Académique Documents
Professionnel Documents
Culture Documents
COATING
PRO. SCOP
PROJECT PART DIS. DOC. SERIAL REV.
E
IGAT 6 D PL PI SPC 0001 05 25 1
PURPOSE OF
REV. PREPARED CHECKED APPROVED DATE REMARKS
ISSUE
ISSUED FOR
DOCUMENT REVISION SHEET
- REVISED SHEETS
REVISED
01 02 03 04 05 REMARK 01 02 03 REMARK
1 x
2 x
3 x
4 x
5 x
6 x
7 x
8 x
9 x
10 x
11 x
12 x
13 x
14 x
15 x
16 x
17 x
18 x
19 x
20 x
21 x
22 x
Table of Contents
1. Introduction...........................................................................................................4
2. SCOPE..................................................................................................................4
3. Definitions............................................................................................................4
4. CODES AND STANDARDS...............................................................................4
5. BASIC REQUIREMENTS...................................................................................5
6. COATING MATERIALS.....................................................................................6
7. MANUFACTURING PROCEDURE.................................................................10
8. INSPECTION AND TESTING..........................................................................16
9. HANDLING AND STORAGE..........................................................................19
ANNEX A 20
1. Introduction
Iranian Gas Engineering & Development Company (I.G.E.D.C) has intended to perform gas
transmission pipeline and gas compressor stations for transferring of 110 MMSCMD of natural
gas from Assalouyeh to Bazargan.
Design of a new 56" gas transmission pipeline from Ahwaz to Dehgolan has been described under
this EPCF Contract.
2. SCOPE
This specification gives minimum technical specifications and general requirements for 3 layer
polyethylene coating as external protection.
3. Definitions
Client: Iranian Gas Engineering & Development Company (IGEDC).
SUPERVISOR: Ghods Niroo Consulting Engineers.
CONSULTANT: Haraz Rah Consulting Engineers.
CONTRACTOR: Gharargah Khatam-AL-Anbia.Niroo Goostar Institute.
5. BASIC REQUIREMENTS
5.1 Three-layer polyethylene coating system consists of the following layers
and is intended for use on external surfaces of line pipes.
First layer: epoxy powder primer
Intermediate layer: adhesive layer
Top layer: polyethylene coating
5.2 The coating system shall provide the following basic requirements and shall
withstand against mechanical and thermal stresses, bio-degradation and
Electro-chemical process of the cathodically protected pipeline.
Minimum cathodic disbanding property
Maximum strength and impact resistance
Adhesion and penetration resistance
Abrasion resistance
Appropriate tensile and elongation properties
5.3 Manufacturer shall be responsible to provide values for all the basic
properties of the material as specified in paragraphs 5.4.1, 5.4.2 and 5.4.3.
5.4 Manufacturer shall set up and maintain such quality assurance and
inspection system as is necessary to ensure that the goods or services
supplied comply in all respects with the requirements of this specification.
5.5 All identification markings, whether internal or external to the pipe shall be
carefully recorded before surface preparation begins.
5.6 The date of coating finish and the Manufacturer marking, including pipe
identification shall be legibly marked on coating surface of each length of
pipe.
5.7 The coating process shall comply with the procedure established in the
relevant coating procedures, section 6.
5.8 Holiday defects and damaged areas due to destructive tests shall be
repaired in accordance with procedures specified by the Manufacturer.
5.9 Rejected coating shall be removed only by the procedures specified by the
Manufacturer. The process shall cause no mechanical damage to the pipe.
6. COATING MATERIALS
6.1 General
6.1.1 The coating material supplied shall be certified by the
Manufacturer ensuring that all materials comply with this
specification prior to application.
6.1.2 Purchaser may make any investigation necessary, by way of
testing, batch sampling, manufacturing and factory inspection, to
satisfy himself of such compliance by the Manufacturer.
6.2 Material Handling & Storage
6.2.1 The materials shall be stored in accordance with the Suppliers
recommended procedure.
6.2.2 The materials shall be handled in such a way that they do not
suffer any damage.
