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The Specification of Heat Shrinkable Sleeve in Pakistan

 

SPECIFICATIONS of HEAT SHRINK SLEEVE

HEAT SHRINKABLE WRAP AROUND SLEEVES FOR CORROSION PROTECTION OF FIELD WELD JOINTS, ON 3-LAYER P.E. COATED PIPELINES OPERATING AT 80°C TEMPERATURE. 

SN-3177/14

 

Clause No. Clause by Clause Specifications.
1. SCOPE

 

These specifications cover the heat shrinkable wraparound sleeves and define the material characteristics and functional properties, qualification tests and quality control program for these sleeves, to be achieved by the manufacturer of product. The sleeves are to be applied for corrosion protection of field weld joints of pre-coated pipes with 3-layer polyethylene Coating comprising of first layer epoxy primer, second layer of copolymer adhesive and on outer layer of extruded radiation cross-linked heat shrinkable polyethylene for operating temperatures not exceeding 80°C. The specifications are applicable to sleeves for line pipe of nominal diameter 6” – 42”. The maximum steel pre-heat temperature for sleeve installation shall be 100-110°C.

1.1 The type and grade of heat shrinkable sleeve shall be suitable for use up to an operating temperature not exceeding 80°C in wet conditions ( as verified by hot water immersion testing) and shall be fully compatible with the factory applied pipe line coatings of 3-layer polyethylene coating. The sleeve shall be suitable for pipes which shall be subjected to Black Bulb temperatures up to 80°C.
1.1.2 These specifications also define the pre-production qualification tests to be carried out on the field joint coating materials.
1.2 TECHNICAL COMPLIANCE

All deviations to this Specifications, other Specifications or attachments shall be stated in the bids

1.3 QUALITY SYSTEM

The MANUFACTURER, which definition shall include Manufacturer’s, Sub- Manufacturers, and suppliers, shall have in effect at all times a QA/QC program certified according to the latest issue of ISO9000/9001/9002. A copy of the ISO certificate verifying conformance to the ISO standards shall be submitted by MANUFACTURER with his offer. Persons performing quality functions shall have sufficient and well defined authority to enforce quality requirements that initiate, identify, recommend and provide solutions to qualify problems and verify the effectiveness of the corrective action. 

 

The MANUFACTURER shall identify in purchase documents to its Sub- MANUFACTURERS all applicable QA/QC requirements imposed by the MANUFACTURER, and shall ensure compliance thereto. On request MANUFACTURER shall provide objective evidence of its QA/QC surveillance of its SUB- MANUFACTURER’S activities. The MANUFACTURER shall submit certified reports of production tests with the materials delivered.

 

The PURCHASER reserves the right to inspect materials and workmanship at all stages of manufacture and to witness any or all tests. The MANUFACTURER shall provide the PURCHASER with a copy of its Manufacturing and Inspection Plant for review and inclusion of any mandatory PURCHASER witness points 30 days after award but prior to the pre-inspection meeting.

2. MATERIALS REQUIREMENTS

All materials supplied shall be strictly in accordance with this specification. The heavy duty high performance shrinkable sleeves shall be manufactured from the cross linked high density polyolefin sheet coated from the inside with a formulated adhesive and bonding primer or other ingredients compatible with the 3-Layer Fusion Bonded Epoxy Polyethylene Coating System. It shall meet the requirements detailed in Table 1. Bidder shall submit an independent Lab Test Report from a reputable Laboratory certifying the test carried out confirming compliance to EN I2068 Class C80 UV/ASTM/DIN standards. 

3. SHRINK SLEEVE THICKNESS AND WIDTH:

The heat shrink sleeve shall provide mechanical protection to the epoxy layer and shall seal onto the epoxy layer and the adjacent line coating. It shall have the following minimum thickness and shall meet the mechanical requirements of EN I2068 Class C80 UV.

