Painting Coating 2

8/10/2019 Painting Coating 2

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Pipecoating Part 2

MODULE 4

APPLICATION of COATING

ELEMENTS IN THIS MODULE:

FBE Application

3 Layer Polyethylene and Polypropylene.

Application

INTRODUCTION PIPE COATING

Module “4” describes the process and the requirements for inspection andecording the identity of pipes when being processed in anti corrosion

oating facilities. Coatings described within this module include Fusion

Bonded Epoxy (FBE), 3 Layer Polyethylene and Polypropylene.

.0 FUSION BONDED EPOXY COATING (FBE)

usion Bonded Epoxy (FBE) is a fairy hard thermosetting material that is

ommonly used for corrosion control of steel surfaces. For pipe coating the

material can be used as a stand alone coating or it can be used as a primer

or multi layer coatings. For greater protection (Mechanical) sometimes two

ayers of FBE are applied simultaneously, this is commonly known as dual

oat FBE

FBE Coating

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Prior to the commencement of FBE coating all incoming materials should

e checked against the material manufacturer’s certification and any other

pecification requirements. The Incoming receipt form IRF stipulates the

ncoming material testing requirements that are to be verified prior to using

he material. Incoming test that are typically Gel Time, Cure Time, Thermal

Analysis and Moisture Content. "See section 3.11 off line tests"

.1 INCOMING PIPE

Pipes are received at the incoming racks. Any contamination or pipe

efects that prevents acceptable coating and cannot be repaired at the

ncoming rack or grinding area shall be cause to hold the pipe. The held

ipe shall be removed from the process and clearly marked (HOLD or

REJECT) and placed into an appropriate holding area for adjudication by

he client representative as to its disposition.

he criteria for steel defects shall be generally in accordance with API (The

ractical detail to be agreed by both parties). See steel defects "Module 2"

Responsibilities:

he incoming Tally man shall be responsible for the recording and

raceability of all the incoming bare pipes. He shall also be responsible in

nsuring that the task is conducted in the safest possible manner.

he incoming Inspector shall be responsible for the release or quarantining

f the incoming bare pipe.

.2 COATING PROCESS



Preheat & Blast Cleaning:

Pipes are be placed onto the incoming blast line rack where bevel

rotectors (if fitted) are removed and end plugs fitted. The pipes are then

e indexed and lowered onto a blast line conveyor and conveyed through a

re-heat oven set to allow for the required preheat temperature to be

chieved.

he pipe surface temperature shall be monitored prior to blast cleaning

sing a hand held surface roller contact pyrometer, optical thermometer or

melt sticks.

he preheat temperature shall be checked as a minimum each hour and

he temperatures recorded. The steel surface temperatures for blast

leaning shall be above the required local dew point requirement, the dew-



oint should be checked twice per shift and recorded on an agreed Climatic

Conditions Report.

After preheating he pipes are then progressed through the first centrifugal

brasive cleaning machine; the blast machine operator shall continually

monitor the blast effectiveness via visual inspection. Abrasive samples (100

ml) shall be taken from the working mix(s) once per shift: the sample shalle passed through 1.18 mm & 0.425-mm mesh sieves. No more than 16%

hall pass the 0.425-mm sieve.

Should the amount of fines exceed this figure, fresh grit shall be added to

he working mix. Each abrasive sample shall be tested for chlorides and

ther contaminants. The results of the analysis shall be recorded on an

greed Abrasive Contamination Test Report

Responsibilities:

he Abrasive Line Supervisor shall be responsible for ensuring that the end

lugs are positioned correctly and that the specified preheat temperature is

onstantly maintained. He shall also ensure that the conveyor line speed is

onstant and that the surface amplitude and pipe cleanliness is maintained

within the specified tolerances. He shall also be responsible in ensuring

hat the task is conducted in the safest possible manner.

he QC Inspector/Auditor shall be responsible for verifying that end plugs

ave been positioned correctly and that the specified preheat temperature

s maintained. He shall also perform climatic conditions testing at the

pecified intervals and review laboratory testing of abrasive materials.

he Laboratory Technician shall be responsible for taking samples of the

brasive and analysing.

.3 Grinding Area:

On completion of the first abrasive blasting the pipes shall be indexed onto

he transfer holding rack (grinding area) and inspected. All pipes are to be

hecked for any steel imperfections i.e. sliver, scabs, lamination's, burrs or

ristles. Defects shall be repaired by grinding or by hand filing. Pipes that

annot be repaired and fail to meet the specified requirements shall be



learly marked (HOLD or REJECT), removed from the process and placed

n a reject rack for adjudication by the client as to its disposition.

Details of pipe defects shall be recorded on an agreed Grinding Inspection

Report.

A salt contamination check of the blasted pipe surface is checked using anSCM 400 salt contamination instrument and the results recorded. Typically

he first pipe then further two pipes per shift are checked, the results are

ecorded on an agreed Salt Contamination Test Report.

On completion of surface defect and salt contamination checks, the pipes

re lowered onto the second centrifugal abrasive cleaning line where the

ipes receive a second blasting process.

After the second blasting operation the blasted surfaces are checked for

urface profile (using Testex Press-O-Film) replicating tape or other agreed

methods and the profile recorded. Typically pipes are checked at

he commencement of each shift then twice more during the shift.

A surface contamination check is typically performed at the commencement

f each shift and twice more during the shift.

o check contamination clear cellotape strips are used and compared

gainst a contamination table. The results of both the surface profile and

ontamination checks are recorded on an agreed Surface Blast Cleaning

nspection Report. Both the Testex film and the dust contamination films

re normally attached to the report.

he blasted surface shall meet or exceed the requirement of the blast

rade as specified by comparing the blasted surface to a pictorial standard

.g. ISO 8501-1. The blast standard shall be monitored and recorded every

hours.

he elapsed time shall between surface preparation and the

ommencement of coating shall be monitored, the maximum elapsed time

hall be 4 hours, no rust blooming shall be apparent prior to the application

f the coating.



Responsibilities:

he Blast Line Supervisor shall ensure that all repairs grinding and filing is

arried out under controlled conditions. If unsure about the disposition of

ipe defects, the QA department should be contacted to assist with any

ueries. The supervisor should also ensure that the pipe has been cleaned

f residue blasting matter both internally and externally. He shall also beesponsible in ensuring that the task is conducted in the safest possible

manner.

he QC Inspector/Auditor shall be responsible for recording disposition of

ipe exhibiting defects and raising NCR report. He shall also perform

eriodic testing in accordance with the agreed project ITP.

he Tally Man shall maintain pipe traceability and ensure that correct

ecords of defective pipe, movement and disposition.

.4 Surface Conditioning

is often a requirement that after abrasive blasting the pipe surfaceshould receive a surface conditioning (chemical treatment), particularly for tandalone FBE coatings.A typical chemical treatment is a Phosphoric Acidreatment: below you will find a typical application procedure.

Note: Any chemical treatments must be applied strictly in accordance with

he chemical supplier’s recommendations.

Phosphoric acid is applied immediately on completion of the blast cleaning;he acid is typically applied using an acid concentration of 10% ± 3% (byolume). The concentration is normally measured and recorded using atration method.

deally the pipes shall be uniformly heated to between 40 and 70 C. Theeating is usually provided a residual heat from the blasting line preheatingystem.

he Phosphoric Acid solution has to be applied in a uniform manner:ormally gravity fed from above the pipe and spread on the pipe surfacesing a brush arrangement. The acid has to remain on the pipe surface for period of time (Dwell time) that allows the reaction process to take place.

is critical that the dwell time is strictly adhered to and is related to the pipeemperature at the time of application. The acid manufacturer normallyrovides a dwell time table for this purpose.

ypical dwell time chart:



8 C - 37 sec’s3 C - 27 sec’s9 C - 25 sec’s4 C - 21 sec’s0 C - 17 sec’s

Note: It is essential that the pipe surfaces remain wet at all times during thePhosphoric Acid treatment.

After the dwell time has elapsed, the pipe surface shall be thoroughlynsed with deionized water having a conductivity of 10µmhos/cm max.

he pressure of the water used shall be sufficient to thoroughly remove allcid residues. The minimum specified pH of the wet surface after rinsinghall be determined by directly touching the pipe surface with a pH paper.he pH paper shall have measurement units of 0.5 pH or less.

On completion of the surface conditioning the appearance of the steelubstrate should be similar to that of the freshly blasted surface (apart fromlight water streaking).

Note: Normally A maximum of four (4) is permitted between the acid prereatment an the coating application

.5 Preheat FBE:

Prior to FBE coating the previously installed end plugs should be removed

nd the internal bore of the pipes checked for contamination. The pipes are

hen preheated prior to the application of the Fusion Bonded Epoxy powder

y passing through an Induction coil heating system.

Induction Heating Coils

he preheat temperatures are controlled so that the pipe is within the

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orrect manufacturers recommended temperature range when the epoxy

owder is applied. The pipe temperature is continuously monitored

mmediately prior to the powder application booth by using a calibrated

urface temperature probe, infrared sensor or "Tempil" sticks. The latter

owever, may not be a permissible method due to oily residues left on the

ipe surface.

Infra Red Thermometer

Infra Red Temperature Read Out

Tempil Stick



Responsibilities:

he Blast Line Supervisor should ensure that the induction heating

quipment is maintained in satisfactory operating condition and that the

ettings are commensurate to the required heating range for the particular

ipe size and wall thickness being heated. He should also ensure that the

onveyor line speed is constantly maintained to allow even pipe preheatnd coating to be achieved. He should also be responsible in ensuring that

he task is conducted in the safest possible manner.

he QC Inspector is responsible for monitoring preheat temperatures at the

pecified periodic intervals.

he Tally Man should ensure that pipe traceability and correct records of ipe movement and disposition.

Coating Parameters:

is always advisable that the production line operating parameters be

ecorded for internal analysis on an internal coating operations parameter

eport..

.6 FUSION BONDED EPOXY POWDER INSPECTION

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Each container of epoxy powder is inspected prior to loading into the

owder delivery systems. (Where dual coat powders are used, the

eparate powders are loaded into the appropriate delivery systems, i.e.

rimer in one system and the top coat in the other. The powders shall not

e mixed or interchanged).

