STANDARDS PUBLICATION

KOC STANDARD FOR

COATING OF FIELD GIRTH WELDS,
FITTINGS AND FLANGES

DOC. NO. KOC-P-004 PART 7

(Rev. 3)

STANDARDS TEAM
 DOC. NO. KOC-P-004 Pt. 7 Page 1 of 43 REV. 3

STANDARDS PUBLICATION

KOC STANDARD FOR

COATING OF FIELD GIRTH WELDS,

FITTINGS AND FLANGES

DOC.NO. KOC-P-004 PART 7

(Rev. 3)

STANDARDS TEAM
 DOC. NO. KOC-P-004 Pt. 7 II
Page 2 of 43
II REV. 3 I

KOC STANDARD FOR

COATING OF FIELD GIRTH WELDS,

FITTINGS AND FLANGES

DOC.NO. KOC-P-004 PART 7

(Rev. 3)

ISSUING AUTHORITY:

STANDARDS TEAM

/J
,...
~~
~~ ~
Issued as
Task Force
3 07.08.2016 KOC
(TF- CP/02)
Standard
AmerJaragh Khalid B. AI-Shammari

Issued as Abdul Razzak

Task Force
2 30062010 KOC S Kumar Hamzah Ahmad
(TF-PC I 02)
Standard AI·Shamari

Prepared TF-Leader TPL Specialist - I Team Leader Standards

Rev. Date Description
by Tel. No. 65428 Tel. No. 61633 Tel. 61896
DOC. NO. KOC-P-004 Pt. 7 Page 3 of 43 REV. 3

TABLE OF CONTENTS
Page No.
FOREWORD 5
1.0 SCOPE 7
2.0 APPLICATION 7
3.0 TERMINOLOGY 7
3.1 Definitions 7
3.2 Abbreviations 8
4.0 REFERENCE STANDARDS, CODES AND SPECIFICATIONS 9
4.1 Conflicts 9
4.2 List of Standards, Codes and Specifications 9
5.0 ENVIRONMENTAL CONDITIONS 13
6.0 HEALTH, SAFETY AND ENVIRONMENT 13
6.1 General 13
6.2 Safety Precautions for Storage, Handling and Mixing 15
6.3 Safety Precautions for Abrasive Blasting and Coating
Equipment 16
7.0 COATING / WRAPPING SYSTEMS AND MATERIALS 17
7.1 Coating Systems 17
7.2 Materials Packaging and Storage 18
7.3 Material Approval 18
7.4 Fusion Bonded Epoxy (FBE) 18
7.5 High Build Epoxy (HBE) 18
7.6 High Build Polyurethane (HBP) 18
7.7 Cold Applied Wrapping Tapes 18
7.8 Heat Shrink Sleeve (HSS) 20
7.9 Viscoelastic Wrapping Tapes 22
7.10 Two (2) Layer Polyethylene 23
8.0 QUALIFICATION OF PROCEDURE AND APPLICATORS 24
9.0 SURFACE PREPARATION AND COATING / WRAPPING
APPLICATION 26
9.1 General 26
9.2 Defect / Imperfection Removal 26
9.3 Blast Cleaning 27
9.4 Application of Fusion Bonded Epoxy (FBE) 28
9.5 Application of High Build Epoxy (HBE) 29
9.6 Application of High Build Polyurethane(HBP) 29
9.7 Application of Tape Wrapping 29
9.8 Application of the Heat Shrink Sleeve (HSS) 30
9.9 Application of Viscoelastic Wrapping Tapes 31
9.10 Application of Two Layer Polyethylene 32
9.11 Coating on Underground to Aboveground Intersection 32
10.0 INSPECTION AND TESTING 33
10.1 General 33
10.2 Material Inspection and Testing 33
10.3 Surface Preparation 33
DOC. NO. KOC-P-004 Pt. 7 Page 4 of 43 REV. 3

10.4 Inspection of Applied FBE Coating 34

10.5 Inspection of Applied HBE Coating 35
10.6 Inspection of Applied HBP Coating 35
10.7 Inspection of Applied Tape Wrapping 35
10.8 Inspection of Applied HSS Coating 35
10,9 Inspection of Applied Viscoelastic Wraps 37
10.10 Inspection of Applied Two Layer (PE) Coating 37
11.0 DOCUMENTATION 37
12.0 APPENDIX-A: TESTS FOR HEAT SHRINK SLEEVE 39-41
ACKNOWLEDGEMENT 42-43

I3I Revision 3: Summary of Major Changes In this Revision (Rev. 3)

Sl.
Clause Description of the Major Changes
No.
1 FOREWORD Updated.
2 1.0 Scope Modified.
“Title” of Clause 2.0, changed to “Application” and its sub-
clauses 2.2 to 2.4 are re-numbered as 2.1 to 2.3.
3 2.0 Clause 2.0 “Coating Systems” and its sub-clause 2.1 is
“Modified” and “Shifted” under Clause 7.0 and re-numbered
to 7.1
4 3.2, 4.2, 5.0 & 6.0 Clauses Modified & Updated.
“Title” of Clause 7.0, changed to “Coating / Wrapping
Systems and Materials”
5 7.0
As New sub-clause 7.1 added, the other sub-clauses under
Clause 7.0 are re-numbered.
Sub-Clause 7.1 re-numbered to 7.2 and sub-clause 7.1.3
7.1
re-numbered to 7.2.3 and modified.
Sub-clauses re-numbered as 7.3, 7.7, 7.8.5 & 7.8.8 and
6 7.2, 7.6, 7.7.5 & 7.7.8 Modified;
Table 1 & Table 3 Modified.
New Sub Clauses Added;
7 7.9 & 7.10 New Tables 4, 5, 6 & 7 Added; subsequent Tables
Numbers are changed accordingly.
Sub Clauses are Modified;
8 8.0
Table 4 Renumbered to Table 8 and Modified.
9.1.4, 9.3.8, 9.3.10,
9 Sub Clauses are Modified.
9.4.3, 9.4.4 & 9.8.10
9.4.5: New Sub Clauses Added and subsequent sub
10 9.2.3, 9.4.5 & 9.8.11 clauses are renumbered;
9.2.3 & 9.8.11: New Sub Clauses Added.
New Sub Clauses Added and subsequent sub clauses are
11 9.9 & 9.10
renumbered.
Existing Sub Clause 9.9 renumbered to 9.11;
12 9.11
Sub Clauses 9.11.1, 9.11.5 & 9.11.7 are Modified.
13 10.3 & 11.4 Sub Clauses are Modified.
14 10.4.2 & 10.4.7 Sub Clause Modified
15 10.9 & 10.10 New Sub Clauses Added.
DOC. NO. KOC-P-004 Pt. 7 Page 5 of 43 REV. 3

FOREWORD I3I

This document “KOC Standard for Coating of Field Girth Welds, Fittings and
Flanges” (KOC-P-004, Part 7, Rev. 3) is intended to provide the minimum technical
requirements of appropriate coatings on field girth welds and ancillaries associated with
buried piping and pipelines. for corrosion protection. The earlier document (KOC-P-004,
Part 7, Rev. 2) issued in June 2010, has been revised for conformance with the
revisions of relevant International / National Standards and incorporation of latest
technical requirements in this field.

This Standard is Part 7 of the KOC-P-004 series on the External Coating of Piping /
Pipelines. The other parts of this series are:
KOC-P-004 Part 4 KOC Recommended Practice for External Coating of Pipelines:
Part 4: Dual Layer Fusion Bonded Epoxy Coating
KOC-P-004 Part 6 KOC Standard for External Coating of Steel Pipes Using Three
Layers Extruded Polyethylene / Polypropylene System
KOC-P-004 Part 8 KOC Standard for External Coating of Underground Piping /
Pipelines - High Build Epoxy Coating
KOC-P-004 Part 9 KOC Standard for External Coating of Underground Piping /
Pipelines - High Build Polyurethane Coating
KOC-P-004 Part 10 KOC Standard for Polyurethane Thermal Insulation and Outer
Casing of Polyethylene for Underground Pre-Insulated Pipes

This KOC Standard (Rev. 3) has been approved by the Standards Team in consultation
with the Standards Technical Committee (STC) for consistent use throughout the
Engineering and Operational Functions of Kuwait Oil Company (K.S.C).

This Standard sets out to achieve the following objectives:

a) To establish the KOC requirements for qualifying tests and approval of coatings that
should suit the intended application on field girth welds, fittings, and flanges of buried
pipelines.

b) To provide the technical guidance for field application, surface preparation, inspection
and testing requirements in order to achieve reliability, quality and safety.

c) To set out minimum requirements and guidance for monitoring compliance of

materials and their testing under the Scope of a Contract.

d) To act as a tool for internal communication from which future safety, environmental
and technological changes can be absorbed.

Feedback as well as any comments or suggestions derived from the application of this
Standard at any stage of design, construction, maintenance and field experiences are
encouraged and should be directed to:

Team Leader Standards

(Chairman, Standards Technical Committee)
Projects Support Services Group, K. O. C.
P.O. Box- 9758, Ahmadi-61008
State of Kuwait
DOC. NO. KOC-P-004 Pt. 7 Page 6 of 43 REV. 3

Task Force Responsible for Revision of this Standard

The revision of this Standard (Rev. 3) has been entrusted by the Standards Technical
Committee (STC) to the Task Force (TF-CP / 02) comprising of the following Members:

Mr. Amer Jaragh Insp. & Corr. (N&WK) Team TF Leader Tel. No. 65428
Mr. Mohd Emam Insp. & Corr. (Projects) Team Member Tel. No. 63693
Mr. Hasan Sabri Insp. & Corr. (S&EK) Team Member Tel. No. 61832
Mr. Umair A. Usmani Standards Team Member Tel. No. 61869
DOC. NO. KOC-P-004 Pt. 7 Page 7 of 43 REV. 3

1.0 SCOPE I3I

1.1 This Standard specifies the minimum requirements for coating and wrapping to
be used in KOC, for the external corrosion protection of buried fittings, flanges
and field girth weld areas of the main pipeline coated with following:

 Dual layer FBE (DFBE),

 Three (3) Layer High Density Polyethylene (3LHDPE),
 Three (3) Layer Polypropylene (3LPP),
 High Build Epoxy (HBE),
 High Build Polyurethane (HBP),
 Coal Tar Enamel (CTE) { for existing pipelines maintenance}.

1.2 This standard provides the minimum requirements for materials, surface
preparation, application and inspection & testing for coating and wrapping in
order to ensure the adequate corrosion protection of buried steel piping and
pipelines.

