Date:

COVER SHEET

Octl / 20 / 2011

SANTOS CMI

I196 ILO PEAKY PROJECT

SPECIFICATION FOR UNDERGROUND PIPE COATING

I196-P011-001-0

Rev.

Date

Prep. By

Chk. By

Appr. By

Description

06-15-2011

HS

MP

AT

Issued for Internal Review

06-21-2011

HS

MP

AT

Issued for Interdisciplinary Review

07-20-2011

HS

MP

AT

Issued for client Review

10-20-2011

HS

MP

AT

Issued for construction

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INDEX
1.0 SCOPE

Pag.

2.0 APPLICABLE CODES AND STANDARDS 1

3.0 DEFINITIONS

4.0 GENERAL REQUIREMENTS

5.0 INSPECTION

6.0 MATERIALS

7.0 COATING SYSTEMS

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1.0 SCOPE
1.1 This Standard defines the minimum mandatory external coating selection
requirements for buried structural steel, vessels, tanks and piping (including
associated fittings and appurtenances) and the mandatory performance
requirements of these coatings.
1.2 This standard shall be attached to, and made part of, purchase orders when
required.
2.0 APPLICABLE CODES AND STANDARDS
The Contractor shall design, fabricate, install and test all materials required by
these specifications in accordance with, but not limited to, the following applicable
codes and standards:
NACE Standard
TM-01

Visual Standards.

SSPC Specifications
Vis 1

Guide to Vis 1 - 89 - Visual Standard for Abrasive

Blast Cleaned Steel

SSPC-Vis
2

Standard Methods of Evaluating Degree of Rusting

on Painted Steel Surfaces

PA 1

Shop, Field and Maintenance Painting

SP 1

Solvent Cleaning

SP 2

Hand Tool Cleaning

SP 3

Power Tool Cleaning

SP 5

White Metal Blast Cleaning

SP6

Commercial blast cleaning

SP 8

Pickling

SP 10

Near-White Blast Cleaning

ASTM Standards
D 570

Standard Test Method for Water Absorption of

Plastics

D 1002

Standard Test Method for Apparent Shear Strength

of Single-Lap-Joint Adhesively Bonded Metal
Specimens by Tension Loading (Metal-to-Metal)

G14

Standard Test Method for Impact Resistance of

Pipeline Coatings (Falling Weight Test).

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G42

Standard Test Method for Cathodic Disbonding of

Pipeline
Coatings
Subjected
to
Elevated
Temperatures

A 123

Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel

Products

A 120

Pipe, Steel, Black and Hot-Dipped Zinc-Coated

(Galvanized)

D 512

Standard Test Methods for Chloride Ion in Water

D 516

Standard Test Method for Sulfate Ion in Water

A 153

Zinc Coating (Hot-Dip) On Iron And Steel Hardware

A 385

Providing High-Quality Zinc Coatings (Hot-Dip)

AWWA American Water Works Association

C203

Coal-Tar Protective Coatings and Linings for Steel

Water Pipeline-Enamel and Tape-Hot Applied

C209

Cold Applied Tape Coatings for Special Sections,

Connections and Fittings for Steel Water Pipelines

C214

Tape Coating Systems for the Exterior of Steel Water

Pipelines

Canadian Standards
CAN/CSA-
Z245.
20-M92

External FBE Coating for Steel Pipe

German Standards
DIN 30670

Polyethyline Coatings for Steel Pipes and Fittings

3.0 DEFINITIONS
Corrosive Industrial Atmosphere: Areas exposed to gases, fumes, mists or
dusts from chemical or industrial facilities. This term does not include direct
contact with splashed or spilled chemicals.
Maintenance Coating/Painting: Application of coating to preserve the useful
state of an existing coating. Repairing is the most common method to maintain a
coating. Replacing completely an existing coating is not maintenance coating.
Mild Atmosphere: Areas not affected by either marine or industrial environments,
but receive enough moisture in the air to cause corrosion if the carbon steel is not
coated.

