PTT PUBLIC COMPANY LIMITED
NGR PIPELINE AND M/R PROJECT
DOCUMENT NO.: SP-Q-1002.NGR-XXXX-006 REVISION A
DOCUMENT TITLE : SPECIFICATION FOR PIPE COATING REPAIR SYSTEM
TABLE OF CONTENT
ARTICLE PAGE
1.0 SCOPE OF WORK .......................................................................................................................... 3
2.0 REFERENCE DOCUMENTS .......................................................................................................... 3
3.0 MATERIAL CONFORMITY AND DELIVERY REQUIREMENTS ................................................ 4
4.0 FUNCTIONAL REQUIREMENTS................................................................................................... 4
5.0 QUALITY ASSURANCE ................................................................................................................. 8
1.0 SCOPE OF WORK
This specification describes the materials and functional performance requirements for heat
applied repair systems for damaged polyethylene (PE) pipe coatings for buried pipelines and
damaged polyethylene coating for pipeline laid by the Horizontal Directional Drilling Method (HDD).
The following definitions shall apply within this Specification.
"Owner" shall mean PTT Public Company Limited
"Owner's Representative" shall mean authorized person assigned from Owner to this project.
"Contractor" shall mean the company assigned from Owner to perform this project.
"Supplier" shall mean the company that have the Contract with Contractor for coating of line pipe.
Contractor shall supply all materials, labor, equipment and plant necessary for the satisfactory
completion of the Work under this Specification, including, but not limited to:
- Supply of patch repair material
- Handling, transport and storage of coating materials
- Surface preparation
- Application, curing, inspection and repair of all external coatings
- Handling, temporary storage and loading for transport
2.0 REFERENCE DOCUMENTS
The following documents or approved equal shall form part of this specification to the extent
specified herein:
SP-Q-1002.NGR-XXXX-001 Specification for 3-Layer Polyethylene External Pipe Coating
ASTM D2565 Standard Procedure for Operating Xenon arc-Type (Water-
Cooled) Light Exposure Apparatus With and Without Water for
Exposure of Plastics
ASTM D149 Standard Test Methods for Dielectric Breakdown Voltage and
Dielectric Strength of Solid Electrical Insulating Materials at
Commercial Power Frequencies
ASTM D257 Standard Test Method for DC Resistance or Conductance
ASTM D638 Standard Test Method for Tensile Properties of Plastics
ASTM E28 Standard Test Method for Softening Point by Ring and Ball
Apparatus
ASTM G42 Standard Test Methods for Cathodic Disbonding of Pipeline
Coatings Subjected to Elevated Temperatures
DIN 30670 Polyethylene Sheathing of Steel tubes and of Steel Shapes and
Fittings, Requirements and Testing
DIN 30672 External organic coatings for the corrosion protection of buried
and immersed pipelines for continuous operating temperatures up
to 50 C - Tapes and shrinkable materials
ISO 62 Plastics. Determination of Water Absorption
ISO R 527 Plastics. Determination of Tensile Properties
ISO 974 Plastics. Determination of the Brittleness Temperature by Impact
ISO 4587 Adhesives. Determination of Lap-Shear Strength of High Strength
Adhesive Bonds
DEP 31.40.30.31 External Polyethylene and Polyethylene Coating for Line Pipe
3.0 MATERIAL CONFORMITY AND DELIVERY REQUIREMENTS
3.1 MATERIAL CONFORMITY AND TEST CERTIFICATES
Test certificates demonstrating raw material conformity shall be furnished. Tests shall be
carried out at the manufacturer's own laboratory or at a reputed laboratory and shall be
subject to inspection by a third-party inspector. Test certificates demonstrating sleeve
conformity shall be furnished.
3.2 MARKING
The materials shall be suitably marked and identified with the following minimum
information:
- Manufacturer's name
- Product number and product identification
- Batch or Lot number
- Date of Manufacture
- Expiry date
- Manufacturing standards and specifications
Materials supplied without the foregoing information shall be rejected.
3.3 PACKING AND STORAGE
Materials shall be packed in containers suitable for export and shipping. Primer kits shall
be supplied in bulk kits. The quantity of primer and size of containers and may vary in
accordance with the shipping requirements.
The supplier shall advise the handling and storage requirements for the bulk store, during
transportation and in the field.
4.0 FUNCTIONAL REQUIREMENTS
4.1 MATERIALS FOR NORMAL BURIED PIPELINE PATCH REPAIR
All materials must be able to withstand the extreme minimum and the maximum pipeline
operating temperatures of -10 C and 65 °C respectively and ambient soil temperature for
the expected 40-year coating life without detrimentally affecting their quality, serviceability,
functional requirements and specified properties.
