specifications & sow

7/28/2019 Specifications & Sow

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GAIL (India) Limited(A Government of India Undertaking)

(A Navratna Company)

TENDER NO. Page 1 of32OF SPECIFICATIONS & SOWSUB: TRANSPORTATION, HYDRO TESTING, WRAPPING COATING & PRESERVATION OF INSURANCE LINE PIPE OF HVJ& DV PIPELINES

AT GAIL, JHABUA.

SECTION-V

SPECIFICATIONS

&SCOPE OF WORK

[SOW]


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AT GAIL, JHABUA.

SCOPE OF WORK & TECHNICAL SPECIFICATION

1.0 INTRODUCTION1.1 M/s GAIL (India) Limited is one of the major natural gas cross country pipeline operator in India & is operating more than

7500 kmof natural gas pipelines in India. These pipelines are feeding Natural Gas to various Petrochemical, Fertilizer, LPG

& Power Plants located along the pipeline route.1.2 The pipeline is designed as per ASME B 31.8 &OISD 138 & 141 standards. Various guidelines under API, DIN, BS,

Canadian Standards, NACE, NFPA, etc are also followed.1.3 GAIL (India) Limited, Jhabua maintains approximately 125.463 kilometers each of HVJ(36OD), DV-I(42OD) & DV-

II(48OD) pipelines from DevgarhBaria [Dahod district of Gujarat, (HBJChainage229.460km), IP-03 for HVJ&SV-08 forDVPL-I&II] to KasarBardi [Jhabua district of Madhya Pradesh, (HBJChainage 354.923), SV-13 for HVJ&SV-15 for DVPL-I &II] and its associated terminal facilities like IP/ RR &SV stations and also has a compression facility consisting of GTC trainsof varying make & capacities along with other auxiliaries required for running the same.

1.4 Maximum Allowable Working Pressure (MAOP) for these HVJ, DV-I & II pipelines under Jhabua jurisdiction is 92 Kg/Cm2g&pipe is operating as per the said operating condition.

1.5 To cater to the emergency requirement GAIL (India) Ltd., Jhabua, intendsa) To carry out the hydro testing ofcoated line pipes kept as insurance sparesb) To take suitable remedial measures to prevent the line pipes from corrosion& ensuring proper preservation.

1.6 The details of line pipes are given in technical detail section.

2.0 OBJECTIVE2.1 The main objective of this tender is to carry out the following jobs:-

a. Shifting of 42 OD coated line pipes from GAIL (India) Limited, Vijaipur to GAIL (India) Limited, Jhabua, as perapproved procedure. Road distance of GAIL, Vijaipur from GAIL, Jhabua is approximately 400 km (Four Hundred).GAIL, Vijaipur is having pin code of 473112 & is situated in district Guna in the state of Madhya Pradesh, India.

b. Hydro testing of 36, 42 & 48 OD coated line pipes of varying wall thickness atrequired pressure as per approvedprocedure

c. Holiday testing of coated line pipes to check the healthiness of the coating as per approved procedured. Field repair of coating of line pipes having damaged coating as per approved proceduree. Inside painting of pipes as per approved proceduref. Stenciling/ painting of pipe details on its outer& inner surface as per approved procedureg. Stacking of pipes as per approved procedureh. Supply/ fabrication & installation of end caps for line pipesi. Proper documentation of hydro testing & other activities for future reference & records

3.0 TECHNICAL DETAIL OF PIPELINE3.1 Detail of 42 OD coated line pipes to be shifted from GAIL, Vijaipur

Sl.

No.

Coated Line Pipe Detail Wall Thickness

of the Line pipe

in mm

Approx imate Total Length

of Coated Line Pipe to be

Shifted in meter

Approx imate Total No.

of Coated Line Pipe to

be Shifted

1 42 OD API 5L GR X-70 20.6 324 27

3.2 Detail of coated line pipes to be hydro testedSl.

No.

Coated Line Pipe Detail Wall Thickness

of the Line pipe

in mm

Approx imate Total Length

of Coated Line Pipe to be

Hydro tested in m eter


of Coated Line Pipe to

be Hydro tested

1 42 OD API 5L GR X-70 20.6 72 06

2 48 OD API 5L GR X 70 23.8 72 06

3 36 OD API 5L GR X 60 22.22 72 06


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3.3 Details of coated line pipes to be holiday tested&internallypaintedSl.

No.

Coated Line Pipe Detail Wall Thickness of

the Line pipe in mm

Approx imate Total Length of

Coated Line Pipe in meter


of Coated Line Pipe

1 42 OD API 5L GR X-70 20.6 324 27

2 36 OD API 5L GR X 60 22.22 154 14

3 36 OD API 5L GR X 60 19.05 262 25

4 36 OD API 5L GR X 60 15.88 178 16

3.4 Detail of line pipes for supply/fabrication and installation of end cap, stenciling/ painting of pipe details on its outer surface& inner surface & stacking.

Sl.

No.

Coated Line Pipe

Detail

Wall Thickness

of the Line pipein mm

Approx imate Total

Length of CoatedLine Pipe in meter

Approx imate Total

No. of Coated LinePipe

Approx imate Total

No. of End Caprequired

1 42 OD API 5L GR X-70 20.6 324 27 54

2 48 OD API 5L GR X 70 23.8 133 11 22

3 48 OD API 5L GR X 80 17.5 112 09 18

4 48 OD API 5L GR X 70 15.9 44 04 08

5 36 OD API 5L GR X 60 22.22 154 14 28

6 36 OD API 5L GR X 60 19.05 262 25 50

7 36 OD API 5L GR X 60 15.88 178 16 32

4.0 DETAILED SCOPE OF WORK4.1 General4.1.1 Transporting, loading & unloading the pipes from GAIL pipe yard to work location (for hydro testing, holiday testing, coating

repair, inside painting etc.) & vice-versa.4.1.2 The line pipes for are PE coated and all possible care must betaken to avoid coating damage during the work. While

handing over the pipeline to contractor for different jobs, a joint inspection by GAILs representative & contractor shall be

done to check the condition of coating. In case of damage of coating occurred during transportation, handling, stacking,other working etc. by the contractor then same shall be repaired as per direction of EIC without any extra cost to GAILincluding supply of all materials.

4.2 Shifting activities of 42 OD coated line pipes from GAIL, Vijaipur, as mentioned at para 3.1 above shall beconsisting but not limited to thefollowing:-

4.2.1 The line pipes required to be shifted from GAIL, Vijaipur are PE coated and all possible care must betaken to to see thatpipes along with coating shall not get damaged at the time of handling, storage & transportation.While handing over the linepipe to contractor for hydro testing, a joint inspection by GAILs representative & contractor shall be done to check thecondition of coating. In case of damage of coating occurred during transportation, handling, stacking etc by the contractorthen sameshall be repaired as per direction of EIC without any extra cost to GAIL including supply of all materials.

4.2.2 All mobile cranes shall have adequately long slings to prevent buckling of pipes and must have hooks with Teflon padding.4.2.3 Coated pipes shall be handled using suitable means & in a manner to avoid damage to coating pipe walls & beveled ends.4.2.4 At the time of transportation pipes shall be stacked in maximum 2(two) layers


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4.2.5 Pipes shall be transported by trailers having requisite load bearing capacity and must have proper & valid legal documents.4.2.6 Trucks/ Trailers shall prior to loading be cleaned of debris or any other substance that might damage the pipe.4.2.7 Coated pipes shall be handled by rolling of the pipes on the level beads and padded racks.4.2.8 Cranes of proper capacity and having valid test certificates (issued by any competent authority) shall be used for lifting,

loading & unloading of coated pipes. In any case Fork Lifts should not be used for handling of coated pipes.

4.2.9 Notarized copy of valid fitness certificate & load test certificate issued by competent authority w.r.t crane & slings (metallic,nonmetallic) deployed for the job shall be submitted to EIC prior to start of the job.

4.2.10 Direct contact with steel or hemp slings or with any material whose shape or nature may deteriorate the pipe shall be strictlyprohibited.

4.2.11 Trucks/ trailers used to transport coated pipes shall have an uninterrupted flat bed of approximately 12 meters length and2.4 meters width equipped with side stanchions of about 0.9m height. Pipes shall be protected against truck bed by meansof at least five nonmetallic cross beams. Nonmetallic separation shall be provided to avoid any damage to coating by sidestanchions.

4.2.12 Wooden slipper shall be made from good quality SHISHAM wood.4.2.13 After loading suitable nonmetallic slings shall be used to tie the load securely to the truck. During transport, the tension of

these slings shall be regularly checked. The pipe ends shall be protected from contact with other metallic materials.4.2.14 Persons engaged in handling, storage & transportation shall follow safety norms.4.2.15 Contractor or his authorized representative (carrying proper photo authentication and duly forwarded by EIC) shall receive

the pipes from store in charge of GAIL, Vijaipur& shall sign on the store issue voucher (SIV).4.2.16 Necessary transit insurance shall be arranged by GAIL.4.2.17 Pictorial representation of stacking arrangement of 42 OD coated pipes on trailer for transportation & coated pipe

transportation arrangement of 42 pipe on trailer has been placed at annexure I & II respectively.4.2.18 All arrangement w.r.t manpower, machinery, materials required for receiving the pipes at GAIL, Vijaipur, loading in trailers,

transportation to GAIL, Jhabua, in transit paper formalities & statutory clearances(if any), unloading at GAIL, Jhabua,stacking etc. shall be the responsibility of the contractor.

