Professional Documents
Culture Documents
CONTRACTORS STAMP:
Minor changes
Millim
Zhao
27.09.2013
5
4
General Update
Millim
Zhao
18.07.2013
General Update
Neumann
Zhao
05.08.2010
General Update
Neumann
Kloos
03.09.2007
General Update
Neumann
Kloos
22.12.2006
General update
Neumann
Casalini
28.04.2006
Kosikova
Bangert
August 2004
Kosikova
Bangert
August 2004
For approval
Rupietta
Bangert
July 2003
PREPARED
CHECKED
DATE
REV
DESCRIPTION
LOCATION:
TITLE:
Specification M02
POLYETHYLENE COATING
SCALE:
DOCUMENT No.:
REV:
SUBCONTRACTOR:
Sheet 1 of 31
Subject:
Doc. - No.:
Page 2 of 31
Rev. 6
LIST OF CONTENTS
1
SCOPE
GENERAL
3.1
Environmental Conditions
3.2
Definitions
3.3
Abbreviations
3.4
TECHNICAL REQUIREMENTS
4.1
4.2
13
4.3
14
4.4
Coating Application
17
18
5.1
General
18
5.2
19
5.3
Production Testing
21
28
6.1
Preservation
28
6.2
Marking
28
6.3
Shipping
29
DOCUMENTATION
29
7.1
Pre-Production Documentation
29
7.2
Production Records
30
7.3
Release Documentation
31
Subject:
Doc. - No.:
Page 3 of 31
Rev. 6
SCOPE
This Specification defines the minimum requirements for the application of threelayer polyethylene coating to the external surface of steel pipe for buried service.
For the factory-applied coating the system shall comprise of a layer of fusion
bonded epoxy (FBE), overlaid with adhesive with an outer layer of high density
polyethylene.
ANSI/AWWA C213
ASTM D 570
ASTM D 638
ASTM D 792
ASTM D 1505
ASTM D 1525
ASTM D 1693
ASTM D 2240
ASTM D 3895
Stress-
Subject:
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Page 4 of 31
Rev. 6
ASTM G 8
Cathodic
CSA Z245.20-02
DIN 30670-2012
ISO 306
ISO 527-2
ISO 527-3
ISO 1873-2
ISO 8501-1
ISO 8502-2
ISO 8502-3
Subject:
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Page 5 of 31
Rev. 6
painting
ISO 8502-4
ISO 8502-5
ISO 8502-9
ISO 8503-1
ISO 8503-2
ISO 9001
ISO 11357
Subject:
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Page 6 of 31
Rev. 6
ISO 15512
ISO 21809-1
NACE RP0490
Besides the a.m. codes and standards the Contractor shall observe the following
specifications:
G02 General Description of Project and Works
G03 Project Execution
M01 Steel Pipes for Mainlines
Subject:
Doc. - No.:
GENERAL
3.1
Environmental Conditions
Page 7 of 31
Rev. 6
Definitions
The terms Contractor, Pipe Supplier, Pipe Coating Contractor, Engineer,
etc. used in this specification shall have the meanings defined in the General and
Special Conditions of Contract.
If the pipe coating works are not directly contracted by the Employer but through
another Contractor, the term Pipe Coating Contractor shall have the meaning of
Pipe Coating Subcontractor.
3.3
Abbreviations
ANSI
API
ASME
ASTM
AWWA
DIN
DSC
ESCR
FBE
HSE
ISO
MFR
NACE
PD
Pipe Diameter
PE
Polyethylene
PQT
Subject:
Doc. - No.:
3.4
Page 8 of 31
Rev. 6
TECHNICAL REQUIREMENTS
4.1
4.1.1 General
Materials shall be handled and stored in accordance with the material
manufacturers recommendations, which shall be available for review by the
Engineer at the Pipe Coating Contractors premises. Materials shall be stored in a
temperature controlled environment until required for use.
Coating materials shall be segregated by type and batch during storage and
handling. Materials from damaged containers shall be rejected unless otherwise
agreed with the Engineer.
The Pipe Coating Contractor shall provide batch certificates supplied by the
manufacturer of each material and shall contain the information given in table
below. The batch certificate shall state test methods and acceptance criteria.
