p264val1 Srx y Sp 0002 b1 Specification for Pipeline External 3lpp Coating

Doc No. P264VAL1-SRX-Y-SP-0002 SATELLITE FIELDS PIPELINE NETWORKS & ASSOCIATED FACILITIES SPECIFICATION FOR PIPELINE EXTERNAL 3LPP COATING

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TABLE OF CONTENTS

1.0

SCOPE ............................... ................................................ .................................. .................................. .................................. ................................. .......................... .......... 3

2.0

REFERENCE DOCUMENTS ................................ ................................................. .................................. ................................. .......................... .......... 3

3.0

PLANT SCALE AND INSTALLATION .................................. .................................................. ................................. ........................... .......... 6

4.0

COATING MATERIAL ............................... ................................................ ................................. ................................. .................................. ..................... .... 6

5.0

FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING SYSTEM .............. SYSTEM .............. 8

6.0

MEASUREMENT AND LOGGING................ LOGGING ................................ ................................. .................................. ................................. ................ 12

7.0

COATING PROCEDURE AND QUALIFICATION QUALIFICATION. ..................................... ..................................................... ..................... ..... 13

8.0

.................................................. .................................. ................................. ................ 18 PIPE SURFACE PREPARATION .................................

9.0

COATING APPLICATION ................................. .................................................. .................................. .................................. ........................... .......... 22

10.0

INSPECTION AND TESTING ............................... ................................................ .................................. ................................. ........................ ........ 24

11.0

HANDLING, TRANSPORTATION AND STORAGE OF MATERIALS MATERIALS .......................... ........................... .. 29

12.0

REPAIR OF COATING ................................. ................................................. ................................. ................................. ................................. ................. 32

13.0

MARKING ................................. .................................................. .................................. ................................. ................................. .................................. ................... .. 33

14.0

QUALITY ASSURANCE .................................. .................................................. ................................. .................................. .............................. ............. 34

15.0

DOCUMENTATION ................................ ................................................. ................................. ................................. .................................. ...................... ..... 34

16.0

PREPARATION PREPARATION FOR SHIPMENT ................................ ................................................. .................................. ................................. ................ 36

17.0

ANNEXURE-A ............................... ................................................ .................................. .................................. .................................. .............................. ............. 37

18.0

APPENDIX 1 ............................... ................................................. .................................. ................................. .................................. ................................. ................ 38

19.0

APPENDIX 2 ............................... ................................................. .................................. ................................. .................................. ................................. ................ 39

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APPENDIX 3 ............................... ................................................. .................................. ................................. .................................. ................................. ................ 40

21.0

APPENDIX 4 ............................... ................................................. .................................. ................................. .................................. ................................. ................ 42

22.0

APPENDIX 5 ............................... ................................................. .................................. ................................. .................................. ................................. ................ 43

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1.0

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SCOPE This specification covers the minimum requirements for supply/arrangement of all materials, plant, equipment, plant sites, consumables, utilities and application including all labor, supervision, supervision, inspection and tests etc. for application application of external anti-corrosion anti-corrosion coating of pipes for buried onshore pipelines carrying liquid/gaseous hydrocarbons by using 3 Layer Polypropylene coating conforming to DIN 30678.

2.0

REFERENCE DOCUMENTS

2.1.

CODES AND STANDARD The latest edition (edition enforce at the time of issue of enquiry) of the following standards, codes and specifications shall establish the minimum standards for the work. AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) ASTM D-149

ASTM D-256

ASTM D-257

Standard Test Methods of Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Material at commercial frequencies. Standard Test Method for Determining the Izod Pendulum Impact Resistance of Plastics Standard Test Methods for D-C Resistance or Conductance of Insulating Materials

ASTM D-543

Standard Method of of Test for Resistance of of Plastics to Chemical Chemical Reagents Reagents

ASTM D-570

Standard Method of of Test for Water Absorption Absorption of Plastics

ASTM D-638

Standard Method of of Test for Tensile Properties Properties of Plastics

ASTM D-746

ASTM D-792 ASTM D-1238 ASTM D-1505 ASTM D-1525

Standard Test Method for Brittleness Temperature of Plastics and Elastomers by Impact Standard Test Method for Density and Specific Gravity (Relative Density) of Plastics by Displacement Test Method for Flow Rates of Thermoplastics Thermoplastics by Extrusion Standard Test Method for Density of Plastics by the Density Gradient Technique Test Method for Vicat Vicat Softening Temperature Temperature of Plastics Plastics

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ASTM D-1603

Test Method for Carbon Carbon Black in Olefin Olefin Plastics

ASTM D-1693

Test Method for Environmental Environmental Stress Stress Cracking of of Ethylene Plastics

ASTM D-2240

Test Method for Rubber Rubber Property - Durometer Durometer Hardness

ASTM D3418

ASTM D-3895 ASTMG-8 ASTMG-42

Standard Test Method for Transition Temperatures and Enthalpies of Fusion and Crystallisation of Polymers Test Method for Oxidative-Induction Time of Polyolefin by Differential Scanning Calorimetry Standard Methods Methods for Cathodic Disbonding Disbonding of of Pipeline Coatings Coatings Tentative Methods for Cathodic Disbonding Disbonding of Pipeline Coatings Subjected to Elevated or Cyclic Temperatures.

ASTM G-14

Impact testing: pipeline pipeline coatings - Impact Impact resistance by falling weight weight test

ASTM D-4285

Standard Test Method Method for Indicating Indicating Oil or Water in Compressed Compressed Air

DEUTSCHES INSTITUTE FUR NORMUNG (DIN) DIN EN 10204

Metallic Products - Types of Inspection Inspecti on Documents

DIN 53735

Testing of Plastics: Determination Determination of Melt Index of Thermoplastics

DIN 30678

Polypropylene Coating for Steel Pipes and Fittings

ASSOCIATION FRANCAISE DE NORMALISATION (AFNOR) NF A49-711

Steel Pipes: External coating with three layer Polypropylene Polypropylene based coating: application by extrusion

API (AMERICAN PETROLEUM INSTITUTE) RP 5L9

External fusion bonded Epoxy Coating of Line pipe.

RL 5L1

Transportation Systems for Hydrocarbons, Liquid, Petroleum Gas, Anhydrous Ammonia, Ammonia, and Alcohols Alcohols

RL 5LW

Recommended Practice for Transportation of Line pipe on Barges and Marine Vessels

INTERNATIONAL ORGANISATION FOR STANDARDISATION (ISO) ISO 868

Plastics and Ebonite – Ebonite – Determination Determination of Indentation Hardness by means of Durometer (Shore Hardness).

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ISO 2808

Paints and Varnishes – Varnishes – Determination Determination of film thickness Recommended Preparation of steel substrates before application of paints and related products - Visual assessment of surface cleanliness - Part 1: ISO 8501-1 Rust grades and preparation grades of uncoated steel substrates and of steel substrates after overall removal of previous coatings Preparation of steel substrates before application of paints and related ISO 8502-2 products - Tests for the assessment of surface cleanliness - Part 2: Laboratory determination of chloride on cleaned surfaces Preparation of steel substrates before application of paints and related products - Tests for the assessment of surface cleanliness - Part 3: ISO 8502-3 Assessment of dust on steel surfaces prepared for painting (pressuresensitive tape method) Preparation of Steel Substrates before Application of Paints and Related Products, Surface Roughness Characteristics of Blast - Cleaned ISO 8503-2 Substrates. Method for the Grading of Surface Profile of Abrasive Blast – Cleaned Steel – Steel – Comparator Comparator Procedure Quality Systems - Model for Quality Assurance in Production, Installation ISO 9002 and Servicing ISO 9003 Quality Systems - Model for Quality Assurance in Final Inspection and Test ISO 9004 Quality Management and Quality System Elements – Guidelines – Guidelines Preparation of Steel Substrates before Application of Paints and Related ISO 11124 Products NATIONAL ASSOCIATION OF CORROSION ENGINEERS (NACE) (N ACE) NACE RP 0185

Extruded Polyolefin Polyolefin Resin Coating Systems with Soft Adhesives for Underground or Submerged Pipe

NACE RP 0274

High- Voltage Electrical Inspection of Pipeline Coatings

NFA 49-711

Steel

Tubes-

3Layer

External

Coating

Based

on

Polypropylene Polypropylene

Application by Extrusion CSA Z245.20-02 Z245.20-02

External Fusion Bonded Epoxy Coating for Steel Steel Pipe. Pipe.

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3.0

PLANT SCALE AND INSTALLATION

3.1.

CONTRACTOR shall size coating plant(s) after evaluating the scale of work and the time schedule required for the works. Coating plant(s), new or existing, shall be installed into a yard whose geometry and dimensions are such as to allow the execution of a continuous work schedule. For this purpose the CONTRACTOR CONTRACTOR shall ensure non-stop work execution owing to prohibitive adverse weather conditions and install requisite equipment and plant in roofed and adequately weather protected areas.

3.2.

Plant equipment, equipment, machinery machinery and other facilities facilities shall be in first class operating operating condition condition to at least meet the job requirements of quality and production. Worn out and improvised plants are not acceptable.

3.3.

The CONTRACTOR CONTRACTOR shall, at his his own responsibili responsibility ty and cost, provide and prepare all necessary area for the storage of bare and coated pipe and all other materials, for coating yard, stock-piling and other temporary installation. For each area, CONTRACTOR shall provide necessary agreements as required with the land owner(s) / relevant Authorities, and, on work completion, to clean and pay settlement and claims for damages, as applicable.

3.4.

The CONTRACTOR shall at its own responsibility responsibil ity and cost, provide for water and power supply and other utilities and consumables and obtain authorization regarding access roads and other permits required for the execution of works conforming to all the requirements requirements of the t he governing Authorities.

