SPECIFICATION THREE LAYER POLYETHYLENE COATING OF LINE PIPEPage 1 of 36

SPECIFICATION THREE LAYER POLYETHYLENE COATING OF LINE PIPE

REVISION HISTORY

APPENDICES

APPENDIX ASUMMARY OF INSPECTION/TESTING FOR PROCEDURE QUALIFICATION TEST (PQT) POLYETHYLENE COATING FOR ONE PIPE DIAMETER

APPENDIX BSUMMARY OF INSPECTION/TESTING FOR PRODUCTION TESTING ON FULL POLYETHYLENE COATING SYSTEM FOR ONE PIPE DIAMETER

APPENDIX CAIR ENTRAPMENT ASSESSMENT

APPENDIX DFLEXIBILITY TEST FOR FBE LAYER COATING PQTAPPENDIX E

HOT WATER RESISTANCE TEST FOR FBE LAYER COATING PQT1.0 GENERAL1.1 PurposeThis specification defines the minimum technical requirements for the application of Three Layer Polyethylene Coating to the external surface of line pipe and piping for buried service from ambient temperature to maximum design temperature, for a minimum service life of 25 years to be used for the PROJECT.This specification supplements the codes listed in Section 2.0 of this specification.

1.2 DefinitionsFor the purpose of this specification, the following definitions shall apply:

2.0 CODES AND STANDARDSThe latest edition, unless specified otherwise, of the following codes and standards shall establish the minimum standards for the work. MANUFACTURER may use alternate standards that meet or exceed those listed if approved by COMPANY.

American Society for Testing and Materials (ASTM)

ASTM D570Standard Test Method for Water Absorption of PlasticsASTM D790Standard Test Method for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating MaterialsASTM D1238Standard Test Method for Melt Flow Rates of Thermoplastics by Extrusion PlastometerASTM D1505Standard Test Method for Density of Plastics by the Density- Gradient TechniqueASTM D1525Standard Test Method for Vicat Softening Temperature of PlasticsASTM D2240Standard Test Method for Rubber Property Durometer HardnessASTM D3417Standard Test Method for Enthalpies of Fusion and Crystallisation of Polymers by Differential Scanning Calorimetry (DSC)ASTM D3418Standard Test Method for Transition Temperatures of Polymers by Differential Scanning CalorimetryASTM D4703Standard Practice for Compression Moulding Thermoplastic Materials into Test Specimens, Plaques or SheetsASTM F372Standard Test Method for Water Vapour Transmission Rate of Flexible Barrier Materials Using an Infrared Detection TechniqueASTM G14Standard Test Method for Impact Resistance of Pipeline CoatingsASTM G17Standard Test Method for Penetration Resistance of Pipeline Coatings (Blunt Rod)ASTM G42Standard Test method for Cathodic Disbonding of Pipelines Subjected to Elevated Temperatures

ASTM G62Standard Test Methods for Holiday Detection in Pipeline Coatings

British Standards (BS)

BS 7079Preparation of Steel Substrates before Application of Paints and Related ProductsDeutsches Institut fr Normung (DIN)

DIN 30678Polyethylene Coatings for Steel PipesInternational Organisation for Standardisation (ISO)

ISO 6964Polyolefin Pipes and Fittings Determination of Carbon Black Content by Calcination and Pyrolosis Test Method and Basic SpecificationISO 8501-1Preparation of Steel Substrates before Application of Paints and Related Products-Visual Assessment of Surface Cleanliness, Part 1- Rust grades and preparation grades of uncoated steel substrates and of steel substrates after removal of previous coatings

ISO 8503-1Preparation of Steel Substrates before Application of Paints and Related Products-Surface roughness characteristics of blast cleaned steel substrates. Specifications and definitions for ISO surface profile comparators for the assessment of abrasive blast cleaned surfaces

ISO 9001:2000Quality Management System Requirements

ISO 9004:2000Quality Management Systems - Guidelines for Performance Improvements

ISO 11420Method for the Assessment of the Degree of Carbon Black Dispersion in Polyolefin Pipe, Fittings and CompoundsEuropean Standard (BN)

EN 10204Metallic Products - Types of inspection documents

National Association of Corrosion Engineers (NACE)

NACE RP0490Holiday Detection of Fusion Bonded Epoxy External Pipeline Coatings of 10 to 30mls (0.25 to 0.70mm)

NACE RP0274High Voltage Electrical Inspection of Pipeline Coatings

Steel Structures Painting Council (SSPC)

SSPC SP1Surface Preparation Specification No. 1, Solvent CleaningCanadian Standard Association (CSA)Z245.20External Polyethylene Coating of Pipe

Z245.21 External Fusion Bonded Epoxy Coating for Steel Pipe.

