Coating Procedure PP

DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
The Petroleum Projects & Technical Consultations Co. ( PETROJET )
CLIENT : AQP
CP-0110-01-PP
Issue Date
SHEET
27 , 12,2011
of
55
PROJECT: NEW 16" SEALINE JOINIG

NAQP- 2 PLATFORM
COATING PROCEDURE
FOR
EXTERNAL PROTECTION OF STEEL PIPELINES
USING SIDE-EXTRUSION POLYPROPYLENE
THREE LAYER SYSTEM
27/12/2011
Issued for approval
20/11/2011
Issued for Client Comment
A.Elwahab
S.REZK
E.Eisa
Rev.
Date
Description
BY
CH'D
APPR.
THIS DOCUMENT IS CONFIDENTIAL AND THE SOLE PROPERTY OF PETROJET
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
2
of
55

NAQP- 2 PLATFORM
TABLE OF CONTENTS
1.
INTRODUCTION
2.
DEFINITIONS AND ABBREVIATIONS
2.1 Definitions
2.2 Abbreviations
5
6
3.
REFERENCE STANDARDS AND CODES
4.
COATING MATERIALS PROPERTIES/VENDORS

4.1 General properties of the coating materials
4.2 List of coating materials vendors
9
10
5.
PRODUCTION TESTING AND INSPECTION
12
6.
REQUIREMENTS OF THE APPLIED COATING
15
6.1 Pipe Surface Preparation

6.2 Cut Back
6.3 Visual Inspection
6.4 Coating Thickness
6.5 Pre-Heating Temperature
6.6 Coating Continuity ( Holiday Detection )
6.7 Adhesion ( Peel-Off ) Test
6.8 Impact Resistance Test
6.9 Indentation Resistance Test
6.10 Tensile Strength and Ultimate Elongation Test
6.11 Durometer Hardness Shore D
6.12 Melt Flow Rate
6.13 Air Entrapment Assessment
6.14 Degree of Cure Of Fusion Bonded Epoxy Primer
6.15 Flexibility Test
6.16 Cathodic Disbonding Resistance Test
6.17 Hot Water Immersion Resistance Test
6.18
15
16
16
16
17
16
16
17
17
18
18
18
18
19
19
19
20
REPAIR OF COATING
STRIPPING OF COATING
PIPE MARKING
22
7.
8.
9.
5.1
5.2
5.2
5.3
5.4
Inspection and Tests

Sampling
Re-tests
Nature and Frequency of Testing and Control
12
13
13
14
23
25
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
10.
11.
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
3
of
55

NAQP- 2 PLATFORM
PIPE RECEIVING, STORAGE, HANDLING AND TRANSPORTATION
26
10.1 PIPE RECEIVING

TRANSPORTATION
10.2 PIPE STORAGE ( STACKING ARRANGEMENT )
10.3 PIPE HANDLING
10.4 TRANSPORTATION OF PIPES
26
26
27
27
PRE-PRODUCTION /QUALIFICATION TESTS
28
Appendix A
VERIFICATION OF PIPE SURFACE PREPARATION
30
Appendix B
33
Appendix C
TEST FOR ASSESSING THE DEGREE OF CURE OF THE FUSION BONDED

EPOXY POWDER COATING
INSPECTION OF THE COATING THICKNESS
Appendix D
HOLIDAY DETECTION TEST
37
Appendix E
IMPACT RESISTANCE TEST
38
Appendix F
PEEL -OFF RESISTANCE TEST
39
Appendix G
DETERMINATION OF ADHESION OF COATINGS
41
Appendix H
INDENTATION RESISTANCE TEST
44
Appendix I
TENSILE AND ELONGATION TEST
45
Appendix J
STABILITY AGAINST ULTRAVIOLET RAYS AGING TEST
47
Appendix K
STABILITY AGAINST THERMAL AGING TEST
48
Appendix L
CATHODIC DISBONDMENT TEST
49
Appendix M
DETERMINATION OF HOT-WATER IMMERSION RESISTANCE
51
Appendix N
DETERMINATION OF FLEXIBILITY OF COATINGS
52
Appendix O
DETERMINATION AIR ENTRAPMENT IN COATINGS
53
Appendix P
DETERMINATION OF HARDNESS OF COATINGS
54
Appendix Q
DETERMINATION OF MELT FLOW RATE OF POLYMERS
55
36
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
1-
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
4
of
55

NAQP- 2 PLATFORM
INTRODUCTION
The procedure provides the requirements of the application, testing and repair of workshop sideextruded polypropylene coatings ( 3 layer system ) on pipes surfaces .
The coating covered by this procedure is suitable for the exterior protection of the steel pipe line which
applied to On-shore and Off-shore pipelines designed to convey and distribute oil, gas or any other
fluid .
This procedure is designed to comply the requirements of NF A 49-711 and DIN 30 678 standards.
The coating system shall consist of three layers and shall be applied in accordance with this
procedure, the composition of the three layers is :
1) Layer of epoxy primer .
2) Layer of polymeric adhesive .
3) Layer of Polypropylene top coat .
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
2-
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
5
of
55

NAQP- 2 PLATFORM
DEFINITIONS AND ABBREVIATIONS
Within the application od this procedure the following definitions and abbreviations shall be apply:
2.1 DEFINITIONS
Coating system The coating technique or process system consisting of the same type of coating
material .
Side extrusion Coating process whereby a hot extruded films of coating materials are wrapped
around the pipe in layers. The pipe is moved past the extrusion head in a spiral motion. The extruded
coating films are fused together to form a continuous adherent sheath around the pipe .
Three layer system Coating system consists of three layers which are epoxy primer, adhesive and
outer layer .
Epoxy primer The first coating layer ( the anti-corrosion layer )
which applied directly onto the

preheated pipe to improve the final adhesion of the final coating to the pipe surface .
Adhesive The intermediate coating layer to improve the adhesion between the primer and the outer
layer .
Outer layer The polypropylene ( PP ) layer .

Coating thickness Understood to be the average thickness of the coating system ( summation of
average thickness for the applied top coat, adhesive and primer layers ) .
Unit of production Set of pipes have the same DN and coated with the same coating system and
the same type of material .
Coating cycle
Any production process have the same DN and coated with the same coating
system, and not interrupted more than 3 days .
Test ring
Day
Production run and shall not more than 24 hrs.
Shift
Production run and shall not more than 12 hrs.
Test sample from a coated pipe.
Batch No. Quantity of PP material not more than 50 tons.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
6
PP
RH
Tg
Tg
J
UV
DSC
MEK
M.D.S
55

NAQP- 2 PLATFORM
2.2 ABREVIATIONS
DN
FBE
of
Pipe nominal diameter

Fusion Bonded Epoxy ( epoxy primer )
Polypropylene
Relative humidity %
Glass transition temperature, expressed in C.
Variation of the glass transition temperature ( Tg2 Tg1 ), expressed in C.
Impact energy in joules.
Ultra Violet .
Differential Scanning Calorimetry
Methayl Ethyel Ketone
Material Data Sheet
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
7
of
55

NAQP- 2 PLATFORM
CLIENT : AQP
3- REFERENCE INTERNATIONAL CODES AND STANDARDS .
This specification makes reference to the documents listed below, where relevant, all work shall
be carried out in accordance with the latest editions of these documents, including all revisions
and addenda . Where conflict occurs between the requirements of this procedure and reference
codes and standards, the requirements of this procedure shall apply .
European Committee for Standardization
PrEN 10286
CEN )
Steel Tubes and Fittings for On and Off-shore Pipelines External Three Layer
Extruded Polypropylene Based Coatings.
LAsaociation Francaise de Normalisation
NF A 49-711
.. (
.. (
AFNOR )
Steel Tubes External Triple-Layer Polypropylene Based Coatings Application By

Extrusion.
Deutsche Institute fur Normung
.. (
DIN )
DIN 53 505
Testing of Rubber, Elastometer and Plastics;Shore Hardness A and D Testing.
DIN 53 455
Testing Of Plastics; Tensile Test .
DIN 30 678
Polypropylene Coatings For Steel Pipes and Fittings, Requirements and Testing
American Society for Testing and Materials
.. (
ASTM )
ASTM D 543
Standard Practices for Evaluating The Resistance of Plastics to Chemical

Reagents .
ASTM D 638
Standard Test Method For Tensile Test Of Plastics .
ASTM D 1238
ASTM D 2240
Standard Test Method For Flow Rates Of Thermoplastics Extrusion Plastometer
ASTM D 3359
Standard Test Method For Measuring Adhesion By Tabe Test
ASTM D 4752
ASTM D 5402
Standard Test Method For Measuring MEK Resistance of Ethyl Silicate ( Inorganic) Zinc-Rich Primers by Solvent Rub .
Standard Test Method For Assessing the Resistance of Organic Coatings
Using Solvent Rubs .
ASTM G 8
Standard Test Method For Cathodic Disbonding Of Pipe Lines Coatings .
Standard Test Method For Rubber Property- Durometer Hardness .
National American Of Corrosion Engineering

NACE RP 0394
.. (
NACE )
Standard Recommended Practice - Application,Performance, and Quality Control

Of Plant-Applied, Fusion Bonded Epoxy External Pipe Coating .
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
8
of
55

NAQP- 2 PLATFORM
Gas Business Engineering .. ( GBE )
GBE/CW6 : part 1
International
Technical Specification For The External Protection Of Steel Line Pipe and
Fittings Using Fusion Bonded Powder and Associated Coating Systems
( Part 1 : Requirementes For Coat materials and Methods Of Test .
Standard
.. (
ISO )
ISO 8501-1
Pictorial Surface Preparation Standards For Painting Steel Surfaces .
ISO 8502-1
Field Test for Soluble Iron Corrosion Products .
ISO 8502-3
Field Test for The Determination Of Dust Contamination
ISO 8502-4
Guidance on the Estimation of the Probability of Condensation Prior to Paint

Application .
Plastics - Determination of the Melt Mass-Flow Rate ( MFR ) and Melt VolumeFlow Rate ( MVR ) of Thermoplastics .
( SIS 05 59 00 )
ISO 1133
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
4-
CP-0110-01-PP
Issue Date
SHEET
27 , 12,2011
of
55

NAQP- 2 PLATFORM
COATING MATERIALS PROPERTIES/VENDORS.
4.1 GENERAL PROPERTIES OF THE COATING MATERIALS

The coating materials used in this project shall be have the following general properties:
4.1.1 PROPERTIES OF EPOXY PRIMER
1- Powder FBE applied as anti-corrosion layer for coating of steel pipe line by polyolefin 3 layer system
.
2- Possess good similarity and compatibility with the polymeric adhesive, and react with it, so that the
reciprocal anchorage is increased.
3- Show high capability to minimize cathodic disbondment when steel pipe is subjected to negative
polarization as per ASTM G 8 and ASTM G 42 standards [ the maximum radius of disbonding
5mm. ] .
4.1.2
PROPERTIES OF ADHESIVE
1- Propylene adhesive suitable for 3 layer coating system .

