17 Field Joint Coating

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JOB PROCEDURE FOR

FIELD JOINT COATING

HINDUSTAN PETROLEUM CORPORATION LIMITED


(HPCL)

CGD NETWORK FOR WEST BENGAL CLUSTER GA’s

DOC. NO. SGAPL/TEPL/HPCL/WB/SCH.04/FJC-JP-17 Rev-00

Rev. Date Description Prepared By Checked By Approved By

0 09.05.2023 For Review &


SGAPL SGAPL TEPL/HPCL
Approval
JOB PROCEDURE FOR
FIELD JOINT COATING

TABLE OF CONTENTS

1 SCOPE
2 REFERENCE
3 EQUIPMENTS DETAIL FOR FIELD JOINT COATING AND REPAIR
4 MAN POWER DETAIL FOR FIELD JOINT COATING AND REPAIR
5 MATERIALS FOR FIELD JOINT COATING AND REPAIR
6 INSTRUMENTS FOR FIELD JOINT COATING AND REPAIR
7 METHODOLOGY OF FIELD JOINT COATING
8 INSPECTIONS AND TESTING
9 METHODOLOGY FOR COATING REPAIR
10 HEALTH, SAFETY & ENVIRONMENT

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JOB PROCEDURE FOR
FIELD JOINT COATING

1. SCOPE
The content of this procedure cover to install anti-corrosion field joint coating on welded pipe sections
and field Tie-in Joints and to rectify joint coating repairs found during holiday inspection of welded pipe
sections and field Tie-in joints during execution of Steel Pipeline Construction.

2. REFERENCE

 Sleeve Manufacturer Application Procedure


 DIN EN-12068 code/standard & DIN-30671

3. EQUIPMENTS DETAIL FOR FIELD JOINT COATING AND REPAIR

 Truck 10 ton 1 Nos


 Compressor 125 cfm 1 Nos
 Hopper for sand Blasting unit
(To achieve SA-2.5 surface finish) 1 set
 Pump (Recommended by manufacturer) 2 Nos
 Blow heating Torch with gas cylinder 4 Nos + 1 Nos (repair)
 Testing + inspection equipments/instruments
 Epoxy applicator pads
 Straight rollers / Teflon rollers
 Vehicle- tractor trolley

4. MAN POWER DETAIL FOR FIELD JOINT COATING AND REPAIR

 Blaster 1 Nos.
 Qualified Insulator 2 Nos.
 Supervisor 1 Nos.
 Helper 2 Nos.

5. MATERIALS FOR FIELD JOINT COATING AND REPAIR:

 Heat Shrinkable Sleeves of Raychem HTLP-80


 Primer Part A Type S1301
 Primer Part B
 Applicator kits
 PERP 80 (for repair )
 PERP Filler / mastic filler

6. INSTRUMENTS FOR FIELD JOINT COATING AND REPAIR:

 Digital Thermometer 1Nos


 Hygrometer 1Nos
 Coat Meter/Elco-meter 1Nos
 Aluminum / rubber / Teflon hand roller 4Nos
 Micrometer 1Nos
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JOB PROCEDURE FOR
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 Press-O-Film/Comparator
 Holiday detector 1set

 Portable Peel Tester Kit 1Nos


 D.C. voltmeter (calibrated for holiday detector)
 Digital Thermometer (Calibration Certificate).
 Wet / dry thickness gauge
 Surface profile gauge
 Hygrometer & Dew point meter
 Digital Coat meter
 Press-O-Film (Coarse grade)
 Skin Type Temperature Gauge.
 Temperature Gun
 Digital Roughness Gauge

7. METHODOLOGY OF FIELD JOINT COATING

General

Procedure qualification shall be carried out in the field in the presence of vendor’s representative and
shall be approved by PMC/Owner.

All insulators shall be qualified by Vendor/PMC and only such qualified insulators shall be put on the job.
All qualified insulators shall be provided with identity cards.

Materials shall not be older than their period of validity at the time of application. The coating material
used Heat Shrinkable Sleeve and epoxy primer, shall be supplied by Contractor & shall be procured from
approved vendors. Test certificate for each batch of materials shall be submitted to PMC/OWNER prior
to use on the job. Material supplied shall be tested in accordance with the requirement of OWNER
Specification. All materials shall be duly inspected by PMC/OWNER.

Prior to start of surface finishing or joint coating, the welded joint shall be cleared / accepted in NDT (RT/
UT) as per QAP.

Contractor shall confirm that before cooling of coating, backfilling or lowering shall not be done. In hot
climate provide shedding from sunlight. Water quenching shall be allowed only when permitted by the
coating material and manufactured recommendation.

Surface Preparation
Any oil, grease, salt or other material detrimental to the finished coating shall be removed completely in
accordance with SSPC – SP 1. White Spirit/Turpentine/Kerosene shall not be used for this purpose.

