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Specification For Three-Layer Polyethylene Line Pipe Coating

This document provides specifications for a three-layer polyethylene coating system for pipelines. It outlines requirements for coating materials, application, inspection, testing, repairs, identification, storage, transportation, and warranty. The coating system consists of a fusion bonded epoxy layer, adhesive layer, and polyethylene backing layer. The specification defines qualifications for coating materials and procedures, as well as inspection and testing methods to ensure the coating meets standards for properties like thickness, holidays, impact resistance, adhesion, and disbondment.

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0% found this document useful (0 votes)
678 views43 pages

Specification For Three-Layer Polyethylene Line Pipe Coating

This document provides specifications for a three-layer polyethylene coating system for pipelines. It outlines requirements for coating materials, application, inspection, testing, repairs, identification, storage, transportation, and warranty. The coating system consists of a fusion bonded epoxy layer, adhesive layer, and polyethylene backing layer. The specification defines qualifications for coating materials and procedures, as well as inspection and testing methods to ensure the coating meets standards for properties like thickness, holidays, impact resistance, adhesion, and disbondment.

Uploaded by

Ammar Jassim
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Document Number:

EBS1-AAAA00-EMPI-REPI-1010
Revision: V00
SPECIFICATION FOR THREE-LAYER POLYETHYLENE LINE PIPE COATING
Rev Date: 2018-10-31
Document Type: SPE Discipline: Anti-Corrosion Page 1 of 42

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East Baghdad South Oilfield


Development Project

Specification for Three-Layer Polyethylene Line Pipe Coating

V00 2018-10-31 IFC

Rev Date Revision memo Prepared by Checked by Approved by Project Auth’d by

This document has been generated by an Electronic Document Management System. When printed it is considered as a for
information only copy. The controlled copy is the screen version and it is the holder's responsibility that he/she holds the latest
valid version.
Document Number:
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DOCUMENT REVISION HISTORY SHEET

REVISION
Rev DATE ISSUED UPDATE / AMENDMENT DETAILS
DESCRIPTION

V00 IFC 2018-10-31 Issued for comments


Document Number:
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CONTENTS
CLAUSE 1.0 INTRODUCTION..................................................................................................... 5
1.1 GENERAL .......................................................................................................................... 5
1.2 WEATHER AND GEOLOGICAL DATA ................................................................................. 5
CLAUSE 2.0 GENERAL............................................................................................................... 7
2.1 SCOPE .................................................................................................................................... 7
2.2 DEFINITIONS .......................................................................................................................... 8
2.3 ERRORS OR OMISSIONS ......................................................................................................... 8
2.4 DEVIATIONS ........................................................................................................................... 8
2.5 CONFLICTING REQUIREMENTS .............................................................................................. 8
2.6 REPORTING PROCEDURE....................................................................................................... 9
CLAUSE 3.0 CODES, STANDARDS AND REGULATIONS .......................................................... 10
CLAUSE 4.0 QUALITY PROGRAM ............................................................................................ 12
CLAUSE 5.0 DESIGN REQUIREMENTS ..................................................................................... 13
CLAUSE 6.0 COATING SYSTEM QUALIFICATION ....................................................................... 14
6.1 GENERAL ............................................................................................................................. 14
6.2 APS ....................................................................................................................................... 14
CLAUSE 7.0 MATERIALS ............................................................................................................ 16
7.1 COMPOSITION OF THE COATING SYSTEM .......................................................................... 16
7.2 QUALIFICATION OF THE COATING MATERIALS .................................................................. 16
7.3 BATCH CERTIFICATE ........................................................................................................... 20
CLAUSE 8.0 COATING APPLICATION ......................................................................................... 22
8.1 SURFACE PREPARATION ..................................................................................................... 22
8.2 FUSION BONDED EPOXY (FBE)............................................................................................ 23
8.3 ADHESIVE............................................................................................................................. 24
8.4 POLYETHYLENE BACKING ................................................................................................... 24
CLAUSE 9.0 INSPECTION ........................................................................................................... 25
9.1 COATING PROCEDURE QUALIFICATION TRIAL (PQT) ........................................................ 25
9.2 PRODUCTION TESTING ........................................................................................................ 25
9.3 VISUAL INSPECTION ............................................................................................................ 25
9.4 COATING THICKNESS........................................................................................................... 26
CLAUSE 10.0 TESTING ............................................................................................................... 27
10.1 HOLIDAY DETECTION ........................................................................................................ 27
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10.2 INDENTATION (PENETRATION) TEST ............................................................................... 27


10.3 IMPACT RESISTANCE TEST ................................................................................................ 27
10.4 ULTRAVIOLET RESISTANCE AND THERMAL AGING .......................................................... 28
10.5 CATHODIC DISBONDMENT TEST ....................................................................................... 28
10.6 DEGREE OF CURE .............................................................................................................. 28
10.7 FLEXIBILITY TEST.............................................................................................................. 29
10.8 HOT WATER IMMERSION TEST .......................................................................................... 29
10.9 ADHESION AND PEEL TESTS ............................................................................................. 29
CLAUSE 11.0 COATING REPAIRS ............................................................................................... 37
11.1 GENERAL ........................................................................................................................... 37
11.2 REPAIR OF POLYETHYLENE COATING .............................................................................. 37
CLAUSE 12.0 IDENTIFICATION & MARKING .............................................................................. 39
CLAUSE 13.0 STORAGE HANDLING & SHIPPING ....................................................................... 40
CLAUSE 15.0 TRANSPORTATION............................................................................................... 42
CLAUSE 16.0 WARRANTY .......................................................................................................... 43
Document Number:
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CLAUSE 1.0 INTRODUCTION


1.1 GENERAL

EBS Petroleum Company Limited (hereinafter referred to as Company) holds rights for
development and production of the contract areas East Baghdad South Oilfield (EBS
Oilfield) which is located in the 14km of northeastern Baghdad, the capital of Iraq, 70
km northwest of EBS oilfield. The oilfield extends about 60km in the NW-SE direction
and 12km in the SW-NE direction. The concession of EBS oilfield covers 658 km2.

EBS oilfield is located in the agricultural area of alluvial plain formed by Tigris and
Euphrates Rivers, 30~40m above sea level. Tigris River is close to the northern part of
the field located in an agricultural area with some villages. The transportation is
convenient, an expressway joins Baghdad and Basra passes by the oilfield.

Except for a few old wellheads, EBS oilfield is completely new to be developed.
According to preliminary development plan, EBS oilfield plans to be comprises of 134
new wellheads, 7 OGMs, 1 FPF and 1 CPF. Produced water, water injection system and
also the supporting utilities and infrastructural facilities need to be developed for the
oilfield. The oil production is estimated to reach 40,000 BOPD.

1.2 WEATHER AND GEOLOGICAL DATA

The Field is located in the dry and hot tropical desert climate zone. In summer (from
May to September), the temperature ranges from 38°C to 50°C. Winters are cool (from
October to April) with the temperature ranging from 2.1°C to 11°C. Winter is the main
rainy season with the average rainfall of about 100mm. Local meteorological data are
shown in the table below:

Table1.2-1 Environment Data

Item Specification

Annual average atmospheric pressure 1010.3 (mbar)

Temperature:

Max. Atmospheric Temp. 55℃


Min. Atmospheric Temp.
-5℃
Wet Bulb Temperature
Min.:3.3℃; Max.:23℃; AVG:25℃

Relative Humidity:

Max. (November-March) 90-100 %


Document Number:
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Item Specification

Min. 10 %

Rain Fall:

Max. 200mm/year (45mm/day)

Rain Fall Season November-March

Wind:

General Direction 85%N. W.-SE

Max. recorded Wind Speed 160km/hr

Wind Speed for Design Purpose 165 km/hr @15m Height (3 seconds gust)

Frequent during summer season. Duration is from


Sand Storm several hours to about a week, especially during
day time.