2.0 APPLICATION I3I

2.1 All the materials and equipment used for qualifying tests of materials, surface
preparation, application, inspection and testing shall conform to the
requirements of this Standard and the referenced standards and codes herein.

2.2 Any exception or deviations from this Standard, along with their merits &
justification, shall be brought to the attention of KOC Controlling Team, for their
review, consideration and amendment by Standards Team (if required).

2.3 Compliance with this Standard does not of itself confer immunity from legal
or statutory obligations.

3.0 TERMINOLOGY

3.1 Definitions

For the purposes of this Standard, the following definitions shall apply.

3.1.1 Applicator
An organization, contractor or subcontractor having the technical capability,
knowledge, equipment, qualified personnel that is approved by KOC for the
coating processes as required by this Standard

3.1.2 Batch
The quantity of coating material produced during a continuous production run
and identified by a sequential batch number

3.1.3 Cathodic Disbondment

The destruction of adhesion between a coating/wrapping and the coated pipeline
surface caused by products of a cathodic reaction
DOC. NO. KOC-P-004 Pt. 7 Page 8 of 43 REV. 3

3.1.4 Company
Kuwait Oil Company and / or its authorized representatives on each specific
coating / wrapping job

3.1.5 Contractor
Vendor or Company that agrees business to furnish materials and/or perform
particular project / services to KOC at specific price (lump-sum) and / or unit
rate under the Contract

3.1.6 Cutback
The length of the steel pipe left uncoated at each end of the pipe for jointing
by welding

3.1.7 Holiday
A discontinuity in a protective coating / wrapping (e.g., cracks, pinholes, voids,
etc.) that exhibits electrical conductivity when exposed to specific voltage.

3.1.8 Manufacturer
The KOC approved party that manufactures or produces coating/wrapping
materials or products

3.1.9 Weld Zone

As used in this Standard, weld zone is the uncoated area on the pipeline that
results when two joints with coating cutback are assembled in the field

3.2 Abbreviations I3I

3LHDPE 3 Layer High Density Polyethylene

3LPP 3 Layer Polypropylene
CP Cathodic Protection
CTE Coal Tar Enamel
DFT Dry Film Thickness
DFBE Dual layer FBE
FBE Fusion Bonded Epoxy
HATE Hydraulic Adhesion Tester
HBE High Build Epoxy
HBP High Build Polyurethane
HSE Health, Safety and Environment
HSS Heat Shrink Sleeve
ITP Inspection & Test Plan
JSA Job Safety Analysis
KOC Kuwait Oil Company (K.S.C)
MSDS / SDS Material Safety Data Sheet / Safety Data Sheet
PD Pipe Diameter
DOC. NO. KOC-P-004 Pt. 7 Page 9 of 43 REV. 3

PE Polyethylene
PIM Pre Inspection Meeting
PP Polypropylene
PPE Personal Protective Equipment
PTW Permit to Work
PQT Procedure Qualification Test
QA Quality Assurance
QC Quality Control
Tg Glass Transition Temperature

4.0 REFERENCE STANDARDS, CODES AND SPECIFICATIONS

4.1 Conflicts

In the event of conflicts between this standard and the latest revision of the
standards / codes referenced herein, or other contractual requirements, the
most stringent requirement shall apply. In case further clarifications are
required, the subject shall be brought to the attention of KOC Controlling Team.

4.2 List of Standards, Codes and Specifications

The latest edition of the following standards, codes and specifications shall
apply:

4.2.1 National / International Standards and Codes

API RP 5LW Recommended Practice for Transportation of Line pipe on

Barges and Marine Vessels

ASTM D570 Test Method for Water Absorption of Plastics

ASTM D638 Standard Test Method for Tensile Properties of Plastics

ASTM D882 Standard Test Method for Tensile Properties of Thin Plastic
Sheeting

ASTM D3276 Standard Guide for Painting Inspectors (Metal Substrates)

ASTM D3418 Standard Test Method for Transition Temperatures and

Enthalpies of fusion and Crystallization of Polymers by
Differential Scanning Calorimetry

ASTM D4541 Standard Test Method for Pull-Off Strength of Coatings

Using Portable Adhesion Testers

DNV RP F102 Pipeline Field Joint Coating and Field Repair of Line Pipe
Coating
DOC. NO. KOC-P-004 Pt. 7 Page 10 of 43 REV. 3

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 8501-3 Preparation of Steel Substrates Before Application of Paints

and Related Products - Visual Assessment of Surface
Cleanliness - Part 3: Preparation Grades of Welds, Edges
and Other Areas with Surface Imperfections

ISO 8502-3 Preparation of Steel Substrates Before Application of Paints

and Related Products - Tests for Assessment of Surface
Cleanliness - Part 3: Assessment of Dust on Steel Surfaces
Prepared for Painting (Pressure-Sensitive Tape Method)

ISO 8502-6 Preparation of Steel Substrates Before Application of Paints

and Related Products - Tests for Assessment of Surface
Cleanliness - Part 6 : Extraction of Soluble Contaminants
for Analysis - The Bresle Method

ISO 8502-9 Preparation of Steel Substrates Before Application of Paints

and Related Products - Tests for Assessment of Surface
Cleanliness - Part 9 : Field Method for the Conductometric
Determination of Water-Soluble Salts

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 Surface profile Comparators for the
Assessment of Abrasive blast-Cleaned Surfaces

ISO 8503-2 Preparation of Steel Substrates Before Application of Paints

and Related Products – Surface Roughness Characteristics
of Blast-Cleaned Steel Substrates - Part 2 : Method of
Grading of Surface Profile Abrasive Blast - Cleaned Steel -
Comparator Method

ISO 8504-2 Preparation of Steel Substrates Before Application of Paints

and Related Products - Surface Preparation Methods -
Part 2 : Abrasive Blast Cleaning

ISO 12944-7 Paints and Varnishes - Corrosion Protection of Steel

Structures by Protective Paint Systems - Part 7: Execution
and Supervision of Paint Work

ISO 17025 General Requirements for the Competence of Testing and

Calibration Laboratories

ISO 21809-1 Petroleum and Natural Gas Industries — External Coatings

for Buried or Submerged Pipelines Used in Pipeline
Transportation Systems - Part 1: Polyolefin Coatings
(3-Layer PE and 3-Layer PP)
DOC. NO. KOC-P-004 Pt. 7 Page 11 of 43 REV. 3

ISO 21809-3 Petroleum and Natural Gas Industries — External Coatings

for Buried or Submerged Pipelines Used in Pipeline
Transportation Systems - Part 3 - Field Joint Coatings

ISO 21809-4 Petroleum and Natural Gas Industries — External Coatings

for Buried or Submerged Pipelines Used in Pipeline
Transportation Systems - Part 4 - Polyethylene coatings
(2-Layer PE)

NACE No. 2 Joint Surface Preparation Standard Near-White Metal Blast

Cleaning

NACE RP0105 Standard Recommended Practice Liquid-Epoxy Coatings

for External Repair, Rehabilitation, and Weld Joints on
Buried Steel Pipelines

NACE RP0274 High-Voltage Electrical Inspection of Pipeline Coatings

NACE RP0287 Field Measurement of Surface Profile of Abrasive Blast-

Cleaned Steel Surfaces using a Replica Tape

NACE SP0490 Holiday Detection of Fusion-Bonded Epoxy External

Pipeline Coatings of 250 to 760 um (10 to 30 mils)

SSPC AB1 Steel Structure Painting Council – Mineral and Slag

Abrasives

SSPC PA2 Steel Structure Painting Council - Procedure for

Determining Conformance to Dry Coating Thickness
Requirements

SSPC SP1 Steel Structure Painting Council - Solvent Cleaning

SSPC SP10 Steel Structure Painting Council - Near -White Metal Blast
Cleaning

SSPC VIS 1 Guide and Reference Photographs for Steel Surfaces

Prepared by Dry Abrasive Blast Cleaning

SSPC VIS 3 Guide and Reference Photographs for Steel Surfaces

Prepared by Power-and-Hand-Tool Cleaning

4.2.2 KOC Standards

KOC-G-002 KOC Standard for Hazardous Area Classification

KOC-G-004 KOC Standard for Packing, Marking and Documentation

KOC-G-007 KOC Standard for Basic Design Data

KOC-L-006 KOC Standard for Fire & Gas Detection Equipment

KOC-L-009 KOC Standard for Fire Protection Systems and Safety

Equipment
DOC. NO. KOC-P-004 Pt. 7 Page 12 of 43 REV. 3

KOC-P-001 KOC Standard for Painting and Coating of External Metal

Surfaces

KOC-P-004 Part 4 KOC Standard for External Coating of Underground Piping

/ Pipelines - Part 4: Dual Layer Fusion Bonded Epoxy
Coating

KOC-P-004 Part 6 KOC Standard for External Coating of Steel Pipes Using
Three Layers Extruded Polyethylene / Polypropylene
System

KOC-P-004 Part 8 KOC Standard for External Coating off Underground Piping
/ Pipelines: Part 8: High Build Epoxy Coating

KOC-P-004 Part 9 KOC Standard for External Coating off Underground Piping
/ Pipelines: Part 9: High Build Polyurethane Coating

KOC-P-004 Part 10 KOC Standard for Polyurethane Thermal Insulation and

Outer Casing of Polyethylene for Underground Pre-
Insulated Pipes

KOC-P-006 KOC Standard for Evaluation and Certification of Coating

Contractor / Applicator Personnel

KOC-Q-014 Project QA / QC Requirements

4.2.3 KOC Health, Safety & Environment Management System (HSEMS) I3I

KOC HSE Policy & KOC HSEMS Guide

KOC.EV.008 Waste Management Procedure

KOC.GE.028 HSE Training, Awareness and Continued HSE Learning

Process

KOC.HE.008 Chemical Hazard Management and Communication

Procedure

KOC.SA.004 Permit to Work Procedure

KOC.SA.007 Entry into Confined Spaces

KOC.SA.010 Procedure for Personal Protective Equipment

KOC.SA.011 High Pressure Water Jetting, Abrasive Blasting and Steam

Cleaning Safety Procedure

KOC.SA.013 Mobile Equipment Procedure

KOC.SA.024 Job Safety Analysis (JSA)

KOC.SA.026 Excavation Safety Procedure

KOC.SA.029 Safety Requirements for Lifting, Shifting and Material

Handling
DOC. NO. KOC-P-004 Pt. 7 Page 13 of 43 REV. 3

KOC.SA.030 HSE Procedure for Painting & Coating

KOC.SA.035 Safe Control & Use of Gas Cylinders

Any other relevant KOC HSEMS Procedures as applicable.

