AG-HTLP60-Inspection-3LPE-REV1-JUL10

INSPECTION PROCEDURE FOR

J&P Avax

HTLP60/1-1.5 SHRINK SLEEVES

ON THREE LAYER POLYETHYLENE COATED PIPES






















AG-HTLP60-Inspection-3LPE-REV2-OCT12 1


INDEX

1. VISUAL INSPECTION CRITERIA

2. VISUAL INSPECTION CRITERIA

3. FIELD JOINT COATING THICKNESS

4. HOLIDAY INSPECTION

5. ADHESIVE PEEL STRENGTH

6. SLEEVE REPAIR PROCEDURE

7. AIR VOIDS & SLEEVE REMOVAL



































AG-HTLP60-Inspection-3LPE-REV2-OCT12 2


1. SCOPE
The scope of the document is to provide J&P Avax contractor (Greece) a guideline for
testing in the field of Covalence HTLP60/1-1.5 sleeves supplied for the construction of
the Ag. Thoeodori to Megalopolis pipeline.


2. VISUAL INSPECTION CRITERIA

A finished HTLP60/1-1.5 sleeve installation shall be inspected for the following points;
Adhesive flow shall be evident at both sleeve edges along the circumference of
the pipe.
There shall be no upstanding sleeve edges, sleeve edges shall be firmly bonded
to the primed PE line coating.
The sleeve surface shall be smooth without cold spots, bubbles, punctures,
pinholes etc
Weld bead profile shall be clearly visible through the sleeve.
Sleeve overlap onto the 3-LPE line coating shall be at least 50 mm on each side
of the joint.


3. FIELD JOINT COATING THICKNESS TEST

The thickness of the cooled field joint coating shall be checked using an approved
magnetic or electro-magnetic thickness gauge.

Test method, based on ISO21809-3 Annex A & Clause. 11.5.2:

Procedure
At the start of each shift, the instrument readings shall be checked using calibrated
plates and shims of the same thickness and temperature range as the FJC and, if
necessary, be adjusted.
On each FJC being inspected, a total of eight measurements shall be carried out on
the body of the pipe: The measurements shall be taken at the 12, 3, 6, 9 oclock
positions on two circumferential lines, one on each side of the weld bead.(zones L
and R)
In addition, four measurements shall be carried out on a circumferential line on top of
the weld bead length.
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Results

The average value shall be >= 2,2 mm

The minimum value for the body and for the weld bead shall be recorded and shall be in
accordance with the following:
On the body >= 1.87 mm
On the weld bead >= 1.1 mm



4. HOLIDAY INSPECTION

Ref. ISO 21809-3 Annex B

After complete cool down, holiday inspection can be done on every joint.
Use a full circumferential contact electrode (spring coil) or brush.
Holiday detection Voltage: 15 KV = 5 KV + 5 KV per mm of coating thickness



5. ADHESIVE PEEL STRENGTH

Ref. ISO 21809-3 c

One out of every 50 sleeves, or alternatively one out of each days production
(whichever is lower) shall be subjected to a manual peel test.
Peel strength inspection shall be done at a sleeve temperature of 23C both the
substrate and the sleeve shall be at this temperature.
AG-HTLP60-Inspection-3LPE-REV2-OCT12 4
Strips of 25 mm x 200 mm shall be cut perpendicular to the pipe axis, either at 9 or 3
o'clock position as per DIN 30670, in the area between the circumferential weld bead
and the mill coating.
Manually remove the first 25 mm to 50 mm of the leading edge of the strip by using a
screwdriver or chisel, make sure that the initial adhesive bond line cut is essentially
centered within the adhesive layer.
Attach the peel gauge to the leading edge of the test strip and fasten clamp.
Holding the test gauge with both hands exert a steady force with a pulling speed of
approximately 100 mm/min or 4 inches/min, and an angle of 90to the circumference
of the pipe.
At 23 C the peel strength shall be greater than 25 N/cm and the bulk of the adhesive
shall remain on the pipe (cohesive peel mode).


6. SLEEVE REPAIR PROCEDURE (PERP)

Sleeves damaged during adhesion testing with single window shall be repaired as
follows.
Cut repair patch from a roll of PERP, approximately 50mm larger in each direction
than the area to be repaired.
Lightly abrade the area all around the damage with a scotch brite pad or fine abrasive
paper.
If the damage is deep down to the steel, the void area should be filled with S1137
filler mastic.
Abrade an area extending at least 25mm beyond the area to be covered by the PERP
repair patch.
Preheat the damaged area with a propane torch with a gentle flame to 70 C to 80 C.
Preheat the PE repair patch with a propane flame on the adhesive side till soft and
shiny.
While adhesive is still soft, apply the patch centrally over the damaged area,
Carefully heat and roll the PERP patch with a roller until the surface becomes smooth,
and the adhesive is visible all around the PERP. When the adhesive is too viscous
and rolling becomes difficult, reheat the area again.



7. AIR VOIDS & SLEEVE REMOVAL

7.1. AIR VOIDS ACCEPTABILITY

Sleeves should be inspected for possible air entrapments.
Air entrapments should be minimal and shall meet the following criteria ;

Shell specification MF 94/0290 - Rev1 Qualification, Application and Inspection of
Shrink Sleeves for Corrosion Protection of Pipeline Field Joints clause 4.11 applies:
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more than 5% of the steel surface shows bare steel or
more than 5% of the circumference on the weld and 20mm at either side of the
weld shows bare steel (wagon tracking) or
more than 10% of the pipe coating is bare or
more than 10% of the surface area shows voids (signs of air inclusions).


7.2. SLEEVE REMOVAL PROCEDURE

The procedure determines the amount of air enclosures and areas of metal or primer
uncovered by the adhesive layer after removal of the polyethylene backing.

The sleeve applied and conditioned at room temperature for at least 12 hours
will be cut with parallel circumferential incisions to reach steel.
The strips will have a width (25 mm) such to allow manual removal.
To facilitate removal in case of low temperature or high adhesion, use a soft
flame without exceeding 40 C measured on the sleeve backing.


Note: This installation instruction and inspection procedure is a guideline. Local circumstances during field
installations may require at any time specific changes. These changes have to be approved by Berry
Plastics Technical Department.