PETRONAS TECHNICAL STANDARDS

DESIGN AND ENGINEERING PRACTICE

TECHNICAL SPECIFICATION

COATING AND WRAPPING OF

LINE PIPE

PTS 20.146
OCTOBER 1994

PREFACE

PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication,
of PETRONAS OPUs/Divisions.
They are based on the experience acquired during the involvement with the design, construction,
operation and maintenance of processing units and facilities. Where appropriate they are based
on, or reference is made to, national and international standards and codes of practice.
The objective is to set the recommended standard for good technical practice to be applied by
PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical
plants, marketing facilities or any other such facility, and thereby to achieve maximum technical
and economic benefit from standardisation.
The information set forth in these publications is provided to users for their consideration and
decision to implement. This is of particular importance where PTS may not cover every
requirement or diversity of condition at each locality. The system of PTS is expected to be
sufficiently flexible to allow individual operating units to adapt the information set forth in PTS to
their own environment and requirements.
When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the
quality of work and the attainment of the required design and engineering standards. In
particular, for those requirements not specifically covered, the Principal will expect them to follow
those design and engineering practices which will achieve the same level of integrity as reflected
in the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his
own responsibility, consult the Principal or its technical advisor.
The right to use PTS rests with three categories of users :
1)
2)
3)

PETRONAS and its affiliates.

Other parties who are authorised to use PTS subject to appropriate contractual
arrangements.
Contractors/subcontractors and Manufacturers/Suppliers under a contract with
users referred to under 1) and 2) which requires that tenders for projects,
materials supplied or - generally - work performed on behalf of the said users
comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with
users, PETRONAS disclaims any liability of whatsoever nature for any damage (including injury
or death) suffered by any company or person whomsoever as a result of or in connection with the
use, application or implementation of any PTS, combination of PTS or any part thereof. The
benefit of this disclaimer shall inure in all respects to PETRONAS and/or any company affiliated
to PETRONAS that may issue PTS or require the use of PTS.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual
arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by
users to any company or person whomsoever and the PTS shall be used exclusively for the
purpose they have been provided to the user. They shall be returned after use, including any
copies which shall only be made by users with the express prior written consent of PETRONAS.
The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe
custody and PETRONAS may at any time require information satisfactory to PETRONAS in order
to ascertain how users implement this requirement.

TABLE OF CONTENTS
1.

INTRODUCTION

1.1

SCOPE

1.2

DISTRIBUTION, INTENDED USE AND REGULATORYCONSIDERATIONS

1.3

DEFINITIONS

1.4

CROSS-REFERENCES

2.

RESPONSIBILITIES

2.1

GENERAL

2.2

PROCEDURES

2.3

CODES AND STANDARDS

3.

MATERIALS

3.1

GENERAL

3.2

PRIMER

3.3

ASPHALT ENAMEL

3.4

GLASS FIBRE REINFORCEMENT

3.5

OUTER WRAP

4.

COATING APPLICATION

4.1

GENERAL

4.2

CLEANING

4.3

PRIMING

4.4

PREPARATION OF ENAMEL

4.5

APPLICATION OF ENAMEL AND WRAPPING

4.6

WHITE WASH

4.7

PIPE STORAGE

5.

INSPECTION AND REPAIRS

5.1

GENERAL

5.2

VISUAL INSPECTION

5.3

HOLIDAY DETECTION

5.4

COUPON REMOVAL

5.5

SOUNDING OF COATING

5.6

ADHESION TESTING

5.7

THICKNESS MEASUREMENT

5.8

LIGHTING

6.

REPAIRS

7.

DOCUMENTATION

8.

REFERENCES

1.

NTRODUCTION

1.1

SCOPE
This SPECIFICATION defines the minimum technical requirements during the performance of all
work necessary to receive, stockpile, clean, prime, coat and wrapx hot asphalt enamel to the
external surface, store and load out after coating the line pipe when such operations are carried
out in a stationary yard.
The CONTRACTOR shall furnish the required coating materials, supervision, labour, equipment,
testing, inspection, the work site, plant space, stockpile areas, services and expenses incidental
to and necessary for the activities listed herein and in a manner satisfactory to the COMPANY.

