CW5

CODE OF PRACTICE FOR

THE SELECTION AND APPLICATION OF FIELD
APPLIED EXTERNAL PIPEWORK COATINGS
JULY 1994
J010 ( Rev 08/98)
.
CW5
J010 ( Rev 08/98) - i -
CONTENTS
Page
FOREWORD iii
BRIEF HISTORY iv
INTRODUCTION 1
1. SCOPE 1
2. REFERENCES 2
3. DEFINITIONS 2
3.1 General 2
3.2 Miscellaneous 2
3.3 Mandatory and non-mandatory requirements 2
4. SAFETY AND WELFARE 2
4.1 Environmental protection 2
4.2 Statutory regulations 2
5. SURFACE PREPARATION 3
5.1 General 3
5.2 Existing pipe coatings 3
5.3 Exposed metal surfaces 3
6. SITE COATING TESTS 4
7. USE OF COLD APPLIED LAMINATE TAPE 4
8. RECOMMENDED FIELD APPLIED COATINGS FOR
THE PROTECTION OF PIPEWORK AND FITTINGS 4
9. PREFERRED MATERIALS FOR ANTI-CORROSION
PROTECTION OF WELDED JOINTS 4
10. SYSTEMS FOR OVERWRAPPING EXISTING PIPE COATINGS 4
11. SYSTEMS FOR COATING PARTIALLY EXPOSED PIPE 4
12. REPAIR COATINGS 5
12.1 Repair coatings for dry surfaces 5
12.2 Repair coatings for damp surfaces 5
13. BACKFILLING AND CONSOLIDATION 5
14. INFORMATION CONCERNING SUPPLIERS, PRODUCTS AND APPLICATION
INSTRUCTIONS 6
14.1 General 6
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Page
14.2 Guidance notes for cleaning procedures 6
14.3 Site test methods and values for field applied coatings 6
TABLES
1 Identification of product groups 7
2 Recommended field applied coatings for the protection of pipework and fittings 7
3 Preferred materials for protection of welded joints 8
4 Systems for overwrapping existing pipe coatings 8
5 Systems for coating partially exposed pipe 9
6 Repair systems for dry surfaces 9
7 Repair systems for damp surfaces 10
8 Site tests required by material group 10
FIGURES
1 Extent of coating for partially exposed pipe 5
APPENDICES
A LIST OF REFERENCES 11
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J010 ( Rev 08/98) - iii -
FOREWORD
This specification has been adopted by Transco and is an editorial revision of the former British Gas TransCo
specification BGES/CW5. It reflects the identity and organizational structure of Transco - a part of BG plc.
This Transco specification has been approved for use throughout Transco.
Comments and queries regarding the technical content of this Transco specification should be directed to:
Lead Engineer
Transco
Norgas House
PO Box 1GB
Killingworth
Newcastle upon Tyne
NE99 1GB
Further copies of this Transco specification can be obtained from Dataform Print Management using the print
requisition form G004 quoting the Form Number of this Transco engineering document (not the designation)
and your cost code.
Transco engineering documents are revised, when necessary, by the issue of new editions. Users should
ensure that they are in possession of the latest edition by referring to the Transco Register of Engineering
Documents available on the Transco Information Library.
Compliance with this engineering document does not confer immunity from prosecution for breach of statutory
or other legal obligations.
Contractors and other users external to Transco should direct their requests for further copies of Transco
engineering documents to the department or group responsible for the initial issue of their contract
documentation.
DISCLAIMER
This engineering document is provided for use by Transco and such of its contractors as are obliged by the terms
of their contracts to comply with this engineering document. Where this engineering document is used by any
other party, it is the responsibility of that party to ensure that the engineering document is correctly applied.
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BRIEF HISTORY
First published as BG/PS/CW5
Amended issue published as BGES/CW5
December 1988
July 1994
BG plc 1994
This Transco specification is copyright and must not be reproduced in whole or in part by any means without
the approval in writing of BG plc.
