S-000-13a0-102 - 1c2 External Coating of Underground Steel Pipe

Oman Refineries and Petrochemicals Company LLC.
General Specification for External

Sohar Refinery Improvement Project Coating of Underground Steel Pipe
Sultanate of Oman S-000-13A0-102
Rev.R1C2
GENERAL SPECIFICATION
FOR
EXTERNAL COATING OF UNDERGROUND STEEL PIPE
Sign
E.B.Nam Sign
H.S.Shin Sign Sign
R1C2 23 May 2014 Issued for Construction J.H.Park Y. S.Yi
C.U,Kim K.H.Seong
E.B.Nam H.S.Shin
R1C1 29 Jan. 2014 Issued for Approval J.H.Park Y. S.Yi
C.U,Kim K.H.Seong
ORIGINAL CHECKED CHECKED APPROVED

REV DATE DESCRIPTION
BY BY BY BY
1 OF 22
Oman Refineries and Petrochemicals Company LLC. General Specification for External
Rev.R1C2
TABLE OF CONTENTS
1. GENERAL ......................................................................................................................................... 3
2. REFERENCES .................................................................................................................................. 3
3. APPLICATION OF COATING AND WRAPPING SYSTEMS ............................................................ 4
3.1 Underground Carbon Steel Piping ........................................................................................ 4
3.2 Underground galvanized steel piping:.................................................................................. 4
4. WRAPPING SYSTEM ....................................................................................................................... 5
4.1 Acceptable Wrapping Materials ............................................................................................. 5
4.2 Handling and Storage of Materials ........................................................................................ 5
4.3 Application Procedure............................................................................................................ 6
4.4 Repairs of Wrapping ............................................................................................................... 8
4.5 Inspection for Wrapping Work ............................................................................................... 8
5. FUSION BONDED EPOXY COATING SYSTEM .............................................................................. 9
5.1 Acceptable Fusion Bonded Epoxy Materials ....................................................................... 9
5.2 Handling and Storage of Materials ........................................................................................ 9
5.3 Application Procedure............................................................................................................ 9
5.4 Repair at Vendor's Shop Work ............................................................................................. 10
5.5 Inspection for Vendor's Shop Work .................................................................................... 10
5.6 Field Application of Repair and Welded Joints for Underground Carbon Steel Piping . 11
5.7 Inspection for Field Application Work ................................................................................ 11
6. HIGH SOILD EPOXY COATING SYSTEM ..................................................................................... 12
6.1 Acceptable High Solid Epoxy Materials .............................................................................. 12
6.2 Handling and Storage of Materials ...................................................................................... 12
6.3 Application Procedure.......................................................................................................... 12
6.4 Inspection for Field Application Work ................................................................................ 12
7. ATTACHMENT-1 ............................................................................................................................. 13
8. ATTACHMENT-2 ............................................................................................................................. 14
9. ATTACHMENT-3 ............................................................................................................................. 22
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Rev.R1C2
1. GENERAL
This specification defines the general requirements for external corrosion protection for
underground steel piping for the Sohar Refinery Improvement Project.
This specification is identical to S-000-13A0-102 General Specification for External Coating

of Underground Steel Pipe (Rev.R1) except for ATTACHMENT-3, changed list.
2. REFERENCES
S-000-1360-001 : General Specification of Piping
SSPC : Steel Structures Painting Council Volume 2
NACE SP-0274 : High Voltage Electrical Inspection of Pipeline Coatings Prior to

Installation
ISO 8501-1 : Preparation of Steel Substrates Before Application of Paints and

Related Products - Visual Assessment of Surface Cleanliness -
Part 1: Rust Grades and Preparation Grades of Uncoated Steel
Substrates and of Steel Substrates After Overall Removal of
Previous Coatings
ISO 8503-1 : Preparation of steel substrates before application of paints and

related products - Surface roughness characteristics of
blast-cleaned steel substrates - Part 1: Specification and
definitions for ISO profile comparators for the assessment of
abrasive blast-cleaned surfaces
SSPC-PA2 :Procedure for Determining Conformance to Dry Coating