2- Be suitably stabilized against aging at its maximum application temperature and free from volatile
or other unstable substances at maximum application temperature ( application temperature
indicated by the manufacturer ) .
3- Show high affinity and strong bond with polypropylene layer (top coat layer), high affinity and strong
bond with primer layer, and assure a strong bond with primer (equal to or higher than that with
PP).
4- Achieve with other layers, at least, a minimum peel-off resistance as per NFA 49-711 and DIN
30 678 standards .
5- Possess the following properties ...
PROPERTY
Density
UNIT
TEST METHOD
g / cm3
ASTM D 1505
g / 10 min.
Melt Flow Index
Elongation at Break
0.860 - 0.915
ASTM D 1238 .
3 - 20
kg / cm2
ASTM D 638
> 150
ASTM D 638
> 400
230 c / 2.16 Kg
Tensile Strength at Break
VALUE
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
10
of

NAQP- 2 PLATFORM
4.1.3 PROPERTIES OF POLYPROPYLENE
1- Fully stabilized PP, in granular state, contains additives for stability and resistance to weather
conditions and its combined action of oxygen, sunlight and temperature .
2- Designed for coating of steel pipe, three layer system, where it is side-extruded directly in
multiple wraps to build-up the requested thickness .
3- Compatible with other layers and show with them, at least, a minimum peel-off resistance as
per NF A 49-711 and DIN 30 678 standards .
4- Possess the following properties ...
PROPERTY
Density
Melt Flow Index
Durometer Hardness
Vicat Softening Point
Tensile Strength at Break
Elongation at Break
UNIT
TEST METHOD
g / cm3
ASTM D 1505
0.895 - 0.920
g / 10 min.
230 c / 2.16 Kg
ASTM D 1238
max. 4
ASTM D 2240
60
ASTM D 1525
> 140
kg / cm2
ASTM D 638
> 190
ASTM D 638
> 400
shore D
55
VALUE
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
SHEET
27 , 12,2011
11
of
55

NAQP- 2 PLATFORM
4.2 LIST OF COATING MATERIALS VENDORS

The typical coating materials to be considered for the anti-corrosion coating of the project shall
be delivered from the following vendors, only one system shall be used for the entire project.
In case of PETROJET requires a change in coating material approved during PQT this request
shall be submitted to the client and shall be subject to apploval by Clien.
4.2.1 FBE POWDER PRIMER:
Product Name
KARUMEL EX 4413-L300
Manufacturer
KCC Corporation
Origin
S. Korea
2- ADHESIVE :
Product Name
POLYGLUE RE340B
Manufacturer
Hyundai Engineering Plastics Co.
Origin
S. Korea
3- POLYPROPYLENE TOP COAT :
Product Name
YUPRENE PT900W
Manufacturer
Hyundai Engineering Plastics Co.
Origin
S. Korea
This list is for client information and PETROJET has the right to use any of the products in this list.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
12
of
55

NAQP- 2 PLATFORM
5- PRODUCTION TESTING AND INSPECTION .
The inspection testing during coating application ( needed to ensure that the coating is being applied in
accordance with the approved specification ) shall be carried out as following:
5.1 INSPECTION S AND TESTS

5.1.1
PIPE SURFACE PREPARATION
The surface preparation operation and prevailing parameters shall be measured at the frequencies
indicated in table ( 1 ) .
- Climatic conditions ( prevailing temperature, humidity, dew point ).
- Surface cleanliness .
- Pipe Surface Temperature ( before blast).
- Surface profile .
- Surface salt contamination .
- Dust control .
5.1.2
PRE-HEATING TEMPERATURE
The preheating temperature of the coating materials shall be measured at the frequencies indicated in
table ( 1 ) to insure application within the manufacturer recommendation limits .
- Pipe temperature .
- PP temperature .
- Adhesive temperature .
5.1.3
COATING SYSTEM THICKNESS
The coating thickness of the system shall be measured at the frequencies indicated in table ( 1 ) and
in accordance with the methode defined in Annex B.
- Thickness of primer layer
- Thickness of adhesive layer
- Total coating thickness
5.1.4
COATING CONTINUITY ( HOLIDAY DETECTION )
The coated pipes shall be holiday detected 100 % at voltage set at 10 Kv per millimeter of nominal
thickness of coating and not exceeding 25 Kv.
The holiday detectIon shall be performed in accordance with the methode defined in Annex C
5.1.5
IMPACT RESISTANCE TEST
The impact resistance of the coating system shall be measured at the frequencies indicated in table (1)
and in accordance with the methode defined in Annex D .
5.1.6
ADHESION ( PEEL OFF ) TEST
The peel-off resistance of the coating system shall be measured at the frequencies indicated in table
( 1 ) and in accordance with the methode defined in Annex E .
5.1.7
MELT FLOW RATE
The melt flow rate of the PP and adhesive for the new and extruded material shall be measured at the
frequencies indicated in table ( 1 ) and in accordance with the methode defined in Annex P.
5.1.8
INDENTATION RESISTANCE TEST
(1)
The indentation resistance of the PP shall be measured at the frequencies indicated in table ( 1 ) and
in accordance with the methode defined in Annex G.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
5.1.9
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
13
of
55

NAQP- 2 PLATFORM
TENSILE STRENGTH and ULTIMATE ELONGATION
The tensile strength at yield and at break and the ultimate elongation of the PP shall be measured at
the frequencies indicated in table (1) and in accordance with the methode defined in Annex H.
5.1.10 DUROMETER HARDNESS - SHORE D
The hardness shore D of the PP shall be measured at the frequencies indicated in table (1) and in
accordance with the methode defined in Annex O.
5.1.11
(1)
DEGREE OF CURE OF PWODER EPOXY
The degree of cure of the F.B.E layer shall be measured at the frequencies indicated in table ( 1 ) and
in accordance with the methode defined in Annex A.
5.1.12
FLEXIBILITY
(1)
QC. Supervisor shall perform the flexibility of the coating at the frequencies indicated in table ( 1 ) and
in accordance with the methode defined in Annex M.
5.1.13 CATHODIC DISBONDING TEST
QC. Supervisor shall perform the cathodic disbonding test for the coating at the frequencies indicated in
table ( 1 ) and in accordance with the methode defined in Annex K .
5.1.14 HOT WATER IMMERSION TEST
QC. Supervisor shall perform the Hot water immersion test for the coating at the frequencies indicated in
table ( 1 ) and in accordance with the methode defined in Annex L .
5.1.15
ENTRAPMENT ASSESSMENT
The air entrapment in the coating shall be measured at the frequencies indicated in table ( 1 ) and in
accordance with the methode defined in Annex N .
5.2 Sampling
Petrojet QC representative or the Client representative shall select, on random bases, the pipes on which
the specified tests shall be carried out.
All desteructive testing shall be carried out on the ends of the pipes
5.3 Re-tests
Test results which are unsatisfactory and not attributable to the quality of the coating could result from:
- Defective sampling of the test piece;
- Devective assembling or abnormal operation of the testing equipment.
In such cases, the test shall be disregarded and the test that failed shall be repeated on the same pipe
and two pipes before and after the pipe thate failed.
If the results are satisfactory, the coating shall be considered acceptable. If not, the coating shall be
considered unacceptable
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CP-0110-01-PP
Issue Date
SHEET
27 , 12,2011
14
of
55

NAQP- 2 PLATFORM
CLIENT : AQP
5.4 Nature and Frequency of Testing and Control

THE MINIMUM QUALITY CONTROL TESTS FREQUENCY
Subclause
Reference
Test method
Frequency At Regular
Production
Surface condition before blast cleaning

Ambient temperature
Relative humidity
Dew point
Pipe surface temperature ( before blast cleaning )
Surface cleanliness ( after blast cleaning )
Roughness of the blast surface
Surface salt(Chloride ) contamination
Cleanliness of blast surface for dust
Abrasive Check For Contamination
Pipe surface temperature ( before FBE application )
PP / Adhesive temperature
6.1
6.1
6.1
6.1
6.1
6.1
6.1
6.1
6.1
6.5.1
6.5.3
M.D.S
M.D.S
Every pipe
test / hr
test / hr
test / hr
test / hr
Every pipe
1 out 10 pipes
1 out 100 pipes
1 out 100 pipes
1test / shift
Every pipe
test / hr.
Thickness of primer layer

Thickness of adhesive layer
Total coating thickness of the system
Visual Inspection
Continuity-holiday- control
Cut back
Peel-off test @ 110 C
Impact test
Indentation Resistance @ 23 &110 C ( 1 )
Tensile strength at Yield and Break
Ultimate elongation
Hardness, Shore D
Melt Flow rate
Entrapment Assessment
Degree of Cure of FBE ( DSC ) ( 1 )
Degree of Cure of FBE ( MEK )
Flexibility, 3 PD @ -10 c ( 1 )
Cathodic disbonding test @ 20&65&90 c
Microscopic Examination
Hot Water Resistance Test @ 65c
6.4.1
6.4.2
6.4.3
6.3
6.6
6.2
6.7
6.8
6.9
6.10
6.10
6.11
6.12
6.13
Annex B
Annex B
Annex B
Annex C
Annex E
Annex D
Annex G
Annex H
Annex H
Annex O
Annex P
Annex N
6.14
Annex A
6.15
6.16
Annex M
Annex K
6.16
Annex M
test / day
test / day
Every pipe
Every pipe
Every pipe
Every pipe
1 out 20 pipes
1 out 20 pipes
1test / shift
1test / shift
1test / shift
Test/ PP batch No.
Test/ PP batch No.
test / shift.
test / shift.
test / day.
2 pipe\week
2 pipe\week
2 pipe\week
1 pipe\week
Properties
Testing and control on the process parameters
Testing and control on the coating
(1)
Tests shall be done at PETROJET- Port Said main coating Lab.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
15
of
55

NAQP- 2 PLATFORM
6- REQUIREMENTS OF THE APPLIED COATING .

