2012A Functional Spec For 3LPP (3 Layer Poly Propelene) Corrosion Coating For Linepipes) (Rev. 0)

Spec. No.
2012 A
Offshore Design Section FUNCTIONAL
Rev. No. 0
Engineering Services SPECIFICATION FOR
Discipline Pipeline
ISO – 9001:2008 3LPP Page: 1 OF 46
FUNCTIONAL SPECIFICATION
FOR
3LPP (3 LAYER POLY PROPELENE)
CORROSION COATING FOR LINE PIPES
RP KPV SBS 46 24.05.11 0
Total No. of
Prepared By Reviewed By Approved By Date Rev. No.
Pages
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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CONTENTS
1 SCOPE
2 REFERENCE DOCUMENTS
3 GENERAL REQUIREMENTS
4 COATING MATERIALS
5 FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING SYSTEM
6 MEASUREMENT AND LOGGING
7 COATING PROCEDURE AND QUALIFICATION
8 PIPE SURFACE PREPARATION
9 COATING APPLICATION
10 INSPECTION AND TESTING
11 HANDLING, TRANSPORTATION AND STORAGE
12 REPAIR OF COATING
13 MARKING
14 QUALITY ASSURANCE
15 DOCUMENTATION
16 PREPARATION FOR SHIPMENT
ANNEXURE – I COATING SYSTEM/ MATERIAL PRE-QUALIFICATION

APPENDIX 1 INSPECTION SUMMARY FOR PROCEDURE QUALIFICATION
TEST ON PP-COATING SYSTEM FOR ONE PIPE DIAMETER
APPENDIX 2 INSPECTION SUMMARY FOR PRODUCTION TESTING ON
FULL PP-COATING SYSTEM FOR ONE PIPE DIAMETER
APPENDIX 3 AIR ENTRAPMENT ASSESSMENT
APPENDIX 4 FOR FBE LAYER COATING PQT
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1.0 SCOPE
This specification covers the minimum requirements for supply/arrangement of all materials, plant,
equipment, plant sites, consumables, utilities and application including all labour, supervision,
inspection and tests etc. for application of external anti-corrosion coating of pipes for sub-sea
pipelines by using 3 Layer Polypropylene coating conforming to DIN-30678.
The requirements specified are to apply externally the 3LPP coating system on the pipes to
protect its corrosion. The coating system shall be suitable for overcoating with concrete coating
and installation using the S-lay method.
2.0 REFERENCE DOCUMENTS
The latest edition (edition enforce at the time of issue of enquiry) of the following standards, codes
and specifications shall establish the minimum standards for the work.
Deutsches Institut für Normung (DIN)
DIN 30678 Polypropylene Coatings for Steel Pipes.
DIN EN 10204 Inspection Documents for Metallic Products.
DIN 53735 Testing of Plastics: Determination of Melt Index of Thermoplastics.
Association Francaise de Normalisation (AFNOR)
NF A49-711 Steel Pipes: External coating with three layer polypropylene based coating:
application by extrusion
API (American Petroleum Institute)
RP 5L9 External fusion bonded Epoxy Coating of linepipe
International Organisation for Standardisation (ISO)
ISO 2808 Paints and Varnishes – Determination of film thickness
ISO 8501-1 Preparation of steel substrates before application of paints and related products -
Visual assessment of surface cleanliness - Part 1: Rust grades and preparation
grades of uncoated steel substrates and of steel substrates after overall removal
of previous coatings
Tests for the assessment of surface cleanliness - Part 2: Laboratory
determination of chloride on cleaned surfaces
Tests for the assessment of surface cleanliness - Part 3: Assessment of dust on
steel surfaces prepared for painting (pressure-sensitive tape method)
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ISO 11124 Preparation of Steel Substrates Before Application of Paints and Related
Products
National Association of Corrosion Engineers (NACE)
NACE RP 0185 Extruded Polyolefin Resin Coating Systems with Soft Adhesives for Underground
or Submerged Pipe
NACE RP 0274 High- Voltage Electrical Inspection of Pipeline Coatings.
NACE RP 0394 Application, Performance and Quality Control of Plant Applied Fusion Bonded
Epoxy External Pipeline Coating
NFA 49-711 Steel Tubes- 3Layer External Coating Based on Polypropylene Application by
Extrusion
CSA Z245.20-02 External Fusion Bonded Epoxy Coating for Steel Pipe.
