SPECIFICATION THREE LAYER

POLYETHYLENE COATING OF LINE PIPE

SPECIFICATION THREE LAYER POLYETHYLENE

COATING OF LINE PIPE

REVISION HISTORY

PAGE 2 OF 36

APPENDICES
APPENDIX A

SUMMARY OF INSPECTION/TESTING FOR PROCEDURE

QUALIFICATION TEST (PQT) POLYETHYLENE COATING FOR ONE
PIPE DIAMETER

APPENDIX B

SUMMARY OF INSPECTION/TESTING FOR PRODUCTION TESTING

ON FULL POLYETHYLENE COATING SYSTEM FOR ONE PIPE
DIAMETER

APPENDIX C

AIR ENTRAPMENT ASSESSMENT

APPENDIX D

FLEXIBILITY TEST FOR FBE LAYER COATING PQT

APPENDIX E

HOT WATER RESISTANCE TEST FOR FBE LAYER COATING PQT

1.0
1.1

GENERAL
Purpose
This specification defines the minimum technical requirements for the application of
Three Layer Polyethylene Coating to the external surface of line pipe and piping for
buried service from ambient temperature to maximum design temperature, for a
minimum service life of 25 years to be used for the PROJECT.
This specification supplements the codes listed in Section 2.0 of this specification.

1.2

Definitions
For the purpose of this specification, the following definitions shall apply:

2.0

CODES AND STANDARDS

The latest edition, unless specified otherwise, of the following codes and standards
shall establish the minimum standards for the work. MANUFACTURER may use
alternate standards that meet or exceed those listed if approved by COMPANY.
American Society for Testing and Materials (ASTM)
ASTM D570

Standard Test Method for Water Absorption of Plastics

ASTM D790

Standard Test Method for Flexural Properties of Unreinforced and

Reinforced Plastics and Electrical Insulating Materials

ASTM D1238

Standard Test Method for Melt Flow Rates of Thermoplastics by

Extrusion Plastometer

ASTM D1505

Standard Test Method for Density of Plastics by the DensityGradient Technique

ASTM D1525

Standard Test Method for Vicat Softening Temperature of Plastics

ASTM D2240

Standard Test Method for Rubber Property Durometer Hardness

ASTM D3417

Standard Test Method for Enthalpies of Fusion and Crystallisation

of Polymers by Differential Scanning Calorimetry (DSC)

ASTM D3418

Standard Test Method for Transition Temperatures of Polymers by

Differential Scanning Calorimetry

ASTM D4703

Standard Practice for Compression Moulding Thermoplastic

Materials into Test Specimens, Plaques or Sheets

ASTM F372

Standard Test Method for Water Vapour Transmission Rate of

Flexible Barrier Materials Using an Infrared Detection Technique

ASTM G14

Standard Test Method for Impact Resistance of Pipeline Coatings

ASTM G17

Standard Test Method for Penetration Resistance of Pipeline

Coatings (Blunt Rod)

ASTM G42

Standard Test method for Cathodic Disbonding of Pipelines

Subjected to Elevated Temperatures

ASTM G62

Standard Test Methods for Holiday Detection in Pipeline Coatings

British Standards (BS)

BS 7079

Preparation of Steel Substrates before Application of Paints and

Related Products

Deutsches Institut fr Normung (DIN)

DIN 30678

Polyethylene Coatings for Steel Pipes

International Organisation for Standardisation (ISO)

ISO 6964

Polyolefin Pipes and Fittings Determination of Carbon Black

Content by Calcination and Pyrolosis Test Method and Basic
Specification

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 removal of previous
coatings

ISO 8503-1

Preparation of Steel Substrates before Application of Paints and

Related Products-Surface roughness characteristics of blast
cleaned steel substrates. Specifications and definitions for ISO
surface profile comparators for the assessment of abrasive blast
cleaned surfaces

ISO 9001:2000

Quality Management System Requirements

ISO 9004:2000

Quality Management Systems - Guidelines for Performance

Improvements

ISO 11420

Method for the Assessment of the Degree of Carbon Black

Dispersion in Polyolefin Pipe, Fittings and Compounds

European Standard (BN)

EN 10204
Metallic Products - Types of inspection documents
National Association of Corrosion Engineers (NACE)
NACE RP0490

Holiday Detection of Fusion Bonded Epoxy External Pipeline

Coatings of 10 to 30 mls (0.25 to 0.70 mm)

NACE RP0274

High Voltage Electrical Inspection of Pipeline Coatings

Steel Structures Painting Council (SSPC)

SSPC SP1

Surface Preparation Specification No. 1, Solvent Cleaning

Canadian Standard Association (CSA)

3.0

Z245.20

External Polyethylene Coating of Pipe

Z245.21

External Fusion Bonded Epoxy Coating for Steel Pipe.

SPECIFICATION DEVIATION/CONCESSION CONTROL

Any technical deviations to the Specifications and its attachments including, but not
limited to, the Data Sheets and Narrative Specifications shall be obtained by the
MANUFACTURER/VENDOR only through CONCESSION REQUEST format.
CONCESSION REQUESTS require COMPANYs review/approval prior to
implementation of the proposed changes. Technical changes implemented prior to
COMPANY approval are subject to rejection.

4.0

QUALITY ASSURANCE/QUALITY CONTROL

Unless otherwise agreed with COMPANY, the VENDORs Quality System shall fully
satisfy all the elements of ISO 9001:2000, Quality Management Systems
Requirements and ISO 9004:2000, Quality Management Systems - Guidelines for
Performance Improvements.
To ensure that all work is being performed consistently and accurately and to the
requirements of the PROJECT Specifications, the VENDOR shall have in effect at all
times, a QA programme, which clearly establishes the authority and responsibilities of
those responsible for the quality system. Persons performing quality functions shall
have sufficient and well-defined authority to enforce quality requirements that they
initiate or identify and to recommend and provide solutions for quality problems and
thereafter verify the effectiveness of the corrective action.
Quality Systems and Quality Control requirements shall be identified and included in
the COMPANYs Purchase documentation. Based on these requirements the
VENDOR will develop a QA/QC programme which shall be submitted to the
COMPANY for review and concurrence. The VENDORs QA/QC programme shall
extend to MANUFACTURER/VENDOR(s) and/or SUBSUPPLIER(s).

COMPANY reserves the right to inspect materials and workmanship standards at all
stages of manufacture and to witness any or all test. The VENDOR shall supply to the
COMPANY, a copy of the relevant Manufacturing, Inspection & Test Plan (ITP) for
review and approval. COMPANY reserves the right for a pre-production meeting to
discuss and approve the ITP. This document shall be in full accordance with the
VENDOR Document Requirement Schedule.
5.0

MATERIAL AND APPLICATION

5.1

MANUFACTURER/VENDOR shall submit a detailed written description of the coating

equipment, procedure and materials for COMPANYs review. The description shall be
accompanied by full details and results of tests on similar coating, or trials performed
by MANUFACTURER/VENDOR, which document the quality of the finished coating.
Such test results and/or trials shall demonstrate, to the satisfaction of COMPANY, that
MANUFACTURER/VENDOR equipment, procedures and materials can supply a
finished coating meeting the requirements of this Specification.