The materials shall be fully UV stabilized and shall resist atmospheric oxygen and ambient
heat for a minimum period of 4800 hours as per DEP 31.40.30.31.
4.2 REPAIR PATCH SHEET MATERIAL
The repair patch sheet shall be manufactured from a radiation cross linked, thermally
stabilized, UV resistant modified polyolefin material.
4.3 HOTMELT ADHESIVE
The repair patch sheet inner surface shall be coated with a controlled thickness of a high
shear strength hotmelt adhesive. The filler tape shall be made from the same adhesive.
4.4 MELT STICK FILLER ADHESIVE
The melt stick filler properties shall be identical to those of the hotmelt adhesive.
4.5 QUALIFICATION
The patch system shall be tested and shall meet the requirements below.
4.5.1 Patch Sheet Material
Property Conditions Unit Requirement Test Method
23 °C, 50 mm/min cross
Tensile Strength MPa 17 minimum ISO R527
head speed
23 °C, 50 mm/min cross
Ultimate Elongation 500% ISO R527
head speed
Impact Brittleness Less than -40 °C ISO 974
Thermal Ageing
100 °C, 100 days DIN 30672
followed by test for
23 °C, 50mm/min cross Change in
Ultimate Elongation ISO R527
head speed Elongation 25%
39 °C, 50% RH, 30 days
cycle: 102 minutes Xe
Weathering
UV light, followed by 18 ASTM D2565
Resistance
minutes combined water
spray and UV light
Followed by test for 23 °C, 50 mm/min cross Change in
ISO R527
Ultimate elongation head speed Elongation25%
Water Absorption 24hrs at 23 °C 0.1% maximum ISO 62
452 Hotmelt Adhesive and Meltstick Filler Adhesive
Property Conditions Unit Requirement Test Method
Softening Point 100 °C minimum ASTM E28
23 °C, 50 mm/min cross
Peel Strength to PE N/cm 15 minimum DIN 30672
head speed
23 °C, 50 mm/min cross
N/cm 3 minimum
head speed
Peel Strength After
conditioning for 100 23 °C, 50mm/min cross
N/cm 45 minimum DIN 30672
head speed days at head speed
70 °C
23 °C, 50mm/min cross 2
Shear Strength N/cm 120 minimum ISO 4587
head speed
23 °C, 50mm/min cross 2
N/cm 400 minimum
head speed
4.5.3 Mastic Filler
Property Conditions Unit Requirement Test Method
Softening Point 75 °C minimum ASTM E28
Peel Strength to 23 °C, 50 mm/min cross
N/cm 5 minimum DIN 30672
Steel head speed
Corrosive Effect 121 °C, 16 hrs No Corrosion ASTM D2671
4.5.4 Patch Functional Properties
Property Conditions Unit Requirement Test Method
No holidays within
Impact Resistance 23 °C, Class C (15 Nm) DIN 30672
30 impacts
Specific Coating 2
23 °C, 100 days Ohm m DIN 30672
Resistance
No holidays when
Freedom from
23 °C tested at 5 kV/mm DIN 30672
Porosity
+ 5 kV
Resistance to
70 °C, 100 days DIN 30672
Thermal Ageing
Followed by test for 23 °C, 50 mm/min cross Change in
head speed Elongation 25% ISO R527
Ultimate elongation
25 mm maximum
Cathodic
increase in
Disbondment 23 °C, 30 days ASTM G42
disbondment
Resistance
radius
4.6 MATERIALS FOR HDD PIPELINE PATCH REPAIR
All materials must be able to withstand the minimum and maximum pipeline operating
temperatures of 20 °C and 65 °C respectively and ambient soil temperature for the
expected 40-year coating life without detrimentally affecting their quality, serviceability,
functional requirements and specified properties.
The materials shall be fully UV stabilized and shall resist atmospheric oxygen and ambient
heat for a minimum period of 4800 hours as per DEP 31.40.30.31.
4.6.1 Repair Patch Sheet Material
The repair patch sheet shall be manufactured from a radiation cross linked,
thermally stabilized, UV resistant modified polyolefin material.
4.6.2 Hotmelt Adhesive
The repair patch sheet inner surface shall be coated with a controlled thickness
of a high shear strength hotmelt adhesive. The filler tape shall be made from the
same adhesive.
4.6.3 Adhesive Filler
The adhesive filler shall be hot melt adhesive and the properties shall be as
shown below.
4.6.4 Melt Stick
The melt stick properties shall be as shown below;
4.6.5 Qualification
The patch system shall be tested and shall meet the requirements below.
