1. INTRUCTION
This document describes the recommended procedure to be followed for the installation of the HSS
(WPC100). Which is applied for FJC system
1.1 Definitions and Abbreviations
Owner:
Contractor: PTSC MC
Subcontractor: Chan Hung Ltd
Manufacture: Berry plastics
FJC: Field Joint
OD: Outside diameter
PQT: Pre-Qualification test
HSS: hear shrink sleeve
HDPUF: High density polyurethane foam
SPU: Solid polyurethane
1.2 Codes, Standards, Regulations and References
The latest edition of the following codes, standards and specifications shall establish the
minimum standards for the work. SUPPLIER may use alternative standards that meet or are more
stringent than those listed if approved by COMPANY.
in case of conflict of provisions/requirements set forth in the below documents and this
specification, the latter shall prevail.
DNV RP F102
Pipeline Joint Coating and Field Repair of Line pipe Coating, October
2003
NFA 49-711
Steel Tubes - Three-Layer External Coating Based on Polypropylene - Application
by Extrusion, November 1992
ASTM D4285
Standard test method for indicating oil or water in compressed air
ISO 8501-1
Preparation of Steel Substrates before Application of Paints and Related
Products Visual Assessment of Surface Cleanliness - Rust Grades and
Preparation Grades of Uncoated Steel Substrates and of Steel Substrates after
Overall Removal of Previous Coatings Preparation Grades after Removal of
Previous Coatings
ISO 8502-3
Preparation of Steel Substrates before Application of Paints and Related Products
- Test for the Assessment of Surface Cleanliness - Assessment of Dust on Steel
Surfaces Prepared for Painting (Pressure- Sensitive Tape Method)
ISO 8503-1
Preparation of Steel Substrates before Application of Paints and Related
Products - Surface Roughness Characteristics of Blast Cleaned Steel
Substrates - Specifications and Definitions for ISO Surface Roughness
Comparators for the Assessment of Abrasive Blast Cleaned Surfaces.
SSPC SP1
Volume 1: Good Painting Practice, Volume 2: Systems and Specification, as
follows: SP 1, Solvent Cleaning.
NACE RP0274
Holiday Test
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ISO 8502-6 & 9
Preparation of steel substrates before application of paints and related
products, test for the assessment of surface cleanliness.
Part 6 extraction of soluble contaminants for analysis – The Bessel Method.
Part 9 field method for conduct metric determination of water soluble salts.
ISO-21809-3
Petroleum and Natural Gas Industries – External Coatings for
Buried or Submerged Pipelines Used in Pipeline Transportation
System – Part 3: Field Joint Coatings.
1.3. Specification information
As Document No:
1.4. Cutback system (Drawing of cutback for FJC will issue later)
Layout of FJC: HSS (3LPE- WPC100) + Overlap 50mm and fulfill by HDPUF (Gas line)
If Max temperature operation of Export Oil line is higher 100oC, we should recommend
HSS-PP and SPU type
1.5. HSS Specification description
1.5.1. WPC 100 is offer for this system
WPC100M is a wraparound heat-shrinkable sleeve specially suitable for higher stress conditions
caused both by elevated temperatures and by soils with severe contraction between wet-dry
cycles. The WPC100M is compatible with most commonly used steel pipe sections and large
radius bends. WPC100M may be cut to the appropriate length to cover all pipe.
WPC is consist of two layer system and PE type, the first layer is visco-elastic adhesive sealant
and second layer is radiation –crosslink high density polyethylene with basically specification as
bellow
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2. Procedure application & QPT for HSS
2.1. Surface Preparation
Clean any exposed steel and adjacent pipe coating with a solvent cleanser to remove the
presence of oil, grease, and other contaminants. The uncoated steel surface shall then be blast
cleaned by blasting machine to get Sa2.5 as requirement. Pre-check surface condition as
environment condition, Dust level, salt-contamination, steel surface profile after cleaning surface
by blasting method. Please see IPT as attached
2.2.1. Pre-heating surface preparation
Upon acceptance of the surface cleanliness and prior to epoxy application, the bare steel
surface shall be pre heated over the surface to remove the moisture and heating up surface to
110-120oC by using Gas-torch or induction heat.