1.2

DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by PETRONAS, the distribution of this PTS is confined to
companies forming part of PETRONAS group and to contractors nominated by them.
This PTS is intended for use in oil refineries, gas handling installations, chemical plants, oil and
gas production facilities, and supply/marketing installations.
If national and/or local regulations exist in which some of the requirements may be more
stringent than in this PTS the Contractor/Seller shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be acceptable
as regards safety, environmental, economic and legal aspects. In all cases the Contractor/Seller
shall inform the Principal of any deviation from the requirements of this PTS which is considered
to be necessary in order to comply with national and/or local regulations. The Principal may then
negotiate with the Authorities concerned with the object of obtaining agreement to follow this
PTS as closely as possible.

1.3

DEFINITIONS
The following definitions shall apply for the SPECIFICATION
Company - PETRONAS (also referred to as the Principal) or any duly appointed Party
authorised to act for, and on its behalf.
Contractor - a Party to a contract with the Company (Principal) that is responsible for the
external coating of line pipe for offshore use. The Company (Principal) may undertake all or part
of the duties of the Contractor.
Principal - a Party, or an agent authorised to act for and on its behalf that generally specifies the
technical requirements, initiates the Work and ultimately pays for the execution of that Work The
Principal shall mean Company unless otherwise specified.
Seller a Party to a purchase order with the Company (Principal) that is responsible for the
supply of all or part of any Facility, Product or Service to perform the duties specified by the
Company (Principal) The Company (Principal) may undertake all or part of the duties of the
Seller/Supplier.
Specification - PTS 20.146 "Coating and. Wrapping of Line Pipe" plus any referenced code,
standard or specification.
Work - The collective term which includes the furnishing of all labour, material, tools and
equipment required to apply an external asphalt enamel coating system onto Company supplied
line pipe plus all quality assurance and control measures to assure compliance with the
SPECIFICATION as documented in the Contractor's Quality Assurance and Quality Control
Manual.
The words Shall and Will indicate a requirement
The word Should indicates a recommendation.
The word May indicates an option.

1.4

CROSS-REFERENCES
Where cross-references to other parts of this document are made, the referenced section
number is shown in brackets thus (-). Other documents referenced in this document are listed
under References.

2.

RESPONSIBILITIES

2.1

GENERAL
The CONTRACTOR shall comply with the requirements for receiving, hauling, handling,
unloading, storage and loading of line pipe and other associated materials as given in PTS
50.013.
The CONTRACTOR shall be fully responsible for the line pipe and for the external coatings after
the coating application. Any damage to the line pipe and/or the coatings shall be repaired in
accordance with COMPANY approved procedures.

2.2

PROCEDURES
The CONTRACTOR shall prepare a fully definitive set of procedures covering all operations
required for the coating of the linepipe, sequenced in the order that the WORK is to be
performed. The procedures shall be submitted to the COMPANY for approval within thirty (30)
days of the award of the contract.
The procedures, submitted to the COMPANY for approval, shall include the following
information:

2.3

Proposed pipe cleaning procedure i e. shot blasting method and details of abrasives
proposed plus type of solvents and other cleaning methods

Manufacturer and trade name of the primer including the methods of application, storage,
handling and the types/names of compatible enamels.

Manufacturer and trade name of the asphalt enamel including the methods of application,
storage, handling plus the types/names of compatible primers and felt outer wraps.
Proposed kettles for melting the asphalt enamel.

Manufacturer and trade name of the felt outer wrap including the methods of application,
storage, handling and the types/names of compatible enamels.

Testing and inspection procedures for all phases of the work.

Proposed coating repair procedures.

Proposed handling and storage of bare and coated line pipe complete with joint
identification/tracing methods, long/short term storage techniques and other relevant
information.

A detailed Quality Assurance and Quality Control Manual. The manual shall be fully
descriptive of all Quality Assurance and Control Procedures proposed, during the
performance of the WORK to ensure compliance with the requirement of the
SPECIFICATION. Prior to the commencement of the WORK the CONTRACTOR shall revise
the manual in accordance with the comments received or justify, to the satisfaction of the
COMPANY, why no revision should be made to the proposed procedures. All inspections by
the CONTRACTOR shall be performed in accordance with the procedures contained in the
approved manual.

CODES AND STANDARDS

The CONTRACTOR shall make available for the COMPANY's use, a legible copy of the relevant
national and international codes and standards, complete with amendments, referenced herein.
The latest revision or edition approved at the date of the tender shall be applicable.
In the event of contradictions between the SPECIFICATION and the referenced codes and
standards, the requirements contained in the SPECIFICATION shall govern.

3.

