Xsy Bafm K Fyfevsm: Gail (India) Limited

SPECIFICATION FOR 3-LAYER DOCUMENT No.
POLYETHYLENE COATING OF 0318-000-16-71-SP-03 Rev. 0

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GAIL (India) LIMITED
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DABHOL PANVEL PIPELINE PROJECT
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SPECIFICATION FOR
3-LAYER POLYETHYLENE COATING OF LINEPIPES
0 03.03.06 ISSUED AS JOB SPECIFICATION

NR RKG DD
Rev. Prepared Checked Approved
Date Purpose
No by by by
Format No. EIL 1641-1924 Rev. 1 PDPL 3LPE SPEC Copyright EIL – All rights reserved
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CONTENTS
1.0 SCOPE
2.0 REFERENCE DOCUMENTS
3.0 PLANT SCALE AND INSTALLATION
4.0 MATERIALS
5.0 FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING
6.0 MEASUREMENT AND LOGGING
7.0 COATING PROCEDURE AND QUALIFICATION
8.0 PIPE SURFACE PREPARATION
9.0 COATING APPLICATION
10.0 INSPECTION AND TESTING
11.0 HANDLING, TRANSPORTATION AND STORAGE
12.0 REPAIR OF COATING
13.0 MARKING
14.0 QUALITY ASSURANCE
ANNEXURE-I COMBINATIONS OF COATING MATERIALS
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1.0 SCOPE
This specification covers the minimum requirements for supply/arrangement of
all materials, plant, equipment, plant sites, consumables, utilities and
application including all labour, supervision, inspection and tests etc. for
application of external anti-corrosion coating of pipes by using 3 Layer Side
Extruded Polyethylene coating conforming to DIN-30670, 1991, `Polyethylene
Coating for Steel Pipes and Fittings' and the requirements of this specification.
2.0 REFERENCE DOCUMENTS
Reference has also been made to the latest edition of the following standards,
codes and specifications. The edition enforce at the time of floating the
enquiry shall be termed as latest edition.
a. ASTM D-149 : Standard Test Methods of Dielectric
Breakdown Voltage and Dielectric Strength of
Solid Electrical Insulating Materials at
Commercial Frequencies.
b. ASTM D-257 : Standard Test Methods for D-C Resistance or
Conductance of Insulating Materials.
c. ASTM D-543 : Standard Method of Test for Resistance of
Plastics to Chemical Reagents.
d. ASTM D-570 : Standard Method of Test for Water
Absorption of Plastics.
e. ASTM D-638 : Standard Method of Test for Tensile
Properties of Plastics.
f. ASTM D-792 : Standard Test Method for Density and
Specific Gravity (Relative Density) of Plastics
by Displacement.
g. ASTM D-1238 : Test Method for Flow Rates of
Thermoplastics by Extrusion
h. ASTM D-1525 : Test Method for Vicat Softening Temperature
of Plastics
i. ASTM D-1603 : Test Method for Carbon Black in Olefin
Plastics
j. ASTM D-1693 : Test Method for Environmental Stress
Cracking of Ethylene Plastics
k. ASTM D-2240 : Test Method for Rubber Property –
Durometer Hardness
l. ASTM D-3895 : Test Method for Oxidative-Induction Time of
Polyolefins
by Differential Scanning Calorimetry
m. ASTM G-42 : Tentative Methods for Cathodic Disbonding of
Pipeline coatings Subjected to Elevated or
Cyclic Temperatures.
n. API RP 5L1 : Recommended Practice for Railroad
Transportation of Linepipe.
o. API RP 5LW : Transportation of Line Pipe on Barges and
Marine Vessels
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p. DIN EN 10204 : Metallic Products – Types of Inspection

Documents
q. DIN 53735 : Testing of Plastics: Determination of Melt
Index of Thermoplastics.
r. ISO 8502 – 3 : Preparation of Steel Stubstrates before
Application of Paints and Related Products –
Part 3 - Assessment of Dust on Steel
Surfaces Prepared for Painting ( Pressure
Sensitive Tape Method)
s. ISO 9002 : Quality Systems : Specification of Production
and Installation
t. ISO 11124 : Preparation of Steel Substrates Before
Application of Paints and Related Products
u. SIS 055900 : Preparation of Steel Substrates before
Application of Paints and Related Products -
Visual Assessment of Surface Cleanliness
v. API 5L : Specification for Line Pipe
w. ASME B31.8 : Gas Transmission and Distribution Piping
Systems.
x. ASME B31.4 : Liquid Transportation Systems for
Hydrocarbons, Liquid Petroleum Gas,
Anhydrous Ammonia, and Alcohols
y. CSA Z245.20-98 : External Fusion Bond Epoxy Coating for Steel
Pipe.
The CONTRACTOR shall be familiar with the requirements of these

documents and shall make them readily available at the coating plant to all
persons concerned with carrying out the works specified in this specification.
3.0 PLANT SCALE AND INSTALLATION
3.1 CONTRACTOR shall size coating plant(s) after evaluating the scale of work
and the time schedule required for the works. Coating plant(s), both new or
existing, shall be installed into a yard whose geometry and dimensions are
such as to allow the execution of a continuous work schedule. For this
purpose the CONTRACTOR shall ensure non-stop work execution owing to
prohibitive adverse weather conditions and install requisite equipment and
plant in roofed and adequately weather protected areas.
3.2 Plant equipment, machinery and other facilities shall be in first class operating
condition to at least meet the job requirements of quality and production. Worn
out and improvised plants are not acceptable.
3.3 The CONTRACTOR shall, at his own responsibility and cost, provide and
prepare all necessary area for the storage of bare and coated pipe and all
other materials, for coating yard, stock-piling and other temporary installation.
For each area, CONTRACTOR shall provide necessary agreements as
required with the land owner(s) / relevant Authorities, and, on work
completion, to clean and pay settlement and claims for damages, as
applicable.
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3.4 The CONTRACTOR shall at its own responsibility and cost, provide for water
and power supply and other utilities and consumables and obtain authorization
regarding access roads and other permits required for the execution of works
conforming to all the requirements of the governing Authorities.
3.5 The CONTRACTOR shall at its own expense provide a fully equipped
laboratory and test facilities with adequate inventory to carry out tests required
for the procedure qualification and regular production. Outside testing for
qualification and regular production is not acceptable to COMPANY.
3.6 The CONTRACTOR shall be fully responsible for adherence to all statutory
regulations applicable for handling and disposal of the hazardous chemicals
during the coating works.
3.7 The CONTRACTOR shall be responsible for obtaining all statutory approvals /
clearances from relevant Authorities including Pollution Control Board, as
applicable for the coating plant(s).
4.0 MATERIALS
4.1 The three layer coating system shall comprise of a powder epoxy primer,
polymeric adhesive and a polyethylene top coat. Coating materials shall be
suitable for the service conditions and the pipe sizes involved. The coating
materials i.e. epoxy powder, adhesive and polyethylene compound shall have
proven compatibility. The coating system and materials shall be pre-qualified
and approved by COMPANY in accordance with provisions Annexure I of this
specification. CONTRACTOR shall obtain prior approval from COMPANY for
the coating system and coating materials.
4.2 The coating materials Manufacturer shall carry out tests for all properties
specified in para 5.3.1 and 5.3.2 for each batch of epoxy, adhesive and
polyethylene compound. In addition, the Manufacturer shall also furnish Infra-
red Scan for each batch of epoxy powder. The coating materials
Manufacturer shall issue test certificates as per DIN EN 10204, 3.1B for each
batch of materials supplied to CONTRACTOR and the same shall be
submitted to COMPANY for approval prior to their use.
4.3 In addition to Manufacturer’s certificate, the CONTRACTOR shall draw
samples from each batch of epoxy, adhesive and polyethylene in the presence
of COMPANY Representative and test for the following properties at the
coating yard at least one week prior to its use, to establish compliance with the
Manufacturer’s test certificates.
a. Epoxy Powder:
i. Gel Time
ii. Cure time
iii. Moisture content
iv. Thermal Characteristics (Tg1, Tg2 , ∆H)
b. Adhesive:
i. Specific Gravity
ii. Melt Flow Rate
iii. Vicat Softening Point
c. Polyethylene:
i. Melt Flow Rate
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ii. Specific Gravity

iii. Vicat Softening Point
iv. Moisture Content
v. Oxidative Induction Time
In case of failure of any of the above tests in a batch, that batch of material
shall be tested for all other tests required as per para 5.3.1 and 5.3.2 including
the tests which failed. If all tests pass, the batch shall be accepted for coating.
If any of the tests fail, entire batch of material shall be rejected and shall not
be used for the coating.
4.4 All materials to be used shall be supplied in sealed, damage free containers
and shall be suitably marked with the following minimum information:
a. Name of the Manufacturer
b. Type of Material
c. Batch Number
d. Place and Date of Manufacture
e. Shelf Life/Expiry Date (if applicable)
f. Quantity
All materials noted to be without above identification shall be deemed suspect
and shall be rejected by COMPANY. Such materials shall not be used for
coating and shall be removed from site and replaced by CONTRACTOR at his
expense.
4.5 CONTRACTOR shall ensure that all coating materials are properly stored in
accordance with the Manufacturer’s recommendation at all times, to prevent
damage and deterioration in quality prior to use.
4.6 CONTRACTOR shall be required to use all materials on a date received
rotation basis, i.e. first in- first used basis.
5.0 FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING
5.1 The coating shall be able to withstand a maximum in service operating
temperature of (+)65°C and shall conform to ‘S’ Type of coating as per DIN
30670. In addition, in open storage the coating must be able to withstand a
temperature of at least (+)80°C, without impairing its serviceability and
properties specified.
5.2 The top coat polyethylene used shall be a black readymade compound, fully
stabilized against influence of ultraviolet radiation (i.e. sunlight), oxygen in air
and heat (due to environmental temperature as specified above). No
appreciable changes shall occur during exposure to such environments up to
at least a period of 6000 hours. The CONTRACTOR shall submit certificate
from Manufacturer in this regard.
5.3 Properties
Properties of coating system and coating material shall comply the
requirements indicated in subsequent paragraphs. In case the coating /
material properties are tested as per test methods / standards other than
specified herein below, the same may be accepted provided the test
procedures and test conditions are same or more stringent than the specified.
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5.3.1 Properties of Epoxy Powder and Adhesive