5.0 ENVIRONMENTAL CONDITIONS I3I

5.1 The environment of Kuwait is severe on all equipment and structures and must
be considered carefully before procurement of coating / wrapping materials. The
atmosphere shall be considered to be dusty, corrosive and humid with high
ambient temperature. The atmosphere may also contain traces of H2S / SO2 /
SOx / NOx gases and airborne chemical contaminants.

5.2 For environmental conditions in Kuwait, refer to KOC-G-007 “KOC Standard for
Basic Design Data”, which provides the detailed design information regarding
the environmental, site and utility supply conditions prevailing throughout the
KOC facilities.

6.0 HEALTH, SAFETY AND ENVIRONMENT I3I

6.1 General

6.1.1 The Contractor shall assure compliance of necessary HSEMS requirements with
a view to minimize the consequences and impacts of hazards on the
surrounding environment and adjoining facilities, as well as the occupational
health and safety of working personnel.

6.1.2 Appropriate permit to work (PTW) with applicable Job Safety Analysis (JSA)
document for the work to be carried out shall be prepared in accordance to
KOC.SA.004 “Permit to Work Procedure” prior to commencement of work. The
PTW and JSA documents shall address all relevant HSE requirements specified
by the Coating Manufacturer and the applicable KOC HSEMS Procedures. KOC
HSE Policy and all applicable KOC HSEMS procedures shall be adhered to
within KOC areas at all times.

Confined space entry shall be in accordance with the requirements specified in

KOC.SA.007 “Entry into Confined Spaces” and control measures mentioned in
the JSA documents shall be implemented at work site and the pertinent hazards
identified in JSA shall be communicated to all workers before commencing the
work.

6.1.3 The Contractor / Applicator personnel, shall take necessary approvals

from the relevant safety authority of KOC, where there is a risk of
flammable atmosphere being present in a particular work area, prior to
performing surface preparation. Flame heating equipment shall not be
used in hazardous areas. Refer to KOC-G-002 “KOC Standard for
Hazardous Area Classification”, which describes the area classification
for various Facilities. A prior approval from KOC shall be obtained
before the use of any flame heating equipment at the job site.
DOC. NO. KOC-P-004 Pt. 7 Page 14 of 43 REV. 3

6.1.4 The Contractor / Applicator personnel, involved in supervisory, inspection /

testing, pipe handling, surface preparation and coating application processes,
shall use the appropriate Personal Protective Equipment (PPE) during the
respective coating process.

6.1.5 The Contractor / Applicator personnel shall take all necessary precautionary
measures to ensure the safe handling of pipes during the coating application as
per KOC HSEMS procedure KOC.SA.029 “Safety Requirements for Lifting,
Shifting and Material Handling”.

6.1.6 All equipment and accessories utilized for the coating application processes,
including pipe handling and cleaning processes, shall be certified to be in safe
condition. Contractor’s mobile plant / equipment entering Gathering Centers /
Booster Stations must be certified – “Fit for Service” by Third Party Inspector
and shall obtain the Clearance Certificate as per KOC.SA.013 “Mobile
Equipment Procedure”. Periodical inspection records of all equipment and
accessories shall be made available on demand.

6.1.7 All chemicals being used for surface preparation & coating applications shall
have a material safety data sheet (MSDS) / Safety Data Sheets (SDS) in the
workplace, storage, handling and application of such chemicals for surface
preparation and coating applications shall be as per Coating Manufacturer’s
recommendations and MSDS / SDS.

6.1.8 The Contractor / Applicator shall follow all necessary requirements as stipulated
in KOC HSEMS procedure KOC.SA.030 “Painting and Coating HSE Procedure”
to ensure safe compliance of the coating application.

6.1.9 Safety precautions for Blast Cleaning Work shall be taken as per KOC HSEMS
Procedure KOC.SA.011 "High Pressure Water Jetting, Abrasive Blast Cleaning
and Steam Cleaning.

6.1.10 All relevant HSE recommendations of the Coating Manufacturer(s) and the
application equipment Manufacturer(s) shall be strictly followed.

6.1.11 All abrasive blasting shall be carried out in a safe manner by suitably trained
and competent personnel in accordance with defined safe working practices
and procedures. Also the controlling team shall ensure that all the risks and
hazards have been identified, documented and authorized under appropriate
work permit prior to commencement of the task.

6.1.12 All waste (Hazardous / non-hazardous) generated from the subject activities
shall be managed as per KOC HSEMS procedure KOC.EV.008 “Waste
Management Procedure”.

6.1.13 An impermeable liner approved by KOC, shall be laid on the ground surface to
avoid soil contamination from paints, oil, thinners and other chemicals during
the contaminants / deposits removal process and other coating operations.
DOC. NO. KOC-P-004 Pt. 7 Page 15 of 43 REV. 3

6.1.14 All Contractor personnel utilized for the works shall have successfully
undergone all the applicable required training. All contractor personnel shall
have attended the awareness course(s) as identified in “Matrix of identified
categories of personnel need “HSE Training” and HSE Awareness for
Contractor’s Employees” under HSEMS procedure KOC.GE.028 “HSE Training,
Awareness and Continued HSE Learning Process” and such personnel shall be
able to produce valid documentary evidence at the time of evaluation.

6.2 Safety Precautions for Storage, Handling and Mixing

6.2.1 All coating materials and thinners shall be stored in the enclosed storage areas
or structures that protect workers, reduce fire risks and improve productivity.
The hazardous liquids shall be stored in code compliant safety cabinets
designed to meet OSHA and NFPA standards and shall adhere to the relevant
KOC HSEMS procedures.

6.2.2 Coating materials shall be protected from temperatures exceeding

Manufacturer’s recommendations and from open flames, electrical discharge
and direct sunlight. Air conditioned storage areas shall be provided when the
excessive ambient temperatures are expected.

In view of the accidental release of the stored material containing

flammable hydrocarbon, the enclosed areas shall be “Classified” as per
API 505 and KOC-G-002 “KOC Standard for Hazardous Area
Classification”, as applicable.

6.2.3 The storage area shall be secluded and no other materials shall be stored in the
enclosed place. The enclosure shall be strictly demarcated as “NO SMOKING”
area. Eating and drinking shall be prohibited in such area. Suitable fire / smoke
detection arrangement shall be provided at the storage area as per KOC-L-006
“KOC Standard for Fire & Gas Detection Equipment”.

6.2.4 All coating materials, thinners, oil and equipment cleaners shall be stored in
closed labeled original containers. Arrangement for containment during
accidental spill shall be provided in storage area. MSDS / SDS of all these
chemicals shall also be provided at the storage areas.

6.2.5 Portable fire extinguishers of suitable quality and appropriate quantity

along with other fire protection measures (First aid, safety shower & eye
wash units, etc.) shall be provided at the storage areas as per KOC
Standard KOC-L-009 “KOC Standard for Fire Protection Systems and
Safety Equipment”. These extinguishers shall be inspected and
approved by KOC Fire Team.

6.2.6 Coating materials shall be packaged and delivered to the factory / site in
original, tightly sealed Manufacturer’s containers with batch numbers, storage
conditions, date of manufacture and date of expiry clearly marked thereon.

6.2.7 Original containers after being emptied shall not be reused for any other
purposes and shall be disposed as hazardous waste as per KOC HSEMS
procedure, KOC.EV.008 “Waste Management Procedure”.
DOC. NO. KOC-P-004 Pt. 7 Page 16 of 43 REV. 3

6.2.8 The Contractor / Applicator shall adhere to Manufacturer’s health, safety and
environment precautions and follow all necessary recommendations as
stipulated in Manufacturer’s procedures for mixing, storage, coating application
and handling of other coating materials.

6.2.9 All safety precautions / recommendations shall be clearly described on the

Product Data Sheet (PDS), Material Safety Data Sheet (MSDS) / Safety Data
Sheet (SDS) and on the containers of the supplied coating materials.

6.3 Safety Precautions for Abrasive Blasting and Coating Equipment

6.3.1 Blasting pot, blasting nozzle, air compressor and spray machine shall be spark
proof and earthed (grounded) to prevent accumulation of an electrostatic
charge.

6.3.2 All abrasive blasting equipment’s including air compressor shall be inspected
and certified by an authorized competent third party inspectors. Pressurized
hoses shall be tested and certified for maximum safe working pressure. All
equipment shall be checked periodically to make sure that any damages like
electrical loose contacts and any other type of wear / tear on hoses, loose
coupling etc. will not lead into a safety hazard.

6.3.3 Blast nozzle and hose shall be equipped with an operational “Dead-man
Handle” located immediately behind the blasting nozzle and shall have anti-
static materials / mechanism to prevent accumulation of an electrostatic charge.
Blasting hose coupling connections shall be equipped with locking pins and
whip lock connector. Any maintenance jobs on the blasting equipment / system
shall not be performed when the blasting pot / system is pressurized or
energized.

6.3.4 Safety warning signs and enclosure shall be provided all around the area where
abrasive blasting is carried out.

6.3.5 A clean positive pressure type air mask (Hood) and other appropriate PPE shall
be worn by abrasive blasting and coating crew members while carrying out
these jobs.

6.3.6 All crew members shall remove their supplied air breathing equipment, only
when they are well away from the work location since dust can remain
suspended in air for longer period.

6.3.7 Abrasive blast operator(s) shall wear a suitable blasting hood and gauntlet-style
leather gloves that can protect them from rebounding abrasives, including their
forearms.

6.3.8 All personnel involved in abrasive blasting and coating operations shall be
provided with all the necessary safety awareness, training on the hazards and
risks, and specific control measures of their related operations.
DOC. NO. KOC-P-004 Pt. 7 Page 17 of 43 REV. 3

7.0 COATING / WRAPPING SYSTEMS AND MATERIALS

7.1 Coating Systems I3I

7.1.1 The coating systems for new piping / pipelines and their girth welds,
fittings and flanges shall be as follows:
NOTE 2
Pipeline Coating Operating Girth Weld Fittings Flanges
Material Temperature Material Material Material
NOTE 1
HSS (PE)
3LHDPE Up to 80°C HBP HBP
2 Layer PE Cold Applied
° Wrapping /
3LPP Up to 110 C HSS (PP) FBE
° Viscoelastic
HBE Up to 95 C HBE HBE Tapes
°
HBP Up to 80 C HBP HBP
°
DFBE Up to 95 C FBE FBE
Under Insulation ° FBE FBE
Up to 140 C NOTE 3 NOTE 3 HBE
DFBE HBE HBE

Note 1: For pipes of sizes greater than 24" in diameter, induction heating shall be
utilized for pre heating the pipe surface. The selection of HSS or HBP is
subject to prior KOC approval.
Note 2: Fittings include Bends, Tees, Elbows, Anchor flanges etc.
Note 3: The HBE coating used in insulated lines shall withstand a minimum operating
temperature of 140°C.