Earthquake ZONE 2A 0.15g

Winter Ground Temp. (1m 18℃


underground)

Summer Ground Temp. (1m 28℃


underground)

Thunder days 13.7days/year


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CLAUSE 2.0 GENERAL


2.1 SCOPE

2.1.1 This specification covers the minimum requirements for the qualification,
application, inspection, testing, handling and storage of materials required for plant-
applied three-layer polyethylene (3LPE) coating externally to bare steel line pipe of EBS
Oilfield Development Project. The 3-layer polyethylene coating system shall be suitable
for design temperature up to 80℃.

2.1.2 All inspection and certification shall be undertaken by a third party certification
body hired by Vendor and approved by the PURCHASER. In addition to the third party
certification, PURCHASER may also appoint its own inspector for the
witnessing/inspection of coating application and tests.

2.1.3 The Vendor shall provide external coating of free-issue line pipes as detailed below:

Maximum
Design
Coating Temperatu Qty.
Item Line Pipe
requirement re (km)
(℃)
1 8" Water Injection Trunkline
(1) Φ219×12.7(mm) API 5L-X52Q Seamless Pipe 3-Layer PE Coating 60 11
2 10" Flowline / Trunkline
(1) Φ273×7.8(mm) API 5L-BNS-PSL2 Seamless Pipe 3-Layer PE Coating 60/80 30
3 12" Flowline / Trunkline
(1) Φ323.8×7.92(mm) API 5L-BNS-PSL2 Seamless Pipe 3-Layer PE Coating 80 18
4 16" Flowline / Trunkline
(1) Φ406.4×9.53(mm) API 5L-BNS-PSL2 Seamless Pipe 3-Layer PE Coating 80 42
5 16" Export Pipeline
(1) API 5L-X52M-PSL2, HFW Pipe -Φ406.4x7.1(mm) 3-Layer PE Coating 80 75
(2) API 5L-X60Q-PSL2, SMLS Pipe -Φ406.4x9.53(mm) 3-Layer PE Coating 80 75
6 10" Export Pipeline
(1) API 5L-X52Q-PSL2, SMLS Pipe -Φ273x7.8(mm) 3-Layer PE Coating 80 17
Note:
1. The actual/final quantities shall be determined by the formal contract.
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2.2 DEFINITIONS

COMPANY China ZhenHua Oil Co., LTD.


PURCHASER The organization responsible for providing the purchase order
requirements
VENDOR The organization awarded a Purchase Order/Contract for supply
of materials, equipment or service required for the Work.
MANUFACTURER The organization responsible for the manufacture of the coating/
coating materials (not necessarily the VENDOR)
EPC Detailed Engineering, Procurement, Construction and
Commissioning
PROJECT EBS Oilfield Development Project
WILL Used in conjunction with an action
SHALL Mandatory requirement
MAY Used if alternatives are equally acceptable

2.3 ERRORS OR OMISSIONS

2.3.1 The review and comment by PURCHASER of any Vendor’s or its Manufacturer’s
drawings, procedures or documents shall only indicate acceptance of general
requirements and shall not relieve the Vendor of its obligations to comply with the
requirements of this specification and other related parts of the contract documents.

2.3.2 Any errors or omissions noted by the Vendor in this Specification shall be
immediately brought to the attention of PURCHASER.

2.4 DEVIATIONS

All deviations to this Specification, other related specifications or attachments shall be


brought to the knowledge of PURCHASER before issuing the procurement document. All
deviations made during the procurement, design, manufacturing, testing and inspection
shall be with written approval of PURCHASER prior to execution of the work. Such
deviations shall be shown in the documentation prepared by the Vendor.

2.5 CONFLICTING REQUIREMENTS

In the event of conflict, inconsistency or ambiguity between the contract scope of work,
this Specification, National Codes & Standards referenced in this Specification or any
other documents, the Vendor shall refer to the PURCHASER whose decision shall prevail.
Document Number:
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2.6 REPORTING PROCEDURE

2.6.1 A reporting and documentation system shall be agreed between the PURCHASER and
the Vendor for the status of procurement, design, manufacturing, inspection, testing and
shipment of the equipment/material to be supplied under this specification. Vendor’s
Manufacturer shall provide reports and summaries for production performance and testing
operations in conformance with a manufacturing schedule approved by PURCHASER.

2.6.2 Daily, weekly, monthly and run summaries of all major aspects of the production
process shall be provided as reports to the PURCHASER.
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CLAUSE 3.0 CODES, STANDARDS AND REGULATIONS


The materials and equipment supplied and work performed under this Specification shall
conform to the latest edition of the industry Codes and Standards, references
recommended practices and project specification listed below:

ASME B31.8 Gas Transmission and Distribution Piping Systems

ASTM D746 Standard Test Method for Brittleness Temperature of Plastics and
Elastomers by Impact

ASTM D792 Standard Test Methods for Density and Specific Gravity (Relative Density)
of Plastics by Displacement

ASTM D1505 Standard Test Method for Density of Plastics by the Density-Gradient
Technique

ASTM D1693 Standard Test Method for Environmental Stress-Cracking of Ethylene


Plastics

ASTM D3895 Standard Test Method for Oxidative-Induction Time of Polyolefins by


Differential Scanning Calorimetry

ASTM D4940 Standard Test method for conductimetric analysis of water soluble ionic
contamination of blasting abrasives

ISO 306 Plastics - Thermoplastic materials - Determination of Vicat softening


temperature (VST)

ISO 527 Plastics – Determination of tensile properties

ISO 868 Plastics and Ebonite - Determination of Indentation Hardness by Means of


a Durometer (Shore Hardness)

ISO 1133 Plastics - Determination of the melt mass flow rate (MFR) and the melt
volume flow rate (MVR) of thermoplastics

ISO 2808 Paints and Varnishes - Determination of film thickness

ISO 8501 Preparation of steel substrates before application of paints and related
products - visual assessment of surface cleanliness

ISO 8502 Preparation of steel substrates before application of paints and related
products - Tests for the assessment of surface cleanliness

ISO 8503 Preparation of steel substrates before application of paints and related
products - surface roughness characteristics of blast cleaned steel
substrates
Document Number:
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ISO 9000/9001 Quality Management and Quality Assurance Standards Guidelines for
Selection and Use

ISO 11357 Plastics - Differential Scanning Calorimetry (DSC)

ISO 15512 Plastics - Determination of water content

ISO 21809-1 Petroleum and natural gas industries-External coatings for buried or
submerged pipelines used in pipeline transportation systems- part
1:Polyolefin coatings (3 layer PE and 3 layer PP)

ISO 21809-2 Petroleum and natural gas industries-External coatings for buried or
submerged pipelines used in pipeline transportation systems- part 2:
Fusion-bonded epoxy coatings

IEC 60243.1 Electric strength of insulating materials - Test methods - Part 1: Tests at
power frequencies

SSPC-SP-1 Solvent Cleaning

SSPC-SP-10 Mechanical Cleaning

The following order of precedence shall apply:

 The Requisition and Data Sheets

 This Specification / Other Referenced Project Specifications

 Other International Codes, Standards and Regulations


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CLAUSE 4.0 QUALITY PROGRAM


A quality control program shall be submitted to the PURCHASER for review and approval
prior to first production. The program shall be in accordance with ISO 9000/ 9001 as the
appropriate standard.