CONTRACTOR shall choose such a brand of epoxy powder and adhesive that
will achieve the functional requirements and properties of coating system as
specified in para 5.1 and 5.3.3 of this specification respectively. Epoxy
powder properties shall be as per CSA Z245.20.98. The colour of epoxy
powder shall be either green or dark red or any other colour approved by
COMPANY except grey colour. Copolymer grafted adhesive shall have the
following properties:
Sl.
Properties Unit Requirement Test Method
No.
Melt Flow Rate g/10

a. 1.0 min. ASTM D 1238
(190°C/ 2.16 kg) minutes
0
b. Vicat Softening Point C 100 min. ASTM D 1525
c. Specific Gravity - 0.926 min. ASTM D 792
5.3.2 Properties of Polyethylene Compound
Sl.
No.
Tensile Strength
a. N/mm2 17 min. ASTM D 638
@ + 250 C
ASTM D
Melt Flow Rate g/10
b. 0.25 min. 1238 or
(190°C / 2.16 kg) minutes
DIN 53735
0.926 min.
Specific Gravity (MDPE)
c. - ASTM D 792
@ + 25 ° C 0.941 min.
(HDPE)
Hardness @ + 25 ASTM D
d. Shore D 50 min.
°C 2240
Water
Absorption, 24
e. hours, % 0.05 max. ASTM D 570
@ + 25 °C
Volume
f. Resistivity @ + Ohm-cm 1015 min. ASTM D 257
25°C
Dielectric
withstand, 1000 Volts/ 30,000
g. ASTM D 149
Volt/sec rise @ + mm min.
25 °C
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Vicat Softening 0 ASTM D

h. C 110 min.
Point 1525
i. Elongation % 600 min. ASTM D 638
Oxidative
Induction Time in
ASTM
j. Oxygen at 220°C, Minutes 10
D3895
Aluminium pan,
no screen
Environmental
Stress Crack
Resistance
(ESCR) (for F50) :
ASTM
k. Hours
-Medium Density- 300 D1693
Condition “C”
-High Density-
Condition “B” 300
Carbon Black ASTM D

l. % 2 min.
Content 1603
5.3.3 Properties of Coating System
Sl.
No.
Bond Strength (using

Type 2 Test Assembly
i.e. Dynamometer)
a. Kg/cm DIN 30670
. @ 20 +/- 5°C
8.0 min
. @ 65 +/- 5°C
5.0 min
Impact Strength
(Min. of 30 impacts on Joules per 7 min
b. body along the length. No mm of coating DIN 30670
breakdown allowed when thickness
tested at 25 Kv)
Indentation Hardness
c. . @ 23 +/- 2°C mm 0.2 max DIN 30670
. @ 70 +/- 2°C 0.3 max
d. Elongation at Failure % 300 min. DIN 30670
e. Coating Resistivity (*) Ohm – m2 108 min. DIN 30670
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Sl.
No.
Melt Flow Rate

shall not deviate by
f. Heat Ageing (*) - DIN 30670
more than 35% of
original value
Melt Flow Rate

shall not deviate by
g. Light Ageing (*) - DIN 30670
more than 35% of
original value
Cathodic Disbondment
mm radius of
. @ + 65° C after 30 disbondment
h. 15 max. ASTM G42
days
(**) 7 max.
. @ + 65°C after 48 hrs
Degree of Cure of Epoxy

i. . Percentage Cure, ∆ H
% 95 CSA Z 245.20-
. ∆ Tg 98(***)
°C +3 / -2
(*) Test carried out in an independent laboratory of national / international

recognition on PE top coat is also acceptable.
(**) Disbondment shall be equivalent circle radius of total unsealed area as
per ASTMG 42.
(***) Temperature to which the test specimens are to be heated during
cyclic heating shall however be as per the recommendations of epoxy
powder manufacturer.
6.0 MEASUREMENT AND LOGGING
CONTRACTOR shall maintain records in computer using MS ACCESS
database Software containing all the relevant data of individual pipe and pipe
coating including pipe number, heat number, diameter, length, wall thickness,
defects, coating number, batches of materials, sampling, testing, damages,
repairs, rejects and any other information that COMPANY considers to be
relevant and required for all incoming bare pipes and COMPANY approved
outgoing coated pipes as applicable. CONTRACTOR’s documentation shall
be designed to ensure full traceability of pie and coating materials through all
stages of coating and testing. CONTRACTOR shall submit this information in
the form of a report at the agreed intervals. The above data shall also be
provided in MS ACCESS format in Compact Disc (CD). CONTRACTOR shall
provide one Computer Terminal to COMPANY Representative for
monitoring/tracking of the above. The CONTRACTOR shall also submit the
material balance details to COMPANY for information at the end of each shift.
7.0 COATING PROCEDURE AND QUALIFICATION
7.1 Upon award of the CONTRACT, the CONTRACTOR shall submit within two
(2) weeks, for COMPANY approval, a detailed report in the form of bound
manual outlining, but not limited to, the following:
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a. Details of plant(s), location(s), layout, capacity and production rate(s).

b. Details of the equipment available to carry out the coating works
including surface preparation, epoxy powder application and its
recycling system, adhesive & polyethylene extrusion, moisture control
facilities available for coating materials.
c. Details of process control and inspection equipment required for the
coating process such as temperature control, thickness control, holiday
testers, etc.
d. Details of chemical pre-treatment facilities including process control
and inspection equipment for phosphoric acid wash, de-ionised water
wash and chromate wash.
e. Facilities in the yard for unloading, handling, transport, production,
storage, stockpiling, loading of bare and coated pipes and warehouses
for storage of other coating materials.
f. Plant Organisation Chart and availability of manpower including
coating specialist
g. Details of utilities/facilities such as water, power, fuel, access roads
and communication etc.
After approval has been given by COMPANY, no change in plant set-up shall
be made. However, unavoidable changes shall be executed only after
obtaining written approval from COMPANY.
7.2 At least four (4) weeks prior to the commencement of production coating, a
detailed procedure of the CONTRACTOR's methods, material proposed, etc.,
shall be formulated by the CONTRACTOR and submitted for COMPANY
approval in the form of a bound manual. The procedure shall include, but not
limited to, the following information and proposals:
a. Pipe inspection at the time of bare pipe receipt.
b. Steel surface preparation, including preheating, removal of steel
defects, method of pipe cleaning, dust removal, abrasive blast cleaning
and surface profile; methods of measurements and consumables.
c. Complete details of chemical pre-treatment viz phosphoric acid wash,
de-ionized water wash, and chromate wash including product data
sheets, health and safety sheets and manufacturer’s recommended
application procedure.
d. Pipe heating, temperatures and control prior to epoxy application.
e. Complete details of raw materials including current data sheets
showing values for all the properties specified together with quality
control and application procedure recommendations from
manufacturer(s).
f. Application of FBE powder, adhesive and polyethylene, including
characteristics, temperature, line speed, application window, curing
time, etc.
g. Quenching and cooling, including time and temperature.
h. Quality Assurance System, Quality Plan, Inspection and Test Plan and
reporting formats, including instrument and equipment types, makes
and uses, etc
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i. Detailed method of repair of coating defects duly classified depending