3.5.

The CONTRACTOR shall at its own expense provide a fully equipped laboratory and test facilities with adequate inventory to carry out tests required for the procedure qualification and regular production. Outside testing for qualification and regular production is not acceptable to COMPANY.

3.6.

The CONTRACTOR CONTRACTOR shall be fully responsible responsible for adherence adherence to all statutory regulations regulations applicable for handling and disposal of the hazardous chemicals during the coating works

3.7.

The CONTRACTOR shall be responsible for obtaining all statutory statuto ry approvals/ clearances from relevant Authorities relevant Authorities including including Pollution Pollution Control Board, Board, as applicable applicable for the coating coating plant(s normally be at a temperature not greater than 25°C) a) Storage instructions (storage shall normally

4.0

COATING MATERIAL

4.1.

The three layer coating coating system system shall comprise of of a powder powder epoxy epoxy primer, polymeric adhesive and a Polypropylene top coat. Additionally, anti-slip Polypropylene granule coat shall be applied. Coating materials shall be suitable for the service conditions and the pipe sizes involved. The coating materials i.e. epoxy powder, adhesive and Polypropylene compound shall have proven compatibility. The coating system and materials shall be prequalified and approved by COMPANY in accordance with provisions of Annexure-A of this specification.

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4.2.

4.3.

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CONTRACTOR shall obtain prior approval from COMPANY for the coating system and coating materials The coating coating materials materials Manufacturer Manufacturer shall carry out tests for all all properties properties specified specified in clause 4.3 for each batch of epoxy, adhesive and Polypropylene compound. In addition, the Manufacturer shall also furnish Infra-red scan for each batch of epoxy powder. The coating materials Manufacturer shall issue test certificates as per the relevant standards/ methods specified in clause 4.3, for each batch of materials supplied to Contractor and the same shall be submitted to Company for approval prior to their use. In addition to Manufacturer‟s certificate, the CONTRACTOR shall draw samples from each batch of epoxy, adhesive and Polypropylene in the presence of COMPANY REPRESENTATIVE and test for the following properties at the coating yard at least one week prior to its use, to establish compliance with the Manufacturer‟s test certificates. a) FBE Powder Gel time Sieve analysis Adhesion Density Moisture content Thermal analysis b) Adhesive Melt flow index Vicat Softening Point Adhesion to FBE and and Polypropylene Polypropylene layers at 25°C, 25°C, 60°C, 110°C 110°C and 120°C 120°C Density c) Polypropylene Material Density Melt flow index Moisture Content Oxidative Induction Time Shore hardness Vicat softening point

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4.4.

The Polypropylene Polypropylene shall be chemically modified for use at at operating temperatures of of up to 85°C on external surface of pipeline section and shall contain additives as required to provide UV protection and shall be suitable for 3-layer Polypropylene Polypropylene coating system. 4.5. In case of failure of any any of the above tests in a batch, batch, that batch of of material shall be tested for all other tests required as per clause 4.3 including the tests which failed. If all tests pass, the batch shall be accepted for coating. If any of the tests fail, entire batch of material shall be rejected and shall not be used for the coating. 4.6. All packages packages of of powder powder shall be marked marked with with the following data as a minimum. minimum. a) Manufacturer b) Material identification c) Batch number d) Place & Date of manufacture e) Shelf Life/ Expiration date (if applicable) applicable) f) Storage instructions (storage shall normally be at a temperature not greater than 25°C) 4.7. All materials without above identification shall be rejected rejected by by Company. Company. 4.8. Such materials materials shall shall not not be used for coating and shall shall be removed from site. 4.9. Contractor shall shall ensure ensure that all coating materials materials are properly properly stored in accordance accordance with the Manufacturer‟s recommendation at all times, to prevent damage and deterioration in quality prior to use. 4.10. Contractor shall be required required to use all materials on a date received received rotation basis, ie first in-first used basis. 5.0

FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING SYSTEM

The coating shall be able to withstand the maximum in service operating temperature of 85°C for onshore pipeline system. 5.2. Properties 5.1.

Properties of coating system and coating material shall comply the requirements indicated in subsequent paragraphs. In case, the coating/ material properties are tested as per test methods/ standards other than specified herein below, the same may be accepted provided the test procedures and test conditions are same or more stringent than the specified 5.3.

Property of FBE Powder Contractor shall select epoxy powder that will achieve the functional requirements and properties of coating system as specified in clause 5.1 and Table 1 of this specification respectively.

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Table 1 (Typical Properties of FBE Powder) Pr oper ties

Requir ement

Applied Standar d

1

Specific Gravity

As defined by Manufacturer

ISO 2811-1

2

Moisture Content

0.5% Max

API RP 5L9

3

Total Volatile content

0.6% Max

API RP 5L9

4

Particle size

API RP 5L9

5

Cure Cycle

0.2% Max Retained on 60 mesh (250 microns) Capable of cure at temperature below 260 OC

Sl No.

API RP 5L9

Tg1 40-75OC

6

Glass Transition Temperature

7

Wet Glass Transition Temperature

Tg2 ≥120 ≥120 OC

Manufacturer's Test

8

Heat of Reaction


NACE RP 0394

9

Gel time


NACE RP 0394

10

Hardness Shore D

80-90

ASTM D 2240

11

Flexibility

Flexibility > (3o/PD) at 0 OC PD: Pipe

API RP 5L9

12

Impact Resistance

2.0 Joule

API RP 5L9

13

Abrasion Resistance

300mg Max (Note-1)

API RP 5L9

14

Cathodic Disbondment

Tg2 0-120OC

5mm at 230C/ 30 days or 0

NACE RP 0394

AFNOR A49-711 A49-711

7mm at 85 C/ 48 hours 15 16

Dielectric Strength Hot water Soak Test

Strength > 500 Volt / mil mil = 25 microns 30% max. of coating can be removed as per rating 2 of standard

ASTM D 149 API RP 5L9

Note 1: Abrasive resistance is equal 300 mg max. by C.S 17 abrasive wheel 1000 gram /1000. 5.4.

Properties of Adhesive Adhesive Contractor shall select adhesive that will achieve the functional requirements and properties of coating system as specified in clause 5.1 and Table 2 of this specification respectively. respectively.

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Doc No. P264VAL1-SRX-Y-SP-0002 SATELLITE FIELDS PIPELINE NETWORKS & ASSOCIATED FACILITIES

Revision

SPECIFICATION FOR PIPELINE EXTERNAL 3LPP COATING

B1

Table 2 (Typical Properties of Adhesive) Sl

Typical Properties (Physical)

Requir ement

Test Method Standar d (Clause)

1

Specific Gravity

0.89-0.92

ASTM D 1505

2

Melt flow rate (MFR) 23 C

0.75 – 0.75 – 1.2 g/10 min

ISO 1133

3

Water Content

Equal or less than 0.1%

ISO 15512

o

Mechanical

4

Tensile Yield Strength

Equal or greater than 20 Mpa

ASTM D 638

5

Tensile Elongation

Equal or greater than 350

ASTM D 638

6

Hardness Shore D

Equal or Greater than 57

ASTM D 2240

7

Brittle Point

-20 C

ASTM D 746

+45 KJ/m

ISO 180

Impact

8

Notched izod impact strength at +23oC Ther mal

9

5.5.

Vicat softening temperature

0

Equal or Greater than 130 C

ASTM D 1525

Properties of Polypropylene Polypropylene Compound The Polypropylene compound shall be UV and thermal stabilized co-polymer, designed for extrusion and suitable for continuous service at operating temperatures of up to 85°C for onshore buried pipeline application Table 3 (Typical Properties of Polypropylene Coating (Top Coat)) Sl.No.

Typical Pr oper ties

Requir ement

Test Method Standar d

0.89

ASTM D 1505

Physical

1

Specific Gravity

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Doc No. P264VAL1-SRX-Y-SP-0002 SATELLITE FIELDS PIPELINE NETWORKS & ASSOCIATED FACILITIES

Revision

SPECIFICATION FOR PIPELINE EXTERNAL 3LPP COATING

2

Water Absorption

3

Water Content

Min 0.02% wgt

B1

ASTM AST M 570

<0.05 %

ISO 15512

Mechanical

4

Tensile Yield Strength

20 Mpa

ASTM AST M D 638

5

Tensile Elongation

400%

ASTM AST M D 638

6

Shore D Hardness

ASTM D 2240

55

Impact Notched izod impact strength at +23 0 C

7

50 KJ/m

ISO 180/ 1A

Thermal

Vicat softening temperature

8

> 115 o C

ASTM D 1525

Table 4 (Properties of Coating System) Properties

Requirement

Applied Standard

a

Appearance and continuity

Uniform colour, free of defects and discontinuities, discontinuities, delamination, delamination, separations separations and pinholes

AFNOR A49711

b

Impact Strength

No failure after 30 impacts, when tested with 25KV

DIN 30678

c

Indentation (mm) at 90±50C

0.3mm

DIN 30678

SL NO

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6.0

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d

Elongation at break of the PP

400%

ASTM D 638

e

UV aging (Elongation break)

260%

AFNOR A49711

100N/cm at 50 ± 50C (at peel off rate 10mm/min)

f

Bond Strength

g

Hot water soak test for FBE cure

No loss of adhesion

API RP 5L9

h

Degree of the cure of the epoxy (1st layer)

Temp. Variation (Max. Tg:2oC to +3oC

AFNOR A49711

i

Porosity of FBE (cross sectional & Interface)

Rating 1

NACE RP 0394

j

Interface contamination of FBE

Maximum 20%

NACE RP 0394

k

Shore D Hardness

57

ASTM 2240

l

Product stability during extrusion of the PP top layer process

≤35% (virgin compound granule before extrusion / extruded foil after extrusion of the same batch)

ISO 1133

m

Average cathodic cathodic disbonding length

0

80 N/cm at 50 ± 5 C (at peel off rate 10mm/min)

≤5mm at 23oC/30 days or ≤ 7mm at 85 oC/ 48 hours

DIN 30678

AFNOR A49711

MEASUREMENT AND LOGGING CONTRACTOR shall maintain records in computer using MS ACCESS database Software containing all the relevant data of individual pipe and pipe coating including pipe number, heat number, diameter, length, wall thickness, defects, coating number batches of materials, sampling, testing, damages, repairs, rejects and any other information that COMPANY considers to be relevant and required for all incoming bare pipes and COMPANY approved outgoing coated pipes as applicable. CONTRACTOR‟s CONTRACTOR‟s documentation shall be designed to ensure full traceability of pipe and coating materials through all stages of coating and testing.