Relevant ASTM standards
The CONTRACTOR shall be familiar with the requirements of these reference documents and
shall make them available, as required, at the coating plant during the execution.
3.0 GENERAL REQUIREMENTS
3.1 The Contractor shall perform all work in accordance with this specification and other
requirements noted.
Contractor shall submit a detailed written description in the form of a manual covering
coating equipment, procedure, materials, inspection, tests and repair etc. for Company
approval.
3.2 The Contractor shall provide the skilled personnel required for execution of this work.
The equipment required shall be in good operating condition. Improvised equipment
shall not be acceptable.
3.3 The Contractor shall supply all coating materials required by this specification and
shall carry out tests on one sample per batch of supply as described subsequently.
The tests shall be carried out by the Contractor at his yard and the results shall be
reported to the Company for approval and acceptance.
3.4 The Contractor shall unload the pipes at the coating plant, tally, store and provide
security for the pipes during coating and storage. The Contractor shall be responsible
for placement of the bare and coated pipes in storage in accordance with the
reference specifications.
3.5 All coating and wrapping operations shall be performed under the supervision of and
performed by, personnel skilled in the application of the coating system. Inspection of
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the coating and wrapping of the pipes shall be performed by qualified inspectors. The
qualification of the inspectors shall be verified and approved by the Company’s
Representative prior to the start of work. Final acceptance of all coating works shall
be determined by the Company’s Representative.
3.6 The Contractor shall provide access, during all phases of work, to the Company and
Company’s Representatives/inspectors. Any expense caused by the Company
inspector stopping the work because it is not being carried out as per this specification
shall be borne by Contractor.
3.7 All tools and equipment furnished by the Contractor shall be of good quality,
maintained in good operating condition and suitable for use to apply materials as per
this specification. All equipment shall be subject to approval by the Company
Representative.
All cleaning, priming and coating machines shall be equipped with rubber or wheels
overlaid with hard fiber to prevent marking or denting the pipe.
3.8 The CONTRACTOR shall be responsible for obtaining all statutory approvals /
clearances from relevant Authorities including Pollution Control Board, as applicable for
the coating plant(s).
4.0 COATING MATERIALS
4.1 The three layer coating system shall comprise of a powder epoxy primer, polymeric
adhesive and a polypropylene top coat. Additionally, anti slip polypropylene granule coat
shall be applied. Coating materials shall be suitable for the service conditions and the
pipe sizes involved. The coating materials i.e. epoxy powder, adhesive and
polypropylene compound shall have proven compatibility. The coating system and
materials shall be prequalified and approved by COMPANY in accordance with
provisions of Annexure-I of this specification. CONTRACTOR shall obtain prior approval
from COMPANY for the coating system and coating materials.
4.2 The coating materials Manufacturer shall carry out tests for all properties specified in
para 5.2 for each batch of epoxy, adhesive and polypropylene compound. In addition,
the Manufacturer shall also furnish Infra-red scan for each batch of epoxy powder. The
coating materials Manufacturer shall issue test certificates as per the relevant standards/
methods specified in para 5.2, for each batch of materials supplied to Contractor and the
same shall be submitted to Company for approval prior to their use.
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4.3 In addition to Manufacturer’s certificate, the CONTRACTOR shall draw samples from
each batch of epoxy, adhesive and polypropylene in the presence of COMPANY
REPRESENTATIVE and test for the following properties at the coating yard at least one
week prior to its use, to establish compliance with the Manufacturer’s test certificates.
a) FBE Powder
• Gel time
• Sieve analysis
• Adhesion
• Density
• Moisture content
• Thermal analysis
b) Adhesive
• Melt flow index
• Vicat Softening Point
• Adhesion to FBE and polypropylene layers at 25°C, 60°C, 110°C and 120°C
• Density
c) Polypropylene Material
• Density
• Melt flow index
• Moisture Content
• Oxidative Induction Time
• Shore hardness
• Vicat softening point
The polypropylene shall be chemically modified for use at operating temperatures of up
to 120°C on external surface of sub-sea pipeline section and shall contain additives as
required to provide UV protection and shall be suitable for 3-layer polypropylene coating
system.
4.4 In case of failure of any of the above tests in a batch, that batch of material shall be
tested for all other tests required as per para 5.2.1 to 5.2.3 including the tests which
failed. If all tests pass, the batch shall be accepted for coating. If any of the tests fail,
entire batch of material shall be rejected and shall not be used for the coating.