Thickness Requirements
AWWA C213 : Fusion-Bonded Epoxy Coating for the Interior and Exterior of
Steel Water Pipelines
3 OF 22
Rev.R1C2
3. APPLICATION OF COATING AND WRAPPING SYSTEMS
Coating and wrapping schedule shall be in accordance with Attachment-1.
3.1 Underground sewer steel piping and steel sleeve pipes (non-pressurized piping
Carbon Steel Piping
Wrapping System or High solid epoxy coating System shall be applied at field shop or field.
Wrapping materials shall be suitable for the installation and operating temperature 50 deg. C
maximum. Refer to Para. 4 below for the detailed requirements for Wrapping System and
Para. 6 for High Solid Epoxy Coating System.
3.2 Underground pressurized Carbon Steel Piping
3.2.1 Pipe
For pipe diameters 1-1/2 and below, high solid epoxy coating system shall be applied. Refer
to Para.6 below for the detailed requirements.
For pipe diameters 2" & above, high solid epoxy coating system or Fusion Bonded Epoxy
coating system (FBE) shall be applied. Refer to Para.5 and 6 for the detailed requirements.
3.2.2 Fitting
For pipe diameters 6" & below, high solid epoxy coating system shall be applied. Refer to
Para.6 below for the detailed requirements.
For pipe diameters 8" & above, high solid epoxy coating system or Fusion Bonded Epoxy
coating system (FBE) shall be applied. Refer to Para.5 and 6 below for the detailed
requirements.
3.2.3 Flange & Valve
For all diameters, wrapping system shall be applied at field shop or field. Refer to Para.4
below for the detailed requirements.
3.3 Underground Galvanized Steel Piping and Stainless Steel Piping
Wrapping System shall be applied at field shop or field. Refer to Para. 4 below for the
detailed requirements.
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Rev.R1C2
4. WRAPPING SYSTEM
4.1 Acceptable Wrapping Materials
4.1.1 Priming for Tape Wrapping
Polyken Primer No. 1027 or equivalent

The primers consist of butyl based elastomers blended with polymeric resins dissolved in an
organic solvent system.
4.1.2 Mastic and Mastic Strip
Polyken No. 939 Polyethylene or equivalent

50 mm wide tape is preferable.
4.1.3 Inner Wrapping for pipes

100 mm or 150 mm wide tape is preferable.
Standard thickness is 35 mils (0.889 mm)
4.1.4 Outer Wrapping for pipes

100 mm or 150 mm wide tape is preferable.
4.1.5 Inner Wrapping for flanges, valves, other fittings and welding connections

4.1.6 Outer Wrapping for flanges, valves, other fittings and welding connections

4.2 Handling and Storage of Materials
All the wrapping materials shall be stored and handled in accordance with the
manufacturer's specification.
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Rev.R1C2
4.3 Application Procedure
The procedure for applying wrapping materials to each part of the piping assemblies is
drawn on the sketches attached hereunder.
Details shall be referred Fig. 1 to 8 of Attachment-2.
4.3.1 General
(1) The wrapping work on the welding points shall be performed after the test for
piping is completed.
(2) Wrapping work shall not be done when it is rainy, dusty, freezing, or in such a
weather as will adversely affect the wrapping work, (except where protective
facilities and sufficient protections are provided).
4.3.2 Surface Preparation
The bare steel pipe shall be free of mud, mill lacquer, wax, oil, grease, rust, mill scale, and
any other foreign material that prevents wrapping system from bonding to the steel surface.
Prior to abrasive cleaning, Oil, grease, and other contaminants shall be removed by a
suitable solvent according to SSPC-SP 1. Salt contamination, chemical cleaning agents and
remaining detergents shall be washed off using potable water.
After performing the pre-cleaning operation, the exterior steel pipe surface shall be abrasive
cleaned to achieve a commercial blast cleaned surface as SSPC-SP-6 or Sa2 (ISO
8501-1). For stainless steel pipe, chlorine-free abrasives shall be used.
Galvanized carbon steel surface shall be etching or sweep blasting for surface preparation.
Cleaned field welds do not require paint priming before the application of the tape primer
and wrapping. The application of the tape primer and wrapping shall be in accordance with
the respective procedures listed below and may be supplemented with the Manufacturers
application procedure.
4.3.3 Priming
Immediately after cleaning and surface preparation, brush applies tape primer or with
roller-spreader in accordance with manufacturers recommendations. Rate of primer
application shall be from 0.1 - 0.2L/m2. Primer shall be applied to a uniform thickness and
shall be free of floods, runs, sags and drips. The primer shall be tacky to dry at the time the
tape is applied.
4.3.4 Tamping of Filler Materials
Mastic and mastic strip shall be used for filling the gaps and molding of the irregular shapes
of the pipeline, such as parts around the bolts and nuts on the flange connection, valve, etc.
(Refer to Fig. 4 and 5) Mastic strip shall be put between wrapped piping and supports for
protection of the wrapped piping (Refer to Fig. 6).
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Rev.R1C2
4.3.5 Innerwrap Tape Wrapping
Wrapping of innerwrap tape shall be conducted when the primer has been half-dried.
Wrapping shall be completed where the primer paste has been coated on that day, and the
primer-coated surface shall not be left without wrapping to the following day.
(1) Straight pipes, elbows and tees, etc. (Refer to Fig. 1, 2 and 3)
Tape shall be applied spirally with a minimum overlap of 50 percent.
The tape shall be applied to ensure uniformity of tension and spiral direction during
application by manual or using wrapping tools.
Basically apply in double layer, completely overlapping tape on the starting and ending
portions of the piping. The tape wrapping shall be finished on the side of the piping
where the end of the tape faces downwards (Refer to Fig. 1). These ends shall be cut
using cutters or knives.
(2) Flanges, valves and other fittings (Refer to Fig. 4 and 5)
Cut tape to adequate lengths according to the configurations of the surfaces to be

