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APGDC - KAKINADA-SRIKAKULAM PIPELINE PROJECT (PHASE-I)


Kind Attn: Mr. Abhishek Agrawal
DRAVUNG/DOCUMENT TRANSMITTAL MECON, New Delhi.

CONTRACTOR'S TRANSMITTAL NO & DATE KPTL/GAIL/KSPP-A-DT-0015 Dated : 26.10.2018


CONTRACTOR'S NAME & ADHITACHIDRESS KYR
CONTRACTOR'S LOCAL CONTACT PERSON Mr. \'ishal Dhongade (MOBILE ' T.N.7506693327)
CLIENT M/s Andhra Pradesh Can Distribution corporation Ltd. (APGDC)
CONTRACT /TENDER NO. APGDC/C&P/KSPL/PL - SEC - II/ 167288/03/ 18 - 19

SUBMISSION FIRST / SECOND / THIRD / FOURTH / FIFTH


SPECIALIST GEN CIVIL / STRL./ ARCH / ELECT / PIPELINE / PIPING / ROT / INST / PED / SED / POSD / SMMS / POD / INSPECTION
(Use separate sheet for each discipline)

CATE MEC Received by MECON Forwarded to Specialist


REV GOR ON
S.N. DOCUMENT NO. DOCUMENT TITLE
NO Y REV
CODE CODE
I ITP - HFW - II 8 - 57 - 01 Manufacturing Procedure Specification 0 A
NIPS - I 8 - 19 - 09 - 01 -00
Manufacturing Procedure Specification 0 A -

Signature Signature :
MPS-CP-18-19-032-01
3 0 A Date (I:NAN) Date (FN/AN)
Manufacturing Procedure Specification (MPS) — 3LPE Coating
WCL-LS-MPS-18-45-01 MANUFACTURING PROCEDURE SPECIFICATION ( LSAW PIPE
0 A
PLANT)
Returned by Specialist Does Collected by
Contractor

Specialist Contractor's Representative


Signature & date Signature & date

CATEGORY CODES A — DRAWINGS WHICH ARE REQUIRED TO BE APPROVED BY MECON

R — DRAWINGS WHICH ARE TO BE SUBMITTED FOR RECORDS/INFORMATION

DOCUMENT DISTRIBUTION - CONTRACTOR — I, SPECIALIST — 1, CLIENT — I, SITE — I / 2, INSPECTION — 1, PROJECT — I

REVIEW CODE REVIEW CENTRE


1 NO COMMENTS
2 PROCEED WITH MANUFACTURE / FABRICATION AS PER COMMENTED DRG / DOCUMENT. REVISED DOCUMENT / DRAWING FtEQD
3 DOCUMENT DOES NOT CONFORM TO BASIC REQUIREMENTS AS MARKED RESUBMIT DOCUCMENT .
R RETAINED FOR RECORDS

Mr
Signature with date
' , Format No. QA/F/021 Rev. 01

ySte' WELSPUN CORP


WELSPU N Document No. MPS/CP/18-19/032/01
Revision 00
Date 31.08.2018
Quality Assurance
Page Page 1 of 10

Document Manufacturing Procedure Specification (MPS) — 3LPE Coating

Manufacturer : Welspun Corp Ltd.

Plant Name & Location : External Coating Plant (Anjar Coating Plant), Gujarat, India

Client : KPTL for Andhrapradesh Gas Distribution Corporation (APGDC)

Project : Kakinada-Srikakulam Pipeline Project (Phase I) (Bid No. 05/51/23QC/APGDC/001(II))

2300113680 Date: 1st September 2018


Purchase Order No.

Wall
Sr. Item Pipe size OD Qty.
thickness (in i ,, t-a
G i de
No. No. (in mm) In Meters
mm)
1 B1 323.9 7.9 API 5L X70 PSL2 (ERW) 6,038
Pipe Size / Pipe Grade : 2 B2 323.9 9.5 API 5L X70 PSL2 (ERW) 6,038
3 Cl 219.1 7.9 API 5L X56 PSL2 (ERW) 6,300
6 D1 114.3 6.4 API 5L X42 PSL2 (ERW) 2,100
Total 90,492

Manufacturing Spec./ • MEC/S/05/21/014 Rev. 0 Edition 1 Dated Feb 2008 : Specification for 3-Layer
Technical Specification/ : Polyethylene Coating of Linepipes
Reference Documents • PJS No. : MEC/23QC/05/21/M/001/S012A PARTICULAR JOB SPECIFICATION

