| % TATA TATA PROJECTS LIMITED Quality Management Standard Procedure | for | COATING & WRAPPING Doc No: TPL/QMD/ MECH/SPROC/003 [Birkel Aye] He | Constrtiction © | 19.02.2014 First Issue skk | csv | ee Gva 1 Reviewed Rev| Date Purpose oftssue | Prepared sy | SVEN" | Reviewed By | Approved By‘TATA STANDRAD PROCEDURE FOR COATING & WRAPPING Proc No.: TPL /QMD/MECH/SPROC / 003 Rev No. & Date: 0 & 19.02.2014 1.0 SCOPE This procedure covers the application, Inspection, testing requirements and acceptance criteria of Coating & Wrapping on Carbon Steel / Mild Steel underground pipeline. 2.0 STANDARD AND SPECIFICATIONS All works covered by this Procedure shall be carried out in accordance with the relevant sections of the following documents. 1S 15337: 2003 ~ Coal Tar based Anticorrosion tape for undersigned MS Pipes ~ Specification. Customer Specification Approved FOP & Drawing 3.0 MATERIALS 3.1 Manufacturer's test certificates for Primer and Coal tar tapes shall and submitted to Customer for their clearance before application and material make shall be as per Technical Specifications or Customer approved make. 4.0 PROCEDURE 4.1 Environmental Conditions Unless otherwise specified by the Tape Coating Manufacturer, no surface preparation or application of tape coating shall take place under the following conditions. > Air temperature is below 10° C Surface temperature is below 5° C Surface temperature is 3° C or less than the Dew Point Relative humidity is 85% or above Wet or Damp atmosphere Wet Surfaces Rain, mist or fog is present Wind speed above 25 kmph Atmosphere contaminated by dirt, dust, oil, product or any pollutant viv 4.2 Surface Preparation 4.2.1 The external surfaces of Pipe / Connected Fittings shall be thoroughly cleaned mechanically and shall be free from mud, mill scale, mill lacquer, wax, coal tar, asphalt, oil, grease, or any other foreign material. Then same shall be cleaned with dry cloth thoroughly. Surface cleaning shall be done by Blast cleaning if called for by Customer Specification. 4.2.2 Priming shall be done within 4 hours of completion of Surface Cleaning. 4.3 Primer application One uniform coat of fast drying synthetic primer as per data sheet shall be applied, and free of floods, sag or runs. It is allowed to dry for about 30 minutes till it becomes touch dry. q Page tof 4 ey, Cease ae Ae, a} \4TATA STANDRAD PROCEDURE FOR COATING & WRAPPING Proc No.: TPL /QMD/MECH/SPROC / 003 Rev No. & Date: 0 & 19.02.2014 44° Coating 4.4.1 The primed surface shall be free from moisture or any foreign matter prior to the application of coating. 4.4.2 Before adhering the tape to the Pipe / Connected Fittings, it is suggested to gently heat the primed Pipe / Connected Fittings by a run of LPG Torch to soften the coating compound. However, care shall be taken to ensure that the compound does not melt. 4.4.3 Remove the bottom polythene seal from the tape and then heat bottom surface of the tape by (PG Torch as per Manufacturer's recommendation and start wrapping the tape either by spiral or circumferential method on the Pipe / Connected Fittings. 4.4.4. Over laps shall be a minimum of 15 to 20 mm. 4.4.5 250 mm from each end of pipes shall be kept free from coating. This shall be done after field joint welding and testing, 4.4.6 The Final thickness of coating shall be ensured as per Project specification 5.0 INSPECTION, TESTING AND ACCEPTANCE CRITERIA 5.1 Holiday Test 5.1.1 The integrity of wrapping coating of all pipes shall be tested with holiday detector equipped with a positive signaling device to indicate any faults, holes, breaks or conductive particles in the protective coating. 5.1.2 Maximum Voltage to be applied shall be 10 kV for 2 mm tape coating thickness, 12 KV for 3 mm tape coating thickness and 1SKV for 4mm tape coating thickness. The Instrument shall have a valid calibration and the same shall be shown to Customer before commencing the test. 5.1.3 Acceptance Criteria: i. Any defect in wrapping shall be repaired. ii, The rectified Pipe / Connected Fittings shall be re-tested for holiday. 