The quality program shall, minimum, include the following:

a) Raw material handling procedures

b) Surface preparation procedure

c) Raw material testing

d) Coating application procedures

e) Inspection & testing of coating procedures

f) Inspection & testing equipment calibration

g) Coating repair procedures

h) Handling & stockpiling

i) Personnel qualification
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CLAUSE 5.0 DESIGN REQUIREMENTS


5.1 Three-layer polyethylene (3LPE) coating consists of a film of fusion bonded epoxy
(FBE) resin primer, a copolymer adhesive and a high density polyethylene (HDPE) top coat.
The coating shall be capable of withstanding the design temperature range from -40°C to
80°C. The type of 3LPE coating shall be HDPE of ISO-21809-1.

5.2 The FBE, intermediate layer of copolymer adhesive and outer polyethylene coating
thickness shall be not less than the minimum thickness shown in Table 5.2-1 below:

Table 5.2-1 Coating Thickness

3LPE Coating System


Line Pipe Minimum total coating
Dimension FBE layer Adhesive layer thickness Remark
OD×Wt (mm) (μm) (FBE + Adhesive +HDPE )
(μm)
(mm)
Φ219×12.7 2.5
Φ273×7.8 2.5
Φ323.8×7.92 ≥150 ≥170 2.5
Φ406.4×9.53 2.5
Φ406.4×7.1 2.5
Note:
1. The type of 3LPE coating shall be HDPE and Class B2 of ISO 21809-1.

5.3 The FBE, intermediate layer of copolymer adhesive and outer polyethylene coating
pipe shall be installed using conventional lifting and laying equipment.

5.4 Vendor shall, at the time of bidding, state and guarantee the maximum interfacial
shear stresses between the FBE and outer polyethylene coating before failure can occur
on the coated pipe for evaluation and acceptance by the PURCHASER.

5.5 Coating system shall withstand the operating and construction conditions like rocky,
water immersed, sandy etc. and soil conditions.
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CLAUSE 6.0 COATING SYSTEM QUALIFICATION


6.1 GENERAL

A detailed coating procedure shall be prepared by the Manufacturer for qualification and
PURCHASER's approval no later than two weeks prior to commencement of coating
application. Each coating system shall be qualified by the Manufacturer.

The Manufacturer shall carry out and report the coatings qualification in accordance with
the requirements of this part. The test report shall contain the results of the qualification
tests and data required in Table 7.2-5, Table 7.3-1 and Table 1 of this specification.

The Manufacturer shall apply coating materials qualified in accordance with the
requirements of section 7.2 of this specification.

The PURCHASER may appoint its own inspector to witness the production of test pipes
and related inspection and testing.

Qualification shall be repeated in case of modifications to the coating line, coating


materials or application procedures.

The Vendor shall submit certified records of all aspects of the qualification procedure to
the PURCHASER for approval.

Any failure to meet any part of the qualification procedure shall require the Vendor to
revise the procedure and repeat the qualification process.

6.2 APS

Prior to the start of coating production and any specified procedure qualification trial
(PQT), the Manufacturer shall prepare an Application Procedure Specification (APS),
including:

a) incoming inspection of pipes and pipe tracking;

b) data sheets for coating materials, including any materials used for coating repairs;

c) data sheets for abrasive blasting materials;

d) certification, receipt, handling and storage of materials for coating and abrasive
blasting;

e) cleaning procedure for all application equipment;

f) preparation of the steel surface including monitoring of environmental parameters,


methods and tools for inspection, grinding of pipe surface defects and testing of
surface preparation;
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g) coating application, including tools/equipment for control of process parameters


essential for the quality of the coating;

h) lay-out sketch or flow diagram for the coating plant;

i) methods and tools/equipment for inspection and testing of the applied coating;

j) repairs of coating defects and any associated inspection and testing;

k) stripping of defective coating;

l) preparation of coating cutback areas;

m) marking and traceability;

n) handling and storage of pipes;

o) any special conditions for dispatch of coated pipes, including protection of pipe ends;

p) documentation
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CLAUSE 7.0 MATERIALS


7.1 COMPOSITION OF THE COATING SYSTEM

The system of 3LPE shall be applied as follows:

Primer:≥150μm Fusion Bonded Epoxy (FBE) Corrosion Protection Coating.

Intermediate:≥170μm intermediate layer of copolymer adhesive.

Outer: high density polyethylene (HDPE) top layer, the information for the thickness of
outer HDPE coating refer to Table 5.2-1 of this Specification

7.2 QUALIFICATION OF THE COATING MATERIALS

7.2.1 General

The Manufacturer shall qualify each type of coating material in compliance with the
requirements of this part. The qualification shall be repeated in case of changes in the
material composition, changes in the production process which influence the material
processing behaviour and change in production facility.

The Manufacturer shall carry out and report the material qualification in accordance with
the requirements of section 6 of this specification and Tables 7.2-1, 7.2-2, 7.2-3 and 7.2-
4. The test report shall contain the results of the qualification tests and the data required
in Table 7.3-1.

The coating materials shall meet the following properties of section 7.2.2, 7.2.3 and 7.2.4.

7.2.2 Fusion Bonded Epoxy (FBE)

Material of Epoxy powder (FBE) shall be in accordance with the requirements of Table
7.2-1.

Table 7.2-1 Minimum Requirements for Epoxy Powder

Properties Standard Requirements


within the manufacturer’s
Cure time Clause A.2 of ISO 21809-2
specification
Within 20 % of the nominal
Gel time at 205 °C± 3 °C
Annex J of ISO 21809-1 value specified by the
(s)
manufacturer
Moisture content Annex K of ISO 21809-1 ≤0.6% mass
≤3.0 on 150 μm sieves
Particle size Clause A.6 of ISO 21809-2
≤0.2 on 250 μm sieves
Within ±0.05 of the
Density
Annex N of ISO 21809-1 manufacturer's specified
(g/L)
nominal value
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Minimum glass
transition
temperature ≥95, and within
Thermal manufacturer's specification
(Tg2) (DSC Annex D of ISO 21809-1
Characteristics
analysis1) (℃)
ΔH (J/g) ≥45
Note:
1. Curing condition (procedure as per manufacturer's specification).

FBE coating shall be in accordance with the requirements of Table 7.2-2.

Table 7.2-2 Minimum Requirements for FBE Coating

Properties Standard Requirements


24 h hot-water adhesion
Clause A.15 of ISO 21809-2 Rating 1 to 2
65 °C ± 3 °C
Cathodic disbondment:
Clause A.9 of ISO 21809-2 ≤5 mm disbondment
24h, 65°C ± 3°C, −3.5 V
Cathodic disbondment:
Clause A.9 of ISO 21809-2 ≤15 mm disbondment
28days, 65°C ± 3°C, −1.5 V
no cracking at 2.0°ppd
Flexibility (0°C, 2°) Clause A.12 of ISO 21809-2
length
Note: The thickness of FBE for laboratory-coated test specimens shall be 350μm-500μm.

7.2.3 Intermediate Co-polymer Adhesive Layer

Material of intermediate co-polymer adhesive layer shall be in accordance with the


requirements of Table 7.2-3.

Table 7.2-3 Minimum Requirements for Intermediate Co-polymer Adhesive Material

Properties Standard Requirements

Elongation at break at 23 °C ± 2 °C1 ISO 527-2 or ISO 527-3 ≥600%


Tensile yield strength at 23 °C ± 2 °C1 ISO 527-2 or ISO 527-3 ≥8MPa
Vicat softening temperature A/50 (9.8 N) ISO 306 ≥85℃
Water Content ISO 15512 ≤0.1%
3
Density (g/cm ) ASTM D792 0.92-0.95
Melt Flow Rate (190℃, 2.16kg) (g/10min) ISO 1133-1 ≥0.7
Low Temperature brittleness (℃) ASTM D746 ≤-50
Oxidation induction time ASTM D3895 ≥10min at 200 °C
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Note:
1. 2 mm-thick compression-moulded sheet, test specimen type according to ISO 527-3,
strained at 50 mm/min

7.2.4 Outer Polyethylene Coating (HDPE)

Outer polyethylene material (HDPE) shall be in accordance with the requirements of


Table 7.2-4.

