CW6 Part 2

CW6: Part 2
TECHNICAL SPECIFICATION FOR

THE EXTERNAL PROTECTION OF STEEL LINE PIPE
AND FITTINGS USING FUSION BONDED POWDER
AND ASSOCIATED COATING SYSTEMS
PART 2 - FACTORY APPLIED COATINGS
JANUARY 1993
J230 (Rev 08/98 )
.
CW6 : Part 2
J230 (Rev 08/98 ) - i -
CONTENTS
Page
FOREWORD v
BRIEF HISTORY vi
SECTION ONE - GENERAL REOUIREMENTS
1. SCOPE 1
2. REFERENCES 1
3. DEFINITIONS 2
4. COATING MATERIALS 2
4.1 Selection of coating materials 2
4.2 Storage of coating materials 2
4.3 Toxicity and handling 2
5. COMPONENTS OR WORK PIECES 2
5.1 Component inspection 2
5.2 Component identification 2
5.3 Protection of weld end preparations 3
5.4 Surface preparation 3
5.5 Chemical pretreatment and primers 4
5.6 Extent of approvals 4
6. INSPECTION AND TESTING 4
7. VARIANTS 4
SECTION TWO - FUSION BONDED POWDER COATINGS ON PIPE
8. PROCEDURE QUALIFICATION 7
8.1 General 7
8.2 Coating procedure specification 7
8.3 Coating procedure approval tests 7
9. PRODUCTION COATING PROCEDURE 9
9.2 Coating process 9
10. VISUAL INSPECTION 9
CW6 : Part 2
- ii - J230 (Rev 08/98 )
Page
11. TESTING OF CURED COATINGS 9
11.1 General requirements 9
11.2 Thickness test 9
11.3 Holiday detection test 9
11.4 Impact resistance test 10
11.5 Adhesion test 10
11.6 Coating cure test 10
11.7 Defect rate 10
11.8 Check procedure 10
12. REPAIRS 11
13. HANDLING OF COATED PIPES 11
14. STRIPPING OF COATING 11
15. IDENTIFICATION 11
SECTION THREE - FUSION BONDED POWDER COATINGS ON FITTINGS
16.1 General 13
19.1 Testing of coated fittings 16
19.6 Coating cure test 17
19.7 Defect rate 17
CW6 : Part 2
J230 (Rev 08/98 ) - iii -
Page
20. REPAIRS 18
21. HANDLING OF COATED FITTINGS 18
SECTION FOUR - MULTI-COMPONENT LIQUID COATINGS ON PIPES AND FITTINGS
24.1 General 19
27.1 Testing of coated pipes and fittings 22
27.4 Hardness and cure of coating test 23
27.7 Heat blister test 23
27.8 Defect rate 23
28. REPAIR OF DEFECTS 24
29. HANDLING OF COATED PIPES AND FITTINGS 24
CW6 : Part 2
- iv - J230 (Rev 08/98 )
Page
TABLES
1 Minimum quality control requirements 5
2 Component diameter ranges, permissible holidays and repairs 6
APPENDIX
A CALIBRATION PROCEDURES FOR THICKNESS MEASUREMENT OF FUSION
BONDED EPOXY POWDER AND MULTI-COMPONENT LIQUID COATINGS 25
CW6 : Part 2
J230 (Rev 08/98 ) - v -
FOREWORD
This specification has been adopted by Transco and is an editorial revision of the former British Gas TransCo
specification GBE/CW6 Part 2. It reflects the identity and organizational structure of Transco - a part of BG
plc.
This Transco specification has been approved for use throughout Transco.
Comments and queries regarding the technical content of this Transco specification should be directed to:
Lead Engineer
Transco
Norgas House
PO Box 1GB
Killingworth
Newcastle upon Tyne
NE99 1GB
Further copies of this Transco specification can be obtained from Dataform Print Management using the print
requisition form G004 quoting the Form Number of this Transco engineering document (not the designation)
and your cost code.
Transco engineering documents are revised, when necessary, by the issue of new editions. Users should
ensure that they are in possession of the latest edition by referring to the Transco Register of Engineering
Documents available on the Transco Information Library.
Compliance with this engineering document does not confer immunity from prosecution for breach of statutory
or other legal obligations.
Contractors and other users external to Transco should direct their requests for further copies of Transco
engineering documents to the department or group responsible for the initial issue of their contract
documentation.
DISCLAIMER
This engineering document is provided for use by Transco and such of its contractors as are obliged by the terms
of their contracts to comply with this engineering document. Where this engineering document is used by any
other party, it is the responsibility of that party to ensure that the engineering document is correctly applied.
CW6 : Part 2
- vi - J230 (Rev 08/98 )
BRIEF HISTORY
First published as BGC/PS/CW6: Part 2
Re-issued as GBE/CW6: Part 2
October 1984
January 1993
BG plc 1993
This Transco specification is copyright and must not be reproduced in whole or in part by any means without
the approval in writing of BG plc.
CW6: PART 2 SECTION 1
J230 ( Rev 15/07/97 ) - 1 -
TECHNICAL SPECIFICATION FOR
THE EXTERNAL PROTECTION OF STEEL LINE PIPE
AND FITTINGS USING FUSION BONDED POWDER
AND ASSOCIATED COATING SYSTEMS:
PART 2 - FACTORY APPLIED COATINGS
SECTION ONE - GENERAL REQUIREMENTS
1. SCOPE
This Part 2 of Transco Technical Specification* CW6 specifies the operations and requirements for the
factory application to pipes and fittings of materials identified in CW6: Part 1. These coatings may be applied
to components used for the transmission and distribution of natural or manufactured gas. There is no
restriction on pressure or nominal size of the components provided they are not operated continuously at
temperatures higher than C 50
0
.
Section One covers general requirements and is applicable to all coatings specified in this specification in
addition to the requirements specified in Sections Two, Three or Four.
Section Two deals with the application of fusion bonded powder as an anti-corrosion coating on steel pipe.
Section Three deals with the application of fusion bonded powder as an anti-corrosion coating on fittings and
Section Four deals with the application of multi-component liquid coating as an anti-corrosion coating on pipe
and fittings.
* Hereinafter referred to as 'this specification'.
2. REFERENCES
This Specification makes reference to the documents listed below. Unless otherwise specified the latest
editions of these documents, including all addenda and revisions, shall apply.