4.3 Hydro testing o f 36, 42 & 48 OD coated line pipes of varying wall thickness at required pressure as per approvedprocedure as mentioned at para 3.2 above shall be consist ing but not limi ted to the following:-

4.3.1 Transporting, loading & unloading the pipes from GAIL pipe yard to hydro testing location & vice-versa.Pipes shall betransported from pipe yard to hydro testing location&after hydro testing same shall be transported to pipe yard as perinstruction of EIC& will be stacked on wooden slipper.

4.3.2 The line pipes for hydro testing are PE coated and all possible care must betaken to avoid coating damage during the work.While handing over the pipeline to contractor for hydro testing, a joint inspection by GAILs representative & contractor shallbe done to check the condition of coating. In case of damage of coating occurred during transportation, handling, stackingetc by the contractor then same shall be repaired as per direction of EIC without any extra cost to GAIL including supply ofall materials.

4.3.3 Wooden slipper having width & thickness: 12 and length: as per requirement of pipes, shall be provided by contractor andsuitable profile/curvature shall be cut in the wooden slipper to stack the line pipes. Wooden slipper shall be made from goodquality SHISHAM wood.

4.3.4 All the welding works including edge preparation etc. required for hydro testing of pipes shall be done by contractor & all the

consumables including welding machine, generator,hydro testing pumps, water, manpower etc. shall be arrange by thecontractor. Utilities like water, electricity etc. may be provided by GAIL on request of contractor on chargeable basis as perterms & conditions of GAIL which shall be completely binding on contractor.

4.3.5 Hydro testing may be done either by welding of hydro test header in each pipe or series of pipes may be welded together forhydro testing. However, due to space constrain it will not be possible to carry out hydro testing of more than 50(fifty) meterof length in a single section. Hydro testing shall be done near pipe yard only & space available shall be used for hydrotesting. While utilizing the space for hydro testing care must be taken for approach to pipe yard & free movement of vehicles&fire tender.

4.3.6 Hydro testing shall be done around at 128.8 Kg/cm2gpressure & hold time shall be minimum four (04) hours in accordanceto specification detailed elsewhere in the tender document. Pressure recording from electronic data recorder shall be done& graph plotted from data recorder shall be submitted along with hydro testing report.

4.3.7 Cleaning, grading of area, removal of all unwanted vegetation & rubbish where hydro testing is to be done shall be done bythe contractor.The contractor shall barricade the layout of proposed area and necessary warning sign boards are to bedisplayed and shall have to take necessary action for safety.


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4.3.8 After hydro testing each pipe shall be cut &beveled. Ultrasonic thickness testing of heat affected zone shall be done tocheck lamination. The beveling shall be done as per instruction of EIC.

4.3.9 To facilitate the hydro test in small sections, stacking and line up for welding including arrangement of supports, cleaning ofinternal surface of line pipe for dirt, dust, mud & other foreign material, repairing of bevels (if required), welding of line pipesshall be done by contractor.

4.3.10 Beveling/edge preparation of line pipe shall be as per API1104.4.3.11 Fabrication of end caps/dish-end from CS plate, stiffening end cover and welding the line pipes shall be as per API1104.CS

plate of required thickness will be arranged by contractor.4.3.12 Fabrication and arrangement of test header shall be in the scope of contractor. Header should have the provision for

connection of pressure gauge, temperature gauge, air vent and drain etc.4.3.13 Making arrangement for hydro test of line pipes including fabrication and welding of test header. The entire fabrication job

will be performed as per API 1104, approved procedure and as per direction of EIC.4.3.14 All welding shall be done by welders qualified in accordance with ASME section IX. Contractor shall submit welder

qualification record for the running welder being deployed for the job. The welder qualification shall be suitable for the D1Aor higher ratingwith proper validity of such qualification.

4.3.15 The whole procedure of hydro testing will be witnessed and certified by EIC or his authorized representative.4.3.16 Dewatering and disposal of water at appropriate place, drying the pipes by air blowing including arrangement of air

compressor and generator, cutting of welded joints after hydro testing, re-beveling, pipe end ultrasonic test, repairing ofcoating damages, holiday checking shall be in the scope of contractor.

4.3.17 All tools, tackles, equipment, instruments (valves, pressure gauges, recorders etc.) and requisite manpower, power andwater supply etc. required to complete the above job in totality will be arranged by contractor as per the requirement anddirections of EIC. Utilities like water, electricity etc. may be provided by GAIL on request of contractor on chargeable basisas per terms & conditions of GAIL which shall be completely binding on contractor.

4.3.18 Test header fabricated by contractor for hydro testing of coated line pipes shall be subjected to hydro test at a pressure of

128.8 Kg/cm2g prior to putting it into service.4.3.19 Ends of the pipes shall be covered by suitable end seal and payment for supply & installation of end cap shall be done as

per relevant SOR.4.3.20 Writing of all necessary information on hydro tested pipes by paints as per direction of EIC

4.3.21 The work shall be treated as complete after completing the work in all respects as per specifications, conditions and asdirected by EIC. It is contractors responsibility to clean and restore the site to the original conditions to the specification ofEIC or his authorized representative.

4.3.22 Rate quoted should be inclusive of all the above factors as well as other factors required for completing the job in all respect& same is not mentioned in the tender document. No separate payment shall be made on this regards.

4.3.23 The average length of each pipe is 12 Mtrs. The pipe length should not be reduced more than 100mm before and after thejob. The bevel angle shall be 37.5 degree with straight face of 1.5mm. The pipe scrap shall be returned back to GAIL

4.3.24 Cranes of proper capacity and having valid test certificates (issued by any competent authority) shall be used for lifting,loading & unloading of coated pipes. In any case Fork Lifts should not be used for handling of coated pipes

4.3.25 Notarized copy of valid fitness certificate & load test certificate issued by competent authority w.r.t crane & slings (metallic,nonmetallic) deployed for the job shall be submitted to EIC prior to start of the job

4.3.26 All the instruments like pressure gauges, dead weight testers etc. which are to be used for hydro test are to be calibrated

from NABL/ Govt. accredited testing lab. The calibration certificates are to be submitted to GAIL before the commencementof the hydro test.The reference for calibration shall be accessible as per ISO.

4.3.27 Before commencement of work, contractor shall submit a hydro test procedure for the above said line pipe for the approvalof EIC.However,ageneral hydro test procedure is enclosed with this tender document which is covering minimumrequirements of supply, works and operations to be performed by CONTRACTOR for hydrostatic testing of line pipes.Thishydro test procedure specificationsshall be read in conjunction with the conditions of all specifications and documentsincluded in the CONTRACTbetween GAIL and CONTRACTOR.

4.3.28 Identity cards should be issued to all the persons deployed by the contractor for carrying out the job. A list of all the personsdeployed shall be given to EIC prior to commencement of work.

4.3.29 The contractor will submit the field management organogram for the persons to be deployed to carry out the tendered workalong with Techno-commercial Bid in enclosed proforma with this document.

4.3.30 All arrangement necessary for carrying out this job shall be the contractors responsibility. However, GAIL will extend allpossible help in this regard but the same shall not relieve the contractor of his responsibilities.

4.3.31 If because of exigency of work, contractor is required to carry out the work round the clock, making all necessary


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arrangements like relieving his personnel, arranging food etc. for his employees shall be the contractors responsibilitywithout any liabilities to GAIL.

4.3.32 The jobs mentioned under Scope of Work shall be carried out as per work procedure, documentation, recommendations ofthe manufacturers procedure and as per the guidelines/directions of EIC or his authorized representative given from time totime to contractor.

4.3.33 All the items supplied by the contractor are to be manufactured and tested as per relevant IS codes.Standard procedure forhydro testing of line pipes as per API/ASME/ANSI.

4.3.34 Contractor shall submit the welding procedure and arrange the qualified welder or welder qualification test in accordancewith API 1104 at his own expense.

4.4 Holiday testing of coated line pipes to check the healthiness of the coating as per approved procedure asmentioned at para 3.3 above shall be consis ting bu t not limited to the following:-

4.4.1 Transporting, loading & unloading the pipes from GAIL pipe yard to testing location & vice-versa.Pipes shall be transportedfrom pipe yard to testing location&after holiday testing same shall be transported to pipe yard as per instruction of EIC& willbe stacked on wooden slipper.

4.4.2 The line pipes for hydro testing are PE coated and all possible care must betaken to avoid coating damage during the work.While handing over the pipeline to contractor for holiday testing, a joint inspection by GAILs representative & contractorshall be done to check the condition of coating. In case of damage of coating occurred during transportation, handling,stacking etc by the contractor then same shall be repaired as per direction of EIC without any extra cost to GAIL includingsupply of all materials.