4.5 All packages of powder shall be marked with the following data as a minimum.
• Manufacturer
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• Material identification
• Batch number
• Place & Date of manufacture
• Shelf Life/ Expiration date (if applicable)
• Quantity
• Safety instructions
• Storage instructions (storage shall normally be at a temperature not greater than 25°C).
All materials without above identification shall be rejected by Company. Such materials
shall not be used for coating and shall be removed from site.
4.6 Contractor shall ensure that all coating materials are properly stored in accordance with
the Manufacturer’s recommendation at all times, to prevent damage and deterioration in
quality prior to use.
4.7 Contractor shall be required to use all materials on a date received rotation basis, i.e.
first in-first used basis.
5.0 FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING SYSTEM
5.1 The coating shall be able to withstand the maximum in service operating temperature of
120°C for sub-sea pipeline system.
5.2 Properties
Properties of coating system and coating material shall comply the requirements
indicated in subsequent paragraphs. In case, the coating/ material properties are tested
as per test methods/ standards other than specified herein below, the same may be
accepted provided the test procedures and test conditions are same or more stringent
than the specified.
5.2.1 Properties of FBE Powder
Contractor shall select epoxy powder that will achieve the functional requirements and
properties of coating system as specified in para 5.1 and 5.2.4 of this specification
respectively.
Typical Properties of FBE Powder shall be as follows:
Sl. Properties Requirement Applied Standard
No.
1. Specific Gravity As defined by Manufacturer ISO 2811-1
2. Moisture content 0.50% Max API RP 5L9
3. Total Volatile content 0.60% Max API RP 5L9
4. Particle size 0.2% Max Retained on 60 API RP 5L9
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Mesh(250 Microns)
5. Cure Cycle Capable of Cure at API RP 5L9
temperature
below 260 ºC
6. Glass Transition Tg1 40-75 ºC NACE RP 0394
Temperature Tg2 >120 ºC
7. Wet Glass Transition Tg2 ≥120 ºC Manufacturer’s
Temperature Test
Procedure
8. Heat of Reaction As defined by Manufacturer NACE RP 0394
9. Gel Time As defined by Manufacturer NACE RP 0394
10. Hardness Shore D 80-90 ASTM D 2240
11. Flexibility Flexibility > (3°/PD) at 0°C PD: API RP 5L9
Pipe Dia.
12. Impact Resistance 2.0 Joule API RP 5L9
13. Abrasion Resistance 300 mg Max (note-1) API RP 5L9
14. Cathodic = 5 mm at 23 °C/28 days or AFNOR A49-711
Disbondment = 7 mm at 95 °C/ 48 hour
15. Dielectric Strength Strength > 500 Volt / mil ASTM D 149
mil = 25 microns
16. Hot Water Soak Test 30% max. of coating can be API RP 5L9
removed as per rating 2 of
standard
Note-1: Abrasive resistance is equal 300 mg max. by C.S 17 abrasive wheel /l000 gram /
1000
5.2.2 Properties of Adhesive
Contractor shall select adhesive that will achieve the functional requirements and
properties of coating system as specified in para 5.1 and 5.2.4 of this specification
respectively.
No.
Physical
1. Specific Gravity 0.89 – 9.2 ASTM D 1505

2. Melt flow rate (MFR) 0.75 – 1.2 g/10 min ISO 1133
230°C/ 2.16 kg
3. Water Content Equal or less than 0.1% ISO 15512
Mechanical
4. Tensile Yield Strength Equal or Greater than 20 Mpa ASTM D 638
5. Tensile Elongation Equal or Greater than 350 ASTM D 638
6. Hardness Shore D Equal or Greater than 57 ASTM D 2240
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7. Brittle Point -20°C ASTM D 746

Impact
8. Notched izod impact +45 KJ/ m ISO 180
strength
at+23°C
Thermal
9. Vicat softening Equal or Greater than 130°C ASTM D 1525
temperature
5.2.3 Properties of Polypropylene Compound

The polypropylene compound shall be UV and thermal stabilized co-polymer, designed
for extrusion and suitable for continuous service at operating temperatures of up to
120°C for sub-sea/ onshore buried pipeline application.
Typical Properties of Polypropylene coating (Top Coat) shall be as follows:

No.