Statutes and Regulations
- Control Of Substances Hazardous to Health (COSHH) Regulations
- The Health and Safety at Work etc. Act 1974
British Standards
BS 5750 - Quality systems
BS 7079 - Preparation of steel substrates before application of paints and related
products
Transco specifications
CW6 - Technical specification for the external protection of steel line pipe
and fittings using fusion bonded powder and associated coating
systems:
Part 1 - Requirements for coating materials and methods of test
DAT35 - Specification for separator straps for use with resin coated pipe
- 2 - J230 (Rev 08/98 )
L3 - Code of practice for handling, transport and storage of steel pipes,
bends and tees.
3. DEFINITIONS
For the purposes of this specification the following definitions shall apply:
Transco: Transco - a part of BG plc.
Transco representative: the person appointed from time to time by Transco and notified in writing to the
Contractor to act as Transco representative for the purposes of the Contract.
Contractor: the person, firm or company with whom Transco enters into a contract to which this
specification applies, including the Contractor's personal representatives, successors and permitted assigns.
Manufacturer: the producer of the coating material or his appointed agents or assigns.
4. COATING MATERIALS
4.1 Selection of coating materials
4.1.1 Before production coating is permitted, the coating system and the application process shall be
defined and qualified in accordance with the coating procedure approval specified in the appropriate Section
of this specification.
4.1.2 Only coating systems which comply with CW6: Part 1 shall be used.
4.1.3 The coating material supplied shall be certified by the Manufacturer in accordance with the
requirements of CW6: Part 1. The Contractor shall obtain and retain all certificates (see 4.2) and
manufacturers' data sheets. Certificates shall be made available on request.
4.2 Storage of coating materials
To ensure that the properties of all coating materials are maintained in compliance with the relevant Section of
CW6: Part 1, all coating materials consigned to the coating plant shall be properly stored in accordance with
the Manufacturers' safety requirements and recommendations, at all times, to prevent damage and
deterioration prior to use. Materials shall be used in date order in which they are manufactured.
4.3 Toxicity and handling
Any hazard, (e.g. toxic, corrosive, fire risks) associated with coating materials offered for use to meet the
requirements of this specification shall be specified by the Manufacturer, together with his recommendations
for safe handling in accordance with the requirements of the Health and Safety at Work etc. Act 1974 and the
COSHH Regulations.
5. COMPONENTS OR WORK PIECES
5.1 Component inspection
The Contractor shall inspect all components on receipt for damage to external surface and weld end
preparations. This shall be recorded for each affected component.
5.2 Component identification
5.2.1 All identification markings, whether internal or external to the component, shall be carefully
recorded before surface preparation begins.
5.2.2 When applicable, identification plates shall be carefully removed and, after the coating has been
accepted, replaced using an adhesive compatible with the coating. Special care shall be taken to ensure that
the original data is re-affixed to the correct component.
J230 ( Rev 15/07/97 ) - 3 -
5.2.3 The Contractor shall provide a documentary procedure for compliance with these requirements (see
also Table 1, item t).
5.3 Protection of weld end preparations
5.3.1 Weld 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 components.
5.3.2 Protection during handling and storage shall be in accordance with L3.
5.3.3 Weld end preparations shall be protected from coating during the process by a method which shall
not be detrimental to the coating process.
The coating shall not be applied within 40 15 mm of the component ends for fusion bonded powder coating
application, and 150 15 mm in the case of multi-component liquid coatings.
5.4 Surface preparation
5.4.1 General
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 5.4.2 to 5.4.7
inclusive plus any special requirements specified by Transco.
5.4.2 Contaminant removal
Where oil, grease or other contaminants are present, they shall be removed, without spreading them over the
surface, with a suitable solvent. For components which have been subjected to contamination, the contaminant
shall be removed by washing either with potable water or a chemical cleaner. If a chemical cleaner is used,
subsequent washing with potable water will be necessary. The component shall be dried before blast cleaning.
5.4.3 Component cleaning
Components shall be blast cleaned in accordance with 9.1 and 17.1 for fusion bonded powder coatings,
and 25.1 for multi-component liquid coatings.
5.4.4 Surface inspection
The metal surface 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 by grinding. After the removal of
defects, the remaining wall thickness shall comply with the relevant component specification. Any rectified
areas shall be blast cleaned to meet the requirements of 5.4.3.
5.4.5 Defects
Any component found to have defects which exceed the levels permitted in the relevant component
specification shall be set aside for examination.
5.4.6 Pre-coating cleaning
Directly before coating, any dust, grit or other contaminants shall be removed from the component surface by
a method established as acceptable by the relevant coating procedure trial and recorded in the relevant coating
procedure.
5.4.7 Rust blooming or further surface contamination
Where rust blooming or further surface contamination (see 5.4.2) has occurred, the component shall be
cleaned again in accordance with 5.4.2 if applicable and again blast cleaned in accordance with 5.4.3.
Coating shall take place before any further contamination or rust blooming occurs.
- 4 - J230 (Rev 08/98 )
5.5 Chemical pretreatment and primers
Chemical pretreatment or primers shall be specified by the Contractor as part of the coating procedure
qualification.
5.6 Extent of approvals
The coating process shall comply with the procedure established in the relevant coating procedure
qualification (see clauses 8, 16 and 24). This qualification will be valid for three years and will cover the
component size range and the coating material tested.
The component size for the coating procedure trial shall be selected from one of the ranges in Table 2, and
approval will qualify all other sizes within that range.
For fusion bonded powder coatings of line pipe, approval should extend to thickness of 50% of the wall
thickness of the pipe tested.
In order to demonstrate continuing product quality, the Contractor may be required to undertake duplicate
cathodic disbondment and watersoak tests on the pipe or fitting test piece from any contract and size range
within the contract. Additionally, for pipe only, flexibility testing shall be carried out in duplicate.
Failure of any of the results of these tests to meet the requirements of this specification shall necessitate a new
coating procedure trial.
Any changes in coating materials, component size range, coating process, plant, or quality history shall
necessitate a new coating procedure trial.
6. INSPECTION AND TESTING
The quality control system shall include each of the requirements listed in Table 1. The actual quality control
requirements may differ depending on the type of coating being used or whether it is being applied to a pipe or
fitting. Table 1 has been prepared to identify these differences.
If, after examination or test, any component has not been cleaned or coated in accordance with this
specification, the Contractor shall be required to remove the coating which is defective or inadequate and to
reclean and recoat the component
7. VARIANTS
A contractor shall only propose variants to this specification where the text indicates that variants would be
considered by Transco.