Note: With FBE powder it is advisable to check production material for moisture content and gel time on at least a daily basis. A high moisture

ontent can cause porosity and cure problems with the coating.

he inspection should also confirm that the epoxy powder is listed on the

Approved IRF". Only powder with current, valid approval shall be used.

Batch numbers shall be recorded on all the relevant inspection and

aboratory test reports. Once the approved status of the epoxy powders are

onfirmed, the powders are loaded into the delivery systems.

Reclaim:

Subject to client approval the amount of reclaim powder applied in any

iven interval shall not exceed 20 % of the total powder application. (When

sing dual coat the reclaim powders shall be controlled separately and

lended with the top coat virgin powder. Reclaim shall not be blended with

he primer powder).

FBE Reclaim

.7 Coating Application

he Fusion Bond Epoxy Powder is applied to the heated pipe using a



eries of electrostatic spray guns. (When using a dual coat system using a

ingle fluid bed, the primer and top coat guns should be set apart in a

manner that allows the correct amount of separation of the two FBE layers.

Alternatively two separate fluid beds may be used).

By balancing the conveyor line speed and the settings of the electrostatics

nd guns, flow rate and pressure of the material feed the material

pplication is controlled to achieve the correct applied coating thickness.he coating should be continuous over the entire length (coating area) of

ach pipe joint. The minimum/maximum thickness shall be as indicated in

he agreed Inspection Project ITP.

FBE Application

On completion of coating and allowing sufficient flow out and set up time of

he powder, the coated pipes continue on through a water quenching

tation where the coating is cooled down using a continuously application

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f water. The pipes are cooled until the pipe is safe to be handled.

Typical FBE Quenching

Caution: The pipe coating should not be quenched to early or the FBE

ure may be compromised.

Note; If and when required, a friction coating shall be sintered (Sinter coat)

nto the FBE surfaces immediately after the FBE application process.

Responsibility:

he Coating Line Supervisor is responsible for maintaining the correct pipereheat temperatures for the line speed being used and ensuring that the

ne speed is at an even rate. Information required to perform this function

s obtained from the coating line controller. He is also responsible in

nsuring that the task is conducted in the safest possible manner.

he QC Inspector/Auditor is responsible for monitoring of all the coating

arameters.

he Powder Booth Operator is responsible for maintaining the application,un settings, flow rates of materials, feed line pressures for the particular

ne speed and pipe diameter and the electrostatics.

he Coating Line Controller is responsible for all line activities for material

oating line. This includes maintaining the correct line speed and pipe

reheat by monitoring inspection reports, control room instrumentation and

hat all the powder coating parameters are maintained.

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.8 COOLING BOARDS & INSPECTION

mmediately after cooling the coated pipe is transferred to the outgoing

padded" pipe rack where the coating is visually inspected for any

etrimental coating defects the pipes are then positioned on end cleaning

otators where the cutbacks are correctly established.

After end cleaning the entire coated surface of each length of pipe shall be

nspected for holidays using a high voltage (pulse type) holiday detector

hat has been previously set and calibrated to the correct test voltage. The

ircumferential search electrode shall maintain intimate contact around the

ntire circumference of the coated pipe at all times. The voltage shall be

hecked and recorded hourly.

he travel speed for holiday detection is a rate of 300 mm per second

maximum. Any holidays or surface defects are clearly marked on the pipe

nd details recorded on an agreed Coating Application Report.

Random adhesion testing are carried out using the St. Andrews cross

method where coating is inscribed through to the metal substrate using a

Stanley knife the coating is prized off to check the coating adherence to the

ubstrate,

St Andrews Cross

he system coating thickness is typically determined by taking the 4

quidistant measurements, 3 on the body and 1 on the weld (if applicable)



ocations at the lead end middle and tail end of each pipe ( a total of 12

measurements). The measurement shall be conducted using an

lectromagnetic thickness gauge. Records of the thicknesses shall be

ecorded on an agreed Coating Application Report.

Thickness Check

Responsibility

he Cooling Board Supervisor is responsible for ensuring that the holiday

etection of each pipe is carried out in a correct manner and at the correct

oltage. Also he should ensure that the pipe cutbacks are correctly

stablished and that the pipe ends and pipe internals are sufficiently

leaned. He should also be responsible in ensuring that the task is

onducted in the safest possible manner.

he QC Inspector/Auditor should be responsible for visual inspection of the

oating and physical testing, monitor the holiday detection and cut back

ength, calibration of the holiday detection equipment prior to the start of

ach shift. He shall also ensure that coating thickness checks are being

arried out and being recorded correctly for each pipe



Note: In some coating facilities an "in line" holiday detector is used.

he Load Out Tally man is responsible for checking the pipe identity and

maintaining pipe traceability on the computerized pipe tracking system

where used).

.9 PIPE MARKING AND IDENTIFICATION:

he identity markings of each pipe shall be established and the details

ntered into the pipe tracking system such that traceability is maintained

fter which the accepted pipes are released for transportation to the

tockpiles or other processes.

Responsibility

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he Load Out Tally Man shall ensure that the correct pipe markings are

pplied in accordance with the agreed marking system. He shall also be

esponsible in ensuring that the task is conducted in the safest possible

manner.

.10 Repairs:

Repairs to the coatings are carried out in accordance with an agreed

Repair Procedure. Coated pipes that cannot be repaired are rejected,

tripped and re coated. Unacceptable pipe are marked up with Red/White

azard tape and recorded on the NCR system.

he maximum allowable holidays that may be repaired are to be agreed

nd should form part of the project ITP. Typically the allowable numbers of

oliday repairs allowed is 1 per metre of pipe length.

Note: In the event that ongoing extensive numbers of holidays are

pparent the coating line should be shut down and the cause of the

roblem investigated.

A typical FBE repair procedure:

Pin hole holidays should be repaired with a melt stick.

he coating surface must be abraded and clean. To ensure good adhesion,

oughen area-using sandpaper and wipe to remove all dust.

Care must be taken when using hot melt sticks as preheat of the FBE

oating surface is required. Heat should be applied to the repair area in a

manner that avoids burning or charring of the epoxy coating. Slight

rowning of the parent coating is acceptable, but charring or blistering is

ot. The use of a noncontaminating heat source, such as portable hand

eld butane torch is required.

Holding the melt stick on or near the repair area continue to heat theleaned area until the coating surface is at the desired temperature at

which point the patch stick begins to melt. The heat source maintains the

emperature of the coating and melts the stick. While continuing to expose

he melt stick to the heat source, apply the patch material by rubbing the

tick in a circular motion on the area to be repaired until the a thickness of

he repair is at least 15 mils (380 microns) greater than the parent coating

hickness. Allow the repair to cool before handling.

arger repairs should be made using a 2 part liquid epoxy patching



ompound.

arger defect repairs.

he defective area should be cleaned and abraded by using abrasive

aper. The exposed steel surface should be power brushed to give a

urface cleanliness equal to St 3 . All surface dust should be removed and

he surface wiped with solvent saturated lint free cloth and the solventllowed evaporate.

Using a 2-part epoxy repair material the two constituent parts should be

horoughly hand mixed in the correct proportions according to the

manufacturers’ written instructions.The material shall be carefully applied to

he abraded area of the steel and FBE. Finally, the surface of the repair

hould be allowed to cure. For neatness and containment of the repair area

masking tape border can be applied around the repair area that is

emoved prior to the repair compound curing

he repaired area should be visually inspected to ensure no voids and/or

ir entrapment.and shall be holiday detected using a portable holiday

etector.

All repairs should be recorded on an agreed repair Quality form

Responsibility

he Repair Foreman is responsible for coating repairs and should ensure

he correct equipment and repair method is used for coating repair. He

hould also be responsible in ensuring that the task is conducted in the

afest possible manner.

he QC Inspector/Auditor is responsible for checking the preparation and

he completed repairs.

.11 OFFLINE TESTING

Besides online testing and inspection requirements there are a series of

Off Line” tests that have to carried out to confirm compliance of the coating

ystem against the specified requirements which include the following

ractices:

Back Side Contamination Checks



Coating Thickness Measurement

Differential Scanning Calorimeter

Gel Time Determination

Holiday Detection

hickness Measurement

Porosity both Inter facial and Cross Sectional

lexibility (Bend) Test

Pull Off Adhesion TestCathodic Disbondment Test

Hot Water Resistance Test

mpact Resistance

Determination of Coating Hardness

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Back Side Contamination - CAN/CSA Z245.20-2

Scope

o determine the extent of backside contamination at the bottom side of an

BE coating chip sample.

Equipment

Sample freezer

Bending machine

0 X microscope

Procedure

A sample section of coated pipe shall be removed from a test ring. Theample section shall be approximately 200 x 50 mm

he sample cut out shall then be placed into a freezer and cooled down to

ear freezing point. After freezing the sample shall be removed from the

reezer and rapidly bent around a suitably sized mandrel causing the FBE

o flake off of the substrate.

Evaluation



Pry off the flake sample, The then examine the sample using a 40 X

microscope and the percentage of contamination is rated

Acceptance cr iteria: The backside contamination shall be within the

pecified tolerance. Typically 30 % max.

Report

Record

Date

ime

Pipe number

Batch number

Backside Contamination expressed in %

Backside Contamination

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COATING THICKNESS MEASUREMENT BS 3900 Part C5 1992

Note: This practice may be modified by the requirements of the customer’s

pecification, see relevant Project Inspection Test Plan (ITP)



Scope

Determine the coating thicknesses of anti corrosion coatings.

Equipment

Calibrated electronic Thickness Gauge

Procedure

he pipe should be suitably cooled immediately after anti corrosion coating

efore measuring the coating thickness.

he coating thickness of the coated pipe is checked by using a calibratedlectronic thickness gauge. The checking position of the inspection probe

hould be in vertical position and at right angles to the coating being

hecked. The coating thickness is measured at the specified locations

long the body of the pipe and on the weld seam where applicable.

Calibration of the measuring instrument

Switch on thickness gauge

Select "CAL" button

Place the probe on top of a certified standard thickness shim which has

een placed on a blast cleaned bare steel area and read the measurement.

Adjust the up or down button to give the actual reading according the

oating thickness standard or certified shim.

Press the "CAL" button again for confirmation calibration.