The mechanical cleaning must be continued to at least 10 cm beyond the existing intact coating, in such a
way that all dirt is removed and the coating is roughened to ensure good adhesion. The intact coating will
be chamfered at the extremities to an angle of 15 to 30° in order to form a perfect joint.

Each field joint shall be blast cleaned using a closed cycle blasting unit or open expandable blasting
equipment. With the first equipment type, steel or chilled shot and iron grit shall be used and garnet
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JOB PROCEDURE FOR
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material with the second one (in case the authority having jurisdiction have no objection, the Contractor
may adopt sand blasting instead of garnet material. During blast cleaning the pipe surface temperature
shall be simultaneously more than 5°C and more than 3°C above ambient dew Point,

Prior to surface cleaning the surfaces shall be completely dry. The surface shall be cleaned to a grade SA
2½ in accordance with Swedish Standard SIS-055900 with a roughness profile of 50-70 microns. While
during blasting activity the ambient relative humidity shall not be greater than 85%.

Surface roughness profile shall be measured using an approved profile comparator in accordance with ISO
8503-1 and shall be calibrated prior to the start of the work in accordance with ISO-8503-3 or ISO – 8503-
4. The blast cleanliness shall be checked on every joint and the roughness profile shall be checked for 1
out of every 10 joints.

Dust, girt or foreign matter shall be removed from the cleaned surface by a suitable industrial cleaner.
The dust contamination allowed shall be of a rating max 2 as per ISO 8502-3.The frequency of checking
for dust contamination shall be 1out of every 10 joints.

Blast cleaned field joint shall be coated within 2-4 hours according to the conditions below:

Relative Humidity (RH) > 80% - 2 Hours


Relative Humidity (RH) 70- 80% - 3 Hours
Relative Humidity (RH) < 70% - 4 Hours

The ends of existing pipe protective coating shall be inspected and chamfered. Unbounded portions of
the coating shall be removed and then suitably trimmed. Portions where parent coating is removed shall
be thoroughly cleaned as specified. The adjacent chamfered areas of the line pipe coating shall be
cleaned and abraded, to expose a clean uniform fresh surface of uncontaminated factory applied coating.

Application Procedure of Heat Shrink Sleeves

i) The wrap around sleeve shall be of a size such that a minimum overlap of 50mm is ensured
(after shrinking) on both sides of the yard applied corrosion coating of pipe.
ii) Immediately after blast cleaning surface shall be wiped to remove the particles left over
from cleaning.
iii) Pre heat joint area using blow heating torch to 70C, Contractor shall ensure the correct
temperature is reached on steel and line coating using a pyrometer.
iv) Apply mix (shall be with ratio 3:1 for part A part B) epoxy to a smooth finish on all exposed
bare metal, including the line coating edge. Minimum wet film thickness for epoxy shall be
maintained 100 micron.
v) Wrap the HTLP 80 sleeve loosely around pipe, centering it over the weld area and evenly
overlapping the adjacent pipe coating by minimum 50 mm on each side & sleeve and closure
patch shall be min 100mm.
vi) Press the closure in position (in 10 or 2 O’ Clock position) centering over the exposed steel
end.
vii) Flame of LPG torch shall be adjusted to produce yellow flame. Heat the closure evenly till the
pattern of fabric reinforcement is visible. Run a small hand roller over the closure to push
out any trapped air.

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JOB PROCEDURE FOR
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viii) Using LPG torches heat the sleeve, as recommended by manufactured circumferentially
around the pipe beginning at the center using a roller up and down motion.
ix) Continue heating towards one end of the sleeve, followed by the other.
x) When sleeve has been shrunk on to the joint area and is still hot and soft, run a small hand
roller over the sleeve to push out any trapped air. Particular attention shall be paid to the
weld and cut back area and if necessary some areas may be re heated to roll out air.
xi) The installed sleeve shall not be disturbed until the adhesive has solidified.
xii) All materials shall be stored in sheltered storage and protect from direct sunlight and the
storage shall be as per the recommendations of manufacturer.

8. INSPECTIONS AND TESTING

Procedure qualification testing:-

Contractor shall furnish the procedure qualification at site as instructed by manufactured


representative and in front of PMC/OWNER representative.

The parameter shall be recorded during qualification of procedure.

Manufacturer representative shall ensure that the qualified insulator are suitable for the job as
required.

Manufactured shall issue the identity card with photograph of insulator.

The insulator shall be qualified in presence of Manufacturer Representative & PMC.

Visual Inspection

Contractor shall ensure the following: -

i) Mastic extrusion on either ends of the sleeve shall be examined.


ii) There shall be no sign of punctures, pinholes or bond failure.
iii) The external appearance of the sleeve shall be smooth, free of dimples/wrinkles, air
entrapment or void formations.
iv) Weld bead profile shall be visible over the sleeve.
v) The entire closer patch shall have changed color uniformly.

