Professional Documents
Culture Documents
CONTRACTORS STAMP:
TENDER DOCUMENTS
HESHAM
MAGDI
10.05.2009
ABDALHAKIM
ALBAZ
26.11.2008
REV
DESCRIPTION
PREPARED
CHECKED
DATE
CONSTRUCTION OF STATIONS
&
LAYING OF PIPELINES CONTRACT
LOCATION:
TITLE:
SPECIFICATIONS M02
POLYETHYLEN COATING
AlTaif - AlBaha
SCALE:
Q C 1 0
REV:
0
SUBCONTRACTOR:
Sheet 1 of 30
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Polyethylene Coating
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LIST OF CONTENTS
SCOPE
1
2
GENERAL
3.1
Environmental Conditions
3.2
Definitions
3.3
Abbreviations
3.4
TECHNICAL REQUIREMENTS
4.1
4.2
12
4.3
13
4.4
Coating Application
16
18
5.1
General
18
5.2
18
5.3
Production Testing
20
27
6.1
Preservation
27
6.2
Marking
27
6.3
Shipping
28
DOCUMENTATION
28
7.1
Pre-Production Documentation
28
7.2
Production Records
29
7.3
Release Documentation
30
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Polyethylene Coating
Rev. 0
SCOPE
This Specification defines the minimum requirements for the application of threelayer polyethylene coating to the external surface of steel pipe for buried service.
For the factory-applied coating the system shall comprise of a layer of fusion
bonded epoxy (FBE), overlaid with adhesive with an outer layer of high density
polyethylene.
ANSI/AWWA C213
ASTM D149
ASTM D257
ASTM D570
ASTM D638
ASTM D746
ASTM D790
ASTM D1238
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Polyethylene Coating
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ASTM D1505
ASTM D1525
ASTM D1531
ASTM D1603
ASTM D1928
ASTM D2240
ASTM D3417
ASTM D4703
ASTM F372
ASTM G 8
DIN 30670
ISO 9001
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Polyethylene Coating
Rev. 0
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Polyethylene Coating
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ISO 8502-5
NACE RP0490
Besides the a.m. codes and standards the Contractor shall observe the following
specifications:
G02 General Description of Project and Works
G03 Project Execution
M01 Steel Pipes for Mainlines
GENERAL
3.1
Environmental Conditions
The environmental conditions, operating conditions, product data, etc. under
which the pipes shall operate are defined in the project description and the
pipelaying specifications.
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3.2
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Polyethylene Coating
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Definitions
The terms Contractor, Pipe Supplier, Pipe Coating Contractor, Engineer,
etc. used in this specification shall have the meanings defined in the General and
Special Conditions of Contract.
3.3
3.4
Abbreviations
ANSI
API
ASME
ASTM
AWWA
DIN
ISO
NACE
TECHNICAL REQUIREMENTS
4.1
4.1.1 General
Materials shall be handled and stored in accordance with the material
manufacturers recommendations, which shall be available for review by the
Engineer at the Pipe Coating Contractors premises. Materials shall be stored in a
temperature controlled environment until required for use.
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Polyethylene Coating
Rev. 0
Coating materials shall be segregated by type and batch during storage and
handling. Materials from damaged containers shall be rejected unless otherwise
agreed with the Engineer.
As a minimum, all packages of the coating materials shall be marked with the
following data:
a)
Name of manufacturer
b)
c)
Batch number
d)
Date of manufacture
e)
Place of manufacture
f)
g)
h)
Hazard warnings
i)
Storage instructions
j)
Quantity
k)
Manufacturing standard
Any material not labeled with the above information shall not be used.
4.1.2 Abrasive Grit
The abrasive shall be steel grit, also in combination with steel shot of the required
grade to achieve the specified surface profile. The use of sand is not permitted.
Blasting abrasives shall be kept dry, clean and free from contamination. When
recovered metallic grit systems are used, a stabilized working mix of blast
cleaning material shall be established. This mix shall be maintained throughout
the entire course of the production, by frequent small additions from fresh or
cleaned stock at a rate sufficient to replenish consumption. Blasting and other
dust producing areas shall be kept separate from coating application areas.
4.1.3 FBE Powder
The FBE powder selected shall be suitable for use at the design temperatures in
the proposed environment and be suitable for a three-layer polyethylene coating
system. The FBE shall be endorsed by the Pipe Coating Contractor of the
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Polyethylene Coating
Rev. 3
adhesive and polyethylene as being compatible with these products under the
specified service conditions.