7.1.2 The coating systems for girth welds, fittings and flanges during the
maintenance of existing pipeline shall be as follows:

Pipeline Girth Weld / NOTE 2

Pipeline Existing Fittings Flanges
maintenance Repair
Coating Material Material Material
Coating Material Material
NOTE 1
HSS (PE)
HBP HBP OR
3LPE
HBP 2 Layer PE Viscoelastic Cold Applied
CTE NOTE 4
Viscoelastic Tapes Wrapping /
NOTE 4
Tapes Viscoelastic
HBE HBE HBE HBE Tapes
HBP HBP HBP HBP
DFBE HBE HBE HBE
Under Insulation NOTE 3 NOTE 3 NOTE 3 NOTE 3
HBE HBE HBE HBE
DFBE

Note 1: For pipes of sizes greater than 24" in diameter, induction heating shall be
utilized for pre heating the pipe surface. The selection of HSS or HBP is
subject to prior KOC approval.
Note 2: Fittings include Bends, Tees, Elbows, Anchor flanges etc.
Note 3: The HBE coating used in insulated lines shall withstand a minimum
Operating temperature of 140°C.
Note 4: Viscoelastic tapes shall be utilized only for the rehabilitation of existing
pipe coatings.
DOC. NO. KOC-P-004 Pt. 7 Page 18 of 43 REV. 3

7.2 Materials Packaging and Storage

7.2.1 Coating / wrapping materials shall be packaged and delivered along with
pertinent Material Safety Data Sheets / Safety Data Sheets (MSDS / SDS) to the
site in original, tightly sealed, Manufacturer's containers with batch code
numbers, date of manufacture and date of expiry clearly marked thereon.

7.2.2 Coating / wrapping materials shall be stored in covered cool dry areas; and shall
be kept clean, dry and free from any contaminants prior to and during
application. Storage shall be as per the coating / wrapping Manufacturer’s
recommendations.

7.2.3 KOC HSEMS procedure KOC.HE.008 “Chemical Hazard Management and

Communication Procedure” shall be strictly adhere to. I3I

7.3 Material Approval I3I

The Manufacturer's material specification of FBE, HBE, HBP, HSS, Viscoelastic

Tapes, 2 Layer Polyethylene and cold wrapping tapes shall be submitted with
the following details for KOC review and approval:

a) Details of Manufacturer, generalized composition, technical

specifications, Material Safety Data Sheets / Safety Data Sheets,
physical properties and laboratory testing certificates,

b) Proven track history for the past five (5) years,

c) Coating / wrapping materials shall have a minimum shelf life of

Twelve (12) Months.

d) Certification from independent testing laboratory certified according

to the requirements of ISO 17025.

7.4 Fusion Bonded Epoxy (FBE)

The FBE materials shall comply with KOC-P-004 Part 4.

7.5 High Build Epoxy (HBE)

The HBE materials shall comply with KOC-P-004 Part 8.

7.6 High Build Polyurethane (HBP)

The HBP materials shall comply with KOC-P-004 Part 9.

7.7 Cold Applied Wrapping Tapes I3I

7.7.1 Tape wrapping shall be polymeric type in accordance with ISO 21809-3 and as
tabulated in Table 1 of this Standard. The data sheets for the primer materials
shall be in accordance with Table 2 of this Standard.
DOC. NO. KOC-P-004 Pt. 7 Page 19 of 43 REV. 3

7.7.2 Cold-applied polymeric tape coatings consist of a primer and multiple layers of
polymeric tapes. Maximum design temperature is 80°C. Specific polymeric
tapes allowing a higher maximum design temperature may be used subject to
qualification.

7.7.3 The putty shall be of either mastic or water based and shall be as recommended
by the wrapping tape manufacturer.

7.7.4 The putty shall be compatible with the wrapping material.

7.7.5 The outer wrap shall meet the requirements of Table 5 of this standard.

Table 1 : Requirements of Inner Wrap Cold Applied Tapes I3I

Sl. Reference
Property Test Requirements
No. Standard
1 Tape thickness > 1 mm
2 Impact resistance at 20°C > 4 J/mm
Indentation resistance, pressure at
23°C and Tmax At
3 – Holiday detection at 5 kV/mm + 5 kV, 1 N/mm2, no holiday
max. 15kV > 0.6 mm
– Residual thickness
Specific electrical insulation resistance
ISO
at 23°C 8 2
4 > 10 Ohm-m 21809-3
– RS100
> 0.8
– RS100 / RS70
Cathodic disbondment resistance at 28
5 <15 mm
days at 23°C
Peel strength between tape layer at
6 23°C
> 1.50 N/mm
–inner/outer
7 Lap shear strength at 23°C > 0.050 N/mm2

Table 2: Typical Data to be provided for the Primer Materials

Sl. Reference
Property Unit
No. Standards
1 Primer trade name - -
2 Generic type - -
3 Solid content % ISO 3251
4 Type of solvent - -
5 Flash point °C ISO 1523
6 Density g/cm3 ISO 2811-1
7 Coverage area M2/l -
8 Dry film thickness μm ISO 2808
Storage conditions
9 – temperature, minimum °C —
– temperature, maximum °C —
10 Shelf life at storage temperature Month -
DOC. NO. KOC-P-004 Pt. 7 Page 20 of 43 REV. 3

7.8 Heat Shrink Sleeve (HSS)

7.8.1 This Standard covers the following types of heat shrink sleeves for coating of
girth welds in conformity with the requirements mentioned herein.

a) Type A (Polypropylene Heat Shrink Sleeves): Consists of High Density

Polypropylene Backing with Polypropylene Adhesive for the use on pipes
at service temperature in the range of 80°C - 110°C.

b) Type B (Polyethylene Heat Shrink Sleeves: Consists of High Density

Polyethylene Backing with High Shear, Hot-Melt Adhesive for the
use on pipes at service temperature of up to 80°C.

7.8.2 The Heat Shrink Sleeve for field joint coating of girth welds shall provide the
same corrosion protection as offered by the factory applied pipe coating.

7.8.3 All types shall be suitable for applications on steel substrate having black metal
temperature of approximately 85°C.

7.8.4 The field joint coating shall consist of a three layer heat shrink sleeve system
comprised of the following components:

a) A two component, 100% solids, solvent-free epoxy based primer

formulated for use with the sleeve adhesive and applied to the abrasive
blast bare steel surface only (No overlap to 3LPP applied coatings)

b) A high shear strength, hot melt adhesive (mastic adhesives shall not be
allowed)

c) A radiation cross-linked and stretched, thermally stabilized, UV-resistant,

semi-rigid polypropylene or polyethylene backing

7.8.5 Each sleeve shall be suitably marked by the sleeve Manufacturer with
identification number, product name and batch number. I3I

7.8.6 After application of the HSS, the overlap of the sleeve onto each side of the
adjacent factory applied pipe coating shall be a minimum of 75 mm for Type A
Polypropylene sleeves and a minimum of 100 mm for Type B Polyethylene
sleeves.

7.8.7 Material to be used for the repair of heat shrink sleeves or factory applied
coatings shall be compatible with the type produced by the same Manufacturer
as the heat shrink sleeves. It shall have a composition and temperature limit to
coincide with the Type A or Type B sleeves used.

7.8.8 To ensure that the sleeve is applicable in the high ambient and black body
temperatures, and high UV levels in Kuwait, the backing and adhesive shall
have a sufficiently high resistance so as not to be damaged or degraded after
installation, while waiting up to Four (4) months under the direct sun for lowering
and burial. I3I
DOC. NO. KOC-P-004 Pt. 7 Page 21 of 43 REV. 3

7.8.9 The applicator shall submit all material test certificates of the HSS materials
characteristics from a recognized independent laboratory for KOC review and
approval. The laboratory shall be accredited in accordance with the
requirements of ISO 17025. Heat Shrink sleeves for the girth weld coating shall
meet the requirements as tabulated in Table 3 of this Standard.

Table 3: Physical Properties of Heat Shrink Sleeve I3I

Acceptance Criteria
Sl. Reference
Qualification Tests Type A Type B
No. Standards
(Polypropylene) (Polyethylene)
1 Dry Film Thickness of Epoxy Primer N/A > 200 µm
Holiday detection at 5 kV/mm +5 kV,
2 ISO 21809 -3 No Holidays No Holidays
max. 15kV
Impact resistance (holiday detection
3 at 5 kV/mm +5 kV, max. 15kV after ISO 21809 -3 > 8 J/mm > 5 J/mm
recovery)
Indentation Resistance (holiday
10 N/mm2 10 N/mm2
detection at 5 kV/mm +5 kV, max.
ISO 21809 -3
4 15kV after recovery) @ Max
Operating Temperature Residual
>0.6mm >0.6mm
thickness
Cathodic Disbondment 28 days
5 @ Max Operating Temperature but ISO 21809-03 < 15 mm < 15 mm
limited to 95°C maximum,
Adhesion to Steel and Main Line
6 > 4.0 N/ mm > 2.5 N/mm
Coating @ 23°C, 100 mm/min ISO 21809 -3
Adhesion to Steel and Main Line
7 Coating @ Max Operating > 2.0 N/mm > 0.2 N/mm
ISO 21809 -3
Temperature, 100 mm/min
Peel strength at 100 mm/min At end of test, At end of test,
to pipe surface and to plant coating Peel adhesion Peel adhesion
8 ISO 21809 -3
after 28-day hot-water immersion test value at 23°C: > value at 23°C:
@ Max Operating Temperature 2 N/mm > 1.5 N/mm
> 2.8 mm
ISO 21809 -3 > 3.0 mm on
9 Installed Sleeve Thickness Over Weld
Sleeve Body
Seam
Overlap onto Main Line Coating (After N/A > 100 mm /
10 > 75 mm / side
Shrinking) side
After 100
ISO 21809-03,
Thermal Ageing Resistance After 100 days, days,
11 Appendix A
@140°C, > 0.75 @ 100°C, >
0.75
Horizontal slippage shall not
ASTM D 3080,
12 Soil Stress Resistance exceed 2.54 mm in 24 hours @
Appendix A
66.73 N load
DOC. NO. KOC-P-004 Pt. 7 Page 22 of 43 REV. 3

7.9 Viscoelastic Wrapping Tapes I3I

7.9.1 The cold applied, corrosion preventing wrap material shall meet the requirements as
tabulated in Table 4 of this Standard..