5.2

The description of the coating procedure shall include:

Preliminary pipe inspection;

Pipe handling, identification and storage procedure;

Pipe cleaning, including acid washing (phosphating);

Pipe pre-heating;

Abrasive Blast Cleaning;

Phosphate Cleaning;

Chromate washing and FBE application method;

Adhesive application method;

Application of PE Layer;

Testing and inspection;

Quality control;

Repair procedures.

The equipment description shall cover all pipe handling, cleaning, coating, testing and
inspection equipment to be used. Details of all materials to be used for pipe coating

shall be provided, including Line Pipe MANUFACTURER, grades and properties for
each of the coating system components.
A procedure for transferring the full traceability of the pipe from the bare pipe to the
external surface of the coated linepipes after coating shall be submitted to the
COMPANY for review and approval.
5.3
6.0

MANUFACTURER/VENDOR shall confirm by his experience and test data,

demonstrating to the satisfaction of COMPANY, that specified thickness of the coating
system will meet the requirements of this specification.
HANDLING AND STORAGE OF MATERIALS

6.1

Acceptance of Pipe

6.1.1

Pipe furnished by COMPANY and received by MANUFACTURER/VENDOR shall be

deemed to be in the custody of MANUFACTURER/VENDOR from the time of receipt
until returned to COMPANY/EPC CONTRACTOR.

6.1.2

MANUFACTURER/VENDOR shall inspect and accept responsibility for each length of

line pipe, and other COMPANY supplied material, immediately on receipt, with the
exception of defective materials that cannot be detected until after blast cleaning.

6.1.3

All pipes shall be checked for bevel damage, weld seam heights, dents, gouges,
laminations and flat ends, corrosion, and other damage. Defects noted shall be
recorded by MANUFACTURER/VENDOR and witnessed by COMPANYs
representative. Inspection of bare pipe for laminations and other steel defects will not
be performed until after blast cleaning.

6.1.4

Bevel protectors shall be removed before the pipe travels through the coating plant
and replaced with same or new caps after the pipe is coated.

6.1.5

Damage caused to pipe while in the custody of MANUFACTURER/VENDOR shall be

reported to COMPANY and repaired by MANUFACTURER/VENDOR to the
satisfaction of COMPANYs representative. The cost of such repair work and the cost
of any material lost shall be borne by MANUFACTURER/VENDOR.
No repair work shall proceed until written procedure has been prepared by
CONTRACTOR and approved by the COMPANY.

6.1.6

Identification marks stencilled on the pipe, shall be recorded by

MANUFACTURER/VENDOR before commencement of surface preparation.
MANUFACTURER/VENDOR shall mark a unique reference number on the inside of
the pipe for tracking during coating operations. After completion of coating, all
identification marks recorded earlier shall be stenciled above the pipe coating.
Certification documents accompanying the pipes shall be preserved by
MANUFACTURER/VENDOR.

6.1.7

All pipes shall be checked for external and internal contamination for items such as oil,
grease, temporary coatings, chlorides or other substances which may affect the blast
cleaning operations.

6.2

Pipe Handling

6.2.1

Pipe shall be handled in a manner to prevent damage to the pipe and its coated
surfaces.

6.2.2

End hooks suitably radiused and lined with plastic or similar approved material, or a
fork lift with suitably padded forks shall be used to pick up pipe. A spreader bar shall
be used between lifting lines. During handling the pipe shall be prevented from
impacts or jars. COMPANYs representative shall be advised of any pipe suffering
impact or jars. Lifting equipment shall be COMPANY approved. Wire ropes shall not
be used in direct contact to lift pipes.

6.2.3

All pipe handling equipment and procedures shall be subject to the COMPANYs
review prior to use.

6.3

Pipe Stacking

6.3.1

Pipe shall be stacked in such a manner so as to prevent damage to the pipe or

coating. Prior to use MANUFACTURER/VENDOR shall submit proposed stacking
arrangements and calculations, including stacking heights, to COMPANY for review
and approval.

6.3.2

All pipes shall be stacked on level ground free from foreign materials, stones and
vegetation and on supports of a proven load bearing capacity. Pipes shall be suitably
spaced from the soil (minimum 150 mm) to prevent any contact with the ground and to
prevent surface water from entering during the entire storage period. Pipe shall be
prevented from exposure to salt spray.

6.3.3

Separation between coated pipe joints shall be provided by use of strips of soft rubber,
rope or other material which will prevent damage to the coating. Pipe stacks shall be
of the same diameter, wall thickness and grade of pipe and shall be clearly marked.

6.3.4

Slings or non-metallic straps shall be used for securing loads during transportation.
They shall be suitably padded at contact points with the pipe.

6.3.5

The maximum outdoor storage time for coated pipes shall be 12 months.

6.4

Damage to Pipe Ends

6.4.1

All major damage to pipe ends/bevels, including dents or gouges, shall be repaired by
removal of damaged pipe material and rebeveling. No welding on the pipe surface
shall be allowed.
Minor damage to pipe ends/bevels may be repaired by grinding. Minor damage shall
mean damage that is not over 0.025 inch in depth and the number of such damages

not more than 3 per pipe. The COMPANYs representative shall be consulted for
damage deeper than 0.025 inch.
6.4.2

Repair by grinding on the pipe ends/bevels outside diameter shall not reduce the wall
thickness to less than the minimum requirements of pipes specification when
measured using ultrasonic thickness measurement equipment and provided the
hardness does not exceed specified limits.

6.4.3

Pipe identification numbers shall be preserved during repair and due allowance for cutoff ends shall be made in the tally of pipe lengths returned to COMPANY.

6.4.4
6.5

Any reduction in pipe lengths shall be input to CONTRACTORs pipe tracking system.
Material Control Records

6.5.1

MANUFACTURER/VENDOR shall record the receipt, issue return or disposal of all

materials supplied by COMPANY and shall permit inspection of those records by
COMPANY at all reasonable times. In particular, the records shall reference the pipe
number of each pipe.

6.5.2

MANUFACTURER/VENDOR shall submit details of material control recording

procedure to COMPANY for review and approval prior to commencement of the works.

6.6

Handling and Storage of Coating Materials

6.6.1

Material used for coating provided by SUB-VENDOR shall be clearly marked with the
following details:

Name of Manufacturer;

Material identification;

Batch number;

Date of manufacture and Expiry Date;

Quantity;

Manufacturing standard;

Safety Instructions.

6.6.2

Materials shall be handled and stored in accordance with applicable safety regulations
and the material Manufacturers recommendations, and shall be used according to the
Manufacturers batch sequence.

6.6.3

The containers or packages of materials shall be properly handled in order to avoid

damage.

6.6.4

Storage temperatures for coating materials shall be as specified by the Manufacturer.

6.6.5

Site Storage of Coated Pipe

Maximum storage time for coated line pipe shall be no greater than 12 months

7.0
7.1

COATING MATERIALS
General
The pipe coating procedure shall consist of the following:

Preliminary pipe inspection;

Pipe handling procedure, identification and storage;

Pipe cleaning, including acid washing (phosphating);

Pipe pre-heat;

Pipe cleaning/dirt and grease removal and blast cleaning abrasives and
technique;

Chemical pre-treatment;

Chromate pre-treatment;

Application of Fusion Bond Epoxy (FBE) layer;

Application of adhesive layer;

Application of Polyethylene (PE) layer;

Inspection and testing;

Repair procedures.