4.4.3 Wooden slipper having width & thickness: 12 and length: as per requirement of pipes, shall be provided by contractor andsuitable profile/curvature shall be cut in the wooden slipper to stack the line pipes.Wooden slipper shall be made from goodquality SHISHAM wood

4.4.4 Each coated pipe length shall be checked over 100% of coated surface by means of a holiday detector of a type approvedby owner for detecting holidays in the coating.

4.4.5 The holiday detector shall be a low pulse DC full circle electronic detectorwith audible alarm and precise voltage control withDIN VDE 0433 Part 2.

4.4.6 The holiday detector shall be clearly identifiable by means of an individual number engraved in an identification tag attached

to the apparatus. A certificate drawn up by the Supervisory Body, will attest that the apparatus complies with the recognizedcode. Verification is effected with a high voltage voltmeter HV-40, calibrated by a calibrated testing bench (ball diameter 20mm) according to 50% method. For a preset scale value of 0.65, the maximum permitted deviation of the output voltage for5 V can be 15%. For a preset scale value of 8.3 the maximum permitted deviation of the output voltage for 25V can be 10%.Besides the calibration, the HV-cable and handle, the sealing ring, the earthing cable and earthing as well as the carryingcase must be accepted by the Supervisory Body. The maximum validity of the certificate is one year.

4.4.7 The holiday detector may only be used when the coating is completely dry and after through removal of dirt from thesurface.

4.4.8 The set voltage for inspection shall be 25 kV. Travel speed shall notexceed 300 mm/s.4.4.9 CONTRACTOR shall calibrate the holiday detector at least once every 4hours of production. CONTRACTOR shall have

necessary instruments ordevices for calibrating the holiday detector.4.4.10 Mark the areas on the line pipe surface where holiday observed with a marker not affecting the coating of the pipe.

4.4.11 Keep records of the defect locations pipe wise with proper traceability.4.4.12 All arrangement w.r.t manpower, machinery, materials required for completing the above job shall be the responsibility of

the contractor.

4.5 Field repair of coating of line pipes having damaged coating as observed after holiday testing as per approvedprocedure

4.5.1 For small defects following procedure shall be adopted:-I. The repair shall be carried out using repair patch made of radiation crosslinked Polyolefin backing, coated on the inside

with semi-crystalline thermoplastic Adhesive.II. The repair patch shall have thermal indicators to ensure correct heat is being appliedIII. The material shall not be older than their period of validity at the time of Application by CONTRACTOR.

Deteriorated/decomposed materials shall not be used.

IV. Material shall be stored in sheltered storages in the manufacturer's original packing andaway from direct sunlight and inaccordance with manufacturer's recommendations.


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V. The repair material shall be :A. Repair patch shall be cross linked polyolefin with semi-crystalline thermoplasticadhesive (PERP 80patch make of

Covalence Raychem or DensolenAS39P tape or equivalent).B. Filler mastic: PERPFILLER of make Covalence Raychem orDensolen mastic W or equivalent.C. Densolen Primer MT25 or equivalent

D. PERP melt stick of make Covalence Raychem or equivalent.E. Certified by DIN to meet the requirement of EN12068 stress class CHT 80.

VI.APPLICATION PROCEDUREA. The application procedure to be followed for Holiday type of damage shall be inaccordance with manufacturers

instructions and minimum requirements specifiedbelow whichever is more stringent.B. Preparation: Remove coating from damaged area with knife, scraper or power brush until the factory coating fully

adheres to the steel surface. Use the half round rasp to bevel the edges.C. Scrap off the damaged area and adjacent coating to remove oil, grease, ruse dirt andmoisture.D. Roughen up the surface of the factory coating with emery paper all-round the damaged area (approx. 100 mm).E. Apply Densolen Primer (MT 25) to the damaged area. At least 100 mm each side of the damaged area must be

primed.F. Preheating: Preheat the exposed bare metal surface to about 80C and adjacent pipecoating to about 60C with a

torch moved back and forth over the surface.G. Application of the Filler: Plastic filler shall be applied to all exposed metal surface. Themastic is heated and

smoothed down with a paint scraper to cover all bare metal in amanner such that all entrapped air is removed.H. Application of repair tape : Cut three (03) patches of DensolenAS39P tape in a manner such that it extends50 mm

beyond the damaged area in all sides, position it over the damaged area, heat until thetemperature sensitive painton the outside of the patch changes colour. It shall besmoothed down to confirm with the contour of lap, and shallbe freed of any airbubbles or wrinkles.

I. Press firmly over the damaged area, one on top of the other, a hard rubber roller may be used to apply morepressure if required. If one patch does not cover the whole area then use 2 per layer.

J. To secure the patches, wrap Densolen tape AS39P with a minimum overlap of 15mm around the damaged areaand then use similar size R20HT tape system to wrap around AS39P tapes.

K. Please follow Annexure-III wherein pictorial representation regarding the repair procedure and material to be usedhas been detailed.VII. INSPECTION, TEST

A. A visual inspection shall be carried out for the following :i. Mastic extrusion on ends of the patch shall be examined.ii. There shall be no sign of punctures or pin holes or bend failure. The externalappearance of the patch shall be

smooth, free from dimples, air entrapment orvoid formation.iii. The entire repair patch shall have changed colour uniformly.

B. HOLIDAY INSPECTIONi. The entire surface of the repaired section shall be inspected by means of a fullcircle holiday detector approved

by owner set to a DC Voltage of at least 25KV. Inspection of repaired patch shall be conducted only after it hascooledbelow 50C.

4.5.2 For cosmetic type of defects such as minor gauging tearing, scratches which do notindicate holiday during holidayinspection, following procedure shall be adopted :I. The defect area shall be roughened to remove loose polyethylene coating, oil grease,dirt etc.II. This shall be followed by application of repair patch, inspection & test as described above.

4.5.3 For bigger defects following procedure shall be adoptedI. Contractor shall supply joint coating materials, all equipment and manpower required for a skillful and adequate

application of coating in the field in accordance with the guideline described below.II. Contractor shall submit and demonstrate to Company proposed materials and worksprocedures for applying field

coating and repair procedures for same. Theseproposed procedures and all materials, equipment and tools used in thework shallbe subject to Companys approval.

III. Field joint anti-corrosion coating material shall becold applied tape suitable for a maximum operating temperature of (+)60C(Tmax) and shall conform to designation EN 12068 C HT 60 UV. In addition the fieldjoint anti-corrosion coating

shall comply with the requirements specified below under the heading Functional requirements of Field Joint Coating.IV. Cold applied tape system shall comprise of primer, an inner wrap and an outer wrap.The inner and outer wraps shall be


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asymmetric 3-ply tape with co-extrudedpolyethylene carrier film and butyl rubber adhesive layers on both sides. Theinnerlayer of butyl rubber adhesive of inner wrap shall have a thickness of min. 1.0 mm. Theinner and outer wraps areto be spirally wrapped with 55% overlap; equivalent to twolayers each providing a total minimum thickness of 3.0 mmon the pipe body and 2.5mm on the weld.The Contractor shall propose only those cold applied tape coating systemsthat havebeen previously used in pipelines of size 16" and above and a length of 50 km andabove in a single project for

similar operating conditions.V. Please follow Annexure-IV wherein pictorial representation regarding the repair procedure and material to be used has

been detailed

4.5.4 Functional Requirements of Field Joint CoatingA.Properties of the PE backing and the as applied joint corrosion coating shall be asfollows :

SN Property Unit Requirement Test Method1 Tensile Strength @+25 N/mm2 12 DIN EN 12068

2 Ultimate Elongation % @+25C 250 DIN EN 120683 Dielectric withstand KV with 1000Volts/sec k 30 ASTM D 149

4 Water absorption@+ 25C for 24 hours 0.05 ASTM D 570

5 Volume Resistivity @+25 Ohm-cm 1015 ASTM D2576 Resistance to thermal aging at 100 Change inelongation 250 DIN 30672

B.Functional Properties of Joint Coating System (As applied)As applied field joint coating system shall comply with the requirements of DIN EN 12068. Table 1 and 2corresponding to designation DIN EN 12068 C HT 60 UV, except asmodified below:i. CathodicDisbondment Resistance at Tmaxi.e. 60Cshallbe20mm when tested as per Annexure K of DIN EN

12068. Test shall be carried out at (+)60C.ii. Peel Strength shall be as follows :

Peel Strength Unit Requirement forMechanical

ResistanceClass C(Minimum)

Test Method as per DIN EN 12068

Inner to Inner +Outer to Inner

@23C N/mm 1.5

Annexure-B@Tmax N/mm 0.3

Outer to Outer @23C N/mm 1.5@Tmax N/mm 0.3

To Pipe Surface @23C N/mm 3.5

Annexure-C@Tmax N/mm 0.3

To FactoryCoating

@23C N/mm 3.5@Tmax N/mm 0.3

Notes: -[Tmaxshall be (+) 60C]Contractor shall obtain prior approval from Company regarding the manufacturer of thejoint coating material. Completetechnical details along with test certificates complyingwith the requirements of clause 4.5.3 and 4.5.4 shall be submitted toCompany for thispurpose. The Contractor shall furnish test certificates from an independent DINrecognized / approvedlaboratory for all the properties required for the specified ENdesignation of field joint coating and the requirements of thisspecification.