Physical
1. Specific Gravity 0.89 ASTM D 1505

2. Water Absorption Min. 0.02% wgt ASTM 570
3. Water Content < 0.05 % ISO 15512
Mechanical
4. Tensile Yield Strength 20 Mpa ASTM D 638
5. Tensile Elongation 400 % ASTM D 638
6. Hardness Shore D 60 ASTM D 2240
Impact
7. Notched izod impact 50 KJ / m ISO 180/1A
strength
at+23°C
Thermal
8. Vicat softening > 130°C ASTM D 1525
temperature
5.2.4 Properties of Coating System

No.
1. Appearance and Uniform colour, free of defects AFNOR A49-711
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continuity and
discontinuities, delamination,
separations and pinholes
2. Impact Strength No failure after 30 impacts, DIN 30678
when tested with 25KV
3. Indentation (mm) at 90 0.3 mm DIN 30678
±5°C
4. Elongation at break of 400 % ASTM D 638
the PP
5. UV aging (Elongation 260 % AFNOR A49-711
break)
6. Bond Strength 100 N/cm at 50±5°C (at peel DIN 30678
off rate 10mm/min)
80 N/cm at 50±5°C (at peel off
rate 10mm/min)
7. Hot water soak test for No loss of adhesion API RP 5L9
FBE
cure
8. Degree of cure of the Temp. variation (Max. ∆Tg):- AFNOR A49-711
epoxy 2°C to +3°C)
(1st layer)
9. Porosity of FBE (cross Rating 1 NACE RP 0394
sectional & Interface)
10. Interface contamination Maximum 20% NACE RP 0394
of
FBE
11. Shore D Hardness 57 ASTM 2240
12. Product stability during ≤35 % (virgin compound ISO 1133
extrusion of the PP top granulate before
layer extrusion/extruded foil after
process extrusion of
the same batch)
13. Average cathodic ≤ 5 mm at 23°C/28 days or AFNOR A49-711
disbanding ≤ 7 mm at 95°C/48 hours
length
6.0 MEASUREMENT AND LOGGING

CONTRACTOR shall maintain records in computer using MS ACCESS database
Software containing all the relevant data of individual pipe and pipe coating including
pipe number, heat number, diameter, length, wall thickness, defects, coating number,
batches of materials, sampling, testing, damages, repairs, rejects and any other
information that COMPANY considers to be relevant and required for all incoming bare
pipes and COMPANY approved outgoing coated pipes as applicable. CONTRACTOR’s
documentation shall be designed to ensure full traceability of pipe and coating materials
through all stages of coating and testing. CONTRACTOR shall submit this information in
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the form of a report at the agreed intervals. The above data shall also be provided in MS
ACCESS format in Compact Disc (CD). CONTRACTOR shall provide one Computer
Terminal to COMPANY Representative for monitoring/tracking of the above. The
CONTRACTOR shall also submit the material balance details to COMPANY for
information at the end of each shift.
7.0 COATING PROCEDURE AND QUALIFICATION
7.1 Upon award of the CONTRACT, the CONTRACTOR shall submit within two (2) weeks,
for COMPANY approval, a detailed report in the form of bound manual outlining, but not
limited to, the following:
a. Details of plant(s), location(s), layout, capacity and production rate(s).
b. Details of the equipment available to carry out the coating works including surface
preparation, epoxy powder application and its recycling system, adhesive &
polypropylene extrusion, moisture control facilities available for coating materials.
c. Details of process control and inspection equipment required for the coating process
such as temperature control, thickness control, holiday testers, etc.
d. Facilities in the yard for unloading, handling, transport, production, storage,
stockpiling, loading of bare and coated pipes and warehouses for storage of other
coating materials.
e. Plant Organisation Chart and availability of manpower including coating specialist
f. Details of utilities/facilities such as water, power, fuel, access roads and
communication etc.
After COMPANY has given approval, no change in plant set-up shall be made. However,
unavoidable changes shall be executed only after obtaining written approval from
COMPANY.
7.2 At least four (4) weeks prior to the commencement of production coating, a detailed
procedure of the CONTRACTOR's methods, material proposed, etc., shall be formulated
by the CONTRACTOR and submitted for COMPANY approval in the form of a bound
manual. The procedure shall include, but not limited to, the following information and
proposals:
a. Pipe inspection at the time of bare pipe receipt.
b. Steel surface preparation, including preheating, removal of steel defects, method of
pipe cleaning, dust removal, abrasive blast cleaning and surface profile; methods of
measurements and consumables.