The color of the FBE shall be easily distinguishable from the color of the steel
substrate.
Each batch of FBE shall be accompanied by a certificate stating the following
tests have been carried out on every batch and results are in accordance with the
coating material manufacturers product specifications:
- Gel time
- Moisture content
- Particle size distribution
- Density
- Bend ability
- Infrared scan
- Thermal analysis
4.1.4 Adhesive
The adhesive selected shall be completely suitable for use at the design
temperatures in the proposed environment and be suitable for a three layer
polyethylene coating system.
Each batch of adhesive shall be accompanied by a certificate stating the
following tests have been carried out on every batch and results are in
accordance with the coating material manufacturers product specifications:
- Adhesion
- Density
- Melt flow index
4.1.5 Polyethylene
The polyethylene selected shall be of high density and shall be completely
suitable for use at the design temperatures in the described environment. The
polyethylene shall be suitable for a three-layer polyethylene coating system.
The polyethylene shall be a high copolymer grade. Polyethylene is obtained by
high or low pressure polymerisation of ethylene. The resultant polyethylene is
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Polyethylene Coating
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Page 11 of 30
Polyethylene Coating
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PROPERTY
ASTM TEST
UNITS
Rev. 0
VALUE
Density:
Base
D 1505
g/cc
0.941
Compound
D 1505
g/cc
0.951
Melt Index
D 1238
dg/min
0.32
D 1603
2.2
Yield strength
D 638
MPa
19.0
Ultimate strength
D 638
MPa
25.0
Elongation
D 638
750
Condition E
Tensile properties:
@ 50 mm/min
(2 in/ min)
Method 1
Flexural Modulus
D 790
MPa
590
Melting Point
D 3417
0C
129
D 1525
0C
119
Brittleness Temp.
D 746
0C
Fo@ -70
Hardness
Property)
D 2240
Shore D
Water Absorption
rate
D 570
Water Vapour
Transmission rate
F 372
g/100 in /
24h/mil
0.8
Dielectric Constant
D 1531
2.54
Dissipation Factor
D 1531
0.0006
Volume resistivity
D 257
ohm-cm
1 x10
17
Insulation
Resistance
D 257
ohm
1 x10
17
(Rubber
DCS
D 3417
D 62
max. 0.01
@
24
hours
0
90% RH. 100 F
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Polyethylene Coating
PROPERTY
Rev. 0
ASTM TEST
UNITS
VALUE
CONDITIONS
D 149
kV/cm
220
@ 500 VDC, 1
min.
D 149
kV/cm
390
Dielectric Strength
(a) @ 3000 micron
(125 mil)
(b) @ 1000micron(40
mil)
4.2
D 1928
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Polyethylene Coating
Rev. 0
4.3
4.3.1 Stages
The principle stages of pipe coating shall be as follows:
- Solvent cleaning followed by steam or hot bath cleaning (if required)
- Abrasive blasting
- Application of fusion bonded epoxy (FBE) layer
- Application of adhesive layer
- Application of polyethylene layer
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Polyethylene Coating
Rev. 0
Following the steam or hot bath cleaning the pipe shall be tested for salt and
chloride contamination in accordance with the requirements of DIN EN ISO 85022, ISO 8502-5 or DIN EN ISO 8502-9.
The removal of hydrocarbon contamination shall be confirmed by a water spray
test, where a fine spray is applied to the surface and uniform wetting confirms the
removal. This check shall be performed before and after blasting, as a prequalification test and as a minimum, once per 100 items during production, or
when necessary.
Items found to be contaminated shall be cleaned as above and re-blasted if
testing after blasting establishes that salt, chloride or hydrocarbon contamination
is still present. The remainder of the batch concerned shall all be checked
individually.
All water used for rinsing or cleaning purposes shall be potable with less than 200
ppm total dissolved solids and 50 ppm chlorides.
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Polyethylene Coating
Rev. 0
Additionally, abrasive materials shall be checked at least once per shift to ensure
that only uncontaminated angular grit with an acceptable size distribution is used.
