05_Vol IIIB-Sec 4.6_Pipeline Specs

7/27/2019 05_Vol IIIB-Sec 4.6_Pipeline Specs

1/178

DESIGN DIVISION

ENGINEERING

SERVICES

SPECIFICATIONS

(Pipeline)

VOL III

Rev. No. 0

TRIPURA GAS GGS AND

PIPELINE PROJECT

Section 4.6

SHEET 1 OF 2

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:DD/SOF/004A DD/SOP/008 TO 015 02 01 12/01/2007

SECTION 4.6

PIPELINESPECIFICATIONS


2/178

DESIGN DIVISION

ENGINEERING

SERVICES

SPECIFICATIONS

(Pipeline)

VOL III

Rev. No. 0

TRIPURA GAS GGS AND

PIPELINE PROJECT

Section 4.6

SHEET 2 OF 2

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:DD/SOF/004A DD/SOP/008 TO 015 02 01 12/01/2007

TABLE OF CONTENTS

SPECIFICATION NO. TITLE

2101 Geotechnical & Hydrographic

Investigation for Water Crossings

2102 3 Layer Polyethylene Coating

2103 Field Joint Coating System

2104 Pipeline welding

2105 Trenchless Operation

2106 Concrete Weight Coating

2107 Line Pipes


3/178

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:

ODS/SOF/004B ODS/SOP/008 TO 015 02 01 01/08/2006

Design Division

Engineering Services

ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

GEO-TECHNICAL

INVESTIGATION &

HYDROGRAPHIC

INVESTIGATION

SPEC. No. 2101

Rev. No. 1

Discipline: Pipeline

PAGE :

1OF

1

FUNCTIONAL SPECIFICATIONS

FOR

GEO-TECHNICAL INVESTIGATION

&

HYDROGRAPHIC INVESTIGATION

FOR

WATER CROSSINGS

PREPARED /REVISED BY

REVIEWED BY APPROVED BYTOTAL No.OF PAGES

DATE REV. No.

KRK SN PKM 15 06.10.2005 1


4/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

GEO-TECHNICAL

INVESTIGATION &

HYDROGRAPHIC

INVESTIGATION

SPEC. No. 2101

Rev. No. 1


PAGE :

2OF

2

PART-A

TECHNICAL SPECIFICATIONFOR

GEO-TECHNICAL INVESTIGATION &HYDROGRAPHIC INVESTIGATION FOR WATER CROSSINGS

1.0 INTRODUCTION

This specification deals with detailed hydrographic survey and collection ofGeotechnical parameters including soil investigation proposed to be carriedout for river crossings.

The number of bore hole to be survey type shall be decided on the basis ofCategory of river/water bodies.

2.0 OBJECTIVE

The objective of Hydrographic investigation is to obtain riverbed profile,nature of bed material, hydrographic data. The purpose of obtaining this datais to establish accurate bed profiles, to map surface features in the rivercrossing and to obtain scour profiles at crossing location.

Similarly, the requirement of soil investigation is to develop various soil

parameters for calculation of scour depth and installation of pipeline.

3.0 SCOPE OF WORK

Depending upon the bank to bank width of river/water body the scope of workshall be decided in consultation with the Company :

3.1 Soil Investigation

The work comprises, but not limited to the following :


5/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

GEO-TECHNICAL

INVESTIGATION &

HYDROGRAPHIC

INVESTIGATION

SPEC. No. 2101

Rev. No. 1


PAGE :

3OF

3

a) Bore Holes up to 10m below GL (At least one for rivers having bank tobank width less than 30 m and 1 nos each at the bank on one side andcenter of river having bank to bank width 30-50 m).

b) Standard Penetration tests and collections of disturbed and undisturbedsoil sample from bore holes at every 2.0m interval and change of strata.

c) Laboratory tests on soil samples collected.d) Submission of reports in four number of copies.

3.1.1 Requirement

The work shall be carried out in line with the relevant clauses of the attachedtechnical specification for soil investigation (Part-I). For boring in water,suitable arrangement shall be made by the Contractor. Borehole shall bemeasured from riverbed level/GL.

3.2 Hydrographic Investigations

The scope of work for hydrological investigations shall be as follows or asdirected by the Company.

i) To carry out hydrographic surveys in river crossings along the proposedpipeline routes.

ii) To collect, store, transport and analyze river bed samples of rivers asspecified.

iii) To process all the survey data in order to establish accurate bed profiles,surfacial features both dry bed as well as under water areas.

iv) To assess geological and geotechnical nature of the material in the closevicinity of the proposed pipeline crossing.

v) To obtain scour profile at pipeline crossing location for the river.

3.2.1 Scope of work for hydrographic investigation work comprises of thefollowing:-

The work shall be carried out in line with the relevant clauses of the attachedTechnical Specification for hydrographic investigation (Part-II).


6/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

GEO-TECHNICAL

INVESTIGATION &

HYDROGRAPHIC

INVESTIGATION

SPEC. No. 2101

Rev. No. 1


PAGE :

4OF

4

The work shall be carried out in line with the relevant clauses of the attachedTechnical Specification for hydrographic investigation (Part-II).

4.0 INSPECTION OF WORK :

4.1 The work is subject to inspection/ supervision at all times by the Company.The Contractor shall carry out all instructions given during inspection andshall ensure that the work is being carried out according to technicalspecifications, the technical documents and the relevant codes of practice.

4.2 All the survey details collected by the Contractor shall be furnished to theCompany in the form of a survey report.

5.0 SITE CLEANING AND RESTORATION :

5.1 The contractor shall take care for cleaning the area from time to time for easyaccess to work site and also from safety point of view.

5.2 Working site should be kept cleaned and ground restoration shall be up to theentire satisfaction of the Company.

a) River Bank Grid Survey As per Technical Specifications attached

b) Historical data collection onHFL/LWL Regime, siltfactor, river course etc.

As available from authentic sources /local enquiry

c) Determination of scourdepth

From the grain size distribution on thebasis of results of exploratory boreholes

d) Submission of Report A draft report in 2 sets and final report in4 sets shall be submitted by contractor.The reports shall include a write-up onproposed methodology for river crossing


7/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

GEO-TECHNICAL

INVESTIGATION &

HYDROGRAPHIC

INVESTIGATION

SPEC. No. 2101

Rev. No. 1


PAGE :

5OF

5

PART I

TECHNICAL SPECIFICATIONS FOR SOIL INVESTIGATION

1.0 SPECIAL INSTRUCTION

1.1 Each boring and field test shall be conducted under the direct supervision ofa qualified and experienced engineer. The bore hole locations shall first befixed at site with reference to a permanent reference point. A reportincorporating all field observation test findings and recommendations forfoundations at different depth with allowable settlements shall be submitted.

1.2 All data/ informations including any unusual data/ information obtainedduring the execution of the work shall be immediately brought to the noticeof the Company.

1.3 Survey and leveling work for establishing location and levels of bore holesand the contractor shall carry out other exploratory work. However,reference point/ lines will be provided by the Company to successful bidderfor carrying out such work. Depending on site condition, the locations andnos of test can be altered at site, if found necessary by the Company.

1.4 All field investigations, laboratory tests and reports etc., shall be done inaccordance with the latest relevant Indian Standard Codes.