6.3 Identification of Materials
6.3.1 All materials supplied for coating operations shall be suitably
marked giving the information such as; Suppliers name and
address, order and batch number, date of manufacture and shelf
life, direction for mixing, thinning, handling and storing.
6.4.3 Polyethylene:
Polyethylene is a thermoplastic resin for use as top coat in a
three-layer polyethylene coating system for steel pipe. It shall be
specifically formulated and designed for extrusion application.
Manufacturer shall comply with specified ranges of values given in
Table 3 and shall provide figures for all properties listed therein.
The polyethylene shall be made of raw material with the best
quality to provide following properties:
Excellent peeling resistance.
Excellent mechanical strength.
Excellent thermal stability.
Excellent Impact resistance.
Excellent penetration resistance.
Strong adhesion to adhesive layer.
Table 1
o o o
3.0 flexibility test at 23 C , 0 C and - No cracking CSA Z 245.20-
-20oC - 06
-
Cathodic disbandment after 28 days at m 7 CSA Z 245.20
65 0C in 3% NaCl solution at -1.5 volts m
(calomel electrode) potential , initial .
defect
diameter Do = 6 mm , max
Moisture content,max % 0.5 ISO 21809-1
b
y
m
a
s
s
Degree of cure (differential thermal -2o C Tg +3 o C ISO 21809-1
analysis) C
Glass transition temperature(Tg2)(DSC 95 ISO 21809-1
analysis) C
Table 2
PHYSICAL PROPERTIES OF ADHESIVE LAYER
PROPERTY UNIT TEST VALUE
METHO
D
Density at 232C gr/cm3 ISO 1183 0.90 -
0.95
Melt flow rate (2.16 kg /190 C) O gr/10 ISO 1133 0.5-0.2
minute
s
Elongation at break at 23 2 C ,min O % ISO 527 600
Melting point (DSC) , min C ISO 105
3146
Vicat softening temperature C ISO 306 95
A/50(9.8N) , min
Tensile strength , at 23 2 C ,min
O MPa ISO 527 8
Water content,max weight ISO 0.1
% 15512
Table 3
PHYSICAL PROPERTIES OF BLACK POLYETHYLENE
TEST
PROPERTY UNIT VALUE
METHOD
Density gr/cm3 ISO 1183 0.94 (Min.)
Melting index gr/10
ISO 1133 0.3 -0.8
(2,16kg/190C) min
Elongation % ISO 527 600 Min.
2
Tensile strength at yield N/mm ISO 527 15 Min.
SHORE
Hardness ISO 868 55 Min.
.D
Vicat softening point C ISO 306 115 (Min.)
Melting point (DSC) C ISO 1133 125 Min.
-70 NO.
Low temperature brittleness C ASTM-D-746
FRACTUR
Stress cracking resistance
Hour ASTM-D-1693 1000 Min.
(Methyl-Ethyl-Ceton)
% by
Carbon black content ASTM-D-1603 2.5 MIN.
mass
Water content % by ISO 15512 0.05
weight
Oxidation induction time minute ISO 11357 30
UV resistance and thermal Annex G
% MFR35
aging ISO 21809-1
7. MANUFACTURING PROCEDURE
7.1 Coating method
Coating method shall generally consist of surface cleaning and
blasting, epoxy primer application, adhesive layer and
polyethylene coating application onto the preheated pipe
surface by simultaneous extrusion in a continuous flow
.process
7.2 Coating Process
Manufacturing process of polyethylene coating system
depends on the type of plant but shall be basically
accomplished by profile extrusion and/or winding extrusion and
.melting of polyethylene in accordance with DIN 30670
7.3 Coating Procedures
7.3.1 Surface Preparation
7.3.1.1 The details of method of surface cleaning and surface
preparation shall be specified by the Manufacturer.
7.3.1.2 Where oil, grease or other contaminants are present, they
shall be removed by a suitable solvent.
7.3.1.3 When a chemical cleaner is used to remove any
contamination on pipes, subsequent washing with fresh
water shall be necessary. The pipes shall then be dried
before blast cleaning.