Report

Record



Date of coating

Pipe number

hickness gauge reading

Report the individual coating thicknesses on both body and weld seam.

Report the minimum average thickness of the coating.

Record instrument calibration details

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DIFFERENTIAL SCANNING CALORIMETER - CAN/CSA Z245.20-2


pecification,see relevant Project Inspection Test Plan (ITP)

Scope

his test is to determine the glass transition temperature (Tg) and the

mount of exothermic heat of reaction (DH) of epoxy powder or fusion-

onded epoxy cured coating.

Equipment

Differential scanning calorimeter (DSC) and accessories

Analytical balance accurate to 0.1mg

Knife or file

Procedure

Obtain a 10+/-1-mg sample of epoxy powder or coating aspplicable. Place the sample in a pre-weighed aluminum pan and put lid in

lace. Crimp the lid into place with the encapsulating press and obtain the

ample weight by subtracting pan and lid weight from the total weight.

Place a small vent hole (pierce) in the lid without damaging the pan.



Place sample and reference (as suggested by the instrument supplier) in

he DSC furnace.

Use nitrogen gas to purge the cell.

or epoxy powder sample, obtain thermal scans for the following cycles in

rder:

a) heat the sample from 25 ± 5ºC to 70 ± 5ºC at a rate of 20ºC/min,

hen immediately cool the sample to 25

5ºC

b) heat the sample from 25 ± 5ºC to 285 ± 10ºC at a rate of 20ºC/min, then

mmediately cool the sample to

5 ± 5ºC; and

c) heat the sample from 25 ± 5ºC to 150 ± 10ºC at a rate of 20ºC/min. For

oating samples, obtain thermal

cans for the following cycles in order:

d) heat the sample from 25 ± 5ºC to 110 ± 5ºC at a rate of 20ºC/min, hold

t 110 ± 5ºC for 1.5 min, then

mmediately cool the sample to 25 ± 5ºC;

e) heat the sample from 25 ± 5ºC to 285 ± 10ºC at a rate of 20ºC/min, then


5 ± 5ºC; and

f) heat the sample from 25 ± 5ºC to 150 ± 10ºC at a rate of 20ºC/min.

Evaluation

he Tg is taken as the point of intersection of the extrapolated baseline of

he low temperature end and the tangents to the curve at the inflection

oint (onset) Calculate the residual exothermic heat of reaction (DH)

ollowing the instructions provided by the manufacturer of the DSC

quipment.DTg = Tg4 – Tg3

Report

Record

Date

Date of coating

Product code for epoxy powder only



Batch number, and date tested.

Pipe number where applicable,

Report Tg1, Tg2 and DH, for epoxy powder

Report Tg3, Tg4, DTg and DH, for coating, including units

ndicate the type of differential scanning calorimeter.

DSC Sample Preparation

DSC Machine



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GEL TIME DETERMINATION - CAN/CSA Z245.20.02



Scope

o determine the gel time of fusion bonded epoxy powder coating material.

Equipment

Hot plate (accurate to ± 3° C)

Stopwatch or electronic timer

Spatula

Stiff wire

Procedure

Gel time shall be determined by placing approximately 1g of coating

material in a hot plate stabilized at 205±3°C. In a smooth motion, deposit

nd draw the epoxy powder across the metal plate while holding the tool at

n angle of approximately 45° to the metal plate. This motion will create a

ongue of epoxy powder approximately 25mm wide. The target thickness of



he cured film is 300 – 400µm. Start the time as soon as the coating

material becomes molten. Stir the coating with a stiff wire or spatula, and

top the watch when the coating becomes resistant to stirring and

elatinous.

Evaluation

he elapsed time to reach this condition is the gel time.

Report

Record

Date

Product

Batch number

Gel time in seconds.

Testing Gel Time

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MOISTURE CONTENT - CAN/CSA Z245.20.02



Scope



Determine the moisture content of FBE powder using the mass loss

method

Equipment

Oven controllable within 3°CBalance accurate to 0.001g

Desiccators; and

Sample container

Procedure

Weigh the sample container to the nearest 0.001g. Transfer approximately

0 g of epoxy powder into the sample container. Weigh the sample

ontainer and epoxy powder to the nearest 0.001g. Place the sample

ontainer with the epoxy powder into the oven for a maximum of two hours

t 105 ± 3°C. Remove the container from the oven and place in the

esiccators to cool. Weigh the sample container when it has cooled to

0 ± 3°C

Evaluation

Calculate the percentage of moisture using the following formula:

M = (B-C)/(B-A) x 100

Where

M = percentage of moisture

B = initial mass of sample container and epoxy powder, g

C = final mass of sample container and epoxy powder, g

A = mass of sample container, g

Acceptance criteria, Typically 0.5 % max

Report

Record

Date

Material Code

Batch number

Moisture expressed in %



Moisture Content

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POROSITY INTERFACE & CROSS SECTIONAL - CAN/CSA Z245.20.02



Scope

) To determine the extent of inter facial porosity at the bottom side of an

BE coating.

B) To determine the extent of cross sectional porosity within an FBE

oating

Equipment

Sample freezer or dry ice & container

Bending machine

0-40 X microscope

Mandrel



Procedure

A sample specimen of coated pipe shall be removed from a test ring. The

ample section shall be approximately 300 x 50 mm. The sample cut out

hall then be placed into a freezer or dry ice and cooled down to near or

elow freezing point. After freezing the sample shall be removed from the

reezer or dry ice and rapidly bent around a suitably sized mandrel causing

he FBE to flake from the substrate. Pry off the flake sample of FBE coatingo allow observation of both the cross section and underside of the coating

ample to be examined.

Evaluation

he sample shall then be viewed both in inter facial and cross sectional

levations using a 40 X microscope and assessed for porosity.

Acceptance cri ter ia, Typically rating 3 max.

Report

Record

Date

Pipe number

nterface Rating 1-5

Cross sectional rating 1-5

Ratings Chart



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LEXIBILITY (BEND) TEST - NACE RP 0394-94 CAN/CSA Z 245.20-02



Scope

his test is to determine the flexibility of coating for field bending.

Equipment

Hydraulic Press

Bending mandrels of fixed radii

Microscope

reezer

Procedure

Specimens shall be removed from test rings (approx. 300mm long x 50mm

wide x pipe wall thickness, with the 300mm dimension parallel to the axis of



he pipe.

Ensure that the specimen edges have all stress raisers removed and that

ubstrate is exposed along the edges. Test temperatures shall be 0ºC and

3ºC +/-2ºC. Typical, Calculate the required mandrel radius (R) using the

ollowing formula:

R= ((57.3)(t)/s))– t/2

Where:

R = mandrel radius, t= effective strap thickness, and

s = strain (deflection) in degrees per pipe diameter (°/PD).

Determine the effective strap thickness (t), which includes the specimen

hickness and any curvature, by placing the specimen on a flat surface and

measuring the thickness as shown in Figure K1 of NACE RP0394-94

Standard. Where a mandrel of the calculated radius is not available; the

mandrel of the next smaller radius shall be used.

Bend the test specimens over the radius so that the uncoated side is in

ontact with the mandrel, completing the bend within 30 seconds. The

end test shall take a minimum of 10 seconds for completion.

Measure the residual bend radius by matching the outer curve of the test

pecimen to the nearest arc from Figures K2, K3, K4 or K5 of NACE

RP0394-94 Standard.

Evaluation

Visually inspect the specimens for cracks, tears in the coating, and

isbonding of the coating after the specimen has warmed to room

emperature. The presence of any such defect within 2.5mm of the strap

dge does not constitute failure. The presence of strain marks alone does

ot constitute failure.

Acceptance cri ter ia, Typically equal to 2° PD (No cracking)

Report

Record

Date

Date tested



Manufacturer code

Batch number

Pipe number

est Temperature

Defect {s} if any Specimen effective strap thickness, permanent (residual)

train radius, angle of deflection in degrees per pipe diameter for passing

end test.

Bend Test

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----------------

PULL OFF ADHESION TEST

Note: This practice may be modified by the requirements of the customer’specification,see relevant Project Inspection Test Plan (ITP)

Scope

o determine either the greatest perpendicular force (intension) that a

urface area can be bear before a plug of material is detached or whether

he surface remains intact at a prescribed force (pass/fail)

Equipment

Hydraulic Adhesion Tester 108

Dolly/Loading Fixture

Adhesive

Procedure



he selected test area must be a flat surface to accommodate the specified

umbers of replicate tests. (Test panel : 300 mm x 450 mm)

oading fixture shall be detach with test panel using adhesive and hold for

day. After 1 day. Insert a decreased FE-fluorocarbon plug into the dolly

ntil the tip protrudes from the surface of the dolly. When applying adhesiveo the dolly, avoid getting adhesive on the plug. Remove plug after holding

he dolly in place for 10 s. Ensure that the black needle of the tester is

eading zero. Connect a test dolly to the head and increase the pressure by

urning the handle clockwise until the pin protrudes from the dolly.

Decrease pressure to zero and remove the test dolly. Connect the head to

he dolly to be tested, by pulling back the snap on ring, pushing the head

nd releasing the snap-on ring. Ensure the tester is held normal to the

urface to be tested and that the hose is straight. Increase the pressure

lowly by turning the handle clockwise until either the maximum stress or

ailure is reached.

Evaluation

Record the force attained at failure or the maximum force applied.

Report

Record

Date

ype and date coating

Sample ID

Maximum Pressure and thickness coating

Batch Number

Pull Off Adhesion Test



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----------------

CATHODIC DISBONDMENT - CAN/CSA Z245.20-02 & CAN/CSA

245.21-02



Scope

o assess the comparative resistance of damaged coatings to loss of be

erformed on a test specimen taken from a pipe or pup piece previously

ubjected to holiday detection, and in which an artificial defect of a defined

ize has been drilled.

Equipment

Stabilized DC Power supply unit with controlled voltage output.

A Cathodic polarization potential of –1.500mV to a saturated

alomel reference electrode (equivalent to UH = -1.260mV, where UH

means the potential of the standard hydrogen electrode shall be

maintained). “E” potential of the “working electrode” with regards to the

reference electrode”. “V” difference of potential between the “working

lectrode” and the “counter electrode”.