6.1 PIPE SURFACE PREPARATION
1- Beforee blast cleaning and application of the coating system, the pipe surface shall be free of all
surface contaminants. Oil, grease and other contaminants shall be removed wiping the contaminated
area by suitable solvent, detergent or potable water .
Note: In case of major Oil, grease or any contaminations which need an additional pre-cleaning
materials/man hours and time delay prior to surface preparation for coating.
PETROJET shall brought
to the attention of client representative to approve the cost of action shall be taken by PETROJET or to
provide the corrective action.
2- All pipes should be visually checked for moisture, if the pipe looks damp or pipe surface Temperature
< 20 c , the pipe must be preheated to up to 65 c to eliminate the moisture, the pipe surface should
be at least 3 c above the dew point Temperature prior to coating .
3- The pipe surface shall be cleaned by shot/grit blast cleaning technique to achieve the requirements
of SA 2 Very thorough blast cleaning in accordance with ISO 8501-1 (SIS 05 59 00) standard
and shall be checked in accordance with the method defined in Annex A.
4- The pipe Surface profile ( peak-to-valley ) shall be in the range of 50 m -100 m and shall be
checked using testex tape(or equivalent ) and shall be measuered in accordance with the method
defined in Annex A.
5- QC supervisor shall verify that the salt contamination for the blasted pipe surface is within the
range of 1 g/cm2 and shall be measuered in accordance with the method defined in Annex A.
6- QC supervisor shall verify that the degree of presence of dust contamination for the blasted pipe
surface is rating 2 in accordance with ISO 8502-3 standard and shall be checked in accordance
with the method defined in Annex A.
7- The blasted pipes shall be inspected for all surface imperfections ( slivers, scabs, dents, ..etc ) which
shall be marked and shall be checked in accordance with the method defined in Annex A.
8- The abrasive material in the blasting machine shall be checked for absence of foreign particles or oil
and greas contamination and shall be checked in accordance with the method defined in Annex A.
9- Prior to induction heater, the pipe surface shall be cleaned from all dust and abrasives which still
remain on the exterior surface of the pipe using mechanical nylon brush supplemented with vacuum
system.
10- Blasted pipes shall be coated within the following maximum times and any pipe delayed beyond this
period shall be re-blasted and re-inspected .
Maximum delay time
% RH
85
TIME
2 hr
80
60
3 hr
4 hrs.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
16
of
55

NAQP- 2 PLATFORM
6.2 CUT BACK

The coating, at pipe ends shall be cut back over length of 120 mm (-0/+20 mm).and beveld at angle
of 30 to 45 , at cut backs the PP and Adhesive layers shall be removed.
6.3 VISUAL INSPECTION

The coating shall be inspected100 % to insure that
1- The coating free from blisters , wrinkles, voids and disbondment.
2- Pipe temperature after cooling shall be 80 c.
6.4 COATING THICKNESS

6.4.1 Epoxy Primer Thickness : The thickness shall be 200 - 400 m.
6.4.2 Adhesive Thickness
: The thickness shall be 250- 350 m.
6.4.3 Total Coating Thickness
The average total thickness is the summation of the thickness of individual layers, the minimum
total thickness as specified in table.
The coating thickness shall be measuered in accordance with the method defined in Appendix C.
Pipe Diameter ( in )
16"
Minimum Coating Thk. ( mm )

@ pipe body
3 mm (-0/+1mm)
6.5 PRE-HEATING TEMPERATURE

The pre-heating temperature of the pipe and the coating materials as following ..
6.5.1 Pipe temperature
The pipe surface temperature should be between 185 C - 230 C using the TEMPIL STICK temperature indicating crayons.
6.5.2 Polypropylene & Adhesive temperature
The temperature of both extruded PP should be less then 260C and adhesive material should be
less then 240C, or as per recommended material data sheet and shall be measured using optical
pyrometer.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
17
of
55

NAQP- 2 PLATFORM
6.6 COATING CONTINUITY ( holiday detection )

The coating system shall be holiday detected 100 % in accordance with the method defined in
Appendix D, the test voltage shall be set at 10 Kv per millimeter of nominal thickness of coating and
not exceeding 25 Kv,The maximum no. of allowed holidays is 5 localized or scattered holidays per
coated pipe .
6.7 ADHESION ( PEEL-OFF ) TEST

The adhesion of the coating shall be determined by measuring the peel-off resistance in accordance
with DIN 30 678, NF A 49-711 standards and the method defined in Annex F.
The minimum force required to lift the coating shall be as indicated in the table below
Force @ 50 C 5 C
Force @ 90 C 5 C
100 N / cm
80 N / cm
6.8 IMPACT RESISTANCE TEST

The impact resistance of the PP coating system shall be tested at Temperature ( 23 3 C ) in
accordance with DIN 30 678 ,NF A 49-711 standards and the method defined in Annex E.
The coating shall have a minimum impact resistance value of
E= ( 8 x ) J per mm of coating thickness ( min. 19 J /pipe )
6.9 INDENTATION RESISTANCE TEST

The indentation resistance of the PP material shall be tested in accordance with DIN 30 678 and NF A
49-711 standards and the method defined in Annex H.
The maximum indentation resistance shall be as following
@ 23 C - 2 C + 2 C
0.1 mm
@ 100 C - 2 C + 2 C
0.4 mm
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
18
of
55

NAQP- 2 PLATFORM
6.10 TENSILE STRENGTH AND ULTIMATE ELONGATION TEST

The tensile strength and ultimate elongation ( elongation at break ) of the PP material in accordance
with DIN 30 678,NF A 49-711, ASTM D 638 standards and the method defined in Annex I.
The PP material should show the following values :
Tensile Strength
( Yield )
Tensile Strength
( Break)
Ultimat Elongation
150 Kg/cm2
210 Kg/cm2
400 %
6.11 DUROMETER HARDNESS SHORE D

The hardness shore D of the PP material shall tested in accordance with ASTM D 2240 and DIN 53
505 standards and the method defined in Annex P.
The PP material should show Hardness 60 shore D.
6.12 MELT FLOW RATE

The melt flow rate ( MFR ) of the PP and adhesive materials shall be tested in accordance with ASTM
D 1238 and the method defined in Appendix Q.
6.12.1 New MFR = shall be within 15 % of the material certificate of analysis or material
data sheet.
6.12.2 Extruded MFR = shall be within 20 % of the New MFR .
6.13 AIR ENTRAPMENT ASSESSMENT

The degree of presence of air entrapment between coating layers in accordance with the method defined
in Appendix O.
A strip of coating from the adhesion test shall be used to determine the level of air entrapment on the
body of the pipe or in the saw weld, The coating should show Not more than 20% of the observed area
contains air entrapment, bubble size in the PP layer shall be limited to less than 1/2 the thickness of the
PP layer in hieght or circumference and not linked together.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
19
of
55

NAQP- 2 PLATFORM
CLIENT : AQP
6.14 DEGREE OF CURE OF FUSION BONDED EPOXY PRIMER

The degree of cure of the FBE coating shall be tested in accordance with the method defined in
Appendix B, the acceptance criteria shall be:
6.14.1 MEK Rub method

The degree of cure of the F.B.E when tested using MEK ( Methyl-Ethyl
Ketone ) double rubs according with ASTM D 5402 standard, The curing of the coating shall be
rating 2 .
6.14.2 Glass Transition Temperature method ( Tg ) The degree of cure of the F.B.E when tested
using Differential Scanning Calorimetry ( DSC ) shall be between -2 oC and +3 oC.
6.15 FLEXIBILITY TEST

The degree of flexibility of the coating shall be tested in accordance with CAN/CSA Z 245.20-M92
standard and the method defined in Appendix N.
The test ring shall be bent over a mandrel at -10 c, The coating shall satisfay the requirements when no
visible cracks is shown in the coating system when bending performed to 3 PD.
6.16 CATHODIC DISBONDING RESISTANCE TEST

The degree of coating to resistance cathodic disbondment shall be tested in accordance with ASTM G 8,
NF A 49-711 standards and the method defined in Appendix L.
The coating should show good resistance to cathodic disbondment when subjected to a potential of
1.5 V, in a 3% NaCl electrolyte solution at the following test conditions
@ 65 C - 5 C + 5
Test Duration
2 days
Max. Disbonding Radius
5 mm
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
20
of
55