Table 7.2-4 Minimum Requirements for Outer Polyethylene Top Layer (HDPE)

Property Standard Value

Density of the base resin ASTM D1505 ≥0.93g/cm3


Elongation at break at 23 °C ± 2 °C1 ISO 527-2 or ISO 527-3 ≥600%
Tensile yield strength at 23 °C ±
ISO 527-2 or ISO 527-3 ≥15MPa
2 °C1
Vicat softening temperature A/50
ISO 306 ≥110℃
(9.8 N)
Water Content ISO 15512 ≤0.05%
Hardness Shore D ISO 868 ≥55
ESCR ≥1 000H Cond. A
(50 °C, F50, Cond. A:10 % Igepal or
ASTM D1693
CO630, ≥300H Cond. B
Or Cond. B: 100 % Igepal CO630)2,3 if density >0,955
≥30min at 210 °C
Oxidation induction time
ISO 11357 (all parts) or
(intercept in the tangent method)
≥10min at 220 °C
UV resistance and thermal ageing3 Annex G of ISO 21809-1 ΔMFR ≤ 35%
Melt Flow Rate (190℃, 2.16kg)
ISO 1133-1 ≥0.15
(g/10min)
Carbon Black Content ISO 6964 ≥2.0%
Tensile Strength ISO 527-2 ≥20MPa
Low Temperature brittleness (℃) ASTM D746 ≤-65
Electrical Strength (MV/m) IEC 60243.1 ≥25
Volume Resistance IEC 60243.1 ≥1×1013
Chemical Resistance4
(7days immersion,23°C ± 3°C)
10%HCl ISO 527-2 or ISO 527-3 ≥85%
10%NaOH ≥85%
10NaCl ≥85%
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Note:
1. Preparation of the test specimen in accordance with ISO 1872-2 for PE, strained at 50
mm/min.
2. In order to validate the ESCR values, data shall be provided by manufacturers to define the
limit in density (MFR) to pass that requirement. This limit shall not be wider than what is
commonly known as fit-for-purpose PE grades for pipe coating.
3. Choice of test condition should be with approval of end user.
4. Retention rate of properties is calculated in accordance with below equation:
Retention rate = Elongation before immersion ÷ Elongation after immersion, or
Retention rate = Tensile strength before immersion ÷ Tensile strength after immersion

7.2.5 Properties of the applied coating (FBE + Adhesive + HDPE)

The properties of the applied coating (FBE + Adhesive + HDPE) shall be in accordance with
the requirements of Table 7.2-5.

Table 7.2-5 Minimum Requirements for Applied Coating (FBE + Adhesive + HDPE)

Property Standard Value


Free of defects and
Continuity Annex B of ISO 21809-1 discontinuities, delaminations,
separations and holidays
Impact strength at 23 °C ± 3 °C1 Annex E of ISO 21809-1 >7J/mm
at 23 °C±3 °C ≤0.2mm
Indentation Annex F of ISO 21809-1
at 80 °C±3 °C ≤0.4mm
Elongation at break of PE at 23 °C ±
ISO 527-3 ≥400%
2 °C2
Annex C of ISO 21809-
≥15N/mm at ≥23 °C
Peel strength2,3,4,8 1,
≥3 N/mm at ≥80 °C
C.5 (hanging mass)
Degree of cure of FBE (1st layer)5 Annex D of ISO 21809-1 According to the manufacturer's
|ΔTg| specification, and ≤5°C
ESCR ≥1 000H Cond. A
(50 °C, F50, Cond. A:10 % Igepal or
ASTM D1693
CO630, ≥300H Cond. B
Or Cond. B: 100 % Igepal CO630)2,3 if density >0,955
≤20 ΔMFR for Classes B
Product stability during application (virgin compounded granulate
ISO 1133
of the PE top layer process before application/coating after
application of the same batch)
at 23 °C/28 d; -1.5
≤7mm
Average radius V
of cathodic at 65 °C/24 h;-3.5 V Annex H of ISO 21809-1 ≤7mm
disbondment6 at 80 °C7/28d;-1.5
≤15mm
V
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No cracking at an angle of 2.0°


Flexibility Annex I of ISO 21809-1
per pipe diameter length
Hot water immersion test Annex M of ISO 21809-1 Average ≤2 and maximum ≤3
Axial (Mpa) ISO 527-2 ≥20
Tensile Circumference
ISO 527-2 ≥20
Strength (Mpa)
Deviation9 — ≤15%
Note:
1. Lower test temperature may be agreed upon using the same acceptance criteria.
2. No single recorded peeling value shall be lower than 30 % of the requirements.
3. Cohesive failure mode in the adhesive if a non-grafted adhesive is used, no disbonding
between steel and epoxy.
4. In case of break at 23 °C, the maximum peel force shall be recorded. The minimum
requirements at 23 °C shall be fulfilled and the test shall then be carried out only at 90 °C (or
at maximum operating temperature if higher than 90 °C).
5. For FBE with a glass transition temperature above 120 °C, testing shall be according to the
manufacturer's recommendation.
6. In production, test only at 65 °C/24h/-3.5 V condition is required.
7. Maximum test temperature shall not be greater than 90 °C.
8. Hanging weight method may be used if agreed with end user.
9. The deviation is the ratio of the difference between the axial & circumference tensile
strengths and the lower one between two.
7.3 BATCH CERTIFICATE

7.3.1 The Vendor shall provide batch certificates supplied by the Manufacturer of each
material and shall contain the information given in Table 7.3-1. The batch certificate
shall state test methods and acceptance criteria.

The Vendor shall identify the materials and shall confirm that the certificates comply and
relate to the specified materials.

Table 7.3-1 Batch Certificate

Coating Material
Content
FBE Adhesive PE top coat

Identification of the manufacturer x x x

Product identification x x x

Batch identification x x x

Date and place of manufacturing x x x

Density x x x

Viscosity of base and hardener


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Solid content of base and hardener

Melt flow rate x x

Gel time x

Particle size x

Moisture/water content x x x

Carbon black content x

Pigment dispersion x1

Thermal characteristic x

Reactive site content x2

1. If applicable.
2. Direct and indirect methods can be proposed by the manufacturer.
7.3.2 The Manufacturer's specification for epoxy materials shall include the following:

 trade name;
 generic type;
 mix ratio (if any);
 maximum thickness, expressed in millimetres or micrometres (see Annex
A of ISO 21809-1);
 maximum and minimum storage temperatures, expressed in degrees
Celsius;
 shelf-life at storage temperature, expressed in months;
 technical properties, in accordance with Table 7.2-1 and Table 7.2-2
7.3.3 The Manufacturer's specification for adhesive and PE/PP materials shall include the
following:

 trade name;
 description of the adhesive;
 colour;
 maximum and minimum storage temperatures, expressed in degrees
Celsius;
 shelf-life at storage temperature, expressed in months;
 technical properties, in accordance with Tables 7.2-3 and 7.2-4.
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CLAUSE 8.0 COATING APPLICATION


8.1 SURFACE PREPARATION

8.1.1 Initial preparation

All dirt, deleterious matter and contaminants, such as oil and grease, shall be removed
from the pipe prior to coating. If necessary, the pipe shall be cleaned in accordance with
the requirements of SSPC-SP1.