upon nature and magnitude of defects and repair thereof including
coating stripping technique
j. Details of instrument and equipment calibration methods including
relevant standards and examples of calibration certificates.
k. Complete details and inventory of laboratory and equipment for
procedure qualification and regular production
l. Pipe handling and stock piling procedures
m. Sample of recording and reporting formats, including laboratory
reports, certificates and requirement as per clause 6.0 of this
specification.
n. Complete details of test certificates for raw materials including test
methods and standards used.
o. Test certificates from PE compound manufacturer for tests for thermal
aging, coating resistivity and aging under exposure to light. These
test certificates shall not be older than three years.
p. Health, Safety and Environment Plans.
q. Storage details of coating materials and chemicals.
r. Continuous temperature monitoring at various stages of coating
Procedure Qualification Tests (PQT) shall be carried out only after obtaining
written approval of the above procedure from COMPANY. No change in the
procedure shall be made after approval has been given by the COMPANY.
However, unavoidable changes shall be executed only after obtaining written
approval from COMPANY.
7.3 Prior to start of production, the CONTRACTOR shall, at his expense, carry out
a coating PQT for each pipe diameter on max. wall thickness, for each type of
pipe, for each coating material combination, and for each plant, to prove that
his plant, materials, and coating procedures result in a quality of end product
conforming to the properties stated in clause 5.3, relevant standards,
specifications and material manufacturer's recommendations.
CONTRACTOR shall give seven (7) working days notice to witness all
procedures and tests.
A batch representing a normal production run, typically 15 pipes, shall be
coated in accordance with the approved coating procedure and the coating
operations witnessed by COMPANY Representative. Out of these pipes, at
least one pipe shall be coated partly with epoxy and partly with both epoxy
and adhesive layers.
At least 5 (five) test pipes shall be selected by COMPANY Representative for
coating procedure approval tests and shall be subjected to procedure
qualification testing as described hereinafter. All tests shall be witnessed by
the COMPANY Representative. Out of 5 (five) test pipes, 1 (one) pipe partly
coated with epoxy and partly coated with both epoxy and adhesive layers shall
be included. Remaining 4 (four) test pipes shall be have all three layers.
During PQT, the CONTRACTOR shall qualify various procedures forming a
part of coating operations as detailed subsequently.
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7.4 Qualification of Procedures

7.4.1 Epoxy Powder Application & Recycling
During pre-qualification, air pressure in the epoxy spray guns, satisfactory
functioning of monitoring system, line speed vs coating thickness, etc. shall be
established. Dew point of air used to supply the fluidised bed, epoxy spray
system and epoxy recycling system shall be recorded during the PQT.
Also, the CONTRACTOR shall remove samples of reclaimed powder from the
reclamation system. These samples of reclaimed powder shall be subject to a
detailed visual examination, thermal analysis and moisture content tests. The
properties of the reclaimed powder shall be within the range specified by the
Manufacturer of epoxy powder. In case the properties of the reclaimed
powder are out of the range specified by the Manufacturer, CONTRACTOR
shall not the use the reclaimed powder during the regular production.
7.4.2 Pipe Pre-heating
The CONTRACTOR shall establish the temperature variation due to in-coming
pipe temperature, line speed variation, wall thickness variation, emissivity,
interruptions, etc. and document the same during the PQT stage. During
PQT, proper functioning of pipe temperature monitoring and recording system
including alarm/hooter shall be demonstrated to the COMPANY
Representative.
7.4.3 Surface Preparation
The procedure to clean and prepare the pipe surface shall be in accordance
with the requirements of this specification. The ratio of shots to grits shall be
established during procedure qualification testing, such that the resultant
surface profile is not dished and rounded. The qualification shall be performed
through a visual inspection, measurement of roughness and check of the
presence of dust in the abrasive blast cleaned pipe surface.
7.4.4 Chemical Pre-treatment
7.4.4.1 Phosphoric Acid Wash followed by De-ionised Water Wash
The procedure to apply the chemical pre-treatment viz. phosphoric acid wash
followed by de-ionised water wash shall be in accordance with the
recommendations of the manufacturer and shall result in intended cleaning
requirements of this specification. Working solution preparation, maintaining
concentration, application procedure including method of spreading, spreading
rate, drying times, etc. depending upon the cleanliness/temperature of the
incoming pipe and the line speed shall be established. Temperature of the
chemical, pipe pre-heat temperature vs line speed vs dwell time, rinsing
procedure, testing & control, rectificatory measures, drying procedure etc.
shall be clearly established during PQT. Also the quality of the deionised
water shall be established during PQT.
7.4.4.2 Chromate Treatment
The procedure to apply the chromate treatment shall be in accordance with
the recommendations of the manufacturer. Working solution preparation,
maintaining concentration, application procedure including method of
spreading, spreading rate, drying times, etc. depending upon the temperature
of the incoming pipe and the line speed shall be established. Temperature of
the chemical, pipe pre-heat temperature vs line speed, pipe heating after
chromating and time limit within which the pipe to be heated, testing & control,
rectificatory measures, shall be clearly established during PQT.
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7.4.5 Coating Application

The COMPANY Representative will check the correctness of each coating
application operation, values of the main parameters of each operation, pre-
heating pipe surface temperature prior to epoxy powder application
temperature, line speed, fusion bonded epoxy curing time, temperature and
flow rate of co-polymer adhesive and polyethylene, etc. and the same shall be
recorded. These values shall be complied with during regular production.
7.5 Qualification of Applied Coating
7.5.1 Tests on pipe coated partly with epoxy and partly with epoxy & adhesive
layers
a. Degree of Cure
Epoxy film samples (minimum 4 no.) shall be scrapped from the coated
pipe and the samples shall be taken for cure test using Differential
Scanning Calorimetry (DSC) procedure. Care shall be taken to remove
the samples of full film thickness avoiding inclusion of steel debris.
Glass transition temperature differential (∆Tg) and % cure (∆H) shall
comply with the specified requirements.
b. Epoxy Layer Thickness
Epoxy layer thickness shall be checked at every one metre spacing at
3, 6, 9 and 12 o’clock positions. The thickness shall comply with the
specified thickness requirements.
c. Adhesive layer Thickness
Adhesive layer thickness shall be checked at every one metre spacing
at 3, 6 , 9 and 12’o clock positions. The thickness shall comply with
the specified thickness requirements.
d. Holiday Inspection
Entire pipe shall be subject to holiday inspection and the test voltage
shall be set to exceed 5 v/micron of epoxy thickness specified for the
portion coated only with epoxy layer.
e. Adhesion Test
i. Adhesion Test (24 hrs or 48 hrs) shall be carried out on the epoxy
coated pipe. Test method, no. of test specimen and acceptance
criteria shall comply CSA Z.245,20-98, Table 4.
ii. Adhesion of FBE shall also be separately determined at ambient
temperature at two locations by the “St Andrews Cross” method and
the test shall comply with the specified requirements.
f. 2.5° Flexibility Test
2.5° Flexibility test shall be carried out on the epoxy coated pipe at
test temperature of 0°C. Test method, no. of test specimen and
acceptance criteria shall comply CSA Z.245,20-98, Table 4.
g. Cross-section & Interface Porosity Test
Cross section porosity and interface porosity tests shall be carried out
on the epoxy coated pipe. Test method, no. of test specimen and
acceptance criteria shall comply CSA Z.245,20-98, Table 4.
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7.5.2 Tests on pipes coated with all three layers

a. Bond Strength:
Three test pipes shall be selected for bond strength tests. On each of
the selected pipes, three bond strength test shall be performed for
each specified temperature i.e. one at each end and one in the middle
of the pipe and specified requirements shall be complied with, i.e. bond
strength as well as mode of separation. Length of peel shall be
minimum 65 mm. None of these samples shall fail.
b. Impact Strength:
Three test pipes shall be selected for impact strength test and the test
shall meet the specified requirements.
c. Indentation Hardness:
Two samples for both temperatures from all pipes shall be taken. If any
one of these samples fail to satisfy the specified requirements, then the
test shall be repeated on four more samples. In this case, none of the
samples shall fail.
d. Elongation at failure:
Six samples each from three coated pipes i.e. 18 samples in all shall
be tested and the test shall comply the specified requirement. Only one
sample per pipe may fail.
e. Cathodic Disbondment Test:
Two CD tests shall be carried out for the total lot of test pipes having
all three layers. One test shall be carried out for 30 days duration and
another test for 48 hours duration. The tests shall comply the specified
requirement. Whenever Procedure Qualification is necessitated for
different pipe size with same coating material combination, 48 hours
test only be conducted. 30 days CD test is not mandatory in this case.
f. Holiday Inspection
All the pipes shall be subject to holiday inspection. The test voltage
shall be as specified in para 10.4. (b).
g. Coating Thickness Measurement
All pipes shall be subject to coating thickness measurements.
Acceptance criteria shall be as per para 10.3.
h. Air Entrapment
One sample each from pipe body and on weld (if applicable) shall be
taken from all four coated pipes and the specified requirements shall
be complied with.
i. Degree of Cure
Epoxy film samples (minimum 4 no., equally spaced) shall be scrapped
from one coated pipe and the samples shall be taken for cure test
using Differential Scanning Calorimetry (DSC) procedure. Care shall
be taken to remove the samples of full film thickness avoiding inclusion
of steel debris. Glass transition temperature differential (∆Tg) and %
cure (∆H) shall comply with the specified requirements.
7.5.3 Inspection of all test pipes
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All pipes shall be subject to the following inspections :

