Final March 13, 2012

Pipeline Construction: Quality Issues and Solutions Action Plans

Field Applied Coatings Best Practices

Field Applied Coatings Best Practices Table of Contents

Team Members ......................................................................................................................... ii Section 1. General/Rationale ................................................................................................... 1 Section 2. Terms and Definitions ............................................................................................ 1 Section 3. Coating Material Handling & Storage .................................................................... 3 Section 4. Training and Qualification ..................................................................................... 3 Section 6. Field Application .................................................................................................... 5 Section 7. Inspection Procedures ........................................................................................... 8 Section 8. Remediation and Re-Inspection ............................................................................ 9 Appendix A. Referenced Standards ...................................................................................... 10 ISOInternational Organization for Standardization ................................................................... 10 NACENational Association of Corrosion Engineers ................................................................. 11 SSPCThe Society for Protective Coatings ................................................................................. 11 ASTMAmerican Society for Testing and Materials ................................................................... 12 Appendix B. Sample Forms for Reporting, Data Management & Certification Procedure Qualification and Quality Control Report ..............................................................................13 Applicator Qualification Report .............................................................................................15 Coating Application and Inspection Report ..........................................................................17 Coating Repair Report ............................................................................................................19 Appendix C. Coating Training Guidance from Team 5, Training Guidance (KISS) for Construction Workers and Inspectors Welding & Coating ............................................... 21

The INGAA Foundation | Field Applied Coatings Best Practices

Team Members Craig Linn, Williams1 Dave McQuilling, Southern Union 2 Mike Adams, Valspar Steve Baker, Denso Robert Bendure, Sheehan Pipeline Construction Matt Cetiner, TransCanada Matt Dabiri, El Paso Joe Glassco, Akzo Nobel David Matlock, Williams Chris McLaren, PHMSA Southwestern Region, Craig Meier, Sunland Construction Tracy Menard Specialty Polymer Coatings Mitch Pfeiffer, Commercial Coating Services Greg Ruschau ExxonMobil Peter Singh, Bredero Shaw Kuruvila Varughese, Dupont Jeff Wilkins, 3M

1 2

Working Group Lead Technical Leads 3 Drafting Team

The INGAA Foundation | Field Applied Coatings Best Practices

ii

Section 1. General/Rationale
The proper application of fusion bond epoxy powder and liquid coatings in the field on a pipeline construction project, either on girth welds or various required repairs, is an essential element to the successful longterm integrity of a pipeline. There are numerous products and procedures used by the industry. The purpose of this work group is to document common-sense best practices in the form of a white paper for use by Operators, Material Suppliers, Applicators and Contractors (corrosion control personnel, design engineers, project managers, purchasers, and construction engineers and managers). It is applicable to immersion and underground steel pipelines with applied Cathodic Protection in the oil and gas gathering, distribution and transmission industries. 1.1. This document presents best practices for establishing field installation parameters and inspection procedures to ensure proper application and performance of field-applied coatings. Included are methods for qualifying and controlling the quality of field-applied products, guidelines for proper application and inspection and repair techniques to ensure long-term performance. These practices are applicable to field applied coating systems used to prevent external corrosion in immersion/buried service. These practices are applicable to new construction, rehabilitation, re-coating and field repairs. All applicable health, safety and environmental codes, rules and regulations shall be followed when using these practices including product and material safety data sheets.

1.2. 1.3. 1.4.

Section 2. Terms and Definitions

For the purposes of this document, the following terms and definitions apply:
application procedure specification - APS document describing procedures, methods, equipment and tools used for coating application applicator company that undertakes the coating application in accordance with the provisions of this part of ISO 21809 batch quantity of material produced in a continuous manufacturing operation using raw materials of the same source and grade batch certificate certificate of analysis issued by the manufacturer bonding agent material applied as a film to the primed metal surface in order to ensure adhesion of the subsequent protective coating certificate of compliance one of the types of inspection documents defined by ISO 10474, issued in accordance with the purchasing requirements coating operative individual undertaking coating activity on the work site, including surface preparation

