VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - BLACK OIL TERMINAL Doc No:254625-300-SP-PIP-016 Rev: A Page 1 of 13

SPECIFICATION FOR COATING & WRAPPING OF UNDERGROUND PIPING

Mott MacDonald Consultants (India) Pvt. Ltd. Kothari House, CTS No. 185 Off Andheri - Kurla Road Andheri (East) Mumbai 400 059

Hindustan Petroleum Corporation Ltd Visakha Dispatch Station VR-ATP Area, Naval Base Post Visakhapatnam - 530 014 Andhra Pradesh

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SPECIFICATION FOR COATING & WRAPPING OF UNDERGROUND PIPING

Client MMCI Project No.

HINDUSTAN PETROLEUM CORPORATION LTD. 254625

Issue and Revision Record: Rev A B C Date 08/04/09 Originator HBS Checked SGN/JP Approved SNA Description Issued for Approval

Group Disclaimer "This document has been prepared for the titled project or named part thereof and should not be relied upon or used for any other project without an independent check being carried out as to its suitability and prior written authority of Mott MacDonald being obtained. Mott MacDonald accepts no responsibility or liability for the consequences of this document being used for a purpose other than the purposes for which it was commissioned. Any person using or relying on the document for such other purpose agrees, and will by such use or reliance be taken to confirm his agreement, to indemnify Mott MacDonald for all loss or damage resulting therefrom. Mott MacDonald accepts no responsibility or liability for this document to any party other than the person by whom it was commissioned.

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List of Content 1 Object and Scope 2 Regulations 3 Limit of Utilisation 4 Material and Procedure of Work 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 Preparation and Cleaning of Piping Priming Coating and Wrapping Application of Hot Coal Tar Enamel and Inner Glass Fibre Wrap

Page No 5 5 5 5 5 6 7 10

Application of Second (Outer) Layer of Coal Tar Enamel Coating & Glass Fibre Wrapping 10 Primer, Coating and Wrapping Application for Field Joints of Pies after Laying at Site. Inspection Testing and Repairs Handling and Supporting coated pipes Adjacent pipe - Lines, Structures etc 11 11 12 12 13

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Abbreviations
AWWA ASTM BS DIN Company : : : : : American Water Works Association American Society of Testing and Materials British Standards Deutsche Institut of Normung Mott MacDonald Consultants (I) Pvt. Ltd.

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Object and Scope

The object of this specification is to describe the method of protecting the underground pipelines by the process of coating and wrapping. The job shall be generally performed in the following operations:1. Cleaning the external pipe surface. 2. Priming with synthetic primer. 3. First coat of coal tar enamel. 4. First layer of inner wrapping with glass fibre. 5. Final coat (2nd coat) of coal tar enamel. 6. Outer wrap of coal tar impregnated glass fibre. 7. White wash. In addition, this specification also covers and defines the material specifications, method of cleaning, priming procedures of coating & wrapping, testing, preparing, handling and storing etc., required for the satisfactory completion of the job.

2
2.1

Regulations
All materials used shall conform to the quality and testing requirement indicated in AWWA C-203-86 or BS 4164, 1987 or ASTM Standards and or as directed by Company Site Representative. All appurtenance and equipment to be used for cleaning, priming, coating and wrapping and testing shall be approved by the Company Site Representative.

2.2

Limit of Utilisation
The underground pipeline protected by coating and wrapping as described in this specification should be able to carry a liquid at a temperature up to 60 deg. C.

4
4.1

Material and Procedure of Work

Preparation and Cleaning of Piping The pipe line shall be thoroughly cleaned of all rust, grease, dirt, mill scales, weld scales, weld burns etc. by means of cleaning machine. The cleaning operation shall be immediately followed by priming with the airless spray priming machine. Alternatively, if permitted by the Company Site Representative, the pipeline shall be adequately scrubbed manually with stiff wire brushes and scrapped where necessary. The primer coating should immediately follow the cleaning of pipes. The primer coating may also be done manaully if permitted by the Company Site Representative. The cleaning and priming operation may be carried out in the contractor's workshop or on site. The entire pipe length shall be cleaned but the ends of the pipes shall be left without coating and wrapping for a distance of 200 mm for joints, which shall be coated and wrapped manually on site after laying, welding and testing the pipes.