2.0 TECHNICAL SPECIFICATION OF WORK

2.1 Field Investigation and Test

2.1.1 Exploratory bore holes and core drilling

a) BY SHELL & AUGER :

All bore holes shall be of minimum 150 mm in diameter. The exploratorywork at site shall be carried out using shell and auger equipment. Theboreholes shall be terminated at a depth whenever with chiseling andsubsequent cleaning with bailer, the bore hole cannot be advanced more

than 300 mm in one hour. The casing shall be extended up to a maximum


8/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

GEO-TECHNICAL

INVESTIGATION &

HYDROGRAPHIC

INVESTIGATION

SPEC. No. 2101

Rev. No. 1


PAGE :

6OF

6

depth which could be possible as per site conditions. No bentonite mudshall be used to advance boring. Chiseling shall be carried out withminimum 0.5 mm tonne cross type chisel falling from a height of 2.0 m.Chiseling and cleaning with bailer shall be done alternately, eachoperating from 5 to 10 minutes. Refusal to chiseling shall be consideredafter one hour of chiseling or when progress is less than 30 cms. for each200 drops, whichever is later. One bore hole thereafter shall be extendedby core drilling method using Nx size drilling bits untill 50% core recoveryis achieved. Cores shall be properly preserved in core boxes and shall be

handed over to the Company,if required. Whenever clay or other softmaterial is interspersed in rocky strata, the drilling shall continue deeperinto rock to ascertain such formation. Disturbed samples from boring shallbe collected every 2.0 m or change in stratum and representative samplesplaced systematically for proper logging of the strata. The existing groundlevel shall be marked. Proper logging shall be done with description ofdifferent strata encountered with their reduced levels. (Profile of thedifferent strata shall be plotted joining all adjacent boreholes apart fromindividual boreholes. All bore holes after completion of work shallimmediately be filled in with a mixture of bentonite slurry and clay sandmixture).

b) BY MUD CIRCULATION DRILLING :

In case the site conditions require the bore drilling shall be employed usingMud circulation method. It should be adopted in all type of soils. Minimumdia of bore holes shall be 150 mm if the rate of progress of boring in hardstrata is observed to be slow (Not more than 20 cm in two hours)contractor may be permitted to adopt core drilling with Nx size bit.However, the bit for core drilling shall be with double tube core barrel andthis core drilling operation shall be at no extra cost to the Company, solong as to core recovery is less than 25%. Commencement of rock coringshall be considered at a depth below which the core recovery is min 25%.For rock strata encountered having RDQ 50% diamond head of Nx sizeshall be used. Termination of bore holes shall be as indicated below. Maxlength cored in rock shall be limited to 10 x Nx if rock available within 2.0m from the Bed/GL level. Length of rock coring will decrease linearly.

2.1.2 Depth of Bore holes :

2.1.2.1 Depths indicated for bore holes or trial pits or any other depth correspondto the depth from general ground level unless otherwise specified.


9/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

GEO-TECHNICAL

INVESTIGATION &

HYDROGRAPHIC

INVESTIGATION

SPEC. No. 2101

Rev. No. 1


PAGE :

7OF

7

2.1.2.2 Boring shall be done to a minimum depth of 10 meter from the ground level/River Bed level of each location marked in the drawing. However, boringshall be terminated in case hard rock is met at depth lesser thanmentioned above with minimum 500 mm core recovery beyond 3 m depthfrom ground level provided provisions of Clause 2.1.1(a) are met with.Alternatively, in case the mud circulation method is employed the criteriacontained in 2.1.1 shall be met with.

2.1.3 Sampling :

In cohesive and semi cohesive soils, undisturbed samples conforming toIS:2132 shall be taken using open tube samples with an area ratio of lessthan 15% so as to obtain a core of sample of 100 mm diameters and 450mm long at every change in stratum or at intervals of 2.0 meter which everis less. The tube shall be properly marked and the ends of the sampletube shall be sealed properly with wax of thickness not less than 25 mmand capped properly immediately after the sample is recovered from thebore holes to ensure no loss of moisture with time while retained in thetube. Sample tubes shall be immediately shifted to the laboratory fortesting.

2.1.3 Disturbed samples

Representative disturbed samples obtained from boring at every staggered2.0 m interval in depth and change in stratum shall be placed in suitable jarslabeled properly for onward transmission to the laboratory. These samplesshall be sent to the laboratory immediately after the boring is completed. AllSPT samples shall also be similarly preserved.

2.1.4 Standing Ground Water Level :

Records shall be maintained of the level at which water is struck and thelevel of any rapid inflow shall also be recorded. On reaching such level theborehole shall be left open for a period of two hours to observe the rise ofwater in the casing. Bore hole can be continued, thereafter, up to the end ofthe day. The level of water in the casing at the end of the day and at thebeginning of the next day shall be recorded properly. For studying theground water table no drilling mud will be permitted for stabilizing the hole.


10/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

GEO-TECHNICAL

INVESTIGATION &

HYDROGRAPHIC

INVESTIGATION

SPEC. No. 2101

Rev. No. 1


PAGE :

8OF

8

2.2 Laboratory Tests :

2.2.1 Introduction :

Laboratory tests shall be conducted on selected samples collected from siteto establish the physical and chemical properties of soil. Following testsshall be done as appropriate in accordance with latest relevant Indian codeof practice.

i) Natural moisture contentii) Void ratioiii) Liquid, Plastic and Shrinkage limitsiv) Specific gravityv) Dry density and Bulk densityvi) Cohesion and Angle of internal frictionvii) Particle size analysisviii) Identification of coreix) Chemical properties of the soil and subsoil water

2.2.2 Atterberg limits :

Liquid and plastic limit test shall be conducted on all cohesive soils forclassification purposes and for predicting engineering properties. Theresults of limits tests shall be plotted on the plasticity chart of A.Casagrande. Shrinkage limit shall also be determined for half of the soilsamples.

2.2.3 Particle Size Analysis

Particle size analysis shall be done on all clayey and sandy samples. Bothsieve and hydrometric Analysis shall be conducted and gradation curvesshall be plotted to show the Particle size distribution.

2.2.4 Shear Tests

Shear tests shall be conducted on the un-disturbed samples. The cohesionvalue and angle of internal friction are to be determined by Mohrs circlemethod.

2.2.5 Specific gravity and Bulk density

These shall be determined as per standard procedure.


11/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

GEO-TECHNICAL

INVESTIGATION &

HYDROGRAPHIC

INVESTIGATION

SPEC. No. 2101

Rev. No. 1


PAGE :

9OF

9

2.2.6 Standard Penetration Tests

Standard Penetration Tests shall be conducted as per IS Specification inbore hole nos. as specified. These shall be conducted at interval of 1.0 mstarting first test of 1.0 m depth below existing ground level. The disturbedrepresentative samples shall be visually classified, labeled for identificationand properly preserved for laboratory testing.

3.0 REPORT

Brief report as per standard specification shall be prepared and submittedto the Company as soon as the field and laboratory works are completed ina draft form for review and comments. All the information as mentionedbelow shall be furnished in the draft copy of final report. After reviewing,contractor shall be informed about comments/ remarks, if any, the sameshall be incorporated. The report shall also include but not limited tofollowing:-

1. A plot plan showing all the test locations with respect to referencechange.

2. General geological information of the site.3. Procedure of investigation and method of various testing adopted.4. Detailed bore-logs indicating co-ordinates, reduced level, ground

water table etc., subsoil section along various profiles indicatingboreholes nos. depth wise in situ tests like SPT.

5. All field and laboratory test results shall be plotted against depth andalso in tabular form.

6. Summary of results obtained from various tests and theirinterpretation to evaluate various soil parameters.

7. Silt factor for scour able soil strata, borehole and depth wise shall befurnished in a tabular form.

8. Stable slope near bank both in natural as well as excavated states.9. Longitudinal lateral friction co-efficient between pipeline and soil.10. Stable trench slope along the width of the river through.11. Proposal on the type of foundation for pipeline and methodology for

river crossing.12. Anti-buoyancy measures at specified locations.13. Presence of high levels of chlorides, sulphates and other chemically

aggressive elements in soils shall be reported and protectivemeasures suggested.

14. All data be digitised and supported with photographs wherever

necessary.


12/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

GEO-TECHNICAL

INVESTIGATION &

HYDROGRAPHIC

INVESTIGATION

SPEC. No. 2101

Rev. No. 1


PAGE :

10OF

10

PART II

TECHNICAL SPECIFICATION FORHYDROGRAPHIC INVESTIGATION

1.0 SCOPE

These specifications cover the Technical requirement and procedure forHydrographic and Topographic Survey of River.

2.0 EQUIPMENT

The Contractor shall provide boats and all equipments required for carryingout the survey works. Details of the boats and survey equipment includingspecifications along with relevant certificates of the equipment to bemobilized for carrying out the survey works shall be submitted by theContractor. Before setting out for survey mobilization status shall beindicated as per Annexure-I.