The SUB-VENDORs trade name and data sheets for each coating material proposed
by the MANUFACTURER/VENDOR shall be submitted for COMPANYs approval prior
to the placing of any order for coating work.
7.2

FBE Powder

7.2.1

All packages of powder shall be marked with the following data as a minimum.

SUB-VENDOR;

Material identification;

Batch number;

Place and date of manufacture;

Expiration date (Shelf Life);

Manufacturing standard;

Health, Safety and Environment Instructions;

Storage instructions (storage shall normally be at a temperature not greater than

25C).
Hazard warnings

Quantity

Manufacturing standard

Material not supplied with the above information shall not be used.
7.2.2

A production batch is assumed to be a quantity of powder produced from one charge

of the extruder. No container shall contain powder from more than one batch.

7.2.3

The MANUFACTURER/VENDOR shall obtain the SUB-VENDORs test records for

typical results of the following data:

Sieve analysis;

Gel time;

Infrared scan;

Density;

Moisture content;

Thermal analysis (including glass transition temperature);

Adhesion;

Impact resistance/impact strength;

Hardness;

7.2.4

Flexibility;

Dielectric breakdown voltage;

Abrasion resistance;

Penetration resistance;

Volumetric electrical resistivity;

Thermal shock resistance;

Thermal conductivity;

Water absorption;

Water vapor transmission;

Salt spray resistance;

Hot water resistance;

Cathodic Disbondment 28 days at ATT & UTT witnessed by COMPANY

approved independent inspection agency;

Strain polarization cracking;

Cure (by glass transition temperature);

Stability.

Each FBE batch shall be accompanied by a certificate (EN 10204) stating the following
tests have been carried out on every batch and results are in accordance with the
SUB-VENDORs product specifications:

Sieve analysis;

Gel time;

Infrared scan;

Density;

Moisture content;

Thermal analysis.

For each batch of powder, the MANUFACTURER/VENDOR shall, in the presence of

the COMPANYs representative, take three 1 kilogram samples of powder.
7.2.5

One sample shall be given to the COMPANYs representative, one sample shall be
stored by the MANUFACTURER/VENDOR at a temperature not to exceed 20C for a
period to be agreed upon between the MANUFACTURER/VENDOR and COMPANY.

7.2.6

The third sample shall be used by the MANUFACTURER/VENDOR to check the

stability of the powder by measuring the following properties:

Gel time;

Sieve analysis;

Flexibility;

Impact resistance;

Adhesion;

Density;

Moisture content;

Cathodic Disbondment 28 days at ATT & UTT;

Cathodic disbondment tests to be witnessed by COMPANY. This test shall be

undertaken at least 8 weeks in advance of coating operations to prove quality of the
applied powder.
7.2.7

The MANUFACTURER/VENDOR shall ensure that the tests on a detached coating

film, as defined below, are carried out by the epoxy powder Manufacturer once per
year or each time a powder formulation change is made.
The tests shall be carried out on detached coating samples which have been prepared
by application on 6 mm thick PTFE coated polished steel plates.

7.2.7.1

Micro-Sectioning
A cross section of the cured film shall be examined at a magnification of X100. The
film shall be homogeneous and essentially free of voids or other defects.

7.2.7.2

Tensile Strength/Elongation
Test specimens shall be tested at a strain rate of 1 mm/min. Values for tensile strength
shall be quoted as maximum strength and strength at break, as well as the elongation
at yield and break.

7.2.7.3

Dielectric Strength
The dielectric strength and dielectric test method of the cured material shall be quoted
by the MANUFACTURER/VENDOR. Units of dielectric strength shall be KV/mm.

7.2.7.4

Water Permeability
The water permeability and permeability test method of the cured material shall be
specified by the MANUFACTURER/VENDOR. Units of water permability shall be
g/24hr/m/m together with the test method.

7.2.7.5

Water Absorption
The quantity of water absorbed after a 3 months immersion test at ATT shall be
quoted by the MANUFACTURER/VENDOR.

7.3
7.3.1

Adhesive
The adhesive layer shall be polyethylene copolymer which shall be providing a
sufficient adhesion between the FBE corrosion coating and the polyethylene
coating. The adhesive layer shall have the following characteristics.

Properties

Test Method

Unit of Measure

Limits

Melt flow rate

ASTM D 1238

g/10min

1.4

Vicat softening point

ASTM D 1525 1 10N

oC

94

Density at C

ASTM D 1505

g/cm3

0.92

Tensile
yield
strength at 23oC

ASTM D 638

Nmm2

>15

Ultimate elongation
at 23oC

ASTM D 638

>850

7.3.2

MANUFACTURER/VENDOR shall obtain the SUB-VENDORs production test records

for each batch of adhesive giving the following data:

Water absorption;

Water vapor transmission;

Shelf life;

Adhesion to FBE and polyethylene layers at ATT and UTT;

Density;

Melt flow index;

Ultimate elongation;

7.3.3

The MANUFACTURER/VENDOR shall test one batch in every ten for compliance with
the MANUFACTURERs certificates described in section 10.3.2 of this Specification for
adhesion, density and melt flow index.

7.4

Polyethylene Material

7.4.1

The polyethylene shall be suitable for use up to design temperatures of the pipeline
and suitable for a 3-layer coating system, and shall match the following properties.
PROPERTIES

ASTM TEST

UNITS

VALUE

CONDITIONS

Base

D1505

g/cm3

0.941

Compound

D1505

g/cm3

0.951

Melt flow rate

D1238

g/10min

0.32

Condition E

Yield

D638

MPa

19.0

@ 50 mm/min

Ultimate

D638

MPa

25.0

(2 in/min)

Elongation

D638

750

Flexural
Modulus

D790

MPa

590

Softness Point

D1525

119

Hardness

D2240

Shore D

D62

Water Absorb.
Rate

D570

0.1

@ 24 hrs

Water Vapors

F372

g/ 100in2

0.8

90% RH, 100F

DENSITY

TENSILES

Method 1

(Vicat)

NOTE:
Tests performed on compression molded plaques made in accordance with ASTM
D4703 Procedure C

7.4.2

ASTM D1928 Procedure C

Dielectric Strength
Carbon Content
Melting Point (ASTM D3417)

220kVlcm
2.18%
129C

Penetration - Probe Dia.

Sample thk.

6.35mm
1mm (ASTM G17)

The MANUFACTURER/VENDOR shall obtain the follow from SUB-VENDOR for each
batch of material the following certified data for each batch of material:

Density;

Melt flow index;

Shore hardness;

Elongation;

Tensile strength;

Melting point

Moisture content;

Carbon black content;

Carbon black dispersion;

Oxidation induction time;

Dielectric breakdown voltage (one off declaration);

Environmental stress cracking resistance (one off declaration);

Brittleness temperature (one off declaration);

7.4.3

The MANUFACTURER/VENDOR shall test one batch in every ten for compliance with
the MANUFACTURERs certificates described in section 10.4.2 of this Specification.