a. surface cleanliness, surface roughness measurements and dust
control immediately after second abrasive blast cleaning and salt test
immediately after De-ionised water wash.
b. pH of pipe surface before and after phosphoric acid wash.
c. visual inspection of chromate coating.
d. visual inspection of finished coating, cut back dimension,
internal/external cleanliness, end sealing and bevel inspection.
Acceptance criteria for all inspection and testing shall be as specified in this
specification.
7.6 After completion of the qualification tests and inspection as per para 7.4 and
7.5 above, the CONTRACTOR shall prepare and issue to COMPANY for
approval a detailed report of the above tests and inspection including test
reports/certificates of all materials and coatings tested. Only upon written
approval from COMPANY, CONTRACTOR shall commence production
coating.
7.7 On successful completion of PQT, coating of all five (5) test pipes shall be
removed and completely recycled as per the approved coating procedure
specification, at CONTRACTOR's expense. Remaining pipes will be accepted
by COMPANY provided they meet the requirements of this specification and
need not be stripped and re-cycled.
7.8 The CONTRACTOR shall re-establish the requirements of qualification and in
a manner as stated before or to the extent considered necessary by
COMPANY, in the event of, but not limited to, the following:
- Every time there is a change in the previously qualified
procedure.
- Every time there is a change in the manufacturer and change in
formulation of any of the raw materials and change in location
of raw material manufacture.
- Every time the coating yard is shifted from one location to the
other or every time the critical coating equipments (induction
heater, epoxy spray system, extruder, etc) are shifted.
- Any change in line speed during coating application
- Any time when in COMPANY’s opinion the properties are
deemed to be suspect during regular production tests.
7.9 COMPANY reserves the right to conduct any or all the test required for
qualification through an independent laboratory or agency at the cost of
CONTRACTOR when in COMPANY's opinion, the results are deemed
suspect. COMPANY's decision shall be final.
8.0 PIPE SURFACE PREPARATION
8.1 Unless specified otherwise, the pipes shall be supplied free from mill applied
oils but may be subject to contamination occurring during transit.
8.2 Prior to cleaning operation, CONTRACTOR shall visually examine the pipes
and shall ensure that all defects, flats and other damages have been repaired
or removed. The CONTRACTOR shall also remove marking stickers, if any,
present within the pipe. Record shall be kept of such marking on the stickers
to ensure traceability of pipe after coating.
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8.3 Any oil, grease, salt or other contaminants detrimental to the formation of a
good coating bond or coating quality shall be removed prior to coating
application. Contaminants may be removed by the use of non-oily solvents.
Gasoline or kerosene shall not be used for this purpose. Visible oil and grease
spots shall be removed by solvent wiping. Solvent cleaning shall be in
accordance with SSPC-SP1. Steel surface shall be allowed to dry before
abrasive cleaning.
8.4 All pipes shall be preheated to a temperature of 65°C to 85°C prior to abrasive
blast cleaning. The external surface of the pipe shall be cleaned using 2 no.
dry abrasive blast cleaning units to achieve the specified surface cleanliness
and profile. After first abrasive blast cleaning, chemical pre-treatment with
phosphoric acid solution as per para 8.6 shall be carried out prior to second
abrasive blast cleaning. However at the option of CONTRACTOR, chemical
pre-treatment with phosphoric acid solution as per para 8.6 may be carried
out after the second abrasive blaster.
The abrasive blast cleaning units shall have an effective dust collection
system to ensure total removal of dust generated during blast cleaning from
the pipe surface. The equipment used for abrasive blast cleaning shall meet
the specified requirements and shall be free from oil, water soluble salts and
other forms of contamination to ensure that the cleaning process is not
impaired. Traps, separators and filters shall be checked for condensed water
and oil at the start of each shift and emptied and cleaned regularly. During
abrasive blast cleaning, the metallic abrasive shall be continuously sieved to
remove “fines” and “contaminants” and the quality checked at every four
hours. Abrasives used for blast cleaning shall comply ISO-11124
8.5 Suitable plugs shall be provided at both pipe ends to prevent entry of any
shot/grit into the pipe during blast cleaning operations. These plugs shall be
removed after blast cleaning. Alternatively the CONTRACTOR may link the
pipes suitably together to prevent the entry of any short/grit into the pipe.
8.6 Chemical Pre-treatment with Phosphoric Acid Solution
8.6.1 All pipes shall be provided chemical pre-treatment with phosphoric acid
solution. 10% solution of phosphoric acid, Oakite 31 / 33 or equivalent, shall
be used to remove all soluble salts and other soluble contaminants.
The CONTRACTOR shall provide data sheets and supporting documentation
for the phosphoric acid to be used. The documentation shall verify that the
phosphoric acid is suitable for the treatment of line pipe prior to the application
of the specific fusion bonded epoxy powder being applied and the final coating
will meet fully the requirements of this specification.
8.6.2 The pipe temperature immediately prior to the phosphoric acid treatment shall
be in the range of 45 to 75 °C. Phosphoric acid treatment shall be followed
immediately by washing with de-ionised water. Deionised water used shall
conform to the following requirements :
Sl.
Properties Unit Requirement
No.
a. Turbidity NTU 1 max.
b. Conductivity µmho/cm 5 max.
c. Hardness - Nil
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d. Total Alkalinity as CaC03 mg/l 2 to 3
e. Chloride as Cl- mg/l 1 max.
f. Sulphate as SO4= mg/l 1 max.
g. PH - 6.5 to 7.5
Tests to determine the above properties shall be carried out in accordance

