GBE-CW6 Part-2-1993

GBE/CW6: PART 2
CONTENTS
Page
FOREWORD v
AMENDMENT RECORD AND BRIEF HISTORY vi
SECTION ONE - GENERAL REQUIREMENTS
1. SCOPE 1
2. REFERENCES 1
3. DEFINITIONS 2
4. COATING MATERIALS 2
4.1 Selection of coating materials 2
4.2 Storage of coating materials 2
4.3 Toxicity and handling 3
5. COMPONENTS OR WORK PIECES 3
5.1 Component inspection 3
5.2 Component identification 3
5.3 Protection of weld end preparations 3
5.4 Surface preparation 3
5.5 Chemical pre-treatment and primers 4
5.6 Extent of approvals 4
6. INSPECTION AND TESTING 5
7. VARIANTS 5
SECTION TWO - FUSION BONDED POWDER COATINGS ON PIPE
8. PROCEDURE QUALIFICATION 9
8.1 General 9
8.2 Coating procedure specification 9
8.3 Coating procedure approval tests 9
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GBE/CW6: PART 2
Page
9. PRODUCTION COATING PROCEDURE 11
9.2 Coating process 11
10. VISUAL INSPECTION 11
11. TESTING OF CURED COATINGS 11
11.1 General requirements 11
11.2 Thickness test 12
11.3 Holiday detection test 12
11.4 Impact resistance test 12
11.5 Adhesion test 12
11.6 Coating cure test 12
11.7 Defect rate 13
11.8 Check procedure 13
12. REPAIRS 13
13. HANDLING OF COATED PIPES 13
14. STRIPPING OF COATING 14
is. IDENTIFICATION 14
SECTION THREE - FUSION BONDED POWDER COATINGS ON FITTINGS
16.1 General 15
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GBE/CW6: PART 2
Page
19.1 Testing of coated finings 19
19.6 Coating cure test 20
19.7 Defect rate 20
20. REPAIRS 21
21. HANDLING OF COATED FITTINGS 21
23. IDENTIFICATION 21
SECTION FOUR - MULTI-COMPONENT LIQUID COATINGS ON PIPES AND FITTINGS
24.1 General 23
27.1 Testing of coated pipes and finings 26
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GBE/CW6: PART 2
Page
27.4 Hardness and cure of coating test 27
27.7 Heat blister test 28
27.8 Defect rate 28
28. REPAIR OF DEFECTS 28
29. HANDLING OF COATED PIPES AND FITTINGS 29
31. IDENTIFICATION 30
TABLES
1 Minimum quantify control requirements 7
2 Component diameter ranges, permissible holidays and repairs 8
APPENDIX
A CALIBRATION PROCEDURES FOR THICKNESS MEASUREMENT OF FUSION

BONDED EPOXY POWDER AND MULTI-COMPONENT LIQUID COATINGS 31
- iv -
GBE/CW6: PART 2
FOREWORD
This Gas Business Engineering Technical Specification having been approved by the Materials and
Construction Group as document MCG 92/780 is published under the authority of British Gas plc for
use throughout the Company.
This Gas Business Engineering Technical Specification accords with the requirements of the EC
Utilities Directive and is a revision of BGC/PS/CW6 Part 2 (dated October 1984), which is hereby
superseded.
This Gas Business Engineering Technical Specification forms Part 2 of a two-part series of
specifications dealing with the performance requirements, methods of test and application of materials
that can be used for the protective external coating on steel line pipe and associated fittings.
The other part of this series (GBE/CW6: Part 1) specifies requirements for coating materials and
methods of test.
Requirements for field applied coatings formerly specified in BGC/PS/CW6: Part 3 (now withdrawn)
are specified in BG/PS/CW5.
This Gas Business Engineering Technical Specification is intended for use by British Gas and
if it is used where British Gas is not involved then care shall be taken to ensure that the
Technical Specification is correctly applied.
Compliance with this Gas Business Engineering Technical Specification does not confer
immunity from compliance with any legal or statutory obligations.
Contract requirements
A Gas Business Engineering specification does not purport to include all the necessary provisions of a
contract.
Contractors and other users external to British Gas plc should direct their requests for further
copies of this Gas Business Engineering Technical Specification in the first instance to the
department responsible for the initial issue of their contract documentation.
Comments regarding the technical content of this Technical Specification should be directed to:
Standards Group
Design Standards Department
British Gas plc
326 High Holborn
London WC1 V 7PT
Application for further copies of this Technical Specification should be directed to:
Standards Production Unit

British Gas plc
Operational Centre
Brick Kiln Street
Coventry Road
Hinkley
Leicestershire
LE10 ONA.
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GBE/CW6: PART 2
REVISION OF GAS BUSINESS ENGINEERING SPECIFICATIONS
Gas Business Engineering specifications are revised, when necessary, by the issue of amendments or
of revised editions. It is important that users should ascertain that they are in possession of the latest
amendments or editions. Any person who, in the course of using a Gas Business Engineering
specification, encounters any inaccuracy or ambiguity is requested to notify the Standards Group
without delay in order that the appropriate action may be taken.
Amendment record
Incorporated into text

Amendment Number Dated
Name Initials
Brief history
First published as BGC/PS/CW6: Part 2 October 1984
Re-issued as GBE/CW6: Part 2 January 1993
 British Gas plc 1993
This Gas Business Engineering specification is copyright and must not be reproduced in whole or in
part by any means without the approval in writing of British Gas plc.
- vi -
GBE/CW6: PART 2
SECTION ONE
GAS BUSINESS ENGINEERING

TECHNICAL SPECIFICATION FOR
THE EXTERNAL PROTECTION OF STEEL LINE PIPE AND FITTINGS USING
FUSION BONDED POWDER AND ASSOCIATED COATING SYSTEMS:
PART 2 - FACTORY APPLIED COATINGS
SECTION ONE - GENERAL REQUIREMENTS
1. SCOPE
This Part 2 of Gas Business Engineering Technical Specification* GBE/CW6 specifies the operations
and requirements for the factory application to pipes and fittings of materials identified in GBE/CW6:
Part 1. These coatings may be applied to components used for the transmission and distribution of
natural or manufactured gas. There is no restriction on pressure or nominal size of the components
provided they are not operated continuously at temperatures higher than 50°C.
Section One covers general requirements and is applicable to all coatings specified in this
Specification in addition to the requirements specified in Sections Two, Three or Four,
Section Two deals with the application of fusion bonded powder as an anti-corrosion coating on steel
pipe. Section Three deals with the application of fusion bonded powder as an anti-corrosion coating on
fittings and Section Four deals with the application of multi-component liquid coating as an
anti-corrosion coating on pipe and fittings.
2. REFERENCES
This Specification makes reference to the documents listed below. Unless otherwise specified the
latest editions of these documents, including all addenda and revisions, shall apply.
Statutes and Regulations
- Control Of Substances Hazardous to Health (COSHH) Regulations
- The Health and Safety at Work etc. Act 1974
British Standards
BS 5750 - Quality systems
BS 7079 - Preparation of steel substrates before application of paints and

related products
*Hereinafter referred to as 'this Specification'.

