MANUFACTURING PROCEDURE SPECIFICATION

of

Three Layer Polyethylene Coating

Coating Specification : CAN/CSA Z.245.21

Coating Thickness : 2 mm
Title Flow Process Diagram

START
Material proposal:

Epoxy Powder, certificate

Adhesive and PE
Material incoming inspection
Material Manufacture Making
1. Inspection of packaging & marking of material

Coating Applicator Material Proposal &

Coating Material
Receiving

Accepted No Separate

Yes Incoming pipe:

Receiving Bare Pipe  Surface defect
 Cleanliness
 Traceabillity record

Pre-Heating
(if Necessary)
Inspection & test on surface appearance:
 Visual & contamination
Blast Cleaning
ipe surface temperature, dew point and RH
 Compared with standard Sa 2 ½ ISO 8501

No  Humidity max 85%

Accepted
 2

Yes

B A
Title Flow Process Diagram

B A

Inspection:
Heating

FBE Application

Parameter check during process:

Adhesive
 Thickness
Application
 Temperature (pipe, adhesive & PE)

PE Application

Rough Coat
Application
(if needed)

Strip Off
Water Cooling

On line inspection

 Holiday detector

No
Accepted

Coating Repair Yes

Application

C D E
Flow Process Diagram

C D E

Final inspection:
 Cut back length
 Coating thickness

No Testing:
Accepted  Peel adhesion (constant rate)
 Impact resistance
 Elongation at break
Cutback
Yes Removal  Cathodic disbondment
 Tensile Stress at Yield

No
Accepted

Yes
Pipe Marking

Temporary Storage/
Delivery
Title Introduction

4.1 Scope
document defines materials, application, inspection, repair, handling and storag e
requirements of factory applied external three layer polyethylene coatings for the
anti-corrosion protection of steel line pipe.

This procedure is written with the intention of being a working instruction for shop
floor personnel by detailing the standard of workmanship and acceptance criteria
throughout each phase of the process.

4.2 Definitions
Supplier : Supplier of coating material
FBE : Fusion Bonded Epoxy
3LPE : Three Layer Polyethylene
Section 5
Title Code, Specifications, Standard and References

The following code, specifications, standards and reference are relevant to this document :

a. CAN/CSA Z.245.21 : External Polyethylene Coating for Pipe.

b. SSPC-SP10 : Surface Preparation Standards for Painting Steel Surface
c. ISO DIS 21809-1 : External coatings for buried or submerged pipelines
used in pipeline transportation systems.
d. ISO 8501-1 : International Organization for Standard Blast Cleaning.
e. ISO 8503-2 : Method for the grading of surface profile of abrasive blast-
cleaned steel — Comparator procedure
f. ISO 8502 : Preparation of steel substrates before application of paint and
related products
g. SSPC-PA2 : Measured of dry coating thickness with magnetic gages
Section 6
Title Responsibilities

6.1 Coating Plant Manager shall be responsible for all labor and equipment necessary
for the required operation. He shall also ensure that the operations are performed
in a safe manner and that the product meets the requirements specified herein.

6.2 QA, QC & CTS Manager responsible for ensuring that the Customer’s agreed quality
requirements are satisfied. He shall also ensure that the Q.C. inspectors inspect and
control the quality of the product in accordance with this document.
Section 7
Title Manufacturing process

7.1 Raw Materials

All materials selected for this process shall meet the requirements. Materials used shall
be informed to Customer.

All material used for production coating shall be visually inspected upon received (i.e.
type of manufactures name, material type, date of manufacture, batch/lot number, and
weight of material as minimum) shall be legible and packaging secure.

7.2 Inspection of incoming pipe

Incoming bare pipes are received and inspected by QC Inspectors. Every pipe will be
visually inspected for corrosion, dents, gouges and ovality. Only superficial defects shall
be accepted. Pipe which have damaged bevels, dents or have ovality shall be set aside
and recorded. The QC personnel shall be informed if any pipe is damaged.