2.1 Small Survey Boat

The Contractor shall mobilize a suitable survey boat/ floating Platformequipped with dual-frequency echo-sounder for conducting soundingsurveys in the river.

2.2 Survey Equipment

A dual-frequency precision echo-sounder/sounding poles, distomats, theodolites, sextants, masts, levels etc., as needed for the land and riversurvey shall be mobilized.

2.3 Grab/ bed Materials Samples

The Contractor shall provide a suitable equipment such as grab or pushsampler to sample the bed material.

3.0 PERSONNEL

The Contractor shall provide necessary experienced personnel foroperation of the survey equipment and for conducting field surveys.


13/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

GEO-TECHNICAL

INVESTIGATION &

HYDROGRAPHIC

INVESTIGATION

SPEC. No. 2101

Rev. No. 1


PAGE :

11OF

11

The Contractor shall provide qualified personnel with relevant experience tocollect and assess hydraulic and sedimentalogical parameters.

4.0 REQUIREMENTS & METHODOLOGY

4.1 River Surveys

Bank grid survey of the river bed shall be carried out upto 20 mtrs. on either

side of the proposed pipe alignment in a grid with the centerline along theproposed alignment. The wing lines shall be located at 10 m intervals oneither side of the proposed pipe line alignment. Cross lines (along the river)shall be run at every 5 m intervals. The dry bed shall be surveyed upto HFLon either side and spot levels shall be taken at 5 m intervals. Closer spotlevels may be taken whenever a change occurs. However, the exactlocation and number of wing lines shall be decided by the Company at sitedepending on the site conditions at the time of survey.

Contractor shall assess change in river bed slope upto 200 m on either sideof the pipeline crossing.

All levels shall be referred to M.S.L.

Fixing the transit marks and using sextant angles shall carry out positioningof the survey boat.

4.2 Historical Data Collection

Contractor shall collect/obtain the HFL and other hydrological data for rivercrossing site from the local/ regional agencies such as CWC, Department ofIrrigation Drainage Works; Flood Control Authority, PWD etc. The data shallbe collected for the nearest available gauge station irrigation and/ ordrainage head works for past ten years.

- Contractor shall provide all the necessary back-up calculations/details for the estimated hydrological data at the point of interest.

- Contractor shall provide detailed methodology and procedures forfield works, data collection and computations of hydrologicalparameters with/ without availability of historic data.


14/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

GEO-TECHNICAL

INVESTIGATION &

HYDROGRAPHIC

INVESTIGATION

SPEC. No. 2101

Rev. No. 1


PAGE :

12OF

12

4.3 Equipment Calibration

Contractor shall carry out calibration/ checks/ trails of all the surveyequipment in the field and obtain necessary approvals for the start ofoperations from the Company.

5.0 OBLIGATIONS OF THE CONTRACTOR

5.1 The Company shall monitor survey procedures, data quality, preparation of

charts and drawings. Contractor shall repeat the work that has not beencertified and accepted by the Company to obtain acceptable quality.

5.2 Contractor shall obtain completion certificate from the Company aftercompletion of all the field works required as per the scope of work.Completion Certificate shall be issued to the Contractor only aftercollections/ obtaining data of acceptable quality.

5.3 The Company shall be informed of the progress of survey at specifiedlocations. Contractor shall provide necessary facilities to access the datacollected at site/base. The Company shall have access to all the data

collected during surveys. All the details regarding positioning, methodologyof surveys, equipment deployment shall be provided to the Company.

5.4 In case of any follow-up field work is required to incorporate comment/suggestions made by the Company on the survey documents submitted bythe Contractor in order to meet technical requirements, the same shall becarried out by the contractor.

5.5 Contractor shall provide the following documentation:

Details including specification of all equipments, survey boats, personneletc., as per Annexure-I.

5.6 The Company shall not accept any liability towards loss/ damage of anyequipment/boat etc. during course of investigations.

5.7 The Company will not collect the data for the Contractor from the regulatoryagencies nor provide any information regarding place of availability or theprocedure to go about the data collection. However, the Company shallprovide to the Contractor any letters of clarifications/ projects detailsaddressed to the agency. Entire data collection is the responsibility of the

Contractor.


15/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

GEO-TECHNICAL

INVESTIGATION &

HYDROGRAPHIC

INVESTIGATION

SPEC. No. 2101

Rev. No. 1


PAGE :

13OF

13

6.0 REPORT

Preliminary Report

The Contractor shall submit within a week of completion of surveys apreliminary report. This report should include:

a) A summary of all work carried out by the Contractor including location of

areas covered.b) Track charts of the boat and the grid points of the surveys carried out.c) Co-ordinates of the shore control station need for positioning the boat.

6.1 Final Report

Detailed report shall be prepared as per specification in addition to thefollowing specific requirement.

The report should consist of :

a) Details of the field surveysb) Final track chartsc) Geological and morphological featuresd) Cross-sectional details each riverbed along with the profiles across

and along the riverbed.e) The grain size distribution curves of the soil samples collected from

the riverbed including data of sampling, locations etc.f) Hydrological data such as HFL for each river-crossing site, based on

the past data. The details of the basis of the data presented shallalso be furnished i.e. details of the data from agencies and methodsof computation.

g) The historical local data available for any bank erosion, scourobserved at nearby bridges etc. change in the river course includingthe source of the data.

h) Scour profile of the riverbed along the pipeline crossing.i) Analysis of pipeline depth and buoyancy calculations for the

specified pipeline.j) All the working drawings shall be in 1:500 scale or as specified by

the Company.k) Proposal and analysis for the pipeline crossing.l) Proposal for anti-buoyancy measures.


16/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

GEO-TECHNICAL

INVESTIGATION &

HYDROGRAPHIC

INVESTIGATION

SPEC. No. 2101

Rev. No. 1


PAGE :

14OF

14

PART-II

(Ref. Clause 5.5 - Documentation to be provide by the Contractor )

ANNEXUREI

Details of Boat, Equipment and Personnel to be mobilised.

1. SURVEY BOAT

Size and other details of small boat and the proposed methodology ofmobilisation at sites.

2. SURVEY EQUIPMENT

a) Echo-sounderb) Positioning system

c) Survey equipment

3. PERSONNEL

Details of qualification and experience of survey personnel required forsmooth

operation:

a) Boat positioning during survey and track plottingb) operation of survey equipment like echo-sounderc) data processing and report preparation

4. Set of all equipment, plant machinery etc. for successful completion of soilinvestigation


17/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

GEO-TECHNICAL

INVESTIGATION &

HYDROGRAPHIC

INVESTIGATION

SPEC. No. 2101

Rev. No. 1


PAGE :

15OF

15

PART-II

ANNEXURE II

LIST OF INDIAN STANDARDS REFERRED

1 IS: 1498 Classification and Identification of Soils for GeneralEngineering Purposes.

2 IS: 1888 Method of Load Tests on Soils.

3 IS: 1892 Code of practice for Site Investigations for Foundations.

4 IS: 2131 Method for Standard Penetration Test for Soils.

5 IS: 2132 Code of Practice for Thin Walled Tube Sampling of Soils.

6 IS: 2720 Method of Test of Soils (Relevant Parts)

7 IS: 4434 Code of practice for In Situ Vane Shear Test for Soils.

8 IS: 4968- Part-I Method for subsurface sounding for soils DynamicMethod Using Cone without Bentonite Slurry.

9 IS: 4968- Part-II Method for subsurface sounding for soils DynamicMethodUsing Cone and Bentonite Slurry.

10 IS: 4968- Part-III Method for subsurface sounding for soils static conepenetration test.

11 IS: 5249 Method of Tests for Determination of In situ DynamicProperties of Soils.


18/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

1OF

1

FUNCTIONAL SPECIFICATION

FOR

3 LAYER POLYETHYLENE

COATING

PREPARED /REVISED BY

REVIEWED BY APPROVED BYTOTAL No.OF PAGES

DATE REV. No.