NAQP- 2 PLATFORM
SUMMARY OF THE REQUIREMENTS OF THE COATING
Properties
Surface cleanliness
Surface profile
Surface salt contamination
Pipe Temperature After Blasting
Cleanliness Of Blast Cleaned Surface For Dust
Total coating thickness.
Peel-off resistance
Cut back
Impact resistance
Indentation resistance
Ultimate elongation
Tensile strength
Hardness, Shore D
Air entrampent
Degree of Cure
Flexibility
Cathodic disbondment
Hot water immersion
Requirements
min SA 2
50 -100 m
1 g/ cm2
3c above dew point
Rating 2
200 - 400 m.
250 - 350 m..
Subclause
6.1
6.1
6.1
6.1
6.1
6.4
6.4
3 mm (-0/+1mm)
6.4
@ 50 C
@ 90 C
100 N / cm
80 N / cm
max. 5 holidays / pipe @ 25 Kv
120 +20/-0 mm
10 J per mm coating thickness
@ 23 C
@ 100 C
0.1 mm
0.4 mm
400
@ Yield
@ break
2
150 Kg/cm
210 Kg/cm2
60
20%
MEK
DSC
rating 2
between -2 oC
and +3 oC
no visible cracks
@ 60 C/2 days
5 mm
@ 60 C/2 days
NO. DISBONDING
6.7
6.6
6.3
6.8
6.9
6.10
6.10
6.11
6.13
6.14
6.15
6.16
6.17
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
21
of
55

NAQP- 2 PLATFORM
7- REPAIR OF COATING
In theory, no coating defect or damage should ever be found during the coating process, but at
practical level it can not however be excluded, so .. some defects may occasionally show up in pipe
coating . Taking the above into consideration , the following repair methods are applied for in plant
damaged coated pipe .
7.1 For local defects ( scratches, cuts, dents, etc. ) of any dimension and any quantity where the
defect not reach the metal surface ( the remaining coating thickness is not less than 80%
of the specified thichness ), no repair is required .
7.2 For same defect mentioned above, where the remaining coating thickness is less than 80% of
the specified thichness, OR where the defect reach the metal surface, these defects could
be repaired using Spot Patch Method
7.2.1 Remove rust or other contaminants, if any, with a hand brush .
7.2.2 Preheat the steel surface of the damaged part .
7.2.3 Apply a piece of sealant material smaller than the size of the damage on the steel
surface .
7.2.4 Heat the sealant then extending the hot sealant with trowel and Apply a piece of sealant
material more and more to mold the damaged part with a sealant more or less thicker than
the polyethylene coating .
7.2.5 Cut a piece of the patch sheet larger by 5 cm than the damaged part, cut the corner of the
patch piece .
7.2.6 Apply the patch piece centering in the damaged part and heat from the center to each
edge.
7.2.7 Tapping from the center to the edge to drive away the trapped air and heat again and
tapping again .
7.2.8 Immediately after heating the repair patch, press all the edges by finger to get an adequate
adhesive strength .
7.3 The maximum level for repair of coating ( exclude repair due to QC tests ) is 5 repairs .
7.4 The quality of the repair shall be examined and tested for appearance and holidays. Each repair
shall be visually inspected for
- The surface of repaired coating shall be smooth, and free of folds or bubbles .
- Holiday detection shall be performed on each repair using a voltage of 25 Kv.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
22
of
55

NAQP- 2 PLATFORM
8- STRIPPING OF COATING
In the event of pipes failing to meet the requirements of sections 6 and 7, the coating of these pipes
shall be stripped and the pipes shall be recoated and re-inspected.
The coating removal shall be performed using the following methods:
8.1 ON LINE STRIPPING

8.1.1 The pipe stripping temperature will be verified by the following method:
An uncoated test pipe (of the same diameter/wall thickness as the pipe to be stripped) shall be run
through the induction coils in the pipe coating plant, and heated to 275C.
8.1.2 The coating conveyor speed and induction system settings shall be noted and recorded.
These settings shall be used for all subsequent stripping operations for a given pipe diameter
and wall thickness.
8.1.3 The pipe to be stripped is moved from the storage yard using a forklift and carefully placed on
the incoming racks. The pipe tally information shall be recorded in order to identify pipes which
pass through the stripping process.
8.1.4 The pipe is moved through the plant to the coating conveyor where it is heated by the
induction system to a temperature of 275C. The induction system and line-speed settings
shall be set to the values established on the bare pipe test, and carefully monitored. The pipe
temperature shall not exceed 275C.
8.1.5 A spiral cut will be made by hand through the PP coating using a cutting knife. The knife cuts
will be at a pitch of approx. 10 -20 cm. Care will be taken to ensure that there is no damage to
the steel.
8.1.6
The PP topcoat shall then be manually peeled off the pipe, and removed in strips.
8.1.7
The pipe will be cooled in the quench.
8.1.8
The pipe is then returned to the coating conveyer and the steps described in points 2 through
3 are repeated to heat the pipe to 275C. The pipe temperature shall not exceed 275C.
8.1.9
The residual FBE and copolymer coating materials shall then be removed by means of a
scraper. This shall be a mild steel plate with a 45 blade held axially on the pipe surface.
Care will be taken to ensure that there is no damage to the steel.
8.1.10 The pipe will be cooled in the quench.

8.1.11 The pipe shall then be moved to the shot/grit blast machine conveyor to blast the pipe and
remove any residual coating materials.
8.1.12 The pipe shall be visually checked after blasting to ensure that all coating materials are
removed, and that there is no damage to the steel from the stripping process. Any pipes with
major steel damage/defects caused by the stripping process shall be quarantined. These
pipes shall be subject to further inspection.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
23
of
55

NAQP- 2 PLATFORM
8.2 OFF- LINE STRIPPING ( manual stripping )

8.2.1 The pipe to be stripped is moved from the storage yard using a forklift and carefully placed on
the stripping rack. The pipe tally information shall be recorded in order to identify pipes which pass
through the stripping process.
8.2.2 The The interior surface of the pipe to be stripped shall be heated using Propane torch, pipe is
heated to a temperature of 250C, and carefully monitored to sure that the pipe temperature shall
not exceed 260C.
8.2.3 A spiral cut will be made by hand through the PP coating using a cutting knife. The knife cuts will
be at a pitch of approx. 10 -20 cm. Care will be taken to ensure that there is no damage to the steel.
8.2.4 The PP topcoat shall then be manually peeled off the pipe and removed in strips.
8.2.5 The residual FBE and copolymer coating materials shall then be removed by means of
manuall scraper.
8.2.6
After the pipe is cooled down, the pipe shall be moved to the shot/grit blast machine
conveyor to blast the pipe and remove any residual coating materials.
8.2.7
The pipe shall be visually checked after blasting to ensure that all coating materials are
removed, and that there is no damage to the steel from the stripping process. Any pipes with
major steel damage/defects caused by the stripping process shall be quarantined. These
pipes shall be subject to further inspection.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
24
of
55

NAQP- 2 PLATFORM
9- PIPE MARKING
- All identification data ( heat number, pipe number and pipe length ), if available, shall recorded
before surface preparation .
- After coating process pipe number, pipe length and Petrojet serial number shall be recorded on
the external surface of the pipe .
- All identification data ( heat number, pipe number, pipe length and Petrojet serial number ) shall
be recorded on the daily pipe tally sheet .
- For pipes have the same DN but differ in wall thickness, each wall thickness shall marked with
special code color .
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
25
of
55

NAQP- 2 PLATFORM
10- PIPE RECEIVING, STORAGE, HANDLING AND TRANSPORTATION

10.1 PIPE RECEIVING
10.1.1 Received pipes shall be percentally checked ( 3% ) for the following :
- Dents .
- Damaged bevels .
-Contamination on pipe that would result in additional pre-cleaning materials/man hours and
time delay prior to surface preparation .
- Pipe interior and exterior Rust grade in accordance with SIS 09 59 00 .
- Manufacturers identification marks ( heat and pipe number ) .
- Pipe diameter and wall thickness .
- Quantity of pipes .
10.1.2 Rejected pipe, or that dose not comply with the shipping documents shall be
segregated from acceptable pipes and reviewed by client Rep.
10.1.3 Pipe that comply with the shipping documents but is damaged or contaminated shall be
segregated until reviewed and approved by client Rep.
10.1.4 Approved pipe shall be coated in accordance to the approved procedure .
10.2 PIPE STORAGE ( STACKING ARRANGEMENT )

10.2.1 The pipes shall be stacked off ground on well prepared beams.
10.2.2 For safety reasons for pipes of any diameter the maximum height for stacking pipes shall not
exceeds the maximum number of layers shown in the following table, the table applies to all
types of steel pipes and wall thickness
Pipe Dia.
Permissible No. of Layers
Up to 10"
12
12" to 16"
18" to 22"
24" to 28"
30"
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
26
of
55

NAQP- 2 PLATFORM
10.3 PIPE HANDLING

10.3.1 BARE PIPE
10.3.1.1 Bare pipe shall be carefully removed from the truck using a crane and stacked on beams at
maximum hight indicated in 10.2.2.
10.3.1.2 Fork lift shall carefully remove the pipe from the storage yard and with equal care place the
pipe on the shot/grit blast machine incoming rack .
10.3.2 COATED PIPE

10.3.2.1 A properly prepared fork lift shall be used to transport the coated pipe to the storage
area provided they have padded forks. Fork lift shall not be used to load coated pipe
onto trucks.
10.3.2.2 The coated pipe may be handled using crane .The pipe can be directly loaded from the
outgoing rack onto the trucks or to the storage area .
10.4 TRANSPORTATION OF PIPES

- Only approved pipes shall be loaded onto trucks ( may directly after coating from the outgoing
rack ) or from the storage area using a crane.
- When available, wooden beams covered with padding shall be used to separate the pipes from
the truck base .
- Pipes shall not be stacked onto the truck any higher than 2.5 meters or any higher than the law
permits or is safe .
- The loaded pipes shall not exceed the maximum allowable weight for the truck or by law or is safe .
- The loaded pipes shall be tied down using Nylon straps or other means to avoid damage to the
coating during transportation .
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CP-0110-01-PP
Issue Date
SHEET
27 , 12,2011
27
of
55

NAQP- 2 PLATFORM
CLIENT : AQP
11. PRE-PRODUCTION/QUALIFICATION TESTS ( PQT )