with “Standard Methods for the Examination of Water and Wastewater”
published jointly by American Public Health Association, American Water
Works Association and Water Pollution Control Federation.
Quality of the deionised water shall be monitored at the start of each shift and
at every four hours interval. Non-compliance of deionised water wrt the above
requirements shall cause for stoppage of the operations.
8.6.3 The pH of the pipe surface shall be determined both before and after the de-
ionised water rinse initially on each pipe and in case of consistent results, the
frequency may be relaxed to once per hour at the discretion of COMPANY
Representative. The measured pH shall be as follows :
Before de-ionised water wash : 1 to 2
After de-ionised water wash : 6 to 7
8.6.4 After the deionised water wash, the pipe shall be dried with dry air and
preheated to a temperature of 65°C to 85°C.
8.6.5 The salt tests shall be carried out after deionised water rinse. One test shall be
carried out at one end of each pipe. The acceptance criteria shall be 2µg/cm2.
An approved salt meter (SCM 400 or equivalent) shall be used to carry out salt
tests and shall be calibrated in accordance with the equipment manufacturer’s
recommendations.
8.7 Abrasive cleaning carried out shall be such that the resultant surface profile is
not dished and rounded when viewed with 30X magnification. The standard of
finish for cleaned pipe shall conform to near white metal finish to Sa 2 ½ of
Swedish Standard SIS 055900 latest edition. Surface of pipe after abrasive
blast cleaning shall have an anchor pattern of 50 to 70 microns(RZ). This shall
be measured for each pipe by a suitable instrument such as surface profile
depth gauge. In addition the pipe surface after blast cleaning shall be checked
for the degree of cleanliness (Sa 2½), degree of dust and shape of profile.
Degree of dust shall comply the requirements of ISO 8502 – 3. Acceptance
limit shall be either quality rating 2 or Class 2.
8.8 All pipes shall be visually examined for presence of any shot/grit/loose
material left inside the pipe during blast cleaning. Suitable mechanical means
(stiff brush) shall be employed to remove the same before the pipes are
processed further. In addition, inside surface of the pipe shall also be visually
inspected for presence of any foreign material or shots and grit (free or
embedded/sticking to pipe inside surface). The pipe inside surface shall be
examined using sharp floodlight focused at the middle of the pipe at one end
while inspection is carried out visually from other end. Any foreign material or
shots/grit present in the pipe shall be completely removed by mechanical
brush, high pressure air jets, by tilting of pipe, etc.
8.9 At no time shall the blast cleaning be performed when the relative humidity
exceeds 85% . The CONTRACTOR shall measure the ambient conditions at
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regular intervals during blast cleaning and coating operations and keep
records of prevailing temperature, humidity and dew point.
8.10 The blast cleaned surface shall not be contaminated with dirt, dust, metal
particles, oil, water or any other foreign material, nor shall the surface or its
anchor pattern be scarred or burnished. All blast cleaned pipe surface shall
be kept in dust free enclosure prior to coating. After blast cleaning, all surfaces
shall be thoroughly inspected under adequate lighting to determine anchor
pattern, quality of blasting and identify any surface defects prior to coating
application. All surface defects such as slivers, scab, burns, laminations,
welds spatters, gouges, scores, indentations, slugs or any other defects
considered injurious to the coating integrity made visible during blast cleaning
shall be reported to the COMPANY Representative and on permission from
COMPANY Representative, such defects shall be removed by filing or
grinding. After any grinding or mechanical repairs, the remaining wall
thickness shall be checked and compared with specified thickness. Any pipes
having thickness less than 95% of specified thickness shall be kept aside and
disposed off as per the instructions of COMPANY Representative. The
method employed to remove surface defects shall not burnish or destroy the
anchor pattern or contaminate the surface. Pneumatic tools shall not be used
unless they are fitted with effective air/oil and water traps. Where burnishing
results in destruction of anchor pattern, the anchor pattern shall be restored by
suitable means. Pipes which have damages repaired by grinding and have
ground areas more than 50mm in diameter shall be re-blasted.
Any dust or loose residues that have been accumulated during blasting and/or
during filing/grinding operations shall be removed by vacuum cleaning.
If contamination of surface occurs, the quality of blast cleaning method and
process shall be examined. If the surface roughness is outside the specified
limit, the blast cleaning material shall be checked and replaced.
8.11 Upon Completion of the blasting operations, the quality control supervisor
shall accept the pipe for further processing or return for re-blasting after
removal of defects/imperfections. In case imperfections are considered
detrimental to the coating quality, the same shall be reported to COMPANY's
Representative for final decision on rejection or re-blasting / removal of
defects. Re-blasting / removal of defects or returning pipe to the yard shall be
at the CONTRACTOR's cost.
COMPANY's Representative, in additions, reserves the right to initiate any of
the above actions during periodic inspections for oil, dust, salt, imperfections,
surface defects, lack of white metal finish, etc.
8.12 In order to ensure that pipe with defects are not processed further, provisions
shall be available to lift the pipes from inspection stand.
8.13 Chemical Pre-treatment with Chromate Solution
8.13.1 Following completion of abrasive blast cleaning, all pipe surface shall be
chemically pre-treated with a 10% strength chromate solution.
8.13.2 The CONTRACTOR shall provide data sheets and supporting documentation
for the chemical to be used. The documentation shall verify that the chemical
is suitable for the treatment of line pipe prior to the application of the specific
fusion bonded epoxy powder being applied and the final coating will meet fully
the requirements of this specification.
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8.13.3 The chemical pre-treatment shall be applied fully in accordance with the
chemical suppliers’ instructions and in a manner that ensures 100% uniform
coverage of the pipe surface without introducing surface contamination.
8.13.4 The CONTRACTOR shall check that the concentration of the chemical pre-
treatment solution remains within the range recommended by the chemical
manufacturer for the pipe coating process. The concentration shall be
checked at the make up of each fresh solution and once per hour, using a
method approved by the chemical manufacturer. The CONTRACTOR shall
also ensure that the chemical pre-treatment solution remains free from
contamination at all times. Recycling of chemical pre-treatment solution is not
permitted.
8.13.5 The CONTRACTOR shall ensure that the temperature of the substrate is
maintained between 40°C and 80°C and the chromate solution temperature
does not exceed 60° or as recommended by the manufacturer.
8.13.6 The chromate coating shall be smooth, even, free from runs, drips or
excessive application and lightly adherent with no flaking of the coating. The
chromate coated steel must be thoroughly dried immediately after application
and shall be achieved by boiling off any residual solution on the surface.
8.14 The total allowable elapsed time between completion of the blasting
operations and commencement of the pre-coating and heating operations
shall be such that no detectable oxidation of the surface occurs. Relative
humidity readings shall be recorded every half an hour during the blasting
operations in the immediate vicinity of the operations. The maximum elapsed
time shall not exceed the duration given below:
Relative Humidity % Maximum elapsed time
> 80 2 hours
70 to 80 3 hours
< 70 4 hours
Any pipe not processed within the above time-humidity requirement shall be
completely re-blasted. Any pipe showing flash rusting shall be re-blasted even
if the above conditions have not been exceeded.
8.15 Pipe handling between abrasive blasting and pipe coating shall not damage
the surface profile achieved during blasting. Any pipe affected by the damage
to the surface exceeding 200mm² in area and/or having contamination of steel
surface shall be rejected and sent for re-blasting.
9.0 COATING APPLICATION
The external surface of the cleaned pipe conforming to clause 8.0 of this
specification shall be immediately coated with 3-layer extruded polyethylene
coating in accordance with the procedures approved by COMPANY, relevant
standards and this specification. In general the procedure shall be as follows:
9.1 Pipe Heating
9.1.1 Immediately prior to heating of pipe, all dust and grit shall be removed from
inside of the pipe by a combination of air blast, brushing and vacuum cleaning.
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Suitable arrangement shall be made to protect the bevel ends from getting
damaged during the coating operation.
9.1.2 Induction heater or gas fired heating shall be used for heating the pipe. The
method shall be capable of maintaining uniform temperature along the total
length of the pipe, and shall be such that it shall not contaminate the surface
to be coated. In case of induction heating, appropriate frequency shall be used
to ensure ‘deep heating’ and intense skin heating is avoided. Gas fired
heating system shall be well adjusted so that no combustion products are
deposited on the steel surface. This shall be demonstrated on bare pipes
prior to start of PQT. Oxidation of the cleaned pipe surfaces prior to coating
(in the form of blueing or other apparent oxide formation) is not acceptable.
9.1.3 External surface of the pipe shall be heated to about 190 °C or within a
temperature range (min. to max.) as recommended by the powder
manufacturer. Required pipe temperature shall be maintained as it enters the
coating chamber.
9.1.4 Temperature of the pipe surface shall be continuously monitored & recorded
by using suitable instruments such as infrared sensors, contact thermometers,
thermocouples etc. The recording method shall allow to correlate each
linepipe. The monitoring instrument shall be able to raise an alarm / activate
audio system (hooter) in the event of tripping of induction heater / gas fired
heater or in the event of pipe temperature being outside the range
recommended by the manufacturer. Any deviation from the application
temperature range recommended by manufacturer shall be rectified. If
immediate rectification is not feasible, the production shall be stopped until
cause of deviation has been removed. Any pipe coated during the duration of
temperature deviation shall be identified by marking and rejected. Such
rejected pipes shall be stripped, re-cleaned and recoated.
9.1.5 Temperature measuring & monitoring equipment shall be calibrated twice
every shift and/or as per COMPANY Representative’s instruction.
9.1.6 CONTRACTOR shall ensure that pipe surface emissivity variations are
minimised during pipe heating. To avoid significant variance, more than once
blasted joints should be coated at the same time and not mixed with joints
blasted only once.
9.2 Pipe Coating
9.2.1 Subsequent to pipe heating, coating consisting of following layers shall be
applied onto the pipe.
i. Electrostatic application of epoxy powder of minimum dry film
thickness 0.150 mm, unless otherwise specified. The maximum
thickness shall not exceed the epoxy thickness specified by epoxy
powder manufacturer.
ii. Grafted co-polymer adhesive application by extrusion, minimum
thickness 0.200 mm.
iii. Polyethylene application by extrusion.
The coated pipe shall be subsequently quenched and cooled in water for a
period that shall sufficiently lower the temperature of pipe coating to permit
handling and inspection.
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9.2.2 Minimum total thickness of finished coating shall be as under:
Minimum Coating Thickness

Pipe Size (mm) (*)
(Specified Outside Diameter) Normal Type Reinforced
(n) Type (v)
Up to 10¾” (273.1 mm) 2.0 2.7
Over 10¾” (273.1 mm) to below

2.2 2.9
20” (508.0 mm)
From 20” (508.0mm) to below

2.5 3.2
32” (813.0 mm)
From 32” (813.0 mm) and above 3.0 3.7
(*) In case HDPE material is used as top coat, 10% reduction in minimum
coating thickness specified is permissible.
Required coating thickness shall be Normal Type (n), unless otherwise
specified.
9.2.3 Coating materials shall be inspected in accordance with the manufacturer’s
recommendation prior to coating application and it shall be ensured that the
materials are moisture free. In case the relative humidity exceeds 80%, the
adhesive and polyethylene material shall be dried using hot dry air as per the
directions of COMPANY Representative.
9.2.4 Prior to starting the application of fusion bonded epoxy powder, the recovery
system shall be thoroughly cleaned to remove any unused powder remaining
from a previous line pipe coating application. The use of recycled powder shall
be permitted subject to :
a) Satisfactory qualification of the reclaimed system during PQT stage
b) The proportion of the reclaimed powder in the working mix does not
exceed 20% at any one time.
c) The quality of the recycled powder being routinely checked during
production, at a minimum frequency of once per shift and consistently
meets the requirements stated at para 5.3.1
9.2.5 Dry air, free of oil and moisture shall be used in the coating chamber and
spraying system and filters, dehumidifier/dryer as required along with control &
monitoring system shall be provided for this purpose. Dew point of air used to
supply the fluidised bed, epoxy spray system and epoxy recycling system shall
be at least (–) 40°C and this shall be shall be monitored during the regular
production.
9.2.6 Air pressure in the epoxy spray guns shall be controlled, continuously
monitored and recorded by using suitable instruments. The air pressure shall
be controlled within the limits established during coating procedure
qualification. The monitoring system shall be able capable of raising an alarm /
activate audio system (hooter) in the event of change in air pressure beyond
the set limits. Any deviation from the pre-set limits shall be rectified. If
immediate rectification is not feasible, the production shall be stopped until
cause of deviation has been removed. Any pipe coated during the duration of
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air pressure deviation shall be identified by suitable marking and rejected.