KRK SN PKM 40 06.10.2005 1


19/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

2OF

2

1.0 SCOPE

This specification covers the minimum requirements for supply /arrangement of all materials, plant, equipment, plant sites, consumables,utilities and application including all labour, supervision, inspection and testsetc. for application of external anti-corrosion coating of pipes by using 3Layer Side Extruded Polyethylene Coating conforming to DIN-30670, 1991,`Polyethylene Coating of Steel Pipes and Fittings' and the requirements of

this specification.

2.0 REFERENCE DOCUMENTS

Reference has also been made to the latest edition of the followingstandards, codes and specifications. The edition enforce at the time offloating the enquiry shall be termed as latest edition.

Sl. Code Description

1. ASTM D-149 :Standard Test Methods of Dielectric Breakdown

voltage and Dielectric strength of solid electricalinsulating materials at commercial frequencies.

2. ASTM D-257 : Standard Test Methods for D-C Resistance orconductance of insulating materials.

3. ASTM D-543 : Standard Method of Test for Ressistance oflastics to Chemical Reagents.

4. ASTM D-570 : Standard Method of Test for WaterAbsorption of Plastics.

5. ASTM D-638 :Standard Test Method for TensileProperties of Plastics.

6. ASTM D-792 :Standard Test Method of Specific Gravity andDensity of Plastics by Displacement.

7. ASTM D-1238 :Test Method for Low Rate of Thermoplastics byExtrusion.

8. ASTM D-1525 :Test Method for Vicat Softening Temperature ofPlastics

9. ASTM D-1603 :Test Method for Carbon Black in OlefinPlastics

10. ASTM D-1693 : Test Method for Environmental StressCracking of Ethylene Plastics


20/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

3OF

3

Sl. Code Description

11. ASTM D-2240 : Test Method for Rubber PropertyDurometerHardness

12. ASTM D-3895 : Test Method for Oxidative Induction Time ofPolyolefins by Differential Scanningcalorimetry

13. ASTM G-42 : Tentative Methods for Cathodic dis-bonding

of Pipeline Coatings subjected to Elevatedor Cyclic Tempertatures.

14. API RP 5L1 : Recommended Practice for RailroadTransportation of Line pipe.

15. API RP 5LW : Transportation of Line Pipe on barges andmarine vessels

16. DIN EN 10204 : Metallic Products Types of InspectionDocuments

17. DN 53735 : Testing of Plastics : Determination of MeltIndex of Thermoplastics.

18. ISO 8502-3 : Preparation of Steel Stubstrates before

application of Paints and RelatedProducts Part-3 Assessment of Dust onSteel Surfaces Prepared for Painting(Pressure Sensitive Tape Method)

19. ISO 9002 : Quality Systems : Specification of Productionand Installation

20. ISO 11124 : Preparation of Steel Substrates BeforeApplication of Paints and Related Products

21. SIS 055900 : Preparation of Steel Substrates beforeApplication of Paints and Related Products

Products Visual Assessment of SurfaceCleanliness.

22. APL 5L : Specification for Line Pipe23. ASME B 31.8 : Gas Transmission and Distribution Piping

Systems24. ASME B 31.4 : Liquid Transportation systems for Hydro-

carbons, Liquid petroleum Gas Anhydrousammonia, and Alcohols

25. CSA Z245.20-98

: External Fusion Bond Epoxy Coating forSteel Pipe


21/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

4OF

4

The Contractor shall be familiar with the requirements of these documentsand shall make them readily available at the coating plant to personsconcerned while carrying out the works specified in this specification.

3.0 PLANT SCALE AND INSTALLATION

3.1 The Contractor shall size coating plant(s) after evaluating the scale ofwork and the time schedule required for the works. Coating plant(s), shall

be installed into a yard whose geometry and dimensions are such as toallow the execution of a continuous work schedule. For this purpose theContractor shall ensure non stop work execution owing to prohibitiveadverse weather conditions and when required the Contractor shall installrequisite equipment and plant in roofed and adequately weather protectedareas.

3.2 Plant equipment, machinery and other facilities shall be in first classoperating condition to at least meet the job requirements of quality andproduction.

3.3 The Contractor shall at his own responsibility provide and prepare allnecessary area for the storage of bare and coated pipe and all othermaterials, for coating yard, stock-piling and other temporary installation. Foreach area, the Contractor shall provide to stipulate servitude agreements asrequired with the relevant Authorities, and, on work completion, to clean,restore and pay servitude and claims for damages, as applicable.

3.4 The Contractor shall at its own responsibility provide for water andpower supply and other utilities and consumables and obtain authorisationregarding access roads and other permits required for the execution ofworks conforming to all the requirements of the governing authorities.

3.5 The Contractor shall provide a fully equipped laboratory and testfacilities with adequate inventory to carry out tests required for theprocedure qualification and during regular production. Outside testing forqualification and regular production is not acceptable to the Company.

3.6 The Contractor shall be fully responsible for adherence to all statutoryregulations applicable for handling and disposal of the hazardous chemicalsduring the coating works.


22/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

5OF

5

3.7 The Contractor shall be responsible for obtaining all statutory approvals/clearances from relevant Authorities including Pollution Control Board, asapplicable for the coating plant(s).

4.0 MATERIALS

4.1 The three layer coating system shall comprise of a powder epoxyprimer, polyethylene adhesive and a polyethylene top coat. Coatingmaterials shall be suitable for the service conditions and the pipe sizesinvolved. The coating materials i.e. epoxy powder, adhesive andpolyethylene compound shall have proven compatibility. The coatingsystem and materials shall be pre-qualified and approved by the Company.The Contractor shall obtain prior approval from the Company for the coatingsystem and coating of all materials.

4.2 All the tests for all properties specified in para 5.3.1 and 5.3.2 for each batchof epoxy, adhesive and polyethylene compound including Infra-red Scanfor each batch of epoxy powder shall be carried out. The Contractor shallfurnish test certificates as per DIN EN 10204, 3.1B issued by the

manufacturer for Companys approval prior to their use.

4.3 Samples from each batch of epoxy, adhesive and polyethylene shall bedrawn in the presence of the Company Representative and test for thefollowing properties at the coating yard at least one week prior to its use, toestablish compliance with the Manufacturers certificates.

a) Epoxy Powder

i. Gel Timeii. Cure Timeiii. Moisture Content

iv. Thermal Characteristics (Tgl, Tg2, .H)

b) Adhesive

i. Specific Gravityii. Melt Flow Rateiii. Vicat Softening Point

c) Polyethylene

i. Melt Flow Rateii. Specific Gravity

iii. Vicat Softening Point


23/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

6OF

6

iv. Moisture Contentv. Oxidative Induction TimeIn case of failure of any of the above tests in a batch, that batch of materialshall be tested for all other tests required as per para 5.3.1 and 5.3.2including the tests which failed. If all tests pass, the batch shall be acceptedfor coating. If any of the tests fail, entire batch of material shall be rejectedand shall not be used for the coating.

4.4 All materials to be used shall be supplied in sealed, damage free

containers and shall be suitably marked and identifiable with the followingminimum information:

a. Name of the manufacturerb. Type of materialc. Batch Numberd. Place and Date of Manufacturee. Shelf Life/ Expiry Date (if applicable)f. Quantity

All materials noted to be without above identification shall be deemed/suspect and shall be rejected by the Company. Such materials shall not be

used for coating and shall be removed from site and replaced by theContractor.

4.5 The Contractor shall ensure that all coating materials properly stored inaccordance with the Manufacturers recommendation at all times, to preventdamage and deterioration in quality prior to use.

4.6 The Contractor shall be required to use all materials on a date receivedrotation basis, i.e. first in-first used basis.

5.0 FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING

5.1 The coating must be able to withstand a maximum in serviceoperating temperature of +65C and shall conform to `S Type of coating asper DIN 30670. In addition, in open storage the coating must be able towithstand a temperature of at least +80C, without impairing itsserviceability and properties specified.

5.2 The top coat polyethylene used shall be black readymade compound,fully stabilized against influence of ultraviolet radiation (.e. sunlight), oxygenin air and heat (due to environmental temperature as specified above). Noappreciable changes shall occur during exposure to such environments up

to at least a period of 6000 hours.


24/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

7OF

7

The Contractor shall submit certificate from Manufacturer in this regard.