3.0 SPECIFICATION DEVIATION/CONCESSION CONTROL

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

4.0 QUALITY ASSURANCE/QUALITY CONTROL

Unless otherwise agreed with COMPANY, the VENDORs Quality System shall fully satisfy all the elements of ISO 9001:2000, Quality Management Systems Requirements and ISO 9004:2000, Quality Management Systems - Guidelines for Performance Improvements.

To ensure that all work is being performed consistently and accurately and to the requirements of the PROJECT Specifications, the VENDOR shall have in effect at all times, a QA programme, which clearly establishes the authority and responsibilities of those responsible for the quality system. Persons performing quality functions shall have sufficient and well-defined authority to enforce quality requirements that they initiate or identify and to recommend and provide solutions for quality problems and thereafter verify the effectiveness of the corrective action.

Quality Systems and Quality Control requirements shall be identified and included in the COMPANYs Purchase documentation. Based on these requirements the VENDOR will develop a QA/QC programme which shall be submitted to the COMPANY for review and concurrence. The VENDORs QA/QC programme shall extend to MANUFACTURER/VENDOR(s) and/or SUBSUPPLIER(s).

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

5.0 MATERIAL AND APPLICATION

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

5.2 The description of the coating procedure shall include:

Preliminary pipe inspection; Pipe handling, identification and storage procedure; Pipe cleaning, including acid washing (phosphating); Pipe pre-heating; Abrasive Blast Cleaning; Phosphate Cleaning;

Chromate washing and FBE application method; Adhesive application method; Application of PE Layer; Testing and inspection; Quality control; Repair procedures.The equipment description shall cover all pipe handling, cleaning, coating, testing and inspection equipment to be used. Details of all materials to be used for pipe coating shall be provided, including Line Pipe MANUFACTURER, grades and properties for each of the coating system components.

A procedure for transferring the full traceability of the pipe from the bare pipe to the external surface of the coated linepipes after coating shall be submitted to the COMPANY for review and approval.

5.3 MANUFACTURER/VENDOR shall confirm by his experience and test data, demonstrating to the satisfaction of COMPANY, that specified thickness of the coating system will meet the requirements of this specification.

6.0 HANDLING AND STORAGE OF MATERIALS

6.1 Acceptance of Pipe6.1.1 Pipe furnished by COMPANY and received by MANUFACTURER/VENDOR shall be deemed to be in the custody of MANUFACTURER/VENDOR from the time of receipt until returned to COMPANY/EPC CONTRACTOR.

6.1.2 MANUFACTURER/VENDOR shall inspect and accept responsibility for each length of line pipe, and other COMPANY supplied material, immediately on receipt, with the exception of defective materials that cannot be detected until after blast cleaning.

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

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

6.1.5 Damage caused to pipe while in the custody of MANUFACTURER/VENDOR shall be reported to COMPANY and repaired by MANUFACTURER/VENDOR to the satisfaction of COMPANYs representative. The cost of such repair work and the cost of any material lost shall be borne by MANUFACTURER/VENDOR.

No repair work shall proceed until written procedure has been prepared by CONTRACTOR and approved by the COMPANY.

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

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

6.2 Pipe Handling6.2.1 Pipe shall be handled in a manner to prevent damage to the pipe and its coated surfaces.

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

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

6.3 Pipe Stacking

6.3.1 Pipe shall be stacked in such a manner so as to prevent damage to the pipe or coating. Prior to use MANUFACTURER/VENDOR shall submit proposed stacking arrangements and calculations, including stacking heights, to COMPANY for review and approval.6.3.2 All pipes shall be stacked on level ground free from foreign materials, stones and vegetation and on supports of a proven load bearing capacity. Pipes shall be suitably spaced from the soil (minimum 150 mm) to prevent any contact with the ground and to prevent surface water from entering during the entire storage period. Pipe shall be prevented from exposure to salt spray.

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

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

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

6.4 Damage to Pipe Ends

6.4.1 All major damage to pipe ends/bevels, including dents or gouges, shall be repaired by removal of damaged pipe material and rebeveling. No welding on the pipe surface shall be allowed.

Minor damage to pipe ends/bevels may be repaired by grinding. Minor damage shall mean damage that is not over 0.025 inch in depth and the number of such damages not more than 3 per pipe. The COMPANYs representative shall be consulted for damage deeper than 0.025 inch.

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

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

6.4.4 Any reduction in pipe lengths shall be input to CONTRACTORs pipe tracking system.

6.5 Material Control Records

6.5.1 MANUFACTURER/VENDOR shall record the receipt, issue return or disposal of all materials supplied by COMPANY and shall permit inspection of those records by COMPANY at all reasonable times. In particular, the records shall reference the pipe number of each pipe.

6.5.2 MANUFACTURER/VENDOR shall submit details of material control recording procedure to COMPANY for review and approval prior to commencement of the works.

