SPECIFICATION FOR 3 LAYER POLYETHYLENE

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SPECIFICATION FOR 3 LAYER POLYETHYLENE

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SPECIFICATION FOR 3 LAYER POLYETHLENE COATING

05 FINAL APPROVED MK AN MM 90.08

04 FINAL APPROVED MK AN MM 90.06
03 IFA MK AN MM 90.06
02 IFA MK AN MM 90.05
01 IFA MK AN MM 90.03

PURPOSE OF
REV. PREPARED CHECKED APPROVED DATE REMARKS
ISSUE

ISSUED FOR
DOCUMENT REVISION SHEET
- REVISED SHEETS

ONLY ATTACHED - REVIEW

- APPROVAL
- ENTIRE DOCUMENT - ENDORSE
RE-ISSUED - PROCUREMENT
- FINAL APPROVED
- INFORMATION
- DESIGN
- ENTIRE DOCUMENT

REVISED

01 02 03 04 05 REMARK 01 02 03 REMARK
1 x
2 x
3 x
4 x


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5 x
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Table of Contents


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1. Introduction...........................................................................................................4
2. SCOPE..................................................................................................................4
3. Definitions............................................................................................................4
4. CODES AND STANDARDS...............................................................................4
5. BASIC REQUIREMENTS...................................................................................5
6. COATING MATERIALS.....................................................................................6
7. MANUFACTURING PROCEDURE.................................................................10
8. INSPECTION AND TESTING..........................................................................16
9. HANDLING AND STORAGE..........................................................................19
ANNEX A 20


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1. Introduction
Iranian Gas Engineering & Development Company (I.G.E.D.C) has intended to perform gas
transmission pipeline and gas compressor stations for transferring of 110 MMSCMD of natural
gas from Assalouyeh to Bazargan.
Design of a new 56" gas transmission pipeline from Ahwaz to Dehgolan has been described under
this EPCF Contract.

2. SCOPE
This specification gives minimum technical specifications and general requirements for 3 layer
polyethylene coating as external protection.

3. Definitions
Client: Iranian Gas Engineering & Development Company (IGEDC).
SUPERVISOR: Ghods Niroo Consulting Engineers.
CONSULTANT: Haraz Rah Consulting Engineers.
CONTRACTOR: Gharargah Khatam-AL-Anbia.Niroo Goostar Institute.

4. CODES AND STANDARDS

Throughout this specification the following codes and standards shall be applied. Unless otherwise
stated, the latest edition or revision of these codes shall be followed.
BS 4232 Specification for surface finish of blast cleaned steel for
painting
BS 7079 Preparation of steel substrates before application of paints
and related products, parts D2 and E
ISO IEC 243-1 Methods of test for electric strength of solid insulating
materials
ASTM D1603 Test method for Carbon black in olefin plastics
ASTM D1643 Test method for gas checking and draft test of varnish film
ASTM G8 Test method for catholic disbanding of pipe line coating
SIS 055900 Preparation of steel substrates before application of paints
and related products-visual assessment of surface
cleanliness


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API 5L5 Recommended practice for marine transportation of line

pipe
NACE RP 0274 High voltage electrical inspection of pipelines coating prior
to installation
IGS-TP-010-1&2 Amendment to 3 Layer Polyethylene Coating System Part
(1&2)

IPS-G-TP-335 Material and construction standard for three layer

polyethylene Coating system

5. BASIC REQUIREMENTS
5.1 Three-layer polyethylene coating system consists of the following layers
and is intended for use on external surfaces of line pipes.
First layer: epoxy powder primer
Intermediate layer: adhesive layer
Top layer: polyethylene coating
5.2 The coating system shall provide the following basic requirements and shall
withstand against mechanical and thermal stresses, bio-degradation and
Electro-chemical process of the cathodically protected pipeline.
Minimum cathodic disbanding property
Maximum strength and impact resistance
Adhesion and penetration resistance
Abrasion resistance
Appropriate tensile and elongation properties
5.3 Manufacturer shall be responsible to provide values for all the basic
properties of the material as specified in paragraphs 5.4.1, 5.4.2 and 5.4.3.
5.4 Manufacturer shall set up and maintain such quality assurance and
inspection system as is necessary to ensure that the goods or services
supplied comply in all respects with the requirements of this specification.