5.2 Adhesion Test (as applicable) 5.2.1 Adhesion Testing of Tape Coating carried out as given below a) Adhesion tests shall be made to determine the proper bond between the tape and the primed Pipe / Connected Fittings. One test per section (of up to 10 meter length) shall be carried out initially, afterwards adhesion test is done as per the advice of Customer. Repair required due to adhesion testing shall be decided by the Customer. b) Temperature of the tape and Pipe / Connected Fittings to be tested shall be between 10 deg C and 27 deg C. If required cold water shall be poured over the test area to bring down the temperature to within the above range. The coating shall be allowed to set at ambient temperature for 72 hours. 4 Page 20f4 av Gamlte a +e ltro) 52 6.0 61 62 7.0 7a 72 73 74 TATA STANDRAD PROCEDURE FOR COATING & WRAPPING Proc No.: TPL /QMD/MECH/SPROC / 003 Rev No. & Date: 0 & 19.02.2014 = Atest area shall be selected where the tape is smooth for 150 mm in the longitudinal direction of the tape. = Two knife cuts of 150 mm long and 50 mm apart shall be made through the tape. Note: After completion of each Coating above tests shall be conducted. = Aflat blade shall be used to pry up 50 mm of the fabric. = The 50 mm flap of fabric shall be grasped firmly in one hand and shall be pulled with a quick motion in the direction of the remaining 100 mm of the 150 mm knife cut. = The adhesion is satisfactory if (i) the tape tears at the point of stripping or (i) the fabric strips from the under lying tape component, leaving no more than 10% or less of the primer or bare metal exposed. ‘Adhesion between tape to tape can be tested following similar procedure as in (b). However, this should preferably be done on a test panel. 2 Acceptance Criteria: Adhesion test is satisfactory if tape tears at the point of stripping or the fabric strips from the underiying coal tar component, leaving exposed not more than 10 percent of the Primer or Metal HANDLING OF FINISHED PIPES / CONNECTED FITTINGSS The coated Pipe / Connected Fittings shall be handled at all times with equipment, such as wide belt slings, wide padded skids, designed to prevent damage to the coating. Bare cables, chains, hooks etc. shall not be permitted to come in contact with the coating, Along the trench side, coated Pipe / Connected Fittings shall be suitably supported above the ground to avoid damage to the coating, ‘TAPE COATING OF FIELD WELD JOINTS The tape is applied over the weld joints after completion of the welding and satisfactory testing, ‘The field joint and uncoated surfaces on the Pipe / Connected Fittingss shall be Hand or Power Tool cleaned to St-3 ‘The procedure for Priming and Tape application and testing shall be same as Para 4.0 & 5.0 Overlaps on each side of the weld joints of Pipe / Connected Fittings coated ends shall be SOmm. 8.0 Repairs for defective Area Repairs shall be done as per approved Specifications and Relevant BIS Codes: IS 15337 9.0 SAFETY 9.1 PERSONNEL 92 All personnel involved in the operations described by this procedure will have received Safety Induction Training and the job specific training required for the particular operation in which they will participate, Toolbox talk shall be conducted prior to proceeding of the Work As Ap age 20t4 Ay93 94 95 10.0 10.1 10.2 103 © rneranco ov s.si Sr. Enginker -QMD_ TATA STANDRAD PROCEDURE FOR COATING & WRAPPING Proc No PL JQMD/MECH/SPROC / 003 Rev No. & Date: 0 & 19.02.2014 Emergency response plan shall be followed in case of emergency. HSE Personal must be present during Hydrostatic testing Relative permits to be taken prior to start the work from TPL. Documentation Coating and Wrapping Examination Report, Format No. FQ/121 shall be made and signature of Customer shall be obtained, All MTC, BTC & Lab Reports Calibration Certificate of Holiday Detector fi 7 ‘Quality Assurance” QMD APPROVED BY real GVRRN Acharyulu Head -OMD Page 4 of 4INSPECTION REPORT TATA FOR Eee TAPE COATING IN PIPE LINE ‘Customer F _ __ Report Sub-contractor Project a Inspection Date : ‘Location = Diameter of Pipe: [st | Joint Surface Surface jisual | Holiday | Peel | Thickness | Remarks No No Preparation: Cleaning & inspection | Checking | Test Check { Pre- Heating : | . eee |anee Today's Progress: ae Previous Progress: _ 7 ‘Cumulative Progress: = | Remarks: | Subcontractor [TPL _ _ | Sign: | Sign: Name: : Name: Date: [Date Form No.FQ/121, Rev.0