WRAPPING PROCEDURE FOR PIPES & FITINGS
1.0 Scope
This specification covers the design requirements, material selection, application
procedure and inspection for the protection of external surface of underground pipes &
fittings.
2.0 Coating System
The coating system shall consist of the following components;
1. a primer layer Polyken #1027
2. a mastic layer tape for filling voids (flanges, valve etc) when necessary
Polyken #939-125
3. an inner-layer tape for corrosion protection; and
4. an outer-layer tape for mechanical protection.
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. 127
2. Mastic filler tape :
Polyken tape no. 939-125
3. Inner-layer tape :
for straight pipe : Polyken tape no. 980-20
for fitting : Polyken tape no. 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 itemns (eg flanges, valve etc) a moulding putty, Polyken
939-125 mastic filler shall be used for filling voids befor 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, aspphalt, oil,
grease, or any other foreign material. Visible oil 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, spatter & weld slags should be removed to achieve a
smooth surface.
4.3 The cleaned exterior pipe surfec 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 warehouse and only the daily rewuirements shall be brought to
the jod site, Only the amount of primer required for immediate use dhall 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 ni separation of solids from solvents prior to filling the open
containers.
5.3 Primer which has become contaminated with foreign matter or thickened because of
evaporation of solvents no be used.
5.4 The primer shall be thoroughly agitated in its container before application to the pipe.
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5.5 Primer shall be either brush or spray applied to the cleaned pipe surface in a unifrom
thin film at minimum covarage of approximately 7.4 square metre per liter of primer
to achieve a wet thickness of 50-75 microns. The prime coat shall be unifrom and free
from floods, runs, sags, drips, or bare spots. The primed pipe surface shall be free of any
foreign subtances 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.
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 applications 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 eupiment approved bt the tape manufacture ini
compliance with tha applicable standard. Hand application is permitted only for tape
width no wider than 6 iches. The inner-layer tape shall be spirally applied with
minimum overlap of 50% of the tape widthbeing 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 effect a wrinkle free
splice which maintains the continuity of the inner-layer tape. The spiral angle of the
new roll should parallel the previous roll’s spirak 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.
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6.6 Details of tape application be in accordance with the following:
Appendix-I : Tape application for field welding points
Appendix-II : Tape applications for elbows
Appendix-III : Tape application for tees
Appendix-IV : Tape application for flanges
Appendix-V : Tape application for post indicator valves
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 contiuous 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.
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 thet the holiday detector should be used
to reveal pin holes and minor faults in the tape wrap. Such defects would not normally
show up on the holiday detector with the specified coating system uncless the voltage
was set at level so high that it would be likely to damage the coating).
7.4 The holiday detector voltage shall be set according to NACE-RP0274 standard 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.
7.9 The holiday dtecetor shall be have a valid calibration certificate.
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7.10 The holding detector type “Ring” shall be apply for main pipe and elbow, for other type
can be use for fitting (tee, olet, etc)
8.0 Repairs to Coating
8.1 All defects in the coating shall be made good immediately afte their detection.
8.2 All holiday 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. (100mm)
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. (100mm) 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
9.0 Handling of Coated Pipe
9.1 All coated piping shall be handled in such a way thet 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 demage 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 demaged 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 intructions.
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10.2 Coating materials shall be handled in such a way that the materials do not suffer damage.
10.3 Any coating materials which show evidence of deterioration due to weathering or demage
due to mishandling shall be replaced.
10.4 Any materials which have been rejected for any reason shall be romoved from the site.
APPENDIX-I
Tape Application for field welding points.
Unless otherwise specified, the following shall be applied.
1. Cleaning of pipe to SSPC-SP2
2. Application of Primer
3. Wrap Tape
Immediately after the application of primer, the tapes shall be wrapped uniformly with
the minimum 50% overlap X 2 (total 4 Layers).
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APPENDIX – II
Tape Application for Elbows
Unless otherwise specified, the following shall be applied.