7.4.4

The MANUFACTURER/VENDOR shall provide the information detailed in section

10.4.2 of this Specification for the COMPANYs approval prior to the start of coating
operations.

8.0

COATING PROCEDURE
The pipe coating procedure shall consist of the following:
Preliminary pipe inspection;
Pipe handling, identification and tracking;
Testing for soluble salts;
Pipe cleaning, including acid washing (phosphating);
Pipe pre-heat
Blast cleaning
Chemical pretreatment
Chromate pre-treatment
Application of Fusion Bond Epoxy (FBE) layer
Application of adhesive layer
Application of Polyethylene (PE) layer

9.0
9.1

CLEANING AND SURFACE PREPARATION

Inspection before Cleaning
Pipes shall be inspected for corrosion in accordance with ISO 8501 Part 1. Pipes in
conditions A and B only shall be accepted for coating.

9.2

Cleaning Prior to Blast Cleaning

9.2.1

Before the blast cleaning, all surface contaminants such as oil, grease, tar, salt, or
other contaminants on the pipe shall be removed by solvent cleaning (xylol-mineral
spirits or similar) followed by steam or hot bath cleaning.

9.2.2

A COMPANY approved salt meter shall be used to carry out salt tests before washing
and after blast cleaning (after first blast if two blast system is used). One test shall be
carried out at each end and one at the center of the pipe. The frequency of the salt
testing shall be one pipe per 500 pipes.
The salt test meter shall be calibrated and used in accordance with the
MANUFACTURERs recommendation. The acceptance criteria shall not exceed 20
micrograms/cm.

9.2.3

The removal of hydrocarbon contamination shall be confirmed by a water spray test,

where a fine spray is applied to the surface and uniform wetting confirms the removal.
This check shall be performed before and after blasting, as a pre-qualification test and
as a minimum, once per 100 items during production.
Items found to be contaminated shall be cleaned as above and reblasted if testing after
blasting establishes that salt or hydrocarbon contamination is still present. The
remainder of the batch concerned shall all be checked individually.
All water used for rinsing or cleaning purposes shall be potable with less than 200 ppm
total dissolved solids and 30 ppm chlorides.

9.3

Surface Preparation

9.3.1

After cleaning and prior to abrasive blasting the pipeline shall be uniformly heated to
60C to remove all moisture and preclude any condensation of moisture on the pipe
after blast cleaning.

9.3.2

Ends of the pipe shall be fitted with plugs so as to prevent entry of abrasive into the
pipe during the blast cleaning operation. The selection of steel abrasives for blast
cleaning shall be in accordance with BS 7079 Parts E2 to E4 to provide the anchor
pattern.

9.3.3

Using dry blasting techniques only, the exterior surface of the pipe joints shall be
abrasively cleaned to remove all mill scale, and other impurities from the surface.
The selection of steel abrasive for blasting shall be in accordance with BS 7079 Parts
E2 and E4 to provide the anchor pattern. A combination of grit or steel shot to remove
mill scale, and other surface impurities is acceptable. The use of sand is not permitted.
Blasting abrasive shall be kept dry, clean and free from contamination. When
recovered metallic grit systems are used, a stabilized working mix of blast cleaning
material shall be established and maintained by frequent small additions from fresh or
cleaned stock at a rate sufficient to replenish consumption. Large additions of new
material shall be avoided. Blasting and other dust producing areas shall be kept
separate from coating application areas.
No blast cleaning shall take place when the prevailing relative humidity is greater than
85 percent unless pipe is preheated to at least 3C above the dew point or 25C
whichever is greater.

9.3.4

The surfaces of the pipes shall be blasted until a finish of ISO 8501-1 Sa 2(Steel
condition A or B) is attained.

9.3.5

The surface profile (anchor pattern) shall be between 50 and 100 microns or as
recommended by the FBE Manufacturer.

9.3.6

The blast cleaned surface shall not be contaminated with dirt, dust, metal particles,
hydrocarbons, water, chlorides, sulfates or any other foreign matter which would be

detrimental to the coating. If pipe was varnish coated, it shall be checked with
magnifying glass (X30) to confirm no residues of varnish remain in the anchor pattern
valleys.
9.3.7

Prior to the coating application, the exterior surface shall be thoroughly inspected
under adequate lighting. All surface imperfections such as slivers, scabs, burrs,
gouges, or sharp edge defects, shall be removed by chiselling or grinding.

9.3.8

Any pipe length containing a dent shall be set aside for the COMPANYs
representative to determine its disposition. Gouges in a dent shall not be grind without
COMPANYs approval.
Pipes with chieselled and ground areas greater than 25 mm diameter shall be
reblasted to meet the requirements as specified in section 11.3.4 and 11.3.5 of this
Specification.

9.3.9

9.3.10

No grinding shall be permitted which reduces the wall thickness of the pipe as stated in
section 9.4 of this Specification.

9.3.11

Any dust or loose residue that has accumulated during blasting and/or grinding
operations shall be removed by the use of clean compressed air or by vacuum
extraction. Alternative methods for removing dust and lint shall require approval of the
COMPANY.

9.3.12

The total elapsed time between the start of blasting of any pipe and the heating of that
pipe to the specified temperature shall not exceed the following time-humidity table:
Percent Relative Humidity

Elapsed Time Hours

85

0.5

80

1.0

70

1.5

60

1.75

50
2.0
Any pipe surface not processed within the above time-humidity table shall be
completely reblasted before coating.
9.4

Chemical Pretreatment

9.4.1

Before application of epoxy powder, the surface to be coated shall be heated to a

temperature of 120 to 150F (49 to 66C), spray washed with a solution of Oakite 33
(phosphoric acid) and spray rinsed with clean hot water 160 to 180F (71 to 82C) to
remove all acid residue.

9.4.2

A uniform pH of 1 or less shall be maintained over the entire surface of the treated
area.

9.4.3

Treatment time shall be a minimum of 20 seconds with the pipe surface temperature
between 110F and 150F (43 to 66C).

9.4.4

High pressure water rinse at 500 to 1000 psi (35 to 67 bar) will be used to remove any
treatment residue. A minimum of 22 gallons of fresh water per 100 square feet of pipe
surface should be used (10 liters/m).

9.4.5

The pH of the pipe surface shall be determined both before and after the fresh water
rinse at a minimum frequency of once per hour. The measured pH shall be as follows:
Before the fresh water rinse:

1 to 2;

Following the fresh water rinse:

6 to 7;

9.4.6

Data sheets and supporting documentation for the proprietary phosphoric acid system
to be used shall be provided. The documentation shall verify that the chemical is
suitable for the treatment of line pipe before the application of the specific fusion
bonded epoxy powder being applied and the final coating will meet the requirements of
this specification.

9.5

Chromate Pretreatment

9.5.1

The MANUFACTURER/VENDOR shall ensure temperature of the substrate is

maintained between 50 and 80C and chromate solution temperature does not exceed
60C.