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CONTRACTOR shall submit this information in the form of a report at the agreed intervals. The above data shall also be provided in MS ACCESS format in Compact Disc (CD). CONTRACTOR shall provide one Computer Terminal to COMPANY Representative for monitoring/tracking of the above. The CONTRACTOR shall also submit the material balance details to COMPANY for information at the end of each shift. 7.0

7.1.

COATING PROCEDURE AND QUALIFICATION Upon award of the CONTRACT, the CONTRACTOR shall submit within two (2) weeks, for COMPANY approval, a detailed report in the form of bound manual outlining, but not limited to, the followi f ollowing: ng: Details of plant(s), location(s), layout, capacity and production rate(s). Details of the equipment equipment available to carry out the coating works including surface preparation, epoxy powder application and its recycling system, adhesive & Polypropylene Polypropylene extrusion, moisture control facilities available for f or coating materials. Details of process control and inspection equipment equipment required for the coating process such as temperature control, thickness control, holiday testers, etc. Facilities in the yard for unloading, handling, transport, production, storage, stockpiling, loading of bare and coated pipes and warehouses for storage of other coating materials. Plant Organization Chart and availability of manpower including coating specialist. Details of utilities/facilities utilities/facilities such as water, power, fuel, access roads and communication etc. After COMPANY has given approval, no change in plant set-up shall be made. However, unavoidable changes shall be executed only after obtaining written approval from COMPANY. At least four (4) weeks prior to the commencement commencement of production coating, a detailed procedure of the CONTRACTOR's methods, material proposed, etc., shall be formulated by the CONTRACTOR and submitted for COMPANY approval in the form of a bound manual. The procedure shall include, but not limited to, the following information and proposals: Pipe inspection at the time of bare pipe receipt. Steel surface preparation, preparation, including preheating, preheating, removal of steel defects, method of pipe cleaning, dust removal, abrasive blast cleaning and surface profile; methods of measurements measurements and consumables. Pipe heating, temperatures temperatu res and control prior to epoxy application. Complete details of raw materials including current data sheets showing values for all the properties specified together with quality control and application procedure recommendations recommendations from manufacturer(s). Application of FBE powder, adhesive and polypropylene, polypropylen e, including characteristics, characteris tics, temperature, line speed, application window, curing time, etc.  

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7.2.

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Quenching and cooling, including time and temperature temperatur e Quality Assurance System, Quality Plan, Inspection and Test Plan and reporting formats, including instrument and equipment types, makes and uses, etc. Detailed method of repair of coating defects duly classified depending depending upon nature and magnitude of defects and repair thereof including coating stripping technique Details of instrument and equipment calibration methods including relevant standards and examples of calibration certificates. Complete details and inventory of laboratory and equipment for procedure qualification and regular production Pipe handling and stock piling procedures Sample of recording and reporting formats, including laboratory reports, certificates and requirement as per clause 6.0 of this specification. Complete details of test certificates for raw materials including test methods and standards used. Test certificates from PP compound manufacturer for tests for thermal aging, coating resistivity and aging under exposure to light. These test certificates shall not be older than three years. Health, Safety and Environment Environment Plans. Storage details of coating materials and chemicals. Continuous temperature monitoring at various stages of coating

Procedure Qualification Tests (PQT) shall be carried out only after obtaining written approval of the above procedure from COMPANY. No change in the procedure shall be made after the COMPANY has given approval. However, unavoidable changes shall be executed only after obtaining written approval from COMPANY. 7.3.

Prior to start start of production, the CONTRACTOR shall, at his his expense, expense, carry out a coating PQT for each pipe diameter on max. wall thickness, for each type of pipe, for each coating material combination, and for each plant, to prove that his plant, materials, and coating procedures result in a quality of end product conforming to the properties stated in clause.4.2, relevant standards, specifications and material manufacturer's recommendations. CONTRACTOR shall give seven (7) working days‟ notice to notice to witness all procedures and tests. A batch representing representing a normal production run, typically 15 pipes, shall be coated in accordance with the approved coating procedure and the coating operations witnessed by COMPANY Representative. Out of these pipes, at least one pipe shall be coated partly with epoxy and partly with both epoxy and adhesive layers At least 5 (five) test pipes shall be selected by COMPANY Representative Representative for coating procedure approval tests and shall be subjected to procedure qualification testing as described hereinafter. COMPANY Representative shall witness all tests.

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7.4. 7.4.1

7.4.2

7.4.3

7.4.4

7.5. 7.5.1

Revision

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Out of 5 (five) test pipes, 1 (one) pipe partly coated with epoxy and partly coated with both epoxy and adhesive layers shall be included. Remaining 4 (four) test pipes shall have all three layers. During PQT, the CONTRACTOR shall qualify various procedures forming a part of coating operations as detailed subsequently. Pipe partly coated with epoxy and partly coated with both epoxy and adhesive layers and the pipes coated with all three layers shall be subjected to complete set of tests as detailed in Clause 7.5 and specified in Appendix-1. Pipes selected for PQT shall pass all the criteria contained in Appendix-1 before production commences. Qualification of Procedures Epoxy Powder Application & Recycling During pre-qualification, air pressure in the epoxy spray guns, satisfactory functioning of monitoring system, line speed vs. coating t hickness, etc. shall be established. Dew point of air used to supply the fluidised bed, and epoxy spray system shall be recorded during the PQT. No epoxy recycling is permitted. Pipe Pre-heating The CONTRACTOR shall establish the temperature variation due to in-coming pipe temperature, line speed variation, wall thickness variation, emissivity, interruptions, etc. and document the same during the PQT stage. During PQT, proper functioning of pipe temperature monitoring and recording system including alarm/hooter shall be demonstrated to the COMPANY Representative. Representative. Surface Preparation The procedure to clean and prepare the pipe surface shall be in accordance with the requirements of Clause 9.0 of this specification. The ratio of shot to grit shall be established during procedure qualification testing, such that the resultant surface profile is not dished and rounded. The qualification shall be performed through a visual inspection, measurement of roughness and check of the presence of dust on the abrasive blast cleaned pipe surface. Coating Application The COMPANY Representative will check the correctness of each coating application operation, values of the main parameters of each operation, pre-heating pipe surface temperature prior to epoxy powder application temperature, line speed, fusion bonded epoxy curing time, temperature and flow rate of co-polymer adhesive and Polypropylene, etc. and the same shall be recorded. These values shall be complied with during regular production. Qualification of Applied Coating Tests on pipe coated partly with epoxy and partly with epoxy & adhesive layers a. Degree of Cure Epoxy film samples (minimum 4 no.) shall be scrapped from the coated pipe and the samples shall be taken for cure test using Differential Scanning Calorimetry (DSC) procedure.

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7.5.2

Revision

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Care shall be taken to remove the samples of full f ilm thickness avoiding avoiding inclusion of steel debris. Glass transition temperature differential (∆Tg) and % cure (∆H) shall comply with the specified requirements. requirements. b. Epoxy Layer Thickness Epoxy layer thickness shall be checked at every one meter spacing at 3, 6, 9 and 12 o‟clock positions. The positions. The thickness shall comply with the specified thickness requirements. c. Adhesive layer Thickness Adhesive layer thickness shall shall be checked at every one meter spacing at 3, 6, 9 and 12‟o clock positions. The thickness shall comply with the specified thickness requirements. requirements. d. Holiday Inspection Entire pipe shall be subject to holiday inspection and the test voltage shall be set @5 v/micron (minimum) of epoxy thickness specified for the portion coated only with epoxy layer. e. Adhesion Test Adhesion Test (24 hrs or 48 hrs) shall be carried out on the epoxy coated pipe. Test method, no. of t est specimen and acceptance criteria shall comply DIN 30678. Adhesion of FBE shall also be separately determined at ambient temperature at two locations by the “St Andrews Cross” method and the test shall comply with the specified requirements. f. 2.5° Flexibility Flexibility Test 2.5° Flexibility test shall be carried out on the epoxy coated pipe at test temperature of 0°C. Test method, no. of test specimen and acceptance criteria shall comply API RP 5L9. g. Cross-section & Interface Porosity Test Cross section porosity and interface porosity tests shall be carried out on the epoxy coated pipe. Test method, no. of test specimen and acceptance criteria shall comply NACE RP 0394. Tests on pipes coated with all three layers a. Bond Strength: Three test pipes shall be selected for bond strength tests. On each of the selected pipes, three bond strength test shall be performed for each specified temperature i.e. one at each end and one in the middle of the pipe and specified requirements shall be complied with, i.e. bond strength as well as mode of separation. Length of peel shall be minimum 65 mm. None of these samples shall fail. b. Impact Strength: Three test pipes shall be selected for impact strength test and the test shall meet the specified requirements. requirements. c. Indentation Hardness:

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Two samples for both temperatures from all pipes shall be taken. If any one of these samples fails to satisfy the specified requirements, then the test shall be repeated on four more samples. In this case, none of the samples shall fail. d. Elongation at failure: Six samples each from three coated pipes i.e. 18 samples in all shall be tested and the test shall comply the specified requirement. Only one sample per pipe may fail. e. Cathodic Disbondment Disbondment Test: Three CD tests shall be carried out for the total lot of test pipes having all three layers. One test shall be carried out for 30 days duration and two tests for 48 hours duration at 230C & 850C respectively. The tests shall comply the specified requirement. requirement. Whenever Procedure Qualification is necessitated for different pipe size with same coating material combination, 48 hours test only be conducted. 30 days CD test is not mandatory in this case. f. Holiday Inspection All the pipes shall be subject to holiday inspection. The test voltage shall be as specified in clause 10.5.2. g. Coating Thickness Measurement Measurement All pipes shall be subject to coating thickness measurements. measurements. Acceptance criteria shall be as per clause 10.4.3. h. Air Entrapment One sample each from pipe body and on weld (if applicable) shall be taken from all four coated pipes and the specified requirements shall be complied with. i. Degree of Cure Epoxy film samples (minimum 4 no., equally spaced) shall be scrapped from one coated pipe and the samples shall be taken for cure test using Differential Scanning Calorimetry (DSC) procedure. Silicon coated sulphite paper shall be placed between the epoxy layer and adhesive layer immediately after epoxy application, to ensure physical separation of epoxy & adhesive as well as to prevent contamination of epoxy with adhesive layer, at a location from where the epoxy samples are to be removed for the test. Care shall be taken to remove the samples of full film thickness avoiding inclusion of steel debris. Glass transition temperature differential (∆Tg) and % cure (∆H) shall comply with the specified requirements. 7.5.3 Inspection of all test pipes All pipes shall shall be subject to the following inspections: inspections: a) Surface cleanliness, cleanliness, surface roughness measurements and dust dust control control immediately immediately after second abrasive blast cleaning and salt test. b) Visual inspection inspection of of finished coating, cut back dimension, dimension, internal/externa internal/externall cleanliness, cleanliness, end sealing and bevel inspection. Acceptance criteria criteria for all inspection inspection and testing testing shall be as specified specified in this specification specification FEED Consultant:

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7.6.

7.7.

7.8.

7.9.

Revision

B1

After completion completion of the qualification tests and and inspection inspection as per per clause 7.4 and 7.5 7.5 above, above, the CONTRACTOR shall prepare and issue to COMPANY for approval a detailed report of the above tests and inspection including test reports/certificates of all materials and coatings tested. Only upon written approval from COMPANY, CONTRACTOR shall commence production coating. On successful successful completion completion of PQT, PQT, coating coating of all five (5) test pipes pipes shall shall be be removed removed and completely recycled as per the approved coating procedure specification, at CONTRACTOR‟s CONTRACTOR‟s expense. Remaining pipes will be accepted by COMPANY provided they meet the requirements requirements of this specification and need not be stripped and re -cycled. The CONTRACTOR CONTRACTOR shall re-establish the requirements requirements of qualification and in a manner as stated before or to the extent considered necessary by COMPANY, in the event of, but not limited to, the following: a) Every time there is a change in the previously qualified procedure. b) Every time there is a change in the manufacturer manufactur er and change in formulation formulati on of any of the raw materials and change in location of raw material manufacture. c) Every time the coating coating yard is shifted from from one location to the other or every every time the critical coating equipment‟s equipmen t‟s (induction heater, epoxy spray system, extruder, etc) are shifted. d) Any change in line speed during coating application e) Any time when in COMPANY‟s opinion the properties are deemed to be suspect during regular production tests. COMPANY reserves the right to conduct conduct any any or all all the test test required required for qualification qualification through an independent laboratory or agency at the cost of CONTRACTOR when in COMPANY's opinion, the results are deemed suspect. COMPANY's decision shall be final.

8.0

PIPE SURFACE PREPARATION

8.1

Unless specified otherwise, the pipes shall be supplied free from mill applied oils but may be subject to contamination occurring during transit. Prior to cleaning operation, CONTRACTOR shall visually examine the pipes and shall ensure that all defects, flats and other damages have been repaired or removed. The CONTRACTOR shall also remove marking stickers, if any, present within the pipe. Record shall be kept of such marking on the stickers to ensure traceability of pipe after coating. Any oil, grease, salt or other other contaminants detrimental to the formation of a good coating bond or coating quality shall be removed prior to coating application. Contaminants may be removed by the use of non-oily solvents. Gasoline or kerosene shall not be used for this purpose. Visible oil and grease spots shall be removed by solvent wiping. Solvent cleaning shall be in accordance with SSPC-SP1. Steel surface shall be allowed to dry before abrasive cleaning.

8.2

8.3

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8.4

8.5 8.5.1 8.5.2

8.5.3

8.5.4

Revision

B1

All pipes shall be preheated to a temperature of 65°C 65°C to 85°C 85°C prior to abrasive abrasive blast cleaning. The external surface of the pipe shall be cleaned using 2 no. dry abrasive blast cleaning units to achieve the specified surface cleanliness and profile. After first abrasive blast cleaning, chemical pre-treatment with chromate solution as per clause 8.5 shall be carried out prior to second abrasive blast cleaning. However at the option of CONTRACTOR, chemical pretreatment with chromate solution as per clause 8.5 may be carried out after the second abrasive blaster. The abrasive blast cleaning units shall have an effective dust collection system to ensure total removal of dust generated during blast cleaning from the pipe surface. The equipment used for abrasive blast cleaning shall meet the specified requirements and shall be free from oil, water soluble salts and other forms of contamination to ensure that the cleaning process is not impaired. Traps, separators and filters shall be checked for condensed water and oil at the start of each shift and emptied and cleaned regularly. During abrasive blast cleaning, the metallic abrasive shall be continuously sieved to remove “fines” and “contaminants” and the quality checked at every four hours. Abrasives used for blast cleaning shall comply ISO-11124. The following specific inspection requirements are to be incorporated. Correct size distribution shall be confirmed by sieve analysis. A test shall be used to check oil contamination contamination of the grit. A test shall be used to check for water contamination. contamination. Suitable plugs shall be provided at both pipe ends to prevent entry of any shot/grit into the pipe during blast cleaning operations. These plugs shall be removed after blast cleaning. Alternatively Alternatively the CONTRACTOR may link the pipes suitably together to prevent the entry of any short/grit into the pipe. Chemical Pre-treatment with Chromate Solution Following Following completion of abrasive blast blast cleaning, all pipe surfaces surfaces shall be chemically chemically pretreated with a 10% strength chromate solution. The CONTRACTOR CONTRACTOR shall shall provide provide data sheets and supporting documentation for the chemical chemical to be used. The documentation shall verify that the chemical is suitable for the treatment of line pipe prior to the application of the specific fusion bonded epoxy powder being applied and the final coating will meet fully the t he requirements of this specification. The chemical pre-treatment pre-treatment shall be applied fully in accordance with the chemical suppliers‟ instructions and in a manner that ensures 100% uniform coverage of the pipe surface without introducing introducing surface contamination. The CONTRACTOR CONTRACTOR shall shall check that the concentration of the chemical pre-treatment solution solution remains within the range recommended by the chemical manufacturer for the pipe coating process. The concentration shall be checked at the makeup of each fresh solution and once per hour, using a method approved by the chemical manufacturer. The CONTRACTOR shall also ensure that the chemical pre-treatment solution remains free from contamination at all times. Recycling of chemical pre-treatment solution is not permitted.

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Revision

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8.5.5

The CONTRACTOR CONTRACTOR shall shall ensure ensure that the temperature of the substrate substrate is maintained between 40°C and 80°C and the chromate solution temperature does not exceed 60° or as recommended by the manufacturer. 8.5.6 The chromate chromate coating shall be smooth, even, even, free from from runs, drips or excessive excessive application application and 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. 8.6 Abrasive cleaning carried out shall be such that the resultant surface profile is not dished and rounded when viewed with 30X magnification. The standard of finish for cleaned pipe shall conform to near white metal finish to Sa 2 ½ of Swedish Standard SIS 055900 latest edition. Surface of pipe after abrasive abrasive blast cleaning shall have an anchor pattern of 50 to t o 70 microns (RZ). This shall be measured for each pipe by a suitable instrument such as surface profile depth gauge. In addition the pipe surface after blast cleaning shall be checked for the degree of cleanliness (Sa 2½), degree of dust and shape of profile. Degree of dust shall comply the requirements of ISO 8502 – 8502 – 3. 3. Acceptance limit shall be either quality rating 2 or Class 2. All pipes shall be visually examined for presence of any shot/grit/loose material left inside the pipe during blast cleaning. Suitable mechanical means (stiff brush) shall be employed to remove the same before the pipes are processed further. In addition, inside surface of the pipe shall also be visually inspected for presence of any foreign material or shots and grit (free or embedded/sticking to pipe inside surface). The pipe inside surface shall be examined using sharp floodlight focused at the middle of the pipe at one end while inspection is carried out visually from other end. Any foreign material or shots/grit present in the pipe shall be completely removed by mechanical brush, high pressure air jets, by tilting of pipe, etc. 8.7 At no time shall the blast cleaning be performed when the relative humidity exceeds 85%. The CONTRACTOR shall measure the ambient conditions at regular intervals during blast cleaning and coating operations and keep records of prevailing temperature, humidity and dew point. 8.8 The blast cleaned surface shall not be contaminated with dirt, dust, metal particles, oil, water or any other foreign material, nor shall the surface or its anchor pattern be scarred or burnished. All blast cleaned pipe surface shall be kept in dust free enclosure prior to coating. After blast cleaning, all surfaces shall be thoroughly inspected under adequate lighting to determine anchor pattern, quality of blasting and identify any surface defects prior to coating application. All surface defects such as slivers, scab, burns, laminations, welds spatters, gouges, scores, indentations, slugs or any other defects considered injurious to the coating integrity made visible during blast cleaning shall be reported to the COMPANY Representative Representative and on permission from COMPANY Representative, such defects shall be removed by filing or grinding. After any grinding or mechanical repairs, the remaining wall thickness shall be checked and compared with specified thickness.