Table 4: Physical Properties of Viscoelastic Tapes

Sl Test Reference
Property Requirements
No. Temp. Standards
Minimum thickness (mm)
1 23 °C >1.5mm ISO 21809-3
Glass transition temperature (°C)
2 < -600C ISO 21809-3

No melting point
3 Melting Point(°C) ISO 21809-3
present
Holiday detection at 5 kV/mm + 5 kV,
4 No holiday ISO 21809-3
max. 15kV
Tmax + No dripping of
5 Drip resistance ISO 21809-3
15 °C compound
Peel strength test to steel and to plant  0.2
6
coating before and after thermal ageing 23 °C  0.02 Cohesive ISO 21809-3
resistance and hot water immersion Tmax failure
test both for 100 days at Tmax (N/mm) Coverage ≥ 95 %

Adhesion test to steel and to plant

coating before and after thermal ageing 23 °C
7 No adhesive failure ISO 21809-3
resistance and hot water immersion Tmax
test both for 100 days at Tmax

 0.02
8
Lap shear strength (N/mm²) 23 °C  0.002 ISO 21809-3
Tmax Cohesive failure
Coverage ≥ 95 %
9 Density (gm/cc) 23 °C 1-4-1.6 NEN1833
10 Elongation, % 23 °C >100 ASTM D-1000
11 Moisture absorption, % 23 °C <0.03 ASTM D-570
12 Permeability (g/m2/24hrs) 23 °C <0.25 ASTM E-96
230C and
13 Adhesion to substrate No adhesive failure EN12068
650C
Cathodic disbondment resistance at 28 23°C and 0 mm, no holiday,
14 ISO 21809-3
days (mm) 65oC self-healing
Specific electrical insulation resistance
- RS100
15 23 °C  108 ISO 21809-3
- RS100/RS70
 0.8a
(.m²)
(a) This requirement shall be fulfilled only if the specific electrical insulation resistance after 70 days is less than 10 times the
requirement of the specific electrical insulation resistance after 100 days.

7.9.2 If required, an outer wrap shall be used over the Viscoelastic Tapes and the
outer wrap shall meet the requirements of Table 5 of this Standard.
DOC. NO. KOC-P-004 Pt. 7 Page 23 of 43 REV. 3

Table 5: Physical Properties of Outer Wraps

Sl. Test Reference

Property Requirement
No. Temp. Standards
1 Outer wrap – PVC
Peel strength, N/mm
2 23 °C ≥ 0.40 ISO 21809-3
outer layer to outer layer
Elongation at break (E100/E0) after
3 thermal ageing test for 100 days at 23 °C  0.9 ISO 21809-3
Tmax

4 Tape thickness 0.5mm +/- 10%

5 Service temperature -5°C to +80°C

6 Tensile strength >10kg/25mm ASTM D-1000

7.10 Two (2) Layer Polyethylene I3I

7.10.1 The coating shall consist of two layers, 1st layer shall be FBE and 2nd layer
shall be a functional Polyethylene layer.

7.10.2 The FBE shall be automatically applied by electrostatic spray.

7.10.3 Preheat and application temperature shall not cause loss of functional properties
to the plant-applied pipe coating made of 3LHDPE system.

7.10.4 The polyethylene shall be applied in a spiral or wraparound method by means of

an automatic or semi-automatic machine to obtain the specified coating
thickness.

7.10.5 The FBE shall have the minimum physical properties as mentioned in Table 6 of
this Standard.

Table 6: Physical Properties of Fusion Bonded Epoxy Primer

Sl. Reference
Property Value Limits
No. Standard
Moisture Content (% by
1 ≤ 0,6
mass)
Minimum Glass
o
2 Transition Temperature ≥ 95 C
(Tg) (DSC) ISO 21809-1 /
CSA Z245.20
Gel time at 205± 3 °C
3 ±20% to supplier’s specification
seconds
± 0,05 to the manufacturer’s
4 Density (g/m³)
specification
(a) 1.5 V, 20 ± 3 °C, for a minimum
of 28 d; and 6.5 mm maximum
Cathodic Disbondment radius
5 CSA Z245.20
Resistance (b) 3.5 V, 65 ± 3 °C, for a
minimum of 24 h. 8.5 mm
maximum radius
DOC. NO. KOC-P-004 Pt. 7 Page 24 of 43 REV. 3

7.10.6 The polyethylene top layer shall have the minimum physical properties as
tabulated in Table 7 of this Standard.

Table 7: Physical Properties of Polyethylene

Sl. Reference
Property Requirement
No. Standards
1 Generic type of material Polyethylene
2 Melt Flow Rate (190°C/2,16 kg) ISO 1133 3 – 5 g/10min
>30 min at 210°C or
3 Oxidation Induction Time ISO 11357-6
>10 min at 220°C
4 Tensile stress at break at 23°C ISO 527 >16 MPa
5 Tensile strain at break at 23°C ISO 527 >600%
6 Tensile strain at break at -45°C ISO 527 >100%
7 Vicat softening temperature A/50 ISO 306 >95°C
8 Hardness Shore D (1 s) ISO 868 >50
Tensile strain at break
9 Thermal ageing 4800 h at 100°C ISO 21809-1
≤25%
10 Volume resistivity ASTM D 257 >1014 cm
11 Brittleness temperature ASTM D 746 <-70°C
ESCR (Environmental Stress ASTM D 1693
12 >2000h
Crack Resistance) Method A or B

8.0 QUALIFICATION OF PROCEDURE AND APPLICATORS I3I

8.1 The application procedure shall be qualified by a PQT. Test methods,

frequencies and acceptance criteria for PQT shall be complied with the
requirements as specified in Table 8 of this Standard.

8.2 The applicator / vendor shall submit all material test certificates of the materials
characteristics from a recognized independent laboratory for KOC review and
approval.

8.3 The contractor shall ensure that the coating / wrapping Manufacturer is available
during the PQT to ensure the correct use of the coating / wrapping material(s)
and to train the Applicator personnel.

8.4 Qualification tests shall be carried out on representative pipes having the same
diameter and thickness of the pipeline and shall be witnessed by KOC.

8.5 Tests shall be carried out on test zones distributed along a pipe coated with the
actual parent (plant-applied) coating. The length of the test zones shall be
equivalent to the field joint coating length. If not available, a circumferential cap
weld shall be added at the center of each of the test zones to simulate the field
weld.

8.6 All tools and equipment (e.g. for induction heating, abrasive blasting, coating
application and inspection) being used for PQT shall be of the same type
intended to be used for the actual field joint coating.
 DOC. NO. KOC-P-004 Pt. 7 Page 25 of 43 REV. 3

Table 8: Test Methods, Frequencies, and Acceptance Criteria for PQT

& Production. I3I

Frequency of Testing
Type of Reference
Sl No Property
Coating In PQT In Production
Standards
Surface condition of the area to
1 All Visual 3 joints Each joint
be coated before preparation
Visual inspection of the cleaned
2 All ISO 8501-1 3 joints Each joint
surface
Surface Profile of the cleaned
3 All ISO 8503-1 3 joints 3 times per shift
surface
Level of soluble salts on cleaned ISO 8502-6
4 All 3 joints 3 times per shift
Surface ISO 8502-9
5 Dust contamination All ISO 8502-3 3 joints 3 times per shift
Inspection of Overlap Area of
6 All Visual 3 joints Each joint
existing main line pipe coating
Temperature of the surface to
7 All - 3 joints Each joint
be coated
FBE &
8 Degree of cure of epoxy ISO 21809-3 3 joints 1 per shift
2LPE
Oxidation induction time
9 2LPE ISO 11357-6 3 joints -
(intercept in the tangent method)
Visual inspection of the applied
10 All - 3 joints Each joint
coating/wrapping
ISO 21809-3
11 Thickness All 3 joints Each joint
/SSPC PA2
ISO 21809-3
12 Holiday detection test All 3 joints Each joint
13 Impact resistance test All ISO 21809-3 3 joints -
14 Indentation resistance test All ISO 21809-3 3 joints -
Peel strength on steel surface Flange
15 and plant coating at ambient Wrap & ISO 21809-3 3 joints Once per shift
temperature HSS
Flange
Peel strength on steel surface
16 Wrap & ISO 21809-3 3 joints -
and plant coating at Tmax
HSS

8.7 At least three (3) test samples shall be coated for PQT. All the joints shall have a
weld bead of height 1.5 – 2 mm for representing the actual site joint conditions.

8.8 Coating / wrapping repairs and stripping of defective coating / wrapping shall be
included in PQT.

8.9 The time for coating application during PQT shall be consistent with the
estimated field joint coating time in the field. Any significant differences in the
PQT environment compared to actual production conditions should be
considered e.g. similarity or differences in lifting equipment.

8.10 The Applicator shall submit a complete report of the qualification test results to
KOC for approval.
 DOC. NO. KOC-P-004 Pt. 7 Page 26 of 43 REV. 3

8.11 To carry out the application of blasting, coating / wrapping and heat shrink
sleeve, the Contractor or Applicator shall use only experienced and qualified
manpower who had been tested by the Manufacturer and KOC. The Applicator’s
Foreman & Supervisor shall possess certificates from the coating / wrapping
Manufacturer as well as KOC Qualification Card as per KOC Standard
KOC-P-006.

8.12 In addition, the Applicator shall appoint a NACE Certified Inspector or equivalent
with relevant field experience of not less than five (5) years. The certified
inspector shall qualify to the requirements of KOC Standard KOC-P-006
“KOC Standard for Evaluation and Certification of Blasting and Coating
Contractor / Applicator Personnel”. The certified inspector shall be responsible
for the proper application of the coating / wrapping system.

9.0 SURFACE PREPARATION AND COATING / WRAPPING APPLICATION

9.1 General

9.1.1 The Applicator shall submit, for KOC review and approval, a surface preparation
procedure, associated inspection methods, monitoring techniques and
details of equipment to be used.

9.1.2 The external surface including the girth welds shall be prepared to the
satisfaction of KOC and in accordance with the requirements of this Standard
and the recommendations of coating Manufacturer.

9.1.3 If not carried out at the coating factory, the mainline coating edge shall be
beveled by the Applicator to 30 degree or less.