Reference ITP • ITP/CP/18-19/032/01

Revision Record

Rev. Approved by
Description Date Prepared by Reviewed by
No. Welspun Client / TPIA
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00 Issued for approval 31.08.2018 Manager-(QA/QC) I Ar3V9A/gcr, ,,,g+4,74-94g4 4
Checked & R
NameMT-R k V • Sign:
Designation/uRFT: CtE- Date: .30 t),-IS
Verified (Design-in-Charcle):
Name/-fP4 ,,,,A Sign:
Date:

Name of Section-OIL&G
MECON LIMITED/ c-P-i-1
Location-Delhi
Format No. QA/F/021 Rev. 01

WELSPUN CORP
W ELSPU N Document No. MPS/CP/18-19/032/01
Revision 00
Date 31.08.2018
Quality Assurance
Page Page 2 of 10

Document Manufacturing Procedure Specification (MPS) — 3LPE Coating

CONTENTS

Clause No. Description Page No.
1.0 Quality policy 03
2.0 Flow chart 04
3.0 Foreword 05
4.0 Coating application 05
5.0 Application and inspection procedure 05
5.1 Purpose 05
5.2 Glossary 05
5.3 References 05
5.4 Responsibility 05
6.0 Coating system requirements 06
6.1 Procedure qualification test 06
7.0 Sequence of operation for 3LPE coating 06
7.1 Bare pipe receiving 06
7.2 Bare pipe inspection at inlet 06
7.3 Preheating 06
7.4 Abrasive blasting 07
7.5 Preheating 07
7.6 Phosphoric acid treatment application 08
7.7 Chromate treatment application 08
8.0 Application station 08
8.1 Fusion bonded epoxy application 08
8.2 Adhesive application 08
8.3 Polyethylene application 08
8.4 Cooling zone 09
9.0 On line inspection station 09
9.1 End cleaning 09
9.2 Holiday test 09
10.0 Lab test 09
11.0 Final inspection 10
12.0 Yard handling and storage 10

Approved by
Prepared by Reviewed by
Client / TPIA

Tarkesh Rathod Atul Mishra Dr. Smita Kumari


Manager-(QA/QC) AGM-QA/QC GM — (QA/QC)
, Format No. QA/F/021 Rev. 01

V V WELSPUN CORP
VVELSPU N Document No. MPS/CP/18-19/032/01
Revision 00
7 ' ,, r,i5 ,,,•.:, -.,

Date 31.08.2018
Quality Assurance
Page Page 3 of 10

Document Manufacturing Procedure Specification (MPS) — 3LPE Coating

1.0 QUALITY POLICY

Welspun Corp Ltd, Anjar, Gujarat, India aims to maintain its leadership position by
embedding the highest Standards of Quality Management System in each segment of
Welded Steel Pipes (SAWL, SAWH, HFW), Hot Pulled Induction Bends and application of
anticorrosion Coating on Pipes and Bends, by using a Process & risk based approach.
• We are committed to:
o Quality; complying with the requirements of applicable National &
International Standards / specification and continual improvement of the
effectiveness of Quality Management System.
o Understand and consistently satisfying the needs & expectations of our
Customers including applicable statuary and regulatory requirements.
o Have transparency to our Customers and their representatives towards
our Quality Systems, Processes and Practices.
o Perform things right the first time, every time.
o Promote the use of the Process and risk based approach.
o Provide communication for the implementation of effective Quality
Management and of conforming to the Quality Management System &
product requirements to all our employees.
o Up gradation of the Technology used in manufacturing, Inspection &
Testing facility through Innovation.
o Ensure that all levels of our management team are held accountable for
preventing problems, constantly seeking opportunities for continual
improvement, and effectively implementing this policy.
o Ensure that the integrity of Quality Management System is maintained
when changes to the Quality management system are planned &
implemented.
o Ensure the integration of the Quality Management System requirements
into the Organization's business process.
o Ensure that the resources needed for the Quality Management System are
available.
o Provide trainings for the development of our employees.

• This Policy shall be periodically reviewed to ensure that it is appropriate to


Welspun Corp Limited, Anjar and is basis for development of Quality Objectives.
• This Policy shall be understood & communicated to all the employees of Anjar
Plant and shall be available to relevant interested Parties.