1. Cleaning of pipe to SSPC-SP2
2. Application of Primer
3. Wrap Tape
Immediately after the application of primer, the tapes shall be wrapped uniformly with the
minimum 50% overlap on the inner side of the elbow greaser than the overlap on the outer
side. Care shall be exercised to avoid the formation of wrinkles and 50% overlap shall be
maintained along the outer surface of the elbow.
Wrap tape with 50% overlap X2 (Total 4 Layers).
Along outer surface for each layer (greater overlap
along inner surface).
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APPENDIX – III
Tape Application for Tees
Unless otherwise specified, the following shall be applied.
1. Cleaning of pipe to SSPC-SP2
2. Application of Primer
3. Tape Wrap
(1) Tape shall be applied in strips where wrapping is impractical and thoroughly
pressed to ensure adhesion.
Care must be taken so as not to form wrinkles and/or air pockets.
(2) Tape shall then be wound in an “X” shape over the neck or joint of the branch
section.
(3) Tape shall be wrapped on the respective straight pipe section towards the joint
and completed with an “X” shape wrap, at least one complete turn around the
joint.
Wrap tape toward center of tee joint and
complete each branch with an “X” shape
wrap at center.
Steel Pipe
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APPENDIX – IV
Tape Application for Falengs
Unless otherwise specified, the following shall be applied.
1. Cleaning of Pipe to SSPC-SP2
2. Application of Primer
Apply primer to flange joint area
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3. Moulding Putty
Immediately after the application of primer, the Moulding Putty shall be applied by
pressing it into the joint and moulded so as to completely cover the flange plates, nuts, and
bolts. The putty shall be moulded so that the overall joint is finished with the surface
smooth and free or projections and indentations. The edges of the moulded putty, shall be
tapered to avoid formation of air packets when the tape is applied.
Apply putty to form smooth rounded shape
4. Tape Wrap
(1) Immediately after filling with the putty, the 1st tape wrap shall be applied in
strips longitudinally over the moulded portion with overlap on the adjacent
pipe surface. Each strip shall be thoroughly pressed to ensure adhesion,
special care shall be taken so as not to form air pockets especially at ends of
moulded putty.
Apply tape in strips and thoroughly press to ensure adhesion
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(2) Immediately after applying for the list tape wrap, the 2nd tape wrap shall be
applied in strips in the same manner as the last tape wrap. In this case 2nd
wrap shall as the 1st tape wrap. In this case 2nd wrap shall be slightly shorter
than the 1st wrap so as to leave approximately 50 mm of the 1st wrap exposed
in either side.
(3) The 2nd wrap shall then be covered with spiral wrap from the exposed section
of the 1st wrap towards the flange without allowing wrinkles to form. The
same procedure shall then be carried out from the other side of the joint.
(4) The final wrap shall be a double cigarette wrao around the center of the
flange.
Wrap twice in a cigarette wrap
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APPENDIS – V
Tape Application for Post Indicator Valves
Unless otherwise specified, the following shall be applied.
1. Cleaning of Pipe and Valve to SSPC-SP2
2. Application of Primer
Apply primer to valved area
Post Indicator Valve
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3. Moulding
After application of primer, the Moulding Putty shall be applied by pressing to fill the
angled section or concaves, and mouled so as to cover the valve, flange plates, bolts and
nuts completely. The Putty shall be moulded by patting and pressing with hands so that the
exterior surface will be smooth and froe of projections and/or indentations. The edge of
the moulded putty should be tapered to avoid the formation of “Air Pockets” when the
tape is applied.
4. Tape Wrapping
(1) Immediately after filling with the putty, the first Tape Wrap shall be applied
by pressing “Patches” vertically with 50% overlap. Special care should be
taken so as to press thoroughly to ensure adhesion of tape, and so as not to
form “Air Pockets”
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(2) Secondary tape wrap shall be appliied by pressing “Patches” horizontally for
pipe axis with 50% overlap.
(3) The overlap length of Tape and pre-applied external coating on pipe surface
should be kept 75 mm minimum.
(4) After applying the first and second wrap, start tape winding with 1 round at
the point where an extra space corresponding to the width of the tape was
given to the end of second wrap.
Then commence spiral wrapping with 50% overlap.