4.6.5.1 Patch Sheet Material
Property Conditions Unit Requirement Test Method
Tensile Strength 23 ° C, CHS '50 mm/min MPa 17 minimum ISO R527
23 °C, 50 mm/min cross
Ultimate Elongation 500% minimum ISO R527
head speed
Impact Brittleness Below -40 °C ISO 974
Thermal Ageing
100 °C, 100 days DIN 30672
followed by test for
23 °C, 50mm/min cross Change in
Ultimate Elongation ISO R527
head speed Elongation 25%
39 °C, 50% RH, 30 days
Weathering cycle: 102 minutes Xe
Resistance by test UV light, followed by 18 ASTM D2565
for minutes combined water
spray and UV light
23 °C, 50 mm/min cross Change in
Ultimate elongation ISO R527
head speed Elongation25%
Water Absorption 24hrs at 23 °C 0.1% maximum ISO 62
4.6.5.2 Hotmelt Adhesive
Property Conditions Unit Requirement Test Method
Softening Point 100 °C minimum ASTM E28
23 °C, 100 mm/min
Peel Strength to PE N/cm 60 minimum DIN 30672
cross head speed
60 °C, 100 mm/min
N/cm 10 minimum
cross head speed
Peel Strength After
conditioning for 100 23 °C, 100mm/min 45 minimum
N/cm DIN 30672
days at 70 °C cross head speed
23 °C, 1 mm thickness
2
Shear Strength 50mm/min cross head N/cm 200 minimum ISO 4587
speed
60 °C, 1 mm thickness
2
50mm/min cross head N/cm 40 minimum
speed
4.6.5.3 Adhesive Filler
Property Conditions Unit Requirement Test Method
Softening Point 100 °C minimum ASTM E28
Peel Strength to 23 °C, 100 mm/min
N/cm 60 minimum DIN 30672
Steel cross head speed
Corrosive Effect 121 °C, 16 hrs No Corrosion ASTM D2671
4.6.5.4 Meltstick
Property Conditions Unit Requirement Test Method
Dielectric Strength 23 ± 2 °C KV/mm 10 IEC 243
Tensile Strength 23 ± 2 °C MPa 5 ISO R 527
Ultimate Elongation 23 ± 2 °C 350 % ISO R 527
Hardness 23 ± 2 °C 30 ISO R 868
DIN 30672
Impact Strength 23 ± 2 °C Joules 15
Class C
Holiday Detection 23 ± 2 °C 5 kV + 5 kV/mm DIN 30672
5.0 QUALITY ASSURANCE
5.1 APPLICATION PROCEDURE QUALIFICATION
Contractor shall furnish his product application procedure. The product shall be applied in
accordance with the application procedure to four areas of damaged coating using coated
pipe identical to the line pipe. The applied patch must pass the qualification inspection
below and a destructive evaluation described below.
5.2 APPLICATION QUALIFICATION
Each applicator shall be trained in patch application in accordance with the written
application procedure. Each applicator candidate shall demonstrate proficiency, at the
conclusion of formal theory and practical instruction, by applying three consecutive patches
passing the visual and destructive evaluations described in the Patch Qualification
Inspection and Destructive Evaluation clauses. Failure to pass the evaluations shall require
re-training until successful completion.
Each qualified applicator shall maintain a 90% pass rate for patches applied in production.
Each patch applied in production shall be inspected by an authority independent of
production and judged in accordance with visual and physical inspection criteria of the
Patch Qualification Inspection Clause. All production patches not passing the Patch
Qualification Inspection requirements must be repaired or replaced depending on the
nature of the defect. Once every seven days, or more frequently when application methods
or tools change, one patch produced by the applicator must pass a destructive
examination for air bubbles and voids as outlined in the Destructive Evaluation clause.
The patch shall meet the following visual requirements:
- Adhesive flow shall be evident around all edges of the patch.
- All thermochromic paint shall have converted color.
- There shall be no upstanding edges.
- The patch surface shall be smooth and free of imperfections or other defects
described in the manufacturer's literature.
- The patch shall overlap the factory coating by a minimum 50 mm around the
complete circumference.
- The sleeve shall resist attempts to lift it from the factory coating at both edges
with the fingernail.
5.3 DESTRUCTIVE EVALUATION
When required for qualification or for other reasons, the patch shall be subject to
destructive evaluation by the following test.
A patch of dimension 200 x 300 mm shall be installed on the pipe. A peel test shall be
conducted on a strip of 25 mm x 200 mm. The patch shall be peeled from the substrate
and inspected for voids and loss of adhesion. The acceptance criteria are:
- Less than 5% voids or adhesive failure and
- Anyone area of loss of adhesion must be less than 20% of the total area.
- The peel value shall be > 7 Kg/25 mm
