Material and Construction Standard: IPS-G-TP-335
Material and Construction Standard: IPS-G-TP-335
Material and Construction Standard: IPS-G-TP-335
FOR
ORIGINAL EDITION
DECEMBER 1997
This Standard is the property of Iranian Ministry of Petroleum. All rights are reserved to the owner.
Neither whole nor any part of this document may be disclosed to any third party, reproduced, stored in
any retrieval system or transmitted in any form or by any means without the prior written consent of the
Iranian Ministry of Petroleum.
Dec. 1997
IPS-G-TP-335
GENERAL REQUIREMENTS
Dec. 1997
IPS-G-TP-335
FOREWORD
The Iranian Petroleum Standards (IPS) reflect the views of the Iranian Ministry of Petroleum and are
intended for use in the oil and gas production facilities, oil refineries, chemical and petrochemical
plants, gas handling and processing installations and other such facilities.
IPS is based on internationally acceptable standards and includes selections from the items
stipulated in the referenced standards. They are also supplemented by additional requirements
and/or modifications based on the experience acquired by the Iranian Petroleum Industry and the
local market availability. The options which are not specified in the text of the standards are
itemized in data sheet/s, so that, the user can select his appropriate preferences therein
The IPS standards are therefore expected to be sufficiently flexible so that the users can adapt
these standards to their requirements. However, they may not cover every requirement of each
project. For such cases, an addendum to IPS Standard shall be prepared by the user which
elaborates the particular requirements of the user. This addendum together with the relevant IPS
shall form the job specification for the specific project or work.
The IPS is reviewed and up-dated approximately every five years. Each standards are subject to
amendment or withdrawal, if required, thus the latest edition of IPS shall be applicable
The users of IPS are therefore requested to send their views and comments, including any
addendum prepared for particular cases to the following address. These comments and
recommendations will be reviewed by the relevant technical committee and in case of approval will
be incorporated in the next revision of the standard.
GENERAL DEFINITIONS:
Throughout this Standard the following definitions shall apply.
COMPANY:
Refers to one of the related and/or affiliated companies of the Iranian Ministry of Petroleum such as
National Iranian Oil Company, National Iranian Gas Company, National Petrochemical Company
and National Iranian Oil Refinery And Distribution Company.
PURCHASER:
Means the “Company” where this standard is a part of direct purchaser order by the “Company”,
and the “Contractor” where this Standard is a part of contract documents.
CONTRACTOR:
Refers to the persons, firm or company whose tender has been accepted by the company.
EXECUTOR:
Executor is the party which carries out all or part of construction and/or commissioning for the
project.
INSPECTOR:
The Inspector referred to in this Standard is a person/persons or a body appointed in writing by the
company for the inspection of fabrication and installation work.
SHALL:
Is used where a provision is mandatory.
SHOULD:
Is used where a provision is advisory only.
WILL:
Is normally used in connection with the action by the “Company” rather than by a contractor,
supplier or vendor.
MAY:
Is used where a provision is completely discretionary.
Dec. 1997 IPS-G-TP-335
1. SCOPE ............................................................................................................................................ 1
2. REFERENCES ................................................................................................................................ 1
3. DEFINITIONS AND TERMINOLOGY ............................................................................................. 3
4. UNITS .............................................................................................................................................. 3
1. SCOPE ............................................................................................................................................ 5
2. REFERENCES ................................................................................................................................ 5
3. DEFINITIONS AND TERMINOLOGY ............................................................................................. 5
4. UNITS .............................................................................................................................................. 5
5. COATING MATERIALS .................................................................................................................. 5
6. EPOXY POWDER ........................................................................................................................... 6
7. BASIC PROPERTIES AND TESTS FOR BONDING AGENT (ADHESIVE) ................................. 8
8. BASIC PROPERTIES AND TESTS FOR POLYETHYLENE ......................................................... 8
9. QUALITY CONTROL REQUIREMENTS ........................................................................................ 9
10. QUALITY SYSTEMS..................................................................................................................... 9
1. SCOPE .......................................................................................................................................... 11
2. REFERENCES .............................................................................................................................. 11
3. UNITS ............................................................................................................................................ 11
4. MATERIALS .................................................................................................................................. 11
5. PIPES IDENTIFICATION .............................................................................................................. 11
6. PROTECTION OF PIPE END PREPARATION ............................................................................ 12
7. SURFACE PREPARATION .......................................................................................................... 12
8. COATING PROCEDURE TESTS ................................................................................................. 12
9. INSPECTION AND TESTING (QUALITY CONTROL) ................................................................. 13
10. QUALITY SYSTEMS................................................................................................................... 13
11. COATING PROCEDURE QUALIFICATION ............................................................................... 14
12. PRODUCTION COATING REQUIREMENTS............................................................................. 17
13. INSPECTION OF FINISHED COATING ..................................................................................... 17
14. COATING REQUIREMENTS AND TEST METHODS ................................................................ 18
15. DEFECT RATE............................................................................................................................ 18
16. HANDLING AND STORAGE REQUIREMENTS ........................................................................ 19
17. TRANSPORTATION LOADING ................................................................................................. 19
18. REPAIRS ..................................................................................................................................... 19
19. STRIPPING OF COATING .......................................................................................................... 19
Dec. 1997 IPS-G-TP-335
APPENDICES:
AMENDMENTS:
1. SCOPE
This Standard deals with factory polyolefin (PP/PE) polyethylene coatings for external surfaces of
buried or submerged steel pipes. The standard is comprised of three parts as follows:
Part 1: Requirements for Factory Applied Coating Materials and Methods of Test.
Part 2: Factory Applied Coatings.
The coating may be 2 or 3 layers as will be specified by the Company.
Two layers polyethylene coating consists of adhesive primer and polyethylene and is suitable for
operating temperature up to 50°C.
Three layers polyethylene coating consists of epoxy primer, adhesive primer and polyethylene and
is intended for operating temperature up to 80°C.