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Revision

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Any pipes having thickness less than 95% of specified thickness shall be kept aside and disposed off as per the instructions of COMPANY Representative. The method employed to remove surface defects shall not burnish or destroy the anchor pattern or contaminate the surface. Pneumatic tools shall not be used unless they are fitted with effective air/oil and water traps. Where burnishing results in destruction of anchor pattern, the anchor pattern shall be restored by suitable means. Pipes which have damages repaired by grinding and have ground areas more than 50mm in diameter shall be re-blasted. Any dust or loose residues that have been accumulated during blasting and/or during filing/grinding operations shall be removed by vacuum cleaning. If contamination of surface occurs, the quality of blast cleaning method and process shall be examined. If the surface roughness is outside the specified limit, the blast cleaning material shall be checked and replaced. 8.8.1 Upon Completion Completion of of the blasting operations, operations, the quality control supervisor shall shall accept the the pipe for further processing or return for re-blasting after removal of defects/imperfections. In case imperfections are considered detrimental to the coating quality, the same shall be reported to COMPANY's Representative for final decision on rejection or re-blasting / removal of defects Re-blasting / removal of defects or returning pipe to the yard shall be at the CONTRACTOR's CONTRACTOR's cost. COMPANY's Representative, in additions, reserves the right to initiate any of the above actions during periodic inspections for oil, dust, salt, imperfections, surface defects, lack of white metal finish, etc. 8.8.2 In order to ensure that that pipe with defects are are not processed further, further, provisions provisions shall be available available to lift the pipes from inspection stand. 8.8.3 The total allowable allowable elapsed time between between completion of of the blasting operations and commencement of the pre- coating and heating operations shall be such that no detectable oxidation of the surface occurs. Relative humidity readings shall be recorded every half an hour during the blasting operations in the immediate vicinity of the operations. The maximum elapsed time shall not exceed the duration given below.

8.8.4

Relative Humidity %

Maximum elapsed time

>80

2 hours

70 to 80

3 hours

<70

4 hours

Any pipe not processed within within the above above time-humidity requirement shall shall be completely completely reblasted. Any pipe showing flash rusting shall be re-blasted even if the above conditions have not been exceeded.

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Revision

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8.8.5

Pipe handling handling between between abrasive abrasive blasting blasting and pipe pipe coating shall not damage the surface profile achieved during blasting. Any pipe affected by the damage to the surface exceeding 200mm² in area and/or having contamination of steel surface shall be rejected and sent for re-blasting. re -blasting.

9.0

COATING APPLICATION The external surface of the cleaned pipe conforming to clause 8.0 of t his specification shall be immediately coated with 3-layer Polypropylene coating in accordance with the procedures approved by COMPANY, relevant standards and this specification. In general the procedure shall be as follows.

9.1 9.1.1

9.1.2

9.1.3

9.1.4

9.1.5 9.1.6

Pipe Heating Immediately prior to heating heating of pipe, pipe, all dust dust and grit grit shall be removed from inside of of the pipe by a combination of air blast, brushing and vacuum cleaning. Suitable arrangement shall be made to protect the bevel ends from getting damaged during the coating operation. Induction heater heater or gas fired fired heating shall shall be used for heating the pipe. pipe. The method method shall be capable of maintaining uniform temperature along the total length of the pipe, and shall be such that it shall not contaminate the surface to be coated. In case of induction heating, appropriate frequency shall be used to ensure „deep heating‟ and intense skin heating is avoided. Gas fired heating system shall be well adjusted so that no combustion products are deposited on the steel surface. This shall be demonstrated on bare pipes prior to start of PQT. Oxidation of the cleaned pipe surfaces prior to coating (in the form of blueing or other apparent oxide formation) is not acceptable. acceptable. The pipe shall shall be uniformly uniformly preheated preheated to a temperature temperature of 220°C 220°C to 235°C 235°C (428 to 455°F) 455°F) as per MANUFACTURER‟s recommendation. The pipe metal temperature shall not exceed 275°C (527°F). Temperature Temperatur e of the pipe surface shall be continuously monitored & recorded by using suitable instruments such as infrared sensors, contact thermometers, thermocouples etc. The recording method shall allow to correlate each linepipe. The monitoring instrument shall be able to raise an alarm / activate audio system (hooter) in the event of tripping of induction heater / gas fired heater or in the event of pipe temperature being outside the range recommended by the manufacturer. Any deviation from the application temperature range recommended by manufacturer shall be rectified. If immediate rectification is not feasible, the production shall be stopped until cause of deviation has been removed. Any pipe coated during the duration of temperature deviation shall be identified by marking and rejected. Such rejected pipes shall be stripped, re-cleaned and recoated. Temperature measuring & monitoring monitoring equipment equipment shall be calibrated calibrated twice every shift shift and/or as per COMPANY Representative‟s instruction. CONTRACTOR shall ensure that pipe surface emissivity variations are minimised during pipe heating. To avoid significant variance, more than once blasted pipes should be coated at the same time and not mixed with pipes blasted only once.

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9.2 9.2.1 9.2.2 9.2.3 9.2.4 9.2.5

9.3 9.3.1 9.3.2

9.4 9.4.1 9.4.2

9.4.3

9.4.4 9.4.5

Revision

B1

FBE Layer Coating Thickness of FBE layer shall be between 350 and 450 microns. 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. Prior to starting the fusion bonded epoxy powder application, application , the recovery systems shall be thoroughly cleaned to remove any unused powder. The use of recycled powder shall not be permitted. Epoxy powder is sprayed using electrostatic spray guns. Pipe must be well grounded during the entire process of coating application. Proper charge on the powder must be maintained. Guns should be positioned to make optimum use of electrostatic properties and to minimize overspray. Adhesive Layer Coating Thickness of adhesive shall be between 250 and 350 microns. The CONTRACTOR CONTRACTOR shall ensure that that the rollers push adhesive adhesive film to eliminate 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 CONTRACTOR shall establish to the satisfaction of COMPANY‟s COMPANY‟ s representative that the adhesive is applied within the gel time window of the FBE and at the temperature recommended by the adhesive MANUFACTURER. The CONTRACTOR shall state the proposed minimum and maximum time interval between FBE and adhesive applications at the pipe temperature range and overlap. Polypropylene Layer Coating The number of wrap wrap and overlapping overlapping shall be such that that they Polypropylene Polypropylene thickness achieved meets the overall specified thickness requirement. Polypropylene Polypropylene may be applied by either the cross-head cross-head or lateral lateral extrusion technique. The Polypropylene shall be applied over the adhesive within the time limits established during preproduction testing. As the concrete concrete weight weight coating will will be applied on the three layer layer Polypropylene Polypropylene system, the coating surface shall be worked in a way to improve friction coefficient and enhance the bonding of concrete to the extruded Polypropylene surface. Granules of Polypropylene shall be spray applied to the hot extruded Polypropylene surface before quenching. Such granules shall not be totally melted to provide a rough surface. The coating shall be cooled to below 80°C before handling. Coating and/or and/or adhesive shall terminate terminate 120 mm (+) 20 / (-) 0 mm mm from pipe ends. The adhesive shall seal the end of applied coating. CONTRACTOR shall adopt mechanical brushing for termination of the coating at pipe ends.

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9.4.6 9.4.7

9.4.8

9.4.9 10.0

Revision

B1

Edge of the coating shall be shaped to form a bevel angle of 30° to 45°. The cut back length shall be 150 (+)20/(-) 0 mm width, bevel 30° to 45° if specified by purchaser (in case of Automatic UT and Automatic Welding). Welding). A maximum of 25mm of of FBE coating shall shall be visible visible beyond beyond the end of the polypropylene polypropylene following cutbacks. Immediately after the coating coating is fully cured, pipe identification marks shall be reapplied to the coated pipe using a method approved by the COMPANY‟s representative. Additional identification shall shall be made in order to monitor the coating and test batches. All such markings shall be within 2 meters of the pipe end. Failure to comply comply with any any of the above above applicable applicable requirement requirement and of of the approved procedure shall be cause for the rejection of the coating and such coating shall be removed in a manner approved by COMPANY at CONTRACTOR's expense. Sintered layer layer shall shall be applied applied to facilitate application application of concrete concrete weight weight when when applicable. applicable.

INSPECTION AND TESTING

10.1

General In addition to the t ests required on the material batches, the CONTRACTOR shall perform the tests detailed below on finished production coatings to demonstrate compliance with this specification. Details of all inspections and testing shall be fully documented in accordance with Section 10. 10.2 Production Testing 10.2.1 Production testing testing shall be performed at the frequency frequency shown in Appendix Appendix 2. 10.2.2 The frequency of tests shown in Appendix 2 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. 10.2.3 One sample of coated pipe pipe shall be sent to COMPANY for storage. storage. 10.3 Visual Inspection The following external surfaces of the coated pipe, shall be carefully inspected: Adjacent to the cut-back at each end of pipe. Adjacent to the longitudinal weld Within the body of the pipe.   

The coating shall be of natural colour, smooth & uniform and shall be blemish free with no dust or other particulate inclusions. The coating shall not show any defects such as blisters, pinholes, wrinkles, scratches, engravings, cuts, swellings, excess material thickness, disbonded zones, air inclusions, tears, voids, etc. In addition, inside surface of the pipe shall also be visually inspected for presence of any foreign material or shots and grit (free or embedded/sticking embedded/sticking to pipe inside surface).