Such rejected pipes shall be stripped and recoated.
9.2.7 Extruded adhesive layer shall be applied before gel time of the epoxy coating
has elapsed and within the window recommended by the manufacturer. The
CONTRACTOR shall establish, to the satisfaction of the COMPANY
Representative, that the adhesive is applied within the gel time window of
epoxy and at the temperature recommended by the adhesive manufacturer.
The CONTRACTOR shall state the minimum and maximum time interval
between epoxy and adhesive application at the proposed pre-heat
temperature and line speed.
9.2.8 Extruded polyethylene layer shall be applied over the adhesive layer within the
time limit established during PQT stage and within the time/temperature range
recommended by the manufacturer. The extrusion temperatures of the
adhesive and polyethylene shall be continuously recorded. The monitoring
instruments shall be independent of the temperature control equipment. The
instruments shall be calibrated prior to start of each shift.
9.2.9 CONTRACTOR shall ensure that there is no entrapment of air or void
formation along the seam weld (where applicable) during application of
coating. Air entrapment below the coating and also along the coating overlap
shall be prevented by forcing the coating on to the pipe using high pressure
roller of suitable design during coating application. In case it is not adequately
achieved, CONTRACTOR shall supplement by other methods to avoid air
entrapment. The methods used shall be witnessed and approved by
COMPANY.
9.2.10 Resultant coating shall have a uniform gloss and appearance and shall be free
from air bubbles, wrinkles, holidays, irregularities, discontinuities, separation
between layers of polyethylene & adhesive, etc.
9.2.11 Coating and/or adhesive shall terminate 150 mm (+) 20 / (-) 0 mm from pipe
ends. The adhesive shall seal the end of applied coating. CONTRACTOR
shall adopt mechanical brushing for termination of the coating at pipe ends.
Edge of the coating shall be shaped to form a bevel angle of 30° to 45°.
9.2.12 Failure to comply with any of the above applicable requirement and of the
approved procedure shall be cause for the rejection of the coating and such
coating shall be removed in a manner approved by COMPANY at
CONTRACTOR's expense.
10.0 INSPECTION AND TESTING
10.1 General
The CONTRACTOR shall establish and maintain such quality assurance
system as are necessary to ensure that goods or services supplied comply in
all respects with the requirements of this specification. The minimum
inspection and testing to be performed shall be as indicated subsequently
herein.
10.2 Visual Inspection
Immediately following the coating, each coated pipe shall be visually checked
for imperfections and irregularities of the coating. The coating shall be of
natural colour and gloss, smooth and uniform and shall be blemish free with
no dust or other particulate inclusions. The coating shall not show any defects
such as blisters, pinholes, scratches, wrinkles, engravings, cuts, swellings,
disbonded zones, air inclusions, tears, voids or any other irregularities.
Special attention shall be paid to the areas adjacent to the longitudinal weld (if
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applicable), adjacent to the cut-back at each end of pipe and within the body
of the pipe.
In addition inside surface of the pipe shall also be visually inspected for
presence of any foreign material or shots and grit (free or embedded/sticking
to pipe inside surface). The pipe inside surface shall be examined using sharp
floodlight focussed at the middle of the pipe at one end while inspection is
carried out visually from other end.
10.3 Coating Thickness
a. The coating thickness shall be determined by taking at least 10
measurements at locations uniformly distributed over the length and
periphery of each pipe. In case of welded pipes, five of the above
readings shall be made at the apex of the weld seam, uniformly
distributed over the length of the coated pipe. All readings must meet
the minimum requirements. However, localized coating thickness of
less than the permissible minimum thickness can be tolerated on the
condition that it does not attain a total extent of more than 5 cm2 per
meter length of coated pipe, and the actual coating thickness does not
drop more than 10% below the permissible minimum coating thickness
at these locations. The frequency of thickness measurement as stated
above shall be initially on every pipe, but may be reduced depending
upon consistency of results, at the sole discretion of COMPANY
Representative. Results of all measurements shall be recorded.
b. Thickness of epoxy and adhesive shall be measured at the beginning
of each shift and whenever the plant re-starts after any stoppage for
compliance. Coating of epoxy and adhesive on portion of pipe required
for this purpose, stripping and recoating of such partly coated pipes
shall be at CONTRACTOR’s expense.
c. Coated pipes not meeting the above requirements shall be rejected.
Rejected coated pipes shall be stripped and re-coated in accordance
with approved procedure, at CONTRACTOR's expense.
10.4 Holiday Detection
a. Each coated pipe length shall be checked over 100% of coated surface
by means of a "holiday detector" of a type approved by COMPANY for
detecting holidays in the finished coating.
b. The holiday detector shall be a low pulse D.C. full circle electronic
detector with audible alarm and precise voltage control complying with
DIN VDE 0433 Part 2. The set voltage for inspection shall be minimum
25 kV. Travel speed shall not exceed 300 mm/s.
c. CONTRACTOR shall calibrate the holiday detector at least once every
4 hours of production. CONTRACTOR shall have necessary
instruments or devices for calibrating the holiday detector.
d. Any pipe coating shall be rejected if more than 1(one) holiday & area
more than 100 cm² in size are detected in its length attributable to
coating process.
e. Holidays which are lesser in size than those mentioned in (d) above,
shall be repaired in accordance with a approved procedure and shall
be at CONTRACTOR's expense.
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10.5 Bond Strength Test

a. CONTRACTOR shall conduct bond strength test for composite coating
as per Clause 5.3.3(a) of this specification. A minimum of 65 mm
length shall be peeled. First 20 mm and last 20 mm shall not be
counted for assessment of bond strength.
b. The frequency of test for cut back portions shall be one pipe in every
fifteen (15) pipes coated and for middle of pipe shall be one pipe in
every sixty (60) pipes coated or one pipe per shift whichever is higher.
On each selected pipe, bond strength shall be performed for each
specified temperature. Test shall be performed at each cut back
portion and one in the middle of pipe. The system shall
disbond/separate cohesively either in adhesive layer or in polyethylene
layer. Majority of the peeled off area on the pipe shall show presence
of adhesive. Disbondment/separation at epoxy to steel interface or
epoxy / adhesive interface or adhesive / polyethylene interface shall
not be permitted. The failure mode shall be recorded for each test.
c. In case the test fails to comply the specified requirement, the
CONTRACTOR shall test the preceding and succeeding coated pipe.
If both pipes pass the test, then the remainder of the pipe joints in that
shift shall be deemed satisfactory. If either pipe fails to meet the
specified requirements, all pipes coated during that shift shall be tested
until the coating is proved acceptable. Rejected coated pipes shall be
stripped and re-coated in accordance with approved procedure, at
CONTRACTOR's expense.
d. The frequency of bond strength test as per para 10.5 (b) for cut back
portion may be reduced depending upon the consistency of result to
one pipe in every twenty five (25) instead of every fifteen pipes, at the
sole discretion of the COMPANY Representative.
10.6 Impact Strength
a. Impact strength test shall be conducted as per clause 5.3.3(b) of this
specification. Initially the frequency of test shall be two (2) coated pipes
per shift that may be further reduced to one coated pipe per 2 weeks
depending upon consistently acceptable results at the sole discretion
of COMPANY's Representative.
b. Minimum thirty (30) impacts located equidistant along the length of
coated pipe shall be performed.
c. Immediately after testing, the test area shall be subjected to holiday
detection at the same voltage as used prior to impact strength test.
The pipe shall be rejected if any holiday is noted in the test area.
d. In case of test failure, retesting and disposal of coated pipe shall be as
per para 10.5 (c) above.
10.7 Indentation Hardness
a. Indentation hardness test shall be as per clause 5.3.3 (c) of this
specification. The frequency of test shall be initially 2 (two) coated
pipes per shift which shall be further reduced to one test each on 2
coated pipes per week at random after 1 week of consistently
acceptable results. Two samples for each temperature shall be taken
from the cut back portion of coated pipe and one in the middle of the
pipe for this test.
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b. In case of test failure, retesting and disposal of coated pipe shall be as

10.8 Air Entrapment Test
a. Strips from bond strength tests or coated pipe may be used to help
determine the porosity of the finished coating. Strip shall be also cut
from longitudinal weld (if applicable) at cut back portion and examined
for the presence of voids.
b. Bond strength strip shall be viewed from the side and at the failure
interface. At the pipe bond strength test location, utility knife shall be
used to cut the edge of the coating to a 45° angle and view with a
microscope. Similar examination shall be done in the coating cut back
area.
c. One sample each either on the bond strength strip or coated pipe and
strip cut from the longitudinal weld (if applicable) shall be examined for
air entrapment per shift. Strips shall be viewed from the side.
d. All examination shall done using a 30X magnification hand-held
microscope. The polyethylene and adhesive layers shall have no more
than 10% of the observed area taken up with air entrapment (porosity
or bubbles). Air entrapment shall not occupy more than 10% of the
thickness in each case. Bubbles shall not link together to provide a
moisture path to the epoxy layer.
e. In case of test failure, retesting and disposal of coated pipe shall be as
10.9 Degree of Cure
a. Epoxy film samples shall be removed from cut back portion of the
coated pipe using hammer and cold chisel and the samples shall be
taken for cure test using DSC procedure. Care shall be taken to
remove the samples of full film thickness avoiding inclusion of steel
debris. Glass transition temperature differential (∆Tg) and % cure (∆H)
shall comply the specified requirements.
b. Frequency of this test shall be once per shift. Pipe shall be selected
randomly by COMPANY Representative during the middle of a shift.
Suitable provisions / arrangements as per the instructions of
COMPANY Representative shall be made by the CONTRACTOR for
this purpose
c. In case of test failure, production carried out during the entire shift shall
be rejected, unless the CONTRACTOR proposes a method to
establish the compliance with the degree of cure requirements of all
pipes coated during that shift.
10.10 Epoxy Layer Adhesion Test
a. Adhesion of epoxy layer shall be determined at ambient temperature
by the “St Andrews Cross” method i.e. by cutting two straight lines
through the epoxy layer with a sharp knife. The incisions shall
intersect at an angle of 30°/150°. The epoxy coating shall resist
disbondment from the steel when attempts are made to flick/lift the
coating from the 30° angle with a sharp knife.
b. Frequency of this test shall be once per shift. The test shall be carried
out at the cut back portion on the pipe from which the Degree of Cure
test has been carried out as per para 10.9 above.
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c. In case of test failure, retesting and disposal of coated pipe shall be as