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5.5 All identification markings, whether internal or external to the pipe shall be
carefully recorded before surface preparation begins.
5.6 The date of coating finish and the Manufacturer marking, including pipe
identification shall be legibly marked on coating surface of each length of
pipe.
5.7 The coating process shall comply with the procedure established in the
relevant coating procedures, section 6.
5.8 Holiday defects and damaged areas due to destructive tests shall be
repaired in accordance with procedures specified by the Manufacturer.
5.9 Rejected coating shall be removed only by the procedures specified by the
Manufacturer. The process shall cause no mechanical damage to the pipe.

6. COATING MATERIALS
6.1 General
6.1.1 The coating material supplied shall be certified by the
Manufacturer ensuring that all materials comply with this
specification prior to application.
6.1.2 Purchaser may make any investigation necessary, by way of
testing, batch sampling, manufacturing and factory inspection, to
satisfy himself of such compliance by the Manufacturer.
6.2 Material Handling & Storage
6.2.1 The materials shall be stored in accordance with the Suppliers
recommended procedure.
6.2.2 The materials shall be handled in such a way that they do not
suffer any damage.
6.3 Identification of Materials
6.3.1 All materials supplied for coating operations shall be suitably
marked giving the information such as; Suppliers name and
address, order and batch number, date of manufacture and shelf
life, direction for mixing, thinning, handling and storing.


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6.4 Specifications of Materials

6.4.1 Primer:
Epoxy powder is a thermosetting material for use as primer in a
three-layer polyethylene coating system for steel pipe. It shall be
specifically formulated and designed so as to be suitable for
electrostatic application and to improve adhesion of coating
system and also provide maximum cathodic disbanding
resistance. Manufacturer shall comply with specified ranges of
values given in Table 1 and shall provide figures for all properties
listed in that Table.
Using an approved method, an infrared spectrogram, preferably
made by using a standard KBr (potassium bromide) disc, shall be
obtained from a first batch of the powder epoxy. This shall
subsequently be used for comparison with type spectrogram.
Thermal analysis data for each batch shall be made available
showing, by use of a DSC (Differential Scanning Calorimeter) the
Glass Transition (GT) of the raw powder and also the enthalpy of
the curing powder. The Glass Transition Temperature (G.T.T) of
the fully cured powder shall also be quoted. The reference curve
shall be provided as part of the production data sheet. The limiting
values of H, TG1 and TG2 shall be identified by the
manufacturer.
6.4.2 Adhesive Layer:
Adhesive layer is used as second layer in a three-layer
polyethylene coating system for steel pipes. It shall be an ethylene
base copolymer, specifically formulated and designed so as to be
suitable for extrusion application. Manufacturer shall comply with


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specified ranges of values given in Table 2 and shall provide

figures for all properties listed therein.
The adhesive shall be uncolored and made of raw material with
the best quality to provide the following properties:
Excellent peeling resistance.
Excellent mechanical strength.
Excellent thermal stability.
Strong adhesion to fusion bonded epoxy film as well as to
steel surface.
Homopolar bond with the polyethylene top coat (third layer).

6.4.3 Polyethylene:
Polyethylene is a thermoplastic resin for use as top coat in a
three-layer polyethylene coating system for steel pipe. It shall be
specifically formulated and designed for extrusion application.
Manufacturer shall comply with specified ranges of values given in
Table 3 and shall provide figures for all properties listed therein.
The polyethylene shall be made of raw material with the best
quality to provide following properties:
Excellent peeling resistance.
Excellent mechanical strength.
Excellent thermal stability.
Excellent Impact resistance.
Excellent penetration resistance.
Strong adhesion to adhesive layer.