9.1.4 The pipeline shall have 500 mm ground clearance for proper work & inspection
access. I3I

9.2 Defect / Imperfection Removal

9.2.1 Prior to blast cleaning of pipe surfaces, foreign materials including deposits, oil,
grease, mill, lacquer, wax, old or temporary coatings, salts, dirt, mud, etc. shall
be removed using applicable method(s) as per the following:

a) Solvent cleaning shall be carried out in accordance with SSPC-SP1. Only

solvents (e.g., hexane, xylol, etc.) or appropriate high-detergent cleaning
(using emulsifying cleaners followed by fresh water washing or steam
rinsing that does not leave any oily residue on the surface shall be used.

b) The cleaned surface shall be allowed to dry before proceeding with further
preparation or coating.

c) Scraping, wire brushing and wiping down with clear rags may be used to
remove dry contaminants from steel surfaces.

d) Subject to KOC approval, heating to remove oil, grease and to stress mill
scale may be used provided the pipe section / fitting is preheated in a
uniform manner to avoid distortion.
 DOC. NO. KOC-P-004 Pt. 7 Page 27 of 43 REV. 3

9.2.2 Before commencement of abrasive blast cleaning, all surface imperfections such
as slivers, scabs, slag, weld spatter, etc. shall be removed or made uniform by
wire brushing, grinding or any other method approved by KOC. If grinding is
needed, the maximum grind area and the minimum acceptable wall thickness
shall be subjected to KOC approval (the maximum allowable grinding areas
shall be specified).

9.2.3 When surface preparation is carried out for the coating rehabilitation work,
where the adjacent coating is weak, the coating is properly wrapped to prevent
extension of damages. I3I

9.3 Blast Cleaning

9.3.1 After pre-cleaning the exterior girth weld joint (weld zone) surface shall be blast
cleaned, using a suitable abrasive material selected in accordance with SSPC
AB 1 to achieve a surface cleanliness as defined ISO 8501-1 Sa 2½ / NACE 2 /
SSPC-SP10 Near White Blast.

9.3.2 Silica sand or Copper slag shall not be used as an abrasive material.

9.3.3 The verification of the quality of abrasive cleaning shall be assessed by use of
SSPC VIS-1 Guide to abrasive blasting.

9.3.4 Abrasive cleaning shall produce a surface profile and verified by NACE RP 0287
and in accordance with the coating / wrapping Manufacturer.

9.3.5 The coating/wrapping application shall not be carried out under the following
conditions when :

a) Ambient temperature is below 10°C.

b) Humidity is greater than 85%.

c) Metal surface temperature is less than 3°C above the dew point.

d) More than four (4) hours have been elapsed after conducting metal
surface blast cleaning.

9.3.6 The total elapsed time between the start of blasting of any girth weld joints,
flanges & fittings and the coating / wrapping application shall not exceed the
time-humidity limits as per Table 9 of this Standard.

Table 9: Time-Humidity Limits

Humidity (RH %) Elapsed Time(Hours)

85 0.5
80 1.0
70 1.5
60 1.75
50 2.0
40 3.0
<40 4.0
 DOC. NO. KOC-P-004 Pt. 7 Page 28 of 43 REV. 3

9.3.7 The adjacent mainline coatings, over which the coating system is to be
applied, shall be sweep blasted (3LPP coated pipes shall not be
sweep blasted) or manually abraded prior to installation. Existing
mainline coatings shall be protected from damage by impact, gouging,
mechanical cleaning, or any other contact.

9.3.8 After blast cleaning, the prepared surface shall be cleaned from any dust,
residual products and blast cleaning materials prior to coating / wrapping
application using a fast method of cleaning such as dry compressed air or by dry
cloth if the area is small. The prepared surface shall meet the requirements of
ISO 8502-3 with a rating of 2 or less. I3I

9.3.9 The chloride level shall be measured and if the concentration is more
than the maximum allowable value as specified in clause 10.3.6 of this
Standard, the pipe surface shall be cleaned with suitable method to be
approved by KOC.

9.3.10 The prepared pipe surface and pipe shall be cleaned from any dust, residual
products and blast cleaning materials prior to coating / wrapping application
using a fast cleaning method such as dry compressed air. I3I

9.3.11 Prior to coating / wrapping, the blast cleaned surfaces shall be visually
inspected. All imperfections that may appear after blast cleaning that
could cause holidays in the coating/wrapping shall be removed by
grinding in such a manner as to give a surface finish suitable for
subsequent application of coating/wrapping.

9.3.12 Blast cleaned surfaces shall be protected from wet, humid, rainfall and
surface moisture conditions. No girth weld joint, fitting and flange shall
be allowed to flash rust prior to coating/wrapping application. If flash
rusting occurs, the surfaces must be re-blasted by abrasive blasting as
above.

9.3.13 During blast cleaning and coating/wrapping application, the workmen

shall use the appropriate PPEs to satisfy HSE requirements for
protection.

9.4 Application of Fusion Bonded Epoxy (FBE)

9.4.1 For field joint coating of FBE coated pipes, a minimum length of 75 mm (3 in)
shall be cleaned by sweep blasting to make sufficient profile for over coating the
FBE joint coating to the main line coating.

9.4.2 The application and curing temperatures of the external pipe surface shall be in
accordance with the Manufacturer's recommendations and shall not exceed
275°C.
 DOC. NO. KOC-P-004 Pt. 7 Page 29 of 43 REV. 3

9.4.3 Heating temperatures shall be monitored and controlled with an optical and
recording pyrometer. Pyrometers installed to monitor pipe temperature before
the coating application shall be checked periodically with a calibrated contact
type thermometer to assure accurate calibration of the instrument. The
temperatures shall be checked at minimum four (4) locations on the pipe (3, 6, 9
& 12 O’clock Positions). The difference in the temperature at the above
locations shall not exceed 25 degree C. I3I

9.4.4 Heating of joint shall be carried out only with suitable induction heating coil
which shall fit within the cut back area. At any case, extension of induction coil
over the pipe coating shall not be acceptable. I3I

9.4.5 Heating shall not result in any visible oxidation of the exposed field joint. I3I

9.4.6 The FBE powder shall be applied uniformly on the external surface of the girth
weld area or the fittings using electrostatic gun.

9.4.7 FBE powder shall not be recycled.

9.4.8 The FBE powder used for joint coating shall be from the same Manufacturer and
shall be fully compatible with the existing pipeline coating.

9.4.9 Field joint coating with FBE shall be of single layer.

9.5 Application of High Build Epoxy (HBE)

The HBE application shall be as per KOC-P-004 Part 8.

9.6 Application of High Build Polyurethane (HBP)

The HBP application shall be as per with KOC-P-004 Part 9.

9.7 Application of Tape Wrapping

9.7.1 Application shall be carried out in accordance with the approved procedure. As a
general guide, the following application requirements shall be complied with.

9.7.2 The surface shall be prepared as specified in the clauses 9.1 to 9.3 of this
Standard.

9.7.3 If the main line coating is HBE / HBP, the flanges shall be coated with the same
main line coating followed by the putty application and wrapping. For other main
line coatings, a thin coat of primer as recommended by the wrapping
Manufacturer shall be applied.

9.7.4 Putty shall be applied on the coated flange surfaces and bolts evenly so as to
make a uniform contour.

9.7.5 The area being coated shall be spirally wrapped with the tape , having an
adequate overlap and using sufficient tension to ensure a complete
conformability of the coating. Any tenting effect or air entrapment shall be
prevented. A manual application tool should be used to achieve these goals.
 DOC. NO. KOC-P-004 Pt. 7 Page 30 of 43 REV. 3

9.7.6 Two Layer of tapes (Inner & Outer) shall be used to wrap the flanges.

9.7.7 The minimum tape overlaps shall be kept as indicated in Table 10 of this
Standard.

Table 10: Minimum Tape Overlap (width)

Tape Width Overlap (Width)

< 50 mm > 50 %
> 50 mm > 25 mm

9.7.8 The wrapping shall be overlapped to the mainline coating to a minimum

of 100 mm

9.7.9 The wrapped joint shall be backfilled within 24 hours; or shall be re-
inspected for sagging prior to backfilling, if it is not done on the same
day.

9.8 Application of the Heat Shrink Sleeve (HSS)

9.8.1 The two components of the liquid epoxy primer shall be thoroughly
mixed and applied to the heated steel field joint surface using a suitable
application tool to achieve a sufficient wet film thickness that will yield a
minimum dry film thickness of 200 μm.

The wet film thickness required shall be determined during the PQT and
shall be checked during application using a wet film thickness comb
gauge. The epoxy primer shall not be allowed to overlap onto 3LPP
factory applied pipe coatings.

9.8.2 Prior to the application of the heat shrinkable sleeve, the epoxy primer
shall be visually inspected for integrity. It shall be uniform, free of runs,
sags, drips, bare spots and other defects. The epoxy primer shall be
cured, according to the recommendations of the HSS manufacturer.

9.8.3 Heating temperatures for Type A Polypropylene heat shrink sleeves

shall be achieved in controlled manner by induction heating so that the
temperature shall not cause damage to the factory applied pipe coating.
Under no circumstances shall the temperature of the steel pipe
surface exceed 200°C.

9.8.4 Heating temperatures for Type B Polyethylene heat shrink sleeves may
be achieved using propane torches for sizes below 24 inches in
diameter, with particular attention paid to ensure that the temperature
shall not cause damage to the factory applied pipe coating.
DOC. NO. KOC-P-004 Pt. 7 Page 31 of 43 REV. 3

9.8.5 Induction heating shall be utilized for thicker pipe wall dimensions
(more than 12mm thick) and larger diameter (more than 24 inches)
pipes to provide additional control and increased speed for pre-heating
operations. Under no circumstances shall the temperature of the
steel pipe surface exceed 200°C. The heating technique shall be
successfully demonstrated that the heating equipment yields the
minimum temperature required during the PQT.

9.8.6 Heat shields shall be used as deemed necessary to provide additional

protection for 3LPP factory applied pipe coatings during installation of
Type A Polypropylene heat shrink sleeve.

9.8.7 Adequately applied heat to the sleeve will be verified by visually

observing that there is no occurrence of the adhesive oozing at all
exposed sleeve edges.

9.8.8 Heat shrink sleeves shall be clean, free from dust and dirt, moisture and
chemical contamination up to and during the time of application. The
sleeve shall be centered over the weld area and appropriately wrapped
around the field joint.

9.8.9 Propane torches having proper characteristics (size, rating,

manufacturer) according to sleeve manufacturer guidelines shall then be
used to heat the HSS circumferentially around the joint starting from the
centre of the joint outwards, on one end of the joint only.

9.8.10 All coated welds / pipes shall be buried within one (1) month of
application. Sleeves left for longer than this period shall be removed and
replaced unless the sleeves are wrapped with KOC approved materials
for UV protection

9.8.11 After application, each sleeve shall be marked to show the applicators
identification number, product name and date of application. I3I

9.8.12 The gas cylinders used shall be of industrial type with proper non return
valve safety system. LPG cylinders issued for domestic purpose shall
not be used. I3I

9.9 Application of Viscoelastic Wrapping Tapes I3I

9.9.1 The inner wrap shall be applied with an overlap of 10 mm and with at
least 100 mm onto adjacent existing pipe coating.