MATERIALS

3.1

GENERAL
The CONTRACTOR is responsible for providing all material required for the performance of the
work. All material shall be supplied, in COMPANY approved packages, with manufacturing
information such as name of manufacturer, batch number, date of manufacture and relevant
manufacturing specification or standard clearly marked on the exterior of the package.
The CONTRACTOR shall provide the COMPANY with supporting documentation from the
manufacture which verify the product supplied complies with the SPECIFICATION. The
documentation shall reference batch number, date of manufacture, testing authority and
certification of product acceptance to the specified standard or specification.
The CONTRACTOR shall be responsible for the storage and handling of the cleaning, priming
and coating materials in accordance with the COMPANY approved procedures The
CONTRACTOR shall be responsible for the removal and disposal of coating materials that, in
the opinion of the COMPANY, have become contaminated with foreign matter or have
deteriorated to a condition that is contrary to the manufacturer recommendations.
The CONTRACTOR shall submit samples of the proposed glass fibre reinforcement and
impregnated felt outer wrap for approval by the COMPANY. The COMPANY's written approval
of the use of the above materials shall be obtained before commencing the coating operation.
The CONTRACTOR shall be responsible for performing and assessing the result of the
performance test as specified in the SPECIFICATION.

3.2

PRIMER
The primer shall comply with the requirements contained in British Standard BS 4147 Type B
(chlorinated rubber/syntethic/fast drying) .
Viscosity test of the primer shall be carried out once per shift/day during the performance of the
WORK. The test shall comply with requirements depicted in BS 4147, Section 7.
Each batch of the primer, proposed for the WORK shall be tested for percentage of volatile
matter. The test shall comply with the requirements in BS 4147, Section 7.
Alternative primer BS-4147 Type A grade b shall comply with the requirements of BS 4147,
Section 6.

3.3

ASPHALT ENAMEL
The asphalt enamel shall be manufactured, stored and handled in accordance with the
requirements contained in BS 4147 Type 2 grade b Certification of the manufacturing
compliance with BS 4147 (i.e. Tables 6 & 7) shall be provided to the COMPANY. The grade of
bitumen utilized during the manufacture of the asphalt enamel shall be blown asphalt bitumen
115/15 (as manufactured by the COMPANY) or a COMPANY approved equivalent.
The CONTRACTOR shall be responsible for the performance of the production testing of the hot
asphalt enamel. Production testing with the exception of penetration and softening point tests,
shall be performed once per batch of enamel or once per shift/day whichever is more frequent
Penetration and softening point tests shall be performed once per batch of enamel or twice per
shift/day whichever is more frequent. Samples for the penetration and softening point tests shall
be taken from the point of asphalt enamel application.
The asphalt enamel shall comply with the following:
Penetrant Test
(100g/5 sec @ 25C)

0.5 mm minimum
2 mm Maximum

Softening Point
(Ring and Ball)

115C Minimum
130C Maximum

Filler Content
(ref. BS 4450)

25% Minimum
35% Maximum

Specific Gravity
@ 25C

1.2 Minimum
1.4 Maximum

In the event the CONTRACTOR elects to use COMPANY's pipe asphalt R11 5/15 export grade
(filled to comply with BS 4147 Type 2 grade b) type asphalt-enamel, notification to the product's
marketing company shall be made of the schedule requirements at the time of contract award.
The CONTRACTOR shall provide adequate space for stockpiling a buffer stock of Shell pipe
asphalt enamel sufficient to supply the scheduled coating program requirements.
The CONTRACTOR is free to propose the use of an alternative type of asphalt enamel and shall
in such case provide full details including the applicable specifications for the proposed enamel
material, compatibility of enamel/primer and so forth.

3.4

GLASS FIBRE REINFORCEMENT

The glass fibre shall be a mat type composite material made of chemically resistance boro
silicate glass (per ASTM C162) hydrolytic class 3 in accordance with ISO 719.
The glass fibre reinforcement shall consist of filaments varying from 13 to 25 microns in
diameter, spread in a uniform pattern pasted together and reinforced in the longitudinal direction.
The reinforcements shall be spaced at a maximum distance of 30 mm in the longitudinal
2
direction. The mat shall possess a porosity of 8 to 16 N/m (Per ASTM D737 modified).
Sampling and testing of the glass fibre shall be performed in accordance with ANSl/AWWA
C203 and ASTM D146.
The glass fibre shall comply with the following minimum physical characteristics:

3.5

Thickness
(ref. ASTM D146)

0.3 mm (Minimum)

Breaking Strength
(ref. ASTM D146)

3 N/mm longitudinal (Minimum)

1.4 N/mm Transverse (Minimum)

Bending
(ref. ANSI/AWWA C203)