The INGAA Foundation | Field Applied Coatings Best Practices

cutback length of pipe left uncoated at each end for joining purposes (e.g. welding) end user company that owns and/or operates the pipeline system field joint area weld zone uncoated area that results when two pipe sections or a pipe section and a fitting with coating cutbacks are assembled, by welding, in the field 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 resources and procedures inspector end user and/or purchasers representative responsible for one or more of the inspections specified in this document manufacturer company responsible for the manufacture of coating material maximum design temperature of field joint coating - Tmax maximum continuous temperature that the field joint coating can resist maximum operating temperature maximum temperature that can be reached during operation of pipeline overlap length of the field joint coating over the plant-applied coating including the coating bevel 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 pre-production trial - PPT application of coating and inspection/testing of its properties, to confirm that the APS is able to produce a field joint coating with the specified properties, carried out in the field immediately prior to start of production primer material applied as a film on substrate (metal and/or plant coating) to ensure adhesion of the subsequent protective coating

The INGAA Foundation | Field Applied Coatings Best Practices

procedure qualification trial - PQT application of a field joint coating and subsequent inspection/testing of its properties, to confirm that the APS is able to produce a coating with the specified properties, carried out at the premises of the applicator or any other agreed location purchaser company responsible for providing the product order requirements wraparound sleeve sleeve that is wrapped, circumferentially, around the steel pipe area being coated

Section 3. Coating Material Handling & Storage

3.1. The applicator shall ensure that the materials used for surface preparation and the coating(s) comply with the material specification and that the manufacturers storage instructions are followed. Powder shall be transported and stored in a sealed container that prevents the ingress of moisture or water. Transportation and storage climate shall be controlled to meet the manufacturers requirements and conformance shall be demonstrated by temperature-indication tags or other logging devices. Contractor shall request special procedures to be prepared by the manufacturer for field storage. Contractor shall load only enough materials to be used for each days shift. Avoid exposing coating materials to adverse climate conditions like sun, rain, snow and humidity. Unused material shall be inspected to ensure useful life. Follow manufacturers recommendation to ensure shelf life is not exceeded. Abrasive blast media shall be stored in a dry and controlled environment.

3.2. 3.3.

3.4. 3.5. 3.6. 3.7.

Section 4. Training and Qualification

4.1. The contractor shall provide a qualified coating foreman/crew by one of the following methods: 4.1.1. Pre-qualified coating foreman/crew members were previously trained by the coating supplier/applicator

4.1.2. The coating supplier provides a technician to train the contractors coating foreman/crew at the job site. Company Representative should be involved in this training.

The INGAA Foundation | Field Applied Coatings Best Practices

4.1.3. Coating foreman/crew members demonstrate on a production weld that they are trained and knowledgeable in the preparation of the pipe and the application of the specific coating being applied as agreed by end user. Recommend verification that the employees have been trained; i.e. card, hard hat sticker, letter, etc. 4.2. 4.3. 4.4. The contractor is responsible for maintaining trained personnel on the project through completion. If Operator Qualification is required, assure that all covered tasks have been completed for the coating foreman/crew. Company inspector shall be trained and knowledgeable in coating application procedures and in use of inspection instruments, have a complete set of inspection instruments and be able to demonstrate their use.

Section 5. Surface Preparation

5.1. 5.2. 5.3. Applicable worker health and safety regulations must be followed Applicable environmental regulations must be followed to contain blast media and removed coatings. Effective containment also minimizes damage to nearby structures or property. Abrasive blasting shall only be permitted under the following environmental conditions: 5.3.1. The temperature of the surface to be blasted or painted is more than 5F (3C) above the dew point temperature. Multiple surface temperature readings may be required for full-sun and shade readings. 5.3.2. The surface temperature and relative humidity is expected to remain reasonably stable for a sufficient time for the completion of abrasive blasting and applying coating. 5.3.3. The pipe and related components are dry. 5.3.4. Adverse conditions (e.g., fog, mist, rain, dust, or excessive wind) do not exist or are controlled. 5.4. Abrasive blast media shall conform to the following requirements: 5.4.1. Shall be supplied in original packaging from supplier/manufacturer 5.4.2. Conform to SSPC AB1, Abrasive Blasting Spec for Mineral and Slag Abrasives 5.4.3. Shall be suitable for achieving the required anchor profile 5.4.4. Blast media shall not be reused, unless utilize an automatic recovery system 5.4.5. If preheating is required due to ambient temperatures, this should be done prior to blasting, however in low ambient temperatures additional heating may be required after blasting while maintaining surface temperature 5F (3C) above the dew point. 5.5. Air compressors utilized for abrasive blasting and/or air cleaning shall meet the following requirements:

The INGAA Foundation | Field Applied Coatings Best Practices

5.5.1. Shall provide moisture and oil free air as verified by a 30-second white rag test. Filters, separation, and/or dehydration equipment shall be utilized as required to meet this requirement. 5.5.2. Shall be capable of providing recommended pressure at abrasive blast nozzle (typically 90-110psi) as measured with a hypodermic needle gauge. 5.6. 5.7. Abrasive blast nozzle orifices are within 25% of their rated sizes. Non-conformant nozzles shall be replaced. The weld zone and surfaces including bare and specified overlap to be coated shall be inspected and cleaned according to SSPC-SP1 to remove mud, oil, grease, moisture, and loosely adhering deposits. Visible oil and grease spots shall be removed by solvent wiping. Only safe, residuefree environmentally approved solvents shall be used. All weld spatter, rough welds, burrs, and sharp steel surfaces shall be ground smooth using an approved grinding method or filing techniques prior to blasting. Grinding or filing shall not reduce the wall thickness below the specified minimum wall thickness of the pipe Blasted surfaces shall be inspected using replica tape or equivalent to verify that the specified anchor profile has been achieved. A minimum of two inspections per shift is required dependent upon applicators performance. Blasted surfaces shall be verified to meet all agreed upon visual standards or equivalent. Special attention shall be given to areas where local geometry complicates proper blasting (e.g., welds, corners, and lap joints). Special attention shall also be given to tight quarters and locations that are difficult to access. All bare surfaces to be coated shall be dry abrasive blast cleaned to "Near-White" metal in accordance with NACE #2/SSPC-SP10 (latest version) per SSPC-Vis 1. The anchor pattern profile shall be a minimum of 2.0 mils to a maximum of 4.5 mils. Variation in required anchor pattern profile may be altered based on manufacturers recommendations with Company approval. Adjacent areas of sound/existing coating shall be feathered in a 1 inch (2.54 cm) minimum radius around the exposed metal or blast area. This process should remove approximately 1 mil of coating. Cleaned surface shall be dry air blasted to remove dust and debris, and shall be coated within 4 hours of blast cleaning. All blast-cleaned surfaces that are not coated before flash rusting occurs shall be re-blasted prior to coating. All spent abrasive shall be disposed of in accordance with applicable regulation.

5.8.

5.9.

5.10. 5.11.

5.12.

5.13.

Section 6. Field Application

6.1. Liquid Coatings 6.1.1. Coating Identification. The liquid coating (epoxy, polyurethane or other) shall meet the requirements outlined by the customer. 6.1.2. Coating Application The INGAA Foundation | Field Applied Coatings Best Practices 5

6.1.2.1.

The coating shall be applied following the manufacturers recommended guidelines and procedures. There are several application methods currently being used today. Spray application via plural component unit is typically employed when the scale of the project warrants its use. Use of this equipment is determined by the applicator. Hand application is also an acceptable means of applying liquid coatings today. Methods of application include roller, brush squeegee and in some applications glove/mitt. Regardless of the application method, always follow the manufacturers recommended guidelines and procedures. If mixing is required, ensure it is carried out in accordance with manufacturers recommendation. Only mix full packages of parts A and B. The coating thickness shall be as specified by the coating manufacturer or the coating specification provided by the pipeline owner. The steel surface temperature shall be at least 5F (3C) higher than the dew point temperature. The relative humidity and the steel surface temperature shall not be higher than the recommended maximum. The contractor shall use industry accepted equipment to monitor these environmental requirements. Application shall be done in such a manner so as to minimize sags and runs, provide adequate coverage in angles and crevices, and to provide a reasonably uniform coating. If several coats are required to achieve the specified coating thickness, follow the coating manufacturers application recommendations for recoat times and procedures. The coating shall be allowed to cure per the coating manufacturers recommendations prior to back filling, installation or handling.

6.1.2.2. 6.1.2.3. 6.1.2.4.

6.1.2.5.

6.1.2.6.

6.1.2.7. 6.2.