All steel defects and irregularities (e.g. laminations, slivers, scratches) shall be removed
in accordance with the APS. Grinding of steel defects shall not reduce the wall thickness
below the specified minimum wall thickness of the pipe.

All pipes shall be dry prior to entering the abrasive blast cleaning unit(s). Pipe
temperature shall be at least 3 °C above the dew point immediately prior to abrasive
blast cleaning.

8.1.2 Abrasive blast cleaning

The abrasives used in the coating plant shall be in accordance with the requirements of
ISO 11124 (all parts). Sand shall not be used for blast cleaning.

The abrasives (including recycled materials) shall be maintained clean, dry and free from
contaminants in accordance with SSPC-AB 1, SSPC-AB 2 and SSPC-AB 3 or ASTM D4940 so
as not to contaminate the substrate.

The cleanliness achieved at entry to the application line shall be in accordance with the
requirements of ISO 8501-1:2007, grade Sa 2.5 (“near-white metal”).

The height of the surface profile attained shall be within 50μm and 100μm, as measured
in accordance with the requirements of ISO 8503-4 (Stylus method) or ISO 8503-5 (Replica
tape method). The Stylus method shall be used for verification. The Replica tape method
may be used when a correlation is established with the Stylus (Profilometer) method with
a cut-off length of 2.5 mm.

If grinding is required after blast cleaning, the maximum allowable area of grinding shall
be 10 cm2 per metre of pipe length or 0.5 % of the pipe surface area, whichever is lower.
If the grinding area required exceeds these limits, the pipe shall be re-blasted.

8.1.3 Surface dust contamination

The dust level shall be measured in accordance with the requirements of ISO 8502-3. The
maximum allowable level shall be Class 2 (for both size and quantity).

8.1.4 Surface cleanliness and pre-treatment


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If the Manufacturer chooses a surface pre-treatment (e. g. deionized water, phosphoric


acid and/or chromate pretreatment), the pre-treatment process shall be agreed with the
PURCHASER.

If surface pre-treatment is used for a PQT, it shall be used for production.

If surface pre-treatment is not used, testing for the presence of soluble salts on the pipe
shall be undertaken in accordance with the requirements of ISO 8502-6 and ISO 8502-9.
The maximum allowable level shall be 20 mg/m2 after blasting.

If levels above 20 mg/m2 of soluble salts are measured, a surface pre-treatment cleaning
process shall be agreed upon by the Manufacturer and the PURCHASER.

8.2 FUSION BONDED EPOXY (FBE)

a) The coating Manufacturer’s specification for the application and curing temperature
and time of the specified Fusion Bonded Epoxy Powder System shall become a part of this
Specification. It is the intention of this provision that the Vendor will be required to make
applications of the coating materials in accordance with the coating Manufacturer’s
recommendations, and to work with the coating Manufacturer and/or the coating
Manufacturer’s representative to eliminate any difficulties that might arise in the
application of the FBE coating. The use of a liquid applied epoxy coating in lieu of the
FBE is not permitted.

Unless otherwise stated, the FBE coating shall be applied by electrostatic spray to
produce a uniform coating with a minimum dry film thickness (DFT) of 150μm.

The pipe shall be uniformly preheated to between the minimum and maximum
temperatures recommended by the powder Manufacturer for optimum application
conditions.

Temperature of each pipe shall be checked continuously by accurately calibrated


indicating and recording pyrometers approved by the PURCHASER. When used, these shall
be checked for error not less than every four hours against calibrated temperature
measuring instruments.

Oxidation of the steel prior to coating in the form of ‘bluing’ or other apparent oxide
formation is not acceptable. If such oxidation should occur, the pipe shall be cooled to
ambient temperature and re-cleaned.

Prior to coating with fusion bonded epoxy powder, the powder application system shall
be thoroughly cleaned to remove any powder other than that in use.

b) The use of recycled powder shall not be permitted.

c) Immediately after application of FBE layers, copolymer adhesive and HDPE will be
coextruded within the gel time of the FBE as per Manufacturer’s requirement.
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8.3 ADHESIVE

The Vendor shall ensure that rollers push the adhesive into the base of welds to eliminate
presence of any air entrapment or voids immediately adjacent to the longitudinal weld.
The adhesive layer shall be applied before the FBE gel time has expired by using either
the crosshead or lateral extrusion technique. Application of the adhesive shall not be
permitted after full curing of the FBE. The Vendor shall establish to the satisfaction of
PURCHASER that adhesive is applied within the gel time window of the FBE and at the
temperature recommended by the adhesive Manufacturer. The Vendor shall state the
proposed time interval (minimum and maximum) between FBE and adhesive applications
at the proposed pipe temperature range and extent of overlap.

The adhesive shall be applied to a minimum thickness of 170μm as approved by the


PURCHASER.

All compressed air used for delivery of FBE in the coating chamber shall be free from
moisture, oil and other contaminants.

8.4 POLYETHYLENE BACKING

a) The polyethylene shall be applied by either the cross-head or annular extrusion


technique by a procedure approved by the PURCHASER. The polyethylene shall be applied
over the adhesive within the time limits established during pre-production testing.

b) The polyethylene topcoat shall have a minimum thickness required in Table 5.2-1 and
shall be able to withstand impact without deterioration of polyethylene coating during
backfilling of the trench after installation. Manufacturer may propose a different
thickness of the outer jacket to suit the application. However, it shall be subject to
approval of the PURCHASER.

c) The coating close to pipe end shall be cut back for the length of 130-140 mm. The end
of the coating shall be beveled to an angle not exceeding 30° measured in the direction
of the pipe axis. Any change in the cut back must be approved by the PURCHASER. 20-
30mm FBE coating should extend from the cutback of the polyethylene coating. Care shall
be taken not to damage the FBE corrosion protection coating when preparing cutbacks.

d) 'Frothing' of the coating at the steel/coating interface shall be avoided.


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CLAUSE 9.0 INSPECTION


In addition to the tests required on the material batches, Manufacturer shall perform the
tests detailed below on finished coatings to demonstrate compliance with this
specification.

9.1 COATING PROCEDURE QUALIFICATION TRIAL (PQT)

Prior to commencing full production, pipes shall be coated with single layer FBE and with
full coating system in accordance with the coating procedure specifications witnessed by
the Vendor for Qualification Trial. Vendor shall cut samples from each pipe, which are
adequately sized to permit the required testing.

Vendor shall select samples from full-system coated pipes. These samples shall be
inspected and tested as per requirements detailed in Table 1.

Pipes selected for PQT testing shall pass all the criteria contained in Table 1 before
production commences.

9.2 PRODUCTION TESTING

9.2.1 Production testing shall be performed at the frequency shown in Table 2. The
frequency shown in Table 2 will be for normal production.

9.2.2 Retesting

Pipes that fail to meet the requirements for inspection of surface preparation of Table 2
shall not be coated until the cause has been identified and corrected. Pipes that have
been coated since the last acceptable test shall be accepted if they meet the
requirements for inspection and testing of applied coating of Table 2.

Pipes that fail to meet the requirements for inspection and testing of applied coating of
Table 2 shall be retested for the parameter(s) found to be out of specification. If the
retest also fails to meet the requirements in Table 2, two pipes in the coating sequence
prior to the pipe that failed and two pipes in the sequence after that pipe shall be
retested.

If the results of all retested pipes are satisfactory, the coating shall be considered
acceptable on all pipes except the pipe that failed. If any of the retests also fail, the
total production back to the last test passed shall be blocked and further testing shall be
initiated by the Manufacturer and agreed with the PURCHASER. In the case of confirmed
failure, the coating shall be rejected.

9.3 VISUAL INSPECTION

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

 Adjacent to the cut back at each end of pipe.