7.3 Surface Preparation

On entering the Plant, pipes shall be placed on incoming racks where they shall be
inspected for contamination by oil or grease. Any contamination identified shall be
removed by proprietary solvent washing in accordance with SSPC-SP1 or steam
cleaning. Where excessive contamination is present, pipe shall be removed from the
system, quarantined for further action.

7.4 End Plugs

End plugs shall be placed inside both ends of the pipe to prevent the ingress of
abrasive during the blast cleaning process. These shall be removed immediately
after blasting, at which time any dust or abrasive accumulating inside the bore of
the pipe shall be removed by compressed air.

7.5 Blast Cleaning

The pipe shall undergo a blast cleaned process to remove surface rust and to raise
any slivers, scabs or other surface defects, allowing adequate steel inspection.

The abrasive shall be a selection of steel grit shot giving cleanliness (in accordance with
ISO 8501-1 SIS Standard- 05-59-00-Sa 2½ or SSPC-SP10) and a peak to trough profile

Residual abrasive/ dust shall be removed from the pipe surface on exit from the blasting
cabinet by means of an air knife, wire brush or other suitable means. Residue
accumulating on the internal surface shall be blown out using compressed air and
removed through the dust collector system.
Section 7
Title Manufacturing process

7.6 Post Blast Inspection

Every pipe entering the inspection area shall be inspected visually for cleanliness, steel
defects such as slivers, laminations and scabs. Surface defects considered detrimental
to the coating shall be removed by manual cosmetic grinding to eliminate any sharp
edges that may damage the corrosion coat or coating.
Any extensive grinding is required i.e., exceed API 5L or customer’s specification are
detected, pipes will be marked and place in the quarantine area for further action.

All pipes shall meet the requirements as specified in the Inspection and Test Plan.

7.7 End Taping or pipe coupling insertion

Before coating, the required cutback length shall be taped externally both ends of pipes
to protect the ends from being coated. Between two pipes shall be taped or pipe
couplings can be fitted onto one end of the pipe.

7.8 Induction
Prepared pipe is then conveyed through the induction coil that heating the entire pipe
length to the temperature range according to the FBE manufacturers recommendation
for 3-layer coating. At no time is the temperature to exceed 275°C so as to cause
`bluing’ or oxide formation on the surface of the pipe.

Air knife, steel brush and vacuum system (dust removal) shall clean the pipe before
entering the coating booth. After passing through the coil random temperature
checks will be carried out using “Tempil stiks” or pyrometer (digital thermometer).
Pipe shall be heated to within a temperature range in accordanc e with the coating
manufacturer recommendations. Pipe heated below the specified minimum and
above the specified maximum shall be reprocessed.

7.9 FBE – Powder Epoxy Application

The application of the Fusion Bonded Epoxy (FBE) powder shall be done by electrostatic
spray method, arranged and directed so as to obtain an even film thickness on the pipe
surface. The over-sprayed powder shall be passing through sieves.

The FBE powder shall be applied in such a manner as to give a dry film thickness as
specified in the Inspection and Test Plan.
Section 7
Title Manufacturing process

7.10 Adhesive (Intermediate Coat) Application

top/side of the pipe. The head is shaped in such a manner that a thin foil is spread
uniformly onto the pipe surface in a wrapping fashion. The foil shall then be pressed
against the pipe with a silicon rubber roller to ensure positive adhesion between the
adhesive and the FBE.

The edges of the adhesive foil shall overlap to give 100% coverage of the pipe surface.
The adhesive shall be applied in such a way as to give the total thickness as specified in
the Inspection and Test Plan.

The operating parameter of the adhesive extruder shall be maintained within the range
recommended by the adhesive’s manufacture.

7.11 Polyethylene (Top Coat) Application

Application of the polyethylene shall be extruded immediately, with the head positioned
at the top/side of the pipe. The head is shaped in such a manner that a thin foil of
polyethylene is produced uniformly onto the pipe surface in a wrapping fashion to
produce spirally overlapping layers to form a homogenous coating. Silicon rubber rollers
are used to ensure good adhesion.