rapped, and apply these pieces of the tape to the surfaces tightly according to the
overlapping allowance specified in the manufacturer's specification.
(3) Welding connections (Refer to Fig. 7)
Apply in single layer, 100 mm wide tape to the weld line tightly as stretching it.
Subsequently, the same wrapping procedure as that for straight pipes, elbows and tees
shall be applied.
(4) Through the wall (Refer to Fig. 8)
After the straight pipe is wrapped as aforesaid, insert the said wrapped pipe into the
penetration hole and fix the pipe in position. Clearance between the pipe and the hole
shall be filled with mastic or materials instructed by Purchaser.
(5) Riser portion
Wrapping shall be applied to the riser portions of the underground piping (incl. pipes,
elbows, tees, flanges, valves and other fittings) up to 300 mm from ground level. Tape
shall be wrapped upward from the bottom of the piping.
4.3.6 Outerwrap Tape Wrapping
In a similar manner to the above, stretch the outerwrap tape and wrap it tightly and uniformly
around the surfaces of the innerwrap tape on straight pipes, elbows, flanges, valves and
other fittings, etc., with a minimum overlap of 50 percent.
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Rev.R1C2
4.4 Repairs of Wrapping
Small defects or damage on the wrapping shall be repaired as follows:

The outer and inner wraps around the damaged area shall be removed and clean to the
bare steel surface. Apply primer immediately to the bare steel surface and patch with the
inner wraps while the primer is tacky. The patch shall overlap by at least 100 mm on each
side over the repair area. Apply primer over the patch area and circumferential repair area
and finish it with the spiral wrap.
4.5 Inspection for Wrapping Work
A holiday test shall be carried out using an adjustable high voltage holiday tester by applying
in accordance with NACE SP-0274. The test voltage shall be checked at least once per shift
using a special high voltage meter. When the holiday test is carried out the external pipe
surface shall be free of moisture. The electrode shall be moved over the pipe surface with a
speed not more than 0.3 meters per second. Holiday test shall be performed on completely
wrapped piping system. Any defects shall be repaired in accordance with paragraph 4.4.
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Rev.R1C2
5. FUSION BONDED EPOXY COATING SYSTEM
5.1 Acceptable Fusion Bonded Epoxy Materials
(1) Interpon HD 3095 or 3055 ( International Paint )
(2) Nap Gard 7-2500 or 7-2501 ( Herberts - O'Brien )
(3) Scotchkote 206N or 226N ( 3M )
(4) Other materials subject to Purchaser's approval.
All the fusion bonded epoxy materials shall be stored and handled in accordance with the
5.3.1 Surface Preparation
Prior to abrasive cleaning, all oil, grease and other deleterious materials shall be removed
by solvent cleaning in accordance with SSPC-SP1 or by detergent washing or steam
cleaning. No residue that will affect adhesion shall be left on the surface.
The surface to be coated shall be abrasive cleaned to a near white metal surface finish
equal to SSPC-SP 10 or Sa2 (ISO 8501-1). Any internal coating shall be protected from
damage by the blasting material at all times.
The blast pattern shall be a uniform angular anchor profile with a height of 40 - 100 m.
( Medium as per ISO 8503-1)
5.3.2 Coating Application
The coating material shall be applied according to the vendor's application procedure which
incorporates manufacturer's recommendation.
The finished coating thickness shall be in the range 350 to 525 m.
The finished coating shall have a cut back at each end in the range of 40 to 65 mm
measured from end of pipe.
9 OF 22
Rev.R1C2
5.4 Repair at Vendor's Shop Work
Touch-up or repairs at vendor's shop work shall be made with FBE or other materials
subject to Purchaser's approval. Touch-up material shall also be approved by the
manufacturer.
5.5 Inspection for Vendor's Shop Work
The vendor's quality assurance system shall include, as a minimum, the following.
(1) Checking cleanliness of pipe immediately prior to blasting
(2) Monitoring of size, shape, dryness and cleanliness of the blasting material and
process.
(3) Checking visually, in good light, the surface of the pipes for metal defects, dust
and surface debris.
(4) Checking pipe surface blast profile
(5) Checking temperature control of the pipe surface.
(6) Checking coating thickness of cured FBE (Refer to SSPC-PA2).
(7) Checking on the coating adhesion properties
At production startup and after every twenty pipe lengths or every hour (whichever is
more frequent) coating adhesion shall be tested and recorded as per the method given
below and in accordance with AWWA C213. If three consecutive tests have been
successful, the frequency shall be reduced to once every 2 hours or 50 pipe lengths,
whichever is more frequent. Two incisions of 1/2" long shall be made through the
coating using a sharp knife of narrow width blade to form an "X" mark. An attempt shall
be made to force the coating to peel off using the knife point, starting from the
intersection of "X". Refusal of the coating to peel off from the substrate constitutes a
PASS. Partial or complete removal of the coating from the substrate shall constitute a
FAILURE. Cohesive failure within the coating shall also be recorded as PASS. But,
cohesive failures caused by voids within the coating film and leaving a honey comb
appearance constitute a FAILURE condition.
Note: Removal of the coating from the intersection to 1mm inwards shall be ignored.
(8) Holiday detection of 100 percent of the coated surface area of all pipes (Refer to
NACE SP-0274).
(9) Checking of coating color, appearances and uniformity.
(10) Cure Test (DSC Analysis)
DSC analysis of the applied coating shall be carried out twice per shift to confirm the
curing of the coating. The difference between Second Glass Transition temperature
(Tg2) and First Glass Transition temperature (Tg1) shall not be more than 4 or
within the range recommended by the manufacturer.
10 OF 22
Rev.R1C2
5.6 Field Application of Repair and Welded Joints for Underground Carbon Steel Piping
5.6.1 Coating Materials
The coating material shall be High solid epoxy.