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New Construction Coating: Application of coating on a completely new and

uncoated facility, equipment or machinery. New coating also applies to the coating
application on completely bare substrate that was previously coated.
Wet-on-Wet Coating Application: Technique of coating application where
additional coating passes are employed over a coating that is still wet, making the
composite film dries as a whole. A wet coat applied over another wet coat is
considered one coat of application.
4.0 GENERAL REQUIREMENTS
For the general requeriments of blasting, material abrasive, painted and coating
application see paragraphs 4.0 and 5.0 of specification for Aboveground Coating,
I184-P011-002
4.1 General Requirements for Coatings
All buried, onshore pipe shall be externally coated. All buried coatings shall
be 100% holiday checked and all holidays repaired prior to burial.
Hand-applied tapes of the "primer activated" type shall not be used. Handapplied tape wraps shall be of the "pressure sensitive" type, meaning they can
be applied over dry primer or no primer without adverse effect on adhesion,
Customer prior approval.
All coatings shall
recommendations.

be

applied

in

accordance

with

Manufacturer's

Blasting and coating shall not be performed if one or more of the following
conditions exist unless the coating is specifically formulated for the averted
condition:
a) The substrate temperature is less than 50F (10C).
b) The substrate contains oil, grease, dirt, loose coating, loose rust, or other
surface contaminants.
Paint systems shall not be used as the primary external coating on buried pipe
(including field girth welds).
At road crossings the minimum allowable surface preparation prior to coating
shall be near white metal Sa 2-1/2.
Cast iron pipe that has been shop coated with enamel (or similar) does not
require additional external coating prior to burial. Bare cast iron pipe shall be
externally coated prior to burial.
Buried stainless steel lines shall be externally coated or with a suitable liquid
coating Customer prior approved.

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5.0 INSPECTION
5.1 Requirements in this section refer only to coating in the following categories:
a) New construction
5.2 The responsibility for quality control and inspection rests with the vendor;
however, purchaser may inspect the materials equipment and painting during
all phases of the work.
5.3 Vendor shall permit purchaser's inspector to have unrestricted access to all
areas of vendors facilities (including subcontractors' facilities) where any
phase of the work covered by this specification is being performed.
5.4 Vendor shall refer all questions relating to quality control, testing and
acceptance of the work to inspector.
Primer coat shall be subject to inspection by purchaser's representative before
being top coated. Misses or skimps in the paint film shall be repaired after initial
primer coat has cured a minimum of two hours. Primer repairs shall be allowed to
cure a minimum of twenty-four hours at 75F (24C) or equivalent, as outlined
above, before top coating.
6.0 MATERIALS
6.1 All coatings must be free of lead and chrome.
6.2 Information about colors (shown in attachment B) must be confirmed by Client
prior to ordering coatings.
6.3 Pipes made from stainless steel, glass fiber, galvanized steel, etc. pipe should
not be painted.
7.0 COATING SYSTEMS
7.1 Shop or Field-Applied Fusion Bonded Epoxy (External)
Uses:
External coating for onshore buried and above ground services. Also suitable for
over theditch coating of the field girth welds on FBE-coated pipe.
b) Service Limitations:
1) Conventional FBE (Temperature up to 257F (125C)).
Temperature:
Min. -4F. (-20C)

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Max. (in immersion): 230F (110C)

