S 000 13A0 102 Wrapping and Coating

JOB No. JGC DOC. No. REV.
Sohar Refinery Company

SOHAR Refinery Project 0-3100-25 S-000-13A0-102 R1
DATE 08 − Apr. − 2003 SHEET 1 OF 17
PROJECT SPECIFICATION PREP’D K. Horikiri
CHK’D K. Takase
APP’D M. Sakai
GENERAL SPECIFICATION
FOR
EXTERNAL COATING OF UNDERGROUND STEEL PIPE
FOR CONSTRUCTION
SOHAR REFINERY COMPANY L. L. C.
SOHAR REFINERY PROJECT
SOHAR, SULTANATE OF OMAN
Reference ITT Doc. No. Rev
REV. DATE PAGE DESCRIPTION PREP’D CHK’D APP’D
0 08 Apr. 2003 All For Approval K.H. K.T. M.S.
1 01 Aug. 2003 All For Approval K.H. K.T. M.S.
R 07 Oct. 2003 All For Construction K.H. M.S. M.S.
R1 12 Jul. 2004 2-4, 8-10 For Construction (JY-OY-E-21405, OY-JY-E-22200, K.H. M.S. M.S.
JY-OY-E-21620, OY-JY-E-22408)
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L-2004
C:¥PDF_Work¥NativeToPDF¥Native Files¥0-3100-2¥09004ed5800bb91a____A4____.doc
SOHAR Refinery Project JOB CODE: 0-3100
DOC NO: S-000-13A0-102 rev.R1
General Specification For External Coating Of
SHEET : 2 of 17
Underground Steel Pipe
CONTENTS
1. GENERAL..................................................................................................................................................... 3
3. REFERENCES.............................................................................................................................................. 3
3. APPLICATION OF COATING AND WRAPPING SYSTEMS.............................................................. 3
4. WRAPPING SYSTEM................................................................................................................................. 4
4.1 Acceptable Wrapping System..................................................................................................................4
4.2 Handling and Storage of materials..........................................................................................................4
4.3 Application Procedure.............................................................................................................................4
4.4 Repairs of Wrapping................................................................................................................................6
4.5 Inspection for Wrapping Work................................................................................................................6

5. FUSION BONDED EPOXY COATING SYSTEM................................................................................... 6
5.1 Acceptable Fusion Bonded Epoxy Materials...........................................................................................6
5.2 Handling and Storage of materials ..........................................................................................................6
5.3 Application Procedure .............................................................................................................................7
5.4 Repair at Vendor's Shop Work.................................................................................................................7
5.5 Inspection for Vendor's Shop Work.........................................................................................................7
5.6 Field Application of Repair and Welded Joints for FBE Piping & Fitting of Pipe Diameters 6 & Below
for and Pipe of Pipe Diameters 1-1/2" & Below for Underground Pressurized Carbon Steel
Piping .......................................................................................................................................................8
5.7 Inspection for Field Application Work....................................................................................................8

6. ATTACHMENT-1.........................................................................................................................................9
7. ATTACHMENT-2.......................................................................................................................................10
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1 GENERAL
This specification defines the general requirements for external corrosion protection for underground
steel piping for the Sohar Refinery Project for subcontracting inquiry.
2 REFERENCES
S-000-1360-001 : General Specification of Piping
SSPC : Steel Structures Painting Council Volume 2
NACE RP-02-74 : High Voltage Electrical Inspection of Pipeline Coatings Prior to Installation
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 : Measurement of Dry Film Thickness with Magnetic gauges
3 APPLICATION OF COATING AND WRAPPING SYSTEMS
Coating and wrapping schedule shall be in accordance with Attachment-1.
(1) Underground sewer steel piping and steel sleeve pipes (non-pressurized piping):
Wrapping 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.
(2) Underground pressurized carbon steel piping:
(a) Pipe
For pipe diameters 1-1/2 and below, high solid epoxy coating system shall be applied at
field shop or field. Refer to Para. 5. 6 below.
For pipe diameters 2" & above, Fusion Bonded Epoxy Coating System (FBE) shall be
applied at vendor's shop. Refer to Para. 5 below for the application at shop and field.
(b) Fitting
For pipe diameters 6" & below, high solid epoxy coating system shall be applied at
field shop or field. Refer to Para. 5. 6 below.
For pipe diameters 8" & above, FBE shall be applied at vendor's shop. Refer to Para. 5
below for the application at shop and field.
(c) 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) Underground galvanized 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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4 WRAPPING SYSTEM
4.1 Acceptable Wrapping Materials
(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.
(2) Mastic and Mastic Strip
Polyken No. 939 Polyethylene or equivalent

50 mm wide tape is preferable.
(3) Inner Wrapping for pipes and welding connections

100 mm or 150 mm wide tape is preferable.
Standard thickness is 20 mils (0.500 mm)
(4) Outer Wrapping for pipes and welding connections

100 mm or 150 mm wide tape is preferable.
(5) Inner Wrapping for flanges, valves and other fittings