The glass fibre shall not break when

bent over mandrel of 3 mm radius at
25C through a 90 arc at a uniform
speed in approximately 2 seconds

Glass Fibre Content After

Annealing(ref. ASTM D146)

45 g/m (Minimum)

Width

150 mm (minimum)

OUTER WRAP
The impregnated felt outer wrap shall consist of a felt of non-asbestos/glass fibre based material
bound together with an inert bonding material impregnated with petroleum bitumen. The
manufacturing, storage and handling of the outer wrap shall comply with the requirements
contained in ANSI/AWWA C203 for glass fibre outer wraps. All material property testing shall be
performed in accordance with the requirements contained in ASTM D146.
The outer wrap shall be reinforced in the longitudinal direction at a spacing of 10 mm centre to
centre. The glass tissue shall consist chemically resistant borosilicate glass (ASTM C162),
hydrolytic crass 3 (ISO 719). The outer wrap shall be impregnated with bitumen (filler content 25
to 35%) in accordance with ANSI/AWWA C203
The CONTRACTOR shall ensure the outer wrap complies with the requirements depicted in the
SPECIFICATION. Sampling and testing of the outer wrap shall be performed in accordance with
ANSI/AWWA C203 and ASTM D146
Sampling and testing shall be performed in accordance with ANSI/AWWA C203 and ASTM
D146. The outer wrap proposed for the WORK shall comply with the following physical
characteristics.
Thickness(ref. ASTM D146)

0.6 mm (Minimum

6.5 N/mm longitudinal (Minimum)

3 N/mm Transverse (Minimum)

The outer wrap shall show no sign of

cracking when the sample is bent around
a mandrel of 25mm cm in diameter
through a 180 arc at a uniform speed in
approximately 2 seconds .

Breaking Strength(ref. ASTM D146)

Bending(ref. ANSI/AWWA C203)

Glass Fibre Content After Annealing

(ref. ASTM D146)

Weight
(ref. ASTM D146)

600g/m2 (Minimum

Width

150 mm (minimum)

2
50 g/m (Minimum)

4.

COATING APPLICATION

4.1

GENERAL
The CONTRACTOR shall clean the pipe joints plus prepare, store, handle and apply the coating
materials in accordance with the COMPANY approved procedures noted in Section 2.2 herein
above. The approved procedures shall comply with the requirements contained within the
SPECIFICATION and ANSI/AWWA C203 plus manufacturer's recommendations.
The coating system to be applied shall consist of the following :
A primer
A layer of asphalt enamel
A layer of glass fibre reinforcement
A layer of asphalt enamel.
A layer of glass fibre reinforcement
A layer of asphalt-enamel.
An impregnated felt outer wrap
The coating system shall have the following finished thickness.
Minimum on pipe body

4.5 mm

Maximum on pipe body

6.5 mm

Minimum on pipe weld (if applicable)

4.0 mm

Upon completion and acceptance of the line pipe coating, by the COMPANY, the
CONTRACTOR shall provide protection against solar heat damage to the coated line pipe. The
solar protection shall consist of a white (lime) wash or a COMPANY approved equivalent.
4.2

CLEANING
Pipes will be provided by the COMPANY, free of mill applied oils, grease, lacquer or
preservatives with the exception of a protective coating over the mill/heat identification numbers .
The CONTRACTOR shall thoroughly clean and dry the line pipe. All subsequent minor
contamination such as dint, dust, rust, scale, mill lacquer, moisture, oil, grease and other
impurities shall be removed from the line pipe surface by the CONTRACTOR.
The ends of the pipe shall be protected by the CONTRACTOR with plugs or other means to
prevent entry of abrasives into the pipe during blast cleaning. Special care shall be exercised to
ensure that the pipe number on the inside of the pipe is protected. Any abrasives entering the
pipe shall be removed prior to coating. The method of protection shall not utilise any oil or
grease compounds that may affect welding on the lay barge.
The external surface of the line pipe shall be cleaned by rotary blast cleaning. After blast
cleaning treatment, the external surface of the line pipe shall correspond to Grade Sa 2.5 of ISO
8501-1 (SIS 05 59 00). The blast cleaning abrasives used shall be a manufactured iron grit or
copper slag. Sand shall not be used as a blast cleaning abrasive.
The cleaning of the line pipe shall be so controlled as to prevent burnishing or injurious abrasion
of the line pipe metal.
The permissible degree of surface roughness or "maximum profile" after blast cleaning shall be
in the average range of 0.05 mm to 0.10 mm as measured by TESTTEX or an approved
equivalent. The "maximum profile" is defined as the greatest vertical distance between the
summit of any peak on the blast cleaned surface and the bottom of an immediately adjacent
trough. Profile measurements shall be performed by the CONTRACTOR at least once per
shift/day at three random locations of a pipe length.
Any surface which shows signs of contamination from blasting and/or handling after blasting
shall be cleaned and reblasted. If necessary, the contaminated surface shall be brushed with a
clean brush made of hair, bristle or fibre, or blown off with compressed air (free from oil, grease
and water) or cleaned by vacuum to remove all traces of the blast cleaning products from the
surface.
The blast cleaning operation shall not be conducted on surfaces that are less than 3C above
the dew point or when the relative humidity is greater than 85 percent, unless preheating of the
line pipe is performed. Blast cleaning under these conditions may be performed provided the line
pipe can be warmed to a temperature (not to exceed 50 C) sufficient to perform the blasting
operation .
The surface shall be thoroughly dry before the primer is applied. Immediately prior to priming,
the cleanliness of the pipe joint shall comply with the requirements of ISO 8501-1 (SIS 05 59 00)
Sa 2.5. Any pipe surfaces which shows signs of rusting prior to priming shall be re blast cleaned
to the required standard.