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GBE/CW6: PART 2
SECTION ONE
British Gas documents
GBE/CW6 - Technical specification for the external protection of steel line pipe and
fittings using fusion bonded powder and associated coating systems:
Part 1 - Requirements for coating materials and methods of test
BGC/PS/DAT35 - Specification for separator straps for use with resin coated pipe
BGC/PS/L3 - Code of practice for handling, transport and storage of steel pipes,
bends and tees.
3. DEFINITIONS
For the purposes of this Specification the following definitions shall apply:
British Gas: British Gas plc
British Gas representative: the person appointed from time to time by British Gas and
notified in writing to the Contractor to act as British Gas representative for the purposes of
the Contract.
Contractor: the person, firm or company with whom British Gas enters into a contract to
which this Specification applies, including the Contractor's personal representatives,
successors and permitted assigns.
Manufacturer: the producer of the coating material or his appointed agents or assigns.
Quality Assurance: the Quality Systems and Quality Audits Department of British Gas.
4. COATING MATERIALS
4.1 Selection of coating materials
4.1.1 Before production coating is permitted, the coating system and the application process shall
be defined and qualified in accordance with the coating procedure approval specified in the
appropriate Section of this Specification.
4.1.2 Only coating systems which comply with GBE/CW6: Part 1 shall be used.
4.1.3 The coating material supplied shall be certified by the Manufacturer in accordance with the
requirements of GBE/CW6: Part 1. The Contractor shall obtain and retain all certificates (see 4.2) and
manufacturers' data sheets. Certificates shall be made available on request.
4.2 Storage of coating materials
To ensure that the properties of all coating materials are maintained in compliance with the relevant
Section of GBE/CW6: Part 1, all coating materials consigned to the coating plant shall be properly
stored in accordance with the Manufacturers' safety requirements and recommendations, at all times,
to prevent damage and deterioration prior to use. Materials shall be used in date order in which they
are manufactured.
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GBE/CW6: PART 2
SECTION ONE
4.3 Toxicity and handling
Any hazard, (e.g. toxic, corrosive, fire risks) associated with coating materials offered for use to meet
the requirements of this Specification shall be specified by the Manufacturer, together with his
recommendations for safe handling in accordance with the requirements of the Health and Safety at
Work etc. Act 1974 and the COSHH Regulations.
5. COMPONENTS OR WORK PIECES
5.1 Component inspection
The Contractor shall inspect all components on receipt for damage to external surface and weld end
preparations. This shall be recorded for each affected component.
5.2 Component identification
5.2.1 All identification markings, whether internal or external to the component, shall be carefully
recorded before surface preparation begins.
5.2.2 When applicable, identification plates shall be carefully removed and, after the coating has
been accepted, replaced using an adhesive compatible with the coating. Special care shall be taken to
ensure that the original data is re-affixed to the correct component.
5.2.3 The Contractor shall provide a documentary procedure for compliance with these
requirements (see also Table 1, item t)).
5.3 Protection of weld end preparations
5.3.1 Weld end preparations shall be protected from mechanical damage during handling, storage,
surface preparation and the coating processes. The methods used shall also ensure that no damage
occurs to the internal surface of the components.
5.3.2 Protection during handling and storage shall be in accordance with BGC/PS/L3.
5.3.3 Weld end preparations shall be protected from coating during the process by a method which
shall not be detrimental to the coating process.
The coating shall not be applied within 40 ± 15 mm of the component ends for fusion bonded powder
coating application, and 150 ± 15 mm in tie case of multi-component liquid coatings.
5.4 Surface preparation
5.4.1 General
The method of surface cleaning and surface preparation shall be specified by the Contractor as part of
the coating procedure qualification and shall take into account the requirements specified in 5.4.2 to
5.4.7 inclusive plus any special requirements specified by British Gas.
5.4.2 Contaminant removal
Where oil, grease or other contaminants are present, they shall be removed, without spreading them
over the surface, with a suitable solvent. For components which have been subjected to
contamination, the contaminant shall be removed by washing either with potable water or a chemical
cleaner. If a chemical cleaner is used, subsequent washing with potable water will be necessary. The
component shall be dried before blast cleaning.
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SECTION ONE
GBE/CW6: PART 2
5.4.3 Component cleaning
Components shall be blast cleaned in accordance with 9.1 and 17.1 for fusion bonded powder
coatings, and 25.1 for multi-component liquid coatings.
5.4.4 Surface inspection
The metal surface shall be inspected immediately after blast cleaning and all slivers, scabs, etc., made
visible by blast cleaning and detrimental to the coating process shall be removed by grinding. After the
removal of defects, the remaining wall thickness shall comply with the relevant component
specification. Any rectified areas shall be blast cleaned to meet the requirements of 5.4.3.
5.4.5 Defects
Any component found to have defects which exceed the levels permitted in the relevant component
specification shall be set aside for examination.
5.4.6 Pre-coating cleaning
Directly before coating, any dust, grit or other contaminants shall be removed from the component
surface by a method established as acceptable by the relevant coating procedure trial and recorded in
the relevant coating procedure.
5.4.7 Rust blooming or further surface contamination
Where rust blooming or further surface contamination (see 5.4.2) has occurred, the component shall
be cleaned again in accordance with 5.4.2 applicable and again blast cleaned in accordance with
5.4.3. Coating shall take place before any further contamination or rust blooming occurs.
5.5 Chemical pre-treatment and primers
Chemical pre-treatment or primers shall be specified by the Contractor as part of the coating
procedure qualification.
5.6 Extent of approvals
The coating process shall comply with the procedure established in the relevant coating procedure
qualification (see clauses 8, 16 and 24). This qualification will be valid for three years and will cover
the component size range and the coating material tested.
The component size for the coating procedure trial shall be selected from one of the ranges in Table 2,
and approval will quality all other sizes within that range.
For fusion bonded powder coatings of line pipe, approval should extend to thickness of ± 50% of the
wall thickness of the pipe tested.
In order to demonstrate continuing product quality, the Contractor may be required to undertake
duplicate cathodic disbondment and watersoak tests on the pipe or fitting test piece from any contract
and size range within the contract. Additionally, for pipe only, flexibility testing shall be carried out in
duplicate.
Failure of any of the results of these tests to meet the requirements of this Specification shall
necessitate a new coating procedure trial.
Any changes in coating materials, component size range. coating process, plant, or quality history
shall necessitate a new coating procedure trial.
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SECTION 1
GBE/CW6: PART 2
6. INSPECTION AND TESTING
The quality control system shall include each of the requirements listed in Table 1. The actual quality
control requirements may differ depending on the type of coating being used or whether it is being
applied to a pipe or fitting. Table 1 has been prepared to identity these differences.
If, after examination or test, any component has not been cleaned or coated in accordance with this
Specification, the Contractor shall be required to remove the coating which is defective or inadequate
and to reclean and recoat the component.
7. VARIANTS
A contractor shall only propose variants to this Specification where the text indicates that variants
would be considered by British Gas.
- 5/6 -
SECTION ONE
TABLE 1 - Minimum quality control requirements

GBE/CW6: PART 2
Fusion bonded Fusion bonded Multi-component

powder coatings powder coatings liquid coatings on
Requirements
on pipe on fittings pipes and fittings
Relevant clause reference
a) Inspection on receipt. 5.1 5.1 5.1
b) Recording of full component 5.2 5.2 5.2

identification
c) Check cleanliness of components 5.4.2 5.4.2 5.4.2

immediately prior to blast cleaning
d) Monitor size, shape and cleanliness 5.4.3 5.4.3 5.4.3

of the blast cleaning material and
process.
e) Check visually, in good light, the 5.4.4 5.4.4 5.4.4

surface of the components for metal
defects, dust and entrapped grit.
f) Check component surface blast 9.1 17.1 25.1

profile.
g) Check for residual contamination of 5.4.6 5.4.6 5.4.6

component surfaces.
h) Check chemical pre-treatment 5.5 5.5 5.5

and/or primer.
i) Check temperature control of the 8.2 d) 17.2.2.2 25.2.6.6

component surface.
17.2.3.1
j) Check recycled coating material for 8.2 l) 16.2.2 N/A

contamination and moisture.
k) Check the coating thickness. 8.3.2 16.3.2 24.3.2
l) Check the cure of coating. 8.3.6 16.3.6 24.3.4
m) Check the strength of film (impact 8.3.4 16.3.4 24.3.5

resistance).
n) Check the coating adhesion. 8.3.5 16.3.5 24.3.6
o) Holiday detection of 100% of the 8.3.3 16.3.3 24.3.3

surface area of all components.
p) Supervision to ensure the adequate 12. 20. 28.