Fusion-bonded epoxy (FBE) powder coatings 6.2.1. Coating identification. The epoxy powder for a single-layer coating and for the base layer of a two-layer coating shall meet the requirements outlined by the customer.

6.2.2. Application of the coatings: General 6.2.2.1. Prior to application, the powder shall be allowed to acclimate for a period of at least 30 minutes or until the powder is at the ambient air temperature prior to opening the sealed bag. Failure to do this could result in the material absorbing water from the air.

6.2.2.2.

Application of the coating shall be carried out in accordance with the material manufacturers application guide and current industry recognized standards. The INGAA Foundation | Field Applied Coatings Best Practices 6

6.2.2.3.

When over-coating existing coating material such as fusion bond epoxy (FBE) in such applications as field joint or abrasion resistant overcoat work, the existing coating shall be sweep blasted to remove the gloss and provide a roughened surface suitable for over-coating. This process should remove approximately 1 mil of coating. Existing coating shall be feathered to a minimum of 1 inch (2.54 cm) when coating adjacent bare steel, such as rehabilitation or girth weld work. Prior to blasting the temperature of the field joint should be made as uniform as possible either by shielding the area from the sun or pre-heating. The more uniform starting temperature of a field joint can optimize the uniformity of the joint temperature when heated to coating application temperature.

6.2.2.4. 6.2.2.5.

6.2.3. Heating CAUTION For pipe grades over X80 the excessive heat can affect the pipe properties. 6.2.3.1. The field joint area should be uniformly preheated, using a calibrated inductionheating coil to +/- 15 deg F, to a temperature as recommended by the powder manufacturer. If a Pre-Qualification Trial is performed, the rate and uniformity of the heat pattern shall be verified and documented. The typical coating range for FBE is between 425F and 488F (218C and 253C). The temperature of the field joint shall be monitored using temperatureindicating non-oily crayons or other temperature measuring device (e.g. hand held, direct reading thermocouple or contact thermometer) to ensure that the application conditions are fully satisfied and the temperature is uniform across the steel substrate and the plant applied coating. The methods of monitoring and recording shall be specified by the customer. The pipe temperature shall be monitored for both the target coating temperature, typically 463F (239 C), and a maximum allowed coating temperature, typically 488F (253C). The amount of crayon used shall be the minimum required for accurate measurement. Any residue left from a temperature indicating crayon shall not be brushed off as brushing of the melted mark only serves to distribute it over a larger surface area. The maximum pipe temperature shall not exceed 527F (275C) or temperature specified by Company The heating time and the temperature shall not: result in oxidation, blueing of the surface of the steel detrimental to the quality of the field joint coating. damage the plant applied coating. With some coatings it should be remembered that re-heating will cause the coating to darken or take on a yellow or brown tinge. The INGAA Foundation | Field Applied Coatings Best Practices 7

6.2.3.2.

6.2.3.3. 6.2.3.4.

6.2.3.5.

If a delay results in surface cooling to below the temperature range specified by the powder manufacturer, the pipe shall be reheated, and if required the abrasive blasting shall be repeated to meet specification requirements.

6.2.4. Application of epoxy powder 6.2.4.1. The FBE shall be applied immediately after the substrate has attained the correct temperature. The field joint shall not be allowed to cool below the minimum application temperature before coating is applied. If the pipe does excessively cool it shall be re-blasted and re-heated. Equipment Preparation Ensure that equipment and hoses are free of powder build-up and contaminants as this has potential to dislodge during application and generate defects on the coating. All powder application equipment and hoses shall be cleaned daily. At the start of the shift and after any break the coating ring needs to be checked to ensure that the powder is uniformly flowing out of all applicators.

6.2.4.2.

6.2.4.2.1.

6.2.4.2.2. 6.2.4.2.3.

6.2.4.3. 6.2.4.4.

The FBE overlap onto the plant applied coating should be a minimum of 1 inch (2.54 cm). The FBE powder should be uniformly applied, by means of a semi-automatic powder ring or carriage which is fitted to and rotates around the pipe to cover the blast cleaned and pre-heated surface, to provide the specified minimum dry film thickness (DFT). Alternative methods may be used with the approval of the end user. The coating shall be allowed to cure for the time recommended by the coating manufacturer prior to any movement or inspection taking place. Cured field applied FBE shall not be over-coated with another layer of FBE.