9.5.2

The diluted solution of chromate (10%) shall be applied to the blast-cleaned steel
surface by a suitable method such as rotating brushes that results in a completely
wetted surface with a uniform film of chromate solution remaining on the surface. Any
drainage concentration, drips, etc., shall be removed by wiping or other suitable
means. Chloride concentration of the chromate solution shall be checked every shift
and shall be maintained at less than 30 ppm.

9.5.3

The coating shall be smooth, even, free from runs, drips, or excessive application and
be of light brown color, lightly adherent with no flaking of the coating. The chromate
coated steel must be thoroughly dried immediately after application and shall be
achieved by boiling off any residual solution on the surface.

9.5.4

The MANUFACTURER/VENDOR shall be fully responsible for adherence to local

regulations and material safety data sheets, for using chromate solution.

10.0

COATING
The application of the coating shall be in accordance with the
MANUFACTURER/VENDORs procedures, which shall require prior approval from
COMPANY.

10.1

FBE Layer Coating

10.1.1

The FBE coating shall be applied to a minimum thickness of 250 to 350 microns or as
otherwise approved by the COMPANYs representative.

10.1.2

Prior to application of the fusion bonded epoxy powder, the powder application and
recovery systems shall be thoroughly cleaned. During coating application no
container/hopper shall contain powder/pellets from more than one batch of material. In
addition, the spray booth shall be cleaned of excess powder at the end of each shift.

10.1.3

The coating shall be applied by electrostatic spray with the pipe at earth potential and
the epoxy powder charged to high potential.

10.1.4

The pipe shall be uniformly preheated using induction heating coil to a temperature of
220C to 235C (425 to 450F) as per MANUFACTURERs recommendation. The pipe
metal temperature shall not exceed 260C (500F).

10.1.5

Pipe temperature shall be checked periodically by tempil sticks or a recording

pyrometer. If a pyrometer is used, it shall be checked for error not less than every four
hours against a calibrated temperature-measuring instrument.

10.1.6

Oxidation of the steel prior to coating in the form of blueing or other apparent oxide
formation is not acceptable. If such oxidation occurs, the pipe shall be set aside and
recleaned.

10.1.7

Prior to starting the fusion bonded epoxy powder application, the recovery systems
shall be thoroughly cleaned to remove any unused powder.

10.1.8

The use of recycled powder shall not be permitted. Different brands of powder shall
not be used.

10.1.9

During application, the bevelled ends and pipe bore shall be protected against
mechanical damages and from contamination with coating material.

10.1.10 Each pipe end shall be left uncoated so that a minimum 25mm FBE to protrude on
steel beyond the polyethylene coating layer cutback.
10.2

Adhesive Layer Coating

10.2.1

The adhesive shall be applied to a minimum thickness of 200 to 350 microns or as

otherwise approved by the COMPANYs representative.

10.2.2

The MANUFACTURER/VENDOR shall ensure that the rollers push adhesive film to
eliminate any air entrapment or voids. The adhesive layer shall be applied before gel
time of the FBE has expired by using either the cross-head or lateral extrusion
technique. Application of the adhesive shall not be permitted after the FBE has fully
cured. The MANUFACTURER/VENDOR shall establish to the satisfaction of
COMPANYs representative that the adhesive is applied within the gel time window of
the FBE and at the temperature recommended by the adhesive Manufacturer. The
MANUFACTURER/VENDOR shall state the proposed minimum and maximum time
interval between FBE and adhesive applications at the pipe temperature range and
overlap.

10.3

POLYETHYLENE LAYER COATING

10.3.1 The high density polyethylene layer shall be applied to a minimum thickness of 2.5 mm
for a pipe diameter equal or greater than 500 mm (20 inch) and 2.0 mm for pipe
diameter less than 500 mm (20 inch).
10.3.2 High density polyethylene may be applied by either the cross-head or lateral extrusion
technique. The polyethylene shall be applied over the adhesive within the time limits
established during pre-production testing.
10.3.3 The coating shall be cooled to below 60C before handling.
10.3.4 The coating cutback from the ends shall be 150 +0/-20 mm. The ends of the coating
shall be beveled at 45. There will be no change in the cutback without approval of the
COMPANY.
10.3.5 Immediately after the coating is fully cured, pipe identification marks shall be reapplied to
the coated pipe using a method approved by the COMPANYS representative. Additional
identification shall be made in order to monitor the coating and test batches. All such
markings shall be within 2 meters of the pipe end.
11.0
11.1

INSPECTION AND TESTING

General
In addition to the tests required on the material batches, the
MANUFACTURER/VENDOR shall perform the tests detailed below on finished
coatings to demonstrate compliance with this specification. Details of all inspections
and testing shall be fully documented in accordance with Section 14 of this
Specification. Inspection activities by the COMPANY or COMPANYs designated
representative will be detailed in the attachments to the purchase order.

11.2

Coating Procedure Qualification Testing

11.2.1

Prior to commencing full production, two pipes shall be coated with each pipe having a
single layer FBE and eight with pipes having a full coating system. In accordance with
the coating procedure specifications, coating shall be witnessed by the COMPANYs
representative for Qualification Testing.

11.2.2

The two FBE coated pipes shall be subjected to complete set of tests as specified in
Appendix-A.

11.2.3

The COMPANY shall select samples from four full system coated pipes. Samples shall
be inspected and tested as per requirements detailed in Appendix-A.

11.2.4

Pipes selected for PQT testing shall pass all the criteria contained in Appendix-A
before production commences.

11.3

Production Testing

11.3.1

Production testing shall be performed at the frequency shown in Appendix-B.

11.3.2

The frequency of tests shown in Appendix-B will be for normal production operations.
This frequency of tests will also be required after a change in normal operations as a
result of material change or quality acceptance.

11.3.3

One sample of coated pipe shall be sent to COMPANY for storage. Samples shall be
taken from the same piece of pipe as the cathodic disbondment test samples and
should be one meter long and half the circumference of the pipe.

11.4

Visual Inspection
The following external surfaces of the coated pipe shall be carefully inspected:

Adjacent to the cut-back at each end of pipe;

Within the body of the pipe;

Adjacent to the longitdudinal welds, if any.

The coating shall be of natural colour, and gloss, smooth and uniform, and shall be
blemish free, with no dust or other particulate inclusions. The coating shall not show
any defects such as blisters, scratches, wrinkles, engravings, cuts, swellings, excess
material thickness, disbonded zones, air inclusions, tears, voids, etc.
11.5

Coating Thickness

11.5.1

The thickness of the cooled polyethylene coating system shall be checked using an
approved magnetic or electro-magnetic thickness gauge. Calibration of this gauge
shall be rechecked every 2 hours. The SUPPLIERs proposed thickness gauge type,
MANUFACTURER and model shall be submitted to COMPANY for review and
Approval.

11.5.2

Measurements shall be made at 12 points uniformly spaced over the length and
circumference of pipe.

11.5.3

The minimum total coating thickness on pipe surface and longitudinal welds for 20
and above pipeline shall be not less than 3 mm.

11.5.4

Any individual reading less than the requirements of section 14.5.3 of this Specification
shall be cause for the coated pipe length to be rejected. Such pipe may be held for
further inspection and possible acceptance by the COMPANYs representative.