6.6 Handling and Storage of Coating Materials

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

Name of Manufacturer; Material identification; Batch number; Date of manufacture and Expiry Date; Quantity; Manufacturing standard; Safety Instructions.6.6.2 Materials shall be handled and stored in accordance with applicable safety regulations and the material Manufacturers recommendations, and shall be used according to the Manufacturers batch sequence.

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

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

6.6.5 Site Storage of Coated Pipe

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

7.0 COATING MATERIALS

7.1 General

The pipe coating procedure shall consist of the following:

Preliminary pipe inspection; Pipe handling procedure, identification and storage; Pipe cleaning, including acid washing (phosphating); Pipe pre-heat; Pipe cleaning/dirt and grease removal and blast cleaning abrasives and technique; Chemical pre-treatment; Chromate pre-treatment; Application of Fusion Bond Epoxy (FBE) layer; Application of adhesive layer; Application of Polyethylene (PE) layer; Inspection and testing; Repair procedures.The SUB-VENDORs trade name and data sheets for each coating material proposed by the MANUFACTURER/VENDOR shall be submitted for COMPANYs approval prior to the placing of any order for coating work.

7.2 FBE Powder

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

SUB-VENDOR; Material identification; Batch number; Place and date of manufacture; Expiration date (Shelf Life); Manufacturing standard; Health, Safety and Environment Instructions; Storage instructions (storage shall normally be at a temperature not greater than 25C).

Hazard warnings

Quantity

Manufacturing standard

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

7.2.2 A production batch is assumed to be a quantity of powder produced from one charge of the extruder. No container shall contain powder from more than one batch.

7.2.3 The MANUFACTURER/VENDOR shall obtain the SUB-VENDORs test records for typical results of the following data:

Sieve analysis; Gel time; Infrared scan; Density; Moisture content; Thermal analysis (including glass transition temperature); Adhesion; Impact resistance/impact strength; Hardness; Flexibility; Dielectric breakdown voltage; Abrasion resistance; Penetration resistance; Volumetric electrical resistivity; Thermal shock resistance; Thermal conductivity; Water absorption; Water vapor transmission; Salt spray resistance; Hot water resistance; Cathodic Disbondment 28 days at ATT & UTT witnessed by COMPANY approved independent inspection agency; Strain polarization cracking; Cure (by glass transition temperature); Stability.7.2.4 Each FBE batch shall be accompanied by a certificate (EN 10204) stating the following tests have been carried out on every batch and results are in accordance with the SUB-VENDORs product specifications:

Sieve analysis; Gel time; Infrared scan; Density; Moisture content; Thermal analysis.For each batch of powder, the MANUFACTURER/VENDOR shall, in the presence of the COMPANYs representative, take three 1 kilogram samples of powder.

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

7.2.6 The third sample shall be used by the MANUFACTURER/VENDOR to check the stability of the powder by measuring the following properties:

Gel time; Sieve analysis; Flexibility; Impact resistance; Adhesion; Density; Moisture content; Cathodic Disbondment 28 days at ATT & UTT;Cathodic disbondment tests to be witnessed by COMPANY. This test shall be undertaken at least 8 weeks in advance of coating operations to prove quality of the applied powder.

7.2.7 The MANUFACTURER/VENDOR shall ensure that the tests on a detached coating film, as defined below, are carried out by the epoxy powder Manufacturer once per year or each time a powder formulation change is made.

The tests shall be carried out on detached coating samples which have been prepared by application on 6 mm thick PTFE coated polished steel plates.

7.2.7.1 Micro-Sectioning

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

7.2.7.2 Tensile Strength/Elongation

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

7.2.7.3 Dielectric Strength

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

7.2.7.4 Water Permeability

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

7.2.7.5 Water Absorption

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

7.3 Adhesive

7.3.1 The adhesive layer shall be polyethylene copolymer which shall be providing a sufficient adhesion between the FBE corrosion coating and the polyethylene coating. The adhesive layer shall have the following characteristics.PropertiesTest MethodUnit of MeasureLimits

Melt flow rateASTM D 1238g/10min1.4

Vicat softening pointASTM D 1525 1 10NoC94

Density at CASTM D 1505g/cm30.92

Tensile yield strength at 23oCASTM D 638Nmm2>15

Ultimate elongation at 23oCASTM D 638%>850

7.3.2 MANUFACTURER/VENDOR shall obtain the SUB-VENDORs production test records for each batch of adhesive giving the following data:

Water absorption; Water vapor transmission; Shelf life; Adhesion to FBE and polyethylene layers at ATT and UTT; Density; Melt flow index; Ultimate elongation;7.3.3 The MANUFACTURER/VENDOR shall test one batch in every ten for compliance with the MANUFACTURERs certificates described in section 10.3.2 of this Specification for adhesion, density and melt flow index.7.4 Polyethylene Material

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

PROPERTIES ASTM TESTUNITSVALUECONDITIONS

DENSITY

Base D1505g/cm30.941

Compound D1505g/cm30.951

Melt flow rateD1238g/10min0.32Condition E

TENSILES

Yield D638MPa19.0@ 50 mm/min

Ultimate D638MPa25.0(2 in/min)

Elongation D638%750

Flexural Modulus D790MPa590Method 1

Softness Point

(Vicat)D1525 oC119

Hardness D2240Shore DD62

Water Absorb. Rate D570 %0.1@ 24 hrs

Water Vapors F372g/ 100in20.890% RH, 100F

NOTE:

Tests performed on compression molded plaques made in accordance with ASTM D4703 Procedure CASTM D1928 Procedure C

Dielectric Strength

220kVlcm

Carbon Content

2.18%

Melting Point (ASTM D3417)

129C

Penetration - Probe Dia.