6.2.4.5. 6.2.4.6.

Section 7. Inspection Procedures

7.1. Abrasive blast cleaning operations shall not be conducted on surfaces that are less than 5F (3C) above dew point. If the surface temperature is less than 5F (3C) above the dew point with Company approval, the exposed bare surfaces shall be pre-heated to 150F (66C). The surface temperature shall be monitored with temperature-indicating sticks such as Tempilstik, or with digital thermometers. Anchor pattern profile shall be measured with either replica tape such as Press-O-Tape or digital surface profile gauges and the measurement results documented. The profile shall be in accordance with Section 4.14. The frequency of required documentation shall be site or projectspecific and approved by Company personnel. The INGAA Foundation | Field Applied Coatings Best Practices 8

7.2.

7.3.

Dry film thickness on liquid and cured FBE shall be measured by an approved mil gauge calibrated twice per shift. 7.3.1. All mud, moisture, or other contamination on the coating shall be removed before jeeping. 7.3.2. Holiday detectors shall be calibrated according to manufacturers specifications at a minimum of twice per day normally at the beginning of the day and approximately 1/2 way through the shift. The test voltage should be verified during calibration. 7.3.3. Jeeping or holiday detection shall be performed at each coating area. Detection voltage should be based on specified nominal pipe coating thickness and calculated in accordance with NACE Holiday Detection Standard, SP 0490, but other detection voltages may be set by the Company. Pulse jeep detectors are also acceptable.

7.4.

The detector shall readily detect and indicate a holiday (natural or artificial [for calibration]) both audibly and visually. Under no circumstances shall brass brushes or angel hair be used for jeeping. The electrode shall be kept free of coating material and in suitable mechanical condition to maintain contact with the coated surface at all times.

Section 8. Remediation and Re-Inspection

8.1. The acceptable size and frequency of field joint coating repairs and the repair procedures shall be subject to agreement between the purchaser and the applicator. The repair procedures shall be included in the Companys specification. Holidays and damaged areas in the FBE coating shall be repaired using two-part epoxy or polyurethane repair materials in accordance with the manufacturers recommended practice and the Companys specification. Due to difficulty in proper application, use of melt sticks is not recommended. Holidays shall be cleaned by removing all rust, scale, dirt, other foreign material, and loose coating. The repair areas, both the holiday and the adjacent coating, shall be suitably roughened in accordance with the repair materials manufacturers recommendations. Dust shall be removed with a clean, dry cloth, brush or air. All repairs shall have a minimum dry film thickness at least equal to the minimum specified coating thickness for the parent coating. The overlap of the repair coating onto the parent coating shall be a minimum of 1 inch (2.54 cm). All repairs shall be holiday tested as described in Section 6.

8.2.

8.3. 8.4.

8.5.

8.6.

The INGAA Foundation | Field Applied Coatings Best Practices

Appendix A. Referenced Standards

ISOInternational Organization for Standardization ISO 8501-1 Preparation of Steel Substrates Before Application of Paints and Related Products - Visual Assessment of Surface Cleanliness - Part 1: Rust Grades and Preparation Grades of Uncoated Steel Substrates and of Steel Substrates After Overall Removal of Previous Coatings Preparation of steel substrates before application of paints and related products. Visual assessment of surface cleanliness. Preparation grades of previously coated steel substrates after localized removal of previous coatings Preparation of Steel Substrates Before Application of Paints and Related Products - Visual Assessment of Surface Cleanliness - Part 3: Preparation Grades of Welds, Edges and Other Areas With Surface Imperfections Preparation of steel substrates before application of paints and related products Tests for the assessment of surface cleanliness Preparation of Steel Substrates Before Application of Paint and Related Products - Tests for the Assessment of Surface Cleanliness - Part 3: Assessment of Dust on Steel Surfaces Prepared for Painting (Pressure-Sensitive Tape Method) Preparation of Steel Substrates Before Application of Paints and Related Products - Tests for the Assessment of Surface Cleanliness - Part 4: Guidance on the Estimation of the Probability of Condensation Prior to Paint Application Preparation of Steel Substrates Before Application of Paints and Related Products - Tests for the Assessment of Surface Cleanliness - Part 6: Extraction of Soluble Contaminants for Analysis - the Bresle Method Preparation of Steel Substrates Before Application of Paints and Related Products - Tests for the Assessment of Surface Cleanliness - Part 9: Field Method for the Conductometric Determination of Water-Soluble Salts Preparation of Steel Substrates Before Application of Paints and Related Products - Surface Roughness Characteristics of Blast-Cleaned Steel Substrates Part 1: Specifications and Definitions for ISO Surface Profile Comparators for the Assessment of Abrasive Blast-Cleaned Surfaces Preparation of Steel Substrates Before Application of Paints and Related Products - Surface Roughness Characteristics of Blast - Cleaned Steel Substrates Part 2: Method for the Grading of Surface Profile of Abrasive BlastCleaned Steel - Comparator Procedure Preparation of Steel Substrates Before Application of Paints and Related Products - Surface Roughness Characteristics of Blast -Cleaned Steel Substrates Part 3: Method for the Calibration of ISO Surface Profile Comparators and for the Determination of Surface Profile - Focusing Microscope Procedure