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 Within the thickness of the coating.


The coating shall be smooth, and shall be blemish free, with no dust or other particulate
inclusions. The coating shall not show any defects such as wrinkles, engravings, deep cuts,
swelling, unbonded zones, air inclusion tears, voids, etc.

9.4 COATING THICKNESS

The thickness of the cooled Three-Layer coating system shall be checked using an
approved eddy current or electromagnetic type gauge.

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

The coating is designated as Class B2 of HDPE specified in ISO 21809-1.

The minimum total thickness of finished coating shall comply with the requirements as
per Table 5.2-1.

Any individual reading less than the values in Table 5.2-1 shall be cause for the coated
pipe length to be rejected.
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CLAUSE 10.0 TESTING


10.1 HOLIDAY DETECTION

Holiday detection test shall be performed as Annex B of ISO 21809-1, the test results shall
be free of defects and discontinuities, delaminations, separations and holidays.

This test shall consist of detecting any porosity of the coating using a scanning electrode
energized by high-arc-voltage. Defects shall be detected by a spark occurring between
the steel and the electrode at the defect accompanied by a sound and/or light signal.

The equipment, procedure, results and test reports and other details refer to Annex B of
ISO 21809-1.

Each pipe shall be inspected for holidays over 100% of its coated surface using high voltage
DC detector. Holiday detection shall be performed on surfaces that are at ambient
temperature and free from moisture or conductive surface contamination.

All holidays and other defects shall be marked for subsequent repair and re-testing. On
re-testing, no holidays shall be permitted in the final coating.

The number of holidays for each pipe length shall be recorded. Any pipe having more than
two holiday or holiday having an axial length greater than 300 mm shall be rejected.

10.2 INDENTATION (PENETRATION) TEST

Indentation (Penetration) test shall be performed as Annex F of ISO 21809-1, indentation


(Penetration) shall not be more than 0.2 mm for a test conducted at 23℃ and 0.4 mm at
maximum design temperature(80℃ ) for extruded coatings as per ISO 21809-1.

The test consists of measuring the indentation of a punch into the coating under fixed
conditions of temperature and load.

The equipment, procedure, results and test reports and other details refer to Annex F of
ISO 21809-1.

10.3 IMPACT RESISTANCE TEST

Impact Resistance Test shall be performed as Annex E of ISO 21809-1, the acceptable
results shall be >7J/mm.

The test shall consist of verifying the strength of the coating by the impact of a punch of
defined shape falling directly onto the coating from a fixed height and at a fixed
temperature. Carry out the test on pipes or cut samples. Do not carry out this test on
pipes with a diameter of less than 50 mm.

The equipment, procedure, results and test reports and other details refer to Annex E of
ISO 21809-1.
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10.4 ULTRAVIOLET RESISTANCE AND THERMAL AGING

Ultraviolet Resistance and Thermal Aging Test shall be performed as Annex G of ISO
21809-1, the choice of test condition should be with approval of end user. The acceptable
results shall be ΔMFR ≤ 35%.

The test of UV ageing shall consist of subjecting PE material test samples to the
continuous irradiation of a xenon lamp under given temperature and humidity conditions.
Evaluation shall be performed by assessing the change in the material through the
variation in its melt flow rate.

The test of thermal ageing shall consist of subjecting PE material test samples to the
effect of dry heat from a thermostatically controlled oven. Evaluation shall assess the
change in the material by the variation in its melt flow rate.

The equipment, procedure, results and test reports and other details refer to Annex G of
ISO 21809-1.

10.5 CATHODIC DISBONDMENT TEST

The test shall consist of assessing the resistance to disbondment of damage to the coating
when exposed to cathodic polarization.

For 3LPE coating, the test shall be performed on test specimens taken from the coated
components previously subjected to holiday detection, in which an artificial defect of a
defined size has been drilled.

Cathodic disbondment testing of 3LPE coating shall be performed as Table 7.2-5, Table 1
and 2.

The equipment, test specimens, procedure, results and test reports and other details
refer to Annex H of ISO 21809-1.

10.6 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 polyethylene. The sample shall be tested for cure using DSC procedure.

The glass transition temperature differential (Tg) shall be the test used to verify cure
along with a visual examination to ensure no residual cure in the portion of the graph
beyond the glass transition.

The required cure characteristics are:

|ΔTg|≤5℃ (  Tg = Tg final –  Tg initial)


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Only a 95% minimum cured coating shall be acceptable.

% Cure = (  H -  H residual) x 100/  H


(H = exothermic heat of reaction)

10.7 FLEXIBILITY TEST

The flexibility of the coating shall be determined once for PQT using coated pipe by the
method described in Annex I of ISO 21809-1, the test results shall be no cracking at an
angle of 2.0° per pipe diameter length.

The test shall consist of assessing the flexibility of three-layer polyolefin coatings, applied
to a bare steel substrate.

The equipment, procedure, results and test reports and other details refer to Annex I of
ISO 21809-1.

10.8 HOT WATER IMMERSION TEST

Hot Water Immersion Test shall be performed as Annex M of ISO 21809-1, the acceptable
results refer to Table 7.2-5 and Table 1 of this Specification.

The test shall consist of a hot water immersion procedure to test the resistance of factory-
applied, three-layer polyolefin coating on pipe to loss of adhesion from a steel substrate
in a wet environment. The testing shall require that samples for testing be cut from line
pipe, and is applicable to PQT, and to system qualification testing, where required.

For pipes larger than 76mm (3 in), test samples shall be cold-cut into 150 mm × 100 mm
segments, with the shorter side transverse to the pipe axis. The exposed surfaces shall
be prepared by wet grinding with 120-grit abrasive paper. Three samples shall be
prepared from the same pipe for each test.

The equipment, procedure, results and test reports and other details refer to Annex M of
ISO 21809-1.

10.9 ADHESION AND PEEL TESTS

The three-layer coating system peel strength shall be determined in accordance with the
methods described in Annex C of ISO 21809-1. The test shall be performed at 23±3℃ and

80±3℃. Tests shall be carried out on pipe body as well as on the weld with same frequency.

The method shall consist of measuring the rate at which the coating is peeled from the
metal substrate of the pipe at constant load (see Figure C.3 of ISO 21809-1).
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The failure mode shall be recorded. The failure should occur as a cohesive failure within
the Three-Layer System or at the adhesive/PE interface or adhesive/FBE interface. If
failure occurs at the FBE/steel interfaces, this will be considered a total failure of the
system.
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TABLE 1
Summary of Inspection and Tests to be Carried-Out for Procedure
Qualification of Line Pipe Coating for Each Pipe Diameter

Frequency
Properties Unit Test method Requirements
qualification
Requirements for inspection of surface preparation
Surface condition Free of
— Visual inspection Each pipe
before blasting contaminations

Environmental Calculation and As determined at


— direct time of Once
conditions measurement measurement
Pipe temperature Minimum 3 above
℃ Thermocouple Once
before blasting the dew point
Water-soluble
Conductivity max.
contamination of mS/cm ASTM D4940 Once
60
abrasives
Conductive
Soluble salt after measurement, Salt content (as
mg/m2 Each pipe
blasting ISO 8502-9 and ISO NaCl) max. 20
11127-6
Surface roughness of
ISO 8503-4 or
blasted surface μm 50 to 100 5 pipes
ISO 8503-5
(Rz/Ry5)
Visual inspection
— ISO 8501-1 Grade Sa 2.5 Each pipe
of blasted surface
Presence of dust
— ISO 8502-3 Max. Class 2 5 pipes
after dust removal
Visual inspection of
pipe prior to
— Visual No rust Each pipe
introduction to
coating line
Temperature of
extruded adhesive °C Thermometer Compliance to APS Once
and polyolefin
Preheating
temperature before °C Pyrometer Compliance to APS Each pipe
coating
Requirements for inspection and testing of applied coating
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Appearance of
— Visual Part 9.3 Each pipe
coating
Minimum FBE ISO 2808 or ASTM
μm Table 5.2-1 1st pipe
thicknessa D4138
Annex D of ISO Table 7.2-5
Degree of cure of FBE — 1st pipe
21809-1 &Section 10.6
Minimum adhesive ISO 2808 or ASTM
μm Table 5.2-1 1st pipe
thicknessa D4138

