ix) x)
xi)

4.0

COATING MATERIAL AND EQUIPMENT

4.1 GENERAL
4.1.1 CONTRACTOR shall be responsible for arranging all equipment and manpower required for application, testing and inspection of coating and all required materials for field joint coating in accordance with this specification.

4.2
4.2.1

HEAT SHRINKABLE WRAPAROUND SLEEVE

Heat Shrinkable Wraparound Sleeve shall be suitable for a maximum in service temperature of 60C. The joint coating system shall consist of a solvent free epoxy primer applied to the pipe surface prior to sleeve application. The backing shall be coated with thermochrome paint which will change colour when the desired heat during shrinking is attained. Heat shrinkable wraparound sleeve shall consist of radiation cross-linked, thermally stabilised, ultraviolet resistant semi-rigid polyolefin backing with a uniform thickness of high shear strength thermoplastic/copolymer hot melt adhesive. The wrap around sleeve shall be supplied in pre-cut sizes to suit the pipe diameter and the requirements of overlap. Thickness of the Field Joint Coating The thickness of field joint coating shall be as follows, Average on the weld -2.0 mm Average on the body -2.3 mm Minimum on the weld-- 1.6 mm Minimum on the body -- 2.0 mm

4.2.2

4.2.3

Properties of Field Joint Coating Material Properties of the backing and the as-applied joint corrosion coating shall conform to the values given in table 1 and 2 be as follows:

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JPKENNYTRIUNE

GSPC CITY GAS DISTRIBUTION PROJECT

SPECIFICATION FOR FIELD JOINT COATING
110000-JPKT-00-P-1-012

Sl No. i) ii) iii) iv) v) vi) vii)

Kg/cm2 Tensile Strength @ 25C % Ultimate Elongation % @ 25C Dielectric withstand kV with 1000 kV Volt/sec Water absorption 24 hours, @ 25C Volume Resistivity @ 25C % Ohmcm

Table 1 : Properties of Backing Requireme Unit Property nt

160 250

Test Method
ASTM-D-638 DIN 30672 ASTM-D-149 OR DIN 30672 ASTM D-570 ASTM D-257

30 0.05 1015

Resistance to Thermal aging @ % 100C Heat Shock at 200C (for heat shrinkable wraparound sleeves)

Change in Elongation DIN 30672 25% No dripping, cracking or ASTM-D-2671 flowing

Table 2 : Properties of Joint Coating System (As applied) Sl No. i) Property

Resistance to impact @ 23C Class C, 30 Blows
-

Unit

Requiremen t
No holidays

Test Method
DIN-EN-12068

ii)

Resistance to peel class C width @ 23C With Metal Surface With Mill coating At layers overlap N/cm @ 50oC With Metal Surface With Mill coating At layers overlap Cathodic disbondment (after 30 days) Test Method A, @ 60C Resistance to indentation, @ 50C

35 min 35min 15min 3 min 2 min 3min

DIN-30672

iii)

mm

20 max.

ASTM-G-42

iv)

mm

0.6 remaining thickness

DINEN-12068

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GSPC CITY GAS DISTRIBUTION PROJECT

SPECIFICATION FOR FIELD JOINT COATING
110000-JPKT-00-P-1-012

v)

Lap shear strength @ 50C, between wrapping & metal N/cm 2 surface and mill coating.

DINEN-12068

4.3

COLD APPLIED PIPE WRAP

Cold applied pipe wrap shall consist of PVC / Polyethylene backing with a uniform thickness of self-adhesive bituminous rubber compound and shall be of the type that can be applied without use of any primer. Thickness of the wraparound sleeve shall be as per Manufacturers standard. Properties of the cold applied pipe wrap shall meet the requirements of this specification. Cold applied pipe wraps shall be supplied in pre-cut sizes complying the requirements of this specification, to enable easy application during laying operations.

4.3.1

Properties of joint corrosion coating material Properties of the backing and the as-applied joint corrosion coating shall be as follows:

Table 3 : Properties of Backing

Sl. No. 1 2 3 4 5 Property Tensile Strength @25 C Ultimate Elongation @ 25 C Dielectric withstand with 1000V volt/sec. Water vapour transmission Heat shock @200 C for 4 (four) hours (for heat shrinkable wraparound sleeve only) Heat shock @ 200 C (for cold applied pipe wrap only) Unit Kg/cm % kV g/24h/m Requirement 160 250 30 0.7 No dripping, cracking, flowing Pass Test of method ASTM D 638 ASTM D 638 ASTM D 149 ASTM E 96 ASTM D 2671

Drumskin method

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JPKENNYTRIUNE

GSPC CITY GAS DISTRIBUTION PROJECT

SPECIFICATION FOR FIELD JOINT COATING Table 4 : Properties of Coating System (as applied)
110000-JPKT-00-P-1-012