J230 ( Rev 15/07/97 ) - 5 -
TABLE 1 - Minimum quality control requirements
- 6 - J230 (Rev 08/98 )
TABLE 1 - (concluded)
TABLE 2 - Component diameter ranges, permissible holidays and repairs
J230 ( Rev 15/07/97 ) - 7 -
SECTION TWO - FUSION BONDED POWDER COATINGS
ON PIPE
8. PROCEDURE QUALIFICATION
8.1 General
Before bulk coating of pipe commences, the requirements of 8.2 shall be met and a detailed sequence of
operations to be followed on the coating of pipe shall be demonstrated.
8.2 Coating procedure specification
The coating procedure specification shall incorporate full details of the following:
a) Quality plan.
b) Powder system to be used together with appropriate data sheets as defined in clause 4.
c) Pipe dimensions.
d) Process temperature profile.
e) Pipe cleaning.
f) Blast cleaning medium and technique.
g) Blast cleaning finish, surface profile, surface cleaning and metal defect removal.
h) Dust removal.
i) Provision of coating cut-back.
j) Line speed.
k) Preheat method, time and temperature.
l) Powder application including use of recycled material.
m) Curing and quenching time and temperature.
n) Post cure time and temperature.
o) Repair technique.
p) Coating stripping technique.
q) Handling procedures.
8.3 Coating procedure approval tests
8.3.1 General
A batch representing a normal production run (typically 15 to 20 pipes) shall be coated in accordance with the
coating procedure (see 8.2), the coating operations being witnessed.
Three pipes from the batch shall be selected for coating procedure approval tests and shall be subjected to the
complete set of tests specified in 8.3.2 to 8.3.10 inclusive.
The Contractor shall ensure that the tests specified in 8.3.2 to 8.3.10 inclusive are carried out in duplicate and
the results of the tests, demonstrating compliance, made available.
Testing shall be witnessed and a full set of test results shall be recorded. No coated pipe shall be dispatched
until the procedure has passed the approval tests.
- 8 - J230 (Rev 08/98 )
8.3.2 Thickness test
The coating thickness shall be a minimum of 350m and a maximum of 500m, unless specified otherwise.
A survey of the coated pipe selected for test shall be carried out by measuring, as a minimum, at 1 m intervals
at the cardinal points, in such a manner as to establish the degree and extent of any thickness variation.
A destructive film thickness test shall be carried out to verify the accuracy of the coating thickness
measurement technique employed.
8.3.3 Holiday detection test
Each pipe shall be checked over 100% of the coated surfaces in accordance with CW6: Part 1, Appendix C
and shall meet the requirements of Table 2.
8.3.4 Impact resistance test
When tested at ambient temperature in accordance with CW6: Part 1, Appendix D, the cured coating shall
withstand an impact of not less than 1.5 J without a holiday being caused.
8.3.5 Adhesion test
The adhesion of the coating, shall be tested and shall meet the pass requirements in accordance with
CW6: Part 1 Appendix E.
8.3.6 Coating cure test
The degree of cure of the coating shall be determined by differential scanning calorimetry (DSC) analysis of a
sample of the coating taken from a location
1
3
of the pipe length from the trailing end in accordance with
CW6: Part 1, Appendix A, clause A.3. The acceptance criterion shall be based on the difference between the
measured Tg
2

and Tg
1

(as detailed in CW6: Part 1, Appendix A, clause A.3). This difference is termed
Tg .
The acceptance range of Tg will depend on the type of powder used (see also 11.6).
8.3.7 Flexibility test
The coated pipe shall be sectioned and subjected to a flexibility test in accordance with CW6: Part 1,
Appendix B. The coating shall not exhibit signs of cracking, disbondment or pinholes and shall pass a holiday
detection test in accordance with CW6: Part 1, Appendix C.
8.3.8 Cathodic disbonding test
The test sections shall be tested by the procedure detailed in CW6: Part 1, Appendix F. The disbondment shall
not extend more than 5 mm radially from the edge of the damaged coating after the test period of 28 days.
8.3.9 Strain/polarization cracking test
The test sections shall be bent and then polarized and tested as detailed in CW6: Part 1, Appendix G. The
area of coating exposed to the electrolyte shall not exhibit signs of cracks, disbondment or pinholes and shall
pass a holiday detection test as specified in CW6: Part 1, Appendix C.
8.3.10 Water immersion test
The test sections shall be prepared and subjected to a water immersion test as detailed in CW6: Part 1,
Appendix E. The coating shall show no loss of adhesion greater than 3 mm after 28 days.
J230 ( Rev 15/07/97 ) - 9 -
9. PRODUCTION COATING PROCEDURE
The surface of the pipe to be coated shall be prepared as specified in 5.4.
Components shall be blast cleaned to a minimum standard of BS 7079 Sa 2
1
2
quality. The surface profile
shall be between 50m and 100m peak to trough height, and shall be angular in nature.
9.2 Coating process
The production coating process shall be carried out using the procedure that fulfils the requirements of 8.3.
The nominal thickness of the cured coating shall be 400m . The actual coating thickness shall be in the
range 350m to 500m.
Where pipe is to be concrete coated, the correct thickness (normally 650mto800m) of anti-corrosion
coatings shall be applied, which depends upon the particular concrete coating process.
Weld end preparations shall be protected as specified in 5.3.
10. VISUAL INSPECTION
The coating colour and appearance shall be uniform and free from runs, sags, blistering, roughness, foaming
and general film defects.
11. TESTING OF CURED COATINGS
11.1 General requirements
Cured coatings on pipes shall comply with the requirements of 11.2 to 11.8 inclusive and, where indicated.
methods of test described in CW6: Part 1 shall be used.
The Contractor shall ensure that the tests specified in 11.4, 11.5 and 11.6 are carried out and the results of the
tests, demonstrating compliance, made available.
11.2 ThIckness test
The coating thickness on each pipe shall be checked for compliance with 8.3.2 at not less than five equidistant
locations spread over the total surface of the pipe. The thickness measuring gauge used shall be suitably
calibrated hourly for the specified thickness range (see Appendix A).
11.3 Holiday detection test
The coated pipes shall be subjected to a holiday detection test over 100% of the coated surface as detailed in
CW6: Part 1, Appendix C.
The number of holidays detected shall comply with Table 2. If,

on any two consecutive pipes, the number of
holidays detected is greater than the normally acceptable level but less than the maximum permissible level,
the cause shall be immediately investigated.
If four further consecutive pipes are detected as having holidays between the normally acceptable level and
the maximum permissible level given in Table 2, all production to that point shall be quarantined until the
reason for the high frequency of holidays is determined and rectified. A total of 5% of daily production will be
accepted with up to the maximum permissible number of holidays provided that the 5% are not consecutive.