Note 1:
This standard specification is reviewed and updated by the relevant technical committee on
Aug. 2002. The approved modifications by T.C. were sent to IPS users as amendment No. 1
by circular No. 192 on Aug. 2002. These modifications are included in the present issue of
IPS.
Note 2:
This standard specification is reviewed and updated by the relevant technical committee on
Feb. 2007. The approved modifications by T.C. were sent to IPS users as amendment No. 2
by circular No. 305 on Feb. 2007. These modifications are included in the present issue of
IPS.
Note 3:
This standard specification is reviewed and updated by the relevant technical committee on
Oct. 2013. The approved modifications by T.C. were sent to IPS users as amendment No. 3
by circular No. 406 on Oct. 2013. These modifications are included in the present issue of
IPS.
2. REFERENCES
Throughout this Standard the following dated and undated standards/codes are referred to. These
referenced documents shall, to the extent specified herein, form a part of this standard. For dated
references, the edition cited applies. The applicability of changes in dated references that occur
after the cited date shall be mutually agreed upon by the Company and the Vendor. For undated
references, the latest edition of the referenced documents (including any supplements and
amendments) applies.
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Dec. 1997 IPS-G-TP-335
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Dec. 1997 IPS-G-TP-335
Batch
A batch shall consist of all materials which is processed at the same conditions and submitted for
inspection at one time.
Homopolymer
A polymer ( as polyethylene) consisting of identical monomer units.
Typical value
A value exhibiting the essential characteristic of a special type of material.
4. UNITS
This Standard is based on International System of Units (SI), as per IPS-E-GN-100 except where
otherwise specified.
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Dec. 1997 IPS-G-TP-335
PART 1
AND
METHODS OF TEST
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Dec. 1997 IPS-G-TP-335
1. SCOPE
1.1 This Part 1 of the Standard specifies materials for use in 3-layer polyethylene coating system. It
deals specifically with the properties, minimum requirements and related methods of tests to
establish suitability for use with Part 2 of this Standard which cover factory applied coatings and
field applied coatings respectively.
1.2 Materials specifications and method of tests for two layer polyethylene coating system shall be
in accordance with DIN 30670.
2. REFERENCES
See General Requirements.
4. UNITS
See General Requirements.
5. COATING MATERIALS
5.1.1 Only coating systems, which comply with this Part one of the General standard shall be used.
5.1.2 The coating materials supplied shall be certified by the manufacturer ensuring that all coating
materials and equipment comply with all of the provisions contained in this Part one of standard
originally and prior to application and the purchaser may make any investigations necessary, by
way of testing, batch sampling, manufacturing and factory inspection, to satisfy itself of compliance
by the contractor.
5.1.3 The contractor shall be responsible for ensuring that the range of values for any material
under consideration will be capable of providing a finished product in compliance with Part 2 of this
Standard when related to the specific mode of operation to be used.
5.1.4 It is intended that this specification be used to encourage and stimulate the development of
progressively better external pipeline coatings. Thus, where certain minimum performance values
are stated, should future coating material test submissions yield better than specification
requirements then, after economic evaluation, these new values may be adopted as the minimum
requirements and the specification would be upgraded accordingly.
6. EPOXY POWDER
6.1.1 General
6.1.1.1 Epoxy powder is a thermosetting material for use as primer in a three layer polyethylene
coating system for steel pipe. It shall be specifically formulated and designed so as to be suitable for
electrostatic application and to improve adhesion of the coating system and also provide maximum
cathodic disbanding resistance.
6.1.1.2 The contractor shall obtain from the manufacturer specified and qualified ranges of values
for all properties listed in Table 1.1 and detailed in 6.1.2 to 6.1.3 inclusive that will ensure an
acceptable coating. The frequency of testing shall be in accordance with Clause 11 of Part 2.
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Dec. 1997 IPS-G-TP-335
TABLE 1.1 - TYPICAL VALUES OF RAW EPOXY POWDER PROPERTIES (SEE PAGE 26)
PROPERTY UNIT TEST METHOD TYPICAL VALUE
Gloss at 60° angle % DIN 67530 65 ±5
Note:
The test for raw epoxy power properties is under the responsibility of manufacturer.
6.2.1 General
6.2.1.1 The tests defined in 6.2.2 to 6.2.6 inclusive shall be carried out, on a laboratory coated steel
plate with a coating thickness of 60 microns.
Prior to coating, the steel surface shall be blast cleaned to a level of Sa 2½ to Swedish Standard
SIS 05 5900 and surface profile of approximately 50 microns peak to valley height.
6.2.1.2 The contractor shall ensure that the powder manufacturer shall carry out the tests specified
in 6.2.2 to 6.2.6 inclusive, on each batch.
6.2.2 Appearance
The coating shall exhibit uniform appearance.
6.2.4 Flexibility/bending
The flexibility/bending shall be measured in accordance with DIN 53152; - typical value < 5 mm.
6.2.5 Hardness
The hardness of the cured epoxy film shall be more than 85 bucholtz when tested in accordance
with DIN 53155.
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Dec. 1997 IPS-G-TP-335
7.1 This adhesive is used as second layer in a three-layer polyolefin (PP/PE) polyethylene coating
system for steel pipes. It shall be an ethylene base copolymer, specifically formulated and designed
so as to be suitable for extrusion application.
7.2 The contractor shall obtain from the manufacturer specified values for all properties listed in
Table 2.1 in accordance with 7.3.
7.3 The contractor shall ensure that the adhesive manufacturer shall carry out the tests Nos. 1, 2 in
Table 2.1 for each batch and the remaining tests shall be carried out as type tests twice per each
order as a minimum.
7.4 The adhesive shall be uncolored and made of raw material with the best quality to provide the
following properties:
- Excellent peeling resistance.
- Excellent mechanical strength.