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Revision

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The pipe inside surface shall be examined using sharp floodlight focused at the middle of the pipe at one end while inspection is carried out visually from other end. 10.4 Coating Thickness 10.4.1 The thickness of the cooled Polypropylene coating system shall be checked using an approved magnetic or electro-magnetic electro-magnetic thickness gauge. 10.4.2 Measurements Measurements shall be made at 12 points uniformly spaced over the length and circumference of pipe. In case of welded pipes, five of the above readings shall be made at the apex of the weld seam, uniformly distributed over the length of the coated pipe. 10.4.3 The minimum coating thickness on pipe surface shall be as per the table below. However, localized coating thickness of less than the permissible minimum thickness can be tolerated on the condition that it does not attain a total extent of more than 5 cm 2 per meter length of coated pipe, and the actual coating thickness does not drop more than 10% below the permissible minimum coating thickness at these locations. Pipe OD (inch)

Coating Thickness (mm)

≤6.625

2.5

>6.625 and ≤12.75

3.0

>12.75 and ≤16

3.5

10.4.4 The frequency of thickness measurement measurement as stated above shall shall be initially on every pipe up to at least 100 pipes but may be reduced depending upon the consistency of result to one pipe in every fifty (50) instead of every pipes, at the sole discretion of the COMPANY Representative. Representative. Results of all measurements shall be recorded. 10.4.5 Thickness of epoxy and adhesive shall be measured at the beginning of each shift and whenever the plant re- starts after any stoppage for compliance. Coating of epoxy and adhesive on portion of pipe required for this purpose, stripping and recoating of such partly coated pipes shall be at CONTRACTOR‟s expense. 10.4.6 Coated pipes not meeting the above requirements shall be rejected. Rejected coated pipes shall be stripped and re-coated in accordance with approved procedure, at CONTRACTOR's expense. 10.5 Holiday Detection 10.5.1 Each coated pipe length shall be checked over 100% of coated surface by means of a "holiday detector" of a type approved by COMPANY for detecting holidays in the finished coating.

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Revision

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10.5.2 The holiday detector shall be a low pulse D.C. full circle electronic detector with audible alarm and precise voltage control complying with DIN VDE 0433 Part 2. The set voltage for inspection shall be minimum 25KV. The operating voltage between electrode and pipe shall be checked at least twice per working shift, and shall be maintained at 25 kilovolts. 10.5.3 CONTRACTOR shall shall demonstrate to the COMPANY that setting of the detector detector is satisfactory for detecting pin holes. CONTRACTOR shall calibrate the holiday detector at least once every 4 hours of production. CONTRACTOR shall have necessary instruments or devices for calibrating the holiday detector. 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. 10.5.4 Any pipe coating shall be rejected if more than 1(one) holiday & area more than 100 cm² in size are detected in its length attributable to coating process. 10.5.5 Holidays which are lesser in size than those mentioned in above, shall be repaired in accordance with an approved procedure and shall be at CONTRACTOR's expense. 10.5.6 Holidays caused by metal surface defects shall require the removal of the defect by grinding or filing of the defect prior to application of the repair material. Under no circumstances shall a steel defect be over coated with repair material. 10.5.7 If there is an excess occurrence of holidays on successive pipes, the CONTRACTOR shall immediately stop the coating operation to determine the cause and r emedy it. 10.6 Adhesion and Peel Strength Test 10.6.1 The coating adhesion shall be determined in accordance with either of the methods described in DIN 30678. The test shall be performed at 90 0C, 1100C and 1200C in accordance with NF A 49-711. 10.6.2 Minimum adhesion strength shall be in accordance with DIN 30678, 80 newtons per centimeter width of strip peeled at 90°C and 40 newtons or 30 newtons per centimeter width of strip peeled at 110°C or 120°C respectively in accordance with NF A 49-711. 10.6.3 The frequency of test for cut back portions shall be one pipe in every fifteen (15) pipes coated and for middle of pipe shall be one pipe in every sixty (60) pipes coated or one pipe per shift whichever is higher. On each selected pipe, adhesion test shall be performed for each specified temperature. temperature. Test shall be performed at each cut back portion and one in the t he middle of pipe. The system shall disbond /separate cohesively either in adhesive layer or in Polypropylene layer. Majority of the peeled off area on the pipe shall show presence of adhesive. adhesive. Disbondment/separation at epoxy to steel interface or epoxy / adhesive interface or adhesive / Polypropylene interface shall not be permitted. The failure mode shall be recorded for each test. 10.6.4 The frequency of adhesion test for cut back portion may be reduced depending upon the consistency of result to one pipe in every twenty five (25) instead of every fifteen pipes, at the sole discretion of t he COMPANY Representative.

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Revision

B1

10.6.5 During adhesion testing, testing, samples of coating shall be examined using 30X microscope for air entrapment on the body of the pipe as per clause 10.10. 10.7 Penetration Indentation Test 10.7.1 Three samples shall be cut from each of three pipes and tested for resistance to indentations in accordance with the method stated in NF A 49 711. The test shall be performed at a temperature of 110°C. 10.7.2 Maximum penetration penetration depth exhibited after testing shall not exceed 0.45 mm. 10.7.3 The frequency of test shall be initially 2 (two) coated pipes per shift which shall be further reduced to one test each on 2 coated pipes per week at random after 1 week of consistently acceptable results. Two samples for each temperature shall be taken from the cut back portion of coated pipe and one in the middle of the pipe for this test. 10.8 Impact Test 10.8.1 A sample of coated pipe shall be impact impact tested in accordance with the procedures procedures specified in both DIN 30678.Tests shall be performed at temperatures of 0°C, 50°C 10.8.2 Acceptance criteria for the number of blows per coating breakdown shall be as detailed in both DIN 30678. 10.8.3 Impact test shall also be carried out at 110°C and the results shall be recorded for COMPANY‟s representative evaluation. 10.8.4 Initially the frequency of test shall be two (2) coated pipes per shift that may be further reduced to one coated pipe per 2 weeks depending upon consistently acceptable results at the sole discretion of COMPANY's Representative. 10.9 Cathodic Disbondment Test 10.9.1 Cathodic disbondment disbondment testing shall be performed for 48 hours at an electrolyte electrolyte temperature of 85°C. The acceptance criteria shall be 7 mm maximum disbondment disbondment from the edge of the predrilled hole. The test shall be performed in accordance with NF A 49-711. The frequency of this test shall be once in every two weeks or one test representing each batch of epoxy powder used, whichever is more frequent. In case the test fails to conform to the specified requirement, at the option of the CONTRACTOR, all pipes coated after the previous acceptable test and prior to next acceptable test shall be rejected or the test shall be repeated using two additional samples taken from the same end of the affected pipe. When both retests conform to the specified requirement, the lot of pipes shall be accepted. When one or both the retests fail to conform to the specified requirement, all coated pipes after previous acceptable test and prior to next acceptable shall be rejected. All rejected pipes shall be stripped, re-cleaned and re-coated. COMPANY may consider a further retest program to determine whether any of the affected pipe meets the criteria for acceptance upon written request by the CONTRACTOR.

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Revision

B1

10.10 Air Entrapment Entrapmen t Assessment 10.10.1 No more than 10% of the observed area shall be taken with air entrapment (porosity or bubbles). Bubble size in the Polypropylene layer shall be limited to less than half the thickness of Polypropylene layer in height or circumference. Bubbles shall not link t ogether to provide a moisture path to the adhesive/FBE layers. 10.10.2 Air entrapment or porosity shall be similarly similarly rated for the adhesive and FBE layers of coating. 10.10.3 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 45° angle along the edge of the remaining coating on the pipe at the test area. See Appendix 3 for Air Entrapment Assessment. 10.11 Degree of Cure A thermal analysis shall be carried out using a Differential Scanning Calorimeter (DSC). 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 Polypropylene. Polypropylene. The sample shall be tested for cure using DSC procedure. The glass transition temperature differential (∆Tg) and % cure (∆H) 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. The required cure characteristics are: are: ∆Tg = -2°C to + 3°C (∆ (∆Tg = ∆Tg final - ∆Tg initial) Only a 95% minimum cured coating shall be acceptable % Cure = (∆ (∆H - ∆H residual)/ ∆H x 100 (∆H = exothermic heat of reaction) Frequency of this test shall be once per shift. Pipe shall be selected randomly by COMPANY Representative during the middle of a shift. Suitable provisions/ arrangements arrangements as per the instructions of COMPANY Representative shall be made by the CONTRACTOR for this purpose. In case of test failure, production carried carried out during the entire shift shift shall be rejected, unless the CONTRACTOR CONTRACTOR proposes a method to establish establish the compliance compliance with the degree degree of cure requirements of all pipes coated during that shift.