(1) Hempel-Hempadur 85531
(2) OASIS Ameron-Nap Gard 7-0055
(3) Interzone 954 or 485
(4) Or equivalent materials subject to Purchaser's approval.
5.6.2 Coating Procedure
Surface Preparation : Sa2 (ISO 8501-1) or SSPC-SP6

No. of coat : 1 or more
5.6.3 Total thickness : 500 to 625 m
5.7 Inspection for Field Application Work
5.7.1 Coating Thickness Test
The coating thickness shall be measured at least once per square meter, in accordance with
SSPC-PA2.
5.7.2 Holiday Detection
The applied coating shall be fully tested for the absence of holiday in accordance with NACE
SP-0274. All holiday shall be repaired in accordance with Para. 5.6 of this specification.
11 OF 22
Rev.R1C2
6. HIGH SOLID EPOXY COATING SYSTEM
6.1 Acceptable High Solid Epoxy Materials
(1) Hempel-Hempadur 85531

(2) OASIS Ameron-Nap Gard 7-0055
(3) Interzone 954 or 485
(4) Or equivalent materials subject to Purchaser's approval.
All the High Solid Epoxy materials shall be stored and handled in accordance with the
6.3.1 Coating Procedure
Surface Preparation : SSPC-SP 3 or Sa2 (ISO 8501-1)

No. of coat : 1 or more
6.3.2 Total thickness : 500 to 625 m
6.4 Inspection for Field Application Work
6.4.1 Coating Thickness Test
The coating thickness shall be measured at least once per square meter, in accordance with
SSPC-PA2.
6.4.2 Holiday Detection
The applied coating shall be fully tested for the absence of holiday in accordance with NACE
SP 0274. All holiday shall be repaired in accordance with Para. 4.3 of this specification.
12 OF 22
Rev.R1C2
7. ATTACHMENT-1
Coating and wrapping schedule for this specification is as follows.
System No. U1
Underground sewer steel piping and steel sleeve pipe (non-pressurized piping)
Wrapping System or High Solid Epoxy Coating System
Refer to paragraph 3, 4 and 6.
System No. U2
1-1/2 and below underground carbon steel piping
Pipe and Fitting: High Solid Epoxy Coating System