4.5.5 For Cold Applied Tape method, preferably following material shall be used:--Primer should be DENSOLEN MT 25.-Inner wrap shall be DENSOLENAS39P tapes having width of 100 mm.-Outer wrap shall be DENSOLENR20HT tapes having width of 100 mm.

4.5.6 The materials shall not be older than their period of validity at the time of application byCONTRACTOR. Deteriorated/decomposed material shall be disposed of and replacedby CONTRACTOR at his own expense.CONTRACTOR shall ensure that the coating materials supplied by him are properlypacked and clearly marked with thefollowing :


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- Manufacturers name- Material qualification- Batch number- Date of manufacturing and date of expiry.

4.5.7 CONTRACTOR shall ensure that the manufacturer has carried out all quality control tests on each batch and manufacturer

shall provide test certificates to certify that thesupplied materials meet the manufacturers specifications as indicated in thepurchase order and as approved by COMPANY. Certificates and data sheets certifying the qualities of the coating materialsshall be submitted by CONTRACTOR to COMPANY prior to application. COMPANY reserves the right to have the materialstested by an independent laboratory.

4.5.8 Materials shall be stored in sheltered storage in the manufacturers original packingand away from direct sunlight and inaccordance with manufacturers instructions.

4.5.9 CONTRACTOR shall provide and maintain mobile facilities which contains allnecessary equipment and its spares forcleaning, coating repairs, inspection and tests.

4.5.10 CONTRACTOR shall furnish sufficient number of the following equipment and therequired spares as a minimum forinspection and test purpose for each crew.a) Fully automatic full circle adjustable holiday detector with a visible and audible signal system for inspection of coatings.b) Thickness gauge for measuring thickness.c) Contact type temperature recording thermometer (Digital Pyrometer with flat probe type contact).d) Roughness profile measuring (Stylus) instrument

4.5.11 APPLICATION PROCEDURE4.5.11.1 General4.5.11.1.1The application procedure shall be in accordance with manufacturers instruction andthe minimum requirements specified

below whichever are the most stringent andshall be demonstrated to and approved by the Company. Manufacturersexpertshall supervise the application and shall be available at site upon request duringqualification of application procedureand during construction at Contractors cost.

4.5.11.1.2Operators for coating application shall be given necessary instructions and training before start of work, by the Contractor.To verify and qualify the applicationprocedures, all coating applied during the qualification test, shall be removedfordestructive testing until the requirements stated in sections Inspection and Testing of this specification are met.

4.5.11.1.3Oil, grease and salt shall be removed from steel surface by wiping with rags soaked with suitable solvents such as naphthaor benzene. Kerosene shall not be used forthis purpose. Solvent cleaning procedure according to SSPC-SP1 shall befollowed.

4.5.11.1.4Each field joint shall be blast cleaned using a closed cycle blasting unit or open expendable blasting equipment. With thefirst equipment type, steel or chilled shot and iron grit shall be used and Garnet material with the second one (in case theauthority having jurisdiction have no objection, the contractor may adopt sand blasting instead of garnet material). Duringblast cleaning the pipe surface temperature shall be simultaneously more than 5 and more than 3C above ambient DewPoint, while the ambient Relative Humidity shall not be greater than 85%. Prior to surface cleaning the surface shall becompletely dry. The surface shall be cleaned to a grade Sa 2 in accordance with Swedish Standard SIS-055900 with aroughness profile of 50-70 microns. Surface roughness profile shall be measured using an approved profile comparator inaccordance with ISO 8503-1 and shall be calibrated prior to the start of the work in accordance with ISO:8503-3 orISO:8503-4. The blast cleanliness shall be checked on every joint and the roughness profile shall be checked 1 every 10

joints.Dust grit or foreign matter shall be removed from the cleaned surface by an industrial vacuum cleaner. The dustcontamination allowed shall be of a rating max 2 as perISO:8502-3. The frequency of checking for dust contamination shallbe 1 every 10 joints.Blast cleaned field joint shall be coated within 2-4 hours according to the conditionsbelow:- Relative Humidity (RH) > 80% - 2 Hours- Relative Humidity (RH) 70-80% - 3 Hours- Relative Humidity (RH) < 70% - 4 HoursPipes delayed beyond this point or pipes showing any visible rust stain shall be blast cleaned again.

4.5.11.1.5The field joint surface shall be inspected immediately after blast cleaning and anyfeature of the steel surface such as weldspatter, scabs, laminations or otherimperfections considered injurious to the coating integrity made visible duringblastcleaning shall be reported to the Company Representative and on permission fromCompany Representative, such

defects shall be removed by filing or grinding. Pipesaffected in this manner shall be then re-blasted cleaned if the defectivearea is largerthan 50 mm in diameter.


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4.5.11.1.6The ends of existing pipe protective coating shall be inspected and chamfered. Unbounded portions of the coating shall beremoved 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 freshsurface of uncontaminated factory applied coating.

4.5.11.1.7All steel joint surfaces shall be thoroughly examined before the application of thecoating in order to ensure the surface are

free of soil, grease, rust, mud, earth or anyother foreign matter. All these substances shall be removed before coating, totheprocedures herein described.

4.5.11.1.8Protection coating shall be applied on the joints immediately after the completion ofcleaning operation.4.5.11.2 Applicat ion of Cold Applied Tapes

In addition to general requirements stated above following shall be taken care of:-4.5.11.2.1Cold applied joint protection tapes shall be of the type which can be applied by spirallywrapping on the pipe.4.5.11.2.2Immediately after the completion of surface preparation the approved primer of wet film thickness 150 microns or as per

manufacturers recommendation whichever is higher to cover the exposed bare metal of the welded field joint and 10 mmmin. onto the adjacent pipe coating if recommended by the manufacturer. Any dirt on the primed surface shall be removed.If the primer is damaged, the damaged area shall be cleaned and re-primed.

4.5.11.2.3Approximately 100 mm of tape interleaving paper shall be peeled back and tape shall be applied with the adhesive side tothe pipe. Whilst continuously removing the interleaving paper, the tape shall be spirally applied to provide a minimum of55% overlap. Sufficient tension shall be applied to ensure good conformity, avoiding air pockets and also continuouslysmooth out as the wrapping proceeds. The wrapping shall start and finish to give a minimum of 50 mm overlap on to theadjoining yard applied coating. Outer wrap shall also be applied in similar method.

4.5.11.2.4DENSOMAT wrapping machines to be used for wrapping of cold applied tapes over pipe surface.4.5.11.2.5Please follow Annexure-IV wherein pictorial representation regarding the repair procedure and material to be used has been

detailed4.5.11.3 Pre-Qualification of Field Joint Coating System

The field joint coating system materials and the procedures proposed by the Contractorshall be pre-qualified during thesleeve installation start-up phase. Five joints (5) shallbe coated with the requirements of this specification and theninspected and tested inaccordance with the requirements of this specification with respect to the following:i) Surface preparation cleanliness, roughness profile and dust contamination

ii) Pre-heat temperature (as applicable)iii) Primer thicknessiv) As applied coating thicknessv) Holiday detectionvi) Peel test at (+) 23C& (+) 60C on pipe surface & factory applied coating andat over laps (as applicable). If

required to achieve the temperature of (+) 60C,suitable thermal blanket may be used.vii) Visual appearance and void after installation on the body, area adjoining theweld and area adjoining the factory

applied coating. (To establish voidsadjoining the weld and factory coating a strip of 50 mm wide and 200 mmlongshall be stripped and examined).

Company Representative shall witness the tests and inspection. Regular application offield joint coating shall commenceonly upon successful completion of the prequalificationtesting.After successful completion of the pre-qualification testing as above, the entire fieldjoint coating shall be removed, the pipe

surface re-blasted and field joint coating reappliedas per the requirements of this specification.4.5.12 INSPECTION4.5.12.1 A visual inspection shall be carried out for the following:

- There shall be no sign of punctures or pinholes or bend failure. The external appearance of the coating shall be smooth,free of dimples, air entrapment or void formation.

4.5.12.2 Holiday InspectionThe holiday detector used shall be checked and calibrated daily with an accurate DC voltmeter. The detector electrode shallbe in direct contact with the surface of coatingto be inspected.The entire surface of the joint section shall be inspected by means of a full circle holiday detector approved by Company setto a DC voltage of at least 25 kV.