Steel pipe shall be pre-heat to 95-100°C at 3LPE overload coated as recommended by
Manufacturer and shall be checked by pyrometer or digital contact temperature indicator.
Digital contact temperature indicator shall be carefully used during heating due to induced
electroma gnetic fields. Access window for monitoring the pipe temperature shall be provided to
ensure uniform distribution of heat circumferentially around the pipe
2.2.3 WPC 100M sleeve installation
The sleeve shall be installed immediately after heating epoxy primed steel to m i n 110°C by
wrapping loosely around the pipe centering over the cut back area and evenly overlapping the
adjacent pipe coating in a cigarette fashion.
Wrap the sleeve loosely around the pipe, ensuring the appropriate overlap. Before finishing
wrapping the sleeve:
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(1) Heat the backing side of the under lap until the backing starts to recover.
(2) Heat the adhesive side of the closure until the adhesive appears glossy.
Press the closure and overlap firmly into place. Gently heat the closure and pat it down with a
gloved hand. Repeating this procedure, move from one side to the other, smooth any wrinkles
by gently working them outward from the centre of the closure with a roller. Ensure the
protective heat shields are securely wrapped around the adjacent mainline coating.
Using the torch, begin heating at the centre of the sleeve and heat circumferentially around the
pipe. Continue heating from the centre toward one end of the sleeve until recovery is complete.
In a similar manner, heat and shrink the remaining side.
Once initial shrinking has been completed, finish shrinking the sleeve with long circumferential
strokes over the coating overlap surface to ensure a uniform bond. Adhesive should begin to
ooze at the sleeve edges all around the circumference.
When the sleeve has been shrunk on to the joint area and is still hot and soft, a small hand
roller shall be run over the same to ensure that the adhesive remains bonded to the mainline
coating surface and to push out any trapped air, particularly paying attention to the weld and
cut back area and if necessary the areas may be reheated to roll out entrapped air.
2.2.4. Visual and Holiday check
Test WPC100M sleeve adhesion by gently pulling the edge of the backing back to ensure
that the adhesive remains in place and is fully bonded to the factory coating. The sleeve is
well bonded when the adhesive and coating remain intimately contacted. If required to
improve bonding, additional heat should be applied to the sleeve.
3.
Visually inspect the installed sleeve for the
following:
 Sleeve is in full contact with the steel joint;
 Adhesive flows beyond both sleeve edges;
 No cracks or holes in sleeve backing
 Holiday test as ITB plan submit(15KV)
High Density Polyurethane Foam application
3.1. Material visual checking
Checking batch lot- valid time
Checking certificated
Checking foaming machine in good operation
3.2. Inject HDPUF
HSS completely testing and get approval from Owner/ PTSC inspector, Grift Joint to be surrounded
by metal steel sheet plate. Using drilling machine to make a hole pin with diameter around 60mm.
Heating around is by using the gas-torch in order to minimize the air inside, it will avoid HPUF to be
foam and ensure the quantity
Base on QPT result, inject directly foam inside FJ with accurate pumping time + 2 second as
requirement
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4. INSPECTION TEST PLAN, PQT
Note:
-
The below ITP are for quality control during Production and PQT;
-
Chan Hung shall be provided previous data with the tests performed on the same FJC system.