Subject:
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Page 9 of 31
Rev. 6
Coating material
Content
FBE
Adhesive
PE
top coat
Trade name
Product identification
Batch identification
Density
Melting point
Gel time
Particle size
Moisture/water content
X (a)
Pigment dispersion
X (a)
Thermal characteristic
X (b)
Colour
HSE instructions
Hazard warnings
Storage instructions
a) If applicable
b) Direct and indirect methods can be proposed by the manufacturer
Any material not labelled with the above information shall not be used.
Subject:
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Page 10 of 31
Rev. 6
Unit
Test method
%
ISO21809-1, Annex K, Class
mass B, or CSA Z245.20-02(12.4B)
Requirements
0.6
95 (b)
(c)
Density
g/l
(d)
>3
Subject:
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Page 11 of 31
Rev. 6
4.1.4 Adhesive
The adhesive selected shall be completely suitable for use at the design
temperatures in the proposed environment and be suitable for a three layer
polyethylene coating system.
The Pipe Coating Contractor shall use adhesive material that is in accordance
with the minimum requirements listed in the table below.
Properties (Adhesive)
Unit
Elongation at break at 23 2 C
(a)
Test method
Requirements
ISO 527-2 or -3 or
ASTM D 638
600
12
Vicat softening
A/50 (9.8 N)
temperature
100
0.05
Subject:
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Page 12 of 31
Rev. 6
The Pipe Coating Contractor shall use PE top coat material that is in accordance
with the minimum requirements listed in the table below.
Unit
Test method
Requirements
0.930
Elongation at break at 23 2
C (a)
ISO 527-2 or -3 or
ASTM D 638
600
MPa
ISO 527-2 or -3 or
ASTM D 638
19
110
0.05
Hardness Shore D
Vicat softening
A/50 (9.8 N)
temperature
min
ASTM D 1693
55
1000 Cond. A
or
300 Cond. B
If
density >0.955
30 at 210C
or
10 at 220C
MFR 35
Subject:
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4.2
Page 13 of 31
Rev. 6
Subject:
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Page 14 of 31
Rev. 6
the minimum requirements of the line pipe specification, when measured using
ultrasonic thickness measurement equipment.
All other damage to pipe ends/bevels shall be advised to the Engineer for review.
Subject to Engineers approval, these defects may be repaired by removal of
damaged pipe material and re-bevelling. No welding on the pipe surface shall be
allowed.
Pipe identification numbers shall be preserved during repair. Any reduction in
pipe lengths shall be recorded in the relevant forms and files.
4.3
4.3.1 Stages
The principle stages of pipe coating shall be as follows:
-
Abrasive blasting
Subject:
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Page 15 of 31
Rev. 6
The surfaces of the pipes shall be blasted until a finish of Grade 2.5 to ISO 85011 is attained. The surface profile shall be between 50 and 100 microns, measured
Subject:
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Page 16 of 31
Rev. 6
85
80
70
60
50
0.5
1.0
1.5
1.75
2.0
Any pipe surface not processed within the above time-humidity table shall be
completely re-cleaned and re-blasted before coating.
The maximum time limit between blasting and coating for humidity below 50%
shall be 4 hours.
Subject:
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4.4
Page 17 of 31
Rev. 6
Coating Application
4.4.1 General
The application of the coating shall be in accordance with the material
manufacturer recommendations and the procedure outlined below.
The Pipe Coating Contractor shall perform coating procedure qualification testing
(PQT) prior to commencing production or on his own risk at the start of
production in accordance with this specification.
Prior to start-up of the coating process the powder application and recovery
systems shall be thoroughly cleaned to remove any powder other than that in
use, minimum once per day and the collected powder shall be disposed of.