11.6

Holiday Detection

11.6.1

Each pipe shall be inspected for holidays over 100% of its coated surface using a high
voltage DC detector, in accordance with ASTM G62 and NACE RP0490.

11.6.2

The detector shall be a type which maintains complete contact with the coating. It may
be either constant or pulsed voltage type. If constant voltage type, holiday detection
shall be carried on a dry coating. The operating voltage between electrode and pipe
shall be checked at least twice per working shift, and shall be maintained at a voltage
calculated as 1kV for each 0.1mm of coating thickness with a maximum of 25 kilovolts.

11.6.3

MANUFACTURER/VENDOR shall demonstrate to the COMPANY that setting of the

detector is satisfactory for detecting pin holes. This setting will be checked once every
two hours. The correct travel speed shall be determined by consistent detection of an
artificial pinhole made in a good coating sample but shall not exceed 300 mm/s.

11.6.4 All holidays and other defects shall be marked for subsequent repair and retesting. On
retesting, no holidays shall be permitted in the final coating. The coating system shall
be free from holidays.
11.6.5

The number of holidays for each pipe length shall be recorded. Coated pipe having
holidays in excess of 1 per 2 square meters shall be stripped and recoated at no
additional cost to the COMPANY.

11.6.6

If
excess
occurrence
of
holidays
on
successive
pipes,
the
MANUFACTURER/VENDOR shall immediately stop the coating operation to
determine the cause and remedy it.

11.6.7

Holiday detection shall be carried out in accordance with NACE RP0274

11.7

Adhesion Test

11.7.1

The coating adhesion shall be determined in accordance with either of the methods
described in DIN 30678. The test shall be performed at 90C and UTT in accordance
with NF A 49-711. Test shall be carried out on body and as well as on the longitudinal
weld.

11.7.2

Three samples shall be cut from each of 4 random selected pipes and tested for
resistance to indentations in accordance with the method stated in DIN 30670. The
test shall be performed at the ATT and UTT in accordance with 4.2.5 and 5.3.5 of DIN
30670

11.7.3

The failure mode shall be recorded. The failure should occur at the
adhesive/Polyethylene interface or adhesive/FBE interface or cohesively in the
polyethylene layer. If failure should occur at the FBE/steel interface this will be
considered a total failure of the system.

11.7.4

During adhesion testing, samples of coating shall be examined using 30X microscope
for air entrapment on the body of the pipe or in the longitudinal welds.

11.8

Penetration Indentation Test

11.8.1

Three samples shall be cut from each of four pipes and tested for resistance to
indentations in accordance with the method stated in NF A 49-711 or ASTM G17. The
test shall be performed at UTT.

11.8.2

Maximum penetration depth exhibit after testing shall not exceed 0.2 mm at ATT and
0.3 mm at UTT.

11.9

Impact Test

11.9.1

A sample of coated pipe shall be impact tested in accordance with the procedures
specified in DIN 30670. Tests shall be performed at temperatures of ATT and UTT.

11.9.2

Acceptance criteria for the number of blows per coating breakdown shall be as
detailed in both DIN 30678 and NF A 49-711.

11.9.3

Impact test shall be also carried at UTT and the results shall be recorded for
COMPANYs representative evaluation.

11.9.4

Impact resistance of pipe with FBE coating alone shall be assessed in accordance with
the procedure described in DIN 30670

11.10 Cathodic Disbondment Test

Cathodic disbondment testing for procedure qualification and production shall be
performed in accordance with modified ASTM G42 for 28 days in a 3 percent sodium
chloride electrolyte at ATT and UTT and at potential of - 1.5 volt.
During production, such a testing shall be performed under the same conditions for 48
hours.
Upon tests completion the maximum radius of disbondment shall be lesss than the
following values, The diameter of the drilled hole for intentional holiday shall be 6mm.
The 28 day tests shall be carried out at least 8 weeks before procedure qualification:
Test temperature
ATT(FBE Only)
UTT

Qualification
(28 days)

Production
(48 hours)

5 mm

3 mm

10 mm

5 mm

Production test at ATT may be exempted based or the review of initial results and
COMPANYs approval.
Sample photographs showing disbonded area shall be included in test report.

11.10.1 Equipment

DC power supply unit;

Platinum or platinum-coated anode wire;

Electrolyte solution consisting of 3% (by weight) soduim chloride (NaCl) in

distillated water;

Plastic cylinder 3-1/2 in (90 mm) diameter, 4 in. (100 mm) long;

High resistance volt/amp meter;

Hot plate or oven capable of maintaining 32-250F (0-120C);

Calomel reference electrode;

Utility knife.

11.10.2 Test specimen

a)

The test specimen shall be a minimum 4 in. (100 mm) square segment cut from
the test ring.

b)

Drill a 6 mm (1/4 in.) diameter holiday in the coating at the centre of the
specimen.

c)

Glue plastic cylinder onto specimen with holiday at centre of cylinder.

11.10.3 Procedure
a)

Pour approximately 350 ml (3/4 pint) of electrolyte into the plastic cylinder.

b)

When testing specimens cut from pipe. It is necessary to employ a heat transfer
medium (e.g., steel shot or grit) in order to provide uniform heating of the
specimen. Use of a metal pan partially filled with the heat transfer medium into
which the specimen is implanted is preferable. Place on a hot plate or in an oven
to maintain the substrate temperature to UTT.

c)

Connect the negative lead from power supply to specimen and positive lead to
anode.

d)

Turn on power supply and apply a negative 1.5 volts with respect to the calomel
reference electrode.

e)

Maintain proper voltage, temperature and electrolyte levels from the start.

f)
g)

After 24 hours remove the test cell from the hot plate or oven, immediately drain
electrolyte from the cell and dismantle the test cell.
Using a utility knife, make radial cuts through the coating to the substrate. The
radial cuts starting at the holiday are to be at least 0.8 in. (20 mm) in length.

h)

After the sample has air cooled to room temperature but within 2 hours test for
cathodic disbondment of the FBE. Insert the blade of the knife under the coating
and using a levering action, chip off the coating. Continue until the coating
demonstrates a definite resistance to the levering action.

i)

Measure the radius of the disbonded area from the holiday edge along each
radial cut and average the measured results.

11.10.4 Reporting and grading

a)

Report pipe joint number, date pipe was coated, material batch numbers and
date of test.

b)

Report average of the radius of disbondment from the holiday edge.

c)

The acceptance criteria shall be 5 mm maximum disbondment from the edge of

the pre-drilled hole.

11.11 Air Entrapment Assessment

11.11.1 No more than 20% of the observed area shall be taken with air entrapment (porosity or
bubbles). Bubble size in the polyethylene layer shall be limited to less than half the
thickness of polyethylene layer in height or circumference. Bubbles shall not link
together to provide a moisture path to the adhesive/FBE layers.
A sample of the applied coating shall be microscopically examined for the presence of
foaming, voids and contamination.
11.11.2 Air entrapment or porosity shall be similarly rated for the adhesive and FBE layers of
coating. (See Appendix-C).
11.11.3 The strips of coating from the adhesion test should be studied to determine the level of
air entrapment at the failure interface. This same area can be used to determine the air
entrapment by cutting the coating at a 45 angle along the edge of the remaining
coating on the pipe at the test area.
11.11.4 See Appendix-C for Air Entrapment Assessment.
11.12 Degree of Cure
Degree of cure for FBE primer shall be measured by means of Differential Scanning
Calorimetery (DSC) IN ACCORDANCE WITH ASTM 3418.