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4.2 4.2.1

Priming Materials, Coal Tar Primer The primer shall be a type B (fast drying, synthetic) certified to meet AWWA C-203-86 or British Standard BS-4164, Section 3. The primer shall consist of chlorinated rubber, synthetic plasticiser and solvents suitably blended to produce a liquid coating which may be applied by brushing or spraying and which will produce effective bond between the metal and subsequent coating of coal tar enamel. Primer should not contain benzol or other toxic and / or highly volatile solvents, added pigments or inert fillers or other substances and shall show no tendency to settle out in containers. The main characteristics of the primer shall be as follows:Drying time to touch at normal humidity @ 30 deg. C (70%) Flash point, BS 2000, part 170 Flow time 4 mm flow cup (ISO) at 23 deg. C; BS 3900, Part A6. Volatile matter (105 - 110 deg. C), max. by mass. BS, Appendix A Coverage Approx. 5 - 15 minutes

23 deg. C (minimum)

35 - 60 sec.

75% loss

8 - 12 Sq. MT/lit/coat

4.2.2

Priming Operation (Cold applications) The primer shall be applied on the pipes in uniform thin film (single coat) leaving no drips or runs. The entire surface of the pipe should be primed without any patch left out. Any unprimed places shall be reprimed immediately. Any flooded areas or primer applied on improperly cleaned pipe shall be cut down to surfaces of pipe and reprimed at Contractor's cost. The primer shall be cold applied to a clean dry surface, immediately after cleaning operation. The surface shall be dry at the time of applying primer coat. Primer shall not be applied during rain or fog or on wet surface. Primer which becomes foul with foreign substances or thickened through evaporation of solvent shall not be permitted. Freshly primed pipe shall be placed on clean square cut skids and shall not be allowed to come in contact with the ground or with any other foreign matter. It shall remain on skids until lifted or cradled for the coating and wrapping operation. All primed pipes which have excessive coat of dust or primer accumulated over them before the primer is dry or where primer has become dead shall be reprimed. Drying time shall be minimum 24 hours. The application of coal tar coating shall be taken up after the primer coat has dried up completely and normally within 24 hours after priming with

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maximum limit of 5 days. Otherwise a fresh coat of primer shall be applied at Contractor's cost. The Company Site Representative shall approve the primer coat before the next coat is applied. The primer shall be applied as received from the manufacturer and should not be thinned under any circumstances.

4.3 4.3.1

Coating and Wrapping Coal Tar Enamel Enamel shall be composed of a specially processed coal tar pitch combined with an inert mineral filler. No asphalt of either petroleum or natural base shall be acceptable as part of the ingredients. The enamel shall have the following physical characteristics conforming to AWWA C 203 / 86 / BS 4164, 1987. Softening point (Ring and Hall) ASTM D36 Filler (Ash) ASTM D-2415 by Wt. Fineness filler, through 200 mesh ASTM D-546 by wt. Specific gravity at 25 deg. C ASTM D 71 Penetration, AWWA C 203-86 Sec. 2.8.1 @ 77 deg. F (25 deg. C) - 100 gm. Wt. - 5 sec. @115 deg. F (46 deg. C) 50. wt. - 5 sec. High Temperature Test (SAG) @ 162 deg. F (71 deg. C) AWWA C-203-86 sec. 2.8.9 Low Temp test @ 10 deg. F, (-23 Deg. C) (Cracking) AWWA C 203-86 Sec. 2.8.10 Impact test @ 77 deg. F (25 deg. C) Direct impact 650 gm ball, 8 ft. AWWA C 203-86 Sec. 2.8.12 Min. 105 Deg. C 25% Max. 115 Deg. C 35%

90% 1.4

1.6

10

12

20

1/16" (1.6 mm)