6.35mm

Sample thk.

1mm (ASTM G17)

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

Density; Melt flow index; Shore hardness; Elongation; Tensile strength; Melting point Moisture content;

Carbon black content;

Carbon black dispersion;

Oxidation induction time; Dielectric breakdown voltage (one off declaration); Environmental stress cracking resistance (one off declaration); Brittleness temperature (one off declaration);7.4.3 The MANUFACTURER/VENDOR shall test one batch in every ten for compliance with the MANUFACTURERs certificates described in section 10.4.2 of this Specification.

7.4.4 The MANUFACTURER/VENDOR shall provide the information detailed in section 10.4.2 of this Specification for the COMPANYs approval prior to the start of coating operations.

8.0 COATING PROCEDURE

The pipe coating procedure shall consist of the following:

Preliminary pipe inspection;

Pipe handling, identification and tracking;

Testing for soluble salts;

Pipe cleaning, including acid washing (phosphating);

Pipe pre-heat

Blast cleaning

Chemical pretreatment

Chromate pre-treatment

Application of Fusion Bond Epoxy (FBE) layer

Application of adhesive layer

Application of Polyethylene (PE) layer

9.0 CLEANING AND SURFACE PREPARATION

9.1 Inspection before Cleaning

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

9.2 Cleaning Prior to Blast Cleaning

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

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

9.2.3 The removal of hydrocarbon contamination shall be confirmed by a water spray test, where a fine spray is applied to the surface and uniform wetting confirms the removal. This check shall be performed before and after blasting, as a pre-qualification test and as a minimum, once per 100 items during production.

Items found to be contaminated shall be cleaned as above and reblasted if testing after blasting establishes that salt or hydrocarbon contamination is still present. The remainder of the batch concerned shall all be checked individually.

All water used for rinsing or cleaning purposes shall be potable with less than 200 ppm total dissolved solids and 30 ppm chlorides.9.3 Surface Preparation

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

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

9.3.3 Using dry blasting techniques only, the exterior surface of the pipe joints shall be abrasively cleaned to remove all mill scale, and other impurities from the surface.

The selection of steel abrasive for blasting shall be in accordance with BS 7079 Parts E2 and E4 to provide the anchor pattern. A combination of grit or steel shot to remove mill scale, and other surface impurities is acceptable. The use of sand is not permitted.

Blasting abrasive shall be kept dry, clean and free from contamination. When recovered metallic grit systems are used, a stabilized working mix of blast cleaning material shall be established and maintained by frequent small additions from fresh or cleaned stock at a rate sufficient to replenish consumption. Large additions of new material shall be avoided. Blasting and other dust producing areas shall be kept separate from coating application areas.

No blast cleaning shall take place when the prevailing relative humidity is greater than 85 percent unless pipe is preheated to at least 3C above the dew point or 25C whichever is greater. 9.3.4 The surfaces of the pipes shall be blasted until a finish of ISO 8501-1 Sa 2(Steel condition A or B) is attained.

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

9.3.6 The blast cleaned surface shall not be contaminated with dirt, dust, metal particles, hydrocarbons, water, chlorides, sulfates or any other foreign matter which would be detrimental to the coating. If pipe was varnish coated, it shall be checked with magnifying glass (X30) to confirm no residues of varnish remain in the anchor pattern valleys.

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

9.3.8 Any pipe length containing a dent shall be set aside for the COMPANYs representative to determine its disposition. Gouges in a dent shall not be grind without COMPANYs approval.

9.3.9 Pipes with chieselled and ground areas greater than 25 mm diameter shall be reblasted to meet the requirements as specified in section 11.3.4 and 11.3.5 of this Specification.

9.3.10 No grinding shall be permitted which reduces the wall thickness of the pipe as stated in section 9.4 of this Specification.9.3.11 Any dust or loose residue that has accumulated during blasting and/or grinding operations shall be removed by the use of clean compressed air or by vacuum extraction. Alternative methods for removing dust and lint shall require approval of the COMPANY.