Electrolyte cell consisting of rigid plastic tube or PVC of with an internal

iameter of 75 ± 3 mm. The height shall be 120 mm.

A rigid plastic cover in which 3 holes shall be drilled to allow the passage of

he electrodes and any other measuring instruments deemed necessary,

nd to allow the escape of hydrogen.

Reference electrodes- the saturated calomel reference electrode or uitable type of reference electrode to give an equivalent potential shall be

laced in an electrode holder situated in a glass tube with a porous end

lug. The end of this assembly shall be placed approx. 10mm from the

urface of the coating and approximately 20mm from the coating defect.

Counter electrode or platinum wire.

Working electrode (cathode)- is represented by the artificial defect, which

hall be 3.2 mm in diameter for FBE & 6.4 mm in diameter for 3 Layer,

which shall penetrate through the coating to expose steel substrate.

Calomel reference electrode

Utility knife

est Specimen

est- Ring Specimen

he test plate specimen shall be a 100mm x 100 mm (square) segment cut

rom the representative test ring.

Procedure

Drill a 3.2 mm (FBE) or 6.4 mm (3 Layer) diameter holiday through the

oating at the center of the specimen.

Glue a plastic cylinder onto the specimen using a sealant to form a water esistant seal. Ensuring the pre drilled holiday is at the center of the

ylinder.

Pour approximately 300ml of Sodium Chloride Solution into the

lastic cylinder.

When testing specimens cut from the pipe, a heat- transfer medium shall

e employed to provide uniform heating of the specimen.



Use a metal pan/tray partially filled with a heat transfer medium (sand) into

which the specimen is implanted. Place on a hot plate or in an oven to

maintain the test temperature as required according to the duration of tests

pecified in the specification.

Connect the negative lead (working electrode) from the power supply to the

pecimen ( Cathode) and the positive lead (Counter electrode) to thenode after the test temperature is reached.

urn on the power supplies and applies voltage to the test specimen:

egative 1.5V or 3.5V with respect to the calomel reference electrode for

he 24 hr, 48-hr (only on accelerated production test) and/or 28-day tests.

Monitor the voltage, temperature and electrolyte level at the start and at

very 24-hr interval thereafter.

or the 28-day test, the electrolyte level need not be monitored on

weekends provided a cover plate is loosely fitted over the test cell. Distilled

water shall be added as required to maintain the electrolyte level.

Evaluation

After 24hrs or 48 hrs (on accelerated production test), dismantle the test

ell and remove the test sample cell from the hot plate or oven.

mmediately drain the electrolyte and air-cool the sample to 20 ± 3° C. The

valuation shall be performed within one hour of removal from the hot plate.

or 28 day test, remove the 28-day test cell using the same procedure.

Using a utility knife, make radial cuts from the edge of the holiday outward

hrough the coating to the substrate. The radial cuts shall be at least 20mm

n length from the centre of the holiday.

nsert the blade of the utility knife under the coating. Using a levering

ction, chip off the coating. Continue until the coating demonstrates aefinite resistance to the levering action.

Measure the radius of the disbonded distance from the holiday edge along

ach radial cut and average the measured results. Maximum allowed CD

adius as measured, is detailed in the controlled ITP drawn for this project.

Acceptance criteria:- Typically 3-4 mm radial disbondment for FBE



Report

Record

Date tested.

Pipe number Coating date.

CD Equipment set up

Cathodic Disbondment sample



----------------------------------------------------------------------------------------

-------------

HOT WATER RESISTANCE - CAN/CSA Z245.20.02


pecification,see relevant Project Inspection Test Plan (ITP)

Scope

Determine the hot water resistance (Adhesion) of FBE coating.

Equipment

emperature controlled water bath

ap water

hermometer

Utility Knife

Procedure

A coated sample of approximately 100 mm x 100 mm removed from a pipeest ring be fully immersed in a tap water filled bath, previously warmed to

he required test temperature of 75°± 3°C. The sample shall remain in the

ath for a minimum period of 24 hrs and the test temperature of the water

hall be controlled throughout the duration of the test.

After 24 hours the test sample shall be removed from the water bath and

whilst still warm, a rectangle 30 x 15 mm shall be incised in the coating

hrough to the steel substrate. The sample shall be air cooled to the



est temperature of 20 ± 3°C

At the correct test temperature insert the tip of a utility knife under the

oating at one of the corners of the incised rectangle. Used a continuing,

evering action in an attempt to remove the coating. Continue the levering

ction until either all the coating is removed from the rectangle or the

oating demonstrates a resistance to the levering action.

On completion of the test, record the rate of adhesion as follows:

Rating 1 Coating cannot be removed cleanly

Rating 2 Less than 50 % of the coating can be removed

Rating 3 More than 50 % can be removed, but the coating demonstrates a

efinite resistance to

the levering action.

Rating 4 The coating can be easily removed in strips or chips

Rating 5 The coating can be completely removed as a single piece.

Acceptance cr iteria, Typically rating 3 however sometimes rating 2 is

equired.

Report

Record

Date

Batch number

Rating 1-5

----------------------------------------------------------------------------------------

------------------------------------

MPACT RESISTANCE - DIN 30670, DIN 30678 & CAN/CSA Z 245.20-02





Scope

Equipment

mpact Tester having)

alling masses 1-kg FBE, 3.5-kg 3LPE, 6-kg 3 LPP

5.8mm (FBE) or 25 mm (3 Layer) diameter ball bearing tup piece (tup

shall have a

Hardness of 50 to 55 HRC)

meter long graduated slotted tube

A wood block measuring approx. 610mm on each side and have a topacing of

Hardwood (for laboratory controlled test procedure).

DC holiday detector

est Specimens

Laboratory test) Shall be approximately 25mm x 200mm x pipe W.T., with

he 200mm dimension parallel to the axis of the pipe.(Field test) Test pipe.

Procedure

he impact test shall be carried at room temperature with the relevant

weight housed within a 1-meter graduated slotted tube. The ball bearing

hall be rotated every 10 impacts to a new location and replaced after 200

mpacts. The distance between each impact shall be 30 mm minimum.

Evaluation

Each pipe shall receive 10 impacts, each impact indentation on the test

pecimen shall be checked for substrate exposure using a holiday detector

et at 5V/micron (FBE) or 7900volts per mm (3 Layer).

Acceptance cr iteria, Typically the impact energy shall be 15 joules (For

BE)

o determine the impact resistance of coating (this practice can be adopted

n both FBE & Three Layer coating systems). The test can be carried out

oth, in a controlled laboratory environment and as a field test (directly on

est pipe surface).



Report

Record

Date

Batch number

Pipe number Coating date.

he applied impact energy (joules)

Holiday detection voltage setting

Impact Resistance

----------------------------------------------------------------------------------------

--------------

DETERMINATION OF HARDNESS - ASTM D 2240



Scope

est to measures the coating hardness using a Shore D hardness gauge.



Specimen

Applied coating or a free film sample usually 3mm or more in thickness.

he surface of the specimen shall be flat and parallel over a sufficient area

o permit the presser foot of the gauge to suitably contact the test area.

Equipment

Shore D Hardness gauge.

Procedure

a free film specimen is used, the specimen shall be placed on a hard, flat

orizontal surface. The Shore D Hardness gauge shall be held in a vertical

osition with the point of indenter at least 12mm from any edge of the

pecimen. Apply the presser foot to the specimen as rapidly as possible,

without shock, keeping the foot parallel to the surface of the specimen.

Apply just sufficient pressure to obtain firm contact between presser foot

nd specimen.

Evaluation

When the presser foot is in firm contact with specimen, the scale reading is

o be recorded within 5 seconds’

Note: The hardness reading may progressively decrease with any time

elay.

Acceptance cri ter ia, Typically Shore 60

Report

Record

Date

Manufacturer code

Batch number

Coating date .



Pipe Number or sample ID if applicable, shall be recorded

Record hardness value obtained.

ype and Serial Number meter

Shore D Hardness Test

.0 POLYETHYLENE & POLYPROPYLENE COATINGS

Polyethylene and Polypropylene coatings are commonly used as an outer

ayer for multi layer coating systems. Due to the nature of these materialshey are suitable for giving coated pipe added mechanical protection.

Polyethylene and Polypropylene coatings are usually applied over an FBE

rimer and have a bonding material (Polymer Adhesive) between the

rimer and outer layer. (Three Layer System).

ypically Polyethylene is used for moderate temperature conditions and

Polypropylene for higher temperature applications. Polymer coating are

ormally applied using a side extrusion method however, the cross headxtrusion method can also be used for pipe diameters up to 26". In this

module i will be describing the side extrusion method of coating.

Typical PE Coating



Typical PP Coating

Prior to the commencement of three layer coating all incoming materials

re checked against the material manufacturer’s certification and any other

pecification requirements. The Incoming receipt form (IRF) should

tipulate the incoming material testing requirements that are to be verified

rior to using the material.

ncoming test are typically Gel Time, Cure Time, Thermal Analysis and

Moisture Content for the FBE and Melt Flow Index MFI and moisture

ontent for the Polymers."See off line tests section 4.5 below"

.1 INCOMING PIPE

Pipes received at the incoming racks are checked for contamination or pipe

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efects that prevents acceptable coating and cannot be rectified at the

ncoming rack or grinding area. Any held pipes shall be removed from the

rocess and clearly marked (HOLD or REJECT) and placed into an

ppropriate holding area for adjudication by the client representative as to

s disposition.

he criteria for steel defects shall be generally in accordance with API (Theractical detail to be agreed by both parties).

See steel defects "Module 2"

Responsibilities:

he incoming rack supervisor should ensure that pipe is handle in a

manner that prevents pipe damage during the load in to the coating facility,

e should also supervise any rectification work required. The supervisor is

esponsible in ensuring that tasks are conducted in the safest possible

manner.

he incoming Inspector shall be responsible for the release or quarantining

f the incoming bare pipe

he incoming Tally man shall be responsible for the recording and

raceability of all the incoming bare pipes.