4.3

PRIMING
The CONTRACTOR shall thoroughly prime the line pipe before coating and shall remove primer
from the bevels and ends of the line pipe. The priming shall be carried out within15 minutes after
the line pipe has been cleaned in accordance with Section 4.2 herein above.
The primer shall be applied by a continual process in a thin layer of a uniform thickness of 0.02
to 0.03 mm dry film thickness (DFT) without runs, sags or drips. Line pipes not so primed shall
be and properly reprimed in accordance with the SPECIFICATION.
The drying time stipulated by the primer manufacturer shall be allowed to pass before
application of the enamel. Freshly primed line pipe shall be supported so that it will not come into
contact with contaminants. All line pipe on which primer has become dead or has accumulated
an excessive coat of dust and/or moisture before the primer is dry or has been exposed to the
weather for more than 48 hours after application of the primer shall be cleaned, and reprimed
before application of the enamel. No primer shall be applied within 50 mm from the ends of the
pipe joints.
The CONTRACTOR shall perform and assess the required production tests as required within
the SPECIFICATION. The wet film thickness of the primer shall be measured at least once per
shift/day to ensure that the correct dry film thickness is achieved.

4.4

PREPARATION OF ENAMEL
The CONTRACTOR shall prepare the asphalt enamel for application in accordance with the
requirements contained in ANSI/AWWA C203 The enamel may be loaded into kettles in either a
liquid or solid form.
In the event the asphalt enamel is provided in the solid form it shall he discharged into the
kettles in such a manner as to avoid contamination with water, dirt or other foreign substances
The kettles shall be cleaned before filling with asphalt enamel and whenever coke or other
deposits have formed on the heating surface.
A 1.6 mm mesh strainer shall be located at the outlet in such a manner that it can be cleaned
easily. The temperature during storage and melting shall not exceed the application temperature
less 28C, until within one hour of the time of application. One hour prior to application the
temperature of the enamel shall be raised to the application temperature recommended by the
enamel manufacturer.
The enamel shall be at a uniform temperature throughout the kettles during the time of use and,
therefore, additional unmelted enamel shall not be added to kettles while the enamel is being
drawn for application. The kettles shall be equipped with mechanical metal stirring devices or
shall be self agitating type kettles.
The kettles shall have thermometers (accuracy 3C) to indicate the temperature in the hottest
part of the kettle. The CONTRACTOR shall ensure that spare thermometers are available. Care
shall be exercised during melting of enamel to prevent localized overheating.
Enamel which in the opinion of the COMPANY has been damaged by prolonged heating or
overheating or by other mishandling shall not be used for the work. Coating operations shall be
carried out only when weather conditions are suitable in the opinion of the COMPANY.
At the end of the shift/day, the kettles used for the work shall be emptied and cleaned.
Recovered enamel products shall not be used under any circumstances.