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

Percent Relative HumidityElapsed Time Hours

850.5

801.0

701.5

601.75

502.0

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

9.4 Chemical Pretreatment

9.4.1 Before application of epoxy powder, the surface to be coated shall be heated to a temperature of 120 to 150F (49 to 66C), spray washed with a solution of Oakite 33 (phosphoric acid) and spray rinsed with clean hot water 160 to 180F (71 to 82C) to remove all acid residue.

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

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

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

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

Before the fresh water rinse:1 to 2;Following the fresh water rinse:6 to 7;9.4.6 Data sheets and supporting documentation for the proprietary phosphoric acid system to be used shall be provided. The documentation shall verify that the chemical is suitable for the treatment of line pipe before the application of the specific fusion bonded epoxy powder being applied and the final coating will meet the requirements of this specification.

9.5 Chromate Pretreatment

9.5.1 The MANUFACTURER/VENDOR shall ensure temperature of the substrate is maintained between 50 and 80C and chromate solution temperature does not exceed 60C.

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

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

9.5.4 The MANUFACTURER/VENDOR shall be fully responsible for adherence to local regulations and material safety data sheets, for using chromate solution.

10.0 COATING

The application of the coating shall be in accordance with the MANUFACTURER/VENDORs procedures, which shall require prior approval from COMPANY.10.1 FBE Layer Coating

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

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

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

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

10.1.5 Pipe temperature shall be checked periodically by tempil sticks or a recording pyrometer. If a pyrometer is used, it shall be checked for error not less than every four hours against a calibrated temperature-measuring instrument.

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

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

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

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

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

10.2 Adhesive Layer Coating

10.2.1 The adhesive shall be applied to a minimum thickness of 200 to 350 microns or as otherwise approved by the COMPANYs representative.

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

10.3 POLYETHYLENE LAYER COATING

10.3.1 The high density polyethylene layer shall be applied to a minimum thickness of 2.5 mm for a pipe diameter equal or greater than 500 mm (20 inch) and 2.0 mm for pipe diameter less than 500 mm (20 inch).

10.3.2 High density polyethylene may be applied by either the cross-head or lateral extrusion technique. The polyethylene shall be applied over the adhesive within the time limits established during pre-production testing.

10.3.3 The coating shall be cooled to below 60C before handling.

10.3.4 The coating cutback from the ends shall be 150 +0/-20 mm. The ends of the coating shall be beveled at 45. There will be no change in the cutback without approval of the COMPANY.

10.3.5 Immediately after the coating is fully cured, pipe identification marks shall be reapplied to the coated pipe using a method approved by the COMPANYS representative. Additional identification shall be made in order to monitor the coating and test batches. All such markings shall be within 2 meters of the pipe end.11.0 INSPECTION AND TESTING

11.1 General

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

11.2 Coating Procedure Qualification Testing

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

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

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

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

11.3 Production Testing

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

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

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

11.4 Visual Inspection

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

Adjacent to the cut-back at each end of pipe; Within the body of the pipe; Adjacent to the longitdudinal welds, if any.

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

11.5 Coating Thickness

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

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

11.5.3 The minimum total coating thickness on pipe surface and longitudinal welds for 20 and above pipeline shall be not less than 3 mm. 11.5.4 Any individual reading less than the requirements of section 14.5.3 of this Specification shall be cause for the coated pipe length to be rejected. Such pipe may be held for further inspection and possible acceptance by the COMPANYs representative.

11.6 Holiday Detection

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

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

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

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

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

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

11.6.7 Holiday detection shall be carried out in accordance with NACE RP0274

11.7 Adhesion Test

11.7.1 The coating adhesion shall be determined in accordance with either of the methods described in DIN 30678. The test shall be performed at 90C and UTT in accordance with NF A 49-711. Test shall be carried out on body and as well as on the longitudinal weld.11.7.2 Three samples shall be cut from each of 4 random selected pipes and tested for resistance to indentations in accordance with the method stated in DIN 30670. The test shall be performed at the ATT and UTT in accordance with 4.2.5 and 5.3.5 of DIN 3067011.7.3 The failure mode shall be recorded. The failure should occur at the adhesive/Polyethylene interface or adhesive/FBE interface or cohesively in the polyethylene layer. If failure should occur at the FBE/steel interface this will be considered a total failure of the system.

11.7.4 During adhesion testing, samples of coating shall be examined using 30X microscope for air entrapment on the body of the pipe or in the longitudinal welds.11.8 Penetration Indentation Test

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

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

11.9 Impact Test

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

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

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

11.9.4 Impact resistance of pipe with FBE coating alone shall be assessed in accordance with the procedure described in DIN 3067011.10 Cathodic Disbondment Test

Cathodic disbondment testing for procedure qualification and production shall be performed in accordance with modified ASTM G42 for 28 days in a 3 percent sodium chloride electrolyte at ATT and UTT and at potential of - 1.5 volt.

During production, such a testing shall be performed under the same conditions for 48 hours.