ISO 8501-2

ISO 8501-3

ISO 8502 - 1 ISO 8502-3

ISO 8502 - 4

ISO 8502-6

ISO 8502-9

ISO 8503-1

ISO 8503-2

ISO 8503-3

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ISO 8503-4

Preparation of Steel Substrates Before Application of Paints and Related Products - Surface Roughness Characteristics of Blast-Cleaned Steel Substrates - Part 4: Method for the Calibration of ISO Surface Profile Comparators and for the Determination of Surface Profile - Stylus Instrument Procedure Preparation of Steel Substrates Before Application of Paints and Related Products - Surface Roughness Characteristics of Blast-Cleaned Steel Substrates - Part 5: Replica Tape Method for the Determination of the Surface Profile

ISO 8503-5

NACENational Association of Corrosion Engineers NACE RP0105 NACE RP0287 NACE RP0394 NACE SP0188 NACE RP0402 NACE RP0490 Standard Recommended Practice Liquid-Epoxy Coatings for External Repair, Rehabilitation, and Weld Joints on Buried Steel Pipelines Field Measurement of Surface Profile of Abrasive Blast Cleaned Steel Surfaces Using a Replica Tape Application, Performance, and Quality Control of Plant-Applied, FusionBonded Epoxy External Pipe Coating Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates Field-Applied Fusion-Bonded Epoxy (FBE) Pipe Coating Systems for Girth Weld Joints: Application, Performance, and Quality Control Holiday Detection of Fusion-Bonded Epoxy External Pipeline Coatings of 250 to 760 Micrometers (10 to 30 Mils) Item No. 21045

SSPCThe Society for Protective Coatings SSPC AB 1 SSPC AB 3 SSPC GUIDE 15 SSPC PA 2 SSPC SP 1 SSPC SP 2 SSPC SP 3 SSPC SP 10 SSPC SP 11 Mineral and Slag Abrasives Newly Manufactured or Re-Manufactured Steel Abrasives Field Methods for Retrieval and Analysis of Soluble Salts on Steel and Other Nonporous Substrates Measurement of Dry Coating Thickness with Magnetic Gages Solvent Cleaning Hand Tool Cleaning Power Tool Cleaning Near-White Metal Blast Cleaning (NACE NO. 2) Power Tool Cleaning to Bare Metal

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ASTMAmerican Society for Testing and Materials ASTM D 4285 ASTM D 4940 ASTM D 5162 ASTM D 6677 Standard Test Method for Indicating Oil or Water in Compressed Air Standard Test Method for Conductimetric Analysis of Water Soluble Ionic Contamination of Blasting Abrasives Standard Practice for Discontinuity (Holiday) Testing of Nonconductive Protective Coating on Metallic Substrates Standard Test Method for Evaluating Adhesion by Knife

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Appendix B. Sample Forms for Reporting, Data Management & Certification Procedure Qualification and Quality Control Report
Coating Procedure Qualification/Quality Control Test Report Applicator Team Leader Name: QC Responsible Name: Test Piece No.: Test Piece Diameter [mm] Product Data Coating Batch/Lot #, Pt A Batch/Lot #, Pt B Batch Size Report No.: Date: Page:

Preheating Method Initial Substrate Temperature, C Final Preheat Temperature, C Remarks