The edges of the Polyethylene foil shall overlap to give 100% coverage of the pipe
surface. The polyethylene shall be applied in such a way as to give an overall final
thickness including FBE and Adhesive as specified in the Inspection and Test Plan.
The operating parameter of the polyethylene extruder shall be maintained within the
range recommended by the polyethylene’s manufacture.
The total coating system thickness (3LPE) Average Minimum 2,5 mm.

7.12 Cooling
Immediately after completion of the 3-layer coating the pipe passes through a water
quench where pipe is cooled by a drenching flood of water to allow further handling.

7.13 Holiday Inspection

After the water quench, the 3-layer coated pipes shall be 100% checked for continuity
by means of a Holiday Detector. The Holiday Detector is a series of brushes or rubbers
that are in constant contact with the coating and are situated after the water
quenching.

The holiday detector will be carried out with voltage shall be set /calibrated at a
frequency as dictated by Inspection and Test Plan. The Holiday Detector is automatic
and holidays will be registered by an alarm. All detected holiday shall be clearly marked
and the number of holidays detected on each pipe shall be written at the end of the
pipe.
Section 7
Title Manufacturing process

7.14 Final Bench Inspection

Every pipe arriving at the final bench shall be visually inspected. The coating shall have
no coating damage.

The pipe shall be inspected for coating thickness by Electronic or magnetic Thickness
Gauges. The thickness shall be recorded and the frequency and acceptance criteria shall
be as specified in the Test and Inspection Plan.

Any pipe with thickness less than specified in the Inspection and Test Plan shall be
marked and placed in the Quarantine area for further action.

During Coating application, pipe number and heat number shall be replaced to ensure
that no pipe joint loses its number or heat number.

7.15 Cut Back

Every pipe shall have the cut-back area prepared at both ends of the pipe. Any material
that has adhered to the pipe surface shall be removed by using an electrical wire brush.
The dimensions of the cut backs shall be as specified in the Inspection and Test Plan.

7.16 Pipe Marking

Marking shall be outside end 1 (E1) of pipe, as the following:

[NPS] [WT] [Length] [Grade] [Type]

[WO No] [Pipe No]
SNI 0039 : 2013 Coated 3LPE 2,5 mm [WO Coating No]
LSPr-054-IDN

7.17 Repair of coating

All holidays or spots with coating defects shall be appropriately marked so that the
damage/holiday is at the centre of the repaired area. Defective coating shall be
removed by knife or chisel and the surrounding area roughened by using sandpaper
or a grinder.

If the damage extends to the steel, apply a layer of two -pack epoxy. If necessary,
a hot air blower may be used to accelerate curing process. The surface of cured
epoxy compound shall be roughened and cleaned prior to repair application of
adhesive layer.
Once cool, the repair shall be fused with the parent coating and any excess
material shall be removed by knife or file, such that a smooth transition is obtained.
Completed repair areas shall be holiday detected.
Minor indentation or scores on topcoat do not require repair.

If one individual damage axial length equal or lower than 300 mm:
 Remove damaged coating with a knife or hand grinder to prevent crack
propagation in the coating
 Clean expose steel and adjacent pipe coating with an approved cleaner (as
Section 7
Title Manufacturing process
 per SSPC SP1) to remove the presence of oil, grease and other contaminant
(if needed)
 Remove adhering rust, coating chalk, dirt and roughen the mill applied
coating in the repair area using an abrasive paper or wire brush
 Apply two-component epoxy (fbe compound) if any repair extend to the
base metal, mixing the two-component epoxy as per technical data sheet.
Apply mixed epoxy to a minimum thickness 100 – 200 micron, wait until
cure as per technical data sheet of material and then apply with PE melt
stick.
 Pre heat the repair area sufficiently to remove moisture and assist in
adhesion
 Heat the PE melt stick with torch gun until it become fluid and then spread
the PE melt stick over the damaged area. Keep the flame moving to prevent
damage to the coating, some ignition of PE melt stick is acceptable.
 Continue spreading the PE melt stick over the repair area until entire area is
covered. After sufficient PE melt stick material is on the surface, apply
additional heat in quick back-and-forth strokes to create a smooth surface.
Ensure that the PE melt stick material completely covers the repair area.