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Table 1


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RAW EPOXY POWDER PROPERTIES

U
N TEST
PROPERTY REQUIREMENTS
I METHOD
T
Density g As per manufacturer's ISO 8130-2
/ specification 0.05
c
m
3

Gel time s Within 20% of ISO 8130-6

e manufacturer's
c specification
Particle size: % CSA Z 245.20-
Maximum powder retained on 150 m 3.0 06
mesh 0.2
Maximum powder retained on 250 m
mesh
Specific coating resistance after 100 O >108 NFA 46-710
days of exposure in 3% NaCl solution h
at 23 oC m
.
m
2

o o o
3.0 flexibility test at 23 C , 0 C and - No cracking CSA Z 245.20-
-20oC - 06
-
Cathodic disbandment after 28 days at m 7 CSA Z 245.20
65 0C in 3% NaCl solution at -1.5 volts m
(calomel electrode) potential , initial .
defect
diameter Do = 6 mm , max
Moisture content,max % 0.5 ISO 21809-1

b
y

m
a
s
s
Degree of cure (differential thermal -2o C Tg +3 o C ISO 21809-1
analysis) C
Glass transition temperature(Tg2)(DSC 95 ISO 21809-1
analysis) C


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Water resistance,1000 hrs at 80oC - no blistering ,swelling < 5% , ASTM D 870

- loss of hardness< 10%
-
Adhesion to pipe surface , max - Rating 2 CSA Z 245.20-
- 06
-


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Table 2
PHYSICAL PROPERTIES OF ADHESIVE LAYER
PROPERTY UNIT TEST VALUE
METHO
D
Density at 232C gr/cm3 ISO 1183 0.90 -
0.95
Melt flow rate (2.16 kg /190 C) O gr/10 ISO 1133 0.5-0.2
minute
s
Elongation at break at 23 2 C ,min O % ISO 527 600
Melting point (DSC) , min C ISO 105
3146
Vicat softening temperature C ISO 306 95
A/50(9.8N) , min
Tensile strength , at 23 2 C ,min
O MPa ISO 527 8
Water content,max weight ISO 0.1
% 15512

Table 3
PHYSICAL PROPERTIES OF BLACK POLYETHYLENE
TEST
PROPERTY UNIT VALUE
METHOD
Density gr/cm3 ISO 1183 0.94 (Min.)
Melting index gr/10
ISO 1133 0.3 -0.8
(2,16kg/190C) min
Elongation % ISO 527 600 Min.
2
Tensile strength at yield N/mm ISO 527 15 Min.
SHORE
Hardness ISO 868 55 Min.
.D
Vicat softening point C ISO 306 115 (Min.)
Melting point (DSC) C ISO 1133 125 Min.
-70 NO.
Low temperature brittleness C ASTM-D-746
FRACTUR
Stress cracking resistance
Hour ASTM-D-1693 1000 Min.
(Methyl-Ethyl-Ceton)
% by
Carbon black content ASTM-D-1603 2.5 MIN.
mass
Water content % by ISO 15512 0.05


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weight
Oxidation induction time minute ISO 11357 30
UV resistance and thermal Annex G
% MFR35
aging ISO 21809-1

7. MANUFACTURING PROCEDURE
7.1 Coating method
Coating method shall generally consist of surface cleaning and
blasting, epoxy primer application, adhesive layer and
polyethylene coating application onto the preheated pipe
surface by simultaneous extrusion in a continuous flow
.process
7.2 Coating Process
Manufacturing process of polyethylene coating system
depends on the type of plant but shall be basically
accomplished by profile extrusion and/or winding extrusion and
.melting of polyethylene in accordance with DIN 30670
7.3 Coating Procedures
7.3.1 Surface Preparation
7.3.1.1 The details of method of surface cleaning and surface
preparation shall be specified by the Manufacturer.
7.3.1.2 Where oil, grease or other contaminants are present, they
shall be removed by a suitable solvent.
7.3.1.3 When a chemical cleaner is used to remove any
contamination on pipes, subsequent washing with fresh
water shall be necessary. The pipes shall then be dried
before blast cleaning.
7.3.1.4 The pipes shall be blast cleaned to a minimum of Sa 2
finish according to Swedish Std. SIS 055900. The blast