As a minimum the following shall be carried out:
- Correct abrasive size distribution shall be carried out by sieve analysis
- Placing a sample of abrasive on a clean, dry sheet of absorbent paper to
determine water contamination
The surfaces of the pipes shall be blasted until a finish of Grade 2.5 to DIN EN
ISO 8501-1 is attained. The surface profile shall be between 50 and 100 microns,
measured in accordance with DIN EN ISO 8503-2. Profile measurements shall be
made with a Keane Tator Profile Comparator, Testex Press-O-Film or other
Engineer approved method suitable for the abrasive being used.
Following abrasive blasting, the surface shall not be contaminated with dirt, dust,
metal particles, hydrocarbons, water, chlorides, sulphates or any other foreign
matter, which would be detrimental to the coating.
Prior to the coating application, the exterior surface shall be thoroughly inspected
under adequate lighting. Any damage such as surface imperfections, slivers,
scabs, burrs, gouges, or sharp edged defects, shall be repaired in accordance
with this specification. Pipes that have damage repaired by grinding and have
ground areas greater than 50 mm diameter shall be re-blasted to meet the
requirements of the clauses above. After grinding or mechanical repairs the wall
thickness shall be ultrasonically examined and compared with the minimum
requirements of the applicable code / standard.
Any dust or loose residue that has accumulated during blasting and/or grinding
operations shall be removed by the use of clean compressed air or by vacuum
extraction. Alternative methods for removing dust and lint shall require approval
of the Engineer.
The elapsed time between the start of blasting and the heating of pipes shall be
indicated in the application procedure submitted by the Pipe Coating Contractor
and shall be reflected on his plant scheme.
The total elapsed time between the start of blasting of any pipe and the heating of
that pipe to the specified temperature shall not exceed the following time-humidity
table:
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Polyethylene Coating
PERCENT RELATIVE
Rev. 0
HUMIDITY
85
80
70
60
50
0.5
1.0
1.5
1.75
2.0
Any pipe surface not processed within the above time-humidity table shall be
completely re-cleaned and re-blasted before coating.
The maximum time limit between blasting and coating for humidity below 50%
shall be 4 hours.
4.4
Coating Application
4.4.1 General
The application of the coating shall be in accordance with the material
manufacturer recommendations and the procedure outlined below.
The Pipe Coating Contractor shall perform coating procedure qualification testing
(PQT) prior to commencing production or on his own risk at the start of
production in accordance with this specification.
Prior to start up of the coating process the powder application and recovery
systems shall be thoroughly cleaned to remove any powder other than that in
use, minimum once per day and the collected powder shall be disposed of.
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Polyethylene Coating
Rev. 0
The use of reclaimed FBE powder is only permitted if the reclaimed powder is
screened to remove foreign or deleterious material before being reintroduced into
the powder application system.
The clean reclaimed powder up to a maximum of 20% shall be introduced back
into the fresh virgin material by means of proportional weight.
During application, the beveled ends and pipe bore shall be protected against
mechanical damage and from contamination with coating material.
4.4.3 Adhesive Layer
The adhesive shall be applied to a thickness of 150 to 250 microns.
The adhesive layer shall be applied before gel time of the FBE has expired.
Application of the adhesive shall not be permitted after the FBE has fully cured.
The Pipe Coating Contractor shall establish to the satisfaction of the Engineer
that the adhesive is applied within the gel time window of the FBE and at the
temperature recommended by the adhesive manufacturer. The Pipe Coating
Contractor shall state the proposed minimum and maximum time interval
between FBE and adhesive applications at the proposed pre-heat temperature.
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Polyethylene Coating
Rev. 0
5.1
General
In order to demonstrate that the manufacturers proposed coating application
procedure is capable of meeting the specification, the Pipe Coating Contractor
shall undertake coating procedure qualification testing (PQT) prior to
commencing production, or at his own risk at the start of production. The Pipe
Coating Contractor shall also be required to test the finished coating during
production to demonstrate continued compliance with this specification. Details of
all inspections and testing shall be fully documented in accordance with this
section.
All stages of the surface preparation, coating and testing shall be subject to 100%
inspection by the Pipe Coating Contractor. The Engineer shall be informed at
least two weeks prior to the start of surface preparation to allow scheduling of
inspection supervision work.
5.2
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Polyethylene Coating
Rev. 0
If any of the tests fails to meet the minimum acceptance criteria defined in this
specification, then the pre-qualification pipes shall be rejected. Further pipes may
be prepared and coated using revised procedures and further tests performed.