Pipes with more holidays than permitted by Table 2 shall be rejected for subsequent stripping (see clause 14)
and recoating.
- 10 - J230 (Rev 08/98 )
All holidays shall be repaired in accordance with clause 12 and satisfactorily retested before dispatch of the
pipe.
Defects detected immediately before dispatch shall not be repaired but shall be conspicuously and
permanently marked on the pipe and recorded on the relevant inspection documentation.
11.4 Impact resistance test
The coated pipe shall be subjected to an impact resistance test as detailed in CW6: Part 1, Appendix D, at
frequencies of once every hour or 20 pipes, whichever is the more frequent. This initial frequency may
subsequently be varied, the revised frequency being based on quality history.
The curedcoating shall meet the requirements specified in 8.3.4.
11.5 Adhesion test
The coated pipe shall be subjected to an adhesion test of the cured coating as detailed in CW6: Part 1,
Appendix E. The test shall be carried out at three locations on the pipe (one metre from each end and at a mid
point) and initially at frequencies of once every hour or 20 pipes, whichever is the more frequent. This initial
frequency may subsequently be varied, the revised frequency being based on quality history.
The cured coating shall meet the initial test procedures, investigation procedures and result reporting
requirements of CW6: Part 1, Appendix E.
11.6 Coating cure test
The cure of the coating shall be checked for compliance with 8.3.6 by DSC analysis at frequencies of once
every hour or 20 pipes, whichever is the more frequent. This initial frequency may subsequently be varied, the
revised frequency being based on quality history.
To confirm the requirements of 8.3.6, the test procedure detailed in CW6: Part 1, Appendix A, clause A.3
shall be carried out.
If a test does not result in a value of Tg within the acceptable range, the following retest procedure shall be
used:
For a measured Tg within + 2
o
C of the upper acceptable limit, a further sample from the pipe
shall be tested. If the value of Tg obtained lies within the acceptable range, the pipe shall be
accepted. If it does not, the pipe shall be rejected and adjacent pipes in the production run shall be
successively sampled and tested until acceptable coating is identified.
11.7 Defect rate
Should tests in any production batch (typically the production from a seven hour shift) show a rejection rate of
more than 10% defective pipe for any one test, every pipe in that batch shall be individually subjected to that
test. In such cases, the Contractor shall simultaneously conduct an investigation to establish the cause of the
defects.
The cost of retrieval of any pipes dispatched from the coating premises and/or any additional expenses
incurred as a result of additional examination shall be borne by the Contractor.
11.8 Check procedure
If any individual pipe fails to meet the requirements of 11.2 to 11.7 inclusive, a check procedure shall be
initiated. This shall involve checking all pipe back to the preceding acceptable pipe. The pipe numbers shall
be available from the final inspection batch. These pipes shall be subjected to an examination similar to that
carried out on the failed pipe. If the number of defects detected is significant, the entire production for that day
shall be quarantined and investigated.
J230 ( Rev 15/07/97 ) - 11 -
12. REPAIRS
All holidays and other coating defects shall be repaired with multi-component materials to ensure
compatibility with the applied coating. Repair methods shall include adequate surface preparation techniques,
suitable overlaps, coating thicknesses and a demonstration of satisfactory adhesion and cure. All repairs shall
be retested for holidays in accordance with the requirements detailed in CW6: Part 1, Appendix C.
The maximum areas of repair for any pipe shall not exceed, in total, the areas given in Table 2. Repairs shall
not be carried out within 200 mm of the end of the coating, but all areas of damage shall be recorded and
marked.
13. HANDLING OF COATED PIPES
13.1 All coated pipes shall be handled and stored in accordance with L3 to prevent damage to the pipe
and coating.
Where the use of pipe separators is required to prevent damage to the cured coating, these shall be as
specified in DAT35.
13.2 Protection from damage and corrosion of the weld end preparations may be required prior to
stacking and load out. The type of protection and the method of application shall be specified by Transco.
(see L3).
14. STRIPPING OF COATING
Rejected coating shall be removed only by a procedure which shall not cause any mechanical damage to the
pipe and shall not cause the steel temperature to exceed 250
0
C.
15. IDENTIFICATION
The Contractor shall be responsible for ensuring that all internal or external identification markings are noted
in accordance with 5.2 before surface preparation begins, and are replaced after the coating process.
- 12 - J230 (Rev 08/98 )
J230 ( Rev 15/07/97 ) - 13 -
SECTION THREE - FUSION BONDED POWDER COATINGS
ON FITTINGS
16.1 General
Before bulk coating of fittings commences, the requirements of 16.2 shall be met and a detailed sequence of
operations to be followed for the coating of fittings shall be demonstrated.
16.2 CoatIng procedure specification
16.2.1 The coating procedure specification shall incorporate full details of the following:
a) Quality plan.
b) Powder system to be used together with appropriate data sheets as defined in clause 4.
c) Fitting dimensions.
e) Fitting cleaning.
h) Dust removal.
j) Preheat method, time and temperature.
k) Powder application.
l) Curing and quenching time and temperature.
m) Post cure time and temperature.
n) Repair technique.
o) Coating stripping technique.
p) Handling procedures.
16.2.2 Recycled powder shall not be used to coat pipeline fittings.
16.2.3 Where fluidized bed dipping is to be used, the applicator shall provide written evidence that the
powder in the fluidized bed at the time of the procedure qualification test complies with CW6: Part 1.
16.3.1 General requirements
A batch of fittings shall be coated in accordance with the approved coating procedure (see 16.2), the coating
operations being witnessed. Pipe pups of equivalent dimensions may be used instead of fittings.
Three coated fittings or pipe pups from the batch shall be selected for coating procedure approval tests and
shall be subjected to the complete set of tests specified in 16.3.2 to 16.3.8 inclusive.
The Contractor shall ensure that the tests specified in 16.3.2 to 16.3.8 inclusive are carried out in duplicate
and the results of the tests, demonstrating compliance, made available.
- 14 - J230 (Rev 08/98 )
Testing shall be witnessed and a full set of test results shall be recorded. No coated fittings shall be dispatched
The coated fittings shall be subjected to a thickness test of the cured coating as specified in 19.2. The
thickness shall be not less than 350m and not greater than 1500m.
The coated fittings shall be subjected to a holiday detection test over 100% of the coated surface as detailed in
CW6: Part 1, Appendix C. The number of holidays detected shall meet the requirements of Table 2.