- Excellent thermal stability.
- Strong adhesion to fusion bonded epoxy film as well as to steel surface.
- Homopolar bond with the polyethylene top coat (third layer).
2) Melting index (2.16 kg/190°C) g/10 Min. DIN 53735 0.5-8 or as suitable for application
As PE (top coat)
Note:
The test for raw epoxy power properties is under the responsibility of manufacturer.
8.1 Polyethylene is a thermoplastic resin for use as topcoat in a three-layer polyethylene coating
system for steel pipe. It shall be specifically formulated and designed for extrusion application.
8.2 The contractor shall obtain from the manufacturer specified values for all properties listed in
Table 3.1 in accordance with 8.3.
8.3 The contractor shall ensure that the polyethylene manufacturer shall carry out the tests Nos. 1,
2, 7, 10 and 14 in Table 3.1 for each batch and the remaining tests shall be carried out as type tests
twice per each order as a minimum.
8.4 The polyethylene shall be made of raw material with the best quality to provide following
properties:
- Excellent peeling resistance.
- Excellent mechanical strength.
- Excellent thermal stability.
- Excellent Impact resistance.
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Dec. 1997 IPS-G-TP-335
8.6 Color
The polyethylene shall be uniform in color and free from obvious foreign matters; the color shall be
black using carbon black; the carbon black characterization, dispersion and content shall be in
accordance with BS 3412-76.
2) Melting index (2, 16 kg/190°C) g/10 Min. DIN 53735 ISO 1133D 0.3 (Typical)
10) Stress cracking resistance Hour ASTM D 1693 or ISO 4599 >1000
(methyl-ethylceton)
10.1 The contractor shall set up and maintain such quality assurance and inspection systems as are
necessary to ensure that the goods or services supplied comply in all respects with the
requirements of this Standard.
10.2 The company shall have the right to undertake inspection or testing of raw materials or
purchased components before application.
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Dec. 1997 IPS-G-TP-335
PART 2
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Dec. 1997 IPS-G-TP-335
1. SCOPE
This Part 2 of the standard specifies the operations and requirements for the factory application of
materials identified in Part 1, to buried steel pipes providing a finished product capable of pipe
laying and operating up to 80°C for 3-layer polyethylene coating.
2. REFERENCES
See General Requirements.
3. UNITS
See General Requirements.
4. MATERIALS
4.1.1 Only polymer systems conforming to this Standard shall be considered for use as coatings
applied in accordance with this Part 2 of this Standard.
4.1.2 The contractor shall be responsible for the conformity with the requirements of this
construction standard. The contractor shall obtain and retain all certificates and manufacturer’s data
sheets. Certificates shall be made available on request to company.
5. PIPES IDENTIFICATION
5.1 All identification markings, whether internal or external to the pipes shall be carefully recorded
before surface preparations begin.
5.2 The date of coating finish and the coating factory markings including pipe identification shall be
legibly marked on coating surface of each pipe.
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Dec. 1997 IPS-G-TP-335
6.1 Pipe end preparations shall be protected from mechanical damage during handling, storage,
surface preparation and the coating processes. The methods used shall also ensure that no
damage occurs to the internal surface of the pipe.
6.2 Pipe end preparations shall be protected from coating during the process by a suitable method
approved by the Company.
6.3 For technical welding reasons the ends of the pipes shall be free of any coating layer (cut back)
over a length of 100 (-0, +20) mm up to pipe size DN 500 mm (20 in.) inclusive and over a length of
150 (-0, +20) mm for sizes over DN 500 mm, unless specified otherwise by the Company.
6.4 The uncoated ends of pipes shall be temporarily protected against atmospheric corrosion by a
temporary paint easily removable by brushing.
7. SURFACE PREPARATION
7.1 The method of surface cleaning and surface preparation shall be specified by the contractor as
part of the coating procedure qualification and shall take into account the requirements specified in
7.2 to 7.5 inclusive, in accordance with (IPS-C-TP-101).
7.2 Where oil, grease or other contaminants are present they shall be removed, without spreading
them over the surface, with a suitable solvent. For pipes, which have been subjected to
contamination, the contaminant shall be removed by washing either with potable water or an
approved chemical cleaner. If a chemical cleaner is used, subsequent washing with potable water
will be necessary. The pipe shall be dried before blast cleaning. All processes shall be in
accordance with IPS-C-TP-101.
7.3 Pipes shall be blast cleaned to a minimum of Sa 2½ finish to SIS 05 5900. The blast profile shall
be between 40 µm and 75 µm height, measured by an agreed method. The blast cleaning medium
used shall be according to IPS-C-TP-101.
7.4 The metal surface (RZ) shall be inspected immediately after blast cleaning and all slivers,
scabs, etc., made visible by blast cleaning and detrimental to the coating process shall be removed
using a method approved by company. After the removal of defects, the remaining wall thickness
shall comply with the relevant pipe specification. Any rectified areas shall be blast cleaned to meet
the requirements of 7.3.
7.5 Any pipe found to have defects which exceed the levels permitted in the relevant pipe
specification shall be set aside for examination by an authorized company representative and no
subsequent action taken without the agreement of the Company.
7.6 Directly before coating, any dust, grit or other contaminants shall be removed from the pipe
surface by a method established as acceptable by the relevant coating procedure test and recorded
in the relevant coating procedure.
7.7 Where rust blooming or further surface contamination has occurred, the pipe shall be cleaned
again in accordance with 7.2 and again blast cleaned in accordance with 7.3 Coating shall take
place before any further contamination or rust blooming appears.
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Dec. 1997 IPS-G-TP-335
9.1 The quality control system shall include as a minimum the requirements listed in Table 1.2.
9.2 All inspections and testings listed in Table 3.2 shall be made by the contractor and witnessed
and certified by the inspector.