.2 COATING PROCESS

Preheat & Blast Cleaning



Pipes are be placed onto the incoming blast line rack where bevel

rotectors (if fitted) are removed and end plugs fitted to the pipe internals

o prevent the ingress of blasting media. The pipes are then indexed and

owered onto a blast line conveyor and conveyed through a pre-heat oven

Usually gas) set to allow for the required preheat temperature to be

chieved. The pipe surface temperature shall be monitored prior to blast

leaning using a hand held surface contact pyrometer, optical thermometer

r melt sticks.

he preheat temperature shall be checked as a minimum each hour and

he temperatures recorded. The steel surface temperatures for blast

leaning shall be above the required local dew point requirement, the dew-

oint (typically 3 C above local dew point) should be checked twice per shiftnd recorded on an agreed Climatic Conditions Report.

After preheating he pipes are then progressed through the first of two

entrifugal abrasive cleaning machine; the blast machine operator shall

ontinually monitor the blast effectiveness via visual inspection.

Abrasive samples (100 ml) shall be taken from the working mix(s) once per

hift: the sample shall be passed through 1.18 mm & 0.425-mm meshieves. No more than 16% should pass the 0.425-mm sieve. In the event

hat the amount of fines exceed this figure, fresh grit shall be added to the

working mix. Each abrasive sample shall be tested for chlorides and other

ontaminants. The results of the analysis shall be recorded on an agreed

Abrasive Contamination Test Report

See Module 2



Responsibilities

he Abrasive Line Supervisor shall be responsible for ensuring that the end

lugs are positioned correctly and that the specified preheat temperature is

onstantly maintained. He shall also ensure that the conveyor line speed is

onstant and that the surface amplitude and pipe cleanliness is maintained

within the specified tolerances. He shall also be responsible in ensuringhat the task is conducted in the safest possible manner.

he QC Inspector/Auditor is responsible for verifying that end plugs have

een positioned correctly and that the specified preheat temperature is

maintained. He shall also perform climatic conditions testing at the

pecified intervals and review laboratory testing of abrasive materials.

see Module 2)

he Laboratory Technician shall be responsible for taking samples of the

brasive and analysing.

.3 Grinding Area:

On completion of the first abrasive blasting operation the pipes shall be

ndexed onto the transfer holding rack (grinding area) and inspected. All

ipes are to be checked for any steel imperfections i.e. sliver, scabs,

amination's, burrs dents or bristles. Defects shall be repaired by grinding or

y hand filing.

Pipes that cannot be repaired and fail to meet the specified requirements

hall be clearly marked (HOLD or REJECT), removed from the process and

laced on a reject rack for adjudication by the client as to its disposition.

Details of pipe defects shall be recorded on an agreed Grinding Area

nspection Report.

A salt contamination check of the blasted pipe surface is checked using an

SCM 400 salt contamination instrument and the results recorded. Typically

he first pipe then further two pipes per shift are checked, the results are

ecorded on an agreed Salt Contamination Test Report.

See Module 2



On completion of surface defect and salt contamination checks, the pipes

re lowered onto the second centrifugal abrasive cleaning line where the

ipes receive a second blasting process.

After the second blasting operation the blasted surfaces are checked for

urface profile (using Testex Press-O-Film) replicating tape or other agreed

methods and the profile recorded. Typically pipes are checked at

he commencement of each shift then twice more during the shift.A surface contamination check is typically performed at the commencement

f each shift and twice more during the shift. To check contamination

lear cellotape strips are used and compared against a contamination

able.

See Module 2

he results of both the surface profile and contamination checks are

ecorded on an agreed Surface Blast Cleaning Inspection Report. Both the

estex film and the dust contamination films are normally attached to the

eport.

he blasted surface shall meet or exceed the requirement of the blast

rade as specified by comparing the blasted surface to a pictorial standard

.g. ISO 8501-1. The blast standard shall typically be a minimum Sa, 2.5

nd be monitored continuously and recorded every 4 hours.

he elapsed time between surface preparation and the commencement of

oating should also be monitored, the maximum elapsed time should be a

maximum of 4 hours, or before any rust blooming apparent.

Responsibilities

he Blast Line Supervisor is responsible for ensuring that all repairs,

rinding and filing is carried out under controlled conditions. If unsure about

he disposition of pipe defects, the QA department should be contacted tossist with any queries. The supervisor should also ensure that the pipe

as been cleaned of residue blasting matter both internally and externally.

He shall further be responsible in ensuring that the task is conducted in the

afest possible manner.

he QC Inspector/Auditor is responsible for recording the disposition of

ipe exhibiting defects and raising NCR report if required. He shall also

erform periodic testing in accordance with the agreed project Inspection



est Plan (ITP).

he Tally Man shall maintain pipe traceability and ensure that correct

ecords of defective pipe movement and disposition.

.4 Preheat FBE:

Prior to FBE coating the previously installed end plugs should be removednd the internal bore of the pipes checked for contamination. The pipes are

hen preheated prior to the application of the Fusion Bonded Epoxy powder

y passing through an Induction coil heating system.

Induction Heating Coils

he preheat temperatures are controlled so that the pipe is within the

orrect manufacturers recommended temperature range when the epoxy

owder is applied. The pipe temperature is continuously monitored

mmediately prior to the powder application booth by using a calibrated

urface temperature probe, infrared sensor or "Tempil" sticks. The latter

owever, may not be a permissible method due to oily residues left on the

ipe surface.

Infra Red Thermometer



Infra Red Temperature Read Out

Tempil Stick

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Cutback taping

Cut back areas are sometimes applied to avoid excessive time on the end

leaning station after coating, the paper used must be flame resistant.

apes have been known to inflame during pre heating and have the

otential to cause a coating booth explosion?

Responsibilities:

he Blast Line Supervisor should ensure that the induction heating

quipment is maintained in satisfactory operating condition and that the

ettings are commensurate to the required heating range for the particular

ipe size and wall thickness being heated. He should alsoensure that the

onveyor line speed is constantly maintained to allow even pipe preheat

nd coating to be achieved. He should also be responsible in ensuring that

he task is conducted in the safest possible manner.

he QC Inspector is responsible for monitoring preheat temperatures at thepecified periodic intervals.

he Tally Man should ensure that pipe traceability and correct records of

ipe movement and disposition.

Coating Parameters:

is always advisable that the production line operating parameters be

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ecorded for internal analysis on an internal coating operations parameter

eport.

.5 MATERIAL INSPECTION

usion Bonded Epoxy Powder

Each container of epoxy powder is inspected prior to loading into the

owder delivery system.

Note: With FBE powder it is advisable to check production material for

moisture content and gel time on at least a daily basis. (A high moisture

ontent can cause coating irregularities.

he inspection should also confirm that the epoxy powder is listed on the

Approved IRF".Only powder with current, valid approval shall be used.

Batch numbers shall be recorded on all the relevant inspection and

aboratory test reports.

Polymers

Each container Polymer shall be inspected prior to loading into the Extruder

opper systems.

Note: With Polymers it is advisable to check for moisture of the pellets

very two hours when in production. A simple way to check for moisture is

o push your bare hand into the box of pellets. If when you withdraw your

and you find pellets adhering to your skin it is an indication that excessive

moisture is present.

he inspection shall also confirm that the Polymers are listed on the

Approved IRF. Only Polymers with current, valid approval shall be used.

Batch numbers shall be recorded on all the relevant inspection andaboratory test reports.

Reclaim:

Subject to client approval the amount of reclaim powder applied in any

iven interval shall notexceed 20 % of the total powder application.

FBE Reclaim



.6 Coating Application

Powder application

he Fusion Bond Epoxy Powder is applied to the heated pipe using a

eries of electrostatic spray guns. By balancing the conveyor line speed

nd the settings of the electrostatics, guns, FBE flow rate and pressure of

he material feed the material application is controlled to achieve the

orrect applied coating thickness. The coating should be continuous over

he entire length of each pipe joint. The minimum thickness shall be asndicated in the agreed Project Inspection Test Plan ( ITP.)

Polymer Application

mmediately after the FBE primer, the co polymer adhesive (intermediate

oat) is applied. The application shall take place within the gel time window

f the FBE to ensure adequate adhesion to the primer. The minimumhickness is as indicated in the agreed project Inspection Test Plan (ITP)

ollowing the adhesive side extrusion application, the Polyethylene or

Polypropylene topcoat is applied by side extrusion process in a single sheet

ayer over the adhesive. Both polymer layers are applied with an overlap.

During the application of the polymers, a pressure roller is applied against

he pipe behind the polymer sheet that presses against the the applied



heet that eliminates air bubbles and ensures intimate contact between the

ayers. The minimum thickness of the PE/PP is as indicated in the agreed

roject Inspection Test Plan (ITP).

PE Application

PP Application

Responsibilities:

he coating line Supervisor shall be responsible for the strict control of all

he heating to maintain the correct pipe preheat temperatures in

ccordance with line speed, pipe diameter and material preheat

equirements. Information required to perform this function is received from



he coating line controller. He shall also be responsible in ensuring that the

ask is conducted in the safest possible manner.

he QC, inspector/auditor shall be responsible for monitoring of the coating

arameters.

he Powder booth foreman shall be responsible for maintaining the

pplication, gun settings, flow rates of materials, feed line pressures for the

articular line speed and pipe diameter and the electrostatics.

he coating line controller shall be responsible for all line activities for

material coating line. This includes maintaining the correct line speed and

ipe preheat by monitoring inspection reports and control room

nstrumentation and that all powder coating and Polymer extrusion

arameters are maintained.

On completion of coating the coated pipe is progressed through a water

uenching tunnel where copious amounts of water is sprayed onto the

nished coating and to cool the pipe for safe handling.

Water Quench

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.3 COOLING BOARDS & INSPECTION

mmediately after cooling the coated pipes are transferred to an outgoing

added pipe rack where the pipes are positioned on end cleaning rotators

he end cleaner brushes remove the coatings from the cut back areas of

he pipe. The entire coating surface is visually inspected for coating quality

nd detrimental coating defects. The cutback distance at both ends of the

ipe are also checked..

After end cleaning and visual inspection the entire coated surface of each

ength of pipe is inspected for holidays using a high voltage (pulse type)oliday detector previously set and calibrated to the correct voltage. The

ircumferential search electrode shall maintain intimate contact around the

ntire circumference of the coated pipe at all times. The voltage shall be

hecked and recorded hourly. The travel speed for holiday detection shall

e at a rate of 300 mm per second maximum. Any holidays or surface

efects shall be clearly marked and recorded on the agreed Coating

Application Report.