7.3.1.4 The pipes shall be blast cleaned to a minimum of Sa 2
finish according to Swedish Std. SIS 055900. The blast
Table 4
Coating Thickness
POWDER EPOXY
ADHESIVE
RESIN Total Thickness
PIPE DIAMETER (in). (ND LAYER 2)
(ST LAYER 1) mm
mm
mm
Up to 10 0.15 0.15 2.0
Notes:
The minimum nominal thickness of epoxy primer coat, which shall be
applied by electrostatic spray gun, shall be 150 microns. Higher
nominal thickness (to be approved) shall be applied if required in
accordance with powder manufacturers instructions.
Indentation resistance
7.7.4.2 These tests to be done & inform client of the date of test
ahead in time (at best 15 day before tests date) & the
client representation will testified the tests & fill the
appropriate format for submission to client for approval.
Table 5
TEST METHODS FOR COATING PROCEDURE APPROVAL TEST
PROPERTY TEST METHOD ACCEPTABLE LIMIT
Surface preparation Visual As specified in Table 2
inspection
Coating thickness Electro- As specified in Table 4
magnetic
thickness
gauge
Annex A ISO
21809-1
Porosity DIN 30670 No defect at 25 kv
Adhesion Annex C Min. 15 N/mm
At 232C ISO 21809-1 Min. 3 N/mm
At 803C
Impact resistance, At 232C Annex E Min. 7 Jul/mm
ISO 21809-1
Elongation at break, At 232C ISO 527 Min. 400% for extruded
coating
Indentation (hardness) Annex F
At 232C ISO 21809 Max 0.2 mm
At max operating temperature Max 0.4 mm
Thermal cycle resistance 1 cycle: -30C No crack
1hr
+ 60C
1hr
No. of cycles:
100
Product stability during extrusion of ISO 1133 MFR20%
the PE top layer process
Degree of cure of the epoxy as first Annex D Tg3C for FBE
layer ISO 21809-1 Scratch test for liquid epoxy
Flexibility at 0C3C Annex I No cracking at 2.0% angle
8.6 Any other tests deemed necessary by the Manufacturer, shall be proposed
with his offer, which will be reviewed and acknowledged by the Client.
8.7 The quality control system shall include as a minimum the requirements
listed in Table 5.
8.8 After examination or test, should the inspector find out that any pipe has not
been cleaned or coated in accordance with this Specification, the Vendor
shall be required to remove the coating which is considered defective or
inadequate, and to reblast and recoat the pipe to the requirements for
approval of the inspector.
8.9 The inspector shall have access at any time to the construction site and to
those parts of all plants that are concerned with the performance of work
under this standard.
8.10 The Manufacturer shall provide the necessary inspection tools and
instruments for the inspector as well as normal facilities necessary for
inspection.
8.11 Requirements for inspection of surface preparation shall be as specified in
Table 4 of IGS-C-TP-010-Amendment 2.
TABLE 6- REQUIREMENTS FOR INSPECTION AND TESTING OF APPLIED COATING
Frequency Frequency Requirements Test Method Unit Properties Item
production Qualification
pipe at start 1 pipe at start 1 FBE:150 ISO 2808 m Epoxy thickness, min 1
up and 1 up and 1 Liquid epoxy 25
*pipe /shift *pipe /shift
pipe at start 1 pipe at start 1 on pipe 150 ISO 2808 m Adhesive thickness, min 2
up and 1 up and 1 body
*pipe /shift *pipe /shift
*pipe / shift 1 *pipe / shift 1 Tg+3 for FBE Annex D o
C Degree of cure 3
ISO 21809-1
Scratch test for
liquid epoxy
Continuously Continuously Uniform color, Visual Annex B --- Appearance and continuity 4
free of defects
and ISO 21809-1
,discontinuities
, Delamination
separations and
each pipe *pipe/shift 3 Table 2 Annex A mm ** Total thickness of coating 5
ISO 21809-1
pipes at 3 pipes at start 3 Annex E J/mm Impact resistance 6
start up and 1 up and 1 7 ISO 21809-1 at 23 2 C O
*pipe / shift 3 *pipe / shift 3 Annex C N/mm .Peel strength (Adhesion) min 7
pipes at 3 pipes at start 3 15 ISO 21809-1 at 23 2 C O
pipe / 50 km pipe / 50 km
pipes at 3 pipes at start 3 Annex F mm Indentation , max 8
start up and 1 up and 1 0.2 at 23 2 CO
pipe / 50 km pipe / 50 km at 80 CO
ANNEX A
"3LPE COATING REPAIR PROCEDURE FOR THE COATING PLANT"
1. SCOPE
In case of the 3LPE coating of pipe is damaged during production , handling , loading and
unloading at the coating plant , the damage to the coating shall be repaired according to
this Annex :
2. COATING REPAIR MATERIAL
Since the repair materials are required to be approved by NIGC , a copy of technical
specification and data sheets of the repair materials including PE melt stick , filler mastic ,
repair patch and heat shrinkable sleeve shall be submitted to NIGC for review and
approval .