9.3 After examination or test, should the inspector find out that any pipe has not been cleaned or
coated in accordance with this Standard, the contractor shall be required to remove the coating
which is considered defective or inadequate, and to reblast and recoat the pipe to the requirements
for approval of the inspector.
9.4 The inspector shall have access at any time to the construction site and to those parts of all
plants that are concerned with the performance of work under this standard.
9.5 The contractor shall provide the necessary inspection tools and instruments for the inspector as
well as normal facilities necessary for inspection.
2. Monitor size, shape and cleanliness of the blast cleaning material and process. 7.3
3. Check visually in good light, the surface of the pipes for metal defects, dust and entrapped grit. 7.4
6. Pipe temperature control of the pipe surface (pipe temperature shall not exceed 250°C). ---
8. Check the coating thickness (first, second layers and total) 14.2
11. Holiday detection of 100% of the surface area of all coated pipes. 14.3
12. Supervision to ensure the adequate and proper repair of all defects. 18
13. Check on coating color and appearance, e.g. uniformity and flow. 13.2
10.1 The contractor shall set up and maintain such quality and inspection systems as are necessary
to ensure that the goods and services supplied comply in all respects with the requirements of this
Standard.
10.2 The Company shall assess such systems against the recommendations of the applicable parts
of ISO 9002 and shall have the right to undertake such surveys as are necessary to ensure that the
quality assurance and inspection systems are satisfactory.
10.3 The Company shall have the right to undertake inspection and testing of the goods and
services during any stage of manufacturing at which the quality of the finished goods may be
affected and to undertake inspection or testing of raw materials and/or purchased pipes.
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Dec. 1997 IPS-G-TP-335
10.5.1 The contractor shall issue the required certificates in accordance with EN 10204 for all
coating production tests identified in 14.1 to 14.3 inclusive and presented to the Company.
10.5.2 For all tests witnessed by the inspector a certificate shall be prepared and issued by the
contractor and certified by the inspector in accordance with EN 10204.
11.1 General
11.1.1 Before bulk coating of pipes commences the requirements of 11.2 and 11.3 shall be met and
a detailed sequence of operations to be followed on the coating of pipe shall be presented to the
Company for checking the compliance with this Standard and formal approval.
11.1.2 The Company shall also specify which coated pipes are to be subjected to the test specified
in 10.3.2 and 10.3.3 for formal approval of coating procedure. No coated pipes shall be dispatched
to the Company or no coating process shall be done until the coating procedure has been approved
and approval confirmed in writing by the Company.
11.3.1 General
11.3.1.1 A batch of 10 to 20 pipes of any specific pipe mill shall be selected by the inspector and
coated by the contractor in accordance with the approved coating procedure specification (see
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Dec. 1997 IPS-G-TP-335
11.2), the coating operations being witnessed by the inspector. Three pipes from the coated pipes
shall be selected by the inspector and subjected to the complete set of tests specified in 11.3.2 and
11.3.3. Testing shall be witnessed by the inspector and a full set of records shall be presented to
the Company for consideration.
11.3.1.2 Bulk coating of pipes shall not commence until all short and long term tests (see 11.3.2 and
11.3.3) results have been approved officially by company, unless the contractor takes responsibility
of failure for any long term test.
11.3.1.3 All test methods shall be in accordance with Table 3.2.
11.3.2.1 Thickness
For this purpose, at least two measurements shall be made in accordance with Table 3.2 at
locations uniformly distributed over the length and periphery of each pipe selected for the test and
checked for compliance with Table 2.2.
50% of these measurements shall be made along and over the longitudinal weld seam, if any.
11.3.2.2 Porosity
Each pipe selected for the test shall be holiday detected over 100% of its coated surface and
checked for compliance with Table 3.2.
11.3.2.3 Adhesion
This test shall be carried out on each pipe at 5 locations uniformly distributed over the length and
periphery of the pipe, in this respect the mean force necessary to pull off the coating shall comply
with Table 3.2. None of these tests must fail.
11.3.3.1 Adhesion
This test shall be carried out at 5 different locations on 5 test sections in accordance with 11.3.2.3,
but after 30 days keeping in the hot air of 80°C. No change in the mean force necessary to pull of
the coating must occur.
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Dec. 1997 IPS-G-TP-335
11.3.3.7 Elongation
The samples taken from the three pipes shall be tested and checked for compliance with Table 3.2.
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12.2.1 The production coating process shall be carried out using a procedure approved in
accordance with Clauses 4, 8 and 11.
12.2.2 The thickness of each layer and the total thickness shall comply with the values in the Table
2.2 when tested in accordance with DIN 30670.
13.1 General
The inspection of finished coating shall be in accordance with Clause 14. The quality and values to
be achieved shall be the same as those identified in 13.2 and Clause 14.
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14.1 General
14.1.1 After formal approval of all short and long term tests by Company, the contractor will be
authorized to commence the bulk production.
14.1.2 The contractor shall perform the routine inspection and tests in accordance with 14.2 to 14.4
inclusive during coating production.
14.1.3 All the inspection and tests witnessed by the inspector shall be certified.
14.1.4 The pipe coating shall comply with all requirements identified in 14.2 to 14.4 inclusive.
14.2 Thickness
This test shall be carried out 3 times during each 8 hour production shift and each time on 4
consecutive pipe lengths in accordance with DIN 30670 (Sections 5.2.1 and 6.3) every pipe which
does not comply with the minimum requirements of Table 3.2 shall be rejected for subsequent
stripping and recoating. Should two consecutive pipes fail to satisfy the requirement, the cause shall
immediately be investigated. If the cause is not resolved after four consecutive pipes, the coating
process shall be stopped for full investigation; this shall involve checking all pipes back to the
preceding acceptable pipe.
14.3 Porosity
Each individual line pipe shall be holiday detected over 100% of its coated surface in accordance
with DIN 30670. Up to 2 holidays per pipe length will be allowed for repair on a max. of 5% of
coated pipe lengths during each 8 hour production shift.