Once acceptable results are obtained and approved by Engineer, the Pipe
Coating Contractors quality plan and procedures shall be revised, and submitted
to the Engineer for approval. All items coated using the rejected procedures shall
be stripped and recoated to the revised procedures.
Acceptable Values
Minor damage/grinding
pipe
Frequency of
Tests
3 per
Each pipe
2 g/cm2
No contamination
3 g/cm2
Each pipe
Each pipe
Each pipe
Each pipe
No surface defects
No holidays
Min/max see clause 4.4.2
See clause 5.3.5
Each pipe
Each pipe
0 per pipe
2 per pipe
6 per pipe
Each pipe
Each pipe
Each pipe
Each pipe
Each pip
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Property
Adhesion
Peel Test
Impact Resistance
% Elongation at
Failure
Cathodic disbondment
Other Tests as per
DIN 30670
5.3
Page 20 of 30
Polyethylene Coating
Rev. 0
Acceptable Values
Frequency of
Tests
2 per pipe
1 per pipe
2 per pipe
2 per pipe
1 per pipe
Production Testing
No holiday
2 g/cm
No contamination
2
3 g/cm
ISO-Sa 2.5
50-100 m
No contamination
See clause 4.2
No surface defects
No holidays
Min/max see clause 4.4.2
See clause 5.3.5
See clause 5.3.3
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Polyethylene Coating
Property
Visual Inspection
Coating
Bare steel at pipe ends
Protruding FBE
PE cut backs
Adhesion
Peel Test
Cathodic Disbondment
at Room Temperature
Rev. 0
Acceptable Values
Minimum
Frequency
No surface defects
120 +10/0 mm width
10 to 40mm width, chamfered
150 +10/-10 mm, bevel 30 to
45
Each pipe
Each pipe
Each pipe
Each pipe
Clause 5.3.10
The frequency of tests shown in the table above will be for normal production
operations. This frequency of tests is subject to change at the discretion of the
Engineer as a result of change of materials or consistent poor production
performance.
Additional after cleaning checks regarding chloride, oil, salt shall be executed
after every stop and start for certain hours.
The Pipe Coating Contractors quality control system shall include the following,
as a minimum:
- Monitoring of blasting grit and shot size
- Visual checks, in good light, of the surface of the blasted pipe
- Temperature control of the pipe surface
- Coating testing as detailed in this Specification
- Supervision of the adequate and proper repair of all defects
The following shall be recorded and logged at least once per shift:
- Air temperature (every 4 hours)
- Relative humidity (every 4 hours)
- Surface temperature of steel
- Dew point
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Polyethylene Coating
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PIPE DIAMETER
PIPE BODY
< 500mm
500mm
3.0 mm
3.5 mm
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Polyethylene Coating
Rev. 0
The thickness of the cooled polyethylene coating system shall be checked using
Engineer approved equipment in accordance with the requirements of DIN
30670.
Film thickness shall be measured by use of an electronic thickness gauge.
Calibration of this gauge shall be rechecked every 2 hours. The Pipe Coating
Contractors proposed thickness gauge type, manufacturer and model shall be
submitted to the Engineer for review and approval.
At least 3 of the measured points per pipe length shall be on the welds.
Any individual reading less than the values above shall be cause for the coated
pipe length concerned to be quarantined. The pipe shall be held for further review
by the Engineer.
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Polyethylene Coating
Rev. 0
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Polyethylene Coating
Rev. 0
as a production test - 48 hours duration, at the frequency of one test per 350
coated pipes at 65 +/- 2C
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Polyethylene Coating
Rev. 0
Items that fail individual tests and that cannot be repaired in accordance with
Section 5.3.12 shall be rejected. Subject to the approval of Engineer, the rejected
coating shall be stripped and the joint shall be re-blasted and coated in the
manner specified for new pipe in this specification.
Where a test relates to a quantity of coated items, e.g. 1 per 50 items or 1 per
100 items etc., the quantity of items represented by the item tested (e.g. 50 or
100) shall be considered to be a batch.
If a test on an item in a batch fails then this item shall be rejected and two further
items shall be randomly selected from the batch for repeat testing. If either of
these tests fails then the whole batch shall be quarantined for review by
Engineer. The cause of failure shall be established and reported to the Engineer
and if deemed necessary by the Engineer the coating procedure shall be
amended and re-qualified. The Engineer will decide whether the whole batch is
rejected and sent for re-blasting and re-coating or whether acceptance may be on
the basis of acceptable tests carried out on individual items.