Prior to the commencement of production, a pre-production trial shall be performed to determine the
working parameters and to verify that the final coating meet the requirements of the specification.
Five test pipes shall be prepared and coated for pre-qualification tests.
PETROJET has the right to commence the coating production befor the final evaluation of the PQT
resualts .
Test
Acceptance
value
Five pipes coated

with FBE only
Five pipes coated with

three-layer system
Surface cleanliness after blast cleaning
min SA 2
Subclause 6.1
Roughness of the blast surface
50-100 m
Subclause 6.1
Surface salt contamination
2 g/ cm2
Subclause 6.1
Cleanliness of blast surface for dust
Rating 2
Subclause 6.1
200 - 400 m.
Annex B
250 - 350 m.
Annex B
min 3 mm
(-0/+1mm)
Annex B
Subclause 6.3
Subclause 6.3
25 Kv
Annex C
Rating 2
Annex F
Peel-off test @ 23 c
75 Kg /5 cm
Annex E
Impact test
8 J per mm
Annex D
> 60
Annex O
Total coating thickness of the system

Visual Inspection
Adhesion test
Hardness, Shore D
Degree of Cure of primer, DSC
between -2 C
and +3 oC
Annex A
Degree of Cure of primer, MEK
rating 2
Annex A
150 Kg/cm2
Annex H
Annex H
400
Annex H
0.4 mm
Annex G
Tensile strength at Yield

Tensile strength at Break
Ultimate elongation
Indentation Resistance @ 100 c
210 Kg/cm
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
Test
Entrapment Assessment
Flexibility
Cathodic disbonding @ 60 c, 2 days
CP-0110-01-PP
Issue Date
SHEET
27 , 12,2011
28
of
55

NAQP- 2 PLATFORM
Acceptance
value
Five pipes coated

with FBE only
Five pipes coated with

three-layer system
20%
Annex N
no visible
cracks
Annex M
5 mm
Annex K
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
29
of
55

NAQP- 2 PLATFORM
Appendix A VERIFICATION OF PIPE SURFACE PREPARATION

A-1 General
This test method covers the procedure of verification and testes performed on pipe surface befor and
after surface preparation to check the quality of the blasted pipe.
A-2 Standard
ISO 8501-1 Pictorial Surface Preparation Standards For Painting Steel Surfaces.
( SIS 05 59 00 )
ISO 8502-1 Field Test for Soluble Iron Corrosion Products.

ISO 8502-3 Field Test for The Determination Of Dust Contamination
ISO 8502-4 Guidance on the Estimation of the Probability of Condensation Prior to Paint Application.
A-3 Apparatus
- Digital Hygrometer or equivelant.

- Digital Thermometer.
- Dail Micrometer.
- Salt Contamination Meter.
A-4 Measurment of the Ambient Conditions
The ambient condations shall be measured befor the commencment of the pipe surface blast cleaning
- Ambient temperature
- Ambient Relative humidity
- Ambient dew point
The pipe surface temperature shall be measured befor the blast cleaningon the incoming rack of the
blast station, the steel surface temperature shall be minimum 3c above the ambient dew point.
A-5 Chek of The Blast Cleaning Abrasive Material
The cleanliness of the blast abbrasive material in the blast machine shall be checked as follows:
1- Small quantity of the abrasive material shal be poured in transparent plastic container filled with
clean water, then the container is closed and shaked.
Once the abrasive material deposited at the bottom of the continer, The water within the continer
does not contain foreign particles.
2- Small quantity of the abrasive material shal be put on a clean white paper, another clean white
paper is put on the top of the blast abrasive sample and rubbes aginst them.
After wards, both pieces of paper shall be examined that thy do not contain any trace of oil, grease
contaminants.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
30
of
55

NAQP- 2 PLATFORM
A-6 Visual Inspection of Pipe Surface Befor Blast Cleaning
The visual inspection shall be carried out on the incoming rack of the blast station in order to verify
that the pipe surface is not contaminated with salt, oil, grease or any other similar contaminant.
Salt, oil, grease and other contaminants if any- shall be removed from the pipe surface by washing
the contaminated area with a solvent or washing method suitable to completely remove the
contaminant.
The pipe surface shall be checked to ensured that there is no moisture present on the pipe surface
and that there is no major steel defects.
A-7 Visual Inspection of The Blast Cleaned Surface
A-7.1 The blast cleaned surface shall be visually inspected after the blast cleaning in order to determine
the steel surface cleanliness degre. The degree of pipe surface cleanliness shall be determined
by visual comparison with photographs in SIS 05 59 00 standard, allowance must be made for
the fact that differences in color can occur due to the type of grit used, spherical grit, for example,
results in a slightly darker surface than that in the photographs in SIS 05 59 00 standard ).
The acceptance criteria: The minimum surface cleanliness grade shall be SA 2 Very thorough
blast cleaning in accordance with ISO 8501-1 (SIS 05 59 00) standard.
A-7.2 The blasted pipes shall be inspected for all surface imperfections ( silvers, scabs, dents, ..etc )
which shall be marked .
- All marked defects shall be brought to the attention of client representative to approve the
action shall be taken by Petrojet or to provide the corrective action .
- Only light cosmetic i.e superficial grinding may be performed. This shall be limited to approx.
0.1-0.2 mm in depth, in general the grinding shall not reduce the pipe wall thickness below the
client requirements or API 5L standard ( all grinding exceeding the light cosmetic defination
shall be followed by a measurment and recording of the wall thickness at the ground area).
- For repaired area more than 100 cm2 the pipe shall be re-blasted and re-inspected .
A-8 Surface Profile Measurment After Blast Cleaning
The pipe Surface profile ( peak-to-valley ) of the blasted surface shall be measured after the blast
cleaning using testex tape ( or equivalent ) in accordance with the following procedure :
- Zero the dial micrometer ensuring the flat contact points are clean .
- Remove paper backing from Testex tape and stick Testex tape to the surface to be measured.
- Rub the Testex tape paste into the troughs using a blunt instrument, until the peaks can be seen
butting up to the transparent plastic .
- Remove the Testex tape from the surface and measure the overall thickness with the dial
micrometer .
- Deduct 50 m for the plastic from the reading to obtain the amplitude ( surface profile ) .
The acceptance criteria: 50 m - 100 m.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
31
of
55

NAQP- 2 PLATFORM
A-9 Salt Contamination Level After Blast Cleaning
The salt contamination level of the blast cleaned surface shall be measured after the blast cleaning using
the Bresl method .
The salt contamination level shall be checked at the cut back area on one pipe end.
The acceptance criteria shall be 1 g/ cm2.
A-10 Dust Contamination Level After Blast Cleaning
The dust contamination level of the blast cleaned surface shall be checked after the blast cleaning at the
cut back area on one pipe end using the transparent adhesive tape in accordance with ISO 8502-3
standard.
The acceptance criteria shall be Rating 2.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
Appendix B
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
32
of
55

NAQP- 2 PLATFORM
TEST FOR ASSESSING THE DEGREE OF CURE OF THE FUSION

BONDED EPOXY POWDER COATING
B-1 General
This test method covers the procedure of determination of the degree of cure of the FBE epoxy film, the
test shall be performed on a test specimen taken from the coated pipe or carried out on the coated pipe .
B-2 METHOD I ( Measurment of glass transitions temperature ( Tg ) )

B-2.1 Standard
CAN/CSA Z 245.20-M92: External Fusion Bond Epoxy Coating For Steel Pipe.
NACE RP 0394: Standard Recommended Practice - Application,Performance, and Quality Control of
Plant-Applied, Fusion Bonded Epoxy External Pipe Coating.
B-2.2 Apparatus
The apparatus used for this test is a differential scanning calorimeter with sufficient calorimetric
sensitivity to determine the glass transition temperature of the epoxy products .
Moreover the following accessories are necessary :
- laboratory scale, accurate to the nearest 0.1 mg.
- sharp tool.
- Sample crucible.
B-2.3 Sampling
Immediately after application , a sample of the epoxy film shall be taken from the coated pipe without
adhesive by using a sharp tool to provide flakes of the coating care shall be taken to remove the sample
from the whole thickness of the film while , at the same time , the inclusion of steel fragments shall be
avoided. the sample may be taken at be broken into small pieces .
Accurately weight sample between 10 mg and 15 mg, sample of wieght not exceeding 25 mg , can be
used if necessary for obtaining the required sensitivity.
B-2.4
procedure
The test procedure and the setting up of the instruments may differ according to the equipment used
.however , the main characteristics of the test method shall be satisfied in order to obtain valid and
comparable results.
1- An empty aluminum pan shall be used as a reference .
2- Weight the sample, put on lid and seal in sample press.
3- Place the sample crucible in the DSC cell together with an empty reference crucible.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
33
of
55

NAQP- 2 PLATFORM
4- Start the temperature program.

- The method consists of raising the temperature of a sample of epoxy coating (layer 1) at constant
rate in a differential thermal calorimeter .
- The samples shall be pre-treated to remove moisture and to provide a uniform thermal state.
- The first plot records the thermal changes in the sample between room temperature and point
located beyond complete polymerization.
- Then the sample shall be cooled down to room temperature
- .A second identical heating cycle identical to the first cycle shall then be carried out .
B-2.5 RESULTS :
The glass transition temperature is defined as being the temperature ( or range of temperatures ) at
which the polymer passes from a hard and often brittle state ( glass ) to a rubbery type .
The transition of the polymer product is visible in the form of a jump in the baseline giving a marked
variation in the steps of the specific heat at Tg . this step usually represents several degrees.
By convention , temperature shall be taken as the point of inflection of the curve .
The curing of the coating is acceptable when variation of the glass transition temperature Tg ( Tg2
Tg1 ) between -2 oC and +3 oC.
B-3 METHOD II ( Determination of FBE curing using MEK )

B-3.1 Standard
ASTM D 4752:
ASTM D 5402:
Standard Test Method For Measuring MEK Resistance of Ethyl Silicate ( Inorganic) Zinc-Rich Primers by Solvent Rub .
Standard Test Method For Assessing the Resistance of Organic Coatings Using
Solvent Rubs .
B-3.2 Apparatus
- MEK Methyl-Ethyl Ketone.