Any individual pipe with more than 2 holidays shall be rejected for subsequent stripping and
recoating. If more than 2 holidays per pipe length are detected on two consecutive pipes, the cause
of the high holiday rate shall immediately be investigated. If the cause is not resolved after four
consecutive pipes, the coating process shall be stopped for full investigation. All holidays detected
on non-rejected pipes shall be repaired in accordance with Clause 15 and satisfactorily retested.
14.4 Adhesion
This test shall be carried out 3 times during each 8 hour production shift, each time on one
individual line pipe. The test shall be carried out at room temperature and at 2 ends of the pipe
coating surface and checked for compliance with Table 3.2. If the coating adhesion at any location
is below the requirement of Table 3.2 the pipe shall be rejected for subsequent stripping and
recoating; in this case the second consecutive pipe shall be checked. Should two consecutive pipes
fail to satisfy the requirement, the cause shall immediately be investigated; if the cause is not
resolved after four consecutive pipes, the coating process shall be stopped for full investigation, this
shall involve checking all pipes back to the preceding acceptable pipe.
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Dec. 1997 IPS-G-TP-335
one test, then every pipe in that shift shall be individually subjected that test.
In such cases the contractor shall simultaneously conduct an investigation to establish the cause of
the defect.
The cost of retrieval and/or any additional expenses incurred as a result of additional examination
shall be borne by the contractor.
16.1 All coated pipes shall be handled and stored in such a manner as to prevent damage to the
pipe walls, the weld end preparations and the coating.
16.2 Nylon slings or protected hooks, which do not damage pipe ends, shall be used for loading,
unloading and stacking.
16.3 The coated pipes shall be stored at all times free from the ground. Storage may be effected by
the use of battens suitably covered with soft material such as rubber sheet.
16.4 The coated pipes may only be stacked to a height such that no flattening of the coating occurs,
in this respect the formula given in API RP 5L5 shall be used for the calculation of static load stress.
16.5 The pipes shall be separated from each other with sufficient and proper dun age.
16.6 During long storage the polyethylene coating shall be protected from contact with petrol, oil or
grease, as some of these substances can cause swelling in the polyethylene layer.
17.1 The loading operations shall be witnessed and certified by the inspector.
17.2 The coated pipes shall be loaded on trucks with provisions of 16.2.
17.3 The Contractor shall provide all necessary means, such as saddles, battens, etc., for safe
transporting of the coated pipes.
18. REPAIRS
The procedure for repairs of holidays and damaged areas due to destructive test should be prepare
by manufacturer and approved by A.R.
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APPENDICES
APPENDIX A
HOLIDAY DETECTION OF COATINGS
A.1 Holiday detection shall be carried out using equipment approved by Company on surfaces,
which are at ambient temperature and free from moisture.
A.2 For all coatings (except adhesive tape) the operating voltage shall be 125 V per 25 µm of
coating thickness (e.g. 2 kV for 400 µm).
The rate of travel of the probe over the surface shall be a maximum of 300 mm/s. All holidays shall
be repaired.
A.3 For fusion bonded epoxy coating systems carbon impregnated neoprene or rolling spring types
of electrodes shall be used. For other coatings the splayed brush electrode may also be used, if
authorized by the Company.
A.4 The brush and carbon impregnated neoprene types of electrode shall be of the curved type,
conforming to the contour of the pipe.
A.5 All holidays, imperfections and damaged areas shall be identified with a waterproof marker.
All markings shall be sufficiently distant from the holiday, imperfection or damaged area to allow
surface preparation and patching to take place without detriment to the adhesion of the coating.
A.6 All holiday detectors shall be calibrated at the start of every workday and additionally when
requested by the Company.
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Dec. 1997 IPS-G-TP-335
APPENDIX B
COATING OF BUTT JOINTS - MATERIAL APPLICATION CHARTS
Notes:
Bare or painted pipe or fittings shall be coated with tape (see Note 1 g Table 1.3) before the
relevant butt joint coating is applied (see 4.2 and 4.3).
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APPENDIX C
APPROVAL OF FIELD JOINT AND FITTING COATING EQUIPMENT
AND APPLICATORS
C.3.1 All operators who carry out successfully the coating including heating when required
applications shall be deemed to be qualified to carry out production work on any contract, using the
same process and equipment within 12 months of completing the trial.
C.3.2 Additional and subsequent operators shall demonstrate their ability to coat joint within the
specification requirements on production work, which shall be supervised or carried out by
previously qualified operators in the ratio of four skilled/two unskilled.
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AMENDMENTS
Tables of IPS Instead
1.1 1
2.1 2
2.2 4
3.1 3
3.2 5,6,7
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Dec. 1997 IPS-G-TP-335
0. INTRODUCTION
This attachment is intended to be used as amendments to the Iranian petroleum standard no. IPS-
G-TP-335.
All new underground steel oil, gas and water line pipes shall be coated in accordance with IPS-G-
TP-335 with the following amendments.
1. TITLE OF STANDARD
Due to addition of the “3 layer polypropylene coating system” to the standard, the title modified as
follows:
“Three layer polyolefin (PP/PE) polyethylene and polypropylene coating for line pipe”
2. GENERAL REQUIREMENTS
The new “general requirements” as attachment no.1 is substituted.
3. PART 1
4. PART 2
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Dec. 1997 IPS-G-TP-335
ATTACHMENT NO. 1
GENERAL REQUIREMENTS
1. SCOPE
This standard deals with plant applied 3 layer PE and 3 layer PP coatings for external surfaces of
buried or submerged steel line pipes. This standard is comprised of two parts as follows:
Part 1: Requirements for coating materials
Part 2: Requirements for plant applied coatings
The coating system shall consist of three layers:
1st layer: Fusion Bonded Epoxy (powders sprayed)
2nd layer: Adhesive (powder sprayed or extruded)
3rd layer: PE/PP top layer (applied by extrusion)
The Polyethylene coating system shall be suitable for the service temperatures of -20ْ C to +80ْ C.