 

Backing Thickness: 0.75- 1.00 mm (as supplied)
Adhesive Thickness: 1.00- 1.5 mm (as supplied)
Coating Thickness (Backing + Adhesive) 1.75- 2.5 mm as supplied
Pipe line Operating Temp. Range: 80°C Max.
Suitable for average cut-back lengths: 100 mm – 150 mm

 

The sleeves on the weld joint shall be wide enough so as to overlap onto the main line coating by a minimum of 50mm on each side once installed.

4 CORROSION COATING PROPERTIES
4.1 EPOXY AND SLEEVE PROPERTIES

The joint anti-corrosion coating shall be suitable for an operating temperature not exceeding 80°C in wet conditions.

4.2 EPOXY PRIMER:

The heat shrinkable sleeve coating system shall incorporate application of epoxy primer to bond steel surface and the adhesive sealant. The first layer of the joint coating system preferably be a 100% solids isocyanate-free and shall be two component epoxy of a minimum dry film thickness of 150 microns (app. 6 mils) when applied on the steel surface. The epoxy layer shall be the primary anti-corrosion barrier and  shall be capable of corrosion protecting the steel surface on a stand alone basis. The epoxy primer shall be compatible with the 3-Layer Fusion Bonded Epoxy Polyethylene (High Density) Coating System and Heat Shrink Sleeves. Epoxy Primers Type ‘A’ & ‘B’ must be from the fresh stock, providing 2 years clean Shelf-Life at point in time of shipment. In the bid, the manufacturer shall specify diameter wise usage/consumption of the epoxies for joint coating of 6” – 42” diameter pipe lines.

4.3 ADHESION SEALANT:

The inner surface of the polyolefin sleeve shall be coated with the controlled/specified thickness of the adhesive sealant and shall meet the requirements of Table-1. The adhesive layer shall be free of inclusions, holes, bare patches, gouges or other defects which could adversely affect the performance of the system.

4.4 POLYOLEFIN BACKING:

The sleeve backing shall be fabricated from a thermally stabilized, ultraviolet resistant, polyolefin and shall be radiation cross linked. The backing of the sleeve shall be homogeneous and free from flaws, defects, pinholes, bubbles, cracks and inclusions. It shall meet the requirements of Table-1. Unless otherwise mentioned, the colour shall be Black.

5. PERFORMANCE REQUIREMENTS
5.1.1 The epoxy and sleeves shall, as a minimum, meet the requirements of Table 1. Bidder shall submit with his bid, detailed characteristics of the Heat Shrink sleeves and epoxy to be supplied.
5.1.2 Manufacturer shall ensure that all material proposed for field joint coating have been tested and have met the requirements as agreed with PURCHASER for physical, chemical and electrical properties.
5.1.3 Manufacturer shall ensure that test certificates are provided for all accepted materials, detailing the information as required in this specification.
5.1.4 The self-adhesive layer of the coating adopted shall be homogeneous, free from flaws, defects, pinholes, bubbles, cracks and inclusions.
5.1.5 The corrosion coat shall be resistant to bacterial attack and shall not deteriorate during the design life of the pipe line.
5.1.6 The sleeve shall be resistant to high Ultra Violet light of the Pakistani summer without requiring any sort of painting or covering. To confirm suitability, the sleeve shall be tested for UV resistance as per EN I2068 standard and shall meet the requirements of table 1. An independent lab test report shall be provided to confirm compliance.
5.1.7 To ensure that the sleeve is applicable in the high ambient temperature and Black Body temperatures of Pakistan in the summer, the backing and adhesive shall be of a high enough temperature rating such that it shall be fully installable without damage. It shall not be necessary, nor will it be allowed, to paint or cover the installed shrink sleeve with any protective cover during the peak of the summer. At this time, under the direct sun in the summer and without any protective coating the sleeve and adhesive shall not become soft and the adhesive shall not flow. Any sleeve which exhibits such softness or flow of adhesive when directly exposed to the sun shall be considered unsuitable and rejected. 
5.2 MATERIALS SUPPLY.
5.2.1 The coating materials shall be handled and stored in accordance with Manufacturer’s instructions or as directed by an authorized representative of the coating Manufacturer.