4.5.12.3 As-applied Coating Thickness


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Coating thickness shall be checked by non-destructed methods for each field joint.Average thickness of the as-appliedcoating on pipe body shall be established basedon measurement at min. eight locations i.e. four measurement on eithersides of thegirth weld at 3, 6, 9, & 12 Oclock positions. To establish the minimum thickness onthe girth weld, fourmeasurements shall be taken on apex on the weld at 3, 6, 9 & 12Oclock positions. All such measurements shall berecorded. CompanyRepresentative reserves the right to ask for additional measurement at any locationon the field joint

coating, whenever doubt arises.4.5.13 REPAIRS4.5.13.1 If a field joint is detected to be unacceptable after testing as per section 4.5.11 the Contractor shall, at his own cost :

- Determine the cause of the faulty results of the field coating.- Mobilize the expert of manufacturer, if required.- Test to the complete satisfaction of the Company, already completed fieldcoatings.- stop field coating until remedial measures are taken against the causes of such faults, to the entire satisfaction of the

Company.4.5.12.2 Contractor shall replace all joint coating found or expected to be unacceptable a persection 4.5.11 of this specification4.5.12.3 Contractor shall, at his own cost repair all areas where the coating has been removed for testing by the Company.4.5.12.4 After the coating work on welded joints, fittings and repairs to the coating have been completed the coating as a whole shall

be again inspected as per section 4.5.11.4.5.13 DOCUMENTATION4.5.13.1 Prior to procurement of coating materials, Contractor shall furnish the following information for qualification of the

Manufacturer and material:- Complete descriptive technical catalogs describing the materials offered along with samples of corrosion coating

materials, its properties andapplication instruction as applicable specifically to the project.- Test certificates and results of previously conducted tests, for all properties listed in clause 4.5.4 of this specification.- Reference list of previous supplies, in last 5 years, of the similar materialindicating the project details such as diameter,

quantity, operatingtemperature, years of supply, project name, contact person and feedback on performance.

Once the Companys approval has been given, any change in material or Manufacturer shall be notified to Company, whoseapproval in writing of all changesshall be obtained before the materials are manufactured.

4.5.13.2 Prior to shipment of materials from the Manufacturers Works, Contractor shall furnishthe following documents:i. Test certificates/ results as per Manufacturers Quality Control Procedure for each batch of materials.ii. Specific application instructions with pictorial illustrations.iii. Specific storage and handling instructions.

4.5.13.3 All documents shall be in English Language only.

4.6 Inside painting of pipes as per approved procedureas mentioned at para 3.3 above shall be consisting but notlimited to the f ollowing:-

4.6.1 Surface Preparation:I. Surface preparation shall be done as perSSPC-SP-10, i.e.blast cleaning to near white metal cleanliness,unit at least

95% of each elements of surface area is free of all visible residues with desired surface profilefollowingSteel StructurePainting Council, U.S.A standard [surface preparations specifications standard(SSPC-SP)].

II. Surface preparation required as per other standards shall be as follows:-a. SWEDISH STANDARD SIS-05-5900 1967 - SA 2 b. NACE USA - NACE #2c. BRITISH STANDARD BS-4232:1967 SECOND QUALITY

III. The contractor shall arrange, at his own cost, to keep a set of latest edition of the above standardsat site.IV. The paint manufacturers instructions shall be followed as far as practicable at alltimes. Particular attention shall be paid

to the following:a. Instructions for storage to avoid exposure as well as extremes oftemperature.b. Surface preparations prior to painting.c. Mixing and thinning.d. Application of paintsand the recommended limit on time intervalsbetween coats.

V. EQUIPMENT


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All tools, brushes, rollers, spray guns, abrasive materials hand/ power tools for cleaning and all equipment, scaffoldingmaterials, shot/ wet abrasive blasting,water blasting equipment& air compressors etc. required to be used shallbesuitable for the work and all in good order and shall be arranged by thecontractor at site and in sufficient quantity.Mechanical mixing shall be used for paint mixing operations in case of two packsystems except that the Engineer-in-Charge may allow the hand mixing of smallquantities at his discretion.

VI. In order to achieve the maximum durability, one or more of following methods ofsurface preparation shall be followed,depending on condition of steel surfaceand as instructed by Engineer-in-Charge. Adhesion of the paint film tosurfacedepends largely on the degree of cleanliness of the metal surface. Propersurface preparation contributes moreto the success of the paint protectivesystem:A. Manual or hand tools cleaning.B. Mechanical or power tool cleaning.C. Blast cleaning.

VII.Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a clean and dry surface is obtained.The minimum acceptable standard incase of manual or hand tool cleaning shall be St. 2 or equivalent, in caseofmechanical or power tool cleaning it shall be St. 3 or equivalent, in case of blastcleaning it shall be Sa 2 orequivalent as per Swedish Standard SIS-055900-1967/ ISO-8501-1-1988. Where highly corrosive condition exits, thenblastcleaning shall be Sa3 as per Swedish Standard.Remove all other contaminants, oil, grease etc. by use of an aromatic solventprior to surface cleaning.

VIII.Blast cleaning shall not be performed where dust can contaminate surfacesundergoing such cleaning or during humidweather conditions having humidityexceeding 85%.

IX. Irrespective of the method of surface preparation, the first coat of primer must beapplied on dry surface. This should bedone immediately and in any case within4 hours of cleaning of surface. However, at times of unfavorableweatherconditions, the Engineer-in-Charge shall have the liberty to control the timeperiod, at his sole discretion and / orto insist on re-cleaning, as may be required, before primer application is taken up. In general, during unfavorableweatherconditions, blasting and painting shall be avoided as far as practicable.

X. Procedure of Surface Preparation.A. Blast Cleaningi. Air Blast Cleaning

The surface shall be blast cleaned using one of the abrasives: AL202 particleschilled casts iron or malleable ironand steel at pressure of 7kg/cm2gatappropriate distance and angle depending on nozzle size maintainingconstantvelocity and pressure. Chilled cast iron, malleable iron and steel shall be in theform of shot or grit of sizenot greater than 0.055 maximum in case of steel andmalleable iron and 0.04 maximum in case of chilled iron.Compressed air shallbe free form moisture and oil. The blasting nozzles should be venturei style withtungstencarbide or boron carbide as the material for liners. Nozzles orifice mayvary from 3/16 to . On completion ofblasting operation, the blasted surfaceshall be clean and free from any scale or rust and must show a greywhitemetallic lusture. Primer or first coat of paint shall be applied within 4 hours ofsurface preparation. Blastcleaning shall not be done outdoors in bad weatherwithout adequate protection or when there is dew on the metalwhich is to becleaned, surface profile shall be uniform to provide good key to the paintadhesion (i.e.35to 50). Ifpossible vacuum collector shall be installed forcollecting the abrasive and recycling.

ii. Water Blast cleaningEnvironmental, health and safety problems associated with abrasive blastcleaninglimit the application of air blastcleaning in many installations. In suchcase water blast cleaning is resorted to.Water blast cleaning can be applied with or without abrasive and high-pressure water blasting. The water usedshall be inhibited with sodium chromate/phosphate. The blast cleaned surface shall be washed thoroughlywithdetergents and wiped solvent and dried with compressed Air. For effectivecleaning abrasives are used. Themost commonly used pressure for highpressure water blast cleaning for maintenance surface preparation is 3000to6000 psi at 35-45 liters/ minute water volume and pressure up to 10000 psi andwater volume of 45 liters/ minuteprovide maximum cleaning.The water blast cleaned surface shall be comparable to SSPC-SP-12/ NACE No. 5. The operation shall be carriedout as per SSPC guidelines for water blastcleaning. The indicative values for sand injection isAir : 300 to 400 Cu.ft/ min.

Water : 5-10 liter/ min. with corrosion inhibitorSand : 200-400 lbs/ hr.


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Nozzle : 0.5 to 1 diaSpecial equipment for water blast cleaning with abrasives now available shallbe used.

iii. Mechanical of Power tool cleaningPower tool cleaning shall be done by using mechanical striking tools, chipping hammers,grinding wheels or rotating

steelwire-brushes. Excessive burnish of surface shallbe avoided as it can reduce paint adhesion. On completion ofcleaning, thedetached rust mill scale etc. shall be removed by clean rags and/ or washed bywater or stream andthoroughly dried with compressed air jet before applicationof paint.

iv. Manual or hand tool cleaningManual or hand tool cleaning is used only where safety problems limit theapplication of other surface preparationprocedure and hence does not appearin the specifications of paint systems.Hand tool cleaning normally consists of the following:i. Hand descaling and/ or hammeringii. Hand scrapingiii. Hand wire brushingRust, mill scale spatters, old coating and other foreign matter, shall be removedby hammering, scrapping tools,emery paper cleaning, wire brushing orcombination of the above methods. On completion of cleaning, loosematerialsshall be removed from the surface by clean rags and the surface shall bebrushed, swept, deducted andblown off with compressed air/ steam to remove all loose matter. Finally the surface may be washed with waterand dried foreffective cleaning.

4.6.2 Coating Procedure and Application:I. Surface shall not be coated in rain, wind or in environment where injuriousairborne elements exists, when the steel

surface temperature is less than 5 Fabove dew point when the relative humidity is greater than 85% or whenthetemperature is below 40 F.

II. Blast cleaned surface shall be coated with one complete application of primer assoon as practicable but in no case laterthan 4 hrsthe same day.

III. To the maximum extent practicable, each coat of material shall be applied as acontinuous film uniform thickness free of

probes. Any spots or areas missed inapplication shall be recoated and permitted to dry before the next coat isapplied.Applied paint should have the desired wet film thickness.IV. Each coat shall be proper state of cure or dryness before the application ofsucceeding coat. Material shall be

considered dry for recoating when anadditional coat can applied without the development of any detrimentalfilmirregularities such as lifting or loose of adhesion of the under coat. Manufacturerinstruction shall be followed forintercoat interval.