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J010 ( Rev 08/98) - 1 -
CODE OF PRACTICE FOR
THE SELECTION AND APPLICATION OF FIELD APPLIED
EXTERNAL PIPEWORK COATINGS
INTRODUCTION
The majority of gas distribution and transmission metallic pipework and associated metallic fittings is buried
and therefore needs to be protected against corrosion. Buried steel pipework systems are normally protected
by a combination of protective coating and cathodic protection (CP) irrespective of the nature of the
environment. The use of CP for iron systems is uncommon and reliance is normally placed upon imported
backfill and/or additional protective coating measures where the situation demands.
The bulk of distribution and transmission steel pipework for in ground use is purchased ready coated.
However, transit damage could occur, maintenance repairs are required in service and a number of items such
as pipe joints and components are left for treatment in the field.
A wide range of factors should be considered before selection of appropriate materials and processes for
coating and/or repair in the field. The factors to be taken into account include the following:
a) Operating temperature.
b) Type of primary coating (factory applied).
c) Ground conditions.
d) Type of labour available.
e) Complexity of shape to be coated.
f) Ambient conditions during application.
There is a wide range of approved commercially available materials from which selection can be made to
meet the particular requirements.
1. SCOPE
1.1 This Transco Engineering Specification* gives guidance on the surface preparation and the coating
processes which are commercially available for field applied external coatings to pipework and gives
guidance on their application.
* Hereinafter referred to as this specification.
1.2 The coating processes are related to product groups which embrace materials of similar
characteristics (see Table 1). For material specifications concerning fusion bonded epoxy powders and
multi-component liquids, reference should be made to CW6: Part 1. For tapes and mastics, refer to CW2.
1.3 Selection of the appropriate material for a particular coating situation should be made by reference
to Tables 2 to 7 inclusive.
1.4 Only materials and product names which have met the performance requirements of CW2, CW6
and listed in The Coatings Register and for which approval in writing has been given by Transco shall be
used. Additions will be made from time to time to the information available in order to cover materials which
are less widely used and new products which are considered to be of sufficient interest.
1.5 Supplements to CW5 are intended to augment information supplied by manufacturers/suppliers and
are available as Application Instructions to all operatives, including those employed by contractors (see
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Appendix A). All Transco Application Instructions are prepared as separate pages, but form part of this
specification and are available on request
2. REFERENCES
This specification makes reference to the documents listed in Appendix A. Unless otherwise specified, the
latest editions of the documents apply, including all addenda and revisions.
3. DEFINITIONS
3.1 General
For the purposes of this specification the definitions given in 3.2 and 3.3 apply.
3.2 Miscellaneous
Contractor: the person, firm or company with whom Transco enters into a contract to which this
specification applies, including the Contractor's personal representatives, successors and permitted assigns.
Engineer: the Engineer appointed from time to time by Transco and notified in writing to the Contractor to
act as Engineer for the purposes of the contract.
3.3 Mandatory and non-mandatory requirements
can: indicates a physical possibility.
may: indicates an option which is not mandatory.
must: indicates a requirement in law and in matters of health and safety.
shall: indicates a Transco requirement.
should: indicates a strong preference, but allows deviations exceptionally.
will: indicates an intention by Transco to do something.
4. SAFETY AND WELFARE
4.1 Environmental protection
All waste materials resulting from coating and wrapping operations must be properly disposed of in
accordance with the requirements of the Environmental Protection Act 1990 (Duty of Care).
When coating operations are being carried out in the vicinity of rivers, lakes or other water courses, special
precautions may be necessary to prevent the possibility of pollution.
Care must be taken to ensure such operations are carried out in accordance with the requirements of the Water
Resources Act 1991.
4.2 Statutory regulations
All operations covered by this Code of Practice are subject to the Health and Safety at Work etc. Act 1974
and other legislation as listed in IGE/SR/12, Appendix 1.
The use and care of protective clothing and other safety aids shall comply with the Personal Protective
Equipment at Work Regulations 1992.
There is an obligation on the employer to ensure that all personnel are made fully aware of relevant safety
aspects, including the dangers of toxic materials, in connection with their works.
Attention is drawn to the Transco publication entitled Handbook on the Safe Handling of Substances in Use
within the Gas Industry or, alternatively, The Computerised Information System for Substances in Use in
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Transco (CISSUB) database. All activities involving these substances shall have been subjected to an
assessment under the Control of Substances Hazardous to Health (COSHH) Regulations 1988.