Approved by
Prepared by Reviewed by
Welspun Client / TPIA
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Tarkesh Rathod Atul Mishra Dr. Smita Kumari
Manager-(QA/QC) AGM-QA/QC GM — (QA/QC)
Format No. QA/F/021 Rey. 01 • •

WELSPUN CORP
V1/ ELSPU N Document No. MPS/CP/18-19/032/01
Revision 00
Date 31.08.2018
Quality Assurance
Page Page 4 of 10

Document Manufacturing Procedure Specification (MPS) — 3LPE Coating

2.0 FLOW CHART

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* THESE ARE OPTIONAL REQUIREMENT AND TO BE APPLIED IF REQUIRED .

Approved by
Prepared by Reviewed by
Welspun Client / TP1A
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Tarkesh Rathod Atul Mishra Dr. Smita Kumari --z,,,,....-


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Manager-(QA/QC) AGM-QA/QC GM — (QA/QC)
Format No. QA/F/021 Rev. 01

WELSPUN CORP
VVELSPU N Document No. MPS/CP/18-19/032/01
Revision 00
Date 31.08.2018
Quality Assurance
Page Page 5 of 10

Document Manufacturing Procedure Specification (MPS) — 3LPE Coating

3.0 FOREWORD
Coating plant shall do the 3LPE coating as per Client specification.

Raw material used for 3LPE shall be complying with Client specification requirements.

The following application facilities will utilized for 3LPE Coating:

Application Facilities

Application stage Facility at Anjar, Gujarat, India

Coating Application External Coating Plant (Anjar Coating Plant) — ECP3

4.0 COATING APPLICATION

As per raw material, manufacturer's recommendations.

5.0 APPLICATION & INSPECTION PROCEDURES


5.1 PURPOSE
The purpose of this procedure is to provide instructions for carrying out and monitoring
the external 3LPEcoating process on bare pipe surface.

5.2 GLOSSARY

• 3LPE --- Three Layer Polyethylene


• ITP --- Inspection & Test Plan
• NTC --- Not To Be Coated
• R.H --- Relative Humidity
• POT --- Procedure Qualification Test
• EOT --- Electrical Overhead Travel
• TPIA --- Third Party Inspector Agency

5.3 REFERENCES

• MEC/S/05/21/014 Rev. 0 Edition 1 Dated Feb 2008 : Specification for 3-Layer


Polyethylene Coating of Linepipes
• PJS No. : MEC/23QC/05/21/M/001/S012A PARTICULAR JOB SPECIFICATION

5.4 RESPONSIBILITY

The Production Manager or his authorized person is responsible for carrying out the
coating process.

Approved by
Prepared by Reviewed by
Welspun Client / TPIA

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Tarkesh Rathod Atul Mishra Dr. Smita Kumari


Manager-(QA/QC) AGM-QA/QC GM (QA/QC)

Format No. QA/F/021 Rev. 01 'a

WELSPUN CORP
WELSF'U N Document No. MPS/CP/18-19/032/01
Revision 00
Date 31.08.2018
Quality Assurance
Page Page 6 of 10

Document Manufacturing Procedure Specification (MPS) — 3LPE Coating

6.0 COATING SYSTEM REQUIREMENTS


6.1 . PROCEDURE QUALIFICATION TEST
As mentioned in the ITP (ITP NO.: ITP/CP/18-18/032/01, Before start of regular production,
15 pipes shall be coated for PQT and 5 (five) test pipes shall be selected for testing. (out of
5 pipes, 4 fully coated with 3LPE, one pipe partly coated with epoxy & partly coated with
epoxy & adhesive layer). PQT shall be carried out for each pipe diameter on maximum wall
thickness as per clause 7.3 of MECON specification.

7.0 SEQUENCE OF OPERATIONS FOR 3LPECOATING

7.1 BARE PIPE RECEIVING


Bare pipes shall be received from client either by purchase order or as a free issue
material. Pipe shall be unloaded by vacuum crane/Mobile / EOT crane with rubber-padded
hooks. Job No. / Order No. Wall thickness, diameter and other relevant marking details
shall be checked and matched with the received packing list from the pipe manufacturer.
Pipe shall be stored in the yard in stacks physically separated by order No./ job No/
diameter/ wall thickness.
7.2 BARE PIPE INSPECTION AT INLET
Pipes are unloaded by vacuum crane/Mobile/ EOT with rubber-padded hooks on to the
rack. The rack is installed with a slope to ensure pipes natural movement towards the
blast-cleaning conveyor and is equipped with kick out device.
Bare pipe shall be visually checked for steel defects, such as bevel damage, dent, flatness,
scratch, lamination and other contamination.
Each pipe shall be identified by its mill number before starting the cleaning operation.
QC inspector at inlet station shall make sure that all data of pipes found is in order &
matching with packing list.
If pipes are contaminated with oil, grease and other contamination, it shall be cleaned by
solvent cleaning as per SSPC SP-1.
7.3 PREHEATING