- Cotton Cloth
B-3.3
procedure
1-Place the forefinger in a cotton closth in such a manner that the forefinger is covered by the cloth.
2-Saturate the cloth with MEK and rub the coating with the forefinger using back and forth motion, the
length of the stroke is to be appoximately 2 inches.
3-Sufficient pressure is to be exerted by the finger to ensure good contact to the film.
4-Rub 30 double rubs ( 30 rubs in each direction ), if the cloth become dry during the test, re-saturate
with MEK .
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
34
of
55

NAQP- 2 PLATFORM
B-3.4 RESULTS :
The degree of cure of the FBE coating tested using MEK double rubs shall be rating 2 after 30
double rubs .
Rating
Criteria
No change of gloss, No softening ( no scratch by finger nail )
Slight loss of gloss, No softening ( no scratch by finger nail )
Slight loss of gloss, Slight softening ( can be scratched by finger nail )
Strong reduction in gloss, Complet softening ( easily scratched by finger nail )
Strong reduction in gloss, Complet softening ( coating partiallly removed )
Removal of coating
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
Appendix C
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
35
of
55

NAQP- 2 PLATFORM
INSPECTION OF THE COATING THICKNESS
C- 1 General
This test method covers the procedure of determination of the dry film thickness ( DFT ) of applied
coatings on magnetic steel substrates .
C- 2 Apparatus
1- Electronic thickness gauge.
2- Standardized calibration foils.
C- 3 Procedure
1- Before thickness measurements are carried out the instrument shall be adjusted and verified using a
calibrated shim of the same thickness range as the coating as follows:
- The coating thickness meter shall be calibrated on a clean steel plate and the display value must
be 0.00 mm.
- In case any other value is displayed, the instrument shall be calibrated manually until 0.00 mm
value is obtained.
- Choose a calibration plate of a thickness close to the thickness you expect to fined.
- At least measurements shall be taken and each displayed value is within the range specified by the
insturement's manufacturer.
- If the displayed value is within the range is not specified the following acceptance criteria shall be
apply: Displayed value = Nominal value of the calibration plate 5%.
2- A series of 12 individual measurements shall be carried out on each pipe to be inspected, the measurements shall be regularly distributed along 3 transverse sections of the tested pipe .
3- At each section the thickness shall be measured at 4 positions, equally spaced around the
circumference of the pipe and at a distance of at least 200 mm from the end of the coating . .
4- When a weld seam is visible, one measurement per section shall be executed on the top of the weld
seam .
C- 4 Results
A calculation of the arithmetic mean of the series of 12 individual measurments shall be made and shall
be the specified thickness .
NOTE : In case of dispute of results , recalibration of the instrument should be undertaken and five
measurements at this pipe should be carried out again . The arithmetic mean of the result of the five
measurements should be calculated.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
Appendix D
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
36
of
55

NAQP- 2 PLATFORM
HOLIDAY DETECTION TEST
D-1 General
This test method covers the procedure of determination of the degree of porosity present in the coating
using a scanning electrode energized by a high arc voltage.
The Porosity shall be detected by a spark occurring between the steel of the pipe and the elec trode of
the detector .
D-2 Standard :
DIN 30 678:
NF A 49-711:
Polypropylene Coatings For Steel Pipes and Fittings, Requirements and Testing.
Extrusion
D-3 Apparatus
-
Holiday detector 0 30 Kv.

Coating thickness gauge.
Scanning electrode in the form of a metal brush, or conductive rubber conforming to the shape of
the pipes.
Conductors which are used to connect the pipe to the holiday detector.
D-4 Procedure :
1- Calibrate the holiday detector as following :
A series of 5 holes of around 1 mm diameter shall be made in the coating, down to the pipe metal,
with a needle; these holes shall be spaced by about 10 cm .
The detector is switched on, the voltage shall be set at 10 Kv per millimeter of nominal thickness
of coating and not exceeding 25 Kv and the electrode is set to pass the test holes .
A spark discharge must be correspondence with every hole .
2- Adjust the test voltage to 25 Kv .
3- The conductive scanning electrode ( brush or ring ) shall be maintained in good contact to the tested
pipe.
4- The coating system shall be holiday detected 100 % ..
5- The maximim number of holidays is 5 per pipe .
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
37
of
55

NAQP- 2 PLATFORM
Appendix E IMPACT RESISTANCE TEST

E-1 General :
This test method covers the procedure of determination of the strength of the coating by the impact of a
punch of defined shape falling directly onto the coating from a fixed height at a fixed temperature.
E-2 Standard :
DIN 30 678:
NF A 49-711:
Extrusion
E-3 Apparatus :
- Heavy duty impact tester 25 mm spherical end.
- Holiday detector 0 30 Kv.
- Coating thickness gauge.
E-4 Procedure :
1- The impact resistance of the coating shall be tested at temperature 25 5 C.
2- A minimum of 30 points shall be selected on the surface of the test pipe/ring, the distance between
each two impact points shall be at least 30 mm .
3- Drop the impact wieght with hemispherical steel head with diameter of 25 mm from pproximately 1
meter height.
4- the weight required to produce the specified energy to the coating is calculated using the following
formula : H = J / 9.81 * W
Where
H = impact height, m.
W = impact mass, Kg.
J = Impact energy, joules.
E-5 Results :
1-This described body shall produce an impact energy, E, equal to ( 8 x ) J per mm of cating
thickness
2- The impacted coating shall not crack or disbond at the point of impact and shall inspected for failure
using holiday detector set at 25 Kv ( see Appendix C ) .
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
38
of
55

NAQP- 2 PLATFORM
Appendix F - PEEL -OFF RESISTANCE TEST

F-1 General
This test method covers the procedure of determination of the adhesion of applied 3LPP coatings on
steel substrates using peel off machine mathod.
F-2 Standard :
DIN 30 678:
NF A 49-711:
Extrusion
F-3 Apparatus :
-
Utility knife ( sharp cutter )

Weights
F-4 Procedure :
1- The test shall be performed at temperatures of 23 C - 2 C + 10 C and 100 C - 2 C + 10 C.
2- For test at elevated temperature >23 C, the back side of the steel shall be heated to the test
temperature which shall be measured at the root the peeled strip by means of optical pyrometer .
3- A strip of coating of minimum length of 160 mm shall be cut in circumferential direction and 50 mm
wide perpendicular to the axis of the pipe shall be isolated from the coated pipe.
4. Manually peel off the coating strip at an angle of 45 to the pipe surface .
5. The test weight ( see sub-clause 5.7 ) shall be suspended to the coating strip, the time ( in minuts )
required to peel off the coating with a pulling rate of 10mm/min. shall be 0.4D +20%/-10% ( where
D = pipe diameter mm ).
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
39
of
55

NAQP- 2 PLATFORM
6-Any pipe that exhibits a peel off value below the required value, the pipe shall receive 2 additional
peel tests to verify the accuracy of the first test .
6.1 If the 2 additional peel tests meet the required value, the pipe is accepted .
6.2 If the 1 out of the 2 additional peel tests is below the required value, the pipe is rejected then 5
previously coated pipes and 5 new coated pipes shall be tested, if below the required value is
detected, the production line shall stopped until the defect is determined .
7. The adhesion test shall be caried out at the cut back area at both ends per test.
F-5 Results :
The adhesion of the coating shall be determined by measuring the peel-off resistance and shall be
calculated as following:
( 9.81 x M x 10 ) / W
( N/10mm )
where: M is the mass of the suspended weight in Kg.
W is the width of the coating strip in mm
The minimum force required to lift the coating shall be as indicated in the table below
Force @ 50 C 5 C
100 N / cm
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
40
of
55

NAQP- 2 PLATFORM
Appendix G- DETERMINATION OF ADHESION OF COATINGS

G.1 General :
This test method covers a procedure for determining the adhesion of applied paints or FBE coatings on
steel substrates.
G.2 Standard :
CAN/CSA Z 245.20-M92: External Fusion Bond Epoxy Coating For Steel Pipe.
ASTM D 3359 : Standard Test Method For Measuring adhesion by Tape Test .
G.3 Apparatus :
- Utility knife ( sharp cutter )
- Adhesive tape.
G.4 METHOD I ( x-cut test method )

G.4.1 Procedure :
1- Two 20 mm ( approximately ) long incision shall be made though the FBE to the substrate.
2- Form an ( X cuts) with an angle of approximately 30 at the intersection point .
3- The point of the knife shall be inserted horizontally ( i.e. the flat of the blade ) under the coating at
the point to intersection of the cuts that the blade point is on the metal surface.
4- Using a levering action to attempt to pries the coating off
G.4.2 Results :
The adhesion of the coating shall satisfay the requirements of rating 1 or 2 When starting at the 30 Vee
intersection, the blade shall be used to attempt to peel the coating from the steel .
Rating
Criteria
No removal of coating other than that caused by insertion of the flat point of
the knife blade at the intersection point ( nominally less than 1 mm ).
No removal of coating more than 2 mm .
Removal of coating more than 5 mm .
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
41
of
55

NAQP- 2 PLATFORM
G.5 METHOD II ( cross-hatch cuts test method )

G.5.1 Procedure :
1- A series of 6 lines ( cut the coating through the metal ) evenly spaced over 1, then 6 similar cuts at
90 through the previously made cuts to produce a cross-hatch cuts .
2- Apply 1 wide tape to the cross-hatch cuts and firmly press with ones thumb nail so as to attain
uniform contact .
3 - Remove the tape with a snap action .
G.5.2 Results :
The adhesion of the coating shall satisfy the requirements of rating 1 or 2 according the following
rating classification.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
42
of
55