None 16 sq. in (10,323 sq.mm) 6 sq. in

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - BLACK OIL TERMINAL Doc No:254625-300-SP-PIP-016 Indirect impact Peel test, AWWA C-203-86 Sec. 2.8.11 Spark test 15 KV low amperage Water absorption, 35 weeks Application temperatures 4.3.2 Glass Fibre Mat for Inner Wrapping The fibre glass mat for inner wrapping shall be thin, flexible, uniform mat composed of chemically resistant borosilicate glass fibre tissue or hydrolytic class 3 - m conforming to DIN-12-111 mono-filaments disturbed in a random open porous structure, bonded together with a thermosetting phenolic type resin which shall be compatible with the coal tar enamel. The inner wrap glass fibre tissue shall be longitudinally reinforced by continuous filament glass yard embedded in mat & shall have nominal thickness of 0.5 (0.02") and shall conform to AWWA C 203-86, Appendix section A.2. No disbonding of individual glass fibre shall occur during or following the embedding process. The glass fibre mat shall not cause bubbling under the condition of application. The glass fibre mat shall be sufficiently porous so that it can be embedded in the hot coal tar enamel as it is applied to the exterior of the pipe. The glass fibre mat shall be free from thin spots, pimples, lamination, uncured binder flows, wrinkles, torn edges, dust, oil and grease etc. The glass fibre mat (reinforced glass wrap) shall also conform to AWWA section A2 and the following characteristics. Weight (min) Nominal thickness Tensile Strength (Average, Breaking Strength) Longitudinal direction Transverse direction Porosity 2277 N/M of WIDTH (min.) 700 N/M of width. The glass fibre mat shall have a porosity of not more than 1.90 mm water gauge measures at pressure difference across the samples at an air velocity of 1.02 m/sec. The glass fibre tissue shall be unaffected under load in hot enamel at 530 deg. F (228 deg. C) for one minute. 41 gms / sq. mt 0.5 mm + 0.1 mm C-203-86 Rev: A Page 8 of 13 225 deg. C (3841 sq. mm) No peeling None 0.3% 245 deg. C

Temp. Resistance

Moisture absorption 5% (max.) by wt. at relative humidity of 95% at 120 deg. F (50 deg. C) for 24 hrs.
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Outer Wrap Coal Tar Impregnated Class Fibre The outer wrap shall be non-woven, thick, reinforced glass fibre mat uniformly impregnated with coal tar enamel and shall conform to AWWA C-203-86, Section 2.10.3 with following characteristics. Glass Tissue base Weight (Finished Material) Thickness Tensile strength (Average Breaking Strength) Longitudinal Direction Transverse Direction Pliability (1" dia mandrel 25 deg. C 2 sec) Weight loss on heating at 82 deg. C for 2 hrs. Moisture absorption Percentage of weight at a relative Humidity of 95% and 120 deg. F (50 deg. C) for 24 hrs. 6130 N/M of width (min.) 4730 N/M of width (min.) 83 gm/sq. mt. (min.) 586-732 gm/sq. mt. (12-15 lbs / 100 sq. ft.) 0.76 mm (30 mills)

No cracking 2% (max.)

5% (max.)