Abrasive blasting is more effective on a dry and hot surface. Preheating of pipes before
abrasive blasting shall be carried out. Heating system is equipped with 2 gas fired oven, of
430000 kcal / h. It can heat up to 100 ton steel per hour and up to 100°C.
Preheating of pipe shall be done at least 65 — 85°C. Pipe Temperature, Relative Humidity,
dew point shall be measured by dew point meter and recorded by QC inspector.
Oxidation of cleaned pipe surface (in term of bluing and other apparent oxide formation is
not acceptable. Proper function of pipe temperature monitoring & recording shall be
shown during PQT stage and during regular production).

Appro ed by
Prepared by Reviewed by
Welspun Client / TPIA

Tarkesh Rathod Atul Mishra Dr. Smita Kumari


Manager-(QA/QC) AGM-QA/QC GM — (QA/QC)
Format No. QA/F/021 Rev. 01

WELSPUN CORP
VVELSPU N Document No. MPS/CP/18-19/032/01
Revision 00
Date 31.08.2018
Quality Assurance
Page Page 7 of 10

Document Manufacturing Procedure Specification (MPS) — 3LPE Coating

7.4 ABRASIVE BLASTING

Two Abrasive blasting machines are placed one after another. Each machine consists of
two turbines with 50 hp motors.
Each machine is capable to clean up to Sa 2 1/2 (ISO 8501-1) cleanliness.
Each machine is equipped with dust vacuum suction, grit reclaim system, grit sieving &
spent particle removal.
After blasting, pipes are moved to blowout station where all dusts, shots & grits are blown
out from inside pipe surface.
Pipes received at blasting inspection rack are checked for below mentioned parameters in
accordance with ITP.
• Cleanliness : Sa 2 1/2 (ISO 8501-1)
• Roughness : 50 — 70 p.m
• Degree of dust : Rating — 2 or Class — 2 maximum(ISO 8502-3)
• Salt contamination : 2 pg/cm 2 maximum

Surface roughness shall be checked each pipe by stylus method. The surface being coated
shall not be exposed for a length of time that can result in flash rust and under no
circumstance shall the time be more than 4 h.

All the measuring instruments are calibrated and verified in accordance with approved ITP.

Any pipe, which is not meeting the ITP requirement will be marked as "NTC" and sent for
rectification/re-blasting.

After inspection of bare pipe, coupling may be attached on one end of pipe for smooth
coating. The coupling will be slightly heated to make up for the heat loss at the time of
induction heating due to additional thickness of the coupling.
Optionally masking tape shall be applied at both ends for required coating cut back length.

7.5 PREHEATING

Preheating of pipes at 45°-75°C before phosphoric acid application shall be carried out.
Heating system is equipped with two gas-fired oven of 430000 kcal / hr each. It can heat
up to 100-ton steel per hour and up to 100°C.

Approved by
Prepared by Reviewed by
Welspun Client / TPIA

.._
7 7

----' 1 /

Tarkesh Rathod Atul Mishra Dr. Smita Kumari


Manager-(QA/QC) AGM-CIA/QC GM — (QA/QC)
Format No. QA/F/021 Rev. 01 - 4

`' WELSPUN CORP


VVELSPU N Document No. MPS/CP/18-19/032/01
Revision 00
Date 31.08.2018
Quality Assurance
Page Page 8 of 10

Document Manufacturing Procedure Specification (MPS) — 3LPE Coating

7.6 PHOSPHORIC ACID TREATMENT APPLICATION

The phosphoric acid treatment is done after blasting and thereafter rinsed with high
pressure de-mineralized water. The acid application cabinet is equipped with four nozzles
of 1.5 M 3/Hr. capacity. Phosphoric Acid treatment shall be done as per raw material
manufacturer's recommendation.

7.7 CHROMATE TREATMENT APPLICATION

To enhance the bond strength between the substrate and fusion bonded epoxy layer,
chromate layer is applied using rubber wiper. The pipe temperature before chromate
application shall be 40°-80°C. Chromate application shall be done as per Raw material
manufacturer's recommendation.

8.0 APPLICATION STATION

8.1 FUSION BONDED EPDXY APPLICATION

Pipes are heated by one induction coils of 2000kw and 600-1500 Hz capacity. Pipe surface
temp is recorded using temperature gauge with roller type probe. The temperature shall
be minimum 190°C or as per epoxy manufacturer's recommendation.
Application of epoxy primer is carried out using 10 electrostatic guns max of capacity 1000
kg/hr (no of guns may vary on thickness requirement).