Holiday Detector

he coating thickness is usually determined by taking the 4 equidistant

measurements (3 on the body and 1 on the weld) at the lead end middle

nd tail end of each pipe (a total of 12 measurements). The measurement

hall be conducted using an electromagnetic thickness gauge. Records of

he thicknesses shall be recorded on the agreed Coating Application



Report

Thickness Check

Responsibilities

Cooling board supervisor shall be responsible for ensuring that the holiday

etection of each pipe is carried out in a correct manner and at the correct

oltage. Also he shall ensure that the pipe cutbacks are correctly

stablished and that the pipe ends and pipe internals are sufficiently

leaned. He shall also be responsible in ensuring that the task is conducted

n the safest possible manner.

he QC, inspector/auditor shall be responsible for visual inspection of the

oating and physical testing. He shall also monitor the holiday detection

nd cut back length. He shall also be responsible for calibration of the

oliday detection equipment prior to the start of each shift.

oad out Tally man, shall be responsible for checking the pipe identity and

maintaining pipe trace ability on the computerized pipe tracking system. He

hall also ensure that coating thickness checks are being carried out andeing recorded correctly for each pipe.

.4 REPAIRS:

Repairs to the coatings shall be carried out in accordance with an approved

Repair Procedure. Coated pipes that cannot be repaired shall be rejected,

tripped and re coated. Unacceptable pipe shall be marked up with

Red/White hazard tape and recorded on the NCR system.



ypical Repair Procedure

his procedure describes methods that enable repairs to be made to the 3

ayer Coating System after the completion of the in line process. This

method statement describes three repair methods and is presented in three

arts:

Part 1: - Repairs using a Hand Held Extruder Gun.

Part 2: - Repairs using Melt sticks.

Part 3: - Repairs using Sleeves.

Part 1: Hand Extruder

here are two types of repair

ype A: - Repairs to the total three layer system.

ype B: - Repairs to the Polyethylene layer only.

YPE A - The defective area shall be removed and the surrounding sound

oating shall be abraded to allow a "key" for the system repair material. An

rea of at least 50 mm diameter will be removed to facilitate the effective

leaning of the steel and FBE. The repair area substrate shall then be

ently preheated to remove surface moisture.

he FBE shall then be feathered using abrasive paper at the FBE/substrate

nterface.The exposed substrate shall then be mechanically roughened,

masking tape (if used) and surface dust shall be removed and two pack

poxy material applied. Mixing/application of the two pack epoxy shall be in

ccordance with manufacturer's data sheet and shall be applied to the

repared area using a clean brush (or pallet knife if compound is used).

After the Epoxy coating has cured, Polymer (as used in the parent coating)

s then extruded from a hand held extruder onto the repair area taking care

hat no air entrapment at the FBE/Polymer interface occurs. The Polymer is

xtruded in layers to bring the repair thickness up to and in excess of thearent coating thickness. Once cool, the repair shall be blended with the

arent coating, any excess Polyethylene removed by scraper and/or rasp.

he completed repair areas shall then be holiday detected.

Hand Extruder



YPE B - The damaged Polymer is removed using a chisel and the

urrounding area roughened using a mechanical burr. Extruded Polymer as used in the parent coating) is then introduced into the prepared area.

Once cool, the repair area shall be blended with the parent coating and any

xcess removed by scraper and rasp. The completed repair areas shall

hen be holiday detected. For repairs of Pinholes and minor defects to the

Polymer coating repairs shall be by using melt sticks.

Any loose or defective coating shall be removed from the damaged area

nd any sharp edges eliminated. The area and adjacent coating is then

leaned thus removing all foreign materials.

he prepared area is then preheated, at the same time the end of the melt

tick is heated such that it becomes “glossy”. The molten adhesive is then

pread onto the damaged area.

Melt stick

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On hardening, the repair shall be smoothed with a rasp such that the repair

rea becomes flush with the existing parent coating.

Part 3: WPC Sleeves

Heat shrinkable sleeves shall be used as an alternative for larger repairs.

he defective coating area shall be removed from the defect area. The full

ircumference around the pipe at the defect locality shall be thoroughly

leaned of surface dust, grease, oil etc using Xylene or bio -degradable

mulsifier. The full circumference of the pipe surface where the sleeve is to

e applied plus 100 mm either side shall be abraded.

he steel substrate at the defect area shall be mechanically roughened and

he repair area warmed slightly to drive off surface moisture. On completion

f preparation a two pack epoxy shall be applied to the steel surface. Mixing

nd application of the two pack epoxy shall be in accordance with the

manufacturer's data sheet. The epoxy shall be applied to the prepared

rea using a clean brush (or pallet knife if compound used).

When the Epoxy compound has cured, a filler shall be applied to the repair

rea to increase the coating thickness at the repair area location. A shrink

leeve shall be prepared to the correct dimensions and made ready for

pplication. When prepared the protective release plastic shall be removed

rom the mastic coating and the sleeve centred over the repair area. The

leeve shall be loosely wrapped around the pipe with ends overlapping by

pproximately 75-100 mm. The overlap shall be in approximately the 11

’clock position of the pipe with the edge of the overlap pointing

ownwards. The ends shall be aligned evenly.

Using a propane gas torch one end of the closure patch shall be heated

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ntil the reinforcing fabric is visible or the thermo-chromic paint has

hanged colour. With a gloved hand, the closure shall be patted down

rmly to the pipe and any wrinkles or bubbles shall be smoothed out. This

rocedure shall be repeated moving across the closure until the opposite

nd is completed. Whilst the closure is still hot and soft, a hand roller shall

e used to smooth out any trapped air and the edges and corners shall be

rmly bonded down.

he heating procedure shall continue around the pipe by heating in the

entre of the sleeve and continue towards the edges. Occasionally the

dhesive flow shall be checked by using finger pressure. After the sleeve

as shrunk and is still hot and soft, use a hand roller over the sleeve to

emove any entrapped air. Re heating of the sleeve is permissible to

omplete the repair.

Responsibilities:

he repair foreman shall be responsible for coating repairs and shall ensure

he correct equipment and repair method is used for coating repair. He shall

lso be responsible in ensuring that the task is conducted in the safest

ossible manner.

QC, Inspector/auditor shall be responsible for checking the preparation and

he completed repairs.

.5 OFFLINE TESTING

Besides online testing and inspection requirements there are a series of

Off Line” tests that have to carried out to confirm compliance of the coating

ystem against the specified requirements which include the following

ractices:

Back Side Contamination Checks

Coating Thickness Measurement

Differential Scanning Calorimeter

Gel Time DeterminationHoliday Detection

hickness Measurement

lexibility (Bend) Test

Cathodic Disbondment Test

mpact Resistance

Melt Flow Index

Moisture content

Adhesion Test



ensile Elongation Test

Determination of Coating Hardness

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Back Side Contamination - CAN/CSA Z245.20-2



Scope

o determine the extent of backside contamination at the bottom side of an

BE coating chip sample.

Equipment

Sample freezer

Bending machine

0 X microscope

Procedure

A sample section of coated pipe shall be removed from a test ring. The

ample section shall be approximately 200 x 50 mm

he sample cut out shall then be placed into a freezer and cooled down to

ear freezing point. After freezing the sample shall be removed from the

reezer and rapidly bent around a suitably sized mandrel causing the FBE

o flake off of the substrate.

Evaluation

Pry off the flake sample, The then examine the sample using a 40 X

microscope and the percentage of contamination is rated

Acceptance criteria: The backside contamination shall be within the

pecified tolerance. Typically 30 % max.

Report

Record



Date

ime

Pipe number

Batch number

Backside Contamination expressed in %

ackside Contamination

------------------------------------------------------------------------------

----------------------------------------

COATING THICKNESS MEASUREMENT



Scope

Determine the coating thicknesses of anti corrosion coatings.

Equipment

Calibrated electronic Thickness Gauge

Procedure

he pipe should be suitably cooled immediately after anti corrosion coating

efore measuring the coating thickness.

he coating thickness of the coated pipe is checked by using a calibrated

lectronic thickness gauge. The checking position of the inspection probe

hould be in vertical position and at right angles to the coating being

hecked. The coating thickness is measured at the specified locationslong the body of the pipe and on the weld seam where applicable.

Calibration of the measuring instrument



Switch on thickness gauge

Select "CAL" button

Place the probe on top of a certified standard thickness shim which has

een placed on a blast cleaned bare steel area and read the measurement.

Adjust the up or down button to give the actual reading according the

oating thickness standard or certified shim.

Press the "CAL" button again for confirmation calibration.

Report

Record

Date of coating

Pipe number hickness gauge reading

Report the individual coating thicknesses on both body and weld seam.

Report the minimum average thickness of the coating.

Record instrument calibration details

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------------------------------

DIFFERENTIAL SCANNING CALORIMETER - CAN/CSA Z245.20-2



Scope

his test is to determine the glass transition temperature (Tg) and the

mount of exothermic heat of reaction (DH) of epoxy powder or fusion-



onded epoxy cured coating.

Equipment

Differential scanning calorimeter (DSC) and accessories

Analytical balance accurate to 0.1mg

Knife or file

Procedure

Obtain a 10+/-1-mg sample of epoxy powder or coating as applicable

Place the sample in a pre-weighed aluminum pan and put lid in place.

Crimp the lid into place with the encapsulating press and obtain the sample

weight by subtracting pan and lid weight from the total weight.

Place a small vent hole (pierce) in the lid without damaging the pan.

Place sample and reference (as suggested by the instrument supplier) in

he DSC furnace.

Use nitrogen gas to purge the cell.

or epoxy powder sample, obtain thermal scans for the following cycles in

rder

a) heat the sample from 25 ± 5ºC to 70 ± 5ºC at a rate of 20ºC/min,

hen immediately cool the sample to 25

5ºC

b) heat the sample from 25 ± 5ºC to 285 ± 10ºC at a rate of 20ºC/min, then


5 ± 5ºC; and

c) heat the sample from 25 ± 5ºC to 150 ± 10ºC at a rate of 20ºC/min. For

oating samples, obtain thermal

cans for the following cycles in order:

d) heat the sample from 25 ± 5ºC to 110 ± 5ºC at a rate of 20ºC/min, holdt 110 ± 5ºC for 1.5 min, then

mmediately cool the sample to 25 ± 5ºC;

e) heat the sample from 25 ± 5ºC to 285 ± 10ºC at a rate of 20ºC/min, then


5 ± 5ºC; and

f) heat the sample from 25 ± 5ºC to 150 ± 10ºC at a rate of 20ºC/min.