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profile shall have 75-100 micron height, measured by an

approved method.
7.3.1.5 The metal surface shall then be inspected thoroughly
after blast cleaning to ensure that all surface
imperfections, weld spatters, sharp projections, etc. have
been removed.
7.3.1.6 Where rust blooming or further surface contamination has
occurred, the pipe shall be cleaned again in accordance
with 6.3.1.2 and again blast cleaned in accordance with
6.3.1.4 Coating shall take place before any further
contamination or rust blooming appears.
7.3.2 Preheating
Preheating, if necessary, depends on ambient temperature and
humidity shall be applied.
7.3.3 Primer Application
Application of primer shall be performed by use of epoxy resin
powder, compatible with subsequent adhesive layer.
7.3.4 Heating
Heating shall be applied by use of induction coil to perform
polyethylene extrusion. Heating temperatures shall be kept within
specified ranges recommended by line pipe Manufacturer.
7.3.5 Adhesive Layer & Polyethylene Application
Adhesive layer and polyethylene top coat shall be applied in a
simultaneous extrusion process (profile and/or winding extrusion
and melting of polyethylene).
7.4 Protection of Weld-end Preparations
7.4.1 Weld-end preparations shall be protected from mechanical damage
during handling, storage, surface preparation and the coating


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process. The methods used shall also ensure that no damage

occurs to the internal surface of the pipe.
7.4.2 The ends of the pipes shall be free of any coating layer over a
length of 150(-0, +20)mm.
7.4.3 The uncoated ends of pipes shall be temporarily protected against
atmospheric corrosion by a temporary paint easily removable by
brushing. Beside the cap end for bevel protection.
7.4.4 Pipe end preparations shall be protected from coating during the
process by a suitable method approved by the Purchaser.
7.5 Coating Thickness
The minimum overall thickness of three-layer polyethylene coating shall be
according the following table.

Table 4
Coating Thickness
POWDER EPOXY
ADHESIVE
RESIN Total Thickness
PIPE DIAMETER (in). (ND LAYER 2)
(ST LAYER 1) mm
mm
mm
Up to 10 0.15 0.15 2.0

up to 20 10 0.15 0.15 2.5

up to 36 20 0.15 0.15 3.0

More than 36 0.15 0.15 3.5

Notes:
The minimum nominal thickness of epoxy primer coat, which shall be
applied by electrostatic spray gun, shall be 150 microns. Higher
nominal thickness (to be approved) shall be applied if required in
accordance with powder manufacturers instructions.


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For Adhesive layer, thickness shall be one of following: Sprayed 150

microns nominal thickness or Extruded 250 to 300 microns nominal
thickness and to be applied under pressure using silicon rubber
rollers.
7.6 Qualification of Coating Procedure Specification
7.6.1 Before bulk coating of pipe commences, the Manufacturer shall
present the Coating Procedure Specification together with a detailed
sequence of operations to be followed on the coating of pipe, to the
Purchaser for formal approval.
7.6.2 The Coating Procedure Specification shall incorporate full details of
the following:
Polyethylene coating system materials
Pipe cleaning
Blast cleaning medium and technique
Blast cleaning finish, surface profile and surface cleaning
Dust removal
Preheat time and temperature
Powder epoxy application
Heating time and temperature
Adhesive layer and polyethylene application, including use of
recycled material
Curing and quenching time and temperature
Repair technique
Coating stripping technique
Inspection and testing
Quality control procedure
7.7 Coating Procedure Approval Test
7.7.1 A batch of 10 to 20 pipes of any specific pipe mill shall be selected
by the Client nominated inspector and coated by the Manufacturer


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in accordance with the approved coating procedure specification,

the coating operations being witnessed by the Client. Three pipes
from the coated pipes shall be selected by the Client and subjected
to the complete set of tests specified in paragraph no. 7.
7.7.2 Testing shall be witnessed by the Client and a full set of records
shall be presented to the Client for consideration. Bulk coating of
pipes shall not commence until all short and long term test (Para.
No. 7) results have been approved officially by Client, unless the
Manufacturer takes responsibility of failure for any long term tests.
7.7.3 Short Term Approval Test
Short term approval test consists of the
following tests based on the criteria specified
.in Table 4. None of these tests must fail
Thickness
Holiday/Pinhole defects
Adhesion
7.7.4 Long Term Approval Test
7.7.4.1 Long term approval test consist of the following tests, and
not limited to them, based on the criteria specified in
Table 4.
Adhesion
Catholic disbanding
Environmental stress cracking resistance
Thermal cycle resistance
Impact resistance
Thermal aging
Elongation
Specific electrical resistance


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Indentation resistance
7.7.4.2 These tests to be done & inform client of the date of test
ahead in time (at best 15 day before tests date) & the
client representation will testified the tests & fill the
appropriate format for submission to client for approval.