10.11 Cathodic Disbondment Test
a. 48 hours CD test shall be conducted as per clause 5.3.3 (h) of this
specification.
b. The frequency of this test shall be once in every two weeks or one test
representing each batch of epoxy powder used, whichever is more
frequent.
c. In case the test fails to conform to the specified requirement, at the
option of the CONTRACTOR, all pipes coated after the previous
acceptable test and prior to next acceptable test shall be rejected or
the test shall be repeated using two additional samples taken from the
same end of the affected pipe.
When both retests conform to the specified requirement, the lot of pipes shall
be accepted. When one or both the retests fail to conform to the specified
requirement, all coated pipes after previous acceptable test and prior to next
acceptable shall be rejected. All rejected pipes shall be stripped, re-cleaned
and re-coated. COMPANY may consider a further retest program to
determine whether any of the affected pipe meet the criteria for acceptance
upon written request by the CONTRACTOR.
10.12. Damages occurring to pipe coating during above tests shall be repaired in
accordance with approved coating repair procedure.
10.13 Repairs occurring on account of the production tests are however excluded
from above mentioned limitations at para 10.4 (d) above.
10.14 COMPANY reserves the right to perform inspection and witness tests on all
activities concerning the pipe coating operations starting from bare pipe to
finished coated pipe ready for despatch and also testing of raw materials.
CONTRACTOR shall give reasonable notice of time and shall provide without
charge reasonable access and facilities required for inspection to the
COMPANY's representative. Inspection and tests performed or witnessed by
COMPANY's representative shall in no way relieve the contractors obligation
to perform the required inspection and tests.
10.15 In case rate of defective or rejected pipes and/or samples tests are 10% or
more for a single shift (typically 8 hours), CONTRACTOR shall be required to
stop production and carry out a full and detailed investigation and shall submit
findings to COMPANY for approval. CONTRACTOR shall recommence the
production only after getting the written permission from COMPANY.
Under no circumstances any action or omission of the COMPANY's
Representative shall relieve the CONTRACTOR of his responsibility for
material and quality of coating produced. No pipes shall be transported from
the coating plant unless authorised by COMPANY in writing.
11.0 HANDLING, TRANSPORTATION AND STORAGE
11.1 The CONTRACTOR shall be fully responsible for the pipe and for the pipe
identification marking from the time of "taking over" of bare pipe from
COMPANY until such time that the coated line pipes are `handed over' and/or
installed in the permanent installation as the case may be according to the
provisions of the CONTRACT.
At the time of "taking over" of bare pipes CONTRACTOR shall inspect and
record all the relevant details referred above including pipe defects in the
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presence of COMPANY. All pipes shall be checked for bevel damages, weld
seam height, dents, gouges, corrosion and other damages. COMPANY
Representative shall decide whether pipe defects / damages are suitable for
repair. Damage to the pipes that occur after the CONTRACTOR has taken
delivery such as dents, flats, or damage to the weld ends shall be cut off or
removed and pipes rebevelled and repaired again as necessary. The cost of
this work, as well as that of the pipe lost in cutting and repair shall be to the
CONTRACTOR's account. All such works shall be carried out after written
approval of the COMPANY. Any reduction in length shall be indicated in the
CONTRACTOR’s pipe tracking system.
11.2 The CONTRACTOR shall unload, load, stockpile and transport the bare pipes
within the coating plant(s) using suitable means and in a manner to avoid
damage to pipes.
The CONTRACTOR shall stockpile the bare pipes at the storage area of the
coating plant. The CONTRACTOR shall prepare and furnish to COMPANY a
procedure/calculation generally in compliance with API RP-5L1 for stacking of
pipes of individual sizes, which shall be approved by COMPANY prior to
commencement.
11.3 The CONTRACTOR shall load, unload, transport and stockpile the coated
pipes within the coating plant using approved suitable means and in a manner
to avoid damage to the pipe and coating. The COMPANY shall approve such
procedure prior to commencement of work.
11.4 Coated pipes may be handled by means of slings and belts of proper width
(minimum 60 mm) made of non- abrasive/non-metallic materials. In this case,
pipes to be stacked shall be separated row by row to avoid damages by
rubbing the coated surface in the process of taking off the slings. Use of round
sectional slings is prohibited. Fork lifts may be used provided that the arms of
the forklift are covered with suitable pads, preferably rubber.
11.5 Bare / coated pipes at all times shall be stacked completely clear from the
ground, at least 300 mm, so that the bottom row of pipes remain free from
any surface water. The pipes shall be stacked at a slope so that driving rain
does not collect inside the pipe. Bare / coated pipes may be stacked by
placing them on ridges of sand free from stones and covered with a plastic
film or on wooden supports provided with suitable cover. This cover can be of
dry, germ free straw covered with plastic film, otherwise foam rubber may be
used. The supports shall be spaced in such a manner as to avoid permanent
bending of the pipes.
Stacks shall consist of limited number of layers such that the pressure
exercised by the pipe's own weight does not cause damages to the coating.
CONTRACTOR shall submit calculations for COMPANY approval in this
regard. Each pipe section shall be separated by means of spacers suitably
spaced for this purpose. Stacks shall be suitably secured against falling down
and shall consist of pipe sections having the same diameter and wall
thickness. The weld seam of pipes shall be positioned always in a manner so
as not to touch the adjacent pipes.
The ends of the pipes during handling and stacking shall always be protected
with bevel protectors.
11.6 The lorries used for transportation shall be equipped with adequate pipe
supports having as many round hollow beds as there are pipes to be placed
on the bottom of the lorry bed. Total width of the supports shall be at least 5%
of the pipe length and min. 3 no. support shall be provided. These supports
LINEPIPES
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shall be lined with a rubber protection and shall be spaced in a manner as to

support equal load from the pipes. The rubber protection must be free from all
nails and staples where pipes are in contact. The second layer and all
following layers shall be separated from the other with adequate number of
separating layers of protective material such as straw in plastic covers or
mineral wool strips or equivalent, to avoid direct touch between the coated
pipes.
All stanchions of lorries used for transportation shall be covered by non-
abrasive material like rubber belts or equivalent. Care shall be exercised to
properly cover the top of the stanchions and other positions such as
reinforcement of the truck body, rivets, etc. to prevent damage to the coated
surface. Slings or non-metallic straps shall be used for securing loads during
transportation. They shall be suitably padded at the contact points with the
pipe
11.7 Materials other than pipes and which are susceptible of deteriorating or
suffering from damages especially due to humidity, exposure to high thermal
excursions or other adverse weather conditions, shall be suitably stored and
protected. Deteriorated materials shall not be used and shall be replaced at
CONTRACTOR's expenses. These materials, shall always be handled during
loading, unloading and storage in a manner so as to prevent any damage,
alteration and dispersion. When supplied in containers and envelopes, they
shall not be dropped or thrown, or removed by means of hooks, both during
the handling operations till their complete use. During unloading, transport and
utilization, any contact with water, earth, crushed stone and any other foreign
material shall be carefully avoided.
CONTRACTOR shall strictly follow Manufacturer's instructions regarding
storage temperature and methods for volatile materials that are susceptible to
change in properties and characteristics due to unsuitable storage. If
necessary the CONTRACTOR shall provide for a proper conditioning.
11.8 In case of any marine transportation of bare/coated line pipes involved, the
same shall be carried out in compliance with API RP 5LW. CONTRACTOR
shall furnish all details pertaining to marine transportation including drawings
of cargo barges, storing/stacking, sea fastening of pipes on the barges/marine
vessels to the company for approval prior to undertaking such transportation
works. In addition contractor shall also carry out requisite analyses
considering the proposed transportation scheme and establish the same is
safe and stable. On-deck overseas shipment shall not be allowed.
12.0 REPAIR OF COATING
CONTRACTOR shall submit to COMPANY, its methods and materials
proposed to be used for executing a coating repair and shall receive approval
from COMPANY prior to use. In open storage the repair coating materials
must be able to withstand a temperature of at least (+) 80°C without impairing
its serviceability and properties. CONTRACTOR shall furnish manufacturer’s
test certificates for the repair materials clearly establishing the compliance of
the repair materials with the applicable coating requirements indicated in this
specification.
All pipe leaving coating plant, shall have sound external coating with no
holiday or porosity on 100% of the surface.
Defects, repairs and acceptability criteria shall be as follows:
- Pipes showing porosities or very small damage not picked up during
holiday test and having a surface less than 0.5 cm2 or linear damage
LINEPIPES
Page 29 of 31
(cut) of less than 3 cm shall be repaired by stick using material of