5.3 Properties

Properties of coating system and coating material shall comply therequirements indicated in subsequent paragraph. In case the coating/material properties are tested as per test methods/ standards other thanspecified herein below, the same may be accepted provided the testprocedures and test conditions are same or more stringent than thespecified.

5.3.1 Properties of Epoxy Powder and Adhesive

The Contractor shall choose such a brand of epoxy powder and adhesivethat will achieve the functional requirements and properties of coatingsystem as specified in para 5.1 and 5.3.3 of this specification respectively.Epoxy powder properties shall be as per CSA Z245.20.98.

Copolymer grafted adhesive shall have the following properties.

Sl Properties Unit Requirement Test Method

a Melt Flow Rate(190C / 2.16 kg)

g/10minutes

1.0 ASTM D1238

b Vicat SofteningPoint

C 90 min. ASTM D1525

c Specific Gravity - 0.926 min. ASTM D792


25/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

8OF

8

5.3.2 Properties of Polyethylene Compound


a Tensile Strength@+25C

N/mm2 17 min. ASTM D 638

b Melt Flow Rate(190C / 2.16 kg)

g/10minute

0.25 min. ASTM D 1238 orDIN 53735

c Specific Gravity@+25 C

- 0.941 min.(HDPE)

ASTM D 792

d Hardness@+25C Shore D 50 min. ASTM D 2240

e Water Absorption,24hours, @+25C

% 0.05 max ASTM D 570

f Volume Resistivity@+25C

Ohm-cm 1015 min ASTM D 257

g Dielectric withstand1000 Volt/sec rise

@+25C

Volts/mm 30,000 min ASTM D 149

h Vicat SofteningPoint

C 110 min. ASTM D 1525

i Elongation % 600 min. ASTM D 638

j Oxidative InductionTime in Oxygen at220C, Aluminiumpan, no screen

Min 10 ASTM D3895

k EnvironmentalStress Crack

Resistance (ESCR)(for F50)Medium Density,Condition CHigh Density,Condition B

Hours

300

300

ASTM D1693

l Carbon BlackContent

% 2 min. ASTM D1603


26/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

9OF

9

5.3.3 Properties of Coating System


a Bond Strength (usingType 2 Test Assemblyi.e.dynamometer)@ 205C@ 605C

Kg/cm

8.0 min5.0 min.

DIN 30670

b Impact Strength (min.of 30 impacts on bodyalong the length.No breakdown allowedwhen tested at 25 kV)

Joulesper mmof coatingthickness

7 min DIN 30670

c Indentation Hardness@ 232C@ 702C

mm0.2 max0.3 max

DIN 30670

d Elongation at Failure % 300 min. DIN 30670

e Coating Resistivity (*) Ohm-m2 10 min. DIN 30670

f Heat Ageing (*) - Melt flow rateshall notdeviate bymore than35% oforiginal value

DIN 30670

g Light Ageing (*) - Melt flow rateshall notdeviate bymore than35% of

original value

DIN 30670

h Cathodic Disbondment@+65C after 30 days@+65C after 48 hrs

mm radiusof dis-bondment

(**)

15 max.7 max.

ASTM G42

i Degree of Cure ofEpoxy PercentageCure, H Tg

%C

95+3/ -2

CSAZ245.20-98(*)


27/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

10OF

10

(*) Test carried out in an independent laboratory of national/ internationalrecognition on PE top coat is also acceptable.

(**) Disbondment shall be equivalent circle radius of total unsealed area asper ASTM G42.

(***) Temperature to which the test specimens are to be heated duringcyclic heating shall however be as per the recommendations of epoxy

powder manufacturer.

6.0 MEASUREMENT AND LOGGING

The Contractor shall maintain records of all the relevant data of individualpipe and pipe coating including heat number, diameter, length, wallthickness, defects, pipe number, batches of materials, materials balance,sampling, testing, damages, repairs, rejects and any other information thatthe Company considers to be relevant and required for all incoming barepipes and the Company approved outgoing coated pipes as applicable. TheContractor shall submit this information in the form of a report at the agreedintervals. The above data shall also be provided in MS EXCEL format inCompact Disc (CD). The Contractor shall also submit the material balancedetails to the Company for information at the end of shift.

7.0 COATING PROCEDURE AND QUALIFICATION

7.1 The Contractor shall submit a detailed report for the Companys approval

indicating but not limited to the following:

a. Details of plant(s), locations, layout, capacity and production rate(s).

b. Details of the equipment available to carry out the coating worksincluding surface preparation, epoxy powder application and its recyclingsystem, adhesive & polyethylene extrusion, moisture control facilitiesavailable for coating materials.

c. Details of process control and inspection equipment required forthe coating process such as temperature control, thickness control,

holiday testers, etc.


28/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

11OF

11

d. Details of chemicals pre-treatment facilities including process control andinspection equipment for phosphoric acid wash, de-ionised - ionisedwater wash and chromate wash.

e. Facilities in the yard for unloading, handling, transport, production,storage, stockpiling, loading of bare and coated pipes and warehousesfor storage of other coating materials.

f Plant Organo-gram Chart and availability of manpower including coatingspecialist.

g Details of utilities /facilities such as water, power, fuel, access roads &communication etc. After approval has been given by the Company, nochange in plant set-up shall be made. However, unavoidable changesshall be executed only after obtaining written approval from theCompany.

7.2 At least four(4) weeks prior to the commencement of production coating, adetailed procedure of the Contractor 's methods, material proposed, etc.,

shall be formulated by the Contractor and submitted for the Company 'sapproval in the form of a bound manual. The procedure shall include, butnot limited to the following information and proposals:

a. Pipe inspection at the time of bare pipe receipt.

b. Steel surface preparation, including preheating, removal of steel defects,method of pipe cleaning, dust removal, abrasive blast cleaning andsurface profile, methods of measurements and consumables.

c. Complete details of chemical pre-treatment viz phosphoric acid wash,deionised water wash, and chromate wash including product datasheets, health and safety sheets and manufacturers recommendedapplication procedure.

d. Pipe heating, temperatures and control prior to epoxy application.

e. Complete details of raw materials including current data sheetsshowing values for all the properties specified together with qualitycontrol and application procedure recommendation frommanufacturer(s).


29/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

12OF

12

f. Application of FBE powder, adhesive and polyethylene, includingcharacteristics, temperature, line speed, application window, curing time,etc.

g. Quenching and cooling, including time and temperature.

h. Quality assurance system, Inspection and testing methods and reportingformats, including instrument and equipment types, makes and uses etc.

i. Detailed method of repair of coating defects duly classified dependingupon nature and magnitude of defects and repairs thereof includingcoating stripping technique.

j. Details of instrument and equipment calibration methods includingrelevant standards and examples of calibration certificates.

k. Complete details and inventory of laboratory and equipment forprocedure qualification and regular production.

l. Pipe handling and stock piling procedures.

m. Sample of recording and reporting formats, including laboratory reports,certificates and requirement as per clause 6.0 of this specification.

n. Complete details of test certificates for raw materials including testmethods standards used.

o. Test certificates from PE compound manufacturer for tests for thermalaging coating resistivity and aging under exposure to light. These testcertificates shall not be older than three years.

p. Health, safety and environment plans.

q. Storage details of coating materials and chemicals.

r. Continuous temperature monitoring at various stages of coating.

Procedure Qualification Tests (PQT) shall be carried out only after obtainingwritten approval of the above procedure from the Company. No change inthe procedure shall be made after approval has been given by theCompany.


30/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

13OF

13

However, unavoidable changes shall be executed only after obtainingwritten approval from the Company.

7.3 Prior to start of production, the Contractor shall carry out a coatingprocedure qualification trial for each pipe diameter, and for each plant, toprove that his plant, materials, and coating procedures result in a quality ofend product conforming to the properties stated in clause 5.3, relevantstandards, specifications and material manufacturers recommendations.The Contractor shall give seven(7) working days notice to witness

procedures and tests.