Table 5
TEST METHODS FOR COATING PROCEDURE APPROVAL TEST
PROPERTY TEST METHOD ACCEPTABLE LIMIT
Surface preparation Visual As specified in Table 2
inspection
Coating thickness Electro- As specified in Table 4
magnetic
thickness
gauge
Annex A ISO
21809-1
Porosity DIN 30670 No defect at 25 kv
Adhesion Annex C Min. 15 N/mm
At 232C ISO 21809-1 Min. 3 N/mm
At 803C
Impact resistance, At 232C Annex E Min. 7 Jul/mm
ISO 21809-1
Elongation at break, At 232C ISO 527 Min. 400% for extruded
coating
Indentation (hardness) Annex F
At 232C ISO 21809 Max 0.2 mm
At max operating temperature Max 0.4 mm
Thermal cycle resistance 1 cycle: -30C No crack
1hr
+ 60C
1hr
No. of cycles:
100
Product stability during extrusion of ISO 1133 MFR20%
the PE top layer process
Degree of cure of the epoxy as first Annex D Tg3C for FBE
layer ISO 21809-1 Scratch test for liquid epoxy
Flexibility at 0C3C Annex I No cracking at 2.0% angle


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ISO 21809-1 per pipe diameter lenght

Hot water soak test Annex J No loss of adhesion
ISO 21809-1
Specific electrical DIN 30670 108 m2 (Min.)
Catholic disbanding Annex H
At 232C/28 days/-1.5V ISO 21809-1 Max 5 mm
Max operating temperature/28 Max 12 mm
days/-1.5V

8. INSPECTION AND TESTING

8.1 Coating surfaces of all pipes shall be visually inspected. Coating shall be
uniform and free from blisters, scratches or any other irregularities and shall
be of uniform color, gloss and thickness.
8.2 Coating thickness of 10% of each daily production lot shall be checked by
electro-magnetic thickness gauge. The measured thickness shall fall within
values specified in section 5.5 with tolerance of 10%, provided that the thin
area does not cover more than 5.0 cm2 per linear meter of pipe. Any
individual length of pipe which does not comply with above requirements
shall be rejected for subsequent stripping and recoating.
8.3 Coating surface of each individual pipe shall be 100% checked with a
holiday detector in accordance with DIN 30670. The holiday detector
system shall be checked for its proper operation periodically at least twice a
day, and at such other time as required by the Client nominated inspector
by implementing an artificial flaw/pin-hole. The out put voltage of holiday
detector shall be checked and calibrated periodically, at least twice per
working day, once at the beginning of each production day.
8.4 If the coating adhesion at any location is below the requirements of Table 4,
the pipe shall be rejected for subsequent stripping and recoating.
8.5 Coating color and appearance shall be uniform and free from runs, sags,
blistering, roughness and foaming and general film defects.