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10.12

Revision

B1

Destructive Tests

For coating destructive tests listed in Appendices 1 and 2, a sufficient length of production pipe shall be cold cut to provide the required number of samples for testing. The coating on the cut end of the pipe length shall be cut back to comply with clause. 9.4.5 of this specification. 10.13 Test Failure 10.13.1 In the t he event that a production coated pipe fails to meet the acceptance criteria for a specified test, the CONTRACTOR shall test the preceding and succeeding coated pipe. If both pipes pass the test, then the remainder of the pipe lengths in that shift shall be deemed satisfactory. If either pipe fails to meet the specified requirements, requirements, all pipes coated during that shift shall be tested until the coating is proved acceptable. Rejected coated pipes shall be stripped and re-coated in accordance with approved procedure, at CONTRACTOR's expense 10.13.2 COMPANY reserves the right to perform inspection and witness tests on all activities concerning the pipe coating operations starting from bare pipe to finished coated pipe ready for dispatch and also testing t esting of raw materials. CONTRACTOR shall give reasonable notice of time and shall provide without charge reasonable access and facilities required for inspection to the COMPANY's representative. Inspection and tests performed or witnessed by COMPANY's representative shall sh all in no way relieve the contractor‟s obligation to perform the required inspection and tests. 10.13.3 In case rate of defective or rejected pipes and/or samples tests are 10% or more for a single shift (typically 8 hours), CONTRACTOR shall be required to stop production and carry out a full and detailed investigation and shall submit findings to COMPANY for approval. CONTRACTOR shall recommence the production only after getting the written permission from COMPANY. Under no circumstances any action or omission of the COMPANY's Representative shall relieve the CONTRACTOR of his responsibility for material and quality of coating produced. No pipes shall be transported from the coating plant unless authorized by COMPANY in writing. 11.0

11.1

HANDLING, TRANSPORTATION AND STORAGE OF MATERIALS The CONTRACTOR CONTRACTOR shall shall be fully responsible responsible for the pipe and for the pipe identification marking from the time of "taking over" of bare pipe from COMPANY until such time that the coated line pipes are `handed over' and/or installed in the permanent installation as the case may be according to the provisions of the CONTRACT. At the time of "taking over" of bare pipes CONTRACTOR shall inspect and record all the relevant details referred above including pipe defects in the presence of COMPANY. All pipes shall be checked for bevel damages, weld seam height, dents, gouges, corrosion and other damages. COMPANY Representative shall decide whether pipe defects / damages are suitable for repair. Damage to the pipes that occur after the CONTRACTOR has taken delivery such as dents, flats, or damage to the weld ends shall be cut off or removed and

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11.2

11.3

11.4

11.5

11.6

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pipes rebevelled rebevelled and repaired again as necessary. The cost of this work, as well as that of the pipe lost in cutting and repair shall be to the CONTRACTOR's account. All such works shall be carried out after written approval of the COMPANY. Any reduction in length shall be indicated in the CONTRACTOR‟s pipe tracking system. The CONTRACTOR CONTRACTOR shall shall unload, unload, load, load, stockpile and transport transport the bare bare pipes pipes within within the coating plant(s) using suitable means and in a manner to avoid damage to pipes. The CONTRACTOR shall stockpile the bare pipes at the storage area of the coating plant. The CONTRACTOR shall prepare and furnish to COMPANY a procedure/calculation generally in compliance with API RP-5L1 for stacking of pipes of individual sizes, which shall be approved by COMPANY prior to commencement. The CONTRACTOR CONTRACTOR shall load, unload, unload, transport transport and and stockpile stockpile the coated pipes pipes within within the coating plant using approved suitable means and in a manner to avoid damage to the pipe and coating. The COMPANY shall approve such procedure prior to commencement of work. Coated pipes may may be handled by means of slings and belts belts of proper proper width width (minimum 60 mm) made of non- abrasive/non-metallic materials. In this case, pipes to be stacked shall be separated row by row to avoid damages by rubbing the coated surface in the process of taking off the slings. Use of round sectional slings is prohibited. Forklifts may be used provided that the arms of the forklift are covered with suitable pads, preferably preferably rubber. Bare / coated pipes at all times shall be stacked completely clear from the ground, at least 300 mm, so that the bottom row of pipes remains free from any surface water. The pipes shall be stacked at a slope so that driving rain does not collect inside the pipe. Bare/coated pipes may be stacked by placing them on ridges of sand free from stones and covered with a plastic film or on wooden supports provided with suitable cover. This cover can be of dry, germ free straw covered with plastic film, otherwise foam rubber may be used. The supports shall be spaced in such a manner as to avoid permanent bending of the pipes Stacks shall consist of limited number of layers such that the pressure exercised by the pipe's own weight does not cause damages to the coating. CONTRACTOR shall submit calculations for COMPANY approval in this regard. Each pipe section shall be separated by means of spacers suitably spaced for this purpose. Stacks shall be suitably secured against falling down and shall consist of pipe sections having the same diameter and wall thickness. The weld seam of pipes shall be positioned always in a manner so as not to touch the adjacent pipes. The ends of the pipes during handling and stacking shall always be protected with bevel protectors. The lorries lorries used for transportation transportation shall shall be equipped with adequate adequate pipe supports having having as many round hollow beds as there are pipes to be placed on the bottom of the lorry bed. Total width of the supports shall be at least 5% of the pipe length and min. 2 no. support shall be provided. These supports shall be lined with a rubber protection and shall be spaced in a manner as to support equal load from the pipes. The rubber protection must be free from all nails and staples where pipes are in contact. The second layer and all following layers shall be

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separated from the other with adequate number of separating layers of protective material such as straw in plastic covers or mineral wool strips or equivalent, to avoid direct touch between the coated pipes. All stanchions of Lorries used for transportation transportation shall be covered by non-abrasive non-abrasive material like rubber belts or equivalent. Care shall be exercised to properly cover the top of the stanchions and other positions such as reinforcement of the truck body, rivets, etc. to prevent damage to the coated surface. Slings or non-metallic straps shall be used for securing loads during transportation. They shall be suitably padded at the contact points with the pipe 11.7 Materials other than pipes and which are susceptible susceptible of deteriorating deteriorating or suffering suffering from damages especially due to humidity, exposure to high thermal excursions or other adverse weather conditions, shall be suitably stored and protected. Deteriorated materials shall not be used and shall be replaced at CONTRACTOR's expenses. These materials shall always be handled during loading, unloading and storage in a manner so as to prevent any damage, alteration and dispersion. When supplied in containers and envelopes, they shall not be dropped or thrown, or removed by means of hooks, both during the handling operations till their complete use. During unloading, transport and utilization, any contact with water, earth, crushed stone and any other foreign material shall be carefully avoided. avoided. CONTRACTOR shall strictly follow f ollow Manufacturer's instructions regarding storage temperature and methods for volatile materials that are susceptible to change in properties and characteristics due to unsuitable storage. If necessary the CONTRACTOR shall provide for a proper conditioning. 11.8 In case of any marine transportation transportation of of bare/coated line pipes pipes involved, involved, the same same shall be carried out in compliance with API RP 5LW. CONTRACTOR shall furnish all details pertaining to marine transportation including drawings of cargo barges, storing/stacking, sea fastening of pipes on the barges/marine vessels to the company for approval prior to undertaking such transportation works. In addition contractor shall also carry out requisite analyses analyses considering the proposed transportation scheme and establish the same is safe and stable. On-deck overseas shipment shall not be allowed. 11.9 Material Control Records 11.9.1 CONTRACTOR 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. 11.9.2 CONTRACTOR shall submit submit details of material control recording procedure to COMPANY for review prior to commencement of the works. CONTRACTOR shall submit details of his traceability procedure for COMPANY‟s review and approval. The complete mill markings on the bare pipe along with the pipe number and project specific description shall be stenciled with indelible markings on both ends on outside surface of the pipe within 200 mm of the ends.

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11.9.3 A detailed procedure procedure for marking and transferring the full traceability traceability of the pipe from the bare pipe to the external surface of the coated line pipes after coating shall be submitted to the COMPANY for review and approval. Material Test Certificates and MANUFACTURER Test Reports shall be traceable to each pipe within the APPLICATOR‟s Coating Book, which s hall be part of the QC Data Book. 11.9.4 All coated line pipes shall be provided with full traceability details stenciled on the external surfaces of the coated pipes as per clause 11.9.3 above. 12.0

REPAIR OF COATING CONTRACTOR shall submit to COMPANY, its methods and materials proposed to be used for executing a coating repair and shall receive approval from COMPANY prior to use. I n open storage the repair coating materials must be able to withstand a temperature of at least (+) 85°C without impairing its serviceability and properties. CONTRACTOR shall furnish manufacturer‟s test certificates for the repair materials clearly establishing the compliance of the repair materials with the applicable coating requirements indicated in this specification. All pipe leaving coating plant, shall have sound external coating with with no holiday or porosity on 100% of the surface. Defects, repairs and acceptability criteria shall be as follows: 







 

Pipes showing porosities or very small damage not picked up during holiday test and having a surface less than 0.5 cm 2 or linear damage (cut) of less than 3 cm shall be repaired by stick using material of same quality. Damages caused to coating by handling such as scratches, cuts, dents, gouges, not picked up during holiday test, having a total reduced thickness on damaged portion not less than 2 mm and an area not exceeding 20 cm 2 shall be rebuild by heat shrink patch only and without exposing to bare metal. Defects of size exceeding above mentioned mentione d area or holidays of width less than 300 mm shall be repaired with heat shrink repair patch by exposing the bare metal surface. Defects exceeding the above and in number not exceeding 2 per pipe and linear length not exceeding 500 mm shall be repaired using heat shrinkable sleeves. Pipes with bigger damage shall be stripped and recoated. In case of coating defect close to coating cut back, CONTRACTOR shall remove the coating throughout the entire circumference of the pipe down to the steel surface and increase the coating cut back length. Now if the coating cut back exceeds 140 mm of linear length of pipe then the coating shall be repaired by the use of heat shrink sleeves thereby making up the coating cut back length of 120 mm.

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Notwithstanding the above, if any defect exceeds 70 mm from the original coating cut back length, the entire coating shall be removed and the pipe shall be recycled through the entire coating procedure. Irrespective of type of repair, the maximum numbers of repair of coating shall be as follows. 



Holiday repair of size ≤ 100 cm2 attributable to process of coating application shall be maximum one number per pipe. In addition to the above, defects to be repaired by heat shrink patch/sleeve patch/sleeve shall be maximum 2 (two) per pipe.