Upon tests completion the maximum radius of disbondment shall be lesss than the following values, The diameter of the drilled hole for intentional holiday shall be 6mm. The 28 day tests shall be carried out at least 8 weeks before procedure qualification:

Test temperature

Qualification

Production

(28 days)

(48 hours)

ATT(FBE Only)

5 mm

3 mm

UTT

10 mm

5 mm

Production test at ATT may be exempted based or the review of initial results and COMPANYs approval.

Sample photographs showing disbonded area shall be included in test report.

11.10.1 Equipment

DC power supply unit; Platinum or platinum-coated anode wire; Electrolyte solution consisting of 3% (by weight) soduim chloride (NaCl) in distillated water; Plastic cylinder 3-1/2 in (90 mm) diameter, 4 in. (100 mm) long; High resistance volt/amp meter; Hot plate or oven capable of maintaining 32-250F (0-120C); Calomel reference electrode; Utility knife.

11.10.2 Test specimen

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

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

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

11.10.3 Procedure

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

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

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

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

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

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

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

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

11.10.4 Reporting and grading

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

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

c) The acceptance criteria shall be 5 mm maximum disbondment from the edge of the pre-drilled hole.

11.11 Air Entrapment Assessment

11.11.1 No more than 20% of the observed area shall be taken with air entrapment (porosity or bubbles). Bubble size in the polyethylene layer shall be limited to less than half the thickness of polyethylene layer in height or circumference. Bubbles shall not link together to provide a moisture path to the adhesive/FBE layers.

A sample of the applied coating shall be microscopically examined for the presence of foaming, voids and contamination.

11.11.2 Air entrapment or porosity shall be similarly rated for the adhesive and FBE layers of coating. (See Appendix-C).

11.11.3 The strips of coating from the adhesion test should be studied to determine the level of air entrapment at the failure interface. This same area can be used to determine the air entrapment by cutting the coating at a 45 angle along the edge of the remaining coating on the pipe at the test area.

11.11.4 See Appendix-C for Air Entrapment Assessment.

11.12 Degree of Cure

Degree of cure for FBE primer shall be measured by means of Differential Scanning Calorimetery (DSC) IN ACCORDANCE WITH ASTM 3418.

Epoxy film samples shall be removed from the coated pipe using hammer and cold chisel. This produces furled coating flakes. Care shall be taken to remove samples of full film thickness but at the same time avoid the inclusion of steel debris and contamination with adhesive or polyethylene.

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

Differential Scanning Calorimetery (DSC) shall determine the glass transition temperature (Tg) and the enthalphy (Hr) by curing of the powder. F or the samples of the applied coating, two scans shall be made to determine the glass transition temperatures Tg1 and Tg2, respectively. The degree of cure is related to the difference between Tg1 and Tg2, which shall be determined as:

Tg = Tg2 Tg1(Tg = -2C to + 3C ((Tg = (Tg final - (Tg initial)

Only a 95% minimum cured coating shall be acceptable.

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

(H

((H = exothermic heat of reaction)

14.12.2FLEXIBILITY OF FBE

The flexibility of the coating shall be determined once on the first day of production of only FBE layer coated pipes (2Nos.). Please refer to Appendix 4 for test details.

14.12.3HOT WATER RESISTANCE OF FBE

Hot water resistance tests shall be carried out on two pipes coated with only FBE layer. Please refer to Appendix 5 for the test details.

11.13 Destructive Tests

11.13.1 For coating destructive tests listed in Appendicies-A and B a sufficient length of production pipe shall be cold cut to provide the required number of samples for testing.

11.13.2 The coating on the cut end of the pipe length shall be cut back to comply with section 12.3.4 of this Specification.

11.14 Test Certification

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

12.0 REPAIRS12.1 MANUFACTURER/VENDOR shall submit detailed coating repair procedures for approval by COMPANY. These shall detail minimum/maximum areas for which each type of repair is applicable.

The maximum number of coating defects allowable, before a joint of pipe shall be classed as reject and recoated, shall not exceed 5 per joint (inclusive of damage caused by testing).

No single defect shall exceed an area of 625 mm. Pipes with a defect exceeding 625 mm shall be cause for rejection.

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

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

12.4 Shrink sleeves are not considered an acceptable repair.

12.5 MANUFACTURER/VENDOR shall submit coating stripping procedure for pipes selected for coating quality.12.6 Repair shall not be made within 5 inch (125mm) at the end of the pipe.13.0 TEST FAILURE13.1 In the event that a production coated pipe fails to meet the acceptance criteria for a specified test or if the number of holidays detected is excessive, the pipe length shall be rejected unless approval is given by COMPANY to accept said pipe.

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

14.0 DOCUMENTATION

The following documentation, written in the English Language, shall be submitted to COMPANY for review.