7.18 Retesting
Pipes/samples which fail to meet the requirement shall be re -tested. If retest also
fails to meet the requirement, two additional samples represented batch of pipe
shall be tested for compliance.
If the result of all retested pipes are satisfactory, all coating in the batch shall be
considered acceptable excluding pi pe that failed.
If one or both sample of the tests fail, the production in that batch rejected until
the next testing is accepted.

7.19 Stripping and re-coating

Stripping operation shall be as follow:
1. The coated reject pipe shall be heated outside the plant with an internal lance
attached with gas burners. The internal lance shall heat the internal steel
surface sufficient enough to soften the applied coating, and then removal of
polyethylene shall begin. At no time shall the pipe temperature exceed 275 0C.
2. The second method to strip off of the coated pipe shall be passed through the
plant and through the pipe-heating units, to soften the Three Layer Coating.
On exit from the pipe-heating units, the softened coating, shall be cut and
remove. At no time shall the pipe temperature exceed 275 0C.
Once the external polyethylene / adhesive heating has been remove the pipe will
be either returned to the plant for the external blasting cleaning / remove of the
FBE coating, or transferred to stock pile to wait re -blasting.

7.20 Sample for Ring Test

Sample Ring test for CD test shall be cut from production/dummy pipe. Re-beveling
after cut off from production pipe will be performed by grinding machine.
Section 8
Title Handling, Transportation and Storage

8.1 Handling
After external coating, pipes shall be rolled on bearing racks for inspection/repair.
Pipe shall be transferred from outgoing racks to trucks or temporary storage or
directly to the internal coating area by means of conveyor or overhead crane or
loader or forklift fitted with suitable padding using rubber protected forks.
After completion of the external and internal coatings, bevel protectors shall be
refitted to the pipe ends to further aid in preventing the possibility of bevel
damage. Coated pipe may be moved by rolling on smooth runners.

Rejected pipes shall be marked with single red circumferential bend for
identification and traceability. Such rejected pipes shall be stored separately for
further process; e.g. re-blasting and re-coating work. Quarantine pipes including
test pipes shall be marked with temporary marking tapes. Such tape/marking shall
be removed cancelled by QC/Tally personnel upon acceptance of repair work,
rectification or customer agreed action, as applicable.

8.2 Transportation
Coated pipes shall be transported by flat bed trucks or pole trailers or loader or
forklift with suitably padded supports to prevent damage to the coating. Front -end
fork loaders may also be used providing the lifting cradle is lined with soft rubber or
foam.

8.3 Storage
Coated pipe shall be stored on sand breams or use soft padded racks until time for
delivery. All pipes shall be stored in stacks segregating the pipe by source, grade,
diameter, wall thickness and coating type. Pipe interiors shall be kept clean and
free from mud splashing or dirt deposits during storage.

Pipe will be stacked with due consideration to impact effects and nested together.
Separators may be used such as sawdust bags or gunnysacks, to avoid coating
contact. Nylon ropes shall not be used as separators. Fixed wedges shall be placed
on the every end of pipe row to prevent pipes from rolling, second and the next
tiers are placed in trapezoidal.
 INSPECTION TEST PLAN
of

Three Layer Polyethylene Coating

Coating Specification : CAN/CSA Z.245.21

Coating Thickness : 2,5 mm
Title Inspection and Test Plan

Frequency
Approval Inspection
Process/ Description Acceptance Criteria Report
Location Production Forms
KPI Customer

DSC, Moisture Content and Gel

FBE Powder Every Batch M R
Time shall be within specified standard Batch
Copolymer Test
Material Every Batch Packaging Secure, Marking Legible M R
Adhesive Cert.
Receipt
Polyethylene Every Batch Packaging Secure, Marking Legible from M R
Manuf.
Packaging Secure, Marking Legible
Abrasive Every Batch M R