4.5

APPLICATION OF ENAMEL AND WRAPPING

The CONTRACTOR shall apply the asphalt enamel and wrapping in accordance with the
requirements contained in ANSI/AWWA C203. (Prior to application of the asphalt enamel the
CONTRACTOR shall ensure that the primed pipe surface is free of dirt, dust and other
deleterious material). Primed pipe joints designated as contaminated by the COMPANY shall be
recleaned and primed to the requirements as specified under Section4.2 and 4.3 respectively.
The CONTRACTOR shall apply the asphalt enamel in an even coating at a temperature to
manufacturers recommendation between 215 C and 245 C over the entire surface of the pipe
length except for a distance of 250 mm 10mm from each end of the pipe. The CONTRACTOR
shall adjust the thickness of the coating system to ensure that any protruding weld has a
minimum coating of 4 mm.
The enamel applied shall be beveled over a length of at least 25 mm at each of the ends.
Tapering of each end of the asphalt enamel layer shall be performed by gas burning and
tapering.
The CONTRACTOR shall apply a total of two layers of glass reinforcement during the
application of the asphalt enamel. The glass reinforcement shall be applied in a uniform spiral
wrap with an overlap of 12 to 25 mm. The glass reinforcement shall be pulled into the enamel
before cooling in order that an even distribution of reinforcement is achieved. The glass fibre
reinforcement shall not touch the primed surface of the line pipe or remain-exposed to the outer
wrap. The glass reinforcement shall be embedded within the middle 33% of the relevant asphalt
enamel layer.
A bitumen impregnated felt outer wrap shall be immediately applied after the application of the
glass fibre reinforcement and asphalt enamel layers. The felt outer wrap shall be applied in a
uniform spiral wrap with an overlap of 12 to 25 mm. The felt wrap shall be applied before the
enamel cools in such a manner that the latter wrap is in contact with the entire surface of the
enamel.
The resultant coating shall be free of wrinkling, pinholes, bubbles, voids, laminations holidays
dry wrap plus any contamination All end laps shall be secured to the line pipe using hot enamel
to form a bond to the pipe surface.

4.6

WHITE WASH
All coated pipe lengths other than those that are to be within 48 hours concrete coated shall be
white washed to reduce solar heat damage. The white wash used shall he made up as follows:
190 litres water
4 litres boiled linseed oil
82 kg. unsalted quick lime
5.5 kg. sodium chloride
The lime and oil (boiling) shall be added to the water at the same time and mixed thoroughly and
the mixture shall be allowed to stand 3 days before using.
The white wash shall be kept in a large container having a self contained mechanically operated
agitator. The white wash shall be applied to the line pipe by a power operated pump through
appropriate sprays and rubbing cloths or other means approved by the COMPANY

4.7

PIPE STORAGE
After the line pipe has been coated it shall be rolled for end trimming inspection and cooling on
solidly constructed racks with retractable pipe stoppers with sufficient length to hold a minimum
of 70 line pipe joints.
No coated line pipe shall be lifted or handled in any way until the coating has cooled down. The
coated line pipe shall be supported at Ieast 150 mm clear of the ground by placing timber skids
beneath the bare ends or by placing on high, broad, double rows of fine sand. The sand rows
shall be covered with polyethylene sheeting to prevent contact between the moist sand and
coating surface.
Pipes shall not be stacked on each other without adequate padding.

INSPECTION AND REPAIRS

5.1

GENERAL
The COMPANY shall have the right to perform destructive and non destructive testing during the
performance of the WORK. Testing by the COMPANY will not negate the CONTRACTOR's
responsibilities to perform the material quality and production testing as specified in the
SPECIFICATION .
Inspection of the coated line pipe shall be in the form of, but not limited to, visual checks, holiday
detection, removal of coupons, sounding of coating, adhesion testing, and thickness
measurements. The CONTRACTOR shall be responsible to document all test including visual
checks required by the COMPANY. The repair of all cut out areas and other defects in the
coating, as a result of the inspection/testing, shall be performed by the CONTRACTOR and
deemed to be included in the WORK.
If the pipe lengths selected for the inspection and testing specified herein show defects or
failures which the COMPANY defines as cause for rejection the CONTRACTOR shall test the
five (5) pipe lengths coated immediately prior to and following the rejected pipe length. If further
defects or failures are detected then the entire production for that shift/day shall be inspected by
the CONTRACTOR. Additional WORK incurred through the inspection and testing of the
additional pipe lengths shall be the responsibility of the CONTRACTOR and deemed to be
included in the WORK.
In the event the total production reject rate per batch is higher than 10% the COMPANY may, at
its discretion, reject the entire batch associated with the defects or failures. Upon rejection of an
entire batch the CONTRACTOR shall immediately instigate an investigation into the cause of the
defects or failures Production shall not recommence until the COMPANY is supplied with an
acceptable explanation, in writing, of the reasons for the defects or failures and actions taken by
the CONTRACTOR to avoid a reoccurrence in the future.