Flange and Valve: Wrapping System
Refer to paragraph 3, 4 and 6

.
System No. U3
2 through 6 underground carbon steel piping
Pipe: Fusion Bonded Epoxy Coating System or High Solid Epoxy Coating System
Fitting: High Solid Epoxy Coating System
Refer to paragraph 3, 4, 5 and 6
System No. U5
8 and above underground carbon steel piping
Pipe: Fusion Bonded Epoxy Coating System or High Solid Epoxy Coating System
Fitting : Fusion Bonded Epoxy Coating System or High Solid Epoxy Coating System
Refer to paragraph 3, 4 ,5 and 6
System No. U7
Underground galvanized steel piping and Stainless Steel piping
Wrapping System
Refer to paragraph 3 and 4
13 OF 22
Rev.R1C2
8. ATTACHMENT-2
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Rev.R1C2
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Rev.R1C2
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Rev.R1C2
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Rev.R1C2
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Rev.R1C2
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Rev.R1C2
21 OF 22
Oman Refineries and Petrochemicals Company LLC.
Sohar Refinery Improvement Project General Specification for External Coating of Underground Steel Pipe
Rev.R1C2
9. ATTACHMENT-3
CHANGED LIST : This specification is identical to S-000-13A0-102 General Specification for External Coating of Underground Steel Pipe
(Rev.R1C1) except followings. Please refer to the following descriptions.
Company
No Clause Before (R1C1) After (R1C2) Contractor Comments
Comments
1 No Changed -
22 OF 22

S-000-13a0-102 - 1c2 External Coating of Underground Steel Pipe

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S-000-13a0-102 - 1c2 External Coating of Underground Steel Pipe

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Oman Refineries and Petrochemicals Company LLC.

General Specification for External

ORIGINAL CHECKED CHECKED APPROVED

This specification is identical to S-000-13A0-102 General Specification for External Coating

S-000-1360-001 : General Specification of Piping

SSPC : Steel Structures Painting Council Volume 2

NACE SP-0274 : High Voltage Electrical Inspection of Pipeline Coatings Prior to

ISO 8501-1 : Preparation of Steel Substrates Before Application of Paints and

ISO 8503-1 : Preparation of steel substrates before application of paints and

SSPC-PA2 :Procedure for Determining Conformance to Dry Coating

3. APPLICATION OF COATING AND WRAPPING SYSTEMS

Coating and wrapping schedule shall be in accordance with Attachment-1.

3.2 Underground pressurized Carbon Steel Piping

3.2.3 Flange & Valve

3.3 Underground Galvanized Steel Piping and Stainless Steel Piping

4.1 Acceptable Wrapping Materials

4.1.1 Priming for Tape Wrapping

Polyken Primer No. 1027 or equivalent

4.1.2 Mastic and Mastic Strip

Polyken No. 939 Polyethylene or equivalent

4.1.3 Inner Wrapping for pipes

Polyken No. 930 Polyethylene or equivalent

4.1.4 Outer Wrapping for pipes

Polyken No. 954 Polyethylene or equivalent

Polyken No. 930 Polyethylene or equivalent

Polyken No. 954 Polyethylene or equivalent

4.2 Handling and Storage of Materials

4.3 Application Procedure

4.3.2 Surface Preparation

4.3.4 Tamping of Filler Materials

4.3.5 Innerwrap Tape Wrapping

Tape shall be applied spirally with a minimum overlap of 50 percent.

(2) Flanges, valves and other fittings (Refer to Fig. 4 and 5)

Cut tape to adequate lengths according to the configurations of the surfaces to be

(3) Welding connections (Refer to Fig. 7)

(4) Through the wall (Refer to Fig. 8)

(5) Riser portion

4.3.6 Outerwrap Tape Wrapping

4.4 Repairs of Wrapping

Small defects or damage on the wrapping shall be repaired as follows:

4.5 Inspection for Wrapping Work

5. FUSION BONDED EPOXY COATING SYSTEM

5.1 Acceptable Fusion Bonded Epoxy Materials

(1) Interpon HD 3095 or 3055 ( International Paint )

(2) Nap Gard 7-2500 or 7-2501 ( Herberts - O'Brien )

(3) Scotchkote 206N or 226N ( 3M )

(4) Other materials subject to Purchaser's approval.

5.2 Handling and Storage of Materials

5.3 Application Procedure

5.3.1 Surface Preparation

5.3.2 Coating Application

The finished coating thickness shall be in the range 350 to 525 m.

5.4 Repair at Vendor's Shop Work

5.5 Inspection for Vendor's Shop Work

(1) Checking cleanliness of pipe immediately prior to blasting

(4) Checking pipe surface blast profile

(5) Checking temperature control of the pipe surface.

(6) Checking coating thickness of cured FBE (Refer to SSPC-PA2).

(7) Checking on the coating adhesion properties

(9) Checking of coating color, appearances and uniformity.

(10) Cure Test (DSC Analysis)

5.6.1 Coating Materials

The coating material shall be High solid epoxy.