V. When the successive coat of the same colour have been specified, alternatecoat shall be tinted, when practical,sufficiently to produce enough contrast toindicate complete coverage of the surface. The tinting material shallbecompatible with the material and not detrimental to its service life.

VI. Air spray application shall be in accordance with the following:A. The equipment used shall be suitable for the intended purpose, shall becapable of properly atomizing the paint to

be applied, and shall beequipped with suitable pressure regulators and gauges. The air caps,nozzles, and needles

shall be those recommended by the manufacturerof the equipment for the material being sprayed. The equipmentshall bekept in satisfactory condition to permit proper paint application.

B. Traps or separators shall be provided to remove oil and condensed waterfrom the air. These traps or separatorsmust be of adequate size andmust be drained periodically during operations. The air from the spraygun impingingagainst the surface shall show condensed water or oil.

C. Ingredients shall be kept properly mixed in the spray pots orcontainers during application by continuousmechanical agitation.

D. The pressure on the material in the pot and of the air at the gun shall beadjusted for optimum sprayingeffectiveness. The pressure on thematerial in the pot shall be adjusted when necessary for change inelevation ofthe gun above the pot. The atomizing air pressure at the gunshall be high enough to properly atomize the paint butnot so high as tocause excessive fogging of paint, excessive evaporation of solvent, orless by overspray.

E. Spray equipment shall be kept sufficiently clean so that dirt, dried paint,and other foreign materials are not

deposited in the paint film.Any solvents left in the equipment shall be completely removed beforeapplying paint tothe surface being painted.


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F. Paint shall be applied in a uniform layer, with overlapping at the edge ofthe spray pattern. The spray patterns shallbe adjusted so that the paintis deposited uniformly. During application the gun shall be heldperpendicular to thesurface and at a distance which will ensure that awet layer of paint is deposited on the surface. The trigger of thegunshould be released at the end of each stroke.

G. All runs and sags shall be brushed out immediately or the paint shall beremoved and the surface repainted.

H. Areas inaccessible to the spray gun shall be painted by brush: if notaccessible by brush, daubers or sheepkingshall be used.

I. All nameplates, manufacturers identification tags, machined surfaceinstrument glass, finished flange faces, controlvalve items and similaritems shall be masked to prohibit coating disposition. If these surfaces arecoated, thecomponent shall be cleaned and restored to its originalcondition.

J. Edges of structural shapes and irregular coated surface shall be coatedfirst and an extra pass made later.K. If spray gun shown choking, immediately dechoking procedure shall befollowed.

VII. Airless spray application shall be in accordance with the following procedure: asper steel structure paint manual vol. 1& vol. 2. By SSPC, U.S.A., Air less sprayrelies on hydraulic pressure rather than air atomization to produce thedesiredspray. An air compressor or electric motor is used to operate a pump to producepressures of 1,000 to 6.000 psi.Paint is delivered to the spray gun at thispressure through a single hose within the gun; a single paint stream isdividedinto separate streams, which are forced through a small orifice resulting inatomization of paint without the use ofair. This result in more repaid coveragewith less overspray. Airless spray usually is faster, cleaner, more economicalandeasier to use than conventional air spray.Airless spray equipment is mounted on wheels, and paint is aspirated in a hosethat sucks paint from any container,including drums. The unit shall have in builtagitator that keep the paint uniformly mixed during the spraying. The unitshallconsist of in built strainer. Usually very small quantities of thinning are requiredbefore spray. In case of High Buildepoxy coating (two pack), 30:1 pump ratiosand 0.020-0.023 tip size will provide a good spray pattern. Ideally fluidhosesshould not be less than 3/8 ID and not longer than 50ft to obtain optimumresults.In case of gun choking, decoking steps shall be followed immediately.

VIII. Brush application of paint shall be in accordance with the following:A. Brushes shall be of a style and quality that will enable proper applicationof paint

B. Round or oval brushes are most suitable for rivets, bolts, irregularsurfaces and rough or pitted steel. Wide flatbrushes are suitable forlarge flat areas, but they shall not have width over five inches.C. Paints shall be applied into all corners.D. Any runs or sags shall be brushed out.E. There shall be minimum of brush marks left in the applied paintF. Surface not accessible to brushes shall be painted by spray, daubers, orsheepkin.G. Manual application by sling (where 6 O clock position of pipe is notapproachable)

A canvas strip (alternatively a tinplate strip) about 450mm wide and 1.5m longsis hold under the pipe by two men.Liquid coating poured on the sling at eachside of the pipe. The men holding this sling move it up and down andwalk slowlyforward while fresh coating is poured on the pipe and they manipulate the slingso that an even coatingis obtainedall-round the bottom. This work shall be donevery carefully and by experienced personnel. There shallnot be any formation ofWhiskers and holes in the coating. The coating film shall be inspected bymirror.

IX. For each coat the painter should know the WFT corresponding to the specifiedDFT and standardise the paintapplication technique to achieve the desiredWFT. This is to be ensured in the qualification trial.

4.6.3 Drying of Coated SurfaceI. No coat shall be applied unit the preceding coat has dried. The material shall beconsidered dry for re-coating when

another coat can be applied without thedevelopment of any film irregularities such as lifting or loss of adhesionofundercoats. Drying time of the applied coat should not exceed maximum specifiedfor it as a first coat; if it exceeds thepaint material has possible deteriorated ormixing is faulty.

II. No paint shall be force dried under condition which will cause checking, wrinklingblistering formation of pores, ordetrimentally after the condition of the paint.No drier shall be added to paint on the job unless specifically called for inthemanufacturers specification for the paint.Paint shall be protected from rain, condensation, contamination snow andfreezing until dry to the fullest extentpracticable.


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4.6.4 Repair of damaged paint surface.I. Where paint has been damaged in handling and in transportation, the repair of damage coating of pre-creation/

fabrication shall be as given below.II. Repair of damaged inorganic zinc silicate primer after erection/ weldding:

Quickly remove the primer from damaged area by mechanical scraping andemery paper to expose the white metal.

Blasts clean the surfaces possible.Feather the primer over the intact adjacent surface surrounding the damaged areaby emery paper.

III. Repair of damaged pre-erection and shop priming in the design temperature of90 C to 500 C.- Surface preparation shall be done as per procedure 4.6.4(II)- One coat of F-9 shall be applied wherever damaged was observed on pre-erection/ pre fabrication/ shop primer ofinorganic zinc silicate coating(F-9) shall not be applied if damaged area is not more than 5 x 5 cm.

4.6.5 PAINT APPLICATIONI. For large flat surface field painting shall be done by airless spray otherwise brushcan be used.

4.6.6 PAINT MATERIALSPaint manufacturers shall furnish all the characteristics of paint materialon printed literature, along with the test certificate forall the specifiedcharacteristics given in thisspecification. All the paint materials shall beof first quality and conform to thefollowing general characteristics as perthe table below.

S No. Description Primer(P-6) Finish Paint(F-7)1 Technical Name Epoxy zinc phosphate

primerHigh build coaltar epoxycoating.

2 Type and composition Two componentpolyamide cured epoxyresin medium, pigmentedwith zinc phosphate.

Two pack polyamide curedepoxy resin blended with coal/tar medium, suitably pigmented.

3 Volume solids (approx) 40 65

4 DFT (Dry dilm thickness) per coat (approx) 40-50 100-1255 Theoretical covering capacity in M2/coat/litre (approx) 8-10 5.2-6.5

6 Welght per litre in kgs/ litre (approx) 1.4 1.5

7 Touch dry at 30 C (approx) After 30 minutes 4 hrs.8 Hard dry at 30 C (approx) Min.: 8 hrs.

Max.: 3-6 months48 hrs.

9 Over Coating Interval (approx.) Min : 8 hrsMax : 3-6 months

Min.: 24 hrs.Max.: 5 day

10 Pot life (approx) at 30 C for two components paints(approx).

8 hrs. 4-6 hrs.

11 Temperature Resistance 80C 125C

Notes:1. Covering capacity and DFT depends on method of application. Covering capacity specified above is theoretical. Allowing the

loose during theapplication, minimum specified DFT should be maintained.2. All primers and finish coats should be cold cured and air drying unless otherwise specified.3. All paints shall be applied in accordance with manufacturers instruction for surface preparation, intervals, curing and

application. The surface preparation, quality and workmanship should be ensured.

4.6.7 List of recommended manufacturers Company Name Brand Names

P-6

(Epoxy Zinc PhosphatePrimer)

F-7

(High Build Coaltar EpoxyCoating)

ASIAN PAINTS (I) LTD. APCODURHB. RO.ZP-PC433 APCODUR CF 300BARGER PAINT LTD. EPILUX 610 EPILUX 555NEROLAC PAINTS LTD. AMERCOAT 71 AMERCOAT 78 HB

J ENSON&NICHOSONPAINTS LTD.