Holiday Inspection

The entire surface of the coated field joint shall be inspected by means of a full circle holiday
detector approved by OWNER. The test voltage shall be 5 KV + 5 KV/mm of total thickness of coating
at the time of lowering, subject to a maximum of 25KV. Inspection of the sleeves shall be conducted
only after the joint has cooled below 50ºC. At the time of holiday test Contractor shall arrange the
Jeep Meter for calibration of holiday detector.
No segment of pipeline shall be covered or lowered in the trench until the field joint coating has
been approved by the owner/owners representatives.

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PEEL TEST

Peel test shall be carried out on one of every 50 joint coating or one joint coating out of every day’s
production as per DIN EN-12068 CODE.

From each test sleeve, strip of size 25 mm x 200 mm shall be cut perpendicular to pipe axis and
slowly peeled off. The required peel strength shall be as per Standard and after removal of strip, the
adhesive layer that remains on the pipe surface shall be essentially free of voids. Contractor shall
undertake repair/replacement of all defects/defective coatings.

The adhesive layer that remains on the pipe surface shall be free from voids resulting from air and
gas inclusion. Repair shall be carried out with Perp-80 as per Joint Coating Repair Procedure

If the sleeve taken away for peel test does not meet the requirement as stated above, adjacent two
sleeves shall be tested. If the adjacent two sleeves are acceptable the test rate shall be increased to
one sleeve for every twenty-five until PMC is satisfied. If either or both the sleeves do not meet the
requirements mentioned above, the field coating shall be stopped for investigation.
Owner’s representatives reserve the right to order 100% removal of sleeve if he is not convinced
with the results.
Coating thickness shall be checked on either side of the girth weld & on
weld at 3, 6, 9 & 12 O clock positions by non distractive method for each field joint.

Thickness Measurement

The thickness of field joint coating materials shall be such that an average thickness of 2.3 mm &
with minimum thickness 2.0mm is guaranteed on the completed field joint coating on pipe body. The
minimum permissible thickness at the apex of weld seam and on weld shall be 1.6mm & average
shall be 2.0mm.

9. METHODOLOGY FOR COATING REPAIR

Surface Preparation

a) Repairing of small defects

The PE surface around the point faults has to be roughening with a brush disk. The PE surface over
the entire pipe surface has to be dried with propane burner at about 30°C. Adhesive plastic wrapping
tape has to be applied over the entire pipe circumference, in accordance with supplier’s
specification.

b) Repairing of other defects.

Cut out the damaged PE surface around the defect to the point where the coating is adhered
properly. The edges of the existing coating have to be chamfered and roughened. The whole surface
has to be cleaned with a brush disk to a degree of cleanliness S.T.2 1/2.
Primer has to be applied to the cleaned steel surface and the PE coating after drying the entire part
at 30°C.
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JOB PROCEDURE FOR
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The hole has to be filled with mastic filler.


Adhesive wrapping tapes over the entire pipe circumference has to be applied as per approved
supplier’s specification.

c) Repairing of PE damage
The method can be applied to all PE damage up to a maximum size of 350 x 350mm except for
directional drilling.
Cut out the damaged PE surface around the defect to the point where the coating is adhered
properly. The edges of the existing coating have to be chamfered and roughened. The whole surface
has to be cleaned with a brush disk to a degree of cleanliness as per S.T.2 1/2.

The entire part has to be dried with a propane burner at 60°C. The uneven holes and spots are to be
filled with mastic filler. Correct size of adhesive plastic repair patch has to be applied. The same to be
heated until the pigment is disappeared.

The material must comply with DIN 30672 classes C-70 (Raychem –PERP-80 or equivalent).

Application Procedure of PERP 80

Pre heat the repair area by using torch heating to approximately 60C to 70C and chamfer the
repair portion.
Wrap the PERP 80 on defect portion centering it over the defect area and evenly overlapping the
adjacent pipe coating by minimum 75 mm on each side.
Using torch, run a small hand roller over the closure to push out any trapped air.
The installed PERP 80 shall not be disturbed until the adhesive has solidified Holiday Inspection
Repair portion shall be checked with full circle Holiday Detector with voltage 5KV + 5KV/mm of total
thickness of coating, subject to a maximum of 25KV or as specified by Manufacturer.

10. HEALTH, SAFETY & ENVIRONMENT

1. It is to be noted that the machine operators Involved shall be an experienced / competent


person.
2. PPE shall be used in this activity.
3. Qualified and Trained personnel shall be deployed for this activity.
4. During fit up operation special care to be taken to avoid personal injury.
5. Personnel around the machine should be cautious about handling and coating of pipes.
6. During the movement of equipment, the operator should blow horn to caution the people
around.
7. All Measuring & Test Equipment used shall be well maintained.

Note:-
In case of any conflict between the requirements of this procedure and that of Owner Specification
and the requirement of Owner Specification shall govern.

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