Evaluation



he Tg is taken as the point of intersection of the extrapolated baseline of

he low temperature end and the tangents to the curve at the inflection

oint (onset) Calculate the residual exothermic heat of reaction (DH)

ollowing the instructions provided by the manufacturer of the DSC

quipment.DTg = Tg4 – Tg3

Report

Record

Date

Date of coating

Product code for epoxy powder only

Batch number, and date tested.

Pipe number where applicable,

Report Tg1, Tg2 and DH, for epoxy powder

Report Tg3, Tg4, DTg and DH, for coating, including units

ndicate the type of differential scanning calorimeter.

DSC Sample Preparation



DSC Machine

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---------------------------------

GEL TIME DETERMINATION - CAN/CSA Z245.20.02







Date

Product

Batch number

Gel time in seconds.

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---------------------------------

MOISTURE CONTENT - CAN/CSA Z245.20.02



Scope

Determine the moisture content of FBE powder using the mass loss

method

Equipment

Oven controllable within 3°C

Balance accurate to 0.001g

Desiccators; and

Sample container

Procedure

Weigh the sample container to the nearest 0.001g. Transfer approximately

0 g of epoxy powder into the sample container. Weigh the sample



ontainer and epoxy powder to the nearest 0.001g. Place the sample

ontainer with the epoxy powder into the oven for a maximum of two hours

t 105 ± 3°C. Remove the container from the oven and place in the

esiccators to cool. Weigh the sample container when it has cooled to

0 ± 3°C

Evaluation

Calculate the percentage of moisture using the following formula:

M = (B-C)/(B-A) x 100

Where

M = percentage of moisture

B = initial mass of sample container and epoxy powder, g

C = final mass of sample container and epoxy powder, g

A = mass of sample container, g

Acceptance criteria, Typically 0.5 % max.

Report

Record

Date

Material Code

Batch number

Moisture expressed in %

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--------------------------------

POROSITY INTERFACE & CROSS SECTIONAL - CAN/CSA Z245.20.02



Scope

o determine the extent of inter facial porosity at the bottom side of an FBEoating.

o determine the extent of cross sectional porosity within an FBE coating

Equipment

Sample freezer or dry ice & container

Bending machine

0-40 X microscope



Mandrel

Procedure

A sample specimen of coated pipe shall be removed from a test ring. The

ample section shall be approximately 300 x 50 mm. The sample cut out

hall then be placed into a freezer or dry ice and cooled down to near or

elow freezing point. After freezing the sample shall be removed from thereezer or dry ice and rapidly bent around a suitably sized mandrel causing

he FBE to flake from the substrate. Pry off the flake sample of FBE coating

o allow observation of both the cross section and underside of the coating

ample to be examined.

Evaluation

he sample shall then be viewed both in inter facial and cross sectional

levations using a 40 X microscope and assessed for porosity.

Acceptance cri ter ia, Typically rating 3 max.

Report

Record

Date

Pipe number

nterface Rating 1-5

Cross sectional rating 1-5

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-------------------------------

DETERMINATION OF HARDNESS - ASTM D 2240



Scope

est to measures the coating hardness using a Shore D hardness gauge.

Specimen

Applied coating or a free film sample usually 3mm or more in thickness.



he surface of the specimen shall be flat and parallel over a sufficient area

o permit the presser foot of the gauge to suitably contact the test area.

Equipment

Shore D Hardness gauge.

Procedure

a free film specimen is used, the specimen shall be placed on a hard, flat

orizontal surface.The Shore D Hardness gauge shall be held in a vertical

osition with the point of indenter at least 12mm from any edge of the

pecimen. Apply the presser foot to the specimen as rapidly as possible,

without shock, keeping the foot parallel to the surface of the specimen.

Apply just sufficient pressure to obtain firm contact between presser foot

nd specimen.

Evaluation

When the presser foot is in firm contact with specimen, the scale reading is

o be recorded within 5 seconds’

Note: The hardness reading may progressively decrease with any time

elay.

Acceptance criteria, Typically Shore 60

Report

Record

Date

Manufacturer code

Batch number

Coating date .

Pipe Number or sample ID if applicable, shall be recorded

Record hardness value obtained.ype and Serial Number meter

Shore D Hardness Test



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---------------------------------

Melt Flow Index - (ASTM D1238)



Scope

his test is primarily useful to raw material manufacturers as a method of

ontrolling material uniformity. While the data from this test is not directly

ranslatable into relative end-use processing characteristics, the melt index

alue is nonetheless strongly indicative of relative “flow ability” of various

ind and grades of Polymer. The property measured by this test is basically

melt viscosity or rate of shear. In general, the materials that are more

esistant to flow are those with higher molecular weight.

Equipment

Extrusion Plastometer (ASTM D1238)

Stopwatch or electric timer

Spatulahermometer

Procedure

he apparatus is preheated to 190°C . Material is put into the cylinder and

he loaded piston is put into place. After 10-15 minutes, the extrudite

ispensing from the orifice is cut off flush, and again one minute later.

hese cuts are discarded. Cuts for the test are taken at 1, 2, 3, or 6



minutes, depending on the material or its flow rate. The melt flow index is

alculated and recorded in grams/10 minutes. For adhesive the test

ondition load is 2.16 kg test for 1 minute only at 230° C.

Calculation

Weigh 4 samples and take average reading; A

Melt Flow Index, g/10min = Aktest is 1 minute, the factor k is 10

test is 3 minutes, the factor k is 3.33

test is 6 minutes, the factor k is 1.67

Report

he following information shall be reported:

Manufacturer, product code, batch number, and date tested.

Pipe size identification

Report MFI results in g/10 min.

ndicate time, and weight used.

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------------------------------

HOLIDAY DETECTION - NACE RP 0188-99/DIN 30670/CAN/CSA

45.20+21-02





Scope

o determine the anti corrosion coating is without any coating defects that

llow continuity between the test electrode and the substrate e.g. pinholes,oids, cracks and/or foreign matter inclusions.

Equipment

n-Plant Holiday Detector (e.g. SPY) which is an electrical device that

ocates discontinuities in the protective coating.

A calibrated Jeep meter crest-void meter which is used to calibrate the In-

Plant Holiday Detector.

Calibration Procedure

he In-Plant Holiday Detector is connected to the Jeep meter. Then both

oliday detector and jeep meter are switched on.

he In-Plant holiday detector is adjusted to the required test voltage and

he voltage value on the Jeep meter checked. The readings shall be of

qual value. Should the value on the jeep meter differ from that as set on

he holiday detector, the holiday detector shall be adjusted to allow the jeep

meter value to be obtained.

Calibration of holiday detector shall be performed at the beginning of each

hift and after any long term pause in production.

est Procedure

he pipe shall be in dry condition before holiday detection to avoid

ppreciable High Voltage DC leakage through the holiday detector circuitwhich can potentially produce a false signal.

he test voltage setting shall be dependant on the coating thickness. The

minimum testing voltage for a particular coating thickness shall be in

ccordance with the specified requirements for the coating being tested,

.g. 3LPP/PE 5 Kv/mm and FBE 5 V/µm.

he holiday detector electrode shall travel along the pipe surface at a



maximum travel speed of 300mm per/sec.

Where a holiday is detected, the defect area shall be clearly marked using

permanent marker and recorded on the appropriate inspection report.

Report


Date

Pipe Identification

Number and type of defect

Holiday detection speed

Calibration details

Holiday Detector

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--------------------------------

LEXIBILITY BEND TEST - NACE RP 0394-94 CAN/CSA Z 245.20-02





Scope

his test is to determine the flexibility of coating for field bending.

Equipment

Hydraulic Press

Bending mandrels of fixed radii

Microscope

reezer

Procedure

Specimens shall be removed from test rings (approx. 300mm long x 50mm

wide x pipe wall thickness, with the 200mm dimension parallel to the axis of he pipe.

Ensure that the specimen edges have all stress raisers removed and that

ubstrate is exposed along the edges. Test temperature shall be 23+/-2ºC.

Calculate the required mandrel radius (R) using the following formula

R= ((57.3)(t)/s))– t/2

Where

R= mandrel radius, t= effective strap thickness, and

= strain (deflection) in degrees per pipe diameter (°/PD).

Determine the effective strap thickness (t), which includes the specimen

hickness and any curvature, by placing the specimen on a flat surface and

measuring the thickness as shown in Figure K1 of NACE RP0394-94



Standard. Where a mandrel of the calculated radius is not available; the

mandrel of the next smaller radius shall be used.

Bend the test specimens over the radius so that the uncoated side is in

ontact with the mandrel, completing the bend within 30 seconds. The bend

est shall take a minimum of 10 seconds for completion.

Measure the residual bend radius by matching the outer curve of theest specimen to the nearest arc from Figures K2, K3, K4 or K5 of NACE

RP0394-94 Standard. Visually inspect the specimens for cracks, tears in

he coating, and disbonding of the coating after the specimen has warmed

o room temperature. The presence of any such defect within 2.5mm of the

trap edge does not constitute failure. The presence of strain marks alone

oes not constitute failure.

Report

he following information shall be reported :

Manufacturer, product, batch number, and date tested.

Pipe number, coating date.