The coated fittings shall be subjected to an impact resistance test at ambient temperature as specified in 19.4
and as detailed in CW6: Part 1, Appendix D. The coating shall withstand an impact of 1.5 J without a holiday
being caused.
16.3.5 Adhesion test
The coated fittings shall be subjected to an adhesion test as specified in 19.5 and as detailed in CW6: Part 1,
Appendix E.
16.3.6 Coating cure test
The degree of cure of the coating shall be determined by DSC analysis of a sample of the coating taken from
the area of thickest coating and any identified 'cool spots', and tested in accordance with CW6: Part 1,
Appendix A. The acceptance criterion shall be based on the difference between the measured Tg
2

and Tg
1
(as defined in CW6: Part 1, Appendix A). This difference is termed Tg .
The acceptance range of Tg will depend on the type of powder used (see also 19.6).
The test sections shall be subjected to a cathodic disbonding test as detailed in CW6: Part 1, Appendix F. The
disbondment shall not extend more than 5 mm radially from the edge of the damaged coating after the test
period of 28 days.
The test sections shall be prepared and subjected to a water immersion test as detailed in CW6: Part 1,
The surface of the fitting to be coated shall be prepared as specified in 5.4.
Components shall be blast cleaned to a minimum standard of BS 7079 Sa 2
1
2
quality. The surface profile
shall be between 50m and 100m peak to trough height and shall be angular in nature.
17.2 Coating process
17.2.1 General
The production coating process shall be carried out using a procedure that fulfills the requirements of 16.3.
The thickness of the coating shall be not less than 350m, and not greater than 1500m.
J230 ( Rev 15/07/97 ) - 15 -
17.2.2 Spray applied coating
17.2.2.1 Operator qualifications
When required, the individual operators carrying out the powder spraying application shall be subjected to a
qualification test in which they will be required to demonstrate proficiency in the spraying process as laid
down in the relevant section of the procedures.
17.2.2.2 Preheating
Preheating shall be carried out using suitable heating equipment and its duration shall not be extended for
more than 30 min beyond the time at which the required surface temperature is reached. The surface
temperature shall be continuously monitored at a selected point by means of a surface pyrometer, or any other
method which may be proposed as a variant for consideration by Transco, which shall be calibrated against a
standard method of surface temperature measurement. If the appearance of the fitting after preheating is
unsuitable, it shall be blast cleaned (see 5.4) before continuing the coating procedure.
17.2.2.3 Spraying equipment
The spraying equipment shall be adequate for applying the powder in accordance with the powder
manufacturer's instructions and the qualification procedure. The equipment shall be maintained in good order
by the Contractor and/or the equipment supplier. All air lines shall be provided with filters and vapour traps to
ensure that the air is free from oil and moisture. All critical parameters shall be monitored.
17.2.2.4 Spraying procedure
The spraying procedure shall be in accordance with the qualification procedure which shall include a total
time allowed for coating. Individual operators shall be experienced in the use of equipment and shall be
suitably qualified (see 17.2.2.1). The temperature of the fitting shall be checked at selected points on the
surface, in such a manner as to ensure that the surface temperature does not fall below that recommended by
the powder supplier. If the limits of time and temperature are exceeded, the fitting shall be cleaned and
recoated.
17.2.2.5 Post cure
If post curing is required by the qualification procedure, the component shall be moved within a defined
period into the post curing oven. The time and temperature shall be monitored as in 17.2.2.2.
17.2.3 Dip applied coatings
17.2.3.1 Preheating
The duration of preheating shall not be extended for more than 30 min beyond the time at which the required
surface temperature is reached. The surface temperature shall be monitored at a selected point by means of a
surface pyrometer or any other method, which may be proposed as a variant for consideration by Transco,
which shall be calibrated against a method of a standard surface temperature measurement. If the appearance
of the fitting after preheating is unsuitable, it shall be blast cleaned (see 5.4) before continuing the coating
procedure.
17.2.3.2 Dipping bath
The dipping bath shall meet the following requirements:
a) The dipping bath shall be of dimensions which enable a fitting of the maximum stated size to
be freely dipped.
b) The method of fluidization shall promote even fluidization and control of powder density
within the bed.
c) The bed shall be renewed completely if the powder ceases to comply with CW6: Part 1 or if
the condition of the powder results in unacceptable deterioration of the finished product.
- 16 - J230 (Rev 08/98 )
17.2.3.3 Dipping procedure
The dipping procedure shall be as follows:
a) When the powder is fluidized to the required density, the fluidized bed shall be made up to a
depth adequate for dipping the fittings.
b) Prior to dipping, the temperature of the fitting shall be checked at selected points on the
surface to ensure that the surface temperature does not fall below that recommended by the
powder supplier.
c) The coating time shall be specified for each type and size of fitting.
d) If limits of time and temperature are not achieved, the fitting shall be cleaned and recoated.
17.2.3.4 Post cure
If post curing is required by the qualification procedure, the fitting shall be moved with the minimum delay
into the post curing oven. The time and temperature shall be monitored as specified in 17.2.3.1.
19.1 Testing of coated fittings
Cured coatings on fittings shall comply with the requirements of 19.2 to 19.7 inclusive and, where indicated,
methods of test described in CW6: Part 1 shall be used.
The Contractor shall ensure that the tests specified in 19.2 to 19.7 inclusive are carried out in duplicate and
the results of the tests, demonstrating compliance, made available.
19.2 Thickness test
The coated fittings shall be subjected to a thickness test of the cured coating at not less than 20 locations
spaced evenly to represent the total area of the coated fitting. The thickness measuring gauge used shall be
calibrated hourly for the specified thickness range (see Appendix A).
The coated fittings shall meet the thickness requirements specified in 16.3.2.
The coated fittings shall be subjected to a holiday detection test over 100% of the coated surface as detailed in
The number of holidays detected shall comply with Table 2. If, on any two consecutive fittings, the number of
holidays detected is greater than the normally acceptable level but less than the maximum permissible level,
the cause shall be immediately investigated.
If four further consecutive fittings are detected as having holidays between the normally acceptable level and
the maximum permissible level given in Table 2, all production to that point shall be quarantined until the
reason for the high frequency of holidays is determined. A total of 5% of daily production will be accepted
with up to the maximum permissible number of holidays provided that the 5% are not consecutive.
Fittings with more holidays than permitted by Table 2 shall be rejected for subsequent stripping
(see clause 14) and recoating.
J230 ( Rev 15/07/97 ) - 17 -
fitting.
permanently marked on the fitting and recorded on the relevant inspection documentation.