and proper repair of all defects.
continued …/
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SECTION 1
TABLE 1 - (concluded)
GBE/CW6: PART 2
Fusion bonded Fusion bonded Multi-component

powder coatings powder coatings liquid coatings on
Requirements
on pipe on fittings pipes and fittings
Relevant clause reference
q) Check on coating colour and 10. 18. 26.

appearance, e.g. uniformity and
flow.
r) Check on flexibility of coating. 8.3.7 - 24.3.7
s) Check for damage to weld end 5.3 5.3 5.3

preparations.
t) Check for replacement of full 5.2.2 5.2.2 5.2.2

identification.
u) Check for inspection on load-out. 13. 21. 29.
TABLE 2 - Component diameter ranges, permissible holidays and repairs
Number of holidays on pipe

Component Maximum total
diameter repair area
Normally acceptable Maximum permissible
range (pipe or fitting)
2
mm Multi-component Multi-component cm
Powder Powder
liquid liquid
15 to 49 4 2 8 4 75
50 to 229 5 2 10 4 125
300 to 599 10 3 20 6 250
600 to 899 12 4 25 8 350
900 to 1200 15 5 30 10 500
> 1200 18 6 35 12 600
NOTE - For fittings, the number of normally acceptable holidays shall be one per square metre of
coated area and maximum permissible shall be two per square metre of coated area.
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GBE/CW6: PART 2
SECTION TWO
SECTION TWO - FUSION BONDED POWDER COATINGS ON PIPE
8. PROCEDURE QUALIFICATION
8.1 General
Before bulk coating of pipe commences, the requirements of 8.2 shall be met and a detailed sequence
of operations to be followed on the coating of pipe shall be demonstrated.
8.2 Coating procedure specification
The coating procedure specification shall incorporate full details of the following:
a) Quality plan.
b) Powder system to be used together with appropriate data sheets as defined in clause 4.
c) Pipe dimensions.
d) Process temperature profile.
e) Pipe cleaning.
f) Blast cleaning medium and technique.
g) Blast cleaning finish, surface profile, surface cleaning and metal defect removal.
h) Dust removal.
i) Provision of coating cut-back.
j) Line speed.
k) Preheat method, time and temperature.
l) Powder application including use of recycled material.
m) Curing and quenching time and temperature.
n) Post cure time and temperature.
o) Repair technique.
p) Coating stripping technique.
q) Handling procedures.
8.3 Coating procedure approval tests
8.3.1 General
A batch representing a normal production run (typically 15 to 20 pipes) shall be coated in accordance
with the coating procedure (see 8.2), the coating operations being witnessed.
Three pipes from the batch shall be selected for coating procedure approval tests and shall be
subjected to the complete set of tests specified in 8.3.2 to 8.3. 10 inclusive.
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GBE/CW6: PART 2
SECTION TWO
The Contractor shall ensure that the tests specified in 8.3.2 to 8.3.10 inclusive are carried out in
duplicate and the results of the tests, demonstrating compliance, made available.
Testing shall be witnessed and a full set of test results shall be recorded. No coated pipe shall be
dispatched until the procedure has passed the approval tests.
8.3.2 Thickness test
The coating thickness shall be a minimum of 350µm and a maximum of 500µm, unless specified
otherwise.
A survey of the coated pipe selected for test shall be carried out by measuring, as a minimum, at 1 m
intervals at the cardinal points, in such a manner as to establish the degree and extent of any
thickness variation.
A destructive film thickness test shall be carried out to verity the accuracy of the coating thickness
measurement technique employed
8.3.3 Holiday detection test
Each pipe shall be checked over 100% of the coated surfaces in accordance with GBE/CW6: Part 1,
Appendix C and shall meet the requirements of Table 2.
8.3.4 Impact resistance test
When tested at ambient temperature in accordance with GBE/CW6: Part 1, Appendix D, the cured
coating shall withstand an impact of not less than 1.5 J without a holiday being caused.
8.3.5 Adhesion test
The adhesion of the coating, shall be tested and shall meet the pass requirements in accordance with
GBE/CW6: Part 1 Appendix E.
8.3.6 Coating cure test
The degree of cure of the coating shall be determined by differential scanning calorimetry (DSC)
analysis of a sample of the coating taken from a location 1/3 of the pipe length from the trailing end in
accordance with GBE/CW6: Part 1, Appendix A, clause A.3. The acceptance criterion shall be based
on the difference between the measured Tg2 and Tg1 (as detailed in GBE/CW6: Part 1, Appendix A,
clause A.3). This difference is termed ∆Tg.
The acceptance range of ∆Tg will depend on the type of powder used (see also 11.6).
8.3.7 Flexibility test
The coated pipe shall be sectioned and subjected to a flexibility test in accordance with GBE/CW6:
Part 1, Appendix B. The coating shall not exhibit signs of cracking, disbondment or pinholes and shall
pass a holiday detection test in accordance with GBE/CW6: Part 1, Appendix C.
8.3.8 Cathodic disbonding test
The test sections shall be tested by the procedure detailed in GBE/CW6: Part 1, Appendix F. The
disbondment shall not extend more than 5 mm radially from the edge of the damaged coating after the
test period of 28 days.
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GBE/CW6: PART 2
SECTION TWO
8.3.9 Strain/polarisation cracking test
The test sections shall be bent and then polarised and tested as detailed in GBE/CW6: Part 1,
Appendix G. The area of coating exposed to the electrolyte shall not exhibit signs of cracks,
disbondment or pinholes and shall pass a holiday detection test as specified in GBE/CW6: Part 1,
Appendix C.
8.3.10 Water immersion test
The test sections shall be prepared and subjected to a water immersion test as detailed in GBE/CW6:
Part 1, Appendix E. The coating shall show no loss of adhesion greater than 3 mm after 28 days.
9. PRODUCTION COATING PROCEDURE
The surface of the pipe to be coated shall be prepared as specified in 5.4.
Components shall be blast cleaned to a minimum standard of BS 7079 Sa 2½ quality. The surface
profile shall be between 50µm and 100µm peak to trough height, and shall be angular in nature.
9.2 Coating process
The production coating process shall be carried out using the procedure that fulfils the requirements of
8.3.
The nominal thickness of the cured coating shall be 400µm. The actual coating thickness shall be in
the range 350µm to 500µm.
Where pipe is to be concrete coated, the correct thickness (normally 650µm to 800µm) of
anti-corrosion coatings shall be applied, which depends upon the particular concrete coating process.
Weld end preparations shall be protected as specified in 5.3.
10. VISUAL INSPECTION
The coating colour and appearance shall be uniform and free from runs, sags, blistering, roughness,
foaming and general film defects.
11. TESTING OF CURED COATINGS
11.1 General requirements
Cured coatings on pipes shall comply with the requirements of 11.2 to 11.8 inclusive and, where
indicated, methods of test described in GBE/CW6: Part 1 shall be used.
The Contractor shall ensure that the tests specified in 11.4, 11.5 and 11.6 are carried out and the
results of the tests, demonstrating compliance, made available.
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GBE/CW6: PART 2
SECTION TWO
11.2 Thickness test
The coating thickness on each pipe shall be checked for compliance with 8.3.2 at not less than five
equidistant locations spread over the total surface of the pipe. The thickness measuring gauge used
shall be suitably calibrated hourly for the specified thickness range (see Appendix A).
11.3 Holiday detection test
The coated pipes shall be subjected to a holiday detection test over 100% of the coated surface as
detailed in GBE/CW6: Part 1, Appendix C.
The number of holidays detected shall comply with Table 2. If, on any two consecutive pipes, the
number of holidays detected is greater than the normally acceptable level but less than the maximum
permissible level. the cause shall be immediately investigated.
If four further consecutive pipes are detected as having holidays between the normally acceptable
level and the maximum permissible level given in Table 2, all production to that point shall be
quarantined until the reason for the high frequency of holidays is determined and rectified. A total of
5% of daily production will be accepted with up to the maximum permissible number of holidays
provided that the 5% are not consecutive.
Pipes with more holidays than permitted by Table 2 shall be rejected for subsequent stripping (see
clause 14) and recoating.
All holidays shall be repaired in accordance with clause 12 and satisfactorily retested before dispatch
of the pipe.
Defects detected immediately before dispatch shall not be repaired but shall be conspicuously and
permanently marked on the pipe and recorded on the relevant inspection documentation.
11.4 Impact resistance test
The coated pipe shall be subjected to an impact resistance test as detailed in GBE/CW6: Part 1,
Appendix D, at frequencies of once every hour or 20 pipes, whichever is the more frequent. This initial
frequency may subsequently be varied. the revised frequency being based on quality history.
The cured coating shall meet the requirements specified in 8.3.4.
11.5 Adhesion test
The coated pipe shall be subjected to an adhesion test of the cured coating as detailed in GBE/CW6:
Part 1, Appendix E. The test shall be carried out at three locations on the pipe (one metre from each
end and at a mid point) and initially at frequencies of once every hour or 20 pipes, whichever is the
more frequent. This initial frequency may subsequently be varied, the revised frequency being based
on quality history.
The cured coating shall meet the initial test procedures, investigation procedures and result reporting
requirements of GBE/CW6: Part 1, Appendix E.
11.6 Coating cure test
The cure of the coating shall be checked for compliance with 8.3.6 by DSC analysis at frequencies of
once every hour or 20 pipes, whichever is the more frequent. This initial frequency may subsequently
be varied, the revised frequency being based on quality history.
To confirm the requirements of 8.3.6, the test procedure detailed in GBE/CW6: Part 1, Appendix A.
clause A.3 shall be carried out.
- 12 -
GBE/CW6: PART 2
SECTION TWO
If a test does not result in a value of ∆Tg within the acceptable range, the following retest procedure
shall be used:
For a measured ∆Tg within + 2 °C of the upper acceptable limit, a further sample from the pipe shall
be tested. If the value of ∆Tg obtained lies within the acceptable range, the pipe shall be accepted. If it
does not, the pipe shall be rejected and adjacent pipes in the production run shall be successively
sampled and tested until acceptable coating is identified.
11.7 Defect rate
Should tests in any production batch (typically the production from a seven hour shift) show a rejection
rate of more than 10% defective pipe for any one test, every pipe in that batch shall be individually
subjected to that test. In such cases, the Contractor shall simultaneously conduct an investigation to
establish the cause of the defects.
The cost of retrieval of any pipes dispatched from the coating premises and/or any additional
expenses incurred as a result of additional examination shall be borne by the Contractor.
11.8 Check procedure
If any individual pipe fails to meet the requirements of 11.2 to 11.7 inclusive, a check procedure shall
be inflated. This shall involve checking all pipe back to the preceding acceptable pipe. The pipe
numbers shall be available from the final inspection bench. These pipes shall be subjected to an
examination similar to that carried out on the failed pipe. If the number of defects detected is
significant, the entire production for that day shall be quarantined and investigated.
12. REPAIRS
All holidays and other coating defects shall be repaired with multi-component materials to ensure
compatibility with the applied coating. Repair methods shall include adequate surface preparation
techniques, suitable overlaps, coating thicknesses and a demonstration of satisfactory adhesion and
cure. All repairs shall be retested for holidays in accordance with the requirements detailed in
GBE/CW6: Part 1, Appendix C.
The maximum areas of repair for any pipe shall not exceed, in total, the areas given in Table 2.
Repairs shall not be carried out within 200 mm of the end of the coating, but all areas of damage shall
be recorded and marked.
13. HANDLING OF COATED PIPES
13.1 All coated pipes shall be handled and stored in accordance with BGC/PS/L3 to prevent
damage to the pipe and coating.
Where the use of pipe separators is required to prevent damage to the cured coating, these shall be
as specified in BGC/PS/DAT35.
13.2 Protection from damage and corrosion of the weld end preparations may be required prior to
stacking and load out. The type of protection and the method of application shall be specified by British
Gas (see BGC/PS/L3).
- 13 -
GBE/CW6: PART 2
SECTION TWO
14. STRIPPING OF COATING
Rejected coating shall be removed only by a procedure which shall not cause any mechanical damage
to the pipe and shall not cause the steel temperature to exceed 25°C.
15. IDENTIFICATION
The Contractor shall be responsible for ensuring that all internal or external identification markings are
noted in accordance with 5.2 before surface preparation begins, and are replaced after the coating
process.
- 14 -
GBE/CW6: PART 2
SECTION THREE
SECTION THREE - FUSION BONDED POWDER COATINGS ON FITTINGS
16. PROCEDURE QUALIFICATION
16.1 General
Before bulk coating of fittings commences, the requirements of 16.2 shall be met and a detailed
sequence of operations to be followed for the coating of fittings shall be demonstrated.
16.2.1 The coating procedure specification shall incorporate full details of the following:
a) Quality plan.
b) Powder system to be used together with appropriate data sheets as defined in clause 4.
c) Fining dimensions.
e) Fitting cleaning.
h) Dust removal.
j) Preheat method, time and temperature.
k) Powder application.
l) Curing and quenching time and temperature.
m) Post cure time and temperature
n) Repair technique.
o) Coating stripping technique.
p) Handling procedures.
16.2.2 Recycled powder shall not be used to coat pipeline fittings.
16.2.3 Where fluidised bed dipping is to be used, the applicator shall provide written evidence that
the powder in the fluidised bed at the time of the procedure qualification test complies with GBE/CW6:
Part 1.
- 15 -
GBE/CW6: PART 2
SECTION THREE
16.3.1 General requirements
A batch of fittings shall be coated in accordance with the approved coating procedure (see 16.2), the
coating operations being witnessed. Pipe pups of equivalent dimensions may be used instead of
fittings.
Three coated fittings or pipe pups from the batch shall be selected for coating procedure approval
tests and shall be subjected to the complete set of tests specified in 16.3.2 to 16.3.8 inclusive.
The Contractor shall ensure that the tests specified in 16.3.2 to 16.3.8 inclusive are carried out in
duplicate and the results of the tests, demonstrating compliance, made available.
Testing shall be witnessed and a full set of test results shall be recorded. No coated fittings shall be
dispatched until the procedure has passed the approval tests.
The coated fittings shall be subjected to a thickness test of the cured coating as specified in 19.2. The
thickness shall be not less than 350µm and not greater than 1500µm.
The coated fittings shall be subjected to a holiday detection test over 100% of the coated surface as
detailed in GBE/CW6: Part 1, Appendix C. The number of holidays detected shall meet the
requirements of Table 2.
The coated fittings shall be subjected to an impact resistance test at ambient temperature as specified
in 19.4 and as detailed in GBE/ CW6: Part 1, Appendix D. The coating shall withstand an impact of 1.5
J without a holiday being caused.
16.3.5 Adhesion test
The coated fittings shall be subjected to an adhesion test as specified in 19.5 and as detailed in
GBE/CW6: Part 1, Appendix E.
16.3.6 Coating cure test
The degree of cure of the coating shall be determined by DSC analysis of a sample of the coating
taken from the area of thickest coating and any identified 'cool spots', and tested in accordance with
GBE/CW6 Part 1, Appendix A. The acceptance criterion shall be based on the difference between the
measured Tg2 and Tg1 (as defined in GBE/CW6: Part 1. Appendix A). This difference is termed a ∆
Tg,
The acceptance range of ∆Tg will depend on the type of powder used (see also 19.6).
The test sections shall be subjected to a cathodic disbonding test as detailed in GBE/ CW6: Part 1,
Appendix F. The disbondment shall not extend more than 5 mm radially from the edge of the
damaged coating after the test period of 28 days.
- 16 -
SECTION THREE
GBE/CW6: PART 2
The test sections shall be prepared and subjected to a water immersion test as detailed in GBE/CW6:
Part 1, Appendix E. The coating shall show no loss of adhesion greater than 3 mm after 28 days.
The surface of the fitting to be coated shall be prepared as specified in 5.4.
Components shall be blast cleaned to a minimum standard of BS 7079 Sa 2 12 quality. The surface
profile shall be between 50µm and 100µm peak to trough height and shall be angular in nature.
17.2 Coating process
17.2.1 General
The production coating process shall be carried out using a procedure that fulfils the requirements of
16.3.
The thickness of the coating shall be not less than 350µm, and not greater than 1500µm.
17.2.2 Spray applied coating
17.2.2.1 Operator qualifications
When required, the individual operators carrying out the powder spraying application shall be
subjected to a qualification test in which they will be required to demonstrate proficiency in the
spraying process as laid down in the relevant section of the procedures.
17.2.2.2 Preheating
Preheating shall be carried out using suitable heating equipment and its duration shall not be extended
for more than 30 min beyond the time at which the required surface temperature is reached. The
surface temperature shall be continuously monitored at a selected point by means of a surface
pyrometer, or any other method which may be proposed as a variant for consideration by British Gas,
which shall be calibrated against a standard method of surface temperature measurement. If the
appearance of the fitting after preheating is unsuitable. it shall be blast cleaned (see 5.4) before
continuing the coating procedure.
17.2.2.3 Spraying equipment
The spraying equipment shall be adequate for applying the powder in accordance with the powder
manufacturer's instructions and the qualification procedure. The equipment shall be maintained in