Max. (in dry ground): 257F (125C)
Spray Applied: 20-30 mils.
Cleaning the pipe by dry abrasive blasting to a near white finish in accordance with
SSPC SP-10.
7.2 Field Applied Epoxy Novolac (External)
Uses:
External coating for onshore buried pipe, suitable for over the ditch coating of the
field girth welds on FBE-coated pipe. High build epoxy novolac that coats, repairs
and rehabilitates pipe operating at maximum temperatures up to 203F (95C). As
an abrasion resistant overlay (ARO) it is compatible with FBE and CTE mainline
coatings and can be used on any metal structure. b) Service Limitations:
Temperature:
Min. 50F (10C)
Max. (in dry ground): 257F (125F)
Cleaning the pipe by dry abrasive blasting to a near white finish in accordance with
SSPC SP-10, Sa 2 1/2.
Manually or Spray Applied: mx. 40 mils
Manufacture:
Powercrete 95.
7.3 Shop Applied Coal-Tar Epoxy System
Uses:
External on buried, onshore pipe that has been cement lined. Up to 158F (70C).
The shop applied coal-tar epoxy system shall consist of:
a. Cleaning the pipe by dry abrasive blasting (grit) to a near-white finish in
accordance with SSPC SP-10. Grease and oils shall be removed by washing
with solvents prior to blasting.
b. Application of two coatings of coal-tar epoxy so that a minimum thickness of 15
mils dry film thickness is achieved. Any individual coating shall be a minimum of
7 mils dry film thickness. The first coat shall be allowed to dry, tack free, before
application of the second coat.

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The following materials or equals approved, shall be used.

Coal-Tar Epoxy Resin
- Sherwin Williams Coal Tar Epoxy 388-99.
- Hemple`s Coal Tar Epoxy Mastic.
- Amercoat 78.
7.4 POLYKEN FIELD COATING APPLICATION SPECIFICATION 980, 955
7.4.1 Materials to be covered:
Polyken N 1027 Primer
Polyken N 980 (anti-corrosion protection innerwrap)
Polyken N 955 white (mechanical protection outerwrap)
7.4.2 MATERIALS
Polyken 1027 Primer is a synthetic rubber/resin blend in a solvent
solution. Polyken 1027 serves to rapidly wet out the pipes surface with
synthetic rubber solids, preparing it for proper bond of the 980,
anticorrosion protection innerwrap, as well as Polyken 933 or Polyken
931.
1.2 Polyken 980 (anti-corrosion protection innerwrap) total thickness of a
laminated butyl rubber adhesive with stabilized, specially blended
polyethylene backing.
Polyken 955 white (adhesive mechanical protection outerwrap) total
thickness of laminated butyl rubber adhesive with stabilized, specially
blended polyethylene backing. Polyken 955 serves as the mechanical
protection layer bonded to and protecting the 980 anti-corrosion protection
innerwrap.
7.4.3 STORAGE CONDITIONS
Polyken primers and tapes should not be stored at temperatures above
105 F (41C).
Polyken products should be stored in a secure, dry location.
Polyken products packaged in cases can be stacked to a limit of 6 feet
(182.9 cm) high. All packages should be stacked right side up at all times.

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7.4.4 PROJECT SITE CONDITIONS

Project site conditions should be routinely monitored. Project site
temperature issues should be used to determine the optimum roll-body
application temperature for Polykens System. Polyken recommends that the
minimum roll body temperature of (980/955) be approximately 70 F (21 C)
during application.
7.4.5 PIPE SURFACE PREPARATION
The pipes surface should be sand, grit or shot blasted to a commercial blast
finish SSPC-SP6 NACE No. 3, or power wire brush per SSPC-SP3. The
steel surface blast pattern should have a profile of 1 to 3 mils (25 to 76
microns). The steel pipe surface should be free of all blast material, dirt, or
foreign debris and should be free of any grease or oils. Proper solvents
should be used to thoroughly remove any surface oil or grease. A Polyken
representative should be contacted for further information regarding use of
solvents for surface cleaning.