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8.6 Any other tests deemed necessary by the Manufacturer, shall be proposed
with his offer, which will be reviewed and acknowledged by the Client.
8.7 The quality control system shall include as a minimum the requirements
listed in Table 5.
8.8 After examination or test, should the inspector find out that any pipe has not
been cleaned or coated in accordance with this Specification, the Vendor
shall be required to remove the coating which is considered defective or
inadequate, and to reblast and recoat the pipe to the requirements for
approval of the inspector.
8.9 The inspector shall have access at any time to the construction site and to
those parts of all plants that are concerned with the performance of work
under this standard.
8.10 The Manufacturer shall provide the necessary inspection tools and
instruments for the inspector as well as normal facilities necessary for
inspection.
8.11 Requirements for inspection of surface preparation shall be as specified in
Table 4 of IGS-C-TP-010-Amendment 2.
TABLE 6- REQUIREMENTS FOR INSPECTION AND TESTING OF APPLIED COATING
Frequency Frequency Requirements Test Method Unit Properties Item
production Qualification
pipe at start 1 pipe at start 1 FBE:150 ISO 2808 m Epoxy thickness, min 1
up and 1 up and 1 Liquid epoxy 25
*pipe /shift *pipe /shift
pipe at start 1 pipe at start 1 on pipe 150 ISO 2808 m Adhesive thickness, min 2
up and 1 up and 1 body
*pipe /shift *pipe /shift
*pipe / shift 1 *pipe / shift 1 Tg+3 for FBE Annex D o
C Degree of cure 3
ISO 21809-1
Scratch test for
liquid epoxy
Continuously Continuously Uniform color, Visual Annex B --- Appearance and continuity 4
free of defects
and ISO 21809-1
,discontinuities


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, Delamination
separations and
each pipe *pipe/shift 3 Table 2 Annex A mm ** Total thickness of coating 5
ISO 21809-1
pipes at 3 pipes at start 3 Annex E J/mm Impact resistance 6
start up and 1 up and 1 7 ISO 21809-1 at 23 2 C O

pipe / 50 km pipe / 50 km 3 CSA Z245.20-06 at -30 3 C O

*pipe / shift 3 *pipe / shift 3 Annex C N/mm .Peel strength (Adhesion) min 7
pipes at 3 pipes at start 3 15 ISO 21809-1 at 23 2 C O

start up and 1 up and 1 3 at 80 3 C O

pipe / 50 km pipe / 50 km
pipes at 3 pipes at start 3 Annex F mm Indentation , max 8
start up and 1 up and 1 0.2 at 23 2 CO

pipe / 50 km pipe / 50 km at 80 CO

0.4 ISO 21809-1

pipes at 3 pipes at start 3 400 ISO 527 % Elongation at break*** at 23 2 C , O
9
start up and 1 up and 1 min
pipe / 50 km pipe / 50 km
pipes at 3 pipes at start 3 Annex H mm Cathodic disbondment,max 10
start up and 1 up and 1 5 ISO 21809-1 at 23 2 C/28 days-1.5 V
O

pipe / 50 km pipe / 50 km 12 at 80 C/28 days-1.5 V

O

pipe per 1 pipe per 1 No cracking at Annex I % Flexibility at 0 OC 3 OC 11

order order 2.5 degree per ISO 21809-1
pipe diameter
length
pipes per 3 pipes per 3 MFR 20 for ISO 1133 % In process degradation of 12
order order PE between raw Polyethylene***
and extruded
material
all pipes pipes per 3 "up to 20 7 100 Measuring Cutback 13
mm
*shift
10for 150
"20
pipes at 3 pipes at start 3 No loss of Annex J --- Hot water soak test at 80 C / 28 days
O
14
start up and 1 up and 1 adhesion NACE RP
pipe / 50 km pipe / 50 km (Rating 1) 0394 : 02
pipes per 1 pipes per 1 95 Annex D o
C Glass transition 15
*shift *shift ISO 21809-1 Temperature (DSC) , min

*Shift: every 8 working hours.

** The total thickness may be reduced by a maximum of 10 % on the weld seam for SAW welded pipes.
***In case of change in batch of PE, retest shall be carried out.


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9. HANDLING AND STORAGE

9.1 All coated pipes shall be handled and stored in such a manner as to prevent
damage to the pipe walls, the weld-end preparation and the coating, in accordance
with approved procedure.
9.2 Wide slings made of nylon shall be used for lifting. When hooks are used, they
shall be rubber lined and shall be of adequate size to fit inside the pipe.
9.3 The coated pipes shall be stored at all times free from the ground. Storage may be
affected by the use of battens suitably covered with soft material such as rubber
sheet.
9.4 The coated pipes may only be stacked to a height such that no flattening of the
coating occurs. In this respect, the formula given in API RP 5L5 shall be used for
the calculation of static load stress.
9.5 The pipes shall be separated from one another with sufficient and proper
dunnage.
9.6 During long storage, the polyethylene coating shall be protected from contact with
petrol, oil or grease, as some of these substances can cause swelling in the
polyethylene layer.
9.7 The loading operations shall be witnessed and certified by the Client.
9.8 The coating Manufacturer shall provide all necessary means, such as saddles,
battens, etc. for safe transportation of the coated pipes.