Subject:
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Page 18 of 31
Rev. 6
4.4.5
5.1
General
In order to demonstrate that the manufacturers proposed coating application
procedure is capable of meeting the specification, the Pipe Coating Contractor
Subject:
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Page 19 of 31
Rev. 6
5.2
Subject:
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Page 20 of 31
Rev. 6
Acceptable Values
Frequency of
Tests
Each pipe
2 g/cm2
No contamination
3 g/cm2
Each pipe
Each pipe
Each pipe
Each pipe
No surface defects
No holidays
Min/max see clause 4.4.2
See clause 5.3.5
Each pipe
Each pipe
10 per pipe
2 per pipe
16 per pipe
Each pipe
Each pipe
Each pipe
Each pipe
Each pipe
2 per pipe
2 per pipe
1 per pipe
2 per pipe
2 per pipe
1 per pipe
Subject:
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Page 21 of 31
Rev. 6
DIN 30670
5.3
Production Testing
Acceptable Values
Minimum
Frequency
Minor damage/grinding 3
per pipe
Each Pipe
2 g/cm2
No contamination
3 g/cm2
ISO-Sa 2.5
50-100 m
No contamination
See clause 4.2
Each pipe
1 pipe per 100
1 pipe per 100
Each pipe
No surface defects
Min/max see clause 4.4.2
See clause 5.3.5
No holidays
After Cleaning
Chloride
Oil
Salt
After Abrasive Blasting
Cleanliness
Profile
Contamination
Pipe Damage
Holidays
Each pipe
No holidays
Each pipe
No surface defects
Each pipe
Subject:
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Page 22 of 31
Rev. 6
Each pipe
Each pipe
Each pipe
Clause 5.3.10
The frequency of tests shown in the table above will be for normal production
operations. This frequency of tests is subject to change at the discretion of the
Engineer as a result of change of materials or consistent poor production
performance.
Additional after cleaning checks regarding chloride, oil, salt shall be executed
after every stop and start for certain hours.
The Pipe Coating Contractors quality control system shall include the following,
as a minimum:
-
The following shall be recorded and logged at least once per shift:
-
Dew point
Subject:
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Page 23 of 31
Rev. 6
The coating shall be black (unless otherwise agreed by the Engineer). The
finished coating shall be blemish-free, with no dust or other particulate inclusions.
The coating shall not have any defects such as blisters, scratches, wrinkles,
engravings, cuts, swellings, excess material thickness, disbonded zones, air
inclusions, tears, voids etc.
PIPE BODY
< 500mm
500mm
3.0 mm
3.5 mm
2.75 mm
3.25 mm
Subject:
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Page 24 of 31
Rev. 6
The thickness of the cooled polyethylene coating system shall be checked using
Engineer approved equipment in accordance with the requirements of DIN
30670.
Film thickness shall be measured by use of an electronic thickness gauge.
Calibration of this gauge shall be rechecked every 2 hours. The Pipe Coating
Contractors proposed thickness gauge type, manufacturer and model shall be
submitted to the Engineer for review and approval.
At least 3 of the measured points per pipe length shall be on the welds.
Any individual reading less than the values above shall be cause for the coated
pipe length concerned to be quarantined. The pipe shall be held for further review
by the Engineer.
Subject:
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Page 25 of 31
Rev. 6
Subject:
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Page 26 of 31
Rev. 6
5C and the other one at 70C 2C) in accordance with DIN 30670 (Section
5.3.5).
Indentation depth shall not exceed 0.2 mm at 20C 5C or 0.3 mm at 70C
2C.
5.3.8 Percentage Elongation at Failure
This test shall be conducted in accordance with DIN 30670 on each of the full
system pre-qualification pipes, but at least the coating of three pipes shall be
tested for elongation at failure, from which five test pieces shall be taken. The
percentage elongation at failure shall be at least 200%.-on each of the full system
pre-qualification pipes, 2 samples per pipe to the requirements of DIN 30670.
5.3.9 Other DIN 30670 Tests
The Pipe Coating Contractor shall demonstrate, for the same system to be
applied for this order, attainment of DIN 30670 requirements for Coating
Resistivity, to Thermal Ageing and Light Ageing as required by DIN 30670.
5.3.10 Cathodic Disbondment Test
Cathodic Disbondment testing shall be conducted:
as a production test - 48 hours duration, at the frequency of one test per 350
coated pipes at 65 +/- 2C
Subject:
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Page 27 of 31
Rev. 6
coating shall be stripped and the joint shall be re-blasted and coated in the
manner specified for new pipe in this specification.
Where a test relates to a quantity of coated items, e.g. 1 per 50 items or 1 per
100 items etc., the quantity of items represented by the item tested (e.g. 50 or
100) shall be considered to be a batch.
If a test on an item in a batch fails then this item shall be rejected and two further
items shall be randomly selected from the batch for repeat testing. If either of
these tests fails then the whole batch shall be quarantined for review by
Engineer. The cause of failure shall be established and reported to the Engineer
and if deemed necessary by the Engineer the coating procedure shall be
amended and re-qualified. The Engineer will decide whether the whole batch is
rejected and sent for re-blasting and re-coating or whether acceptance may be on
the basis of acceptable tests carried out on individual items.