NAQP- 2 PLATFORM
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
43
of
55

NAQP- 2 PLATFORM
Appendix H INDENTATION RESISTANCE TEST

H-1 General
This test procedure covers the determination of the indnetation ( penetration ) resistance of
Polypropylene material
H-2 Test Standard

DIN 30 678:
NF A 49-711:
Extrusion
H-3 Apparatus :
The apparatus shall consist of :
1- Chamber or a bath thermostatically to ( up to 120 C )
2- Penetrometer comprising:
- Cylindrical punch of diameter 1.8 mm, on the top of which is mounted a weight . the assembly ,
punch plus weight , shall produce a force of 25 N ;
- Dial gauge or any other measurement system accurate to 10 - 2 mm .
H-4 Procedure
1- A sample of PP of thickness 4 mm shall be taken from a pipe where neither the primer nor the
adhesive have been applied .
2- The sample shall be subjected to an indentor with flat face and 1.8 mm diameter , The total mass
of the indentor assembly shall be 25 N .
3- The indentor shall be slowly and carefully lowered on the test sample , the Zero ( T0 ) reading set
at penetometer within 5 sec. then after 24 h, the final reading ( T ) of the penetometer is recorded
The indentation depth is given by the following equation :Indentation ( mm ) = T - T0
H-5 Results :
Indentation resistance of the PP material shall be as following
@ 23 C - 2 C + 10 C
0.1 mm
@ 100 C - 2 C + 10 C
0.4 mm
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
Appendix I-
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
44
of
55

NAQP- 2 PLATFORM
TENSILE AND ELONGATION TEST
I-1 General
This test procedure covers the determination of the tensile strength at yield, tensile strength at break
and ultimate elongation of Polypropylene material.
I-2 Test Standard

DIN 30 678:
NF A 49-711:
ASTM D 638:
Extrusion
Standard Test Method For Tensile Test Of Plastics .
I-3 Apparatus :
-
Tensile testing machine The apparatus shall consist of a tensile testing machine which makes it
Micrometer
possible to record the force and which can operate constant speed .
I-4 Sampling
The test sample shall be free from FBE, adhesive and taken from a pipe in the extruded direction .
The sample shall be of type IV in ASTM D 638.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
45
of
55

NAQP- 2 PLATFORM
I-5 Test Procedure

1- A sample of PP of thickness 3mm shall be taken from a pipe where neither the primer nor the
adhesive have been applied .
2 - Determine the cross-section of the test sample ( cm2 ) .
3- The sample shall be hold between the tensile grips .
4- The grips shall be moved away at constant speed = 50 mm / min.
5- Record the tensile force at the yield point, tensile force at the break point and the extension at
break point .
I-6 Results :
The tensile strength and ultimate elongation ( elongation at break ) of the PP material shall be as
following :
Tensile Strength
( Yield )
Tensile Strength
( Break)
Ultimat
Elongation
150 Kg/cm2
170 Kg/cm2
400 %
-Calculation and expression of results
Tensile strength at yield ( kg / cm2 ) = F0 /A

Tensile strength at break ( kg / cm2 ) = F/A
Elongation at break ( % ) = L / L . 100
where
F0
F
A
L
L
= is the tensile force at yield point ( kgf ) .

= is the tensile force at break point ( kgf ) .
= is the cross-section of the test sample ( cm2 ) .
= is the initial gauge length of the test sample ( mm )
= is the increase in the sample length between gauge marks ( mm ) .
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
46
of
55

NAQP- 2 PLATFORM
Appendix J - STABILITY AGAINST ULTRAVIOLET RAYS AGING TEST

J-1 General
This test method covers the procedure of determination of The stability of Polypropylene when a test
sample subject to the continuous irradiation of a xenon lamp under given temperature and humidity
condition.
The change in the Polypropylene shall be assessed by the variation in melt flow rate .
J-2 Test Standard

DIN 30 678:
NF A 49-711:
Extrusion
J- 3 Apparatus
The apparatus shall consist of an irradiation chamber equipped with a xenon lamp ( see ISO 4892 2 ).
J-4 Sampling
The test shall be carried out on a sample of Polypropylene sheet taken from a pipe in the extruded
direction. The sample is free from adhesive and primer .
J-5 Procedure
1- The melt flow rate of the test sample shall be measured in accordance with ASTM D 1238 before the
sample stored at the heating oven ( zero value ) .
2-The test sample shall be stored in Solar box ( Xenon test ) for 800 hrs continuous exposure under
the following condidtions:
- Artificial weathering by Xenon Lamp of Power:400 W
- Toal radiant energy 5 GJ / m2
- Relative humidity ( 65 + 5 ) % ;
- Spray cycle : ( 18 + 0.5 min ) spray, ( 102 + 0.5 min ) dry.
3- At intervals of 200 hrs the melt flow rate measurement shall be undertaken on the piece in accordance
with ASTM D 1238, the arithmetic mean of MFR, shall be calculated.
J-6 Results :
The variation of the melt flow rate ( MFR ) after 800 hrs. must remain within 25% from the original
MFR and shall be expressed as a percentage using the following equation :
MFR = ( MFR1 - MFRo ) / MFRo X 100
Where :
MFR is the variation in MFR of PP material after exposure expressed in percent ( % ) .
MFRo is the initial melt flow rate measured before exposure .
MFR1 is the melt flow rate measured after exposure.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
47
of
55

NAQP- 2 PLATFORM
Appendix K - STABILITY AGAINST THERMAL AGING TEST

K-1 General
This test method covers the procedure of determination of The stability of Polypropylene when a test
sample subject to the effect of dry heat from a thermostatically controlled oven.
The change in the Polypropylene shall be assessed by the variation in its melt flow rate.
K-2 Test Standard

DIN 30 678:
NF A 49-711:
Extrusion
K-3 Apparatus
The apparatus shall consist of a thermostatically controlled oven with air circulation which can maintain
a temperature within 3 C .
K-4 Sampling
The test shall be carried out on a sample of Polypropylene free of adhesive and taken from a pipe.
K-5 Procedure
1- The melt flow rate of the test sample shall be measured in accordance with ASTM D 1238 before the
sample stored at the heating oven ( zero value ) .
2-The test shall be stored at heating oven, the temperature is maintened at (150 3 ) C for exposure
time of 2000 hrs .
3- At intervals of 400 hrs the melt flow rate measurement shall be undertaken on the piece in accordance
with ASTM D 1238, the arithmetic mean of MFR, shall be calculated.
K-6 Results
The variation of the melt flow rate ( MFR ) after 2000 hrs must remain within 50% from the original
MFR and shall be expressed as a percentage using the following equation :
MFR = ( MFR1 - MFRo ) / MFRo X 100
Where :
MFR is the variation in MFR of PP material after exposure expressed in percent ( % ) .
MFRo is the initial melt flow rate measured before exposure .
MFR1 is the melt flow rate measured after exposure.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
48
of
55

NAQP- 2 PLATFORM
Appendix L CATHODIC DISBONDMENT TEST
This test method covers the procedure of determination of the resistance of coating to disbondment of
when steel pipe is subjected to negative polarization.
L-2 Standard
NF A 49-711:

Extrusion
ASTM G 8:
Standard Test Method For Cathodic Disbonding Of Pipe Lines Coatings.
ASTM G 42:
Standard Test Method For Cathodic Disbonding Of Pipe Lines Coatings at elevated
temperature.
L-3 Apparatus
- Stabilized DC power supply .
- Digital voltmeter /Digital Ammeter.
- Variable resistor.
- Reference electrode ( saturated CuCuso4 or AgAgCl ).
- Platinum anode.
- Heating Equipment
- Sharp knife
L-4 Electrolyte
K.4-1 The electrolyte shall consist of a solution of 3% NaCI concentration in potable water
k-4-2 The PH of the electrolyte shall be maintained during the test period in the range of 6 to 8.5 ( at
ambient temperature).
L-5 Test Temperature

K.5.1 For test at elevated temperature 100 C - 2 C + 10 C where the cell is constructed on the pipe
sample, the test sample shall be placed in a thermostatically sand or grit bath.
The bath temperature shall be adjusted and controled to maintain the required test temperature on
steel surface.
L-6 Procedure :
1. Three holes of 6 mm diameter shall be drilled through the coating to the metal surface .
2. A rigid plastic container of 100 mm diameter from which the bottom is cut-out, the container is fixed
to the coated sample using a silicon rubber adhesive.
3. The container filled with electrolyte, the electrolyte shall be maintained during test period at the PH
as described in ( K-4-2 ) and the test temperature as per ( K-5 ).
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
49
of
55

NAQP- 2 PLATFORM
4. A voltmeter is connected with the reference electrode , the variable resistor is adjusted until the
voltmeter reads ( 1.5V ) with respect to the calomel electrode.
5. At intervals of 24 hr the voltmeter reading is recorded and the variable resistor is adjusted to correct
any drift from the ( 1.5V ) setting .
6. After Test period the container shall removed and the sample is dried, the degree of disbonding is
evaluated as following
6.1 A series of 2 radial cuts are made through the coating in the longitudinal direction of the pipe and
2 similar cuts shall be made in the circumferential direction.
6.2 Each pair of cuts being 5 mm apart and approx. following the tangent of the test defect, the length
of the cuts shall be aprox. 20 mm each side of the defect.
6.3 Using a sharp knife, the strips of coating between the cuts shall be peeled from the pipe surface
as far as possible starting at the test defect .
6.4 The distance over which the coating is detached and the metal is exposed is measured from the
edge of the original test defect.
6.5 record the measurments for all directions, The result of the cathodic disbondment test is defined
as the arithmetic mean value of at single values for the radial lengths in millimeters.
L-7 Results :
The coating should show the a maximum disbondment as following
Test Duration
Max. Disbonding Radius
@ 65 C - 2 C + 10 C
2 days
5 mm
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
50
of
55