9.9.2 The outer wrap application shall be done with proper tension with an
overlap of minimum 50% (width).

9.9.3 The inner and outer wraps shall be applied without any air entrapments.
DOC. NO. KOC-P-004 Pt. 7 Page 32 of 43 REV. 3

9.10 Application of Two Layer Polyethylene I3I

9.10.1 The application temperature of the external pipe surface shall be as per
the manufacturer’s recommendation shall be monitored contentiously

9.10.2 The plant-applied coating in the overlap area shall be heated to the
specified temperature and shall be monitored during coating application.

9.11 Coating on Underground to Aboveground Intersection I3I

9.11.1 For those areas of pipes located in the soil to air interface (as shown
below), the underground main line coating shall be extended to at least
300 mm and shall not exceed 750 mm above the ground level. Where
the mill applied coating cannot be extended above ground level,
viscoelastic tapes shall be applied.

Air

Soil

9.11.2 Ground grade level shall be marked on the pipe prior to deciding the
height of overlap.

9.11.3 Prepare the extended underground coating by feathering the edges and
roughening the surface using a power tool.

9.11.4 For high build polyurethane coated pipe lines, apply a coat of aliphatic
polyurethane to a minimum thickness of 50 microns to provide Ultra
Violet Protection for the extended underground coating.

9.11.5 The overlapped polyurethane coating shall provide a uniform

appearance with the aboveground coating system. Viscoelastic
wrapping tapes shall be wrapped with UV resistant wrap material for
both mechanical & UV protection.

9.11.6 Flanges located within 30 cm from the ground level shall be wrapped as
per clause 9.7 of this standard.

9.11.7 Heat shrink sleeves shall not be applied or extended above the ground
level. If any joint is expected within 30 cm below the ground level, high
build polyurethane, high build epoxy or Viscoelastic tapes shall be
applied. Application of such coating shall be as per company standard
KOC-P-004 Part 8 or 9.
DOC. NO. KOC-P-004 Pt. 7 Page 33 of 43 REV. 3

10.0 INSPECTION AND TESTING

10.1 General

An inspection & Test plan (ITP) for the coating application and inspection shall
be prepared by the contractor and approved by the KOC. The ITP shall be
prepared in line with the KOC-Q-014 and shall include Pre Inspection Meeting
(PIM).

10.1.1 KOC shall have the right to inspect at all times any tools, materials or
equipment used in the performance of surface preparation and coating
application to ensure compliance with this Standard.

10.1.2 KOC shall have the right to carry out inspection and testing at all stages
of the surface preparation and coating application works.

10.1.3 The Contractor shall perform all inspections and tests that are
necessary to assure that the coating complies with the requirements of
this Standard.

10.1.4 Inspections shall be performed in accordance with ASTM D3276

“Standard Guide for Painting Inspectors (Metal Substrates)”.

10.2 Material Inspection and Testing

10.2.1 All coating materials shall be inspected / tested to ensure conformance

with the requirements of clause 7.0 of this Standard. Coated sample
shall be submitted to KOC, for approval, prior to application. Product
data sheets used for sales purposes or printouts from catalogs are
not considered acceptable as test certificates.

10.2.2 Test certificates from an independent recognized laboratory for the

coating materials characteristics shall be provided by the Contractor for
KOC review and approval. The laboratory shall be accredited in
accordance with the requirements of ISO 17025.

10.3 Surface Preparation I3I

10.3.1 Each cleaned girth welds / fittings / flanges / repair locations shall be
visually inspected for contaminants, surface defects and surface
imperfections that may cause holidays in the coating.

10.3.2 Surface contaminants or imperfections shall be removed in accordance

with this Standard. Girth welds / fittings / flanges having surface defects
shall be rejected or repaired at the applicator's cost.

10.3.3 Surface finish shall be Sa 2½ as per ISO 8501-1 (NACE 2 / SSPC-

SP10) Near White Blast. The frequency of the test shall be 100%.

10.3.4 The abrasive blasting shall produce an angular surface profile of 50 to

100 microns as verified by NACE RP 0287 and in accordance with the
coating Manufacturer.
DOC. NO. KOC-P-004 Pt. 7 Page 34 of 43 REV. 3

10.3.5 The dust rating on the prepared surface shall meet the requirements of
ISO 8502-3 with a rating of 2 or less.

10.3.6 The maximum chloride level shall not be more than 5 ugIcm2 (except for FBE
field joint coatings) immediately before coating commences as tested with Bristle
or Chlor-Test kits as per ISO 8502-6 & 9.

10.3.7 Those surfaces exceeding this limit shall be pressure wash cleaned with
potable water, until the contamination level is within the acceptable
limit (< 5 ugIcm2). If any test fails to meet the requirements of clause
9.0 of this Standard, One (1) joint / fitting / flange before and One (1)
joint / fitting / flange after the joint that failed the test, shall be tested until
such time as the joints that are not conforming to the requirements of
this Standard are identified and corrected.

10.3.8 The surface profile, dust and chloride level shall be as per test
frequencies in Table 8.

10.4 Inspection of Applied FBE Coating

10.4.1 Visual examination shall be conducted to ensure that the protective coating has
been applied in a manner representing quality workmanship. The coating shall
be free from any puckers, voids, breaks, wrinkles, folds or any other defects.

10.4.2 The fully cured FBE coating shall have a minimum thickness of 500 microns as
per SSPC PA 2. The frequency of the cure test shall be once per shift. I3I

10.4.3 Adhesion test shall be carried out on a cured FBE coating as per ISO 21809-3,
and the result shall be in the 2 rating. The frequency of the adhesion test shall
be at least a joint per shift.

10.4.4 All coated areas shall be 100% electrically tested for continuity with a suitable
holiday detector as recommended by the FBE coating Manufacturer and
approved by KOC.

10.4.5 Coated joints having holidays shall be repaired, provided that the number of
holidays / repairs does not exceed Three (3) holidays / repairs per pipe length
and the each individual repair shall not exceed 10 cm2.

Where the quantity and size of holidays / repairs exceeds the above specified
number, the affected joint shall be re-blasted and coated at the Contractor /
Applicator expense.

10.4.6 Repair epoxy coating system shall be applied on the prepared areas and the
adjacent coating in accordance with the Manufacturer's recommendations.
Irrespective of defect size, melt sticks shall not be used.
DOC. NO. KOC-P-004 Pt. 7 Page 35 of 43 REV. 3

10.4.7 Degree of cure I3I

The degree of cure of the epoxy powder shall be determined on at least one joint
per shift by differential thermal analysis of a sample of the epoxy layer taken
from the field joint coating.

The acceptance criterion, ΔTg shall be within -2°C to 3°C.

10.5 Inspection of Applied HBE Coating

Inspection shall be carried as per KOC-P-004 Part 8.

10.6 Inspection of Applied HBP Coating

Inspection shall be carried as per KOC-P-004 Part 9.

10.7 Inspection of Applied Tape Wrapping

All the coated flange shall be visually checked for holidays, air entrapments
and other discontinuities.

10.8 Inspection of Applied HSS Coating

10.8.1 Application temperature shall be monitored and controlled within the

limits specified by the HSS Manufacturer.

10.8.2 If the solvent free epoxy coating is forced cured prior to the application
of HSS, dry film thickness shall be measured in accordance with the
method described in SSPC-PA2. If the HSS is applied on to a wet
primed surface, wet film thickness shall be measured and recorded.

10.8.3 The overlap profile contour shall be visible and the overlap of the tape
shall be firmly bonded to the underlying layer. No upstanding edges
shall be allowed.

10.8.4 The curing temperature and schedule shall be monitored and controlled
in accordance with the HSS manufacturer's recommendations.

10.8.5 The temperatures shall be checked at minimum four (4) locations on the
pipe (3, 6, 9 & 12 O’clock Positions). The difference in the
temperature at the above locations shall not exceed 25 degree C.

10.8.6 Visual examination shall be conducted to ensure that the HSS coating
has been applied in a manner representing quality workmanship. The
HSS shall be smooth and free from dimples, bubbles, punctures, burn
holes, or any other signs of holidays in the coating or of entrapment of
foreign matter in the underlying adhesive.
DOC. NO. KOC-P-004 Pt. 7 Page 36 of 43 REV. 3

10.8.7 Peel (adhesion) strength test shall be made at least Once per working
shift. This test should be carried out at a sleeve temperature of 25°C.
Slight heating or cooling using cold water may be utilized. While carrying
out the test the following shall be considered:

a) Strips of 25 mm x 200 mm shall be cut up to the metal

perpendicular to the pipe axis either at 3 or 9 o'clock position (as
per ISO 21809- 3).

b) The leading edge (first 30 to 40 mm) of the strip shall be manually

removed including the adhesive using a screwdriver from the metal.

c) The peel strength test gauge shall be attached to the leading edge
of the strip. Holding the test gauge with both hands, a steady force
shall be exerted so as to obtain a pulling speed of 100 mm / min.
with an angle of 90°C to the pipe circumference.

d) Peel strength shall be as specified in the Table 3 of this standard.

The peel failure mode shall be cohesive within the adhesive layer.

e) If any voids extending to bare metal (or factory applied pipe

coating) or areas of no adhesion are found, their extent shall be
determined, if necessary by removing the entire backing.

f) In the event of a peel test failure, one (1) joint before and one (1)
joint after the joint that failed the test shall be re-tested until such
time as the joints that are not conforming to the requirements of this
Standard are identified and corrected.

g) All the defective areas and peel tested areas shall be repaired as
per the repair procedure.

h) On the sleeve to be peel tested, at least one (1) test shall be carried
out along the field girth weld, and another one in the body of the
sleeve

10.8.8 All HSS joints shall be 100% electrically tested with a suitable holiday
detector as recommended by the HSS Manufacturer and approved by
KOC in accordance with NACE RP 0274. Calibration of the holiday
detector shall be carried out per shift or as required by the KOC
inspector. While carrying out the Holiday detection the following shall be
considered:

 The electrode used for locating holidays shall be designed to

ensure direct contact with the coating (no visible gaps) and
provide complete coverage of the whole coated surface.

 Holiday detection shall not be conducted if the surface

temperature of the coating is above 50°C. All identified holidays
electrically detected shall be marked for repair.
DOC. NO. KOC-P-004 Pt. 7 Page 37 of 43 REV. 3

10.8.9 Repairs required due to holiday or destructive testing shall be identified,

marked, and repaired in accordance with the manufacturer’s
specifications as identified in its application procedures and shall be
holiday tested.