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(5) Tape shoulld be wrapped by “CROSS WRAPPING” on the moulded section
so as to form on opened area.
(6) End of wrapping should be applied by the same way as starting of tape
wrapping.
(7) Finally tape should be wrapped by “Double Cigarette Wrap”. Tape shall be
applied vertically against the pipe axis on the both side of moulded section.
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APPENDIX-VI
Tape Application for repairing of holidays
REAPIR SKETCH OF HOLIDAY
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TRANSPORTATION AND HANDLING OF COATING PIPE
1. Pipe shall be handled in such a manner as to protect the pipe and the coating from all possible
damage.
2. Let-off racks which can comein contact with the coatedpipe must be sufficiently padded so as
not to damage the coating. Any protruberances, such as nails, must be fully covered and
padded.
3. All bearing surfaces of a fork lift apparatus must be padde with suitable padding material.
Any pipe moving equipment, such as web belts, slings and/or end hooks, shall be of a type
that will not damage the coating. If possible, the pipe should be handled from cut-back ends.
4. If possible. It is highly recommended that 0 rings be placed around both ends of each pipe
joint prior to stacking of the pipe in the storage yard and/or transportation to the job site.
These rings may be fabricated from corrugated board or rubber.
5. Stringing and storing of coated pipe shall be done with padde skids or dirt berms that are free
of any rocks. If 0 ringsare not used, as described in 4, each tier of stored pipe shall be
separated with suitable padded spacers or materials that will not banage the coatning and
disallow the coated pipe joints from coming in contact with each other.
6. Spiral welded pipe shall be “square stacked” only. Use of a horizontal separator strip between
successive rows of pipe is necessary to prevent damage to the pipe coating.
7. The weld seam of DSAW pipe shall not make contact with the adjacent pipes in pyramid
stacking.
8. In preparation for transporting the coated pipe, the use of web slings are preferred for tie
downs. If cables, chains, or metal banding are used, they must be propely padded with
suitable material as required to protect the coating while in transit.
9. When transporting pre-coated pipe by truck, rail, or barge, each tier shall be separated with
suitable materials. This precaution is ini addition to the padded cahins, belt or cables that may
be necessary for tie-downs.
10. All trailers and/or stringing rigs shall have rock guards over all wheels such that the truck
tires cannot “kick-up” rock and dirt into the pipe nest.
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HANDLING INSTALLATION OF COATING PIPE AT JOB SITE
1. At all times during construction of the pipeline, the contractor shall take every precaution to
prevent damage to the protective pipe coating. No metal tools or heavy objects shall be
permitted to come into contact unnecessarily with the finished coating.
2. Contractor’s personnel shall not be permitted to wal; upon the coating except when absolutely
necessary, in which case they shall wear shoes with rubber or composition soles and heels or
other suitable footwear shich will not damage the coating.
3. Pipe will be supported from the ground at the ditch site by skids that are sufficiently wide
enough and have resilient pads to resist cutting of the coating. Dirt berms are also suitable for
this operation.
4. During the joint welding operation a suitably sized heat-resistant material shall be draped
over the top half of the pipe on each side of the coating cut back to avoid damage to the
coating by hot weld splatter. Any damage to the coating caused during the welding must be
repaired prior to lowering the pipe into the ditch.
5. If coated pipe joints are double-jointed prior to job-site transport, the double jointing rack
should be padded to avoid any coating damage. The cut-back areas are to be protected in the
same manner as 4.
6. Pipe shall be lowered into the ditch by means of wide belt slings or use of end hooks.
Metal chains, cables, tongs or other equipment likely to couse damage to the coating will not
be permitted.
7. On the lowering-in operation, every care shall be taken to prevent swinging impact or
scuffing on the sides of the ditch.
8. In rocky soils or in blasted or ripped ditcg padding has not bees prescribed by the supevising
engineer, the use of suitable rock shield in accordance with standard prstice shall be required
at this discreation. Rock shield of suitable cushioning capacity to prevent coating damage
shall be utilized whenever anchor weights are mounted over the coating.
9. If possible, back filling shall be done as immediately as feasible after lowering-in
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