3. QUALIFICATION OF REPAIR PROCEDURE
The repair procedure shall be qualified at the presence of NIGC inspector . In this case a
line pipe with damaged coating shall be repaired in accordance with the instructions
recommended by the repair material manufacturer . The repaired area shall then be
inspected for minimum thickness , adhesion and holiday detection and if satisfactory
results achieved , the repair procedure will be considered acceptable . The inspection
findings shall then be recorded and signed by both parties and kept as a proof of repair
procedure qualification .
4. ACCEPTABLE NUMBER OF REPAIRS IN A LINE PIPE
The maximum acceptable number of damage in any coated line pipe , may be up to three
points , provided that the total damaged areas do not exceed 200 cm2 , however the total
number of pipes with coating repairs , shall not exceed 2% of total number of coated
pipes in any individual order .
5. UNREPAIRABLE DAMAGE
The following damage are not allowed to be repaired :
5.1 If in every 200 pipes the damage to the coating , is reached to the FBE layer in only
one pipe .
5.2 No repair will be allowed on coating edges at either sides of pipe coating .
5.3 The maximum surface of 3 repaired areas in any line pipe , shall not exceed 200 cm2
.
In such cases the pipe coating shall be fully stripped and the pipe recleaned and
recoated.
6. REPAIRABLE DAMAGE
The damage which is allowed to be repaired is limited to the following :
6.1 Minor Damage
If the damaged depth is less than 1.5 mm and the related area is less than 5 cm2 ,
the damage may be repaired by PE melt stick .
6.2 Intermediate Damage
If the damaged depth is less than the thickness of PE and adhesive layers (3 mm
maximum) and the maximum area of the damages does not exceed 50 cm2 , with the
biggest dimension of 10 cm , the damage shall be repaired by filler mastic and repair
patch .
6.3 Major Damage
If the damage depth is less than the thickness of PE and adhesive layers (3 mm
maximum) and the maximum area of the damage does not exceed 100 cm2 with the
biggest dimension of 30 cm , the damage shall be repaired by filler mastic together with a
wraparound heat shrinkable sleeve .
Note : Any repair activities shall be performed fully in accordance with the instructions
recommended by the repair material manufacturer .
7. REPAIR QUALITY CONTROL
All repaired areas shall be subjected to visual inspection , thickness measurements ,
holiday inspection and adhesion when repair patch is used . In case of any failure , the
repaired portion shall be removed , recleaned and repaired again .
Repair material shall be suitable for maximum operating pressure and also other physical
properties to be matchable with 3 layer polyethylene coating .
The coater shall obtain the approval of NIGC for type and technical properties of repair
material .
8.RETEST
In case of failure of any required test, the Coater shall test two additional linepipes, one
linepipe before and one after the failed one. If the follow up tests are successful, all
coated linepipes since the last acceptable test shall be considered satisfactory, except for
the failed linepipes that will be rejected .
If the follow up tests also fail to meet the requirements of this specification, all coated
linepipes since the last acceptable test shall be rejected .