good order by the Contractor and/or the equipment supplier. All air lines shall be provided with filters
and vapour traps to ensure that the air is free from oil and moisture. All critical parameters shall be
monitored.
- 17 -
GBE/CW6: PART 2
SECTION THREE
17.2.2.4 Spraying procedure
The spraying procedure shall be in accordance with the qualification procedure which shall include a
total time allowed for coating. Individual operators shall be experienced in the use of equipment and
shall be suitably qualified (see 17.2.2. 1). The temperature of the fitting shall be checked at selected
points on the surface, in such a manner as to ensure that the surface temperature does not fall below
that recommended by the powder supplier. If the limits of time and temperature are exceeded, the
fitting shall be cleaned and recoated.
17.2.2.5 Post cure
It post curing is required by the qualification procedure, the component shall be moved within a defined
period into the post curing oven. The time and temperature shall be monitored as in 17.2.2.2.
17.2.3 Dip applied coatings
17.2.3.1 Preheating
The duration of preheating shall not be extended for more than 30 min beyond the time at which the
required surface temperature is reached. The surface temperature shall be monitored at a selected
point by means of a surface pyrometer or any other method, which may be proposed as a variant for
consideration by British Gas, which shall be calibrated against a method of a standard surface
temperature measurement. If the appearance of the fitting after preheating is unsuitable, it shall be
blast cleaned (see 5.4) before continuing the coating procedure.
17.2.3.2 Dipping bath
The dipping bath shall meet the following requirements:
a) The dipping bath shall be of dimensions which enable a fitting of the maximum stated size
to be freely dipped.
b) The method of fluidisation shall promote even fluidisation and control of powder density
within the bed.
c) The bed shall be renewed completely if the powder ceases to comply with GBE/CW6: Part
1 or if the condition of the powder results in unacceptable deterioration of the finished
product
17.2.3.3 Dipping procedure
The dipping procedure shall be as follows:
a) When the powder is fluidised to the required density, the fluidised bed shall be made up to
a depth adequate for dipping the fittings.
b) Prior to dipping, the temperature of the fitting shall be checked at selected points on the
surface to ensure that the surface temperature does not fail below that recommended by
the powder supplier.
c) The coating time shall be specified for each type and size of fitting.
d) If limits of time and temperature are not achieved, the fitting shall be cleaned and
recoated.
- 18 -
GBE/CW6: PART 2
SECT ION THREE
17.2.3.4 Post cure
If post curing is required by the qualification procedure, the fitting shall be moved with the minimum
delay into the post curing oven. The time and temperature shall be monitored as specified in 17.2.3. 1.
19.1 Testing of coated fittings
Cured coatings on fittings shall comply with the requirements of 19.2 to 19.7 inclusive and, where
indicated, methods of test described in GBE/CW6: Part 1 shall be used.
The Contractor shall ensure that the tests specified in 19.2 to 19.7 inclusive are carried out in duplicate
and the results of the tests, demonstrating compliance, made available.
19.2 Thickness test
The coated fittings shall be subjected to a thickness test of the cured coating at not less than 20
locations spaced evenly to represent the total area of the coated fitting. The thickness measuring
gauge used shall be calibrated hourly for the specified thickness range (see Appendix A).
The coated fittings shall meet the thickness requirements specified in 16.3.2.
The coated fittings shall be subjected to a holiday detection test over 100% of the coated surface as
detailed in GBE/CW6: Part 1, Appendix C.
The number of holidays detected shall comply with Table 2. If, on any two consecutive fittings, the
number of holidays detected is greater than the normally acceptable level but less than the maximum
permissible level, the cause shall be immediately investigated.
If four further consecutive fittings are detected as having holidays between the normally acceptable
level and the maximum permissible level given in Table 2, all production to that point shall be
quarantined until the reason for the high frequency of holidays is determined. A total of 5% of daily
production will be accepted with up to the maximum permissible number of holidays provided that the
5% are not consecutive.
Fittings with more holidays than permitted by Table 2 shall be rejected for subsequent stripping (see
clause 14) and recoating.
of the fitting.
- 19 -
GBE/CW6: PART 2
SECTION THREE
permanently marked on the fitting and recorded on the relevant inspection documentation.
Initially, the impact resistance of the coating shall be checked for compliance with 16.3.4 determined at
five locations chosen to represent the area coated, as detailed in GBE/CW6: Part 1, Appendix D.
The frequency of testing shall, initially, be once every two hours or five fittings, whichever is the more
frequent. Subsequently, this test frequency may be varied based on quality history.
19.5 Adhesion test
The coated fittings shall be subjected to an adhesion test of the cured coating, at one location on the
fitting, as detailed in GBE/CW6: Part 1, Appendix E.
The frequency of testing shall, initially, be once every two hours or five fittings, whichever is the more
frequent. Subsequently, this frequency may be varied based on quality history.
19.6 Coating cure test
In order to meet the acceptance requirements of 16.3.6, the DSC test procedure detailed in
GBE/CW6: Part 1, Appendix A, shall, initially, be carried out on each fitting. Subsequently, this rate of
testing may be varied based on quality history.
If a test does not result in a value of ∆Tg within the acceptable range, the following retest procedure
shall be used:
a) For a measured ∆Tg within +2°C of the upper acceptable limit, a further two samples from
the test section shall be tested. All glass transition temperature values shall be expressed
as corrected temperatures.
b) If the value of ∆Tg obtained lies within the acceptable range, the fitting shall be accepted.
c) If the value of ∆Tg obtained does not lie within the acceptable range, the fitting shall be
rejected and adjacent fittings in the production run shall be successively sampled and
tested until acceptable coating is identified.
19.7 Defect rate
Should tests in any production batch (typically the production from a seven hour shift) show a rejection
rate of more than 20% defective fittings for any one test, every fitting in that batch shall be individually
subjected to that test. In such cases, the Contractor shall simultaneously conduct an investigation to
establish the cause of the defects.
The cost of retrieval of any fittings with defective coatings dispatched from the coating premises and/or
any additional expenses incurred as a result of additional examination shall be borne by the
Contractor.
- 20 -
GBE/CW6: PART 2
SECTiON THREE
If any fitting fails the requirements of 19.2 to 19.6 inclusive, a check procedure shall be initiated. This
will involve checking all fittings back to the preceding acceptable fitting. The fitting numbers shall be
available from the final inspection bench. These fittings shall be subjected to an examination similar to
that carried out on the failed fitting. If the number of defects detected is significant, the entire coating
production for that day shall be quarantined and investigated.
20. REPAIRS
All holidays and other coating defects shall be repaired with multi-component materials to ensure
compatibility with the applied coating. All repairs shall be retested for holidays in accordance with GBE/
CW6: Part 1, Appendix C.
The maximum repair area shall be in accordance with Table 2.
Repairs shall not be carried out within 200 mm of the end of the coating, but all areas of damage shall
be recorded and marked.
21. HANDLING OF COATED FITTINGS
All coated fittings shall be handled and stored in accordance with the relevant fitting standard and
BGC/PS/L3 to prevent damage to the fitting and coating.
The fitting ends may be required to be protected from damage and corrosion. The type of protection
and the method of application shall be specified by British Gas (see BGC/PS/L3).
Rejected coating shall be removed by a procedure which shall not cause mechanical damage to the
fitting and shall not cause the steel temperature to exceed 250°C.
23. IDENTIFICATION
The Contractor shall be responsible for ensuring that all internal or external identification markings are
noted before surface preparation begins, and are replaced after the coating process in accordance
with 5.2.
- 21/22 -
GBE/CW6: PART 2
SECTION FOUR
SECTION FOUR - MULTI-COMPONENT LIQUID COATINGS ON PIPES AND FITTINGS
24. PROCEDURE QUAILIFICATION
24.1 General
Before bulk coating of pipes and fittings commences, the requirements of 24.2 shall be met and a
detailed sequence of operations to be followed for the coating of pipes and fittings shall be
demonstrated.
The coating procedure specification shall incorporate full details of the following:
a) Quality plan.
b) Multi-component liquid coating to be used together with appropriate data sheets as