Sl. No. 1 2 3

Property Resistance to impact @ 25 C Resistance to peel between coating and steel @25 C Cathodic disbondment (after 30 days) Test method A, @60 C

Unit Kg-cm Zone-A Kg/cm mm

Requirement 20 2.75 30

Test of method DIN 30672 DIN 30672 ASTM G 42

4.3.2

CONTRACTOR shall purchase field joint coating materials from OWNER approved Vendor / Manufacturers. Complete technical details along with test certificates complying with the requirements of section 4.2.3 of this specification shall be submitted to OWNER for approval. CONTRACTOR shall submit certificates/reports for each batch of the materials. Materials shall not be older than their period of validity at the time of application. Deteriorated materials shall be disposed of and replaced by CONTRACTOR at his own expense. CONTRACTOR shall ensure that the coating materials supplied by him are properly and clearly marked with the following: Manufacturer' s name Material Description Batch Number Date of Manufacturing Date of expiry Specific storage and handling instructions

4.3.3 4.3.4

4.3.5

4.3.6

All materials shall be stored and handled by the CONTRACTOR in such a manner to prevent damage or deterioration. Manufacturer' s instruction shall be strictly followed.

4.3.7 A fully automatic full circle adjustable holiday detector with a visual and audible signal shall be used for inspection of coating. 5.0 5.1 APPLICATION PROCEDURE GENERAL
The field joint corrosion coating application procedure shall be in accordance with manufacturer' s instructions and the minimum requirements specified hereinafter whichever is more stringent. CONTRACTOR shall submit and demonstrate to OWNER, the proposed materials and work procedures. OWNER may demand for the presence of Vendor/Manufacturer at the time of qualification / demonstration. Proposed procedures and all materials and equipment shall be subject to OWNER' s approval.
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JPKENNYTRIUNE

GSPC CITY GAS DISTRIBUTION PROJECT

SPECIFICATION FOR FIELD JOINT COATING
110000-JPKT-00-P-1-012

5.2
5.2.1

SURFACE PREPARATION
Oil, grease, salts and other contaminations shall be removed from steel surface by wiping with rags soaked with suitable solvents such as naphtha or Benzene. Kerosene or gasoline shall not be used for this purpose. Solvent cleaning procedure shall be according to SSPC-SP-1.

5.2.2

Surface shall be blast cleaned to a finish equivalent to SA 2 of Swedish Standard SIS055900. Prior to surface cleaning, the surfaces shall be completely dry. No blasting shall be carried out if relative humidity is more than 90%. The ends of existing pipe protective coating shall be inspected and chamfered prior to application of field joint coating and cleaned as necessary. Unbonded portion of the coating shall be removed and then suitably trimmed. Portions where parent coating is removed shall also be prepared as specified in section 5.2.2. Field joint coating shall be applied immediately after completion of surface preparation. APPLICATION OF JOINT COATING (HEAT SHRINKABLE SLEEVES) The wrap around sleeve shall be of a size such that a minimum overlap of 50mm is ensured (after shrinking) on both sides of the yard applied corrosion coating of pipe. Before centering the wraparound sleeve, the bare steel surface shall be preheated over the surface to remove the moisture. The minimum preheat temperature shall be as recommended by the manufacturer and shall be checked by means of pyrometer or temperature crayons. The solvent free epoxy primer (whenever applicable) shall be applied prior to sleeve application as per manufacturer' s recommendations. The wraparound sleeve shall be applied as per approved procedure and manufacturers recommendations. Overlap between the sleeve and closure patch shall be minimum 100mm. A heat shrinking procedure shall be applied to shrink the sleeve in a manner such that all entrapped air is removed using gloved hands and hand rollers. The complete shrinking of the entire sleeve shall be obtained without undue heating of existing pipe, sleeve and pipe coating. Heating shall be carried out until the thermochrome paint has completely changed its colour as recommended by the Manufacturer. Resulting coating shall be free of wrinkles, cold spots and weld profile visible on the sleeve. APPLICATION OF COLD APPLIED PIPE WRAP Cold applied pipe wrap shall be applied on the surface immediately after the surface cleaning operation. It shall be ensured that no moisture is present on the surface. If moisture is present, the same shall be removed by suitable means such as wiping, heating etc. Cold applied pipe wrap shall consist of one 450mm wide center wrap and two 100mm wide end wraps. The field joint shall be wrapped first with 450mm wide wrap, applied in a single continuous layer Cigarette Wrap centering on the line of the weld with a minimum of 100mm end lap. Then 100mm wide end wrap shall be applied at each end of the 450mm wide wrap, overlapping the yard applied coating by minimum 50mm and center wrap with
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5.2.3

5.3 5.3.1 5.3.2

5.3.3

5.3.4

5.4

JPKENNYTRIUNE

GSPC CITY GAS DISTRIBUTION PROJECT

SPECIFICATION FOR FIELD JOINT COATING
110000-JPKT-00-P-1-012

minimum 50mm. Sufficient tension during application shall be maintained to avoid air pockets and wrinkles.