Initially, the impact resistance of the coating shall be checked for compliance with 16.3.4 determined at five
locations chosen to represent the area coated, as detailed in CW6: Part 1, Appendix D.
The frequency of testing shall, initially, be once every two hours or five fittings. whichever is the more
frequent. Subsequently, this test frequency may be varied based on quality history.
19.5 Adhesion test
The coated fittings shall be subjected to an adhesion test of the cured coating, at one location on the fitting, as
detailed in CW6: Part 1, Appendix E.
The frequency of testing shall, initially, be once every two hours or five fittings, whichever is the more
frequent. Subsequently, this frequency may be varied based on quality history.
19.6 Coating cure test
In order to meet the acceptance requirements of 16.3.6, the DSC test procedure detailed in CW6: Part 1,
Appendix A, shall, initially, be carried out on each fitting. Subsequently, this rate of testing may be varied
based on quality history.
If a test does not result in a value of Tg within the acceptable range, the following retest procedure shall be
used:
a) For a measured Tg within +2
0
C of the upper acceptable limit, a further two samples from
the test section shall be tested. All glass transition temperature values shall be expressed as
corrected temperatures.
b) If the value of Tg obtained lies within the acceptable range, the fitting shall be accepted.
c) If the value of Tg obtained does not lie within the acceptable range, the fitting shall be
rejected and adjacent fittings in the production run shall be successively sampled and tested
until acceptable coating is identified.
19.7 Defect rate
Should tests in any production batch (typically the production from a seven hour shift) show a rejection rate of
more than 20% defective fittings for any one test, every fitting in that batch shall be individually subjected to
that test. In such cases, the Contractor shall simultaneously conduct an investigation to establish the cause of
the defects.
The cost of retrieval of any fittings with defective coatings dispatched from the coating premises and/or any
additional expenses incurred as a result of additional examination shall be borne by the Contractor.
If any fitting fails the requirements of 19.2 to 19.6 inclusive, a check procedure shall be initiated. This will
involve checking all fittings back to the preceding acceptable fitting. The fitting numbers shall be available
from the final inspection batch. These fittings shall be subjected to an examination similar to that carried out
on the failed fitting. If the number of defects detected is significant, the entire coating production for that day
shall be quarantined and investigated.
- 18 - J230 (Rev 08/98 )
20. REPAIRS
All holidays and other coating defects shall be repaired with multi-component materials to ensure
compatibility with the applied coating. All repairs shall be retested for holidays in accordance with
The maximum repair area shall be in accordance with Table 2.
Repairs shall not be carried out within 200 mm of the end of the coating, but all areas of damage shall be
recorded and marked.
21. HANDLING OF COATED FITTINGS
All coated fittings shall be handled and stored in accordance with the relevant fitting standard and L3 to
prevent damage to the fitting and coating.
The fitting ends may be required to be protected from damage and corrosion. The type of protection and the
method of application shall be specified by Transco (see L3).
Rejected coating shall be removed by a procedure which shall not cause mechanical damage to the fitting and
shall not cause the steel temperature to exceed 250
0
C.
23. IDENTIFICATION
The Contractor shall be responsible for ensuring that all internal or external identification markings are noted
before surface preparation begins, and are replaced after the coating process in accordance with 5.2.
J230 ( Rev 15/07/97 ) - 19 -
SECTION FOUR - MULTI-COMPONENT LIQUID COATINGS
ON PIPES AND FITTINGS
24.1 General
Before bulk coating of pipes and fittings commences, the requirements of 24.2 shall be met and a detailed
sequence of operations to be followed for the coating of pipes and fittings shall be demonstrated.
24.2 Coating procedure specification
The coating procedure specification shall incorporate full details of the following:
a) Quality plan.
b) Multi-component liquid coating to be used together with appropriate data sheets as defined in
clause 4.
c) Pipe or fitting dimensions.
e) Pipe or fitting cleaning.
h) Dust removal.
j) Preheat method time and temperature (if specified).
k) Residual surface contamination.
l) Multi-component liquid and primer (if used) mixing and application.
m) Curing regime.
n) Repair technique.
o) Coating stripping technique.
p) Handling procedures.
24.3.1 General requirements
Three test pieces for the coating procedure approval tests shall be selected from pipe or fittings coated in
accordance with the curing regime (see 24.2). Test pieces shall be subjected to the complete set of tests
specified in 24.3.2 to 24.3.10 inclusive after curing in accordance with the Manufacturer's recommendations.
Testing shall be witnessed and a full set of test results recorded. No coated pipe or fittings shall be dispatched
The Contractor shall ensure that the tests specified in 24.3.2 to 24.3.10 inclusive are carried out and the
results of the tests, demonstrating compliance, made available.
The coated test pieces shall be subjected to a thickness test of the cured coating as specified in 27.2. The
cured coating thickness shall be not less than 1.5 mm and uniform for all tests.
- 20 - J230 (Rev 08/98 )
The coated test pieces shall be subjected to a holiday detection test over 100% of the coated surface as
detailed in CW6: Part 1, Appendix C. The number of holidays detected shall not exceed those specified in
Table 2.
24.3.4 Hardness and cure test
The coated test pieces shall be subjected to a hardness and cure test as specified in 27.4.
The coated test pieces shall be subjected to an impact resistance test at ambient temperature as detailed in
CW6: Part 1, Appendix D. The cured coating shall withstand an impact of 5 J without a holiday being caused.
24.3.6 Adhesion test
The coated test pieces shall be subjected to an adhesion test as detailed in CW6: Part 1, Appendix E.
24.3.7 Flexibility test (for pipe only)
The coated test pieces shall be sectioned and subjected to a flexibility test as detailed in CW6: Part 1,
Appendix B. The coating shall not exhibit signs of cracking, disbondment or pinholes and the test pieces shall
also pass a holiday detection test as detailed in CW6: Part 1, Appendix C.
The coated test pieces shall be subjected to a cathodic disbonding test as detailed in CW6: Part 1,
Appendix F. The disbondment shall not extend more than 5 mm radially from the edge of the damaged coating
after the test period of 28 days.
24.3.9 Strain/polarization cracking test (for pipe only)
The coated test pieces shall be bent and then polarized as detailed in CW6: Part 1, Appendix G. After 28 days
polarization, the test pieces shall show no visible cracking or pinholing of the coating and the test pieces shall
also pass a holiday detection test as detailed in CW6: Part 1, Appendix C.
The coated test pieces shall be prepared and subjected to a water immersion test as detailed in CW6: Part 1,
The surface of the pipe or fitting to be coated shall be prepared as specified in 5.4, except that the quality
required shall be to BS 7079 Sa 2
1
2
and the profile shall be within the range 75m to 100m peak to
trough height and angular in nature.