defined in clause 4.
c) Pipe or fitting dimensions.
e) Pipe or fitting cleaning.
h) Dust removal.
j) Preheat method time and temperature (if specified).
k) Residual surface contamination.
l) Multi-component liquid and primer (if used) mixing and application.
m) Curing regime.
n) Repair technique.
c) Coating stripping technique.
p) Handling procedures.
24.3.1 General requirements
Three test pieces for the coating procedure approval tests shall be selected from pipe or fittings
coated in accordance with the curing regime (see 24.2). Test pieces shall be subjected to the
complete set of tests specified in 24.3.2 to 24.3.10 inclusive after curing in accordance with the
Manufacturer's recommendations. Testing shall be witnessed and a full set of test results recorded.
No coated pipe or fittings shall be dispatched until the procedure has passed the approval tests.
- 23 -
SECTION FOUR
GBE/CW6: PART 2
The Contractor shall ensure that the tests specified in 24.3.2 to 24.3.10 inclusive are carried out and
the results of the tests, demonstrating compliance, made available.
The coated test pieces shall be subjected to a thickness test of the cured coating as specified in 27.2.
The cured coating thickness shall be not less than 1.5 mm and uniform for all tests.
The coated test pieces shall be subjected to a holiday detection test over 100% of the coated surface
as detailed in GBE/CW6: Part 1, Appendix C. The number of holidays detected shall not exceed those
specified in Table 2.
24.3.4 Hardness and cure test
The coated test pieces shall be subjected to a hardness and cure test as specified in 27.4.
The coated test pieces shall be subjected to an impact resistance test at ambient temperature as
detailed in GBE/CW6: Part 1, Appendix D. The cured coating shall withstand an impact of 5 J without
a holiday being caused.
24.3.6 Adhesion test
The coated test pieces shall be subjected to an adhesion test as detailed in GBE/CW6: Part 1,
Appendix E.
24.3.7 Flexibility test (for pipe only)
The coated test pieces shall be sectioned and subjected to a flexibility test as detailed in GBE/CW6:
Part 1, Appendix B. The coating shall not exhibit signs of cracking, disbondment or pinholes and the
test pieces shall also pass a holiday detection test as detailed in GBE/CW6: Part 1, Appendix C.
The coated test pieces shall be subjected to a cathodic disbonding test as detailed in GBE/CW6: Part
1, Appendix F. The disbondment shall not extend more than 5 mm radially from the edge of the
damaged coating after the test period of 28 days.
24.3.9 Strain/polarisation cracking test (for pipe only)
The coated test pieces shall be bent and then polarised as detailed in GBE/CW6: Part 1, Appendix G.
After 28 days polarisation, the test pieces shall show no visible cracking or pinholing of the coating and
the test pieces shall also pass a holiday detection test as detailed in GBE/CW6: Part 1, Appendix C.
The coated test pieces shall be prepared and subjected to a water immersion test as detailed in
GBE/CW6: Part 1, Appendix E. The coating shall show no loss of adhesion greater than 3 mm after 28
days.
- 24 -
GBE/CW6: PART 2
SECTION FOUR
The surface of the pipe or fitting to be coated shall be prepared as specified in 5.4, except that the
quality required shall be to BS 7079 Sa 2½ and the profile shall be within the range 75µm to 100µm
peak to trough height and angular in nature.
25.2 Coating process
25.2.1 General
The production coating process shall be carried out using a procedure approved in accordance with
clauses 4, 5.4 and 24. This shall normally be a spray coating process, but brush application may be
used on small areas.
The thickness of the coating shall be not less than 1.5 mm.
25.2.2 Pre-mix agitation
Each coating component shall, when necessary, be mixed to a homogeneous state before any part of
the component is withdrawn from its container.
25.2.3 Mixing for use
The components (e.g. base and curing agent) of a coating material are normally supplied separately
packed. They shall be mixed in accordance with the Manufacturer's instructions.
If preheating of one or more of the coating material components is required prior to mixing and
application, the procedure shall be monitored and controlled to avoid excessive heating which might
affect application or the integrity of the coating.
Material cure time is dependent on ambient temperature. Should it be necessary to shorten the cure
time, this may be achieved by the application of heat to the prepared surface before coating
commences.
Thinners shall not be used unless recommended by the Manufacturer.
25.2.4 Spraying equipment
The spraying equipment shall be adequate for applying the coating in accordance with the coating
manufacturer's instructions and the qualification procedure. The equipment shall be maintained in
good order by the Contractor and/or the equipment supplier. All air lines shall be provided with filters
and vapour traps to ensure that the air is free from oil and moisture. All critical parameters shall be
monitored.
Tools and equipment shall be cleaned using only such solvents as are recommended by the coating
material manufacturer.
25.2.5 Operator qualifications
When required, the individual operators carrying out the multi-component liquid spraying application
shall be subjected to a qualification test in which they will be required to demonstrate proficiency in the
spraying process as laid down in the relevant section of the procedures.
- 25 -
GBE/CW6: PART 2
SECTION FOUR
25.2.6 Spraying procedure
25.2.6.1 The spraying procedure shall be in accordance with the qualification procedure which
shall include a total time allowed for coating. Individual operators shall be experienced in the use of
equipment and shall be suitably qualified (see 25.2.5).
25.2.6.2 Solvent flushing of spray equipment used for rapid cure materials is normally employed to
prevent coating material gelling in the gun when spray operations cease for significant periods of time.
It is essential that, on recommencement of spraying, the operator ensures that solvent-free material
only is applied to the work to avoid ensuing problems caused by solvent blistering of the coating.
Additionally, all solvent flushing operations shall be carried out by discharging the solvent into a
suitable container. Solvent shall not be discharged at random on to the surrounding work area.
25.2.6.3 Coating material filters shall be installed as part of the spray equipment to ensure that
particles which would be detrimental to the coating application are not deposited on to the surfaces
being coated. Regular inspection and maintenance of the filters is recommended,
25.2.6.4 The coating component feed lines to the spray-gun shall be equipped with a pressure
gauge fittedwith a pulsation damper, to facilitate pressure readings. The location of this gauge shall be
downstream of all pressure drop devices and as near to the gun tip as is reasonably practicable.
25.2.6.5 The coating contractor shall monitor and record all relevant ambient conditions during
application and cure.
25.2.6.6 The temperature of the metal surface at the time of application shall be not lower than
10°C. Ideally, for optimum results, the metal surface temperature should be between 25°C and 35°C,
but, it is essential that care be taken to avoid contaminating the surface. The relative humidity shall be
80% or less during application and the ensuing first hour of cure time.
25.2.6.7 Coating operations shall be stopped when the conditions are such that an inferior coating
will result. Such conditions include inadequate surface preparation, unsatisfactory application
procedure, poor coating material performance and when the steel temperature at any stage of the