10.9 Inspection of Applied Viscoelastic Wraps I3I

10.9.1 The tape shall have minimum 100 mm overlap to the existing mainline
coating.

10.9.2 For the inner wrap, high voltage Holiday test shall be done at 15kV. Any
holiday shall be repaired with the patch of new material and retested.

10.10 Inspection of Applied Two Layer Polyethylene (PE) Coating I3I

Test
Sl. No Property Value Test Method
Temperature
Minimum Main Pipe
1 Total coating thickness, mm Line Coating SSPC-PA2
thickness
2 Epoxy layer thickness in Micron Minimum 300 SSPC-PA2
3 Holiday detection, kV/mm 25KV ISO 21809-4
0
4 Peel strength, N/mm 23 C & Tmax 15 N/mm & 3N/mm ISO 21809-4
Adhesion to pipe surface and plant
5 coating after 28-day hot-water 80 °C 15 N/mm ISO 21809-4
immersion test at Tmax
ΔTg given by the
6 Degree of cure, °C ISO 21809-4
manufacturer
Cathodic disbondment at 28 days
7 23 °C &Tmax </= 7 & 10(Tmax) ISO 21809-4
(mm)

8 Impact resistance, J/mm 20 °C 5*A*B ISO 21809-4

Indentation resistance at a pressure of

9 Tmax <1 ISO 21809-4
10 N/mm2 (mm)

Oxidation induction time at 200°C

10 >15 ISO 11357-6
(intercept in the tangent method) C Min

A= 0.7 for coating thickness less than or equal to 2 mm;

A= 1.0 for coating thickness greater than 2 mm;
B= 0.7 for pipe with nominal diameter less than 65 mm;
B= 0.85 for pipe with nominal diameter from 65 mm to less than 200 mm;
B= 1.0 for pipe with nominal diameter from 200 mm and above.

11.0 DOCUMENTATION

11.1 All correspondence, instructions, data sheets, drawings, procedures,

ITP and any other written information shall be in English language. In
case of dual languages, one language shall be in English

11.2 All dimensions, units of measurement, physical constants etc. shall be in

SI units unless otherwise specified. (Pipe sizes to be generally
mentioned in inches)
DOC. NO. KOC-P-004 Pt. 7 Page 38 of 43 REV. 3

11.3 All documents (text, data sheets, specifications, method statements etc.)
shall be provided with electronic files in the approved software (MS
Word, Excel, AutoCad etc.) as applicable.

11.4 The applicator shall submit, for KOC review and approval, a surface
preparation and application procedure and details of equipment to be
used. The field joint coating application procedure shall include the
following items: I3I

a) Coating PQT procedure;

b) Inspection & Test Plan;
c) Operator training and certification procedure;
d) Surface preparation of field joint coating area and factory coating overlaps;
e) Inspection of field joints after surface preparation;
f) Pre-heat method and description of equipment;
g) Liquid epoxy primer application procedure;
h) Heat shrink sleeve installation procedure;
i) Field repair procedure for heat shrink sleeves and factory applied coatings;
j) Equipment list including all cleaning, heating, coating, testing and
inspection equipment to be used.
DOC. NO. KOC-P-004 Pt. 7 Page 39 of 43 REV. 3

APPENDIX- A: TESTS FOR HEAT SHRINK SLEEVE

A1.0 ADHESIVE PROPERTIES

Thermal Mechanical Analysis (TMA) test shall be made to determine the

melting temperature of the adhesive and percent retained strength. The
test method consists of accurately measuring the penetration of an
indentor into the adhesive under a specified contact pressure as
function of temperature.

A1.1 Sample Test Procedure

Adhesive sample shall be removed from the backing and shall be placed
into TMA test apparatus at room temperature and at 1.38 N/cm2 (2 psi)
pressure. Temperature will be raised at a rate of 5°C per minute, until
plunger has penetrated 50% of the thickness of the backing. Penetration
versus temperature test results shall be recorded on X-Y graph. The
percent-retained strength shall be calculated at the melting point of
adhesive.

A1.2 Adhesive Acceptance Criteria

The adhesive melting point shall be:

> 140°C for Type A Polypropylene Heat Shrink Sleeves
> 120°C for Type B Polyethylene Heat Shrink Sleeves
and percentage retained strength at the melting point: 95% minimum.

A2.0 SOIL STRESS (SHEAR TEST)

A2.1 Scope

To determine the ability of a coating to transmit shear forces between soil and a
pipeline when the pipe is operating at elevated temperature.

A.2.2 Materials Required

a) An oven capable of maintaining temperature over the range from room

temperature to 120°C.

b) Two steel plates (steel plate No.1 and steel plate No. 2), each having
dimensions of 152.4 mm x 30.5 mm x 6.4 mm. These two plates will be
used for the test. A third steel plate (steel plate No.3 - not shown in Fig.1)
having dimensions of 177.8 mm x 50.8 mm x 6.4 mm will be used for
preparation only.

c) Heat shrink sleeve test specimen shall be bonded to cleaned, shot blasted
and preheated steel plate No. 1 (see below clause A2.3 for sample
preparation details).

d) Test fixture per Figure 1.

DOC. NO. KOC-P-004 Pt. 7 Page 40 of 43 REV. 3

A.2.3 Sample Preparation

a) Test specimens of the coating are cut 50.8 mm x 177.8 mm in order to be

larger than steel plate No.1 to which it will be bonded. Excess specimen will
be trimmed after bonding.

b) Steel plates No.1 & 3 and the 66.73 N shear weight, are placed in an oven
preset to about 70°C above maximum rated operating temperature of the
test coating; e.g. 170°C for type-A, 150°C for Type-B, etc. These items will
be kept in the oven for one (1) hour to insure thermal equilibrium.

Then the above materials are removed from the oven and the 50.8 mm x
177.8 mm coating sample are placed with adhesive down onto top of
preheated steel plate No. 1, then immediately place flat preheated steel
plate No. 3 on top of the coating, and then place the 66.73 N weight on top
of this sandwich.

c) This sandwich is allowed to cool to room temperature, or quenched after 20

minutes with water.

d) The 66.73 N weight and steel plate No.3 are then removed and excess
coating is trimmed off the steel plate No.1 to which the coating has been
bonded.

A.2.4 Test Procedure

a) Steel plate (1) is placed in the slot of the test fixture. Steel plate (2) (to which
80-grit sandpaper has been bonded) is next placed on top of the bonded
coating. The 182.38 N weight is placed on top of this sandwich and the
entire fixture is placed into an oven preset to the desired test temperature
for four (4) hours to insure thermal equilibrium.

b) The 66.73 N shear load is now applied.

c) After 10 minutes (in order to allow for any elastic deformation) the dial
indicator is zeroed.

d) After 24 hours, the amount of horizontal slippage is recorded. Movement of

2.54 mm or less is considered passing, but any larger deflection is a
failure.

A2.5 Test Acceptance Criteria

When applying a 66.73 N shear load for 24 hours, the amount of horizontal
slippage shall not exceed 2.54 mm. Larger movement exceeding 2.54 mm
shall be considered as failure.

A2.6 References

Alaska Test Procedure No. TP-206 & ASTM D-3080

DOC. NO. KOC-P-004 Pt. 7 Page 41 of 43 REV. 3

A3.0 SHRINKAGE AFTER HEATING

A3.1 Backing Samples

Backing samples will be shrunk by 10 minutes heat exposure in an oven pre-set

to 150°C (or the Vendor recommended temperature). Samples dimensions shall
be measured before heating and after cooling.

A3.2 Acceptance Criteria

The difference between the expanded length and the recovered length of the
backing material shall be at least 20%.
DOC. NO. KOC-P-004 Pt. 7 Page 42 of 43 REV. 3

ACKNOWLEDGEMENT

This KOC Standard (Rev. 3) has been approved by the Standards Technical Committee
(STC) consisting of the following Members:

Mr. Khalid B. Al-Shammari TL Standards Team Chairman

Mr. Mohd. Emam Insp. & Corr. (Projects) Team Deputy Chairman
Mr. A. Unnikrishnan Standards Team Secretary / Member
Mr. G. Unnikrishnan Tech. Exp. Team Member
Mr. Mohd. Aslam Imadi Gas Proj. Mgmt. Team Member
Mr. Nandkumar Aravind HSE Systems Team Member
Mr. Mohammad Al-Ajmi C & N Team Member
Mr. Haitham Aboughaith Gen. Projects Team Member
Mr. Amer Jaragh Insp. & Corr. (N&WK) Team Member
Mr. M. Javid Masood Project Mgmt. (NK) Team Member

The Draft of this Standard (Rev. 3) had been circulated to the KOC User Teams for review
and responses were received from the following Teams:

PROJECTS SUPPORT SVCS. GROUP PROCESS SAFETY MGMT. GROUP

Team Leader PMC Management Team Leader Insp. & Corr. (S&EK)
Team Leader Insp. & Corr. (N&WK)
Team Leader Insp. & Corr. (Projects)

OPERATIONS GROUP (HO) AHMADI PROJECT GROUP

Team Leader OTS (HO) Team Leader HSE (CSD)

OPERATIONS SUPPORT GROUP (S&EK) SUPPORT SERVICES GROUP (WK)

Team Leader HSE (S&EK) Team Leader HSE (WK)
Team Leader Project Management I (WK)

HEALTH, SAFETY & ENV. GROUP SUPPORT SERVICES GROUP (S&EK)

Team Leader Safety Team Leader Project Management - (EK)
Team Leader Health & Environment

OPERATIONS SUPPORT GROUP (NK) OPERATIONS GROUP (EK)

Team Leader HSE (NK) Team Leader Maintenance (EK-II)

EXPORT OPERATIONS GROUP PRODUCTION & PROJECTS (GAS)

Team Leader HSE (EO & MO) Team Leader Jurassic Projects Mgmt.

GAS OPERATIONS GROUP OPERATIONS SUPPORT GROUP (GAS)

Team Leader Consumers Networks Team Leader HSE (Gas)
 DOC. NO. KOC-P-004 Pt. 7 Page 43 of 43 REV. 3

Task Force Responsible for Revision of this Standard

The revision of this Standard (Rev. 3) has been entrusted by the Standards Technical
Committee (STC) to the Task Force (TF-CP / 02) comprising of the following Members:

Mr. Amer Jaragh Insp. & Corr. (N&WK) Team TF Leader Tel. No. 65428
Mr. Mohd Emam Insp. & Corr. (Projects) Team Member Tel. No. 63693
Mr. Hasan Sabri Insp. & Corr. (S&EK) Team Member Tel. No. 61832
Mr. Umair A. Usmani Standards Team Member Tel. No. 61869