Prior to the start of production operations, MANUFACTURER/VENDOR shall submit the following documentation to the COMPANY:

Coating and Testing Procedures; Detailed Description of Coating Equipment and Materials; Pipe Handling Equipment Description and Procedures; Pipe Stacking Arrangements; Material Control Recording Procedure; Inspection Quality Plan; Repair Procedure; Procedures for all PQT and Production Tests.MANUFACTURER/VENDOR shall submit to COMPANY the following documentation prior to the return of coated pipe to COMPANY:

Mill Certificates for Line Pipe Received; Manufacturers Certificates for Each Batch of Coating Materials; Certification/Calibration Certificates for all Testing and Coating Equipment; Inspection and Test, Records, Results, and other Documentation of all Material and Coating Tests.All reports shall be signed by MANUFACTURER/VENDOR to signify compliance with the requirements of this specification.

APPENDIX A

SUMMARY OF INSPECTION/TESTING FOR PROCEDURE QUALIFICATION TEST (PQT) POLYETHYLENE COATING FOR ONE PIPE DIAMETER

PropertyRelevant ClauseAcceptable ValuesNumber of Tests

Before CleaningPipe condition

Chlorides

Oil contamination12.1

12.2.2

12.2.3Conditions A&B of ISO 8501 (part I)

5 g/cm2No indications of oil contamination10

30 (3x10 pipe)

10

After Cleaning

Cleanliness

Profile

Chloride

Dust and Oil12.3.4

12.3.5

12.3.6

12.3.6Sa 21/2

50 - 100 (m.

2 g/cm2No indications of dust or oil contamination.10

10

30 (3x10 pipe)

10

Coating Thickness

FBE coated

FBE + Adhesive + PE.13.1.1

14.5.3250 (m -350 (m

as per section 14.5.3 24 (12x2 pipes)

48 (12x4 pipe)

Holidays

FBE

FBE + Adhesive + PE.14.6

14.6No holidays with detector operating voltage between electrode and pipe maintained at 25 kilovolts.

2

5 Random

Visual aspect

FBE

FBE + Adhesive + PE.14.4

14.4Smooth with no surface defects

Smooth with no surface defects2

8

Adhesion

FBE

FBE + Adhesive + PE.Knife X Cut test

Test 14.7.2Refusal to peel or a cohesive failure

8035N/cm at ATT, 15N/cm at UTT2 (2x1 Random) at ATT

10 (2x5 Random) at UTT

Impact Resistance

FBE

FBE + Adhesive + PE.14.9.2(Impact Resistance Tests shall be carried out at ATT and UTT in accordance with procedure described in clause 12.12 of CAN/CSA/Z245-20-M92)

1.8J (minimum)

Electrical breakdown after 30 impacts 2

5 Random

Penetration (indentation) testing

FBE + Adhesive + PE.14.8.20.2 mm max. ATT, 0.3 mm at UTT12 (3x4 pipes) at ATT & at UTT

Degree of Cure

FBE

FBE + Adhesive +PE.14.12

-2( C ( (Tg ( + 3( C2 (2x1 pipes)

3 Random

Flexibility Bend Test

FBESee

Appendix-DNo cracking/disbondment pinholes2 (1x2 pipes)

Hot Water Resistance

FBESee

Appendix-ENo peel or cohesive break 2mm long

No adhesive/brittle break 2 mm long 2 pipes

Cathodic disbondment

FBE

FBE + Adhesive + PE.14.10

Max. radius of disbondment 5 mm at ATT

Average Max. radius of disbondment 10 mm at UTT2 (2 x 1 Random)

6 (2 x 3 Random)

Air Entrapment

FBE

FBE + Adhesive + PE.See

Appendix-C

14.11No air entrapment in pipe or cut back or longitudinal welds.2

8

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

APPENDIX B

SUMMARY OF INSPECTION/TESTING FOR PRODUCTION TESTING ON FULL POLYETHYLENE COATING SYSTEM FOR ONE PIPE DIAMETERPropertyRelevant ClauseAcceptable ValuesMINIMUM Frequency *

Before Cleaning

Pipe condition

Chloride

Oil12.1

12.2.2

12.2.3Conditions A&B of ISO 8501 (Part I)

2 (g/cm2No indication of oil contamination.Each Pipe

1 per 100 pipe at 3 locations

1 per 100 pipe

After Cleaning

Cleanliness

Profile

Chloride

Dust

Oil12.3.4

12.3.5

12.3.6

12.3.6

12.3.6ISO-Sa 21/2

50 - 100 (m

2 (g/cm2No indications of dust contamination

No indications of oil contaminationEach pipe

Each pipe

1 per 100 pipe

1 per 100 pipe

1 per 100 pipe

Chemical Pretreatment

Solution of Oakite 33

Chlorides

Chromate solution

Chlorides

Temperature12.4.4

12.4.4

12.5.1( 50 ppm

( 50 ppm

( 60( C Once per shift

Once per shift

Once per shift

Coating Thickness (minimum)14.5as per section 14.5.3 Each pipe

Holidays14.6No holidays with detector operating voltage between electrode and pipe maintained at 25 kilovolts.