process falls to within 3°C of the dew point measured in the work area.
27.1 Testing of coated pipes and fittings
Cured coatings on pipe and fittings shall comply with the requirements of 27.2 to 27.8 inclusive and,
where indicated. methods of test described in GBE/CW6: Part 1 shall be used.
The Contractor shall ensure that the tests specified in 27.2 to 27.8 inclusive are carried out and the
results of the tests, demonstrating compliance, made available.
- 26 -
SECTION FOUR
GBE/CW6: PART 2
27.2 Thickness test
The coating thickness on each pipe shall be checked at not less than five equidistant locations spread
over the coated surface of the pipe and the coating thickness of each fitting shall be tested in 20
locations spaced evenly to represent the total area of the fittings coated. All readings of the dry film
thickness shall meet the requirements specified in 24.3.2. The thickness measuring gauge used shall
be calibrated hourly for the specified thickness range (see Appendix A). Values less than those
specified in 24.3.2 shall constitute cause for rejection.
Every pipe and fitting shall be subjected to a holiday detection test over 100% of their coated surfaces
as detailed in GBE/CW6: Part 1, Appendix C.
The number of holidays detected shall comply with Table 2. If, on any two consecutive pipes or fittings,
the number of holidays detected is greater than the normally acceptable level, but less than the
maximum permissible level, the cause shall be immediately investigated.
If four further consecutive pipes or fittings are detected having holidays between the normally
acceptable level and the maximum permissible level given in Table 2, all production to that point shall
be quarantined until the reason for the high frequency of holidays is determined. A total of 5% of daily
production will be accepted with up to the maximum permissible number of holidays provided that the
5% are not consecutive.
Pipes or fittings with more holidays than permitted by Table 2 shall be rejected for subsequent
stripping (see clause 14) and recoating.
of the pipes or fittings.
permanently marked on the pipe or fitting and recorded on the relevant inspection documentation.
27.4 Hardness and cure of coating test
The hardness and cure of the coating on every pipe and fitting shall be determined
The value of the hardness obtained shall be within the range specified by the Manufacturer of the
material to indicate the correct degree of cure of the coating.
The coated pipes and fittings shall be subjected to an impact resistance test of the cured coating as
detailed in GBE/CW6: Part 1, Appendix D.
The frequency of testing shall be, for pipes, initially once every two hours or 20 pipes and, for fittings,
initially once every two hours or five fittings, whichever is more frequent.
The cured coating shall withstand a minimum impact of 5 J without resulting in a breakdown or loss of
adhesion of the coating.
27.6 Adhesion test
The coated pipes and fittings shall be subjected to an adhesion test of the cured coating as detailed in
GBE/CW6: Part 1, Appendix E.
- 27 -
GBE/CW6: PART 2
SECTION FOUR
The frequency of testing shall be, for pipes, initially once every two hours or 20 pipes and, for fittings,
initially (at one location on the fitting) once every two hours or five fittings, whichever is the more
frequent.
This initial test frequency may subsequently be varied, the revised test frequency being based on
quality history.
27.7 Heat blister test
After initial cure, a test plate of representative wall thickness, coated at the same time as the batch of
pipe and fittings with multi-component liquid systems, shall be subjected to a heat blister test by
heating the steel to a temperature in the range 50°C to 60°C and holding the temperature within that
range for one hour.
After heating, the test plate shall be inspected for blisters. In the event of blistering being observed, an
investigation into the cause of the defect shall be immediately undertaken. Samples of coating may
have to be removed for nitrogen analysis or other appropriate tests and the coating operations may
have to cease during the period of the investigation. When the cause of the defect has been
established, components in the coating sequence during which the plate has been coated, shall be
tested until an acceptable coating is identified.
For pipes, testing shall normally be carried out at a frequency of once every two hours or 20 pipes,
whichever is the more frequent. For fittings, testing shall normally be carried out at a frequency of once
every two hours or five fittings, whichever is the more frequent. These test frequencies may be varied,
and the applicator may also have to vary the test frequency.
Localised blisters shall be repaired.
27.8 Defect rate
Should tests in any coating production batch (typically the production from a seven hour shift) show a
rejection rate of more than 10% defective pipes or fittings for any one test, then every component in
that batch shall be individually subjected to that test. In such cases the Contractor shall simultaneously
conduct an investigation to establish the cause of the defects.
The cost of retrieval of any pipes and fittings dispatched from the coating premises and/or any
additional expenses incurred as a result of additional examination shall be borne by the Contractor.
If any pipe or fitting has defects in excess of the requirements of 27.2 to 27.8 inclusive, a check
procedure shall be initiated. This shall involve checking all pipes or fittings back to the preceding
acceptable one. The pipe or fitting numbers shall be available from the final inspection bench. These
pipes or fittings shall be subjected to an examination similar to that carried out on the failed pipe or
fitting. If the number of defects is significant, the entire coating production for that day shall be
quarantined and investigated.
28. REPAIR OF DEFECTS
All repairs to holidays and other coating defects shall be with multi-component liquid materials to
ensure compatibility with the applied coating. Repair methods shall include adequate surface
preparation techniques, agreed overlaps, coating thicknesses and a demonstration of satisfactory
adhesion and cure. All repairs shall be retested for holidays as detailed in GBE/CW6: Part 1, Appendix
C.
Maximum areas of repair shall be not greater than those given in Table 2.
- 28 -
SECTION FOUR
GBE/CW6: PART 2
The area to be overlapped shall extend to at least 75 mm from the periphery of the defect. The repair
material shall be applied to the prepared surfaces using a scraper, palette knife or paint brush.
Care shall be taken to ensure that the thickness over the repair area is not less than 1.5 mm when
cured.
29. HANDLING OF COATED PIPES AND FITTINGS
All coated pipes and fittings shall be handled and stored in accordance with BGC/PS/L3 and the
relevant fitting standard where appropriate to prevent damage to the component and coating.
The weld end preparations and fitting ends may be required to be protected from damage and
corrosion. The type of protection and the method of application shall be specified by British Gas.
Rejected coatings shall be removed by a procedure which shall not cause mechanical damage to the
pipe or fitting and shall not cause the steel temperature to exceed 250°C.
It should be noted that multi-component liquids give off toxic fumes when heated and due care shall
be taken not to inhale any combustion products.
31. IDENTIFICATION
The Contractor shall be responsible for ensuring that all internal and external identification markings
are noted before the surface preparation begins, and are replaced after the coating process in
accordance with 5.2.
- 29/30 -
GBE/CW6: PART 2
APPENDIX A
CALIBRATION PROCEDURES FOR THICKNESS MEASUREMENT OF FUSION BONDED EPOXY