A batch representing a normal production run, typically 15 pipes, shall becoated in accordance with the approval coating procedure and the coatingoperations witnessed by the Company Representative. Out of these pipes,at least one pipe shall be coated partly with epoxy and partly with bothepoxy and adhesive layers. At east 5 (five) test pipes shall be selected byCompany Representative for coating procedure approval tests and shall besubjected to procedure qualification testing as described hereinafter. Alltests shall be witnessed by the Companys representative. Out of 5(five) testpipes 1(one) pipe shall be coated partly with epoxy and partly with both

epoxy and adhesive layers. Remaining 4(four) test pipes shall be coatedwith all three layers.

During PQT, the Contractor shall qualify various procedures forming a partof coating operations as detailed subsequently.

7.4 Qualification of Procedures

7.4.1 Epoxy Powder Application & Recycling

During pre-qualification, air pressure in the epoxy spray guns, satisfactoryfunctioning of monitoring system, line speed vs coating thickness, etc. shallbe established. Dew point of air used to supply the fluidised bed, epoxyspray system and epoxy recycling system shall be recorded during thePQT. Also, the Contractor shall remove samples of reclaimed powder fromthe reclamation system. These of reclaimed powder shall be subject to adetailed visual examination, thermal analysis and moisture content tests.The properties of the reclaimed powder shall be within the range specifiedby the Manufacturer of epoxy powder. In case the properties of thereclaimed powder are out of the range specified by the Manufacturer, theContractor shall not the use the reclaimed powder during the regular

production.


31/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

14OF

14

7.4.2 Pipe Pre-Heating

The Contractor shall establish the temperature variation due to in-comingpipe temperature, line speed variation, wall thickness variation, emissivity,interruptions, etc. and document the same during the PQT stage. DuringPQT, proper functioning of pipe temperature monitoring and recordingsystem including alarm/ hooter shall be demonstrated to the Company.

7.4.3 Surface Preparation

The procedure to clean and prepare the pipe surface shall be inaccordance with the requirements of this specification. The ratio to shotsto grits shall be established during procedure qualification testing, suchthat the resultant surface profile is not dished and rounded. Thequalification shall be performed through a visual inspection, measurementof roughness and check of the presence of dust in the abrasive blastcleaned pipe surface.

7.4.4 Chemical Pre-Treatment

7.4.4.1 Phosphoric Acid Wash followed by De-ionised Water Wash

The procedure to apply the chemical pre-treatment viz. phosphoric acidwash followed by de-ionised water wash shall be in accordance with therecommendation of the manufacturer and shall result in intended cleaningrequirements of this specification. Working solution preparation,maintaining concentration, application procedure including method ofspreading, spreading rate, drying times, etc. depending upon thecleanliness/ temperature of the incoming pipe and the line speed shall beestablished. Temperature of the chemical, pipe pre-heat temperature vsline speed vs dwell time, rinsing procedure, testing & control, rectificatorymeasures, drying procedure etc. shall be clearly established during PQT.Also the quality of the de-ionised water shall be established during PQT.

7.4.4.2 Chromate Treatment

The procedure to apply the chromate treatment shall be in accordancewith the recommendation of the manufacturer. Working solutionpreparation, maintaining concentration, application procedure includingmethod of spreading, spreading rate, drying times, etc. depending upon

the temperature of the incoming pipe and the line speed shall be


32/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

15OF

15

established. Temperature of the chemical, pipe preheat temperature vsline speed, pipe heating after chromating and time limit within which thepipe to be heated, testing & control, rectificatory measures, shall beclearly established during PQT.

7.4.5 Coating Application

The Company will check the correctness of each coating applicationoperation, values of the main parameters of each operation, preheating

pipe surface temperature prior to epoxy powder application temperature,line speed, fusion bonded epoxy curing time, temperature and flow rate ofcopolymer adhesive and polyethylene etc. and the same shall berecorded. These values shall be complied with during regular production.

7.5 Qualification of Applied Coating

7.5.1 Tests on pipe coated partly with epoxy and partly with epoxy &adhesive Layers

a. Degree of Cure

Epoxy film samples (min 4 Nos.) shall be scrapped from the coatedpipe using hammer and cold chisel and the samples shall be taken forcure test using Differential Scanning Calorimatry (DSC) procedure.Care shall be taken to remove the samples of full film thicknessavoiding inclusion of steel debris. Glass transition temperaturedifferential (.Tg) and % cure (.H) shall comply the specifiedrequirements.

b. Epoxy Layer Thickness

Epoxy layer thickness shall be checked at every one meter spacing at3, 6, 9 and 12 oclock positions. The thickness shall comply thespecified thickness requirements.

c. Adhesive Layer Thickness

Adhesive layer thickness shall be checked at every one meter spacingat 3, 6, 9 and 12 oclock positions. The thickness shall comply thespecified thickness requirements.


33/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

16OF

16

d. Holiday Inspection

Entire pipe shall be subject to holiday inspection and the test voltageshall be set to exceed 5 v/micron of epoxy thickness specified for theportion coated only with epoxy layer.

e. Adhesion Test

i) Adhesion Test (24 hrs or 48 hrs) shall be carried out on theepoxy coated pipe. Test method, no. of test specimen andacceptance criteria shall comply CSA Z.245,20-98, Table 4.

ii) Adhesion of FBE shall also be separately determined at ambienttemperature at two locations by the St Andrews Cross methodand the test shall comply with the specified requirements.

f. 2.5 Flexibility Test

2.5 Flexibility test shall be carried out on the epoxy coated pipe at test

temperature of 0C. Test method, no. of test specimen and acceptancecriteria shall comply CSA Z.245,20-98.

g. Cross-section & Interface Porosity Test

Cross section porosity and interface porosity tests shall be carried outon the epoxy coated pipe. Test method, no. of test specimen andacceptance criteria shall comply CSA Z.245,20-98, Table-4.

7.5.2 Tests on pipes coated only with all three layers

a. Bond Strength

Three test pipes shall be selected for bond strength tests. On each ofthe selected pipes, three bond strength test shall be performed for eachspecified temperature i.e. one at each end and one in the middle of thepipe and specified requirements shall be complied with, i.e. bondstrength as well as mode of separation. Length of peel shall be minimum65mm. None of these samples shall fail.


34/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

17OF

17

b. Impact Strength

Three test pipes shall be selected for impact strength test and the testshall meet the requirement.

c. Indentation Hardness

Two samples for both the temperatures from all pipes shall be taken. Ifany one of these samples fail to satisfy the requirements, then the test

shall be repeated on four more samples. In this case, none of thesamples must fail.

d. Elongation at Failure

Six samples each from two coated pipes i.e. 18 samples in all shall betested and the test shall comply the specified requirement. Only onesample per pipe may fail.

e Cathodic Disbondment Test

Two CD test shall be carried out for the total lot of test pipes having allthree layers. One test shall be carried out for 30 days duration andanother test for 45 hours duration The tests shall comply the specifiedrequirement. Whenever Procedure Qualification is necessitated fordifferent pipe size with same coating material combination, 48 hours testonly be conducted. 30 days CD test is not mandatory in this case.

f Holiday Inspection

All the pipes shall be subject to holiday inspection. The test voltageshall be as specified in para 10.4(b)

g Coating Thickness Measurement

All pipes shall be subject to coating thickness measurement.Acceptance criteria shall be as per para 10.3

h Air Entrapment

One sample each from pipe body and on weld (if applicable) shall betaken from all four coated pipes and the specified requirements shall be

complied with.


35/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

18OF

18

i. Degree of Cure

Epoxy film samples (minimum 4 no., equally spaced) shall be scrappedfrom one coated pipe and the samples shall be taken for cure test usingDifferential Scanning Calorimetry (DSC) procedure. Care shall be takento remove the samples of full film thickness avoiding inclusion of steeldebris. Glass transition temperature differential (.Tg) and % cure (.H)shall comply with the specified requirements.

7.5.3 Inspection of all test pipes

All pipes shall be subject to the following inspections:

a. Surface cleanliness, surface roughness measurements and dust controlimmediately after second abrasive blast cleaning and salt testimmediately after De-ionised water wash.

b. PH of pipe surface before and after phosphoric acid wash.c. Visual inspection of chromate coating.d. Visual inspection of finished coating, cut back dimension, internal/

external cleanliness, end sealing and bevel inspection.