Each pipe

Visual Inspection

Coating

Longitudinal Welds

PE cut backs14.4

14.11

12.3.4No surface defects

No air entrapment

150 + 0/-20 mm width, bevel 45(Each pipe

Adhesion

At ATT

At UTT14.7.2

14.7.235 Newtons per cm width of strip peeled

15 Newtons per cm width of strip peeled1 per 100 pipe

1 per 100 pipe

Cathodic Disbondment

At ATT

At UTT 14.10Max. radius of disbondment < 3 mm

Max. radius disbondment < 5 mmFirst pipe, last pipe and at intervals of every 350 pipes

Note:COMPANY reserves the rights to increase inspection and testing frequency if warranted by the circumstances.APPENDIX C

AIR ENTRAPMENT ASSESSMENT

A3-1.0SCOPE

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

A3-2.0EQUIPMENT

a) Microscope - Hand Held 30 X.

b) Utility knife.

A3-3.0TEST SPECIMEN

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

A3-4.0 PROCEDURE

A3-4.1Adhesion strip shall be viewed from the side and the failure interface.

A3-4.2Cathodic disbondment samples shall be viewed from the side before tests begins. Scraping with a sharp knife to remove cutting damage on the edge of the coating may be necessary to provide a smooth surface for viewing.

A3-4.3At the pipe adhesion test site use a utility knife to cut the edge of the coating to a 45( angle and view with a microscope.

A3-4.4Perform a similar test in the cut back area. This should be used for information to determine if further testing is needed.

A3-5.0REPORTING AND GRADING

A3-5.1Report pipe joint number, date pipe was coated, coating batch number, and date of test.

A3-5.2Report rating of cross-section and interface entrapment.

A3-5.3A rating of 1 or 2 is passing.

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

Rating

1. Very Good-Passing

2. Good

-Passing

3. Fair

-Failing

4. Poor

-Failing

5. Very Poor-Failing

Rating for each area of concern:

o o o o

o o oNo. 1 Rating - Passing

Less than 10% of are with bubbles.

o o o o o o

o o o o oNo. 2 Rating -Passing

Less than 20% / more than 10%

o o o o o o o o o o o

o o o o o o o oNo. 3 Rating - FailingLess than 30% / more than 20%

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

o o o o o o o o o o o No. 4 Rating - Failing

Less than 40% / more than 30%

ooooooooooooooooooooooooooooooooooooo

ooooooooooooooooooooooooooooooooooooNo. 5 Rating - Failing

Over 50% of area taken by air entrapment (bubbles).

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

FLEXIBILITY TEST FOR FBE LAYER COATING PQT

A4-1.0TEST METHOD

The flexibility of the coating shall be determined once on the first day of production of only FBE layer coated pipes (2 Nos.) by the following method:

Coated samples (300 mm x 50 mm x thickness of pipe wall) taken from a FBE coated pipe joint shall be subjected to a bend test at a temperature of 0(C and 20(C to induce a 2% and 3% strain respectively in the sample.

At each temperature the test shall be carried out twofold.

The deflection loading rate during bend testing shall be 25 ( 2 mm/min.

The mandrel sizes shall be selected according to the following formula:

D = t (1-s) s

Where,

D = mandrel diameter (mm)

t = specimen wall thickness (mm)

s = 0.02 at 0(C

0.03 at 20(C

A4-2.0ACCEPTANCE CRITERIA

The coating shall not exhibit any signs of cracking, disbondment or pinholes.APPENDIX-E

HOT WATER RESISTANCE TEST FOR FBE LAYER COATING PQT

1. Test Method

Hot water resistance tests as detailed below shall be carried out on two pipes coated with only FBE layer.

A coated sample of 200 mm x 100 mm machined from a pipe ring of the coated pipe shall be immersed in tap water of 85(C for 5 hours.

The bare edges of the sample shall be coated to prevent ingress of moisture beneath the coating.

Directly after 5 hours exposure, the coated sample shall be removed from the water bath and allowed to cool to ambient temperature. Subsequently the coating adhesion shall be tested as follows :

Using a sharp and pointed knife, two incisions of approximately 15 mm in length shall be made through to the steel surface to form an X with an angle of intersection of approximately 30 degrees. Commencing at the intersection, an attempt shall be made to lift the coating from the steel substrate using the blade of the knife.

2. Acceptance Criteria

Refusal of the coating to peel or a cohesive break less than 2 mm long entirely within the coating in the absence of excessive voids caused by foaming constitutes a pass.

Any adhesive break away from the intersection point or brittle break away of flakes of more than 2 mm long constitute a failure.

Cohesive failure caused by voids in the coating leaving a honeycomb structure on the steel surface also constitutes a failed condition.

In addition, the coating shall not show any tendency towards disbonding or blistering. A slight discoloration of the coating is acceptable.