5.3.12 Coating Repairs
The Pipe Coating Contractor shall submit detailed coating repair procedures for
approval by Engineer. These shall include procedures for repair of pin-hole,
small area and large area defects. The minimum and maximum areas for which
each type of repair is applicable shall be stated taking into consideration the
below mentioned requirements.
The maximum number of coating defects allowable, before a joint of pipe shall be
classed as rejected and recoated, shall not exceed 1 per 1 square metre
(exclusive of damage caused by testing).
The area shall be swabbed with solvent and abraded with an emery cloth, to
ensure that the surrounding polyethylene is well bonded, the surface shall be
roughened for a distance of at least 25 mm beyond the damage area. An
approved hot melt mastic shall be applied to the damaged area and smoothed
flush. The mastic and surrounding area shall be warmed with hot air or propane
torch until the surrounding polyethylene has as slight sheen. An approved
polyethylene patch material shall be applied overlapping the damage but not
overlapping the pre-abraded areas. Torch heat and smoothing pressure shall be
applied to fuse the patch and ensure that no blisters are formed.
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Polyethylene Coating
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No single defect shall exceed an area of 625 mm. Pipes with a coating defect
exceeding 625 mm shall be cause for rejection and shall be subsequently
reblasted and recoated. All rejections shall be recorded.
Repairs shall provide a finished coating equal in effectiveness to that of the
parent coating. The limit of the repair area shall be revised.
Each repaired area shall be holiday inspected in accordance with chapter 5.3.4 of
this specification.
The Pipe Coating Contractor shall submit coating stripping procedure for pipes
rejected for coating quality. The rejected coating may be stripped by heating in an
oven. Under these circumstances, the temperature of the pipe joint shall not be
allowed to rise above 400 C.
6.1
Preservation
The bare ends of each pipe shall be painted outside with a removable varnish as
temporary corrosion protection during transportation.
Bevel protectors of a type to be approved by the Engineer shall protect the bare
ends of each pipe.
6.2
Marking
In addition to the marking required by API 5L, the specification M01 Steel Pipes
for Mainlines and other applicable project specifications, the Pipe Coating
Contractors unique coating number shall be marked to the internal surface of the
pipe with synthetic resin paint.
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Polyethylene Coating
Rev. 0
Further marking details like colour coding etc. shall be agreed upon with the
Engineer.
The marking shall have at least a distance of 150 mm to the pipe end.
6.3
Shipping
Shipping and Loading preparation shall be in accordance with API Specification
5L or otherwise stated in the contract documents.
The Pipe Coating Contractor shall submit detailed loading-, stacking- and
shipping procedures for approval by the Engineer.
DOCUMENTATION
7.1
Pre-Production Documentation
The Pipe Coating Contractor shall submit the following documentation to the
Engineer for approval prior to commencing production:
a)
The manufacturers trade name and data sheets for all proposed coating
materials. This includes cleaning and abrasive blasting consumables.
b)
c)
Handling procedure.
d)
Stacking procedure.
e)
f)
g)
h)
i)
The results of the batch tests for batches to be used for pre-qualification
tests.
j)
k)
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l) Full test results from the coating Procedure Qualification Test (PQT).
m) Repair procedure and results of tests on demonstration of repairs.
n) Project specific Quality Plan.
Work shall not commence until these procedures have been reviewed and
approved by the Engineer.
The selection of proposed coating materials shall be subject to Engineers
approval.
7.2
Production Records
A daily log containing the following data shall be maintained and be available for
inspection by the Engineer during and/or after production. Data shall be recorded
against the pipe unique identification number.
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
The unique identification number of all items that are stripped for recoating
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7.3
Page 30 of 30
Polyethylene Coating
Rev. 0
Release Documentation
The Pipe Coating Contractor shall submit to the Engineer the following
documentation in hard copy and softcopy (format to be agreed upon with the
Engineer) with each batch of pipes released:
a)
b)
c)
d)
e)
Pipe length
f)
Length of the coated portion of each pipe and total coated lengths of all
pipes.
g)
h)
Date of coating
i)
b)
c)
All reports shall be signed by the Pipe Coating Contractor to signify compliance
with the requirements of this specification.