JOB PROCEDURE FOR INTERNAL FIELD JOINT COATING OF PIPE LINE

A) INSPECTION OF PIPES AT YARD:

1. All weld slag and spatters shall be removed and cleaned.

2. No pipes with weld slag and spatters will be accepted at Blasting/Painting yard.

3. Whenever corrections are required as per the requirement, the pipe fabricator shall do it.

4. The above requirements will apply to field weld joints also.

5. No Hot work is permitted on the pipe after coating. Hence all hot work activities like
external wrap coating, welding of support saddles etc. shall be completed before the pipe is
given for coating.

6. DCPPL/IOCL shall inspect the Pipes when they are delivered at DCPPL’s shop/yard.

B) ABRASIVE BLAST CLEANING PROCESS INSPECTION

1. Abrasive media will be dry and non-contaminated Cu slag.

2. Compressed air dryness will also be checked.

C) COATING MATERIAL INSPECTION

Check points for inspection of coating material are as follows:-

1. Physical receipt & condition of goods in unopened tins.
2. Batch Number.
3. Date of Manufacturing.
4. Material test certificates.

These check points to be conformed and record in Coating Material Inspection report.

Note: - Coating Material shall be stored in a cool and dry place at temperature below 24 0 C (Preferably in
an Air Conditioned container/Room).
D) APPLICATION CONDITION:

1. Atmospheric Condition Requirement-This section deals with the atmospheric condition

requirements to be checked while doing the job.
A. When temperature of the surface to be coated is less than 30C above the dew point, or the
relative humidity is higher than 85%.
B. When the base metal temperature is greater than 600C.
C. When the atmospheric temperature is below 40C.
D. When there is, in the opinion of DCPPL, the likely hood of an unfavorable change in the
weather condition within 2 hours after coating.
E. When there is deposition of moisture in the form of rain or condensation.

2. Humidity shall be measured with a calibrated hygrometer.

3. Record will be maintained throughout the execution period. Reading will be taken once in
every 4 hours up to the time work is in progress. The frequency of reading should be
increased during adverse weather conditions.

4. While working in unfavorable weather conditions ( like monsoons ) check no flash rusting of
the blasted surface is take place till the time it receives a coat.

5. In case temperature goes below 10 deg C warming up the work front like use of halogen
lights, room heaters etc. to be adopted.

6. Humidity is to be taken at the location where the blasting/coating operations are taking
place.

7. Base Metal Temperature to be recorded before blasting and Coating.

E) PRELIMINARY CHECK REQUIREMENTS

1. ABRASIVE DRYNESS CHECK:

The abrasive to be used will be checked for dryness by taking a small quantity of abrasive on a
filter/tissue paper and checking for traces of moisture absorbed in the filter/tissue paper.
This test shall be done once in a day performed before starting of blasting operation.

2. COMPRESSED AIR DRYNESS CHECK.

Compressed air to be used for blasting shall be free from oil & moisture.
This test shall be done once in a day performed before starting of blasting operation.
F) WELD JOINT COATING:

a. Before welding of pipes edges, 50 mm from both the edges should be checked for
cleanliness. Mechanical/Solvent Cleaning should be carried out to remove the welding flux,
oil, grease etc form the pipe.

b. For Pipe low diameter pipes viz. 50mm to 500 mm, internal coating machine would be used.
First the inspection boom with WEBCAM would be allowed to check the surface wellness.

c. Internal spray machine to be allowed to travel up to weld Joint area.

d. After positioning of the boom COATING MATERIAL would be spray applied.

e. At least 2 passes of spray is to be used to get required thickness.

f. For pipes 600mm dia and above, weld joint would be coated manually and the procedure
would be followed as mentioned form step a to e.

G) CURING & FINISH

1. Curing: The Initial cure and Final Cure shall be as given in respective product data sheets.
The data sheets give cure times as at 25 deg centigrade. The initial cure time shall come
down with increase in ambient temperature. The initial cure time is judged by touching the
coated surface with a gloved hand. Total track freeness shall indicate initial cure releasing
the Coated Component for further processing activities like, final coats, grinding, buffing
cleaning, DFT & holiday testing etc.

2. The final cure has relevance to taking the coated component into service. Hence, irrespective
of ambient temperatures the final cure period in terms of days as given in data sheet shall be
adhered to. Client will be specially informed by site personnel regarding the date when the
coated vessel/Pipe can be taken into service by means of an entry in the Final inspection
format.

3. Finish: It is to be noted that the coating will follow the profile of the substrate. Any
unevenness or other defects in the substrate will be in the finished coating also.

On completion of testing, any defects should be locally repaired as per the above Repair
procedure.