5.2

VISUAL INSPECTION
The CONTRACTOR shall perform visual inspection on the quality of the materials and
application of the various coating components. The visual inspections shall be performed once
per shift/day and shall include the primer, asphalt enamel, glass fibre reinforcement wrap and
bitumen impregnated felt outer wrap. Visual checks shall be made of pipe-ends to ensure the
required cut back distances are free of coating. Additionally the interior of all coated pipe lengths
shall be visually inspected to ensure that all dirt, grit/shot or other foreign contaminants are
removed.

5 .3

HOLIDAY DETECTION
The CONTRACTOR shall furnish, operate and maintain holiday detectors, approved by the
COMPANY for the WORK. The CONTRACTOR shall also ensure that the following spares are
available at all times during the operation: holiday detectors, fully charged batteries, detector
springs, rings and brushes .
Every coated pipe shall be spark tested with the holiday detector Test voltage shall be as
specified in NACE Standard RP0274. All holiday detection shall be performed prior to the
application of the white wash type solar protection
All holiday detectors utilized for the WORK shall be calibrated in accordance with manufacturer's
recommendations and COMPANY approved procedures. Calibration of the holiday detectors
shall be performed by the CONTRACTOR at the beginning of each shift/day to the satisfaction of
the COMPANY.
The CONTRACTOR shall provide the necessary equipment and qualified personnel to calibrate
the holiday detectors. after the calibration of the holiday detector the electrode shall be passed
over the coated pipe length surface at a rate ranging from 250 to 350 mm/sec.
In the event that the CONTRACTOR is unable to satisfactorily detect holidays, at the direction of
the COMPANY, the coating operation shall be immediately stopped until a satisfactory detector
is provided. The COMPANY may choose to furnish holiday detectors if it so desires.

5.4

COUPON REMOVAL
The CONTRACTOR shall perform an inspection of the distribution of the glass fibre
reinforcements within the asphalt enamel layers, by the removal of coupons from COMPANY
selected pipe lengths. These coupons may serve to determine the thickness and bonding of the
coating at discretion of the COMPANY. The coupon, size 100 mm x 150 mm, shall he taken from
the 1/4, 1/2 and 3/4 position along the pipe length. One of the coupons shall be removed along
the longitudinal weld, if one exists.
The removal of coupons shall be performed at a frequency of one (1) in twenty (20) pipe lengths
coated for the first one hundred pieces. If the results of the tests are acceptable, the testing
frequency may be reduced to two (2) pipe lengths per shift day, at the discretion of the
COMPANY.
If any of the coupons taken indicate that the coating is not in accordance with the
SPECIFICATION, the CONTRACTOR shall remove the defective coating along the entire pipe
length .

5.5

SOUNDING OF COATING
The CONTRACTOR shall perform an inspection for voids within the coating by sounding or
ringing along the pipe length. The coating shall be sounded or rung out by mean of tapping with
a blunt instrument or mallet to detect voids The sampling frequency for the sounding shall be
one (1) in twenty (20) coated pipe lengths.
Voids detected during the sounding shall be repaired in accordance with Section 6.
If more than five voids are detected in one pipe length the coating shall be removed for the entire
length of the pipe.

5.6

ADHESION TESTING
The CONTRACTOR shall perform adhesion testing on one (1) pipe in every twenty (20) coated.
Tests shall be performed at the 1/4, 1/2 and 3/4 positions along the pipe length to the
satisfaction of the COMPANY. One (1) sample specified for adhesion testing shall be positioned
perpendicular to the longitudinal weld, if one exists
Adhesion testing shall be performed on pipe lengths selected by the COMPANY. Adhesion
testing shall be carried out between twelve (12) and twenty four (24) hours after coating. The
surface temperature of the pipe length to be tested shall be at ambient temperature of not less
than 21 C and not more than 30 C.
Adhesion testing shall be performed on a sample made by using a heated sharp blade to cut out
a section 150 mm long by 25 mm wide. The section shall be cut perpendicular to the two edges
at one end only. A flat spatula of 25 mm width, shall be inserted at the perpendicular cut. Once
sufficient coating is lift from the pipe surface an attempt shall be made to peel the coating by
pulling the sample away from the surface of the pipe
The test shall be acceptable if no adhesion failure of the coating and/or no cohesive failure
within the coating occurred on any sample tested. If any of the samples taken indicate that the
coating is not in accordance with the SPECIFICATION, the CONTRACTOR shall remove the
defective coating along the entire pipe length.
If the total number of pipe lengths is larger than hundred (100) and if the result of the testing is
acceptable, the COMPANY may elect to reduce the frequency from one (1) in every twenty (20)
to two (2) pipe lengths per shift/day.