7.4.6 POLYKEN COATING APPLICATION CONDITIONS

A. Polyken 1027 Primer (minimum material temperature of 40 F (4.5 C)
should be well mixed and applied to a thoroughly prepared steel surface
to a single coat dry film thickness of approximately 0.5 mils. The 1027
Primer can be applied in a variety of ways including brushing, rolling,
spraying, rugging, or flood wiping. Primer coverage should be between
approximately 200 and 400 square feet per gallon. Metric 18.5 to 37
square meters per gallon (1 gallon = 3.785 liters = 9.8 m2 per liter).
B. Application of Polyken 980 (anti-corrosion protection inner wrap) to the
1027 primed pipe. Important application issues: Roll body temperature
Proper application tension of the 980 during application as determined
through routine tape neck down measurements. The application tension
of the Polyken tape systems is directly related to and should be monitored
by measuring the neck down or reduction of the products width. Polyken
980 6 inches x 200 feet (15.24 cm X 60.69 m) rolls, should neck down
approximately 1/8 or 3.2mm during application to achieve the specified
tension 12-18 lb. per inch of width (21 to 32 N/10 mm width).
The 980 roll body temperature is important for two application reasons:
The minimum roll body temperature of 70 F (21 C) allows neck down to
occur within the 12-18lb. per inch width (21 to 32 N/10 mm width)
application range. This corresponds to a 1/8 inch / 3.2 mm neckdown. If

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the tape is colder than 70 F (21 C), it will take more than 12-18lb. per
inch width (21 to 32 N/10 mm width) width to achieve the 1/8 or 3.2 mm
neck down specification.
The 70 F (21 C) and above roll body temperature reduces the effect of
thermal expansion of the cold applied tape system on warmer operating
temperature pipelines, thus maintaining the proper amount of tangential
force on the wrapped tape system.
B.1 The 980 should be applied by a Polyken approved power wrapping
machine incorporating a Polyken approved brake tensioning device in a
spiral fashion with a (1.9 cm) to 1 (2.54 cm) overlap. Application
tension on 980 should begin only after the first third of the pipes
circumference is wrapped. This prevents crawl back of the tape, which
could otherwise be induced, from high tension at the very beginning of
the wrapping process. Once the application of 980 is completed, it can be
holiday tested using a holiday detector and NACE standard RP-02-74
(square root of coating thickness in mils x 1250 +/- 20%). Using this
industry standard, the voltage for 980 would range between 5,000 and
7,500 volts. If holidays are detected, they should be patch/repaired using
the practice described in the Patch/Repair.

C. Application of Polyken 955 White (mechanical protection outerwrap) over

the 980 (anticorrosion protection inner wrap).
Important Application Issues:
Roll body temperature
Tension applied to the 955 during application as determined through
product neck down measurements.
C.1 Polyken 955 should be applied with a Polyken approved power wrapping
machine in a spiral fashion with a (1.9 cm) to 1 (2.54 cm) overlap.
The beginning wrap of 955 should start so its mid-width is placed directly
over the overlap of the 980. Application practice should be identical to
980. The Polyken 955 should be applied at a tension of 12-18 lb. per inch
width (21 to 32 N/10 mm width). The application tension of 955 should be
monitored by the neck down of the tapes width. Polyken 955-5 6 inch x
200 feet (15.24 cm x 60.96 m) should neck down approximately 1/8 (3.2
mm) during application to achieve the 12-18 lb. per inch of width (21 to 32
N/10 mm width) specification. The 955 roll body temperature is important
for the same reasons as for 980. The wrap of the 955 should begin with
the beginning lap facing in a down side position on the pipe (8 to 10
oclock or 2 and 4 oclock position). The wrapping process should proceed
from that point (clockwise or counter-clockwise respectively) around the
pipe. This process prevents back fill from potentially working against or

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pulling away the 955, which could occur if the beginning lap was facing
upward.
Special Note: The overlap of 955 can be increased to a 50% overlap to
achieve thicker outerwrap for rocky back fill areas (refer to Special
Conditions, 7.0) The entire 50 mil (1.27mm) system can be holiday tested
at a voltage of 8,000 minimum and 11,000 maximum.

RECOMMENDED APPLICATION TENSION