(6) Outer Wrapping for flanges, valves and other fittings

4.2 Handling and Storage of Materials
All the wrapping materials shall be stored and handled in accordance with the manufacturer's
specification.
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.
(1) General
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(a) The wrapping work on the welding points shall be performed after the test for piping is
completed.
(b) 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).
(2) Surface Preparation
Steel surface of pipes, fittings and field welds shall be cleaned by power tool to SSPC-SP 3 combined
with hand tool to SSPC-SP 2. Weld spatters, projections, sharp edges or indentations, burrs shall be
ground smooth. 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. 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 Manufacturer’s
application procedure.
(3) Priming
Immediately after cleaning and surface preparation, brush applies tape primer or with roller-spreader
in accordance with manufacturer’s 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) 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).
(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.
(a) 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.
(b) 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

wrapped, and apply these pieces of the tape to the surfaces tightly according to the
overlapping allowance specified in the manufacturer's specification.
_ __ (c) Welding connections (Refer to Fig. 7)
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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.
(d) 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 JGC.
(e) 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.
(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.
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 RP-02-74. 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.
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
All the fusion bonded epoxy materials shall be stored and handled in accordance with the
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5.3 Application Procedure
(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. 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 micrometers.
( Medium as per ISO 8503-1)
(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 micrometers.
The finished coating shall have a cut back at each end in the range of 40 to 65 mm measured from end
of pipe.
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. 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.
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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
RP-02-74).
(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 deg. C or within the range
recommended by the manufacturer.
5.6 Field Application of Repair and Welded Joints for FBE Piping & Fitting of Pipe Diameters 6" &
Below and Pipe of Pipe Diameters 1-1/2" & Below for Underground Pressurized Carbon Steel Piping
(1) Coating Materials
The coating material shall be High solid epoxy, Hempel-Hempadur 8553 or OASIS Ameron-Nap Gard
7-0055 or equivalent.
(2) Coating Procedure
Surface Preparation: SSPC-SP 3

No. of coat : 1 or more
(3) Total thickness : 500 to 625μm
5.7 Inspection for Field Application Work
(1) Coating Thickness Test
The coating thickness shall be measured at least once per square meter, in accordance with SSPC-PA2.
(2) Holiday Detection
The applied coating shall be fully tested for the absence of holiday in accordance with NACE
RP-02-74. All holiday shall be repaired in accordance with Para. 5.6 of this specification.
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6 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
Refer to paragraph 3 and 4.
System No. U3
2” through 6” underground pressurized carbon steel piping
Pipe: Fusion Bonded Epoxy Coating System

Fitting: High Solid Epoxy Coating System
Flange and Valve: Wrapping System
Refer to paragraph 3, 4 and 5
System No. U5
8” and above underground pressurized carbon steel piping
Pipe and Fitting: Fusion Bonded Epoxy Coating System

System No. U7
1-1/2” and below underground pressurized carbon steel piping
Pipe and Fitting: High Solid Epoxy Coating System

System No. U9
Underground galvanized steel piping
Wrapping System
Refer to paragraph 3 and 4
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7 ATTACHMENT-2
Fig. 1 UNDERGROUND PIPING (STRAIGHT PIPE)
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Fig. 2 UNDERGROUND PIPING (ELBOW)
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Fig. 3 UNDERGROUND PIPING (TEES)
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Fig. 4 UNDERGROUND PIPING (FLANGE)
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Fig. 5 UNDERGROUND PIPING (VALVES)
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Fig. 6 UNDERGROUND PIPING (SUPPORTS)
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Fig. 7 UNDERGROUND PIPING (WELDING POINT)
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Fig. 8 UNDERGROUND PIPING (THROUGH THE WALL)
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JOB No. JGC DOC. No. REV.

Sohar Refinery Company

EXTERNAL COATING OF UNDERGROUND STEEL PIPE

SOHAR REFINERY COMPANY L. L. C.

SOHAR REFINERY PROJECT

SOHAR, SULTANATE OF OMAN

Reference ITT Doc. No. Rev

REV. DATE PAGE DESCRIPTION PREP’D CHK’D APP’D

0 08 Apr. 2003 All For Approval K.H. K.T. M.S.

1 01 Aug. 2003 All For Approval K.H. K.T. M.S.

R 07 Oct. 2003 All For Construction K.H. M.S. M.S.

4.2 Handling and Storage of materials..........................................................................................................4

4.3 Application Procedure.............................................................................................................................4

4.4 Repairs of Wrapping................................................................................................................................6

4.5 Inspection for Wrapping Work................................................................................................................6

5.2 Handling and Storage of materials ..........................................................................................................6

5.3 Application Procedure .............................................................................................................................7

5.4 Repair at Vendor's Shop Work.................................................................................................................7

5.5 Inspection for Vendor's Shop Work.........................................................................................................7

5.7 Inspection for Field Application Work....................................................................................................8

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

SSPC : Steel Structures Painting Council Volume 2

SSPC-PA2 : Measurement of Dry Film Thickness with Magnetic gauges

3 APPLICATION OF COATING AND WRAPPING SYSTEMS

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

(2) Underground pressurized carbon steel piping:

(c) Flange & Valve

(3) Underground galvanized steel piping:

4.1 Acceptable Wrapping Materials

(1) Priming for Tape Wrapping

Polyken Primer No. 1027 or equivalent

(2) Mastic and Mastic Strip

Polyken No. 939 Polyethylene or equivalent

(3) Inner Wrapping for pipes and welding connections

Polyken No. 980 Polyethylene or equivalent

(4) Outer Wrapping for pipes and welding connections

Polyken No. 955 Polyethylene or equivalent

(5) Inner Wrapping for flanges, valves and other fittings

Polyken No. 930 Polyethylene or equivalent

(6) Outer Wrapping for flanges, valves and other fittings

Polyken No. 954 Polyethylene or equivalent

4.2 Handling and Storage of Materials

4.3 Application Procedure

(2) Surface Preparation

(4) Tamping of Filler Materials

(5) Innerwrap Tape Wrapping

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

• Basically apply in double layer, completely overlapping tape on the starting

(b) 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

_ __ (c) Welding connections (Refer to Fig. 7)

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

(e) Riser portion

(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