 

TABLE – 1

Performance requirements of Heat Shrink Sleeve System for maximum continuous pipe operating temperature up to 80°C

HEAT SHRINKABLE WRAPAROUND SLEEVES

PERFORMANCE  PARAMETER TEST METHOD UNITS SPECIFICATION VALUE
Full compliance with ENI2068 Class C HT 80 UV requirements EN I2068   Independent Laboratory Test report
EPOXY      
Adhesion of cured epoxy to bare steel ASTM D-4541 PSI >  2,000
Thin film water absorption ASTM D-570 % < 0.1
Cathodic Disbondment at 95°C after 30 days ASTGM  G-42 Mm r < 20
SHRINK SLEEVE BACKING      
Tensile strength @ 23°C ASTM D-638 Psi 2200
Elongation to

 break

ASTM D-638 % >  400
Hardness ASTM D-2240 (Shore D) 55 Min
Volume Resistivity @ 23°C ASTM D-257 Ohm-cm 1 x 1015 (Min)
Heat Aging @ 150°C for 14 days followed by elongation to break at 23°C ASTM D-638 % 350 (Min)
SHRINK SLEEVE ADHESIVE      
Ring and Ball Softening Point of adhesive ASTM E-28 °C 115 ± 10°C
Lap Shear Strength of adhesive @ 23°C

(cross head pulling speed 2”/min) & @ 80°C

ASTM D-1002 N/cm2 OR

N/mm2 OR

Psi

≥ 180 N/ cm2

OR 1.8 N/ mm2 OR 261 Psi

≥ 34 N/ cm2

OR 0.35 N/ mm2  OR 50 Psi

INSTALLED SHRINK SLEEVE SYSTEM      
Peel Strength to Steel @ 23°C EN I2068 N/mm ≥ 1.0
Peel Strength to Factory Coating @ 23°C EN I2068 N/mm ≥ 0.4
Indentation Resistance @ 80°C EN

I2068

Residual thickness>

0.6mm and no Holiday at 15kV

No Holiday at 10 KV
Impact Resistance at 23°C EN I2068 J (Inch-lb) ≥ 11 (95)
Thermal Ageing EN I2068   Pass
Cathodic Disbondment at 80°C after 28 days EN I2068 mmr < 20
Dielectric Breakdown at 23°C A

TM D-149

Kv ≥ 17 KV
Moisture Vapor Transmission of sleeve at 38°C, 90% RH ASTM E-398 Gm / 24hr/ 100 sq.in < 0.08
Water Absorption @ 23°C for 24 Hours. ASTM-D570   0.1 % Min.
Soil Stress Creep Resistance of installed sleeve at 80°C TP-206 Inch after 24

rs

< 0.1
Hot water immersion resistance at 80°C for 120 days ASTM D-870   No de-lamination blisters, or water under sleeves
Holiday Detection     Pass at 20 Kv

 

 

6. TEST METHODS
6.1 APPLICABLE STANDARDS:

The following standards as applicable form part of the specification.

 