Environment Data No. Location Ambient Temperature C Substrate Temperature C Humidity % Dew Point C Remarks

Post-Curing Method Post-Heat Temperature Duration, minutes Remarks

Test Data for Coating Controlling Document # Test Results No. 1 2 3 4 Test Abrasive Compressed Air Quality Pre-coating Visual Check Salt Contamination Test Criteria Conformance with SSPC AB 1 or SSPC AB 3 No visible contamination per ASTM D 4285 Visual per ISO 8501-1 and ISO 8501-3 Less than 20 mg/m (1.4x10-3 grains/ft2) equivalent NaCl ISO 8502-6 or ISO 8502-9 or SSPC GUIDE 15 SA2.5 ISO 8503-4 or ISO 8503-5 SA2.5, NACE RP0394 Within Manufacturer's stated criteria Test Results Remarks

5 6 7

Blast Cleaning Surface Profile Blast Cleaning Degree of Cleanliness Application Temperature [C]

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Coating Application Surface Visual Check

No popping, sagging, pinholes, or contamination. Defect density no greater than one defect or cluster per 1 m2 (12 ft2). 0.6 to 1.25 mm (24-49 mils) per SSPC PA 2 Per NACE SP0188, no holidays on test piece. Per ASTM G 14, 3.5 J (13 in.-lb) minimum Rating 1 to 3 per NACE RP0394, or 6 to 10 per ASTM D 6677 < 10% of DFT per ASTM G 17 Per NACE RP0394, 24hour, < 6.0 mm (0.25 in.) radius

9 10 11 12

Coating Application Thickness Holiday Detection Test Impact Test Water Soak/Adhesion Test Penetration Resistance Cathodic Disbondment (CD) Test CD Test No. 2 CD Test No. 3 Repair Procedure - visual Repair Procedure Holiday Detection

13 14 15 16 17 18 Notes:

No visible defects. No holiday in or at edge of repair.

Result of the Procedure Qualification Test Qualified Not Qualified APPLICATOR Name Signature Date

We certify that the statements in this record are correct and that the application was done in accordance with the relevant procedure. CONTRACTOR

APPROVALS COMPANY Name Signature Date OWNER

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Applicator Qualification Report

Coating Applicator Qualification Test Report Applicator Team Leader Name: QC Responsible Name: Test Piece No.: Test Piece Diameter [mm] Product Data Coating Batch/Lot No., Pt A Batch/Lot No., Pt B Batch Size Report No.: Date: Page:

Environment Data No. Location Ambient Temperature C Substrate Temperature C Humidity% Dew Point C Remarks

Applicator Qualification Test Name of Applicator Date of Birth Place of Birth Qualifications

Test Results No. 1 Test Coating Application Surface Visual Check Criteria No popping, sagging, pinholes, or contamination. Defect density no greater than one defect or cluster per 1 m2 (12 ft2). 0.6 to 1.25 mm (2449 mils) per SSPC PA 2 Per NACE SP0188, no holidays on test piece Per ASTM G 14, 3.5 J (13 in.-lb) minimum Rating 1 to 3 per NACE RP0394 < 10% of DFT per ASTM G 17 Per NACE RP0394, 24hour, < 6.0 mm (0.25 in.) radius Results Remarks

2 3 11 12 13 14 15 16 4 5

Coating Application Thickness Holiday Detection Test Impact Test Water Soak/Adhesion Test* Penetration Resistance* Cathodic Disbondment (CD) Test* CD Test No. 2* CD Test No. 3* Repair Procedure visual Repair Procedure Holiday Detection

No visible defects No holiday in or at edge of repair

* Tests to be performed only during PQT activities

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Notes

Result of the Applicator Qualification Test Qualified Not Qualified APPLICATOR Name Signature Date

We certify that the statements in this record are correct and that the application was done in accordance with the relevant procedure CONTRACTOR

APPROVALS COMPANY Name Signature Date OWNER

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Coating Application and Inspection Report

Coating Inspection Report Applicator Team Leader Name: QC Responsible Name: Report No.: Date: Page: Product Data No. Coating Batch/Lot No., Pt A Batch/Lot No., Pt A Batch Size