ATTACHMENTS:
1. Data Sheet WPC100
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Process
Property
Material Receipt
Test Method
Induction Coil Heating
Approved Inspection
Alphal
ECC
PV GAS
Batch/Lot Certificates Present
All Batch/Lots and Materials "in- date"
W/RR
W/R
W/R
One per shift Check Validity
M/RR
R
R
Heat distribution time
shall be determined
for pre-heat/curing
Check 1 joint prior to Check 1 joint Even heat profile across joint and
temperatures each
Start
prior to Start cutback
pipe OD and wall
thickness
M/R
W/R
W/R
Dry and free oil, grease, other
contamination
M/RR
H/W/R
H/W/R
Pipe substrate surface at least
3°C higher than dew point and
temperature greater than 10°C
M/RR
H/W/R
H/W/R
Less than 20 mg/m
M/RR
H/W/R
H/W/R
Check Certificate of
analysis
All Batch/Lots
Start PQT
Compressed Air Quality ASTM D 4285
Blasting
Acceptance Criteria
Chan
Hung
Calibration Certificates
(QC Equipments)
Preparation
Frequency (PQT)
Frequency
(Production)
Start PQT
One per shift
Every 4 hours
Every 4 hours
Environmental
Conditions
Ambient and Steel
Temperature,
Relative Humidity,
Dew Point
Salt Contamination
ISO 8502.3 SCM
Elcometer
Steel Surface Profile
ISO 8503 Replica
tape and dial gauge
Every 4 hours
Every 4 hours 50 to 100 microns
M/RR
H/W/R
H/W/R
Surface Cleanliness
Dust Level
ISO 8502:3 Clear
Tape Visual Test
Every 4 hours
Every 4 hours Max Level 2
M/RR
H/W/R
H/W/R
Blast cleaning
ISO 8501-1
M/RR
H/W/R
H/W/R
One per shift
Every joint
One per shift
Every joint
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SA 2.5
Process
Property
Test Method
WPC100 Sleeve
Installation Pre-Heat
Temp.
Digital Thermometer
Visual Inspection of
WPC100
Visual
Holiday Detection Test
on WPC100
Impact test
Frequency (PQT)
Frequency
(Production)
Acceptance Criteria
Approved Inspection
Chan
Hung
Alphal
ECC
PV GAS
170-195oC on steel
100-120oC on 3LPP
(0, 3, 6, 9 o'clock)
M/RR
H/W/R
H/W/R
Every joint
Every joint
Every joint
Every joint
Free of defects, air voids and
pinholes
M/RR
H/W/R
H/W/R
ISO 21809-3,
Annex B
Every joint
Every joint
No holidays on test piece, at
5kV/mm + 5kV but Max 25 kV
M/RR
H/W/R
H/W/R
ISO 21809-3,
Annex G
Every
N/A
≥ 8J/mm @ ambient temperature
M/RR
H/W/R
H/W/R
Every Joint
N/A
Update from data sheet
M/RR
H/W/R
H/W/R
Every Joint
N/A
< 10mm
M/RR
H/W/R
H/W/R
Peel strength (Adhesion)
at 10mm/min to pipe
surface and to plant
ISO 21809-3,
coating after 28 day-hot- Annex I
water immersion test at
95oC
N/A
N/A
Update from data sheet
M/RR
H/W/R
H/W/R
ISO 21809-3,
Annex H
N/A
N/A
Update from data sheet
M/RR
H/W/R
H/W/R
Peel strength (Adhesion)
at 10mm/min to pipe
HSS WPC100 surface primed with
Application epoxy and to plant
ISO 21809-3,
coating @ 23oC
Annex D
CD test @ 28 days @
23oC
Indentation resistant
ISO 21809-3,
Annex F
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Process
Property
Repairs
Symbol
RR
Test Method
Visual
Frequency (PQT)
As Necessary
Frequency
(Production)
No blemishes, cavities, or
As Necessary bubbles. No drips, sags, runs or
air entrapment
Legend
Record & Raise Documents
R
Review
M
Monitor
Approved Inspection
Acceptance Criteria
Chan
Hung
Alphal
ECC
PV GAS
W/RR
W/R
W/R
Symbol
Legend
W
Witness
H
Hold Point
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