Sr. No. Standards Specifications
1. ASTM-D 149 Standard Test Method for dielectric breakdown voltage and dielectric strength of solid electric insulating materials at commercial power frequencies.
2. ASTM-D 257 Standard Test Method for D-C resistance or conductance.
3. ASTM-D 543 Resistance of plastics to chemical reagents.
4. ASTM-D 570 Test for water absorption of plastics.
5. ASTM-D 638 Standard Test Method for tensile properties of plastics.
6. ASTM-D 746 Test for brittleness temperature of plastics and elastomer by impact.
7. ASTM-D 792 Standard Method of Test for specific gravity and density of plastics by displacement.
8. ASTM-D 870 Test Method for Hot water immersion.
9. ASTM-D 1000 Standard Method of testing pressure-sensitive adhesive coated tapes used for electrical insulation.
10 ASTM-D 1002 Standard Test Method for strength properties of adhesives in shear by tension loading (Metal-to Metal)
11. ASTM-D 1044 Test for resistance of transparent plastics to Abrasion (Modified).
12. ASTM-D 1693 Environmental stress cracking of ethylene plastics.
13. ASTM-D 2240 Indentation hardness of rubber and plastics by means of a durometer.
14. ASTM-D 2249 Test Method for Rubber Property (Durometer-hardness)
15 ASTM-D 2671 Standard methods of testing heat –shrinkable tubing for electrical use.
16. ASTM-D 28 Standard test methods for softening point by Ring and ball apparatus.
17. ASTM-E96 Test for water Vapour transmission of materials in sheet form.
18. ASTM-E398 Standard test methods for water Vapour transmission rate of sheet materials using a rapid technique for dynamic measurement.
19. ASTM-G6 Abrasion resistance of pipe line coatings.
20. ASTM G-10 Standard test methods for Bend ability of pipe line Coatings.
21. ASTM-G 14 Standard methods for impact resistance of pipe line coatings (Falling Weight Test).
22. ASTM-G 17 Standard Test Methods for penetration resistance of pipe line coatings (Blunt Rod).
23. ASTM-G 21 Determining resistance of synthetic polymeric materials to fungi.
24. ASTM-G 22 Determining resistance of plastics to bacteria.
25. ASTM-G 42 Standard Test Methods for Cathodic disbanding of pipe line coatings subjected to elevated or cyclic temperatures.
26. DIN-30672 Polyethylene sheathing of steel tubes and steel shapes and fittings.
27. EN I2068 External organic coatings for the corrosion protection of buried of immersed steel pipe lines used in conjunction with Cathodic protection – Tapes and shrinkable materials.
28. ISO 9000/9001/9002 Quality Systems.
7. QUALIFICATION TESTS
7.1 QUALIFICATION INSPECTION:

The wraparound shrinkable sleeves furnished to this specification shall have been tested and met the requirements of Tables 1. As part of the manufacturing test program, for each production batch, the manufacturer shall carry out these tests. The supplier is responsible for the performance of all inspection tests specified herein and may use his own or any other inspection facility and services acceptable to the BUYER. The inspection/test record shall be kept complete and made available to the BUYER.

7.2 ACCEPTANCE INSPECTION:

The following tests shall be carried  out on each batch of the sleeves or upon the sleeve Component, where applicable:

a.    Visual inspection for defects.

b.   Measurement of dimensions.

c.   Hot tensile strength (backing only).

d.   Longitudinal and transverse orientation (backing only).

e.   Elongation.

f.   Adhesive softening point (ASTM E-28)

g.   Adhesive viscosity at 300°F.

h.   Physical Shrinkage Test.

Any condemned material not conforming to this Specification shall be rectified by the Manufacturer at no expense to the PURCHASER. Any condemned tools, instruments, materials or equipment shall be replaced or rectified.

7.3 REJECTION / RETESTING:

Failure to any of the applicable requirements of the specification shall be caused for rejection of the lot represented. Material rejected shall have to be replaced at the Supplier’s /Manufacturer’s cost. 

8. MARKING /TRACEABILITY

Manufacturer shall ensure that all materials are supplied in sealed , damage-free, clearly marked containers or pallets and each heat shrink and epoxy box/packing containers shall be clearly marked for traceability with following information Data:

°      Purchase Order No.

°      Manufacturer’s name.

°      Grade/type of products contained.

°      Batch number of the products.

°      Shelf Life /Expiry dates where applicable.

°      Safety instructions

In addition to the above each sleeve shall be marked as follows:

°      Product Identification No.

°      Date of manufacture /production.

°      Purchase Order No.

9. REQUIREMENT OF SAMPLES

Bidders, introducing a field joint coating system from a manufacturer that has never been used in SNGPL in the past, shall submit a sizeable sample of their coating system for field performance testing. The sample size should be sufficient for coating minimum 10 joints of 42” Dia and should include HS Sleeves, Closure Patches, Primers and any other component required to satisfactorily install the field joint coating system.

10. TRAINING REQUIREMENT:-

 

The bidder shall quote separately for optional 05 days training for two engineers of SNGPL at the manufacturer premises/manufacturing unit at the manufacturer’s country taking into account, all expenses relating  to the training and visit including boarding and lodging of trainees.

 

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