Visual Inspection All pipes Contamination & defect Free --- M R

Incoming
Confirm Pipe No., Heat No., &
Racks Verify pipe
All pipes Length is still legible. Reinstate --- M R
identity
where necessary.
Check pipe Pipe temperature after blasting shall be
temperature and 3°C above dew point minimum, but less than
Issued by
relative humidity, 1 per shift 150o C M R
Coater
ambient
temperature Relative Humidity Max. 85%

Inspected blast
finish and for Sa 2 ½ Issued by R
1 per shift M
steel Coat within 4 hours max. Coater
defects.
Surface
Preparation Check surface
Issued by R
profile using 1 per shift 30 - 115μm M
Coater
Press “O” Film

Issued by R
Dust Level 1 per shift Max. level 2 of ISO 8502-3 M
Coater
Salt
Issued by R
Contamination 1 per shift 20 mg/m2 Maximum (2 μg/cm2) M
Coater
test
Compressed Air Issued by R
1 per shift Free from oil, water and other contaminant M
Test Coater
Pipe Temp. 180 – 220o C
Application Approximate range for
Temperature FBE 180-220°C Issued by
Monitor M R
(using Adhesive: 210 – 240o C Coater
pyrometer) PE: 210 – 240o C or as per
Coating
manufacture recommendation
Application
Continuous monitoring of the sheet
Extrusion application, to ensure smooth and
Monitor --- M R
Application even application, free of visible
defects.

M Manufacture Inspection / Implementation I Inspection (Spot Check)

LEGEND R Review Document W Witness (Shall be informed to Client before commencement)
H Hold Point
Title Inspection and Test Plan

Frequency Approval Inspection

Process/ Report
Description Production Acceptance Criteria
Location Forms KPI Customer

- FBE thickness min. 120 micron

Issued by R
Individual Thickness Once - Adhesive thickness min. 100 micron M
Coater
- Polyethylene thickness min. 2.28 mm

Total coating thickness,

Final measured with Issued by R
All pipes Total coating thickness min 2,5 mm M
Inspection electromagnetic Coater
gauge.

Maximum 2
Holiday detection Issued by R
All pipes holidays. Holiday shall be repaired M
at 15 KV as per manufacturer recommendation. Coater

End Cleaning Cutback Removal All pipes Minimum 100 ± 10 mm from bevel end -- M R

On External surface at R
Markings All pipes Pipe no, Length and Work Order No -- M
one end

Issued by R
Impact Test 1 per shift Min 3 Joule/ mm, no holiday at 15 kV M
Coater

Peel constant rate of 150 N min/25 mm. at ambient test Issued by R

1 per shift M
peeling temperature Coater

6.4 mm Ø hole,-3.5 volts 3% NaCI

Cathodic disbonding PE
solution 24 hour test @ 23 +/- 3o C, at Issued by R
coating remain in 1 per week M
maximum 7 mm. Coater
place during testing
Laboratory
Testing
1 per week Issued by R
Tensile Stress at Yield Min. 17 MPa M
Coater

Elongation at Break 1 per week Issued by R

300% minimum elongation. M
(ASTM D638) Coater

Flexibility at a No cracking, test shall be conducted Issued by R

1 per week M
deflection of 2,5o at ambient temperature Coater

M Manufacture Inspection / Implementation I Inspection (Spot Check)

LEGEND R Review Document W Witness (Shall be informed to Client before commencement)
H Hold Point
Title Inspection and Test Plan

Report Tolerance Approval Inspection

Equipment Frequency Method
Process Forms
KPI Customer

Calibrate with std Thickness

Shim/block, the std thickness
Adjustable to ±
Profile Gauge Startup block shall be physically Issued by Coater M R
5% of Target
inspected prior to use for any
Value
damage.

Calibrate with std Thickness

Calibration Shim/block, the std thickness Adjustable to ±
Coating Thickness Startup M R
block shall be physical inspected Issued by Coater 5% of Target
Gauge
prior to use for any damage. Value

Calibrate against calibrated Adjustable ±5% of M R

Holiday Detector Startup Voltmeter Issued by Coater
Target Value

M Manufacture Inspection / Implementation I Inspection (Spot Check)

LEGEND R Review Document W Witness (Shall be informed to Client before commencement)
H Hold Point