ANNEX A
"3LPE COATING REPAIR PROCEDURE FOR THE COATING PLANT"
1. SCOPE
In case of the 3LPE coating of pipe is damaged during production , handling , loading and
unloading at the coating plant , the damage to the coating shall be repaired according to
this Annex :
2. COATING REPAIR MATERIAL
Since the repair materials are required to be approved by NIGC , a copy of technical


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specification and data sheets of the repair materials including PE melt stick , filler mastic ,
repair patch and heat shrinkable sleeve shall be submitted to NIGC for review and
approval .
3. QUALIFICATION OF REPAIR PROCEDURE
The repair procedure shall be qualified at the presence of NIGC inspector . In this case a
line pipe with damaged coating shall be repaired in accordance with the instructions
recommended by the repair material manufacturer . The repaired area shall then be
inspected for minimum thickness , adhesion and holiday detection and if satisfactory
results achieved , the repair procedure will be considered acceptable . The inspection
findings shall then be recorded and signed by both parties and kept as a proof of repair
procedure qualification .
4. ACCEPTABLE NUMBER OF REPAIRS IN A LINE PIPE
The maximum acceptable number of damage in any coated line pipe , may be up to three
points , provided that the total damaged areas do not exceed 200 cm2 , however the total
number of pipes with coating repairs , shall not exceed 2% of total number of coated
pipes in any individual order .
5. UNREPAIRABLE DAMAGE
The following damage are not allowed to be repaired :
5.1 If in every 200 pipes the damage to the coating , is reached to the FBE layer in only
one pipe .
5.2 No repair will be allowed on coating edges at either sides of pipe coating .
5.3 The maximum surface of 3 repaired areas in any line pipe , shall not exceed 200 cm2
.
In such cases the pipe coating shall be fully stripped and the pipe recleaned and
recoated.

6. REPAIRABLE DAMAGE
The damage which is allowed to be repaired is limited to the following :
6.1 Minor Damage
If the damaged depth is less than 1.5 mm and the related area is less than 5 cm2 ,
the damage may be repaired by PE melt stick .
6.2 Intermediate Damage
If the damaged depth is less than the thickness of PE and adhesive layers (3 mm
maximum) and the maximum area of the damages does not exceed 50 cm2 , with the
biggest dimension of 10 cm , the damage shall be repaired by filler mastic and repair
patch .
6.3 Major Damage
If the damage depth is less than the thickness of PE and adhesive layers (3 mm
maximum) and the maximum area of the damage does not exceed 100 cm2 with the
biggest dimension of 30 cm , the damage shall be repaired by filler mastic together with a
wraparound heat shrinkable sleeve .
Note : Any repair activities shall be performed fully in accordance with the instructions
recommended by the repair material manufacturer .
7. REPAIR QUALITY CONTROL
All repaired areas shall be subjected to visual inspection , thickness measurements ,


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holiday inspection and adhesion when repair patch is used . In case of any failure , the
repaired portion shall be removed , recleaned and repaired again .
Repair material shall be suitable for maximum operating pressure and also other physical
properties to be matchable with 3 layer polyethylene coating .
The coater shall obtain the approval of NIGC for type and technical properties of repair
material .

8.RETEST
In case of failure of any required test, the Coater shall test two additional linepipes, one
linepipe before and one after the failed one. If the follow up tests are successful, all
coated linepipes since the last acceptable test shall be considered satisfactory, except for
the failed linepipes that will be rejected .
If the follow up tests also fail to meet the requirements of this specification, all coated
linepipes since the last acceptable test shall be rejected .

In case of change in batch of PE , retest shall be carried out .