Containers and any associated packaging must, where appropriate, be marked in accordance with the
Classification, Packaging and Labelling of Dangerous Substances Regulations 1984.
5. SURFACE PREPARATION
5.1 General
The condition of the surface to which a coating is to be applied in the field will directly affect its performance.
Surfaces to be considered are as follows:
a) any existing pipe coating which is required to be overlapped;
b) the surface of exposed metal to be coated.
Details of the appropriate surface preparation and the procedures to be adopted are given in Application
Instruction CA/13.
5.2 Existing pipe coatings
Existing pipe coatings which are to be overlapped should be:
a) checked for adhesion;
b) assessed as to the appropriate removal method (see Application Instruction CA/13,
Table 1);
c) contoured to eliminate crevices or steps;
d) checked for the most appropriate compatible material group;
e) cleaned and primed where applicable in accordance with Application Instruction CA/13 and
the particular group/material Application Instruction.
5.3 Exposed metal surfaces
Two basic methods of surface preparation (cleaning) are available for metal surfaces. These are, in order of
effectiveness:
a) blast cleaning (conventional or recovery systems);
b) wire brushing (mechanical or hand).
The choice of method a) or b) above will be dictated by technical and environmental considerations, the type
of coating to be used and by economic considerations related to the size of the project.
For high pressure transmission pipelines and installations, the preferred method is blast cleaning.
Other methods of surface preparation may be proposed by the Contractor as a variant for consideration by
Transco.
The degree of surface preparation is defined in Application Instruction CA/13, Table 2 against the chosen
field coating group.
Where general corrosion or mechanical damage has occurred, the Engineer will decide what action is
required.
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6. SITE COATING TESTS
It is essential that field testing and inspections be carried out by competent persons on all completed site
coatings. Varying levels of test should be used dependent upon the type of coating in question. The
appropriate tests are specified in the relevant Application Instruction and summarized in Table 8. It is
recognized that 100% holiday testing may not always be possible and, in such cases, its use should be left to
the discretion of the Engineer.
The various test methods and values required, where applicable, are detailed in Application Instruction
CA/14.
7. USE OF COLD APPLIED LAMINATE TAPE
7.1 Generally, heavy duty cold applied laminate tapes are the preferred option. Where difficulty is
experienced in the use of heavy duty cold applied laminate tapes (e.g. conforming to irregular shapes or on
smaller diameter pipes), consideration should be given to the use of light duty cold applied laminate tapes.
7.2 Where soil loading/stressing conditions are anticipated (e.g. at elevated temperatures and in the
presence of high shrinkage clay soil), consideration should be given to overwrapping with cold applied self
adhesive wrapping tape in accordance with Application Instruction CA/1 and with reference to clause 13 on
suitability of backfill.
8. RECOMMENDED FIELD APPLIED COATINGS FOR THE PROTECTION OF PIPEWORK
AND FITTINGS
The pipework and fittings given in Table 2 are divided into three groups with a preferred coating system
identified.
The alternative 1st and 2nd options are also identified in case site or operating conditions preclude the use of
the preferred system.
9. PREFERRED MATERIALS FOR ANTI-CORROSION PROTECTION OF WELDED JOINTS
The products given in Table 3 specify the preferred weld joint coating considered to be most compatible with
the various types and combinations of field/factory applied coating.
Where site or operating conditions preclude the use of the preferred product, options are given, where
appropriate.
10. SYSTEMS FOR OVERWRAPPING EXISTING PIPE COATINGS
When overcoating of existing factory/field applied coating is necessary, the preferred product is given in
Table 4.
Where site or operating conditions preclude the use of the preferred product, an alternative has been given.
11. SYSTEMS FOR COATING PARTIALLY EXPOSED PIPE
Special consideration is necessary for pipework that will not be adequately protected by a cathodic protection
(CP) system and where standard painting systems are not suitable (e.g. pipe risers). The preferred product is
given in Table 5.
Where site or operating conditions preclude the use of the preferred product, an alternative has been given.
The existing coating should be removed and grit blasted to a minimum of 500 mm both above and below
ground level. For pipes other than vertical, this measurement should be to the nearest surface of the pipe to
above and below ground level (see Figure 1).