Defects exceeding the above limits shall cause pipe coating rejection, stripping and recoating. The above is exclusive of the t he repairs warranted due to testing as per this specification. All repairs carried out to coating for whatever reason shall be to the account of CONTRACTOR. Cosmetic damages occurring in the Polypropylene layer only need not be repaired by exposing up to steel surface, as deemed fit by the COMPANY Representative. In any case the CONTRACTOR shall establish establish his material, methods and procedure of repair that result in an acceptable quality of product by testing and shall receive approval from COMPANY prior to use. Testing of repairs shall be in the same form as testing of coating. All repairs shall result in a coating thickness no less than the parent coating thickness. CONTRACTOR shall test repairs to coating as and when required by COMPANY. 13.0

MARKING CONTRACTOR shall place marking on the outside surface of the coating at one end of the coated pipe, and marking shall indicate, but not limited to the following information: a. b. c. d. e. f. g.

Pipe number, Heat number Diameter & Wall thickness Coated pipe number Colour band Any other informatio information n considered relevant by COMPANY. Pipe Manufacturer Name Inspection Mark/Punch

CONTRACTOR shall obtain prior approval on marking procedure to be adopted from the COMPANY.

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14.0

QUALITY ASSURANCE

14.1

The CONTRACTOR shall have established within his organisation organisati on and, shall operate for the contract, a documented Quality System that ensures that the requirements of this specification are met in all aspects. The Quality System shall be based upon ISO 9001/2 or equivalent.

14.2

The CONTRACTOR CONTRACTOR shall have established a Quality Quality Assurance Assurance Group Group within within its organisation organisation that shall be responsible for reviewing the Quality System and ensuring that it is implemented.

14.3

The CONTRACTOR CONTRACTOR shall shall submit submit the procedures procedures that comprise the Quality Quality System to the COMPANY for agreement.

14.4

The CONTRACTOR‟s Quality System shall pay particular attention to the control of Suppliers and Sub- contractors and shall ensure that the requirements of this specification are satisfied by the Suppliers and Sub- contractors operating Quality system in their organisation.

14.5

The CONTRACTOR CONTRACTOR shall, shall, prior to the commencement commencement of work, prepare prepare and issue issue a Quality Plan for all of the activities required satisfying the requirements of this specification. The plan shall include any sub-contracted work, for which the sub-contractors Quality Plans shall be submitted. The plan shall be sufficiently detailed to indicate sequentially for each discipline the requisite quality control, inspection, testing and certification activities with reference to the relevant procedures and the acceptance standards.

14.6

The CONTRACTOR‟s Quality system and associated procedures may, with due notice, be subject to formal audits. The application of quality control by the CONTRACTOR will be monitored by the COMPANY Representatives who will witness and accept the inspection, testing and associated work required by this specification.

15.0

DOCUMENTATION APPLICATOR shall submit the type and quantity of details and documentation documentation for CONTRACTOR‟s authorization or information as listed in the individual Material Requisitions Requisitions and Purchase Orders. Reports shall be kept of all relevant data for each item coated. This shall include, but not be limited to the following: 



  

Material batch numbers and certificates detailing all the information information required for each each batch as defined in t his specification Details of blasting blasting abrasive, abrasive, measurement of surface surface profiles, profiles, surface surface preparation preparation standard and recording of environment environment conditions prevailing during blasting Recording of steel surface defects and repairs Surface temperature of items prior to coating Results of all tests as defined in this specification

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

 

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Details of repairs repairs to coating defects exposed during testing and and the repair repair techniques used. Details of rejected items, with reasons for failure Information on items which, after rejection, require complete recycling

Such information shall be submitted daily by the APPLICATOR to the CONTRACTOR. Absence of documentation documentation shall be considered a just cause for rejection rejection of coating system. system. The following documentation, written in the English Language, shall be submitted to COMPANY for review. Prior to the start of Production Operations, CONTRACTOR shall submit the following documentation documentation to the COMPANY:

          

Quality Plan Production Schedule Coating and Testing Procedures Detailed Description of Coating Equipment and Materials Pipe Handling Equipment Description and Procedures Pipe Stacking Arrangements Arrangements Material Control Recording Procedure Inspection Quality Plans Inspection and Testing Plan Repair Procedure Procedures for all PQT and Production Tests

CONTRACTOR shall submit to COMPANY the following documentation prior to the return of coated pipe to COMPANY:    

  

Mill Certificates Certif icates for Line Pipe Received MANUFACTURER‟s MANUFACTURER‟s Certificates for Each Batch of Coating Materials Certification/Calibration Certification/Calibration Certificates for all Testing and Coating Equipment Inspection and Test, Records, Records, Results, and other Documentation of all all Material Material and Coating Tests Certificate Certific ate of conformance and dimensional check report Verification certificates for standard compliance All concession requests

All reports shall shall be signed by by CONTRACTOR to signify signify compliance compliance with the requirements requirements of this specification. specification.

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16.0

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PREPARATION FOR SHIPMENT The CONTRACTOR shall submit shipping and handling procedures to the COMPANY for approval. The procedures should adequately address storage, shipping and handling in view of the long voyage from manufacturing locations and climatic extremes at the job site. An appropriate design of end cap shall be fitted t o each opening to protect the butt weld ends and prevent ingress of foreign material. Handling shipping and storage procedure shall incorporate requirements given in Section 7 of NACE 0185.

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17.0

ANNEXURE-A

17.1

List of Acceptable Combinations of Coating Materials

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The following combinations of coating materials‟ manufacturers are considered acceptable. In case any of the combinations listed below are offered, details regarding the offered materials and its properties need not be furnished with bid. However, In the event of award of contract, manufacturer‟s manufacturer‟s trade name and data sheets/ properties for each coating material proposed by the CONTRACTOR and compatibility certificate for the proposed combination combination (s) from the raw materials Manufacturers, shall be submitted for COMPANY‟s approval prior to the placing of any order for Epoxy Powder

Adhesive

PE Compound

(Manufacturer)

(Manufacturer)

(Manufacturer)

JOTUN

DUPONT

DUPONT

Or

Or

Or

Base

LYONDELLBASELL

LYONDELLBASELL

Or

Or

Or

3M

BOREALIS

BOREALIS

Although the above above combinations combinations would be acceptable to COMPANY, COMPANY, the responsibility responsibility of suitability for application, performance and compliance to t he coating system requirements shall unconditionally lie with the CONTRACTOR.

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18.0

APPENDIX 1

18.1

Inspection Summary for Procedure Procedure Qualification Test on PP Coating Coating System for One Pipe Diameter

In addition to the above tests the following tests shall also be done    

Hardness testing. Resistance to hot water immersion testing. Bend flexibility testing. Density testing.

Number of Tests can be increased at the sole discretion of COMPANY.

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19.0

APPENDIX 2

19.1

Inspection Summary For Production Production Testing On Full Full PP-Coating PP-Coating System For One Pipe Diameter

Note 1: The cut back length shall be 150 (+) 20/( -) 0 mm width, bevel 30° to 45° if specified by purchaser ( in case of Automatic UT and Automatic Welding). COMPANY reserves the rights to increase inspection and testing frequency if warranted by the circumstances. FEED Consultant:

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20.0

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APPENDIX 3

20.1 Air Entrapment Assessment 20.1.1 Scope To determine the amount of cross section and interface air entrapment (porosity or bubbles) in the plant applied coating. 20.1.2 Equipment Microscope - Hand Held 30 X. Utility knife. 20.1.3 Test Specimen Strips from Adhesive Tests, coating disbondment (CD) test samples, and coated pipe may all be used to help determine the rating. 20.2 Procedure Adhesion strip shall be viewed viewed from the side and and the failure interface. interface. 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. At the pipe adhesion adhesion test site use a utility knife to cut cut the edge of the coating coating to a 45° angle and view with a microscope. Perform a similar test in the cut back area. This should be used for information to determine if further testing is needed. 20.3

Reporting and Grading Report pipe joint number, date pipe was coated, coating batch number, and date of test Report rating of cross-section and interface entrapment. A rating of 1 or 2 is passing Rating will be on a scale of 1 to 5 as follows: Rating 1. Very Good – Good – Passing Passing (Less than 10% of are with bubbles) 2. Good – Good – Passing Passing (Less than 20% / more than 10%) 3. Fair – Fair – Failing Failing (Less than 30% / more than 20%) 4. Poor – Poor – Failing(Less Failing(Less than 40% / more than 30%) 5. Very Poor – Poor – Failing Failing (Over 50% of area taken by air entrapment (bubbles))

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21.0

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APPENDIX 4

21.1 For FBE Layer Coating PQT 21.1.1 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 subjected to a bend bend test at a temperature temperature of 0°C and 20°C to induce induce a 2% and 3% strain respectively in the sample At each temperature temperature the test shall be be carried out twofold. 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 D = mandrel diameter (mm) t = specimen wall thickness (mm) s = 0.02 at 0°C 0.3 at 20°C 21.1.2 Acceptance Criteria The coating shall not exhibit any sign of cracking, disbondment or pinhole.

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22.0

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APPENDIX 5 HOT WATER RESISTANCE TEST FOR FBE LAYER COATING (PQT)

22.1

TEST METHOD Hot water resistance tests as detailed below shall be carried out on 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 potable water of 85 0C for 5 hours. The bare edges of the sample shall be coated to prevent ingress of moisture beneath the coating. After 5 hours exposure to hot water, the coated sample shall be removed from the t he water bath and allowed to cool to ambient temperature. Subsequently Subsequent ly the coating adhesion shall be tested as follows: Using a sharp and pointed knife, two incision incision 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 Commencing at the intersection an attempt shall be made made to lift the coating from the steel substrate using the blade of the t he knife.

22.2

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

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p264val1 Srx y Sp 0002 b1 Specification for Pipeline External 3lpp Coating

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