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c. Pipe heating, temperatures and control prior to epoxy application.

d. Complete details of raw materials including current data sheets showing values for all
the properties specified together with quality control and application procedure
recommendations from manufacturer(s).
e. Application of FBE powder, adhesive and polyepropylene, including characteristics,
temperature, line speed, application window, curing time, etc.
f. Quenching and cooling, including time and temperature.
g. Quality Assurance System, Quality Plan, Inspection and Test Plan and reporting
formats, including instrument and equipment types, makes and uses, etc.
h. Detailed method of repair of coating defects duly classified depending upon nature
and magnitude of defects and repair thereof including coating stripping technique
i. Details of instrument and equipment calibration methods including relevant standards
and examples of calibration certificates.
j. Complete details and inventory of laboratory and equipment for procedure qualification
and regular production
k. Pipe handling and stock piling procedures
l. Sample of recording and reporting formats, including laboratory reports, certificates
and requirement as per clause 6.0 of this specification.
m. Complete details of test certificates for raw materials including test methods and
standards used.
n. Test certificates from PP compound manufacturer for tests for thermal aging, coating
resistivity and aging under exposure to light. These test certificates shall not be older
than three years.
o. Health, Safety and Environment Plans.
p. Storage details of coating materials and chemicals.
q. Continuous temperature monitoring at various stages of coating
Procedure Qualification Tests (PQT) shall be carried out only after obtaining written
approval of the above procedure from COMPANY. No change in the procedure shall be
made after the COMPANY has given approval. However, unavoidable changes shall be
executed only after obtaining written approval from COMPANY.
7.3 Prior to start of production, the CONTRACTOR shall, at his expense, carry out a coating
PQT for each pipe diameter on max. wall thickness, for each type of pipe, for each
coating material combination, and for each plant, to prove that his plant, materials, and
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coating procedures result in a quality of end product conforming to the properties stated
in clause 5.2, relevant standards, specifications and material manufacturer's
recommendations.
CONTRACTOR shall give seven (7) working days’ notice to witness all procedures and
tests.
A batch representing a normal production run, typically 15 pipes, shall be coated in
accordance with the approved coating procedure and the coating operations witnessed
by COMPANY Representative. Out of these pipes, at least one pipe shall be coated
partly with epoxy and partly with both epoxy and adhesive layers.
At least 5 (five) test pipes shall be selected by COMPANY Representative for coating
procedure approval tests and shall be subjected to procedure qualification testing as
described hereinafter. COMPANY Representative shall witness all tests. Out of 5 (five)
test pipes, 1 (one) pipe partly coated with epoxy and partly coated with both epoxy and
adhesive layers shall be included. Remaining 4 (four) test pipes shall have all three
layers.
During PQT, the CONTRACTOR shall qualify various procedures forming a part of
coating operations as detailed subsequently. pipe partly coated with epoxy and partly
coated with both epoxy and adhesive layers and the pipes coated with all three layers
shall be subjected to complete set of tests as detailed in para 7.5 and specified in
Appendix-1.
Pipes selected for PQT shall pass all the criteria contained in Appendix-1 before
production commences.
7.4 Qualification of Procedures
7.4.1 Epoxy Powder Application & Recycling
During pre-qualification, air pressure in the epoxy spray guns, satisfactory functioning of
monitoring system, line speed vs coating thickness, etc. shall be established. Dew point
of air used to supply the fluidised bed, and epoxy spray system shall be recorded during
the PQT. No epoxy recycling is permitted.
7.4.2 Pipe Pre-heating
The CONTRACTOR shall establish the temperature variation due to in-coming pipe
temperature, line speed variation, wall thickness variation, emissivity, interruptions, etc.
and document the same during the PQT stage. During PQT, proper functioning of pipe
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temperature monitoring and recording system including alarm/hooter shall be

demonstrated to the COMPANY Representative.
7.4.3 Surface Preparation
The procedure to clean and prepare the pipe surface shall be in accordance with the
requirements of para 8.0 of this specification. The ratio of shot to grit shall be established
during procedure qualification testing, such that the resultant surface profile is not dished
and rounded. The qualification shall be performed through a visual inspection,
measurement of roughness and check of the presence of dust on the abrasive blast
cleaned pipe surface.