25.2 Coating process
25.2.1 General
The production coating process shall be carried out using a procedure approved in accordance with clauses
4.5.4 and 24. This shall normally be a spray coating process, but brush application may be used on small
areas.
The thickness of the coating shall be not less than 1.5 mm.
J230 ( Rev 15/07/97 ) - 21 -
25.2.2 Pre-mix agitation
Each coating component shall, when necessary, be mixed to a homogeneous state before any part of the
component is withdrawn from its container.
25.2.3 Mixing for use
The components (e.g. base and curing agent) of a coating material are normally supplied separately packed.
They shall be mixed in accordance with the Manufacturer's instructions.
If preheating of one or more of the coating material components is required prior to mixing and application,
the procedure shall be monitored and controlled to avoid excessive heating which might affect application or
the integrity of the coating.
Material cure time is dependent on ambient temperature. Should it be necessary to shorten the cure time, this
may be achieved by the application of heat to the prepared surface before coating commences.
Thinners shall not be used unless recommended by the Manufacturer.
25.2.4 Spraying equipment
The spraying equipment shall be adequate for applying the coating in accordance with the coating
manufacturer's instructions and the qualification procedure. The equipment shall be maintained in good order
by the Contractor and/or the equipment supplier. All air lines shall be provided with filters and vapour traps to
ensure that the air is free from oil and moisture. All critical parameters shall be monitored.
Tools and equipment shall be cleaned using only such solvents as are recommended by the coating material
manufacturer.
25.2.5 Operator qualifications
When required, the individual operators carrying out the multi-component liquid spraying application shall be
subjected to a qualification test in which they will be required to demonstrate proficiency in the spraying
process as laid down in the relevant section of the procedures.
25.2.6 Spraying procedure
25.2.6.1 The spraying procedure shall be in accordance with the qualification procedure which shall include
a total time allowed for coating. Individual operators shall be experienced in the use of equipment and shall be
suitably qualified (see 25.2.5).
25.2.6.2 Solvent flushing of spray equipment used for rapid cure materials is normally employed to prevent
coating material gelling in the gun when spray operations cease for significant periods of time. It is essential
that, on recommencement of spraying, the operator ensures that solvent-free material only is applied to the
work to avoid ensuing problems caused by solvent blistering of the coating. Additionally, all solvent flushing
operations shall be carried out by discharging the solvent into a suitable container. Solvent shall not be
discharged at random on to the surrounding work area.
25.2.6.3 Coating material filters shall be installed as part of the spray equipment to ensure that particles
which would be detrimental to the coating application are not deposited on to the surfaces being coated.
Regular inspection and maintenance of the filters is recommended.
25.2.6.4 The coating component feed lines to the spray-gun shall be equipped with a pressure gauge fitted
with a pulsation damper, to facilitate pressure readings. The location of this gauge shall be downstream of all
pressure drop devices and as near to the gun tip as is reasonably practicable.
25.2.6.5 The coating contractor shall monitor and record all relevant ambient conditions during application
and cure.
- 22 - J230 (Rev 08/98 )
25.2.6.6 The temperature of the metal surface at the time of application shall be not lower than C 10
0
.
Ideally, for optimum results, the metal surface temperature should be between C 25
0
and C 35
0
, but, it is
essential that care be taken to avoid contaminating the surface. The relative humidity shall be 80% or less
during application and the ensuing first hour of cure time.
25.2.6.7 Coating operations shall be stopped when the conditions are such that an inferior coating will result.
Such conditions include inadequate surface preparation, unsatisfactory application procedure, poor coating
material performance and when the steel temperature at any stage of the process falls to within 3
0
C of the
dew point measured in the work area.
27.1 Testing of coated pipes and fittings
Cured coatings on pipe and fittings shall comply with the requirements of 27.2 to 27.8 inclusive and, where
indicated, methods of test described in CW6: Part 1 shall be used.
The Contractor shall ensure that the tests specified in 27.2 to 27.8 inclusive are carried out and the results of
the tests, demonstrating compliance, made available.
27.2 Thickness test
The coating thickness on each pipe shall be checked at not less than five equidistant locations spread over the
coated surface of the pipe and the coating thickness of each fitting shall be tested in 20 locations spaced
evenly to represent the total area of the fittings coated. All readings of the dry film thickness shall meet the
requirements specified in 24.3.2. The thickness measuring gauge used shall be calibrated hourly for the
specified thickness range (see Appendix A). Values less than those specified in 24.3.2 shall constitute cause
for rejection.
Every pipe and fitting shall be subjected to a holiday detection test over 100% of their coated surfaces as
detailed in CW6: Part 1, Appendix C.
The number of holidays detected shall comply with Table 2. If, on any two consecutive pipes or fittings, the
number of holidays detected is greater than the normally acceptable level, but less than the maximum
permissible level, the cause shall be immediately investigated.
If four further consecutive pipes or fittings are detected having holidays between the normally acceptable level
and the maximum permissible level given in Table 2, all production to that point shall be quarantined until the
reason for the high frequency of holidays is determined. A total of 5% of daily production will be accepted
with up to the maximum permissible number of holidays provided that the 5% are not consecutive.
Pipes or fittings with more holidays than permitted by Table 2 shall be rejected for subsequent stripping (see
clause 14) and recoating.
pipes or fittings.
permanently marked on the pipe or fitting and recorded on the relevant inspection documentation.
J230 ( Rev 15/07/97 ) - 23 -
27.4 Hardness and cure of coating test
The hardness and cure of the coating on every pipe and fitting shall be determined.
The value of the hardness obtained shall be within the range specified by the Manufacturer of the material to
indicate the correct degree of cure of the coating.
The coated pipes and fittings shall be subjected to an impact resistance test of the cured coating as detailed in
CW6: Part 1, Appendix D.
The frequency of testing shall be, for pipes, initially once every two hours or 20 pipes and, for fittings,
initially once every two hours or five fittings, whichever is more frequent.
The cured coating shall withstand a minimum impact of 5 J without resulting in a breakdown or loss of
adhesion of the coating.
27.6 Adhesion test
The coated pipes and fittings shall be subjected to an adhesion test of the cured coating as detailed in
CW6: Part 1, Appendix E.
The frequency of testing shall be, for pipes, initially once every two hours or 20 pipes and, for fittings,
initially (at one location on the fitting) once every two hours or five fittings, whichever is the more frequent.
This initial test frequency may subsequently be varied, the revised test frequency being based on quality
history.