Abrasive Blast Media No. Media Type/Brand Lot Nos. Length/No. sections Remarks

Environmental Data No. 1 2 Notes: Time Ambient Temperature C Substrate Temperature C Humidity% Dew Point C Remarks

Identification Pre-coating inspection Pre-heating No. Joint or bend Visual Check Salt Cont. Oil/ Grease check/ Pre-heat No. (OK?) (reading) clean (OK?) temperature C

Coating Inspection Blast Cleaning Visual Checks Coating Application Post-curing Holiday Test Adhesion Notes (No. holidays) Test (rating) Compressed Air Surface Profile Surface TemperatureC Visual Check Thickness Temperature C Time at Cleanliness Quality (OK?) (mils) (OK?) Check (avg.) Temperature (Sa or SSPC (min)
designation)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Notes

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APPLICATOR Name Signature Date

CONTRACTOR

COMPANY

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Coating Repair Report

Coating Repair Report Applicator Team Leader Name: QC Responsible Name: Report No.: Date: Page: Environment Data No. 1 2 Coating Repaired Coating No. Pipe/ Joint Number Product Name Location of the Defect Length Position Type of Repair (Application Method) Brush Roller Spray Coating Repair Check Visual Check (OK?) Holiday Test (OK) Post-Curing Temp (C) Time (min) Notes Time Ambient Temperature C Substrate Temperature C Humidity % Dew Point C Remarks

1 2 3 4 5 6 7 8 9 10 11 12 13 14 Notes:

APPLICATOR Name Signature Date

CONTRACTOR

COMPANY

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Appendix C. Coating Training Guidance from Team 5, Training Guidance (KISS) for Construction Workers and Inspectors Welding & Coating

QUALITY CONTROL FIELD INSPECTION AND TEST PLAN Weld Joint Coating Procedure Page 1 Item No. 1 Activity Project Procedure Frequency Acceptance Criteria Contractor Responsibility Coating Foreman

Rev. 0
Operator Responsibility Action/Record

Safety JSA Prior to performing ANY duties the coating foreman must ID ALL Hazards

Safety Manual

Daily

Ensure ALL employees are wearing proper PPE for the relevant task at hand

Tailgate safety Appropriate P.P.E Complete & sign JSA Blasting Hood/Fresh Air Canister/Air Lines Gloves CO2 monitor Excavation safety review Demonstrates knowledge of manufacturing installation methods / techniques Field Verification report or equivalent Inspect & Examine pipe for non-visible contaminates. Blast and check profile Remove all Frayed/Loose coating near cutback Brush Blast existing FBE Daily coating foreman report.

Applicator qualifications

Manufacturers Specifications

Per Project

Inspection & Surface prep, (blasting)

Weld Joint

2 per shift

Understanding of manufacturing installation techniques Verification of Operator Qualification as applicable Test Pipe to see if non-visible contaminates exist. Clean as per Operator specification. Blasted to a NEAR WHITE finish per NACE #2 or SSPC-SP 10 Surface Profile will be checked and documented per NACE

Coating Foreman

Coating Foreman

Coating / Utility Inspector

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RP0287-2002 as applicable

Coating Application

Weld Joint

2 per shift

As per application specification. Pipe temperature has to be 5 degrees above dew point. Pre-heat pipe as per specification

Coating Foreman

Coating / Utility Inspector

Pipe Coating Inspection

Weld Joint

Each joint

No damage All coated pipe shall be tested at a minimum of three times: to locate holidays, after the holidays are patched, and just before pipe is lowered into the ditch. Check for appropriate coating thickness. Utilize holiday detector with voltage setting as specified in NACE SP 0490. In addition the holiday detectors batteries shall be checked every 4 hours and replaced/recharged if required. Calibrate holiday detector daily All holiday detection and holiday repairs shall be conducted to the satisfaction of the Coating Inspector.

Coating Foreman

Coating / Utility Inspector

Document temperatures Do not handle, lower in, or backfill until completely cured Measure dew point temperature and pipe temperature Daily coating foreman report Visual Inspect Jeep No record

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Coating repair

Weld Joint

As needed

Repair with two part epoxy in accordance with Operator specifications. Maintained and stored in accordance with manufacturing specifications.

Coating Foreman

Coating / Utility Inspector

No Record

Storage & Handling

Daily

Coating Foreman

Ensure proper Storage

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