7.4.4 Coating Application
The COMPANY Representative will check the correctness of each coating application
operation, values of the main parameters of each operation, pre-heating pipe surface
temperature prior to epoxy powder application temperature, line speed, fusion bonded
epoxy curing time, temperature and flow rate of co-polymer adhesive and polypropylene,
etc. and the same shall be recorded. These values shall be complied with during regular
production.
7.5 Qualification of Applied Coating
7.5.1 Tests on pipe coated partly with epoxy and partly with epoxy & adhesive layers
a. Degree of Cure
Epoxy film samples (minimum 4 no.) shall be scrapped from the coated pipe and the
samples shall be taken for cure test using Differential Scanning Calorimetry (DSC)
procedure. Care shall be taken to remove the samples of full film thickness avoiding
inclusion of steel debris. Glass transition temperature differential (∆Tg) and % cure (∆H)
shall comply with the specified requirements.
b. Epoxy Layer Thickness
Epoxy layer thickness shall be checked at every one metre spacing at 3, 6, 9 and 12
o’clock positions. The thickness shall comply with the specified thickness requirements.
c. Adhesive layer Thickness
Adhesive layer thickness shall be checked at every one metre spacing at 3, 6, 9 and
12’o clock positions. The thickness shall comply with the specified thickness
requirements.
d. Holiday Inspection
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Entire pipe shall be subject to holiday inspection and the test voltage shall be set @5
v/micron (minimum) of epoxy thickness specified for the portion coated only with epoxy
layer.
e. Adhesion Test
i. Adhesion Test (24 hrs or 48 hrs) shall be carried out on the epoxy coated pipe. Test
method, no. of test specimen and acceptance criteria shall comply DIN 30678.
ii Adhesion of FBE shall also be separately determined at ambient temperature at two
locations by the “St Andrews Cross” method and the test shall comply with the
specified requirements.
f. 2.5° Flexibility Test
2.5° Flexibility test shall be carried out on the epoxy coated pipe at test temperature
of 0°C. Test method, no. of test specimen and acceptance criteria shall comply API RP
5L9.
g. Cross-section & Interface Porosity Test
Cross section porosity and interface porosity tests shall be carried out on the epoxy
coated pipe. Test method, no. of test specimen and acceptance criteria shall comply
NACE RP 0394.
7.5.2 Tests on pipes coated with all three layers
a. Bond Strength:
Three test pipes shall be selected for bond strength tests. On each of the selected pipes,
three bond strength test shall be performed for each specified temperature i.e. one at
each end and one in the middle of the pipe and specified requirements shall be complied
with, i.e. bond strength as well as mode of separation. Length of peel shall be minimum
65 mm. None of these samples shall fail.
b. Impact Strength:
Three test pipes shall be selected for impact strength test and the test shall meet the
c. Indentation Hardness:
Two samples for both temperatures from all pipes shall be taken. If any one of these
samples fail to satisfy the specified requirements, then the test shall be repeated on four
more samples. In this case, none of the samples shall fail.
d. Elongation at failure:
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Six samples each from three coated pipes i.e. 18 samples in all shall be tested and the
test shall comply the specified requirement. Only one sample per pipe may fail.
e. Cathodic Disbondment Test:
Three CD tests shall be carried out for the total lot of test pipes having all three layers.
One test shall be carried out for 30 days duration and two tests for 48 hours duration at
65ºC & 95ºC respectively. The tests shall comply the specified requirement. Whenever
Procedure Qualification is necessitated for different pipe size with same coating material
combination, 48 hours test only be conducted. 30 days CD test is not mandatory in this
case.
f. Holiday Inspection
All the pipes shall be subject to holiday inspection. The test voltage shall be as specified
in para 10.5.2.
g. Coating Thickness Measurement
All pipes shall be subject to coating thickness measurements. Acceptance criteria shall
be as per para 10.4.3.
h. Air Entrapment
One sample each from pipe body and on weld (if applicable) shall be taken from all four
coated pipes and the specified requirements shall be complied with.
i. Degree of Cure
Epoxy film samples (minimum 4 no., equally spaced) shall be scrapped from one coated
pipe and the samples shall be taken for cure test using Differential Scanning Calorimetry
(DSC) procedure. Silicon coated sulphite paper shall be placed between the epoxy layer
and adhesive layer immediately after epoxy application, to ensure physical separation of
epoxy & adhesive as well as to prevent contamination of epoxy with adhesive layer, at a
location from where the epoxy samples are to be removed for the test. Care shall be
taken to remove the samples of full film thickness avoiding inclusion of steel debris.