Specimen effective strap thickness, permanent (residual) strain radius,

ngle of deflection in degrees per pipe diameter for passing bend, and test

rocedure used.

est Temperature

Defect {s} if any

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--------------------------------

ADHESION TESTING - CAN/CSA Z245.20.02



Scope

o determine Peel Adhesion of Polyeofins (Constant rate of peel method)

o determine Peel Adhesion of Polyeofins (Hanging weight method)

Equipment (Constant Rate of Peel Method)

ensile testing machine able to measure a load to an accuracy of 1%



Utility Knife

Attachment Clamp

Equipment (Hanging Weight Method)

Masses 0.3, 2.0, 15.3 kg

Attachment clamp

Utility Knife

Stop watch

Procedure (Constant Peel Method)

Cross head speed 10 +/- 1 mm/min

Normal specimen length of peel 75 mm for test

Normal specimen width 25 +/- 1 mm

Peel orientation shall be circumferential

Procedure

Prior to conducting the test condition the sample to test temperature for a

eriod of 1 hour minimum. Cut the required dimension test strip through to

he steel substrate. Make a cut at right angle to the test strip to enable

fting of the start tab. On the bonded area of the test strip mark the

equired test length

Attach the pull clamp to the tab of the test strip and proceed to peel the

trip at the prescribed 10 +/- 1 mm/min. Record the load required to peel

he sample. If more than 5 % of the total peeled length has a peeling load

elow the specified minimum value, the sample fails the test. If a small

ortion (less than 5 %) of the total peeled load is below the specified

minimum, accept the test as satisfactory. If the polyeofin breaks more than

hree times during the test, terminate the test and accept as being

atisfactory’

Calculate the minimum peel strength as follows:

P = Lp x 9.81

Where

P = minimum peel strength, N

p = minimum peel load, kg



Report (Constant Rate Test)

Sample ID

est date

Minimum peel strength

est temperature

Procedure (Hanging weight method)

Width of peel sample 25 +/- 1 mm

Peel orientation shall be circumferential

Make two cuts 25 +/- 1 mm apart through the coating to the substrate and

ircumferential from the 90° position to the 180° position. The coating shall

e cut at right angle at the 90° position and the peel shall be down towards

he 135° position.

he appropriate mass shall be attached to the free end of the peel strip

Mass for System

A1 0.3 kg

A2 2.0 kg

B 15.3 kg

he peeling time in minutes from the 135° position terminating at the 180°

osition shall be measured. The peeling may also be terminated when theest time calculated by using the following formula has been exceeded.

= 0.125 x 3.14 x D ÷ 10

Where



= test time in minutes

D = Nominal pipe outside diameter in mm

Measure the distance peeled in mm from the time the test was initiated

ntil it was terminated. Calculate the peeling speed using the following

ormula;

PS = d ÷ t

Where

PS = peeling speed in mm/min

= distance peeled in mm

= peeling time in min

the peeling speed is in excess of 10 mm/min at the test temperature the

est shall be considered a failure.

Report (Hanging Weight Test)

Sample ID

est date

est temperature

Pipe OD

Mass used in kg

Distance peeled mm

Peeling time minutesPeeling speed mm/min

Peel Adhesion Machine



Peel Adhesion Sample

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----------------------------------

ENSILE at BREAK & ELONGATION - ASTM D 638



Scope

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http://2.bp.blogspot.com/_f7Ox0EF0T94/TNEWMl5_c-I/AAAAAAAAAek/LuqDxM9i7GY/s1600/Peel.jpg



o assess of the tensile and elongation properties in material. The force

ecessary to pull the specimen apart is determined, along with how much

he material stretches before breaking. The elastic modulus (modulus of

lasticity or tensile modulus) is the ratio of stress to strain below the

roportional limit of the material.

Specimen

Specimen can be machined from compression molded plaques or

xtrudate. Samples to be suitably conditioned prior to testing.

Specimen is typically 1/8” thick (3mm) and made up to a type 5 barbell

onfiguration test piece.

Equipment

Universal Testing Machine, or equivalent

Computer complete with printer to plot graphical result

Procedure

Both ends of the specimen are firmly clamped in the jaws of a tensile

esting machine. The jaws may move apart at rates of 5, 12, 50 or 500 mm

er minute, pulling the sample from both ends.

Prior to starting the test, the original area (to be stretched) of the test

pecimen is measured and recorded.

he applied yield load is first recorded. After the yield load is obtained, the

nstrument is reset to get a second reading for the break point.

he stretched area of the sample is then measured to use in calculating the

reaking or stress at break of the specimen.



or the elongation of specimen, the stress is automatically plotted against

train (elongation) on graph paper.

Note : In case there is no graphical plotter is available, the elongation shall

e recorded as a percentage using the equation

A0, % = (L1 – L0)/L0 x 100

Where

0 = initial free length between gauge length.

1 = distance between gauge length at the time of breaking

he arithmetic mean of 5 results (A0) shall be determined.

Report

he following information shall be reported :

Manufacturer, product, batch number and date tested.

Pipe number, coated date.

Report Yield and Ultimate strength results in MPa.

Report Elongation in Percentage, %

Record results on relevant laboratory test report.

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---------------------------------

CATHODIC DISBONDMENT- CAN/CSA Z245.20-02 & CAN/CSA

245.21-02





Scope

o assess the comparative resistance of damaged coatings to loss of

dhesion by disbondment when exposed to Cathodic polarization. The test

hall be performed on a test specimen taken from a pipe or pup piece

reviously subjected to holiday detection, and in which an artificial defect of

defined size has been drilled.

Equipment

Stabilized DC Power supply unit with controlled voltage output.

A Cathodic polarization potential of –1.500mV to a saturated calomel

eference electrode (equivalent to UH = -1.260mV, where UH means the

otential of the standard hydrogen electrode shall be maintained). “E”

otential of the “working electrode” with regards to the “referencelectrode”. “V” difference of potential between the “working electrode” and

he “counter electrode”.

Electrolyte cell consisting of rigid plastic tube or PVC of with an internal

iameter of 75 ± 3 mm. The height shall be 120 mm.



A rigid plastic cover in which 3 holes shall be drilled to allow the passage of

he electrodes and any other measuring instruments deemed necessary,

nd to allow the escape of hydrogen.

Reference electrodes- the saturated calomel reference electrode or

uitable type of reference electrode to give an equivalent potential shall be

laced in an electrode holder situated in a glass tube with a porous endlug. The end of this assembly shall be placed approx. 10mm from the

urface of the coating and approximately 20mm from the coating defect.

Counter electrode or platinum wire.

Working electrode (cathode)- is represented by the artificial defect, which

hall be 3.2 mm in diameter for FBE & 6.4 mm in diameter for 3 Layer,

which shall penetrate through the coating to expose steel substrate.

Calomel reference electrode

Utility knife

est Specimen

est- Ring Specimen

he test specimen shall be a 100mm x 100 mm (square) segment cut from

he representative test ring.

Procedure

Drill a 3.2 mm (FBE) or 6.4 mm (3 Layer) diameter holiday through the

oating at the center of the specimen.

Glue a plastic cylinder onto the specimen using a sealant to form a water



esistant seal. Ensuring the pre drilled holiday is at the center of the

ylinder.

Pour approximately 300ml of Sodium Chloride Solution into the plastic

ylinder.

When testing specimens cut from the pipe, a heat- transfer medium shall

e employed to provide uniform heating of the specimen.

Use a metal pan/tray partially filled with a heat transfer medium (sand) into

which the specimen is implanted. Place on a hot plate or in an oven to

maintain the test temperature as required according to the duration of tests

pecified in the specification.

Connect the negative lead (working electrode) from the power supply to the

pecimen ( Cathode) and the positive lead (Counter electrode) to the

node after the test temperature is reached.

urn on the power supplies and applies voltage to the test specimen:

egative 1.5V or 3.5V with respect to the calomel reference electrode for

he 24 hr, 48-hr (only on accelerated production test) and/or 28-day tests.

Monitor the voltage, temperature and electrolyte level at the start and at

very 24-hr interval thereafter. For the 28-day test, the electrolyte level

eed not be monitored on weekends provided a cover plate is loosely fitted

ver the test cell. Distilled water shall be added as required to maintain the

lectrolyte level.

Evaluation Procedure

After 24hrs or 48 hrs (on accelerated production test), dismantle the test

ell and remove the test sample cell from the hot plate or oven.

mmediately drain the electrolyte and air-cool the sample to 20 ± 3° C. The

valuation shall be performed within one hour of removal from the hot plate.

or 28 day test, remove the 28-day test cell using the same procedure.



Using a utility knife, make radial cuts from the edge of the holiday outward

hrough the coating to the substrate. The radial cuts shall be at least 20mm

n length from the centre of the holiday.

nsert the blade of the utility knife under the coating. Using a levering

ction, chip off the coating. Continue until the coating demonstrates aefinite resistance to the levering action.

Measure the radius of the disbonded distance from the holiday edge along

ach radial cut and average the measured results. Maximum allowed CD

adius as measured, is detailed in the controlled ITP drawn for this project.

Report


Date tested.

Pipe number and coating date.

Average disbonded radius.

PE CD SAMPLE

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----------------------------------- -



MPACT TEST - DIN 30670, DIN 30678 & CAN/CSA Z 245.20-02

ote: This practice may be modified by the requirements of the customer’s specification,

ee relevant Project Inspection Test Plan (ITP)

cope

o determine the impact resistance of coating (this practice can be adopted on both FBE &

hree Layer coating systems). The test can be carried out both, in a controlled laboratory

nvironment and as a field test (directly on test pipe surface).

quipment (Impact Tester having)

alling masses 1-kg FBE, 3.5-kg 3LPE, 6-kg 3 LPP

5.8mm (FBE) or 25 mm (3 Layer) diameter ball bearing tup piece (tup shall have a

ardness of 50 to 55 HRC)

meter long graduated slotted tube

wooden block measuring approx. 610mm on each side and have a top facing of

ardwood (for laboratory controlled test procedure).

C holiday detector

est Specimens

Laboratory test) Shall be approximately 25mm x 200mm x pipe W.T., with the 200mm

mension parallel to the axis of the pipe.

Field test) Test pipe.

rocedure

he impact energy shall be 15 joules (FBE) or 5 joules/mm (3 Layer)

he impact test shall be carried at room temperature with the relevant weight housed

ithin a 1 -meter graduated slotted tube. The ball bearing shall be rotated every 10 impacts

o a new location and replaced after 200 impacts. The distance between each impact shall

e 30 mm minimum.



ach pipe shall receive 10 impacts, each impact indentation on the test specimen shall be

hecked for substrate exposure using a holiday detector set at 5V/micron (FBE) or

900volts per mm (3 Layer).

eport


roduct batch number and date tested.

ipe number and coating date.

he applied impact energy (joules)

oliday detection voltage setting according to the type of coating being tested.

Impact Test

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Documents

Painting Coating 2