POLYKEN PIPELINE COATING

WRAPPING PROCEDURE FOR PIPES & FITTINGS

1.0 Scope

This specification covers the design requirements, material selection, application

2.0 Coating System

The coating system shall consists of the following components:

3.0 Materials

3.1 Materials for the coating and wrapping shall be of Polyken coating system as
described below:

1. Primer :
Polyken primer no. 1027

2. Mastic filler tape :

3. Inner-layer tape :
for straight pipe : Polyken tape no. 980-20
for fitting : Polyken tape no. 930-35/ 905-30

4. Outer-layer tape :
for straight pipe : Polyken tape no. 955-20
for joint & fitting : Polyken tape no. 955-15

3.2 In case of irregular shaped items (e.g. flanges, valves etc) a moulding putty, Polyken
939 mastic filler shall be used for filling voids before application of inner-layer
tape.

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4.0 Surface Preparation

4.1 Bare pipe shall be free from mud, mill scale, mill lacquer, wax, coal tar, asphalt, oil,
grease, or any other foreign material. Visible oil and grease spots shall be removed
by solvent wiping. Only solvents that do not leave a residue shall be used.

4.2 After drying and removal of all loosely adhering foreign materials, the pipe surface
shall be cleaned to a minimum ST2 power wire brush surface finish or an SA2.5
commercial blast finish. All burrs & weld slags should be removed to achieve a
smooth surface.

4.3 The cleaned exterior pipe surface shall be protected from conditions of high humidity,
rainfall, or surface moisture. No pipe shall be allowed to flash rust before coating.

4.4 In no case shall more surface area be prepared in one day than can be satisfactorily
coated in the same day. All prepared surface shall be coated on the same day it was
cleaned. If any flash rusting occurs, the affected surface must be prepared again in
accordance with this specification.

5.0 Primer Application

5.1 Prior to any primer application, the pipe shall be cleaned to remove any wetness or
other contamination.

5.2 Primer shall be kept at a warehouse and only the daily requirements shall be brought
to the job site, Only the amount of primer required for immediate use shall be emptied
from the drums into open containers. After obtaining the quantity required, bungs
shall be immediately replaced in the drum to prevent the loss of solvents by
evaporation. Care shall be taken that the contents of the drum have been properly
agitated to ensure that there has been no separation of solids from solvents prior to
filling the open containers.

5.3 Primer that has become contaminated with foreign matter or has thickened because of
evaporation of solvents shall not be used.

5.4 The primer shall be thoroughly agitated in its container before application to the pipe.

5.5 Primer shall be either brush or spray applied to the cleaned pipe surface in a uniform
thin film at a minimum coverage of approximately 7.4 square meters per liter of
primer to achieve a wet thickness of 50-75 microns. The prime coat shall be uniform
and free from floods, runs, sags, drips, or bare spots. The primed pipe surface shall be
free of any foreign substances such as sand, grease, oil, grit, rust particles, or dirt.

5.6 The prime coat shall be dry to tacky at the time the inner-layer tape is applied.

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6.0 Tape Installation

6.1 All irregular shaped items with voids shall be pre-coated with 2 inches wide of mastic
filler tape such that smooth, rounded shapes are formed prior to application of inner-
layer tape. This is to avoid formation of wrinkles and/or air pockets during the inner-
layer tape application.

6.2 The inner-layer tape shall be applied directly onto the primed pipe surface by means
of suitable mechanical wrapping equipment approved by the tape manufacturer in
compliance with the applicable standard. Hand application is permitted only for tape
width no wider than 6 inches. The inner-layer tape shall be spirally applied with
minimum overlap of 50% of the tape width being used. The application tension on
the tape shall be approximately 1% of tape width in width drawdown (approximately
5 to 10 lbs per inch width of tape). A tight, smooth, wrinkle-free coating should be
observed throughout the application.

6.3 The end of each new roll of tape shall overlap the end of the preceding roll by a
minimum of 6 inches. This end lap slice shall be hand applied to affect a wrinkle free
splice that maintains the continuity of the inner-layer tape. The spiral angle of the
new roll should parallel the previous roll’s spiral angle.

6.4 The outer-layer tape shall be applied over the inner-layer tape using the same method
used to apply the inner-layer tape. The seam for the outer-layer tape shall overlap the
exposed seam of the inner-layer tape by a distance of half the tape width so that they
do not coincide.

6.5 The overlap widths and application tension of the outer-layer tape shall be the same as
in para. 6.1. The minimum end lap of two rolls shall be same as in para. 6.2.

6.6 Details of tape application shall be in accordance with the following:

Appendix-I : Tape application for field welding points

7.0 Inspection And Testing

7.1 All coating shall be subject to 100% visual inspection and 100% inspection with an
electrical holiday detector.

7.2 Visual inspection shall ensure that the coating is continuous that the overlap is
correctly maintained and that there are no wrinkles voids, blisters, pinholes, open
seams, entrapped air or any other defects likely to cause failure of the coating.

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7.3 The holiday detector shall be used to check that there is a continuous coating over the
pipe surface. Particular attention shall be given to areas where the tape has been
spliced or repaired. (Note : It is not intended that the holiday detector should be used
to reveal pinholes and minor faults in the tape wrap. Such defects would not normally
show up on the holiday detector with the specified coating system unless the voltage
was set at a level so high that it would be likely to damage the coating).

7.4 The holiday detector shall be set at a test voltage of 11,000 volts during the inspection
of the tape coating.

7.5 The holiday detector setting shall be checked at least twice per day while it is in use.

7.6 The holiday detector shall be operated strictly in accordance with the manufacturer’s
instructions at all times.

7.7 At no time shall be the holiday detector be permitted to remain stationery around a
coated pipeline with the operating voltage switched on.

7.8 All defects, whether discovered visually or by means of the holiday detector, shall be
clearly marked.

8.0 Repairs to Coating

8.1 All defects in the coating shall be made good immediately after their detection.

8.2 All holidays shall be repaired by peeling back and removing the outer and inner layers
from the damaged area. The exposed area shall then be coated with primer, and
either (1) a length of inner-layer tape shall be wrapped around the pipe to cover the
defective area or (2) a patch of inner-layer tape shall be applied directly to the
defective area as specified by the purchaser. The minimum lap at the damaged area
shall be 4 in. (100 mm) all around. The repaired area shall be tested with a holiday
detector after the repair is completed. If holidays are not found, the repaired area
shall then be covered with the outer-layer tape with a minimum lap of 4 in. (100 mm)
beyond the inner-tape patch.

8.3 Details of repair procedure as in para. 8.2 shall be in accordance with the following:

Appendix-VI: Tape application for repairing of holidays

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9.0 Handling of Coated Pipe

9.1 All coated piping shall be handled in such a way that the coating does not suffer
damage. Coated pipe shall be handled at all times with wide non-abrading belts or
other equipment designed to prevent damage to the coating. All skids used to support
coated pipe shall be padded.

9.2 All coated pipes shall be stored under shed or cover and away from direct exposure of
sunlight.

9.3 If the pipeline protective coating suffers damage between the coating and laying
operations, the damaged portion of the coating shall be replaced or repaired in
accordance with this specification.

10.0 Storage and Handling of Coating Materials

10.1 Coating materials shall be stored in weather proof, ventilated conditions strictly in
accordance with the manufacturer’s instructions.

10.2 Coating materials shall be handled in such a way that the materials do not suffer
damage.

10.3 Any coating materials that show evidence of deterioration due to weathering or
damage due to mishandling shall be replaced.

10.4 Any materials that have been rejected for any reason shall be removed from the site.

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