EPILAC ZINC PHOSPHATEPRIMER

EPILACSOLVENTLESS COAL TAREPOXY COATING


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4.6.8 PAINT SYSTEMSURFACE

PREPARATION

PAINT SYSTEM TOTAL DFT IN

MICRONS(MIN)PRIMER FINISH PAINT

SSPC-SP-10 1 COATS OF P-6@40DFT/ COAT

2 COATS OF F-7@125DFT/ COAT

2 x 125 =250

290

4.6.9 STORAGEAll paints and painting materials shall be stored only in rooms to bearranged by contractor and approved by Engineer-inCharge for thepurpose. All necessary precautions shall be taken to prevent fire. Thestorage building shall preferably beseparate from adjacent building. Asignboard bearing the words PAINT STORAGE NO NAKED LIGHTHIGHLYINFLAMMABLE shall be clearly displayed outside.

4.6.10 COLOUR CODE FOR PIPINGFor identification of pipeline, the colour code shall be as per below Table. Paint material for color-coding shall be asspecified in clause- 4.6.6.

DESCRIPTION GROUND COLOUR FIRST COLOUR BAND SECOND COLOUR BAND

Natural Gas Canary Yellow Grey Dark Violet

4.6.11 Colour BandsAs a rule minimum width of colour band for pipes of 36OD& higher shall be 100 mm. Colour band(s) shall be arranged inthe sequence shown in clause 4.6.10 and the sequence follows the direction of flow. The relative proportionalwidth of thefirst colour band to the subsequent bands shall be 4:1,minimum width of any band shall be as per Clause 4.6.11.Paintmaterial for color-coding shall be as specified inclause- 4.6.6.

4.6.12 INSPECTION AND TESTING

4.6.12.1 All painting materials including primers and thinners brought to site bycontractor for application shall be procured directlyfrom manufacturers asper specifications and shall be accompanied by manufacturers testcertificates. Paint formulationswithout certificates are not acceptable.

4.6.12.2 Engineer-in-Charge at his discretion may call for tests for paintformulations. Contractor shall arrange to have such testsperformedincluding batch wise test of wet paints for physical & chemical analysis. Allcosts there shall be borne by thecontractor.

4.6.12.3 The painting work shall be subject to inspection by Engineer-in-Charge atall times. In particular, following stagewiseinspection will be performedand contractor shall offer the work for inspection and approval of everystage before proceedingwith the next stage. The record of inspectionshall be maintained in the registers. Stages of inspection are as follows:a. Surface preparationb. Primer applicationc. Each coat of paint

Any defect noticed during the various stages of inspection shall berectified by the contractor to the entire satisfaction ofEngineer-in-Chargebefore proceeding further. Irrespective of the inspection, repair andapproval at intermediate stages ofworkContractor shall be responsiblefor making good any defects found during final inspection/ guaranteeperiod/ defectliability period as defined in general condition of contract.Dry film thickness (DFT) shall be checked and recorded afterapplicationof each coat and extra coat of paint should be applied to make-up theDFT specified without any extra costtoowner, the extra cost should haveprior approval of Engineer-in-Charge.

4.6.13 Primer ApplicationAfter surface preparation the primer should be applied to cover the crevices, corners, sharp edges etc. in the presence ofinspector nominated by Engineer-in-Charge.

4.6.13.1 The shades of successive coats should be slightly different in colour in order to ensure application of individual coats, thethickness of each coat and complete coverage should be checked as per provision of this specification. This should beapproved by Engineer-in-Charge before application of successive coats.


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4.6.13.2 The contractor shall provide standard thickness measurement instrumentwith appropriate ranges(s) for measuring.Dry filmthickness of each coat, surface profile guage for checking ofsurface profile in case of blast cleaning. Holiday directors andpinholedetector and positector whenever required for checking in case ofimmersion conditions.

4.6.13.3 At the discretion of Engineer-in-Charge, the paint manufacturer mustprovide the expert technical service at site as and whenrequired. Thisservice should be free of cost and without any obligation to the owner, asit would be in the interest of the

manufacturer to ensure that both surfacepreparation and application are carried out as per their recommendations.4.6.13.4 Final inspection shall include measurement of paint dry film thickness.Adhesion Holiday detection check of finish and

workmanship. Thethickness should be measured at as many points/ locations as decided by Engineer-in-Charge and shallbe within + 10% of the dry thickness,specified in the specifications.

4.6.13.5 The contractor shall arrange for spot checking of paint materials for Sp.Gr.,flow time (ford cup) and spreading rate.4.6.14 GUARANTEE4.6.14.1 The contractor shall guarantee that the chemical and physical properties of paint materials used are in accordance with the

specificationscontained herein/ to be provided during execution of work.4.6.14.2 The contractor shall produce test report from manufacturer regarding the quality of the particular batch of paint supplied.

The Engineer-in-Charge shall have the right the test wet samples of paint at random, for quality of same as stipulated inclause 4.6.6 above. Batch test report of manufacturers for each batch paint supplied shall be made available bythecontractor.

4.6.15 PROCEDURE FOR APPROVAL OF NEW COATING MATERIALS ANDMANUFACTURERSFollowing procedure is recommended to be followed for approval of newmanufacturers.

4.6.15.1 The manufacturer should arrange testing of the inorganic zinc silicatecoating materials as per the list of tests given in para4.6.15.5 below from oneof the reputed Government laboratories.

4.6.15.2 Samples of coating should be submitted to the Govt. laboratory in sealed containers with batch no. and test certificate onregular format of manufacturers testing laboratory. The sampling shall be certificate and sealed by a citifying agency.

4.6.15.3 All test panels should be prepared by govt. testing agency colouredphotographs of test panels should be taken before andafter the test should be enclosed alongwith test report. Sample batch. No. and manufacturers test certificate should beenclosed alongwith the report. Test reports contain details of observation and rusting if any, as per the testing code.Suggested government laboratories are:

RRL, HayderabadHBTI, KanpurDMSRDE, KanpurIIT, MumbaiBIS LaboratoryUDCT, MumbaiRITES, CalcuttaPDIL

4.6.15.4 Manufacturers should intimate the company, details of sample submittedfor testing name of Govt. testing agency, date,contact personnel of theGovt. testing agency. At the end of the test the manufacturer should submit the test report to thecompany for approval. The manufacturer(s) shall be qualified based on the result of these tests and other assessment andthe Companys decision in this regard shall be final and binding on the manufacturer.

4.6.15.5 Tests required for evaluation of acceptance of coating materials foroffshore application.Test ASTM Test MethodDensity D 1475Dipping properties D 823

Film CharacteristicsDrying time D 1640Flexibility D 1737/ D 522Hardness D 3363Adhesion D 2197Abrasion resistance D 968/ D 1044DFT/ Coat AS PER SSPC GUIDELINESStorage Stability D 1849Resistance to Humidity for 2000 hrs. D 2247


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Salt Spray for 2000 hrs. B 117Accelerated Weathering D 822% Zn in DFT G 53

4.7 Stenciling/ painting of pipe details on its outer & inner surface as per approved procedureas mentioned at para 3.4

above shall be consisting but not limited to the following:-4.7.1 Subsequent to completion of hydro testing, holiday testing & its repair, painting of internal surfaces, following things to be

written:-4.7.1.1 On each hydro tested pipe (as detailed at para 3.2 above) at both ends on internal surface:-

A. Pipe OD (e.g. 42)B. Pipe Material (e.g. API 5L GR X-70)C. Wall Thickness (e.g. 20.6 mm)D. Pipe Length (e.g. 11.42 meter)E. Heat No.

F. Hydro test Pressure (e.g. 128.8 kg/cm2g)G. Date of Hydro testing (e.g. 15.05.2012)

H. GAIL Material Code (e.g 1234567890)4.7.1.2 On each non hydro tested pipe (out of the lot as detailed at para 3.4 above) at both ends on internal surface:-A. Pipe OD (e.g. 42)B. Pipe Material (e.g. API 5L GR X-70)C. Wall Thickness (e.g. 20.6 mm)D. Pipe Length (e.g. 11.42 meter)E. Heat No.F. GAIL Material Code (e.g 1234567890)

4.7.1.3 Oneach pipe as detailed at para 3.4 above on the outer surface at two locations (approximately diametrically opposite)A. HYDRO TESTED / NON-HYDRO TESTED INSURANCE PIPE (as the case may be) AGAINST HBJ / DVPL-I / DVPL-II(as the case may be)B. Pipe OD (e.g. 42)

C. Pipe Material (e.g. API 5L GR X-70)D. Wall Thickness (e.g. 20.6 mm)E. Pipe Length (e.g. 11.42 meter)F. GAIL Material Code (e.g 1234567890)

4.7.2 Font style & its size shall be decided later on considering its visibility & space availability.4.7.3 Paint color shall be contrast to background color for easy visibility.4.7.4 Paint material shall be suitable considering pipe coating material.

4.8 Stacking of pipes as detailed at para 3.4 above as per approved procedure

4.8.1 The CONTRACTOR shall load, unload, transport and stockpile the coated pipes usingapproved suitable means and in amanner to avoid damage to the pipe and coating.CONTRACTOR shall submit to the COMPANY, a complete procedure

indicating themanner and arrangement used for handling and stacking of coated pipes for COMPANYapproval prior tocommencement of handling operations.