Acceptance criteria for all inspection and testing shall be as specified in thisspecification.

7.6 After completion of the qualification tests and inspection as per para 7.4and 7.5 above, the Contractor shall prepare and issue to the Company forapproval a detailed report of the above tests and inspection including testreports / certificates of all materials and coatings tested. Only upon writtenapproval from the Company, the Contractor shall commence productioncoating.

7.7 On successful completion of PQT, coating of all five(5) test pipes shall beremoved and completely recycled as per the approval coating procedurespecification. Remaining pipes will be accepted by the Company providedthey meet the requirements of this specification and need not be strippedand re-cycled.

7.8 The Contractor shall re-establish the requirements of qualification and in amanner as stated before or to the extent considered necessary by theCompany, in the event of, but not limited to, the following :

Every time there is a change in the previously qualified procedure.


36/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

19OF

19

Every time there is a change in the manufacturer and change informulation of any of the raw materials and change in location of rawmaterial manufacture.

Every time the coating yard is shifted from one location to the other orevery time the critical coating equipments (induction heater, epoxy spraysystem, extruder, etc) are shifted.

Any change in line speed during coating application. Any time when in the Companys opinion the properties are deemed to

be suspect during regular production tests.

7.9 The Company reserves the right to conduct any or all the test required forqualification through an independent laboratory or agency at the cost of theContractor when in the Companys opinion, the results are deemed suspect.the Companys decision shall be final.

8.0 PIPE SURFACE PREPARATION

8.1 Unless specified otherwise, the pipes shall be supplied free from millapplied oils but may be subject to contamination occurring during transit.

8.2 Prior to cleaning operation, the Contractor shall visually examine thepipes and shall ensure that all defects, flats and other damages have beenrepaired or removed. The Contractor shall also remove marking stickers, ifany, present within the pipe. Record shall be kept of such marking on thestickers of ensure traceability of pipe after coating.

8.3 Any oil, grease, salt or other contaminants detrimental to the formation of agood coating bond or coating quality shall be removed prior to coatingapplication. Contaminants may be removed by the use of non-oily solvents.Gasoline or kerosene shall not be used for this purpose. Visible oil andgrease spots shall be removed by solvent wiping. Solvents cleaning shall

be in accordance with SSPC-SP1. Steel surface shall be allowed to drybefore abrasive cleaning.

8.4 All pipes shall be preheated to a temperature 65C to 85C prior toabrasive blast cleaning. The external surface of the pipe shall be cleanedusing 2 no. dry abrasive blasting cleaning units to achieve the specifiedsurface cleanliness and profile. After first abrasive blast cleaning, chemicalpre-treatment with phosphoric acid solution as per para 8.6 shall be carriedout prior to second abrasive blast cleaning. However at the option of theContractor, chemical pretreatment with phosphoric acid solution as per para8.6 may be carried out after the second abrasive blaster.


37/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

20OF

20

The abrasive blast cleaning units shall have an effective dust collectionsystem to ensure total removal of dust generated during blast cleaning fromthe pipe surface. The equipment used for abrasive blast cleaning shall meetthe specified requirements and shall be free from oil, water soluble saltsand other forms of contamination to ensure that the cleaning process is notimpaired. Traps, separators and filters shall be checked for condensedwater and oil at the start of each shift and emptied and cleaned regularly.During abrasive blast cleaning the metallic abrasive shall be continuouslysieved to remove fines and contaminates and the quality checked at

every four hours. Abrasive used for blast cleaning shall comply ISO- 11124.

8.5 Suitable plugs shall be provided at both pipe ends to prevent entry ofany shot/grit into pipe during blast cleaning operations. These plugs shallbe removed after blast cleaning. Alternatively the Contractor may link pipessuitably together to prevent the entry of any short/grit into the pipe.

8.6 Chemical Pre-treatment with Phosphoric Acid Solution

8.6.1 All pipes shall provided chemical pre-treatment with phosphoric acidsolution. 10% solution of phosphoric acid, Oakite 31 / 33 or equivalent, shallbe used to remove all soluble salts and other soluble contaminations.

The Contractor shall provide data sheets and supporting documentation forthe phosphoric acid to be used. The documentation shall verify that thephosphoric acid is suitable for the treatment of line prior to the application ofthe specific fusion bonded epoxy powder being applied.

8.6.2 The pipe temperature immediately prior to the phosphoric acid treatmentshall be in the range of 45 to 75 C. Phosphoric acid treatment shall befollowed immediately by washing with de-ionised water. Deionised waterused shall conform to the following requirements :

Sl Properties Unit Requirementa Turbidity NTU 1 max.

b Conductivity mho/cm 5 max.

c Hardness - Nil

d Total Alkalinity as CaCO3 mg/l 2 to 3

e Chloride as Cl mg/l 1 max.

f Sulphate as SO4 mg/l 1 max.

g PH - 6.5 to 7.5


38/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

21OF

21

Tests to determine the above properties shall be carried out in accordancewith Standard Methods for the Examination of Water and Wastewaterpublished jointly by American Public Health Association, American WaterWorks Association and Water Pollution Control Federation.

Quality of the deionised water shall be monitored at the start of each shiftand at every four hours interval. Non-compliance of deionised water wrt theabove requirements shall cause for stoppage of the operations.

8.6.3 The pH of the pipe surface shall be determined both before and after thedeionised water rinse initially on each pipe and in case of consistentresults, the frequency may be relaxed to once per hour at the discretion ofthe Company. The measured pH shall be as follows :

Before de-ionised water wash : 1 to 2After de-ionised water wash : 6 to 7

8.6.4 After the de-ionised water wash, the pipe shall be dried with dry air andpreheated to a temperature of 65C to 85C.

8.6.5 The salt tests shall be carried out after de-ionised water rinse. One testshall be carried out at one end of each pipe. The acceptance criteria shallbe 2g/cm2. An approved salt meter (SCM 400 or equivalent) shall be usedto carry out salt tests and shall be calibrated in accordance with theequipment manufacturers recommendation.

8.7 Abrasive cleaning carried out shall be such that the resultant surfaceprofile is not dished and rounded when viewed with 30X magnification. Thestandard of finish for cleaned pipe shall conform to near white metal finishto Sa 2 of Swedish Standard SIS 055900 latest edition. Surface of pipeafter abrasive blast cleaning shall have an anchor pattern of 50 to 70microns(Rz). This shall be measured for each pipe by a suitable instrumentsuch as surface profile depth gauge. In addition the pipe surface after blastcleaning shall be checked for the degree of cleanliness (Sa 2), degree ofdust and shape of profile. Degree of dust shall comply the requirements ofISO:8502 3. Acceptance limit shall be either quality rating 2 or Class 2.

8.8 All pipes shall be visually examined for presence of any shot/ grit/ loosematerial left inside the pipe during blast cleaning. Suitable mechanicalmeans (stiff brush) shall be employed to remove the same before the pipes

are processed further. In addition, inside surface of the pipe shall also be


39/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

22OF

22

visually inspected for presence of any foreign material or shots and grit (freeor embedded/ sticking to pipe inside surface). The pipe inside surface shallbe examined using sharp floodlight focused at the middle of the pipe at oneend while inspection is carried out visually from other end. Any foreignmaterial or shots/ grit present in the pipe shall be completely removed bymechanical/ brush, high pressure air jets, by tilting of pipe etc.

8.9 At no time shall the blast cleaning be performed when the relative humidityexceeds 85%. The Contractor shall measure the ambient conditions at

regular intervals during blast cleaning and coating operations and keeprecords of prevailing temperature, humidity and dew point.