27.7 Heat blister test
After initial cure, a test plate of representative wall thickness, coated at the same time as the batch of pipe and
fittings with multi-component liquid systems, shall be subjected to a heat blister test by heating the steel to a
temperature in the range 50
0
C to 60
0
C and holding the temperature within that range for one hour.
After heating, the test plate shall be inspected for blisters. In the event of blistering being observed, an
investigation into the cause of the defect shall be immediately undertaken. Samples of coating may have to be
removed for nitrogen analysis or other appropriate tests and the coating operations may have to cease during
the period of the investigation. When the cause of the defect has been established, components in the coating
sequence during which the plate has been coated, shall be tested until an acceptable coating is identified.
For pipes, testing shall normally be carried out at a frequency of once every two hours or 20 pipes, whichever
is the more frequent. For fittings, testing shall normally be carried out at a frequency of once every two hours
or five fittings, whichever is the more frequent. These test frequencies may be varied, and the applicator may
also have to vary the test frequency.
Localized blisters shall be repaired.
27.8 Defect rate
Should tests in any coating production batch (typically the production from a seven hour shift) show a
rejection rate of more than 10% defective pipes or fittings for any one test, then every component in that batch
shall be individually subjected to that test. In such cases the Contractor shall simultaneously conduct an
investigation to establish the cause of the defects.
The cost of retrieval of any pipes and fittings dispatched from the coating premises and/or any additional
expenses incurred as a result of additional examination shall be borne by the Contractor.
- 24 - J230 (Rev 08/98 )
If any pipe or fitting has defects in excess of the requirements of 27.2 to 27.8 inclusive, a check procedure
shall be initiated. This shall involve checking all pipes or fittings back to the preceding acceptable one. The
pipe or fitting numbers shall be available from the final inspection batch. These pipes or fittings shall be
subjected to an examination similar to that carried out on the failed pipe or fitting. If the number of defects is
significant, the entire coating production for that day shall be quarantined and investigated.
28. REPAIR OF DEFECTS
All repairs to holidays and other coating defects shall be with multi-component liquid materials to ensure
compatibility with the applied coating. Repair methods shall include adequate surface preparation techniques,
agreed overlaps, coating thicknesses and a demonstration of satisfactory adhesion and cure. All repairs shall
be retested for holidays as detailed in CW6: Part 1, Appendix C.
Maximum areas of repair shall be not greater than those given in Table 2.
The area to be overlapped shall extend to at least 75 mm from the periphery of the defect. The repair material
shall be applied to the prepared surfaces using a scraper, palette knife or paint brush.
Care shall be taken to ensure that the thickness over the repair area is not less than 1.5 mm when cured.
29. HANDLING OF COATED PIPES AND FITTINGS
All coated pipes and fittings shall be handled and stored in accordance with L3 and the relevant fitting
standard where appropriate to prevent damage to the component and coating.
The weld end preparations and fitting ends may be required to be protected from damage and corrosion. The
type of protection and the method of application shall be specified by Transco.
Rejected coatings shall be removed by a procedure which shall not cause mechanical damage to the pipe or
fitting and shall not cause the steel temperature to exceed 250
0
C.
It should be noted that multi-component liquids give off toxic fumes when heated and due care shall be taken
not to inhale any combustion products.
31. IDENTIFICATION
The Contractor shall be responsible for ensuring that all internal and external identification markings are
noted before the surface preparation begins, and are replaced after the coating process in accordance with 5.2.
CW6: PART 2
J230 ( Rev 15/07/97 ) - 25 -
APPENDIX A
CALIBRATION PROCEDURES FOR THICKNESS MEASUREMENT OF FUSION
BONDED EPOXY POWDER AND MULTI-COMPONENT LIQUID COATINGS
A.1 GENERAL
The following calibration procedures for inferential thickness measurement gauges shall be used as
appropriate. Calibration of gauges using standard shims on a flat steel substrate will produce a higher reading
than when calibrating on a surface with a grit-blasted profile. The difference in reading is proportional to the
profile height. With coatings in excess of one millimetre thickness, the calibration 'profile factor' is not
significant. In cases of dispute, the thickness shall be measured by a direct method, typically using a pipeline
inspector's gauge (PIG).
A.2 CALIBRATION USING PLASTICS FOIL SHIMS OF KNOWN THICKNESS ON GRIT-
BLASTED STEEL
This method shall be used when it is possible to calibrate the instrument on a clean dry grit-blasted area of the
pipe or fitting which is representative of the steel cleanliness and surface roughness at the time of coating. To
obtain accurate thickness readings using magnetic 'pull-off' and eddy current instruments the following
precautions shall be taken during calibration:
a) Non-metallic shims of known thickness with certification traceable to national standards shall
be used.
b) The shims shall be examined before use to ensure that they are in good condition with no sign
of roughness or wear.
c) The shims selected for calibration shall be close to the expected thickness of the coating being
evaluated.
d) The steel substrate being used for calibration shall be a representative area of the pipe or
fitting and shall be free of oil, dirt, rust, adhesive, pre-treatment or other contaminant.
e) The surface profile and steel cleanliness when calibration is being carried out shall be typical
of the steel condition at time of coating.
f) The steel substrate shall be at ambient temperature.
g) The probe on the thickness gauge shall be clean and free from contaminants.
h) Where repeated thickness measurements are being made, the instrument shall be re-calibrated
at hourly intervals.
A.3 CALIBRATION USING PLASTICS FOIL SHIMS ON A FLAT STEEL SURFACE
Where it is not possible to obtain a representative area of the pipe or fitting, calibration shall be carried out on
flat steel plates of at least 1 mm thickness using plastics foil shims of known thickness. As an alternative,
American National Bureau of Standards (NBS) or Deutscher Institut fur Normalisierung (DIN) coated test
plates may be used. Plastics foil shims or test plates shall be accompanied by thickness certification traceable
to national standards.
The following precautions shall be taken to ensure accurate measurements:
a) Test certificates for plastics foil shims or coated test plates shall be available.
b) The shims or test plates shall be in good condition with no sign of wear or roughness.
c) The shim or coated test plate selected for calibration shall be close to the expected thickness of
the coating being evaluated.
CW6: PART 2
- 26 - J230 (Rev 08/98 )
d) The steel substrate shall be dry, clean and free from rust or any contaminant.
e) The test plate shall be flat and at least one millimetre thick.
f) Where repeated thickness measurements are being taken, the instrument shall be re-calibrated
at two-hourly intervals.

CW6 Part 2

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