The Polypropylene coating system shall be suitable for the service temperatures of -30ْ C to 110ْ C.
2. REFERENCES
Throughout this Standard the following dated and undated standards/codes are referred to. These
referenced documents shall, to the extent specified herein, form a part of this standard. For dated
references, the edition cited applies. The applicability of changes in dated references that occur
after the cited date shall be mutually agreed upon by the Company and the Vendor. For undated
references, the latest edition of the referenced documents (including any supplements and
amendments) applies.
ISO
10B INTERNATIONAL ORGANIZATION FOR STANDARDISATION
ISO 179 -1 Plastics: Determination of Charpy impact properties – Part 1: Non-
instrumented impact test
ISO 179 -2 Plastics: Determination of Charpy impact properties – Part 2:
Instrumented impact test
ISO 306 Plastics: Thermoplastic materials — Determination of Vicat
softening temperature (VST))
ISO 527-2 Plastics: Determination of tensile properties — Part 2: Test
conditions for moulding and extrusion plastics
ISO 527-3 Plastics: Determination of tensile properties — Part 3: Test
conditions for films and sheets
ISO 868 Plastics and ebonite: Determination of indentation hardness by
means of a durometer (Shore hardness)
ISO 1133 Plastics: Determination of the melt mass-flow rate (MFR) and the
melt volume-flow rate (MVR) of thermoplastics
ISO 1183 (all parts) Plastics: Methods for determining the density and relative density
of non-cellular plastics
ISO 1872 Plastics: Polyethylene (PE) moulding and extrusion materials –
Part 2: Preparation of test specimens and determination of
properties
ISO 1873 –2 Plastics: Polypropylene (PP) moulding and extrusion materials –
Part 2: Preparation of test specimens and determination of
properties
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Dec. 1997 IPS-G-TP-335
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Dec. 1997 IPS-G-TP-335
NF FRENCH STANDARD
NF A 49-710 Steel Tubes-Three-Layer External Coating Based on
Polyethylene - Application by Extrusion
EN EUROPEAN STANDARD
EN 728 Plastics Piping Systems - Polyolefin Pipes and Fittings -
Determination of Oxidation Induction Time
EN 10204 Metallic Products - Types of Inspection Documents
SSPC SOCIETY OF PROTECTIVE COATINGS
SSPC SP1 “Solvent Cleaning”
DIN (DEUTCHES INSTITU FÜR NORMUNG)
DIN 30670 Polyethylene Sheathing of Steel Tubes and Steel Pipes and
Fittings
DIN 30678 Polypropylene Coatings for Steel Pipes
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Dec. 1997 IPS-G-TP-335
Contractor (applicator)
Company which undertakes the coating application in accordance with the provisions of this
standard specification.
Cut-back
Length of pipe left uncoated at each end for joining purposes (e.g. welding).
Design Temperature Range
Temperature range including maximum and minimum temperature likely to be reached during
transport, handling, installation and operation.
End User
Company operating the pipeline system.
Holiday
Coating discontinuity that exhibits electrical conductivity when exposed to a specific voltage.
Inspection and Testing Plan (ITP)
Document providing an overview of the sequence of inspections and tests, including appropriate
resources and procedures Symbols and abbreviated terms.
Manufacturer
Company responsible for the manufacture of coating material(s).
Manufacturer’s Specification
Document which specifies the characteristics, test requirements and application recommendations
for the coating materials.
Operating Temperature
Temperature experienced by the pipe or pipeline system during operation which should not exceed
the design temperature.
Pipeline
Those facilities through which fluids are conveyed, including pipe, pig traps, components and
appurtenances, up to and including the isolating valves.
Pipeline System
Pipeline with compressor or pump stations, pressure control stations, flow control stations,
metering, tankage, supervisory control and data acquisition system (SCADA), safety systems,
corrosion protection systems, and any other equipment, facility or building used in the transportation
of fluids.
Procedure Qualification Trial (PQT)
Application of a coating and subsequent inspection/testing of its properties to confirm that the APS
is adequate to produce coating of specified properties.
Purchaser
Company responsible for providing the product order requirements.
Test Report
Document that provides the quantitative test results for tests conducted in accordance with the
requirements of this standard specification.
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Dec. 1997 IPS-G-TP-335
Symbols:
Abbreviations:
PE Polyethylene
PP Polypropylene
4. UNITS
This Standard is based on international System of Units (SI), except where otherwise specified.
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Dec. 1997 IPS-G-TP-335
ATTACHMENT NO.2
1. MATERIAL APPROVAL
1.1 The coating materials within the three-layer coating system shall be approved by company
before application. The polymeric adhesive and polyolefin compound shall be supplied by the same
coating materials manufacturer.
1.2 The manufacturer shall qualify each type of coating material in compliance with the
requirements of this part of standard. The qualification shall be repeated in case of changes in the
material composition, changes in the production process which influence the material processing
behaviour and change in production facility.
1.3 The supplier shall obtain from the coating material manufacturer technical data sheets showing,
at least, the properties described in Table 1, Table 2 and Table 3.
1.4 A certificate of analysis (COA) should be issued by the manufacturer of each component. The
manufacturer shall supply an inspection certificate for each batch.
1.5 Each batch of all coating materials shall be accompanied by a certificate of analysis (COA)
according to EN 10204, 3.1.B stating that all the tests have been carried out and results are in
accordance with the manufacturer’s product specifications and requirements of Table 1, Table 2
and Table 3.
2. COATING MATERIAL
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Dec. 1997 IPS-G-TP-335
31
Dec. 1997 IPS-G-TP-335
ATTACHMENT NO.3
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Dec. 1997 IPS-G-TP-335
Grit blast cleaning shall be carried out by machine as per ISO 8504 part 2, to a cleanliness standard
of Sa 2½ in accordance with ISO 8501/1.