8.10 The blast cleaned surface shall not be contaminated with dirt, dust, metalparticles, oil, water or any other foreign material, nor shall be surface or itsanchor pattern be scarred or burnished. All blast cleaned pipe surface shallbe kept in dust free enclosure prior to coating. After blast cleaning, allsurfaces shall be thoroughly inspected under adequate lighting to determineanchor pattern, quality of blasting and identify any surface defects prior tocoating application. All surface defects such as slivers, scab, burns,laminations, welds spatters, gouges, scores, indentations, slugs or any

other defects considered injurious to the coating integrity made visibleduring blast cleaning shall be reported to the Company and on permissionfrom the Company, such defects shall be removed by filing or grinding. Afterany grinding or mechanical repairs, the remaining wall thickness shall bechecked and compared with specified thickness. Ay pipes having thicknessless than 95% of specified thickness shall be kept aside and disposed off asper the instructions of the Company. The method employed to removesurface defects shall not burnish or destroy then anchor pattern orcontaminate the surface. Pneumatic tools shall not be used unless they arefitted with effective air/ oil and water traps. Where burnishing results indestruction of anchor pattern, the anchor patter shall be restored by suitablemeans. Pipes which have damages repaired by grinding and have groundareas more than 50 mm in diameter shall be recycling-blasted.

Any dust or loose residues that have been accumulated during blastingand/ or during filing/ grinding operations shall be removed by vacuumcleaning.

If contamination of surface occurs, the quality of blast cleaning method andprocess shall be examined. If the surface roughness is outside the specifiedlimit, the blast cleaning material shall be checked and replaced.


40/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

23OF

23

8.11 Upon Completion of the blasting operations, the quality control supervisorshall accept the pipe for further processing or return for re-blasting afterremoval of defects/ imperfections. In case imperfections are considereddetrimental to the coating quality, the same shall be reported to theCompany for final decision on rejection or re-blasting/ removal of defects.Re-blasting/ removal of defects or returning pipe to the yard shall be theContractors responsibility.

The Company, in additions, reserves the right to initiate any of the aboveactions during periodic inspections for oil, dust, salt, imperfections, surfacedefects, lack of white metal finish etc.

8.12 In order to ensure that pipe with defects are not processed further,provisions shall be available to lift the pipes from inspection stand.

8.13 Chemical Pre-treatment with Chromate Solution

8.13.1 Following completion of abrasive blast cleaning, all pipe surface shall be

chemically Pre-treated with a 10% strength chromate solution.

8.13.2 The Contractor shall provide data sheets and supporting documentation forthe chemical to be used. The documentation shall verify that the chemicalis suitable for the treatment of line pipe prior to the application of thespecific fusion bonded epoxy powder being applied and the final coatingwill meet fully the requirements of this specification.

8.13.3 The chemical pre-treatment shall be applied fully in accordance with thechemical suppliers instructions and in a manner that ensures 100% uniform coverage of the pipe surface without introducing surfacecontamination.

8.13.4 The Contractor shall check that the concentration for the chemicalpretreatment solution remains within the range recommended by thechemical manufacturer for the pipe coating process. The concentrationshall be checked at the make up of each fresh solution and once per hour,using a method approved by the chemical manufacturer. The Contractorshall also ensure that the chemical pre-treatment solution remains freefrom contamination at all times. Recycling of chemical pre-treatmentsolution is not permitted.


41/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

24OF

24

8.13.5 The Contractor shall ensure that the temperature of the substrate ismaintained between 40C and 80C and the chromate solutiontemperature does not exceed 60 or as recommended by themanufacturer.

8.13.6 The chromate coating shall be smooth, even, free from runs, drips orexcessive application and lightly adherent with no flaking of the coating.The chromate coated steel must be thoroughly dried immediately afterapplication and shall be achieved by boiling off any residual solution on

the surface.

8.14 The total allowable elapsed time between completion of the blastingoperations and commencement of the pre-coating and heating operationsshall be such that no detectable oxidation of the surface occurs. Relativehumidity readings shall be recorded every half on hour during the blastingoperations in the immediate vicinity of the operations. The maximumelapsed time shall not exceed the duration given below :

Any pipe not processed within the above time-humidity requirement shallbe completely re-blasted. Any pipe showing flash rusting shall be re-blasted even if the above conditions have not been exceeded.

8.15 Pipe handling between abrasive blasting and pipe coating shall notdamage the surface profile achieved during blasting. Any pipe affected bythe damage to the surface exceeding 200mm2 in area/ or havingcontamination of steel surface shall be rejected and sent for re-blasting.

9.0 COATING APPLICATION

The external surface of the cleaned pipe conforming to clause 8.0 of thisspecification shall be immediately coated with 3-layer extrudedpolyethylene coating in accordance with the procedures approved by theCompany, relevant standards and this specification. In general, theprocedure shall be as follows:

Relative Humidity% Maximum elapsed time

> 80 2 hours70 to 80 3 hours

< 70 4 hours


42/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

25OF

25

9.1 Pipe Heating

9.1.1 Immediately prior to heating of pipe, all dust and grit shall be removed fromboth inside and outside of the pipe by a combination of air blast, brushingand vacuum cleaning. Suitable arrangement shall be made to protect thebevel ends from getting damaged during the coating operation.

9.1.2 Induction heater or gas furnace shall be used for heating the pipe.The method shall be capable of maintaining uniform temperature alongthe total length of the pipe, and shall be such that it shall not contaminate

the surface to be coated. In case of induction heating, appropriatefrequency shall be used to ensure `deep heating and intense skin heatingis avoided. Gas fired heating system shall be well adjusted so that nocombustion products are deposited on the steel surface. This shall bedemonstrated on bare pipes prior to start of PQT. Oxidation of the cleanedpipe surfaces prior to coating (in the form of bluing or other apparent oxideformation) is not acceptable.

9.1.3 External surface of the pipe shall be heated to about 190C or within atemperature range (min. to max.) as recommended by the powdermanufacturer. Required pipe temperature shall be maintained as it enters

the coating chamber.

9.1.4 Temperature of the pipe surface shall be continuously monitored &recorded by using suitable instruments such as infrared sensors, contactthermometers, thermocouples etc. The recording method shall allow tocorrelate each line pipe. The monitoring instrument shall be able to raisean alarm/ activate audio system (hooter) in the event of tripping ofinduction heater/ gas fired heater or in the event of pipe temperature beingoutside the range recommended by the manufacturer. Any deviation fromthe application temperature range recommended by manufacturer shall berectified. If immediate rectification is not feasible, the production shall be

stopped until cause of deviation has been removed. Any pipe coatedduring the duration of temperature deviation shall be identified by markingand rejected. Such rejected pipes shall be stripped and recoated.

9.1.5 Temperature measuring & monitoring equipment shall be calibratedtwice every shift and/ or as per the Company s instruction.

9.1.6 The Contractor shall ensure that pipe surface emissivity variationsare minimized during pipe heating. To avoid significant variance, morethan once blasted joints should be coated at the same time and not mixedwith joints blasted only once.


43/178



Design Division


ISO9001:2000

FUNCTIONAL

SPECIFICATION FOR

3 LAYER

POLYETHYLENE

COATING

SPEC. No. 2102

Rev. No. 1


PAGE :

26OF

26

9.2 Pipe Coating

9.2 .1 Subsequent to pipe heating, coating consisting of following layers shallbe applied onto the pipe.

i. Electrostatic application of epoxy powder of minimum dry filmthickness 0.150 mm, unless otherwise specified. The maximumthickness shall not exceed the epoxy thickness specified by epoxy

powder manufacturer.

ii. Grafted co-polymer adhesive applied by extrusion, minimumthickness 0.200 mm.

iii. Polyethylene coating by extrusion.

The coated pipe shall be subsequently quenched and cooled in water for aperiod which shall sufficiently lower the temperature of pipe coating to permithandling and inspection.

9.2.2 Minimum total thickness of finished coating shall be as under :

(*) HDPE material is to be used as top coat.

Required coating thickness shall be normal type (n), unless otherwisespecified.

9.2.3 Coating materials shall be inspected in accordance with the manufacturersrecommendation prior to coating application and it shall be ensured that thematerials are moisture free. In case the relative humidity exceeds 80%, theadhesive and polyethylene material shall be dried using hot air as per thedirections of the Company.

Pipe SizeSpecified outside diameter (mm)

Min. Coating Thickness (mm)(*)

Normal Type

05_Vol IIIB-Sec 4.6_Pipeline Specs

Documents

Transcript of 05_Vol IIIB-Sec 4.6_Pipeline Specs