Specification For Three-Layer Polyethylene Line Pipe Coating
Specification For Three-Layer Polyethylene Line Pipe Coating
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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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 2 of 42
REVISION
Rev DATE ISSUED UPDATE / AMENDMENT DETAILS
DESCRIPTION
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
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 4 of 42
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.
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:
Item Specification
Temperature:
Relative Humidity:
Item Specification
Min. 10 %
Rain Fall:
Wind:
Wind Speed for Design Purpose 165 km/hr @15m Height (3 seconds gust)
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.
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 8 of 42
2.2 DEFINITIONS
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
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:
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 9 of 42
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.
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 10 of 42
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 D4940 Standard Test method for conductimetric analysis of water soluble ionic
contamination of blasting abrasives
ISO 1133 Plastics - Determination of the melt mass flow rate (MFR) and the melt
volume flow rate (MVR) of thermoplastics
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:
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 11 of 42
ISO 9000/9001 Quality Management and Quality Assurance Standards Guidelines for
Selection and Use
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
i) Personnel qualification
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 13 of 42
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:
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.
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 14 of 42
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.
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:
b) data sheets for coating materials, including any materials used for coating repairs;
d) certification, receipt, handling and storage of materials for coating and abrasive
blasting;
i) methods and tools/equipment for inspection and testing of the applied coating;
o) any special conditions for dispatch of coated pipes, including protection of pipe ends;
p) documentation
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 16 of 42
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
7.2.1 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.
Material of Epoxy powder (FBE) shall be in accordance with the requirements of Table
7.2-1.
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).
Note:
1. 2 mm-thick compression-moulded sheet, test specimen type according to ISO 527-3,
strained at 50 mm/min
Table 7.2-4 Minimum Requirements for Outer Polyethylene Top Layer (HDPE)
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
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)
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.
Coating Material
Content
FBE Adhesive PE top coat
Product identification x x x
Batch identification x x x
Density x x x
Gel time x
Particle size x
Moisture/water content x x x
Pigment dispersion x1
Thermal characteristic x
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.
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 22 of 42
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.
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.
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).
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.
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.
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.
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.
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 24 of 42
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.
All compressed air used for delivery of FBE in the coating chamber shall be free from
moisture, oil and other contaminants.
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.
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.
9.2.1 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.
The following external surfaces of the coated pipe shall be carefully inspected:
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 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.
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 27 of 42
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.
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.
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.
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 28 of 42
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.
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.
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 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.
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.
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).
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 30 of 42
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.
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 31 of 42
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
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
voids, breaks, or
other defaults.
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
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
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.
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
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
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
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
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
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
Document Type: SPE Discipline: Anti-Corrosion Page 42 of 42