The abrasive used shall be steel or chilled shot and iron grit conforming to ISO 11124 parts 1-4.
Abrasive material that becomes worn or dirty shall be replaced with frequent small additions of new
grit. Infrequent large addition shall be avoided. The compressed air for blasting shall be free of
water and oil. Adequate separators, filters or traps shall be provided. Supplier shall submit for
approval a procedure to periodically verify re-cycled grit quality in accordance with ISO 11125 parts
1-7.
The surface profile shall be within the range Rz 60 to 100 microns and shall be measured according
to ISO 8503/4 (measured with 2.5 mm cut off) or using replica tape system. Surface profile shall be
checked at a frequency of once every hour. The value shall be recorded in the in the inspection
report.
The steel surface shall be 100% visually inspected immediately after blast cleaning and all defects
shall be removed by filling/grinding. The blast cleaned surface shall not be contaminated with dust,
metal particles, hydrocarbons, water, etc. or foreign matters which could be detrimental to the
applied coating. Test for dust contamination shall be carried out in accordance with ISO 8502/3.
Requirements for dust contamination shall be class 2 maximum. The coating process shall
commence after completion of blast cleaning of the steel surface. The total elapsed time between
the start of blasting of any line pipe and the heating to the specified temperature shall not exceed
the following time-humidity table:
Any pipe surface not processed within the above time-humidity table shall be completely re-blasted
before coating.
Note:
In order to avoid risk of condensation, temperature of environment and/or steel surface must be 3C
higher than the dew point.
After blast cleaning and before application of the epoxy primer, Soluble salts (Chloride
contamination) on the steel surface shall be checked using an approved salt detector instrument
measuring conductivity, SCM400 or equivalent. Soluble salt content shall not excess 2
2 2
micrograms/cm . Line pipes with Chloride contamination in exceed of 2 micrograms/cm shall be
subject to chemical pretreatment using an approved Phosphoric acid solution.
The surface to be coated shall be heated to a temperature of 45 - 65C, and treated with a low
pressure (0.5 – 2.0 bar) spray application of a max. 10% v/v solution of an approved acid washing
material and process. A uniform PH of 1 or less shall be maintained over the entire surface of the
treated area. The acid washed pipe surface shall remain wetted for approximately 20 seconds (15 –
30) and then rinsed with clean potable water, before its starts to dry out.
High-pressure water rinses at 700-1000 psi (50-70 bar) shall be used to remove any treatment
residue. The wetted surface of the rinsed pipe shall have a PH of 6 or greater.
Water must be clean with less than 200 ppm total dissolved solids and <50 ppm chlorides, and a
conductivity of <100 microns Siemens. The water shall not be reused.
The chloride level shall be retested.
The Contractor shall ensure that the temperature of the substrate is maintained between 45 -60C
and Chromate solution temperature does not exceed 45C.
The diluted solution of Chromate (typically 10% v/v in clean potable water as in 2.2 above) shall be
applied to the blast-cleaned steel surface by a suitable method that results in a completely wetted
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Dec. 1997 IPS-G-TP-335
surface with a uniform film of Chromate solution remaining on the surface. Any drainage
concentration, drips, etc. shall be removed by wiping or other suitable means.
The Contractor shall be fully responsible for adherence to local regulations and material safety
sheets for using chromate solution.
The pipe shall be uniformly heated in accordance with the manufacturer's specified temperature
limits, but shall not exceed 270C.
The surface temperature of the pipe immediately prior to epoxy powder application shall be
monitored and controlled within the limits recommended by the powder manufacturer.
The temperature control shall be in accordance with the description in paragraph 1.4.2.
Oxidation of the steel prior to coating in the form of "blueing" or other apparent oxide formation is
not acceptable. If such oxidation occurs, the pipe shall be set aside and re-cleaned.
The coating shall be applied to the pipe surface by electrostatic spray with the pipe at earth potential
and the epoxy powder charged to high potential.
Pipe temperature shall be checked and recorded periodically by Tempil sticks (3-6 times per pipe
joint) or a recording Pyrometer.
If a Pyrometer is used, it shall be checked for error not less that every four hours against a
calibrated temperature measuring instrument.
Prior to starting the FBE powder application, the recovery system shall be thoroughly cleaned to
remove any unused powder.
Recycled powder is permitted only when collected and processed through a closed system, which
controls the ratio of recycled to virgin powder. The ratio of recycled powder to virgin powder shall
not exceed 20%.
When coating application on a pipe length is discontinuous, the pipe shall be rejected, stripped of its
coating and prepared for recoating.
The minimum thickness of the FBE layer at any point shall be 200µm.
The contractor shall ensure that the rollers push adhesive film to eliminate any air entrapment or
voids. The adhesive layer shall be applied before gel time of the FBE has expired by using either
the Cross-head or Side extrusion technique. Application of the adhesive shall not be permitted after
the FBE has fully cured. The Contractor shall establish to the satisfaction of purchaser's
representative that the adhesive is applied within the gel time window of the FBE and at the
temperature specified by the FBE manufacturer. The Contractor shall state the proposed minimum
and maximum time interval between FBE and adhesive applications at the pipe temperature range
and overlap.
The minimum thickness of the adhesive shall be 150µm and in accordance with the coating material
manufacturer's recommendations.
The H.D.PE/PP shall be applied over the adhesive immediately after the adhesive layer. The
extrusion process shall be controlled such that no air is trapped between the adhesive and
polyethylene/Polypropylene layer or internally within the polyethylene/Polypropylene. The tension
applied to the polyethylene/Polypropylene layer shall be kept at a minimum level to prevent
additional stresses being built into top coat.
The polyethylene/Polypropylene top coat shall be applied to have a minimum three-layer coating
total thickness as specified in table 4.