5.7

THICKNESS MEASUREMENT
The CONTRACTOR shall perform thickness measurements, using a COMPANY approved film
thickness gauge on each pipe length coated. Three locations shall be randomly selected, or as
specified by the COMPANY, for measurement of the applied coating. In particular, if a
longitudinal weld seam exists, thickness measurements shall be taken at two locations along the
weld.
The film thickness gauge, provided by the CONTRACTOR, shall be the magnetic or electro
magnetic type. The gauge shall be calibrated as a minimum twice daily. Calibration of the
instrument shall be performed in accordance with the manufacturers recommendation and
COMPANY approved procedures.
The first ten pipes in every shift shall be subjected to a minimum of 12 thickness checks at three
equidistant locations spread over the total length of the pipe at the 3, 6, 9 and 12 o'clock position
around the circumference. For welded pipe one of these positions shall be over the weld. In the
event the average of coating thickness is less than 4.5 mm the coating shall be removed for the
entire length of the pipe. If the average is more than the 4.5 mm then for low spots measuring
less than 75% of 4.5 mm i.e. Iess than 3.4 mm, the coating shall be removed around the low
spot plus an extra 20 mm. The coating shall then be repaired in accordance with Section 6.

58

LIGHTING
A proper lighting system shall be provided by the CONTRACTOR in the cleaning, priming
coating and inspection areas. Minimum light intensities shall be as follows:

6.

Generally

300 Im/m

Surface Inspection

500 Im/m

REPAIRS
Any defective part of the coating such as holidays, voids tears or damaged spots and so forth
shall be clearly marked and repaired by the CONTRACTOR to the satisfaction of the COMPANY
Repairs shall be effected using procedures previously approved by the COMPANY.
Repairs to the enamel coating shall be made by removing the wrap over the damaged coating in
a manner that does not disbond the adjacent coating. The repair area shall be heated to remove
any moisture, primed and hot enamel shall be poured or "ragged" over the area The felt wrap
shall then be embedded and bonded to the asphalt enamel. All coating repairs shall be made
with the wrap smoothly applied and without wrinkles or buckles. Repairs shall be at least equal in
effectiveness to the coating applied to the principal part of the line pipe All repairs shall
successfully pass testing by the electronic holiday detector

7.

DOCUMENTATION
The identity of each line pipe joint shall be preserved during the performance of the WORK. Each
joint of line pipe shall be identified after coating by a sequential number using low stress
stamping. The sequential number system shall reference the length of each pipe length together
with the original pipe mill identification plus heat numbers recorded inside the line pipe at each
end of the pipe.
A certified permanent record shall contain the original copies of all documentation produced
during the performance of the WORK. The permanent record shall be supplied to the COMPANY
showing the sequential and serial numbers, pipe mill, pipe mill number, heat number, joint length
and date of coating for each pipe length. Additionally the permanent record shall contain the
results of all production testing performed by the CONTRACTOR as required by the
SPECIFICATION. The production test records shall include a statement by the CONTRACTOR
indicating the acceptability or rejection of the test.

8.

REFERENCES
The latest revisions/editions are applicable:
PETRONAS TECHNICAL STANDARDS
PTS 50.013

Handling, Storage and Preservation of Materials/Equipment.

External Standards
ANSI/AWWA C203

Coal-Tar Protective Coatings and Linings for Steel Water Pipelines,

Enamel and Tape. Hot Applied

ASTM C162

Glass and Glass Products, Definition of Terms

ASTM D146

Methods of Sampling and Testing Bitumen Saturated Felts and

Fabrics used in Water Proofing and Roofing.

ASTM D737

Test Method for Air Permeability of Textile Fabrics.

BS 4147

Bitumen based hot applied coating materials for protecting iron and
steel, including suitable primers where required.

BS 4450

Determination of ash from petroleum products.

ISO 719

Hydrolytic resistance of glass at 98C method of test and classification.

ISO 8501-1

Preparation of steel substrates before application of paints and related

products. Visual acceptance of surface cleanliness (pictorial surface
preparation standard for painting steel surfaces)

(SIS 05 59 00)
NACE RP0274

High Voltage Electrical Inspection of Pipeline Coatings Prior to

Installation. 1 .0