6.0
6.1

INSPECTION Visual inspection of the field joint coating shall be carried out to ensure the following: Mastic extrusion on either ends of the sleeve There shall be no sign of punctures or pinholes or bend failure. The external appearance of the sleeve shall be smooth, free of dimples, air entrapment or void formation. Weld bead profile shall be visible through the sleeve. The entire closure patch shall have changed colour uniformly

6.2

HOLIDAY INSPECTION The holiday detector used shall be checked and calibrated daily before the commencement of work with an accurate D.C. voltmeter. The detector electrode shall be in direct contact with the surface of coating to be inspected. The entire surface of the coated field joint shall be inspected by means of a full circle holiday detector approved by OWNER. The test voltage shall be 5 KV + 5 KV/mm of total thickness of coating, subject to a maximum of 25KV. Inspection of the sleeves shall be conducted only after the joint has cooled below 50C.

6.3

No segment of the pipeline shall be covered or lowered in the trench until the field joint coatings have been approved by the OWNER. TESTING OWNER reserves the right to remove and test one out of every 50 joint coatings or one joint coating out of every day' s production whichever is more stringent. CONTRACTOR shall provide all assistance in removing and testing of field joint coating. From each test sleeve, one or more strips of size 25mm x 200mm shall be cut perpendicular to the pipe axis and slowly peeled off. This test shall be conducted between wrapping and metal and mill coating and between layers at overlap with joint coating (where applicable). The required peel strength shall meet the requirements of section 4.2.3 as applicable for 23C to 50C whichever is feasible. After removal of strip the bulk of adhesive shall remain adhered to the pipe showing no bare metal, otherwise, test shall be unacceptable. The adhesive layer that remains on the pipe surface shall be free of voids resulting from air or gas inclusion

7.0
7.1

7.2

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JPKENNYTRIUNE

GSPC CITY GAS DISTRIBUTION PROJECT

SPECIFICATION FOR FIELD JOINT COATING
110000-JPKT-00-P-1-012

7.3

If the sleeve taken away for test does not meet the requirements of section 7.2 the adjacent two sleeves shall also be removed and inspected. If the adjacent two sleeves are acceptable the test rate shall be increased to one sleeve out of every twenty five until OWNER is satisfied. OWNER may at his discretion reduce the test as per section 7.1. If anyone or both the adjacent two sleeves do not meet the requirements of section 7.2 the field joint coating shall be stopped. (Refer section 8.0)

7.4 7.5

OWNER Representative reserves the right to order 100% removal of sleeves if he is not convinced that the requirements of section 7.2 are achieved. Coating thickness shall be checked by non-destructive methods for each field joint. REPAIRS If a field joint is detected to be unacceptable after testing as per section 7.0 of this specification the CONTRACTOR shall, at his own cost: Determine the cause of the faulty results of the field coating. Mobilise the expert of manufacturer, if required. Stop field joint coating until remedial measures are taken against the causes of such faults, to the satisfaction of the OWNER.

8.0
8.1

8.2 8.3

CONTRACTOR shall replace all field joint coatings found or expected to be unacceptable as per section 7.0 of this specification. After the coating work on welded joints, fittings and repairs to the coating have been completed the coating as a whole shall be tested with a spark-tester before lowering or jacking the pipeline. OWNER reserves the right to check the coating on buried pipelines or part of pipelines with equipment such as the "Pearson Meter" and the resistance meter. If coating defects are established, the CONTRACTOR shall be responsible for excavation at such points, repairing the coating, spark testing and backfilling the excavations without extra charge.

8.4

9.0
9.1

DOCUMENTATION Prior to procurement of coating material, CONTRACTOR shall furnish four copies of the following for qualification of the field joint coating material and Manufacturer as a minimum requirement. i) Complete description and technical catalogues describing the materials offered along with samples of corrosion coating materials, its properties and application instruction as applicable specifically to the project. Test certificates and results of previously conducted test, for all properties listed
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ii)

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GSPC CITY GAS DISTRIBUTION PROJECT

SPECIFICATION FOR FIELD JOINT COATING
110000-JPKT-00-P-1-012

in section 4.2.3 of this specification. iii) Reference list of previous supplies of the similar material indicating the project details such as pipe diameter, quantity, operating temperature, year of supply, project name, contact person and feed back on performance. Once the OWNER' s approval has been given, any change in material or Manufacturer shall be notified to OWNER, whose approval in writing of all changes shall be obtained before the materials are manufactured. 9.2 Prior to shipment of materials from the Manufacturer' s Works, CONTRACTOR shall furnish six copies of the following test certificates/results as per Manufacturer' s Quality Control Procedure for each batch of materials: i) Specific application instructions with pictorial illustrations. ii) Specific storage and handling instructions

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