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Dec. 1997 IPS-G-TP-335
Up to DN
0.2 (200) 0.15 (150) 2.5 2.5
500 (20)
DN 500 (20) up
0.2 (200) 0.15 (150) 3.0 2.5
to DN 900 (36)
Note:
The increased cut back length up to 30 Cm. on maximum 2% of coated line pipes may be Acceptable,
subject to the purchaser's approval. In this case, the applicator shall Supply the suitable size and
quantities of Heat Shrinkable sleeve and relevant accessories.
The minimum tests to be carried out and the frequencies in qualification (pre-production) and
production stages are specified in table 6 and table 7. All tests listed in table 6 and table 7 shall be
addressed in the APS.
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Dec. 1997 IPS-G-TP-335
Indentation resistance
At 23 ± 2C e ISO 21809-1 ≤0,2 ≤0,1
mm
at maximum class (Annex F) ≤0,4 ≤0,4
temperature
Elongation at break at 23±
% ISO 527 ≥400% ≥400%
2C e
ISO 21809-1
Flexibility at 0C - No cracking at 2.5/ pipe diameter length
(Annex I)
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Dec. 1997 IPS-G-TP-335
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Dec. 1997 IPS-G-TP-335
Minimum adhesive thickness ISO 2808 150 mm on pipe body at start up once per shift
ISO 21809-1
Degree of cure of the Epoxy (Annex D) -2C ≤ ΔTg ≤ +3C at start up once per shift
ISO 11357-2
Uniform colour, free of
defects and
Appearance Visual discontinuities, continuously continuously
declamations and
separations
ISO 21809-1
Holiday detection No holidays at 25 Kv. each pipe each pipe
(Annex B)
ISO 21809-1
Total thickness of coating Table 4 5 pipe every 10 pipes
(Annex A)
ISO 21809-1 Table 5
Impact resistance 3 pipe once per PE/PP batch
(Annex E)
Peel strength @ 23C ISO 21809-1 Table 5 5 pipe every 4 h
a)
@ Tmax (Annex C) 3 pipe once per 100 pipe
Indentation resistance @ Table 5
ISO 21809-1
23C once once per PE/PP batch
(Annex F)
@ Tmax
Table 5
Elongation at break ISO 527 once once per PE/PP batch
Cathodic disbondment test
once once per 4000 pipe
@ 23C/28 days/-1.5V ISO 21809-1
Table 5 once once per week
@ 65C/2 days/-1.5V (Annex H)
- once per order
@ 80C/28 days/-1.5V
ISO 21809-1 Table 7
Flexibility once -
(Annex I)
Average: 25gauss
Residual magnetism See 4.1 each pipe each pipe
Max: 30 gauss
Δ MFR max. 35% for
In process degradation of PP;
ISO 1133 once once per PE/PP batch
PE/PP 20% for PE between raw
and extruded material
Thermal cycle resistance Thermal cycle resistance
1 cycle: -30C/1 hr 1 cycle: -30C/1 hr
- See Note "b" below No crack
1 cycle: +70C/1 hr 1 cycle: +70C/1 hr
No. of cycles: 100 No. of cycles: 100
No voids or air
Porosity (Air entrapment) See 4.5 5 pipes every 4 h
entrapment
Bonding of coating on No voids or air
See 4.4 Once Once per week
longitudinal weld entrapment
Hot water soak test (for FBE) No disbondment or
See 4.3 2 pipes Once per FBE batch
hours @ 80C blistering
Refusal to peel or a
Adhesion of FBE See 4.2 2 pipes Once per FBE batch
cohesive failure
Specific Electrical Insulation DIN 30670
≥ 10 Ω.m
10 2
Once Once per PE/PP batch
Resistance DIN 30678
UV Resistance and Thermal ISO 21809-1 Max. ±35% change of
Once Once per PE/PP batch
ageing (Annex G) MFI
100 ±5 mm up to 20"
Cutback Measuring each pipe each pipe
150 ±10 mm ≥20"
Visual/Holiday
once for
Coating repairs detection (see no holidays each defect
demonstration
clause 6)
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Dec. 1997 IPS-G-TP-335
Notes:
,
a) For peel testing at Tmax a sample of coated pipe shall be conditioned (or heating the internal surface
of the pipe at test location) for at least one hour at the test temperature. The surface temperature shall
be monitored during the test and the results reported.
The test sections shall be notched with a length of 30 mm and a depth of 0.3 mm and then Tested.
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Dec. 1997 IPS-G-TP-335
5. RE-TEST
In case of failure of any required test, the Coater shall test two additional pipes, one pipe before and
after the failed one. If the follow-up tests are successful, all pipe coated since the last acceptable
test shall be considered acceptable except for the failed pipe that will be rejected.
If the follow-up tests also fail to meet the requirements of this specification, all pipes coated since
the last acceptable test shall be rejected.
All the repairs carried out on defects with exposed steel, shall be recorded by the Applicator.
The Applicator shall prepare detailed coating repair procedure, including all types of expected
defects, and coating stripping procedure for line pipes. Coating repair and stripping procedures shall
be both approved and qualified by Purchaser before start of production.
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Dec. 1997 IPS-G-TP-335
1. SCOPE
Determining the presence of air entrapment (porosity or bubbles) in the plant applied coating.
2. EQUIPMENT
Microscope – Hand Held 30X.
Utility knife.
3. TEST SPECIMEN
Strips from adhesive (peeling) tests of coated line pipe shall be used to determine the air
entrapment.
4. PROCEDURE
Adhesion (peeling) strip shall be viewed from the side and the failure interface. At the line pipe
adhesion (peeling) test site use a utility knife to cut the edge of the coating to a 45 angle and
view with a microscope.
Perform a similar test in the cutback area. This should be used for information to determine if
further testing is required.
5. REPORTING
Report line pipe number, date pipe was coated, coating batch number, and date of test.
Report cross-section and interface air entrapment (if any).
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