Epoxy film samples shall be removed from the coated pipe using hammer and cold
chisel. This produces furled coating flakes. Care shall be taken to remove samples of
full film thickness but at the same time avoid the inclusion of steel debris and
contamination with adhesive or polyethylene.
The glass transition temperature differential (TG) shall be the test used to verify cure
along with a visual examination to ensure no residual cure in the portion of the graph
beyond the glass transition temperature.
Differential Scanning Calorimetery (DSC) shall determine the glass transition
temperature (Tg) and the enthalphy (Hr) by curing of the powder. F or the samples of
the applied coating, two scans shall be made to determine the glass transition
temperatures Tg1 and Tg2, respectively. The degree of cure is related to the difference
between Tg1 and Tg2, which shall be determined as:
Tg = Tg2 Tg1
Tg = -2C to + 3C (Tg = Tg final - Tg initial)
Only a 95% minimum cured coating shall be acceptable.
% Cure = (H - H residual) x 100
H
(H = exothermic heat of reaction)
14.12.2 FLEXIBILITY OF FBE
The flexibility of the coating shall be determined once on the first day of production of
only FBE layer coated pipes (2Nos.). Please refer to Appendix 4 for test details.
14.12.3 HOT WATER RESISTANCE OF FBE
Hot water resistance tests shall be carried out on two pipes coated with only FBE layer.
Please refer to Appendix 5 for the test details.
11.13 Destructive Tests
11.13.1 For coating destructive tests listed in Appendicies-A and B a sufficient length of
production pipe shall be cold cut to provide the required number of samples for testing.
11.13.2 The coating on the cut end of the pipe length shall be cut back to comply with section
12.3.4 of this Specification.
11.14

Test Certification
Type of inspection and test certification should be EN 10204 3.1.

12.0
12.1

REPAIRS
MANUFACTURER/VENDOR shall submit detailed coating repair procedures for
approval by COMPANY. These shall detail minimum/maximum areas for which each
type of repair is applicable.
The maximum number of coating defects allowable, before a joint of pipe shall be
classed as reject and recoated, shall not exceed 5 per joint (inclusive of damage
caused by testing).
No single defect shall exceed an area of 625 mm. Pipes with a defect exceeding 625
mm shall be cause for rejection.

12.2

Repairs shall provide a finished coating equal in effectiveness to that of the parent
coating.

12.3

Each repaired area shall be holiday inspected in accordance with section 13.6 of this
Specification.

12.4

Shrink sleeves are not considered an acceptable repair.

12.5

MANUFACTURER/VENDOR shall submit coating stripping procedure for pipes

selected for coating quality.

12.6

Repair shall not be made within 5 inch (125mm) at the end of the pipe.

13.0

TEST FAILURE

13.1

In the event that a production coated pipe fails to meet the acceptance criteria for a
specified test or if the number of holidays detected is excessive, the pipe length shall
be rejected unless approval is given by COMPANY to accept said pipe.

13.2

The pipe joint preceding and following a rejected joint in the same production run shall
be similarly tested. If both are acceptable, the remainder of the pipe lengths in that
batch shall be accepted. If either pipe joint fails the same test, the
MANUFACTURER/VENDOR shall provide a test schedule for COMPANYs approval,
that will determine what pipes may be defective since the last passing test pipe.

14.0

DOCUMENTATION
The following documentation, written in the English Language, shall be submitted to
COMPANY for review.
Prior to the start of production operations, MANUFACTURER/VENDOR shall submit
the following documentation to the COMPANY:

Coating and Testing Procedures;

Detailed Description of Coating Equipment and Materials;

Pipe Handling Equipment Description and Procedures;

Pipe Stacking Arrangements;

Material Control Recording Procedure;

Inspection Quality Plan;

Repair Procedure;

Procedures for all PQT and Production Tests.

MANUFACTURER/VENDOR shall submit to COMPANY the following documentation

prior to the return of coated pipe to COMPANY:

Mill Certificates for Line Pipe Received;

Manufacturers Certificates for Each Batch of Coating Materials;

Certification/Calibration Certificates for all Testing and Coating Equipment;

Inspection and Test, Records, Results, and other Documentation of all Material
and Coating Tests.

All reports shall be signed by MANUFACTURER/VENDOR to signify compliance with

the requirements of this specification.

APPENDIX A
SUMMARY OF INSPECTION/TESTING FOR PROCEDURE QUALIFICATION TEST (PQT)
POLYETHYLENE COATING FOR ONE PIPE DIAMETER
Property
Before Cleaning
Pipe condition
Chlorides
Oil contamination
After Cleaning
Cleanliness
Profile
Chloride
Dust and Oil
Coating Thickness
FBE coated
FBE + Adhesive + PE.
Holidays
FBE
FBE + Adhesive + PE.
Visual aspect
FBE
FBE + Adhesive + PE.
Adhesion
FBE
FBE + Adhesive + PE.
Impact Resistance

Relevant Clause

Acceptable Values

Number of Tests

12.1
12.2.2
12.2.3

Conditions A&B of ISO 8501 (part I)

5 g/cm2
No indications of oil contamination

10
30 (3x10 pipe)
10

12.3.4
12.3.5
12.3.6
12.3.6

Sa 21/2
50 - 100 m.
2 g/cm2
No indications of dust or oil contamination.

10
10
30 (3x10 pipe)
10

13.1.1
14.5.3

250 m -350 m
as per section 14.5.3

24 (12x2 pipes)
48 (12x4 pipe)

14.6
14.6

No holidays with detector operating voltage

between electrode and pipe maintained at 25
kilovolts.

2
5 Random

14.4
14.4

Smooth with no surface defects

Smooth with no surface defects

2
8

Knife X Cut test

Test 14.7.2

Refusal to peel or a cohesive failure

8035N/cm at ATT, 15N/cm at UTT

2 (2x1 Random) at ATT

10 (2x5 Random) at UTT

(Impact Resistance Tests shall be carried out

at ATT and UTT in accordance with
procedure described in clause 12.12 of
CAN/CSA/Z245-20-M92)
FBE
FBE + Adhesive + PE.
Penetration (indentation) testing
FBE + Adhesive + PE.

14.9.2

1.8J (minimum)
Electrical breakdown after 30 impacts

2
5 Random

14.8.2

0.2 mm max. ATT, 0.3 mm at UTT

12 (3x4 pipes) at ATT & at

UTT

14.12

-2 C Tg + 3 C

2 (2x1 pipes)
3 Random

See
Appendix-D

No cracking/disbondment pinholes

2 (1x2 pipes)

See
Appendix-E

No peel or cohesive break 2mm long

No adhesive/brittle break 2 mm long

2 pipes

Cathodic disbondment
FBE
FBE + Adhesive + PE.