same quality.
- Damages caused to coating by handling such as scratches, cuts,
dents, gouges, not picked up during holiday test, having a total
reduced thickness on damaged portion not less than 2 mm and an
area not exceeding 20 cm2 shall be rebuild by heat shrink patch only
and without exposing to bare metal.
- Defects of size exceeding above mentioned area or holidays of width
less than 300 mm shall be repaired with heat shrink repair patch by
exposing the bare metal surface.
- Defects exceeding the above and in number not exceeding 2 per pipe
and linear length not exceeding 500 mm shall be repaired using heat
shrinkable sleeves of HTLP 80 or equivalent.
- Pipes with bigger damage shall be stripped and recoated.
- In case of coating defect close to coating cut back, CONTRACTOR
shall remove the coating throughout the entire circumference of the
pipe down to the steel surface and increase the coating cut back
length. Now if the coating cut back exceeds 170 mm of linear length of
pipe then the coating shall be repaired by the use of heat shrink
sleeves thereby making up the coating cut back length of 150 mm.
Not withstanding the above, under no circumstances, if the defect exceeds 70
mm from the original coating cut back length, the entire coating shall be
removed and the pipe shall be recycled through the entire coating procedure.
Irrespective of type of repair, the maximum numbers of repair of coating shall
be as follows:
- Holiday repair of size ≤ 100 cm2 attributable to process of coating
application shall be maximum one number per pipe.
- In addition to the above, defects to be repaired by heat shrink
patch/sleeve shall be maximum 2 (two) per pipe.
Defects exceeding the above limits shall cause pipe coating rejection,
stripping and recoating. The above is exclusive of the repairs warranted due to
testing as per this specification.
All repairs carried out to coating for whatever reason shall be to the account of
CONTRACTOR.
Cosmetic damages occurring in the polyethylene layer only need not be
repaired by exposing up to steel surface, as deemed fit by the COMPANY
Representative. In any case the CONTRACTOR shall establish his material,
methods and procedure of repair that result in an acceptable quality of product
by testing and shall receive approval from COMPANY prior to use.
Testing of repairs shall be in the same form as testing coating. All repairs shall
result in a coating thickness no less than the parent coating thickness.
CONTRACTOR shall test repairs to coating as and when required by
COMPANY.
13.0 MARKING
CONTRACTOR shall place marking on the outside surface of the coating at
one end of the coated pipe, and marking shall indicate, but not limited to the
following information:
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Page 30 of 31
a. Pipe number, Heat number

b. Diameter & Wall thickness
c. Coated pipe number
d. Colour band
e. Any other information considered relevant by COMPANY.
f. Pipe Manufacturer Name
g Inspection Mark/Punch
CONTRACTOR shall obtain prior approval on marking procedure to be
adopted from the COMPANY.
14.0 QUALITY ASSURANCE
14.1 The CONTRACTOR shall have established within his organisation and, shall
operate for the contract, a documented Quality System that ensures that
the requirements of this specification are met in all aspects. The Quality
System shall be based upon ISO 9001/2 or equivalent.
14.2 The CONTRACTOR shall have established a Quality Assurance Group within
its organisation that shall be responsible for reviewing the Quality System and
ensuring that it is implemented.
14.3 The CONTRACTOR shall submit the procedures that comprise the Quality
System to the COMPANY for agreement.
14.4 The CONTRACTOR’s Quality System shall pay particular attention to the
control of Suppliers and Sub-contractors and shall ensure that the
requirements of this specification are satisfied by the Suppliers and Sub-
contractors operating Quality system in their organisation.
14.5 The CONTRACTOR shall, prior to the commencement of work, prepare and
issue a Quality Plan for all of the activities required to satisfy the requirements
of this specification. The plan shall include any sub-contracted work, for which
the sub-contractors Quality Plans shall be submitted. The plan shall be
sufficiently detailed to indicate sequentially for each discipline the requisite
quality control, inspection, testing and certification activities with reference to
the relevant procedures and the acceptance standards.
14.6 The CONTRACTOR’s Quality system and associated procedures may, with
due notice, be subject to formal audits. The application of quality control by
the CONTRACTOR will be monitored by the COMPANY Representatives who
will witness and accept the inspection, testing and associated work required
by this specification.
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Page 31 of 31
ANNEXURE-I
LIST OF ACCEPTABLE COMBINATIONS OF COATING MATERIALS
The following combinations of coating materials are considered acceptable. In

case any of the combinations listed below are offered, details regarding
properties of the offered materials need not be furnished with bid. However, In
the event of award of contract, CONTRACTOR shall furnish the
combination(s) proposed and re-confirmation of compatibility of the proposed
combination (s) from the raw materials Manufacturers.
Epoxy Powder Adhesive PE Compound

(Manufacturer) (Manufacturer) (Manufacturer)
CORRO-COAT EP-F 2001 FUSABOND 158D SCLAIR 35 BP HDPE

(JOTUN) (DUPONT) (NOVACOR)
PE 50-8190/8191 LUCALEN G3510H LUPOLEN 3652 D SW 00413

(BASF) (BASF) (BASF)
or
CORRO-COAT EP-F 2001
(JOTUN)
PE 50-6109 ME 0420 HE 3450

(BASF) (BOREALIS) (BOREALIS)
or
CORRO-COAT EP-F 2001
(JOTUN)
or
SCOTCHKOTE 226N
(3M)
CORRO-COAT EP-F 2001 LE – 149 V ET 509 B

(JOTUN) (S K CORPORATION) (S K CORPORATION)
SCOTCHKOTE 226N ME 0420 PB 48A004

(3M) (BOREALIS) (GAIL)
Although the above combinations would be acceptable to COMPANY, the

responsibility of suitability for application, performance and compliance to the
coating system requirements shall unconditionally lie with the CONTRACTOR.

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SPECIFICATION FOR 3-LAYER DOCUMENT No.

POLYETHYLENE COATING OF 0318-000-16-71-SP-03 Rev. 0

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0 03.03.06 ISSUED AS JOB SPECIFICATION

ANNEXURE-I COMBINATIONS OF COATING MATERIALS

p. DIN EN 10204 : Metallic Products – Types of Inspection

The CONTRACTOR shall be familiar with the requirements of these

ii. Specific Gravity

5.3.1 Properties of Epoxy Powder and Adhesive

Melt Flow Rate g/10

c. Specific Gravity - 0.926 min. ASTM D 792

5.3.2 Properties of Polyethylene Compound

Vicat Softening 0 ASTM D

i. Elongation % 600 min. ASTM D 638

Carbon Black ASTM D

5.3.3 Properties of Coating System

Bond Strength (using

d. Elongation at Failure % 300 min. DIN 30670

e. Coating Resistivity (*) Ohm – m2 108 min. DIN 30670

Melt Flow Rate

Melt Flow Rate

Degree of Cure of Epoxy

(*) Test carried out in an independent laboratory of national / international

a. Details of plant(s), location(s), layout, capacity and production rate(s).

i. Detailed method of repair of coating defects duly classified depending

7.4 Qualification of Procedures

7.4.5 Coating Application

7.5.2 Tests on pipes coated with all three layers

All pipes shall be subject to the following inspections :

a. Turbidity NTU 1 max.

b. Conductivity µmho/cm 5 max.

d. Total Alkalinity as CaC03 mg/l 2 to 3

e. Chloride as Cl- mg/l 1 max.

f. Sulphate as SO4= mg/l 1 max.

Tests to determine the above properties shall be carried out in accordance

Relative Humidity % Maximum elapsed time

9.2.2 Minimum total thickness of finished coating shall be as under:

Minimum Coating Thickness

Up to 10¾” (273.1 mm) 2.0 2.7

Over 10¾” (273.1 mm) to below

From 20” (508.0mm) to below

From 32” (813.0 mm) and above 3.0 3.7

air pressure deviation shall be identified by suitable marking and rejected.

10.5 Bond Strength Test

b. In case of test failure, retesting and disposal of coated pipe shall be as

c. In case of test failure, retesting and disposal of coated pipe shall be as

shall be lined with a rubber protection and shall be spaced in a manner as to

(cut) of less than 3 cm shall be repaired by stick using material of

a. Pipe number, Heat number

LIST OF ACCEPTABLE COMBINATIONS OF COATING MATERIALS

The following combinations of coating materials are considered acceptable. In

Epoxy Powder Adhesive PE Compound

CORRO-COAT EP-F 2001 FUSABOND 158D SCLAIR 35 BP HDPE

PE 50-8190/8191 LUCALEN G3510H LUPOLEN 3652 D SW 00413

PE 50-6109 ME 0420 HE 3450

CORRO-COAT EP-F 2001 LE – 149 V ET 509 B

SCOTCHKOTE 226N ME 0420 PB 48A004