The finished reinforced glass fibre mat outer wrap shall have a smooth, uniform surface free of visible defects. When unrolled at a temperature from 0 deg. C to 50 deg. C, the outer wrap shall not crack or stick to such an extent as to cause breaking or tearing. The outer wrap shall be purchased in tightly wound tied rolls with a 3" diameter core in widths and lengths as specified at the time of purchase. The rolls shall be packed to exclude dust and dirt during shipping and handling and shall have cardboard separators and end shields adequate to prevent roll damage when stacked. The sides of the rolls shall be clean, smooth and squared cut and shall have no telescoping. The white wash used as a final coat shall be manufactured in accordance with white wash formulas as specified in AWWA C-203-86, Section 2.11. 4.3.4 Preparation of Coating Materials The coal tar enamel shall be furnished in expandable sheet metal or drums that shall be cropped or cut out on a suitable platform to prevent the enamel from coming in contact with weeds, cinders, grass and other forms of contamination. The cropped or cut pieces of enamel may not weigh more than 10 kgs. The pieces of enamel shall be covered when they are in danger of contamination because of atmospheric conditions. The broken enamel shall be placed in a clean melting kettle and slowly heated at a uniform rate of 225 deg. C to 245 deg. C (application temperature) or manufacturer's recommended temperature. Any coating material heated to more than the above mentioned temp shall be rejected. Spilled material which has become contaminated shall not be returned to the melting kettle.
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The coating being prepared for use by coating machine shall be agitated in melting kettles having continuous mechanical agitators. Small melting kettles without mechanical agitators can be used with the approval of the Company Site Representative. The melted enamel in these kettles shall be stirred at an interval of not more than 15 minutes during heating with metal agitators. Wooden paddles or sticks shall not be used for stirring. Accurate thermometers shall be used on heating kettles in such a way as to read clearly. The thermometer bulb shall be within 100 mm from the bottom of kettle and shall have temperature range from 100 deg. C - 300 deg. C. Any coating material that has been heated in the kettles to a temperature in excess or what is specified herein or by manufacturer's recommendation shall be condemned and shall not be used. 4.4 4.4.1 Application of Hot Coal Tar Enamel and Inner Glass Fibre Wrap First coat of hot coal tar enamel shall be applied over the adequately cured primed surface to a minimum thickness of 2.0 mm. The Company Site Representative shall cut samples and test the thickness of coating and further work of outer coating shall be taken up only after the inner coating has been approved by the Company Site Representative. Simultaneoulsy with the first coat of coal tar the fibrous glass mat shall be mechanically applied in machine. It is preferable to pass the fibre glass mat through a bath of hot coal tar enamel before being applied over the pipe. Sufficient tension shall be applied to the rolls of fibrous mat to embed it in the coal tar enamel before it cools to furnish a proper bond with the next layer of coal tar enamel. The fibrous glass mat shall be of suitable uniform width for smooth spiral application. The overlap of the fibrous mat shall not be less than 1/2 inch (12 mm). A second coat of hot coal tar enamel shall then be applied of such a thickness that finished thickness of two layers of enamel inner and outer wraps shall be a minimum of 4.0 mm. 4.4.2 By manual Application The already primed pipe is placed in a fixed position. The coal tar enamel heated to 225 deg 245 deg. C is then applied by means of sling as follows:A canvass strip (alternatively a tinplate strip) about 450 mm wide and 1.5 m long is held under the pipe by two men. Molten enamel is poured on the sling at each end of the pipe and some on top of the pipe. The men holding this sling move it up and down and walk slowly forward whilst fresh enamel is poured on the pipe and they manipulate the sling so that an even coating is obtained all around. This work shall be done very carefully and by experienced personnel. There shall not be any formation of "whiskers" and holes in the coating must be made good. The glass fibre material wrapping may be applied with hand with the approval of the Company Site Representative. 4.5 Application of Second (Outer) Layer of Coal Tar Enamel Coating & Glass Fibre Wrapping Immediately after application of the 2nd layer of coal tar enamel, outer wrap of coal tar impregnated glass fibre shall be applied in a tight uniform spiral and shall be spirally wound round the pipe with a minimum of 15 mm of overlap on each spiral.
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The thickness of final coat of enamel shall be so adjusted that the total finished thickness of double coating & wrapping in dividing outer wrap in maintained minimum 4.0 mm. The coating and wrapping must be free of pin holes, bubbles or holidays. The Company Site Representative shall cut samples from the coating from time to time to determine the thickness and bond of coating. 4.6 4.6.1 Primer, Coating and Wrapping Application for Field Joints of Pies after Laying at Site. Primer shall be applied with brushes after cleaning the pipe thoroughly (Joints portion etc.) as per specification. When the primer has dried one coat of coal tar enamel shall be applied and glass fibre mat inner wrap shall be spirally wound round the pipe over enamel. Final coat of coal tar enamel along with outer wrap of coal tar impregnated glass fibre shall be applied so that total thickness of coating and wrapping shall be maintained minimum 4.0 mm. The overlaps for the outer wrap and glass fibre mat shall be minimum 100 mm over the original coating and wrapping including tapering portions, if any. No wrinkling in the wrapper shall be allowed and all the overlaps shall be cemented down with hot coal tar enamel to secure a firm wrapping. This coating must be absolutely free of pinholes, bubbles and holidays. Inspection The work 'Inspector' means a person designated by the Company Site Representative for inspection and approval of the work under this specification. The entire procedure of applying the protective coating material as herein specified will be rigidly inspected from the time the bare pipe is received until the coated pipe is laid in the trench and back-filled and / or installation of coated pipe is complete. Such inspection shall not relieve the contractor of his responsibility to furnish material and perform work in accordance with these specifications and shall not relieve him of the guarantees under this contract. All coating and wrapping work to be acceptable must be applied in the presence of the inspector, and all such work done in his absence will be subject to rejection unless the continuance of the work during his absence is specifically allowed by the inspector. If at any time it is found that the procedure of applying the protective coating and wrapping material is not in accordance with these specifications, all such coating work may be rejected. The coating and wrapping work will be inspected in stages namely after cleaning of the pipes, application of primer coat, application of coal tar enamels, fibre glass inner wrap and outer wrap, coal tar impregnated glass fibre. Prior to approval of the contractor's material, samples of materials submitted by the contractor will be tested by the contractor for various tests as per the relevant standards and if any sample is found not to conform to these specifications, material represented by such samples will be rejected. If samples of contractor's approved materials are found not to conform to the specifications all such materials will also be rejected. Samples submitted to the Company Site Representative will be tested in an approved responsible commercial laboratory, designated by the Company Site Representative. The expenses of testing of all samples of materials offered by the Contractor and the expenses of all subsequent tests due to failure of samples of material originally offered to comply with these specifications will be borne by the contractor.
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4.6.2