4.8.2 Use of vacuum lifting equipment is preferred. Hooks may also be used for handling the pipes provided they have sufficientwidth and depth to fit the inside of the pipe andcovered with soft material like rubber, teflon or equivalent, so as not to causedamages to bevel or pipe ends. During hoisting, cables/wire ropes shall have sufficient inclination compared to pipe axis sothat they do not come into contact with external coating.

4.8.3 Coated pipes may be handled by means of slings and belts of proper width (minimum60mm) made of non-metallic/non -abrasive materials. In this case, pipes to bestacked shall be separated row by row to avoid damage by rubbing the coatedsurface in the process of taking off the slings. Use of round sectional slings is prohibited.

4.8.4 During handling, suitable handling equipment with proper length of booms shall be used. Before lifting operations it isessential to ensure that the pipe surface is free from foreign material with sharp edges. Belts/slings when used shall becleaned to remove hard materials such as stone, gravel etc. Coated pipes shall not be bumped against any other pipe or

any other objects. Rolling, skiding or dragging shall be strictly forbidden.4.8.5 Coated pipes at all times shall be stacked completely clear from the ground so that thebottom rows of pipes remain free


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from any surface water.4.8.6 The coated pipes at all times shall be stacked by placing them on wooden supports provided with suitable cover. This cover

can, for example, consist of dry, germ free straw with a plastic film, otherwise foam rubber (each having thickness ofminimum 0.5) may be used. Thickness of The supports shall be spaced in such a manner so as to avoid permanentbending of the pipes. The pipes shall be stacked so that theuncoated beveled ends are in line at one end thus making

differences in length clearly noticeable.4.8.7 Stacks shall consist of limited number of layers so that the pressure exercised by thepipe's own weight does not cause

damages to the coating. Each pipe section shall be separated by means of spacers suitably spaced for this purpose. Stacksshall be suitably secured against falling down and shall consist of pipe sections having the same diameter and wallthickness. The weld bead of pipes shall be positioned in such a manner so as not to touch the adjacent pipes.

4.8.8 The CONTRACTOR shall prepare and furnish to COMPANY aprocedure/ calculation generally in compliance with API 5LRP 5L1 for pipe stacking, which shall be approved by COMPANY prior to commencement. However in general no. of layersduring stacking shall not exceed four (04) which can be increased if only supported by calculation as per API 5L RP 5L1.

4.8.9 All mobile cranes shall have adequately long slings to prevent buckling of pipes and must have hooks with Teflon padding.4.8.10 Coated pipes shall be handled using suitable means & in a manner to avoid damage to coating pipe walls & beveled ends.4.8.11 Cranes of proper capacity and having valid test certificates (issued by any competent authority) shall be used for lifting,

loading & unloading of coated pipes. In any case Fork Lifts should not be used for handling of coated pipes.4.8.12 Notarized copy of valid fitness certificate & load test certificate issued by competent authority w.r.t crane & slings (metallic,

nonmetallic) deployed for the job shall be submitted to EIC prior to start of the job.4.8.13 Direct contact with steel or hemp slings or with any material whose shape or nature may deteriorate the pipe shall be strictly

prohibited.4.8.14 Wooden slipper on which pipes shall be stacked shall be made from good quality SHISHAM.Wooden slipper having width &

thickness: 12 and length: as per requirement of pipes, shall be provided by contractor and suitable profile/curvature shall becut in the wooden slipper to stack the line pipes (The radius of curvature of the wooden sleeper shall not be less than thepipe radius).

4.8.15 For an approximately 12mtr length pipe three(03) nos. wooden sleeper shall be provided along the length of the pipe& threenos. dust pad separator/ nylon bound saw (dimension 670 x 75 x 35 mm) shall be provided in between each pipe which isstacked over other pipe(s).

4.8.16 The bearing supports to be spaced equidistant & the distance of supports from pipe end shall not be less than 85 cm andnot more than 1.8 mtr.4.8.17 Pipes having same OD, thickness & gradeshall be stacked together.4.8.18 Persons engaged in handling, storage & transportation shall follow safety norms.4.8.19 All arrangement w.r.t manpower, machinery, materials required for proper stacking of the pipes as detailed above shall be in

the scope of the contractor.

4.9 Supply/ fabrication & installation of end caps for line pip es as detailed at para 3.4 above4.9.1 End cap for the line pipes mentioned in 3.4 shall be fabricated/supplied and installed by the contractor and it shall consist

but not limited to followings;4.9.2 Supply & installation of end cap for the line pipes mentioned in 3.4. End cap shall be made of either plastic/rubber/GI

sheet/MS sheet.

4.9.3 End covers should have provision for easy taking out & refitting so that in case of requirement of inspection of internalsurfaces of the line pipes at a later date, same can be done easily.

4.9.4 These end caps are required as a measure against corrosion prevention.

5.0 MATERIAL TO BE SUPPLIED BY CONTRACTOR

5.1 All the materials, equipment, instruments, manpower (skilled, unskilled), consumables, tool-tackles, required to carry out the

jobs are in the scope of contractor. The contractor will famish the details of the tools tackles/equipment, instruments etc

deployed at the site.

5.2 All the material required (like nipple, weldolet/Sockolet/thredolet, valves, line pipes etc) for fabrication of test header shall be

in the scope of contractor.

5.3 Any special tool-tackles, recorders, dead weight tester, pressure recorder/plotter, power source etc. including any other

requisite materials for carrying out the work shall be arranged and brought to the site by the contractor without any extracost of GAIL.


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5.4 The contractor shall arrange & deploy the requisite qualified manpower to carry out the job mentioned in tender document.

5.5 Materials required for stacking & holding the pipes during welding & hydro testing. During hydro testing pipes shall be hold

firmly to avoid any deflection/movement and all the arrangement shall be done by the contractor.

5.6 Arrangements of Cranes, trailers, vehicles suitable for lifting and transportation of line pipes to carry out the tendered works.

5.7 Arrangement like water for hydro testing & their disposal after hydro testing, hydro testing pumps, manpower, data recorderetc& other tools required for hydro testing. Utilities like water, electricity etc. may be provided by GAIL on request of

contractor on chargeable basis as per terms & conditions of GAIL which shall be completely binding on contractor.

5.8 Arrangement of water and power/electricity to carry out the tendered work. Utilities like water, electricity etc. may be

provided by GAIL on request of contractor on chargeable basis as per terms & conditions of GAIL which shall be completely

binding on contractor.

6.0 WORK PROCEDURE/ HYDROSTATIC TEST PROCEDURE

6.1 Before commencement of work, contractor shall submit a hydro test procedure in detail for the above mentioned line pipe

for the approval of EIC. The procedure shall strictly comply with the requirements of this tender and shall be submitted to

EICfor approval well in advance.

6.2 The pipeline shall be tested in accordance with the requirements of the latest edition of ANSI B 31.8 or ANSI B 31.4, OISD

226, API-1110 as applicable, and requirements as laid down below.

6.3 The line pipe shall be hydrostatically tested at pressure 128.8 Kg/Cm2g; however, the maximum hydrostatic pressure shall

not exceed the pressure required to produce a hoop stress equal to 95 percent of SMYS of the pipe material based on

minimum wall thickness in the test section.

6.4 The test duration shall be a minimum 04(four) hours.

6.5 Pressure variations during testing shall be acceptable, if caused by factors other than leakage, like temperature variations.

6.6 Welding shall be done as per API 1104. Only qualified welder shall be deputed on the site. Welder qualified by

EIL/BV/Tractabel/Mecon/JP Kenny for welding of similar line pipes shall be acceptable & welder should not be idle for more

than six months.

6.7 Before starting welding, contractor shall submit the welding procedure as per API 1104 for approval of EIC. Contractor shall

also submit the detail of electrode to be used along with their batch test certificate.Arrangement of welding electrode shall

be in the scope of the contractor.

6.8 HYDROSTATIC TEST PROCEDURE MANUAL

Hydro testing procedure to be submitted by bidder shall also have following information in addition to information given in

6.1.

6.8.1 A schematic diagram indicating all fillings, vents, valves, temporary connections and other provision of test header. The

diagram shall also indicate injection locations, intake and discharge lines.

6.8.2 Estimated amount of test water, water sourcesincluding required concentration ofcorrosion inhibitors and additives,

procedure for inhibitor injection and control ofconcentration.

6.8.3 Filling and flushing procedures, including a complete description of all proposedequipment and instruments (includingspares), their location and set-up.

6.8.4 Procedures for leveling and stabilization after filling and for pressurization and to allowfor temperature stabilization.

6.8.5 Pressure testing procedure including a complete description of all proposed equipment and Instruments (Including spares),

their location and set-up and proposed system for observation and recording of data during the pressure test.

6.8.6 Procedure for deflection and location of leaks.

6.8.7 Procedure for dewatering the pipeline section(s) after testing, including a complete description of all proposed equipmentand instruments, (including spares), their location and set-up.

6.8.8 Forms for recording the test data.6.9 The entire work shall be carried out in the presence of GAILs authorized representative deputed by the EIC

6.10 Before stacking holiday testing of line pipes shall be done & if defect found shall be repaired. However, material required for

repairing the same shall be done by supplied by GAIL as free issue material.


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