The system is also equipped with fluidized bed with venture pumps, surplus powder
suction & recycling plant.

8.2 ADHESIVE APPLICATION

The system is equipped with lifting platform. It is provided with vacuum feeding unit and a
hopper neck with heating control unit.
Adhesive Extruder capacity of 150 Kg/Hr.
Adhesive film temperature is measured using digital infrared thermometer.

8.3 POLYETHYLENE APPLICATION

The system is equipped with adjustable platform.


It is provided with vacuum feeding unit and a hopper neck with heating control unit.
PE extruder of 550KW and having capacity of 1200 Kg/Hr.
PE film temperature is measured using digital infrared thermometer.

Approved by
Prepared by Reviewed by
Welspun Client / TPIA

Tarkesh Rathod Atul Mishra Dr. Smita Kumari


Manager-(QA/QC) AGM-QA/QC GM — (QA/QC)
--1 Format No. QA/F/021 Rev. 01

Nsf WELSPUN CORP VVELSF'U N Document No. MPS/CP/18-19/032/01


Revision 00
Date 31.08.2018
Quality Assurance
Page Page 9 of 10

Document Manufacturing Procedure Specification (MPS) — 3LPE Coating

8.4 COOLING ZONE

In the cooling zone coated pipe shall be subsequently quenched & cooled in water for a
period which shall sufficiently lower the temp of pipe coating to permit handling &
inspection. This zone is 32 M Long, provided with water distribution system, hydraulic
power units & motors.
Chiller capacity 12 m 3/hr., 75 tr
Cooling water circulation rate 300m 3/hr

9.0 ON LINE INSPECTION STATION

Here the thickness of the applied coating is measured by digital thickness gauge.
Inspection checks shall be in accordance with approved ITP.
If any imperfection appears on coating such as coating damage, the pipe is then sent to the
repair bed for rectification.

9.1 END CLEANING

Brushing machines equipped with 2 electric motors of capacity 60 hp. with adjustable
brush to create bevel to PE.
Brushes to remove coating up to steel and form taper end.
After brushing cutback ends shall be abrading by emery paper, emery disc or mop wheels
for clean the steel surface. Cutback length shall be in accordance with approved ITP.

9.2 HOLIDAY TEST

Each pipe is passed through the holiday ring to check for any discontinuity in coating.
The holiday detector is low pulse D.C. full circle electronic detector with audible & precise
voltage control.
If any holiday observed it is marked and repaired in accordance with approved repair
procedure.
After holiday color codification is given in accordance with approved ITP.

10. LAB TEST

Lab tests on raw materials and coating shall be conducted in accordance with approved
ITP.

Approved by
Prepared by Reviewed by
Welspun Client / TPIA
----
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) L. — sir 1 1. - •

Tarkesh Rathod Atul Mishra Dr. Smita Kumari


Manager-(QA/QC) AGM-QA/QC GM — (QA/QC)
Format No. QA/F/021 Rey. 01 • •

WELSPUN CORP
VV ELSF'U N Document No. MPS/CP/18-19/032/W.
Revision 00
Date 31.08.2018
Quality Assurance
Page Page 10 of 10

Document Manufacturing Procedure Specification (MPS) — 3LPE Coating

11. FINAL INSPECTION


Coated pipes are visually checked. Coating film shall be uniform in thickness and free from
any irregularities. Bevel ends shall be free of coating material.
Repair should be done in accordance with approved repair procedure.
Accepted coated pipes are assigned with unique COAT no i.e. a type of acceptance no from
coating unit) and 1D barcode sticker on both end of pipe. (After final inspection).
Stencil marking at the end of external surface of the coated pipes is carried out in
accordance with approved ITP.
Any coated pipe is not meeting the specification requirements in accordance with
approved ITP; the coating shall be rejected and sent for stripping. After stripping, the pipe
again shall be sent for coating.
12. YARD HANDLING AND STORAGE
After final Inspection, coated pipes are fitted with bevel protectors and lifted from final
skid by EOT/cranes padded with rubber hooks and loaded on trailers for transportation to
stockyard.

Approved by
Prepared by Reviewed by
WeIspun Client / TPIA
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Tarkesh Rathod Atul Mishra Dr. Smita Kumari


Manager-(QA/QC) AGM-QA/QC GM — (QA/QC)