4.6.3

4.7 4.7.1

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In addition to above, the contractor shall submit manufacturer's certificates, in original for each batch of materials used on the job. The contractor shall furnish the inspector reasonable facilities and space without charge for the inspection testing and obtaining of such information as he desires regarding the characteristics of materials used and the manner in which the work is progressing. The Field Bond Test Procedure, as per AWWA C-203-86 section 2.8.11 or BS 4164 Appendix L shall be applied to each pipe initially till the Company Site Representative relaxes it later to a random of one in ten pipes The pipe shall be thoroughly inspected for any holidays, pinholes, torn, abraided or mutilated spots. The contractor shall furnish and operate at his own cost, a high voltage electronic holiday detector of type acceptable to Company Site Representative. The detector will have to be calibrated by the contractor at his own cost before use and the calibration shall be witnessed and approved by the Company Site Representative. 4.8 4.8.1 Testing and Repairs All the finished insulation shall meet with the requirements of spark tests to be applied with Holiday detector. All pinholes, voids, holidays, air bubbles, cracks and other breaks, shall be carefully marked. Repairs may be made immediately following the coating and wrapping operation or may be deferred but in any case shall be repaired and re-inspected prior to installation. Repairs to coal tar enamel coating shall be made by removing the damaged coating back to the pipe surface, hot coal tar enamel shall then be poured over this area and a piece of outer wrap of similar size shall then be embedded and bonded to the enamel. All coating repairs shall be made with the wrap smoothly applied and without wrinkles or buckles. Repair shall be atleast equal in effectiveness to the coating applied to the principal part of the line. All repairs must successfully pass a test by the electronic holiday detector. The thickness of coating and wrapping shall be checked with suitable instrument by the contractor at his own cost. If the thickness is found insufficient, the contractor shall have to modify the same to the satisfaction of the Company Site Representative without any extra cost. Handling and Supporting coated pipes Contractor shall develop the method of stock piling and loading out coated pipes and shall receive approval from Company Site Representative prior to handling of coated pipes. The coated pipes shall be carefully handled so as not to damage them in any way. No wire ropes or chains shall be used to lift the coated pipe. Canvas or rubber belts of minimum 300 mm width and sufficient strength shall be used. The use of tongs, bare pinch bars, chain slings, protruding rivets, pipe hooks without proper padding or any other handling equipment that may injure the coating shall not be permitted. If the pipes are coated in a ship, one pipes should not placed above another during transit in wagon or truck. The pipe shall be carried on suitable paddle skids mounted on the wagon or truck to ensure that the coating will not be damaged in any way.

4.8.2

4.9 4.9.1

4.9.2

4.9.3

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Pipes shall be stored in the field under covered protection during rains. Pipe shall be kept on clean square cut padded wooden skids protected with fibre glass mat. felt or straw until ready to be lowered in the trench. The contractor handling and transporting the pipe shall conform to standards as set out in AWWA C-203-86 section 4.1 "Transporting and Handling Enameled Pipe". Adjacent pipe - Lines, Structures etc If any damage is caused to the coating and wrapping of adjacent pipes or any other existing structure during excavation of subsequent work or during coating and wrapping of field joints the contractor shall carry out necessary repairs at his own cost in a manner as directed by the Company Site Representative. Repair of Pipe Any damage to the pipe, such as dents, gauges, flattering or damage caused by contractor to bevels shall be cut out, the pipe beveled and if necessary, re-welded with prior approval of Company Site Representative. All such rewelding shall conform to the applicable provisions of codes. The cost of work, plus the cost of pipe lost due to repair will be to the account of contractor.

4.9.5

4.10 4.10.1

4.10.2

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