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FIGURE 1 - Extent of coating for partially exposed pipe
12. REPAIR COATINGS
12.1 Repair coatings for dry surfaces
The main factory applied coating given in Table 6 will require repair when damaged. The preferred repair
system is given in Table 6.
Two further options are given for situations where the preferred method is precluded by site or operating
conditions.
12.2 Repair coatings for damp surfaces
Repairs to coatings which are permanently damp require special products which are tolerant to surface
moisture. Details of these systems related to the factory/field applied coatings are given in Table 7. However,
in all cases, practical steps should be taken to ensure that the surface to be coated is as free from moisture as
possible.
13. BACKFILLING AND CONSOLIDATION
It is important that due care is taken during backfilling and consolidation to prevent damage to any coating.
Imported backfill materials, such as sand, may be deemed necessary in any of the following circumstances:
a) Where brushing mastics have been used.
b) Where excessive soil stresses may be expected (e.g. in clay soils).
c) Where stoney or rocky ground is present. (In these cases, the use of proprietary energy
absorbent perforated plastics shields may also be considered).
d) Where existing backfill material is deemed to be unsuitable.
The additional overwrapping of cold applied laminate tapes with self-adhesive tapes may also be necessary as
detailed in 7.2.
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14. INFORMATION CONCERNING SUPPLIERS, PRODUCTS AND APPLICATION
INSTRUCTIONS
14.1 General
The products used for field applied external pipe coatings, their suppliers and the reference number of the
Application Instructions for the appropriate product groups are listed in The Coatings Register.
The number allocated to each product group is also applied to the associated Application Instruction.
All products should be obtained from an approved supplier and comply with CW2 or CW6: Part 1, as
applicable.
Particular attention should be taken of the manufacturer's instructions concerning the use of materials which
contain toxic or hazardous substances.
14.2 Guidance notes for cleaning procedures
General cleaning information relevant to Application Instructions CA/1 to CA/12 inclusive are contained in
Application Instruction CA/13.
14.3 Site test methods and values for field applied coatings
Information concerning tests, relevant to Application Instructions CA/1 to CA/4 inclusive and CA/6 to CA/11
inclusive are contained in Application Instruction CA/14.
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TABLE 1 - Identification of product groups
TABLE 2 - Recommended field applied coatings for the protection of pipework and fittings
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TABLE 5 - Systems for coating partially exposed pipe
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APPENDIX A
LIST OF REFERENCES
This specification makes reference to the documents listed below (see clause 2).
Statutes and Regulations
Classification, Packaging and Labelling of Dangerous Substances Regulations 1984
Control of Substances Hazardous to Health (COSHH) Regulations 1988
Environmental Protection Act 1990 (Duty of Care)
Health and Safety at Work etc. Act 1974
Personal Protective Equipment at Work Regulations 1992
Water Resources Act 1991
Institution of Gas Engineers (IGE) publication
IGE/SR/12 - Handling of methanol
British Standard
BS 7079 - Preparation of steel substrates before application of paints and related
products
Transco specifications
CW2 - Performance tests for the supply of cold applied wrapping tapes and
tape systems
CW6 - Technical specification for the external protection of steel line pipe
and fittings using fusion bonded powder and associated coating
systems:
Part 1 - Requirements for coating materials and methods of test
Part 2 - Factory applied coatings
CW5 - CA/1 - Cold applied self adhesive overwrap tapes
Supplements CA/2 - Light duty cold applied laminate tapes
CA/3 - Heavy duty cold applied laminate tapes
CA/4 - Grease based tapes
CA/5 - Fillers
CA/6 - Brushing mastics
CA/7 - Shrinkable materials (sleeves, tapes, wraparound materials
and repair patches)
CA/8 - Fusion bonded epoxy powders
CA/9 - Spray applied multi-component liquids
CA/l0 - Brush/trowel applied multi-component liquids for dry
surfaces
CA/11 - Multi-component liquid repair materials
CA/12 - Multi-component liquid coatings for damp surfaces
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CA/13 - Guidance notes for cleaning procedures
CA/14 - Site test methods and values for field applied coatings
Transco publications
Handbook on the Safe Handling of Substances in Use within the Gas Industry
The Coatings Register
Transco data base
Computerised Information System for Substances in Use in Transco (CISSUB).