Annex B of ISO
Continuity Table 7.2-5 Each pipe
21809-1
Total thickness Annex A of ISO
mm Table 5.2-1 5 pipes
of coating 21809-1

Annex E of ISO
Impact resistance J/mm Table 7.2-5 3 pipes
21809-1
Annex C of ISO
Peel strengthb N/mm Table 7.2-5 5 pipes
21809-1
Annex F of ISO
Indentation mm Table 7.2-5 Once
21809-1
ISO 527-2 or
Elongation at break % Table 7.2-5 Once
ISO 527-3
Cathodic
Annex H of ISO
disbondment of 3LPE mm 65 °C/24H/−3.5 V Once
21809-1
coating
Hot water Annex M of ISO
mm Table 7.2-5 Once
immersion test 21809-1

Degrees
per pipe
length Annex I of ISO
Flexibility Table 7.2-5 Once
21809-1
diamete
r
ΔMFR:
In process max. 20 for PE
% ISO 1133 Once
degradation of PE between raw and
applied material
Cutback mm Measuring 130-140 Each pipe

Appearance of Once for


— Visual Smooth surface.
coating repairs Free of wrinkles, validation
Document Number:
EBS1-AAAA00-EMPI-REPI-1010
Revision: V00
SPECIFICATION FOR THREE-LAYER POLYETHYLENE LINE PIPE COATING
Rev Date: 2018-10-31
Document Type: SPE Discipline: Anti-Corrosion Page 33 of 42

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voids, breaks, or
other defaults.

Holiday of coating Annex B of ISO Once for


— No holidays
repairs 21809-1 validation

Peel strength of Annex C of ISO Once for


N/mm Section 11.1.2
coating repairs 21809-1 validation
a For FBE and adhesive thickness, it is measured on part-coated pipes over the length of pipe
partially coated at start-up.
b Each pipe shall be tested at 23°C at both ends with an additional test at 80°C.
Document Number:
EBS1-AAAA00-EMPI-REPI-1010
Revision: V00
SPECIFICATION FOR THREE-LAYER POLYETHYLENE LINE PIPE COATING
Rev Date: 2018-10-31
Document Type: SPE Discipline: Anti-Corrosion Page 34 of 42

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TABLE 2
Summary of Inspections and Tests to be Carried-Out for Production of
Coating of Line Pipe System for Each Pipe Diameter

Frequency
Properties Unit Test method Requirements
production
Requirements for inspection of surface preparation
Surface condition Free of
— Visual inspection Each pipe
before blasting contaminations

Environmental As determined at
Calculation and
— time of Every 4 h
conditions direct measurement
measurement
Pipe temperature Minimum 3 above
℃ Thermocouple Every 4 h
before blasting the dew point

Water-soluble
Conductivity max.
contamination of mS/cm ASTM D4940 1/shift
60
abrasives
Conductive
Every 4 h, if
Soluble salt after measurement, Salt content (as
mg/m 2 salt presence
blasting ISO 8502-9 and ISO NaCl) max. 20
is indicated
11127-6
Surface roughness of
ISO 8503-4 or Twice×2pipes
blasted surface μm 50 to 100
ISO 8503-5 /shift
(Rz/Ry5)
Visual inspection
— ISO 8501-1 Grade Sa 2.5 Each pipe
of blasted surface
Presence of dust after Twice×2pipes
— ISO 8502-3 Max. Class 2
dust removal /shift
Visual inspection of
pipe prior to
— Visual No rust Each pipe
introduction to coating
line
Temperature of 4 times/shift
extruded adhesive and °C Thermometer Compliance to APS
polyolefin (≤12h/shift)

Continuous
Preheating
monitor and
temperature before °C Pyrometer Compliance to APS
record, 1
coating
record/h
Document Number:
EBS1-AAAA00-EMPI-REPI-1010
Revision: V00
SPECIFICATION FOR THREE-LAYER POLYETHYLENE LINE PIPE COATING
Rev Date: 2018-10-31
Document Type: SPE Discipline: Anti-Corrosion Page 35 of 42

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Requirements for inspection and testing of applied coating


Appearance of coating — Visual Part 9.3 Each pipe
ISO 2808 or ASTM
Minimum FBE thicknessa μm Table 5.2-1 1/shift
D4138
Annex D of ISO Table 7.2-5 1st pipe and
Degree of cure of FBE —
21809-1 &Section 10.6 1/shift
Minimum adhesive ISO 2808 or ASTM
μm Table 5.2-1 1/shift
thicknessa D4138
Annex B of ISO
Continuity Table 7.2-5 Each pipe
21809-1
Pipes of 1km,
5km, 10km.
Total thickness of Annex A of ISO
mm Table 5.2-1 And then pipes
coating 21809-1
of every
10km.
Annex E of ISO Once per PE
Impact resistance J/mm Table 7.2-5
21809-1 batch
Annex C of ISO
Peel strengthb N/mm Table 7.2-5 1/shift
21809-1
Annex F of ISO
Indentation mm Table 7.2-5 Each PE batch
21809-1
ISO 527-2 or Pipes of every
Elongation at break % Table 7.2-5
ISO 527-3 50km

ISO 527-2 or Pipes of every


Tensile Strength — Table 7.2-5
ISO 527-3 50km

Pipes of 10km,
20km, 30km.
Cathodic disbondment Annex H of ISO
mm 65 °C/24H/−3.5V And then pipes
of 3LPE coating 21809-1
of every
50km.
ΔMFR:
In process degradation max. 20 for PE 1st pipe per
% ISO 1133
of PE between raw and shift
applied material
Recorded once
Cutback mm Measuring 130-140
per hour
Smooth surface.
Appearance of coating Free of wrinkles,
— Visual Each repair
repairs voids, breaks, or
other defaults.
Document Number:
EBS1-AAAA00-EMPI-REPI-1010
Revision: V00
SPECIFICATION FOR THREE-LAYER POLYETHYLENE LINE PIPE COATING
Rev Date: 2018-10-31
Document Type: SPE Discipline: Anti-Corrosion Page 36 of 42

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Holiday of coating Annex B of ISO


— No holidays Each repair
repairs 21809-1

Peel strength of Annex C of ISO Once/shift


N/mm Section 11.1.2
coating repairs 21809-1 (≤8h/shift)
a For FBE and adhesive thickness, it is measured on part-coated pipes over the length of pipe
partially coated at start-up.
b Each pipe shall be tested at 23°C at both ends with an additional test at 80°C.
Document Number:
EBS1-AAAA00-EMPI-REPI-1010
Revision: V00
SPECIFICATION FOR THREE-LAYER POLYETHYLENE LINE PIPE COATING
Rev Date: 2018-10-31
Document Type: SPE Discipline: Anti-Corrosion Page 37 of 42

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CLAUSE 11.0 COATING REPAIRS


11.1 GENERAL

11.1.1 The Vendor shall submit a repair procedure for the approval of the PURCHASER
prior to the start of production.

11.1.2 The Vendor shall demonstrate that the repair is as strong as the parent material.

11.1.3 Defects in the finished coating caused by the application process, transportation,
handling and storage in the coating plant or in the storage area, as well as those that
have been subjected to destructive testing, shall be repaired.