14.10

2 (2 x 1 Random)
6 (2 x 3 Random)

Air Entrapment
FBE
FBE + Adhesive + PE.

See
Appendix-C
14.11

Max. radius of disbondment 5 mm at ATT

Average Max. radius of disbondment 10 mm
at UTT
No air entrapment in pipe or cut back or
longitudinal welds.

Degree of Cure
FBE
FBE + Adhesive +PE.
Flexibility Bend Test
FBE
Hot Water Resistance
FBE

Note:

2
8

Number and frequency of tests can be increased at the sole discretion of COMPANY.

APPENDIX B
SUMMARY OF INSPECTION/TESTING FOR PRODUCTION TESTING ON FULL
POLYETHYLENE COATING SYSTEM FOR ONE PIPE DIAMETER
Property
Before Cleaning
Pipe condition
Chloride
Oil
After Cleaning
Cleanliness
Profile
Chloride
Dust
Oil
Chemical Pretreatment
Solution of Oakite 33
Chlorides
Chromate solution
Chlorides
Temperature
Coating Thickness (minimum)
Holidays

Visual Inspection
Coating
Longitudinal Welds
PE cut backs
Adhesion
At ATT
At UTT
Cathodic Disbondment
At ATT
At UTT

Note:

Relevant Clause

Acceptable Values

MINIMUM Frequency *

12.1
12.2.2
12.2.3

Conditions A&B of ISO 8501 (Part I)

2 g/cm2
No indication of oil contamination.

Each Pipe
1 per 100 pipe at 3
locations
1 per 100 pipe

12.3.4
12.3.5
12.3.6
12.3.6
12.3.6

ISO-Sa 21/2
50 - 100 m
2 g/cm2
No indications of dust contamination
No indications of oil contamination

Each pipe
Each pipe
1 per 100 pipe
1 per 100 pipe
1 per 100 pipe

12.4.4

50 ppm

Once per shift

12.4.4
12.5.1

Once per shift

Once per shift

14.5
14.6

50 ppm
60 C
as per section 14.5.3
No holidays with detector operating voltage
between electrode and pipe maintained at 25
kilovolts.

14.4
14.11
12.3.4

No surface defects
No air entrapment
150 + 0/-20 mm width, bevel 45

Each pipe

14.7.2
14.7.2

35 Newtons per cm width of strip peeled

15 Newtons per cm width of strip peeled

1 per 100 pipe

1 per 100 pipe

14.10

Max. radius of disbondment < 3 mm

Max. radius disbondment
< 5 mm

First pipe, last pipe and at

intervals of every 350 pipes

Each pipe
Each pipe

COMPANY reserves the rights to increase inspection and testing frequency if

warranted by the circumstances.

APPENDIX C
AIR ENTRAPMENT ASSESSMENT
A3-1.0

SCOPE
To determine the amount of cross section and interface air entrapment (porosity or
bubbles in the plant applied coating.

A3-2.0

EQUIPMENT
a)
b)

A3-3.0

Microscope - Hand Held 30 X.

Utility knife.

TEST SPECIMEN
Strips from Adhesive Tests, coating disbondment (CD) test samples, and coated pipe
may all be used to help determine the rating. Strips shall also be cut from longitudinal
welds and examined for the presence of voids.

A3-4.0

PROCEDURE

A3-4.1

Adhesion strip shall be viewed from the side and the failure interface.

A3-4.2

Cathodic disbondment samples shall be viewed from the side before tests begins.
Scraping with a sharp knife to remove cutting damage on the edge of the coating may
be necessary to provide a smooth surface for viewing.

A3-4.3

At the pipe adhesion test site use a utility knife to cut the edge of the coating to a 45
angle and view with a microscope.

A3-4.4

Perform a similar test in the cut back area. This should be used for information to
determine if further testing is needed.

A3-5.0

REPORTING AND GRADING

A3-5.1

Report pipe joint number, date pipe was coated, coating batch number, and date of
test.

A3-5.2

Report rating of cross-section and interface entrapment.

A3-5.3

A rating of 1 or 2 is passing.

Rating will be on a scale of 1 to 5 as follows:

Rating
1. Very Good

Passing

2. Good

Passing

3. Fair

Failing

4. Poor

Failing

5. Very Poor

Failing

Rating for each area of concern:

o

o
o

o
o

o
o

o
o

o
o

Less than 10% of are with bubbles.

o
o

No. 2 Rating -Passing

Less than 20% / more than 10%

No. 1 Rating - Passing

o
o

No. 3 Rating - Failing

Less than 30% / more than 20%

o o o o o o o o o o o o o o o o

No. 4 Rating - Failing

Less than 40% / more than 30%

o o o o

o o o

ooooooooooooooooooooooooooooooooooooo

No. 5 Rating - Failing

oooooooooooooooooooooooooooooooooooo

Over 50% of area taken by air

entrapment (bubbles).

By looking at the top (outside) surfaces the same type rating system can be used

APPENDIX D
FLEXIBILITY TEST FOR FBE LAYER COATING PQT
A4-1.0

TEST METHOD
The flexibility of the coating shall be determined once on the first day of production of
only FBE layer coated pipes (2 Nos.) by the following method:
Coated samples (300 mm x 50 mm x thickness of pipe wall) taken from a FBE coated
pipe joint shall be subjected to a bend test at a temperature of 0C and 20C to induce
a 2% and 3% strain respectively in the sample.
At each temperature the test shall be carried out twofold.
The deflection loading rate during bend testing shall be 25 2 mm/min.
The mandrel sizes shall be selected according to the following formula:
D = t (1-s)
s
Where,

A4-2.0

= mandrel diameter (mm)

= specimen wall thickness (mm)

= 0.02 at 0C
0.03 at 20C

ACCEPTANCE CRITERIA
The coating shall not exhibit any signs of cracking, disbondment or pinholes.

APPENDIX-E
HOT WATER RESISTANCE TEST FOR FBE LAYER COATING PQT
1.

Test Method
Hot water resistance tests as detailed below shall be carried out on two pipes coated
with only FBE layer.
A coated sample of 200 mm x 100 mm machined from a pipe ring of the coated pipe
shall be immersed in tap water of 85C for 5 hours.
The bare edges of the sample shall be coated to prevent ingress of moisture beneath
the coating.
Directly after 5 hours exposure, the coated sample shall be removed from the water bath
and allowed to cool to ambient temperature. Subsequently the coating adhesion shall be
tested as follows :
Using a sharp and pointed knife, two incisions of approximately 15 mm in length shall be
made through to the steel surface to form an X with an angle of intersection of
approximately 30 degrees. Commencing at the intersection, an attempt shall be made to
lift the coating from the steel substrate using the blade of the knife.

2.

Acceptance Criteria
Refusal of the coating to peel or a cohesive break less than 2 mm long entirely within the
coating in the absence of excessive voids caused by foaming constitutes a pass.
Any adhesive break away from the intersection point or brittle break away of flakes of
more than 2 mm long constitute a failure.
Cohesive failure caused by voids in the coating leaving a honeycomb structure on the
steel surface also constitutes a failed condition.
In addition, the coating shall not show any tendency towards disbonding or blistering. A
slight discoloration of the coating is acceptable.