5.3.12 Coating Repairs
The Pipe Coating Contractor shall submit detailed coating repair procedures for
approval by Engineer. These shall include procedures for repair of pin-hole,
small area and large area defects. The minimum and maximum areas for which
each type of repair is applicable shall be stated taking into consideration the
below mentioned requirements.
The maximum number of coating defects allowable, before a joint of pipe shall be
classed as rejected and recoated, shall not exceed 1 per 1 square metre
(exclusive of damage caused by testing).
The area shall be swabbed with solvent and abraded with an emery cloth, to
ensure that the surrounding polyethylene is well bonded, the surface shall be
roughened for a distance of at least 25 mm beyond the damage area. An
approved hot melt mastic shall be applied to the damaged area and smoothed
flush. The mastic and surrounding area shall be warmed with hot air or propane
torch until the surrounding polyethylene has as slight sheen. An approved
polyethylene patch material shall be applied overlapping the damage but not
overlapping the pre-abraded areas. Torch heat and smoothing pressure shall be
applied to fuse the patch and ensure that no blisters are formed.
Subject:
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Page 28 of 31
Rev. 6
Heat shrink-wrapping pipe sleeves shall be used for repair according to the
following procedure:
-
- Warm the shrink sleeve to a temperature above 150C with a propane torch
or a warm-air ring
No single defect shall exceed an area of 625 mm. Pipes with a coating defect
exceeding 625 mm shall be cause for rejection and shall be subsequently
reblasted and recoated. All rejections shall be recorded.
Repairs shall provide a finished coating equal in effectiveness to that of the
parent coating. The limit of the repair area shall be revised.
Each repaired area shall be holiday inspected in accordance with chapter 5.3.4 of
this specification.
The Pipe Coating Contractor shall submit coating stripping procedure for pipes
rejected for coating quality. The rejected coating may be stripped by heating in an
oven. Under these circumstances, the temperature of the pipe joint shall not be
allowed to rise above 400 C.
6.1
Preservation
The bare ends of each pipe shall be painted outside with a removable varnish as
temporary corrosion protection during transportation.
Bevel protectors of a type to be approved by the Engineer shall protect the bare
ends of each pipe.
6.2
Marking
In addition to the marking required by API 5L, the specification M01 Steel Pipes
for Mainlines and other applicable project specifications, the Pipe Coating
Contractors unique coating number shall be marked to the internal surface of the
pipe with synthetic resin paint.
Subject:
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Page 29 of 31
Rev. 6
Further, marking details like colour coding etc. shall be agreed upon with the
Engineer.
The marking shall have at least a distance of 150 mm to the pipe end.
6.3
Shipping
Shipping and Loading preparation shall be in accordance with API Specification
5L or otherwise stated in the contract documents.
The Pipe Coating Contractor shall submit detailed loading-, stacking- and
shipping procedures for approval by the Engineer.
DOCUMENTATION
7.1
Pre-Production Documentation
The Pipe Coating Contractor shall submit the following documentation to the
Engineer for approval prior to commencing production:
a)
The manufacturers trade name and data sheets for all proposed coating
materials. This includes cleaning and abrasive blasting consumables.
b)
c)
Handling procedure.
d)
Stacking procedure.
e)
f)
g)
h)
i)
The results of the batch tests for batches to be used for pre-qualification
tests.
j)
k)
Subject:
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Page 30 of 31
Rev. 6
l)
Full test results from the coating Procedure Qualification Test (PQT).
m)
n)
Work shall not commence until these procedures have been reviewed and
approved by the Engineer.
The selection of proposed coating materials shall be subject to Engineers
approval.
7.2
Production Records
A daily log containing the following data shall be maintained and be available for
inspection by the Engineer during and/or after production. Data shall be recorded
against the pipe unique identification number.
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
The unique identification number of all items that are stripped for recoating
m)
Subject:
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7.3
Page 31 of 31
Rev. 6
Release Documentation
The Pipe Coating Contractor shall submit to the Engineer the following
documentation in hard copy and softcopy (format to be agreed upon with the
Engineer) with each batch of pipes released:
a)
b)
c)
d)
e)
Pipe length
f)
Length of the coated portion of each pipe and total coated lengths of all
pipes.
g)
h)
Date of coating
i)
b)
c)
All reports shall be signed by the Pipe Coating Contractor to signify compliance
with the requirements of this specification.