POWDER AND MULTI-COMPONENT LIQUID COATINGS
A.1 GENERAL
The following calibration procedures for inferential thickness measurement gauges shall be used as
appropriate. Calibration of gauges using standard shims on a flat steel substrate will produce a higher
reading than when calibrating on a surface with a grit-blasted profile. The difference in reading is
proportional to the profile height. With coatings in excess of one millimetre thickness, the calibration
'profile factor' is not significant. In cases of dispute, the thickness shall be measured by a direct
method, typically using a pipeline inspector's gauge (PIG).
A.2 CALIBRATION USING PLASTICS FOIL SHIMS OF KNOWN THICKNESS ON

GRIT-BLASTED STEEL
This method shall be used when it is possible to calibrate the instrument on a clean dry grit-blasted
area of the pipe or fitting which is representative of the steel cleanliness and surface roughness at the
time of coating. To obtain accurate thickness readings using magnetic 'pull-off’ and eddy current
instruments the following precautions shall be taken during calibration:
a) Non-metallic shims of known thickness with certification traceable to national standards

shall be used.
b) The shims shall be examined before use to ensure that they are in good condition with no
sign of roughness or wear.
c) The shims selected for calibration shall be close to the expected thickness of the coating
being evaluated.
d) The steel substrate being used for calibration shall be a representative area of the pipe or
fitting and shall be free of oil, dirt, rust, adhesive, pre-treatment or other contaminant.
e) The surface profile and steel cleanliness when calibration is being carried out shall be
typical of the steel condition at time of coating.
The steel substrate shall be at ambient temperature
g) The probe on the thickness gauge shall be clean and free from contaminants.
h) Where repeated thickness measurements are being made, the instrument shall be
re-calibrated at hourly intervals.
A.3 CALIBRATION USING PLASTICS FOIL SHIMS ON A FLAT STEEL SURFACE
Where it is not possible to obtain a representative area of the pipe or fitting, calibration shall be carried
out on flat steel plates of at least 1 mm thickness using plastics foil shims of known thickness. As an
alternative, American National Bureau of Standards (NBS) or Deutscher Institut fur Normalisierung
(DIN) coated test plates may be used. Plastics foil shims or test plates shall be accompanied by
thickness certification traceable to national standards.
- 31 -
GBE/CW6: PART 2
The following precautions shall be taken to ensure accurate measurements..
a) Test certificates for plastics foil shims or coated test plates shall be available.
b) The shims or test plates shall be in good condition with no sign of wear or roughness.
c) The shim or coated test plate selected for calibration shall be close to the expected
thickness of the coating being evaluated.
d) The steel substrate shall be dry, clean and free from rust or any contaminant.
e) The test plate shall be flat and at least one millimetre thick.
f) Where repeated thickness measurements are being taken, the instrument shall be
re-calibrated at two-hourly intervals.
- 32 -

GBE-CW6 Part-2-1993

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GBE/CW6: PART 2

AMENDMENT RECORD AND BRIEF HISTORY vi

SECTION ONE - GENERAL REQUIREMENTS

4.1 Selection of coating materials 2

4.2 Storage of coating materials 2

4.3 Toxicity and handling 3

5. COMPONENTS OR WORK PIECES 3

5.1 Component inspection 3

5.2 Component identification 3

5.3 Protection of weld end preparations 3

5.4 Surface preparation 3

5.5 Chemical pre-treatment and primers 4

5.6 Extent of approvals 4

6. INSPECTION AND TESTING 5

SECTION TWO - FUSION BONDED POWDER COATINGS ON PIPE

8.2 Coating procedure specification 9

8.3 Coating procedure approval tests 9

9. PRODUCTION COATING PROCEDURE 11

9.1 Surface preparation 11

9.2 Coating process 11

9.3 Protection of weld end preparations 11

10. VISUAL INSPECTION 11

11. TESTING OF CURED COATINGS 11

11.1 General requirements 11

11.2 Thickness test 12

11.3 Holiday detection test 12

11.4 Impact resistance test 12

11.5 Adhesion test 12

11.6 Coating cure test 12

11.7 Defect rate 13

11.8 Check procedure 13

13. HANDLING OF COATED PIPES 13

14. STRIPPING OF COATING 14

SECTION THREE - FUSION BONDED POWDER COATINGS ON FITTINGS

16. PROCEDURE QUALIFICATION 15

16.2 Coating procedure specification 15

16.3 Coating procedure approval tests 16

17. PRODUCTION COATING PROCEDURE 17

17.1 Surface preparation 17

17.2 Coating process 17

17.3 Protection of weld end preparations 19

18. VISUAL INSPECTION 19

19. TESTING OF CURED COATINGS 19

19.1 Testing of coated finings 19

19.2 Thickness test 19

19.3 Holiday detection test 19

19.4 Impact resistance test 20

19.5 Adhesion test 20

19.6 Coating cure test 20

19.7 Defect rate 20

19.8 Check procedure 21

21. HANDLING OF COATED FITTINGS 21

22. STRIPPING OF COATING 21

SECTION FOUR - MULTI-COMPONENT LIQUID COATINGS ON PIPES AND FITTINGS

24. PROCEDURE QUALIFICATION 23

24.2 Coating procedure specification 23

24.3 Coating procedure approval tests 23

25. PRODUCTION COATING PROCEDURE 25

25.1 Surface preparation 25

25.2 Coating process 25

25.3 Protection of weld end preparations 26

26. VISUAL INSPECTION 26

27. TESTING OF CURED COATINGS 26

27.1 Testing of coated pipes and finings 26