11.1.4 The defect area shall not exceed 10 cm2 and the total number of defects being
repaired shall not exceed 1 defect per metre length of pipe, unless otherwise specified.
If the size or number of defects exceeds these limits, the affected pipe shall be stripped
and recoated in accordance with the APS.

11.1.5 Defects shall be repaired and inspected using materials and procedures in
accordance with the APS and any PQT. Repair materials shall be compatible with the
applied coating.

11.1.6 If it is required to strip a pipe, it shall be carried out in accordance with the APS.

11.2 REPAIR OF POLYETHYLENE COATING

Damaged line coating shall be repaired as per the following criteria:

a) Small Damages Extending up to 10mm of diameter or not less than 50% of coating
thickness

Small damages to 3LPE should be repaired using PE melt sticks or polyethylene powder
matching with line pipe coating.

b) Damages Extending up to 30 mm

Polyethylene repair patches precoated with hotmelt adhesive, should be used in


conjunction with a hotmelt filler adhesive and epoxy primer (if bare steel visible) as per
manufacturer’s recommendations. Repair patches when installed should overlap the
damaged area by minimum 50 mm all round. Surface shall be mechanically cleaned before
the application of FBE primer.

c) Damages Extending Over 10cm²

In case the damages extend over 10cm2, the pipe shall be rejected.
Document Number:
EBS1-AAAA00-EMPI-REPI-1010
Revision: V00
SPECIFICATION FOR THREE-LAYER POLYETHYLENE LINE PIPE COATING
Rev Date: 2018-10-31
Document Type: SPE Discipline: Anti-Corrosion Page 38 of 42

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The Vendor shall warrant that if the coating is found defective or not meeting the
required performance the Vendor shall repair or replace the defective coating. The
warranty shall be valid for 12 months from the acceptance date of pipeline facility.

Careful inspection shall be carried out for all of the repair areas. It includes appearance
check, holiday detecting and peel strength. Any of wrinkles, voids, breaks, or other
defaults are not allowed. The detection voltage shall be based on the coating thickness.
Peel strength shall also be checked as Table 2. The Manufacturer’s instructions shall be
followed during the inspection.
Document Number:
EBS1-AAAA00-EMPI-REPI-1010
Revision: V00
SPECIFICATION FOR THREE-LAYER POLYETHYLENE LINE PIPE COATING
Rev Date: 2018-10-31
Document Type: SPE Discipline: Anti-Corrosion Page 39 of 42

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CLAUSE 12.0 IDENTIFICATION & MARKING


12.1 The Vendor shall maintain the pipe identification throughout the process of cleaning
and coating of the pipe. If the pipe identification is removed during the coating operation,
it shall be replaced.

12.2 Additional markings shall be applied 50 mm from the end of the coating and outside
the pipe at each end. Letters and numerals shall be 25 mm in height.

12.3 Pipe which has undergone repair in accordance with section 10 shall be marked with
a band painted around the entire circumference of the coated pipe and not more than
75mm from the cutback at each end. These pipe sections will be retained as spares by
the PURCHASER.

12.4 All markings shall be stencilled and spray applied with a paint compatible with the
coating material and of a contrasting color.

12.5 Pipes of different wall thickness shall be color coded with different color bands.
Document Number:
EBS1-AAAA00-EMPI-REPI-1010
Revision: V00
SPECIFICATION FOR THREE-LAYER POLYETHYLENE LINE PIPE COATING
Rev Date: 2018-10-31
Document Type: SPE Discipline: Anti-Corrosion Page 40 of 42

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CLAUSE 13.0 STORAGE HANDLING & SHIPPING


13.1 The coated pipe shall at all times be handled in a manner to avoid damage to the
coating.

13.2 The coated pipe shall be supported only by the uncoated ends until the coating has
cooled to ambient temperature.

13.3 The coated pipe shall be stored in an area, which will not result in accumulation of
dust or dirt either from the environment or surrounding.

13.4 The coated pipe shall be protected to avoid degradation from ultraviolet light
radiation.

13.5 Any coated pipe section that shows contamination in any form whatsoever from the
environment or surrounding shall be adequate grounds for stripping the entire coating
and completely re-coating the pipe with 3-layer polyethylene and/or FBE as considered
appropriate by PURCHASER’s representative.

13.6 All pipes which have undergone repair shall be stockpiled separately from non-
repaired joints or shall be color coded for ease of identification.

13.7 A padding approved by the PURCHASER shall be provided between the pipe stacked
after coating during storage, transportation and shipment.

13.8 The number of rows of pipes to be stacked up shall not exceed four.

13.9 Coated pipes at all times shall be stacked completely clear from the ground, so that
bottom row remains free from surface water.

13.10 Coated pipes shall be handled by means of slings and padded hooks made of none
abrasive nor metallic material. Rolling skidding or dragging shall be strictly forbidden.

13.11 Steel bevel end protector shall be applied after cut back and final inspection of
coating. Bevel protector shall be furnished by the PURCHASER and it shall be approved
by the owner prior to its installation.
Document Number:
EBS1-AAAA00-EMPI-REPI-1010
Revision: V00
SPECIFICATION FOR THREE-LAYER POLYETHYLENE LINE PIPE COATING
Rev Date: 2018-10-31
Document Type: SPE Discipline: Anti-Corrosion Page 41 of 42

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CLAUSE 14.0 DOCUMENT SUBMITTALS

14.1 The Vendor shall submit copies of each of the following documents to the PURCHASER
as set forth below:

No of
Document Submittal
Copies
Quality Control and Application Procedures Before PQT 2
Coating Repair Procedures Before PQT 2
Storage, Handling and Transportation Procedures Prior to Coating 2
Qualification Test Report Prior to Coating 2
Certified Material Test Certificates Prior t o Coating 2
Certified Inspection Report Weekly 1
Tally Record of Pipe Received Weekly 1
Tally Record of Pipe Coated/Loaded Out Prior to Shipping 6
Coating Repairs Undertaken Reported Daily 1
Daily Progress Report Report Daily 1

14.2 All certificates shall be in English language and with SI units of measure. Certificates
shall be visibly signed by the Vendor.

14.3 The Vendor shall maintain a complete record of the pipe from the time it first enters
the coating yard until the completion of load out of coated pipe. Pipe joint length and
date of the coating application shall be recorded for each joint of pipe. The Vendor shall
provide this information to the PURCHASER according to the schedule specified above.
Document Number:
EBS1-AAAA00-EMPI-REPI-1010
Revision: V00
SPECIFICATION FOR THREE-LAYER POLYETHYLENE LINE PIPE COATING
Rev Date: 2018-10-31
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CLAUSE 15.0 TRANSPORTATION


The Vendor shall be responsible for the good condition of the coated pipes. In all cases,
the Vendor shall be responsible for the repair of coated pipes until the pipeline is taken
over by the PURCHASER. On receipt of coated pipes, at Site, the PURCHASER shall be
invited for the inspection of coating. The Vendor shall arrange for the re-coating or
replacement of pipes found to be excessively damaged.
Document Number:
EBS1-AAAA00-EMPI-REPI-1010
Revision: V00
SPECIFICATION FOR THREE-LAYER POLYETHYLENE LINE PIPE COATING
Rev Date: 2018-10-31
Document Type: SPE Discipline: Anti-Corrosion Page 43 of 42

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CLAUSE 16.0 WARRANTY


The Vendor shall warrant that if the coating is found defective or not meeting the
required performance the Vendor shall repair or replace the defective coating. The
warranty shall be valid for 24 months from the acceptance date of the pipeline facility.

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