NAQP- 2 PLATFORM
Appendix M DETERMINATION OF HOT-WATER IMMERSION RESISTANCE

M.1 General:
This test method covers the procedure for determination of the resistance of coating to loss of adhesion
due to water absorption when subject to hot water immersion .
M.2 Standard :
GBE/CW6 : part 1 : Technical Specification For The External Protection Of Steel Line Pipe and Fittings
Using Fusion Bonded Powder and Associated Coating Systems ( Part 1 :
Requirements For Coat materials and Methods Of Test .
M.3 Apparatus :
-
Heating element, or water bath

Sharp knife
M.4 Procedure :
1. Three holes having diameter 5 mm are drilled through the coating material to the metal surface .
1. A rigid plastic container of 100 mm diameter from which the bottom is cut-out, the container is fixed
to the coated sample using a silicon rubber adhesive .
2. The container shall be filled with potable water .
3. Heat the test sample to 100 C - 2 C + 10 C in a thermostatically sand or grit bath The bath
temperature shall be adjusted and controled to maintain the required test temperature on steel
surface.
4. After Test period ( 2 days ) the container shall removed and the sample is dried, the degree of
disbonding is evaluated as following
4.1 A series of 8 radial cuts are made through the coating at the area subjected to cathodic
disbonding.
4.2 Using a sharp knife, the strips of coating between the cuts shall be peeled from the pipe surface
as far as possible starting at the test defect .
4.3 The distance over which the coating is detached and the metal is exposed is measured from the
edge of the original test defect.
4.4 record the measurments for all directions, The result of the disbondment test is defined as the
arithmetic mean value of at single values for the radial lengths in millimeters.
M.5 Results :
The coating shall not show disbonding greater than 2 mm or blistering ( a slight discoloration of the
coating is acceptable ).
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
51
of
55

NAQP- 2 PLATFORM
Appendix N DETERMINATION OF FLEXIBILITY OF COATINGS

N.1 General:
This test procedure covers the determination of the flexibility characteristics of applied 3 L PP coating .
N.2 Standard
NF A 49-711:

Extrusion
CAN/CSA Z 245.20-M92:
External Fusion Bond Epoxy Coating For Steel Pipe.
N.3 Apparatus :
-
Hydrolic press.
Freezer
Bending manderal
N.4 Procedure :
1- Smooth the coating on the edge of the sample to remove any potential stress riser .
2- Determine the sample thickness ( t )
3- Place the test specimen in the freezer , cool it to 0 O c or 10 3 Oc and for minimum 1 h .
4- Determine the the manderal radius that corresponds to the angle of deflection of 3O per pipe
diameter length by using the following formula
R = 19.6 t
where :
R = requried manderal radius mm
t = sample thickness
5- Bend the specimen over the raduis determine in the above step. The bending rate shall be such
that the specimen is bent within 10 s and the dent shall be completed within 30 s of removal of
specimen from the freezer
6- Warm the bent specimen to 20 5 Oc and hold this temperature for a minimum of 2 hour before
visual inspection.
N.5 Results :
The coating shall accepted when no visible cracks is shown when bending performed to 3 PD .
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
52
of
55

NAQP- 2 PLATFORM
Appendix O DETERMINATION AIR ENTRAPMENT IN COATINGS

O-1 General :
This test method covers the procedure for determining the amount of cross section and interface air
entrapment ( foaming /porosity ) in applied 3LPP coatings on steel substrates.
O-2 Apparatus :
- Knife ( sharp cutter ).
O-3 Procedure :
1- A strip of coating from the adhesion test shall be used to determine the level of air entrapmet on the
body of the pipe or in the saw weld. .
2- The strip shall be visually inspected.
3- Evaluate the edge of the sample and rate the cross section and interface porosity using the scale
provided.
O-4 Results :
The coating should show No visually detectable air-entrapment and air voids shall be accepted.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
53
of

NAQP- 2 PLATFORM
Appendix P DETERMINATION OF HARDNESS OF COATINGS

P.1 General :
This test procedure covers the determination of the Durometer Hardness of Polypropylene material.
P.2 Standard
ASTM D 2240: Standard Test Method For Rubber Property- Durometer Hardness .
P.3 Apparatus :
-
55
SHORE D hardness meter
P.4 Procedure:
- Sample of PP of thickness 3 mm shall be taken from a pipe free from FBE, adhesive.
- Place the sample on the steel plates of the tester
- The sample shall be subjected to a durometer dial to which total mass of 5 kg is attached.
- The durometer shall be placed without shock on the sample making a firm contact with it.
- The hardness SHORE D shall be read off 3 second after the presser foot of the duometer has made
complete contact with the sample
P.5 Results :
The hardness shore D of the PP material shall be 60 shore D
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
54
of
55

NAQP- 2 PLATFORM
Appendix Q DETERMINATION OF MELT FLOW RATE

Q.1 General :
This test procedure covers the determination of the rate of extrusion of molten resins through a die of a
specified length and diameter under constant conditions of temperature , load , and piston position in
the barrel as the timed measurement is being made
Q.2 Standard
ASTM D 1238: Standard Test Method For Flow Rates Of Thermoplastic By Extrusion Plastomer
Q.3 Apparatus :
-
Extrusion Plastomer
Stop watch
Electronic balance
Q.4 Specimen
The test specimen may be in any form that can be introduced into the bore of cylinder for example
powder, granules, and strips of film
Q.5 Procedure
12345-
Heat the plastometer to 230 c for 15 minutes.

Insert the test sample ( PP or Adhesive ) in the heating barrel.
Fit the piston on the sample and fit to the piston a weight 2.16 Kg ( or as recommended in M.D.S ).
Each 10 minutes cut the sample extruded from bore ( minimum 5 cuts ).
Weight each sample and recorded it.
DOCUMENT
DESCRIPTION
COATING PROCEDURE
DOCUMENT No.
REV.
1
CLIENT : AQP
CP-0110-01-PP
Issue Date
27 , 12,2011
SHEET
55
of
55

NAQP- 2 PLATFORM
Q.6 Results :
The melt flow rate ( MFR ), expressed in grams per 10 minutes and is given by the following equation :MFR ( , mnom ) = tref . m / t
Where :
= is the test temperature, C .

mnom = is the nominal load, Kg .
tref = is the reference time ( 10 minutes ), 600 sec.
m
= is the average mass of the cut-offs, gr. .
t
= is the cut-off time interval, sec.
- New MFR = shall be within 15 % of the material certificate of analysis or material data sheet .
- Extruded MFR = shall be within 20 % of the New MFR .

Coating Procedure PP

Uploaded by

Copyright:

Available Formats

Coating Procedure PP

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Coating Procedure PP

Uploaded by

Copyright:

Available Formats

What is the purpose of this document?

What is the purpose of this document?

What testing procedures are outlined in the appendices?

What testing procedures are outlined in the appendices?

DOCUMENT

PROJECT: NEW 16" SEALINE JOINIG

Issued for approval

Issued for Client Comment

THIS DOCUMENT IS CONFIDENTIAL AND THE SOLE PROPERTY OF PETROJET

PROJECT: NEW 16" SEALINE JOINIG

DEFINITIONS AND ABBREVIATIONS

REFERENCE STANDARDS AND CODES

COATING MATERIALS PROPERTIES/VENDORS

PRODUCTION TESTING AND INSPECTION

REQUIREMENTS OF THE APPLIED COATING

6.1 Pipe Surface Preparation

Inspection and Tests

THIS DOCUMENT IS CONFIDENTIAL AND THE SOLE PROPERTY OF PETROJET

PROJECT: NEW 16" SEALINE JOINIG

PIPE RECEIVING, STORAGE, HANDLING AND TRANSPORTATION

10.1 PIPE RECEIVING

PRE-PRODUCTION /QUALIFICATION TESTS

VERIFICATION OF PIPE SURFACE PREPARATION

TEST FOR ASSESSING THE DEGREE OF CURE OF THE FUSION BONDED

HOLIDAY DETECTION TEST

IMPACT RESISTANCE TEST

PEEL -OFF RESISTANCE TEST

DETERMINATION OF ADHESION OF COATINGS

INDENTATION RESISTANCE TEST

TENSILE AND ELONGATION TEST

STABILITY AGAINST ULTRAVIOLET RAYS AGING TEST

STABILITY AGAINST THERMAL AGING TEST

CATHODIC DISBONDMENT TEST

DETERMINATION OF HOT-WATER IMMERSION RESISTANCE

DETERMINATION OF FLEXIBILITY OF COATINGS

DETERMINATION AIR ENTRAPMENT IN COATINGS

DETERMINATION OF HARDNESS OF COATINGS

DETERMINATION OF MELT FLOW RATE OF POLYMERS

THIS DOCUMENT IS CONFIDENTIAL AND THE SOLE PROPERTY OF PETROJET

PROJECT: NEW 16" SEALINE JOINIG

THIS DOCUMENT IS CONFIDENTIAL AND THE SOLE PROPERTY OF PETROJET

PROJECT: NEW 16" SEALINE JOINIG

DEFINITIONS AND ABBREVIATIONS

Epoxy primer The first coating layer ( the anti-corrosion layer )

which applied directly onto the

Outer layer The polypropylene ( PP ) layer .

the same type of material .

Production run and shall not more than 24 hrs.

Production run and shall not more than 12 hrs.

Test sample from a coated pipe.

Batch No. Quantity of PP material not more than 50 tons.

THIS DOCUMENT IS CONFIDENTIAL AND THE SOLE PROPERTY OF PETROJET

PROJECT: NEW 16" SEALINE JOINIG

Pipe nominal diameter

THIS DOCUMENT IS CONFIDENTIAL AND THE SOLE PROPERTY OF PETROJET

PROJECT: NEW 16" SEALINE JOINIG

3- REFERENCE INTERNATIONAL CODES AND STANDARDS .

European Committee for Standardization

LAsaociation Francaise de Normalisation