Glass transition temperature differential (∆Tg) and % cure (∆H) shall comply with the
7.5.3 Inspection of all test pipes
All pipes shall be subject to the following inspections:
a. surface cleanliness, surface roughness measurements and dust control immediately
after second abrasive blast cleaning and salt test.
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b. visual inspection of finished coating, cut back dimension, internal/external cleanliness,

end sealing and bevel inspection.
Acceptance criteria for all inspection and testing shall be as specified in this
specification.
7.6 After completion of the qualification tests and inspection as per para 7.4 and 7.5 above,
the CONTRACTOR shall prepare and issue to COMPANY for approval a detailed report
of the above tests and inspection including test reports/certificates of all materials and
coatings tested. Only upon written approval from COMPANY, CONTRACTOR shall
commence production coating.
7.7 On successful completion of PQT, coating of all five (5) test pipes shall be removed and
completely recycled as per the approved coating procedure specification, at
CONTRACTOR’s expense. Remaining pipes will be accepted by COMPANY provided
they meet the requirements of this specification and need not be stripped and re-cycled.
7.8 The CONTRACTOR shall re-establish the requirements of qualification and in a manner
as stated before or to the extent considered necessary by COMPANY, in the event of,
but not limited to, the following:
- Every time there is a change in the previously qualified procedure.
- Every time there is a change in the manufacturer and change in formulation of
any of the raw materials and change in location of raw material manufacture.
- Every time the coating yard is shifted from one location to the other or every time
the critical coating equipments (induction heater, epoxy spray system, extruder,
etc) are shifted.
- Any change in line speed during coating application
- Any time when in COMPANY’s opinion the properties are deemed to be suspect
during regular production tests.
7.9 COMPANY reserves the right to conduct any or all the test required for qualification
through an independent laboratory or agency at the cost of CONTRACTOR when in
COMPANY's opinion, the results are deemed suspect. COMPANY's decision shall be
final.
8.0 PIPE SURFACE PREPARATION
8.1 Unless specified otherwise, the pipes shall be supplied free from mill applied oils but
may be subject to contamination occurring during transit.
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8.2 Prior to cleaning operation, CONTRACTOR shall visually examine the pipes and shall
ensure that all defects, flats and other damages have been repaired or removed. The
CONTRACTOR shall also remove marking stickers, if any, present within the pipe.
Record shall be kept of such marking on the stickers to ensure traceability of pipe after
coating.
8.3 Any oil, grease, salt or other contaminants detrimental to the formation of a good coating
bond or coating quality shall be removed prior to coating application. Contaminants may
be removed by the use of non-oily solvents. Gasoline or kerosene shall not be used for
this purpose. Visible oil and grease spots shall be removed by solvent wiping. Solvent
cleaning shall be in accordance with SSPC-SP1. Steel surface shall be allowed to dry
before abrasive cleaning.
8.4 All pipes shall be preheated to a temperature of 65°C to 85°C prior to abrasive blast
cleaning. The external surface of the pipe shall be cleaned using 2 no. dry abrasive blast
cleaning units to achieve the specified surface cleanliness and profile. After first abrasive
blast cleaning, chemical pre-treatment with phosphoric acid solution as per para 8.6
shall be carried out prior to second abrasive blast cleaning. However at the option of
CONTRACTOR, chemical pre-treatment with phosphoric acid solution as per para 8.6
may be carried out after the second abrasive blaster.
The abrasive blast cleaning units shall have an effective dust collection system to ensure
total removal of dust generated during blast cleaning from the pipe surface. The
equipment used for abrasive blast cleaning shall meet the specified requirements and
shall be free from oil, water soluble salts and other forms of contamination to ensure that
the cleaning process is not impaired. Traps, separators and filters shall be checked for
condensed water and oil at the start of each shift and emptied and cleaned regularly.
During abrasive blast cleaning, the metallic abrasive shall be continuously sieved to
remove “fines” and “contaminants” and the quality checked at every four hours.
Abrasives used for blast cleaning shall comply ISO-11124.
8.5 Suitable plugs shall be provided at both pipe ends to prevent entry of any shot/grit into
the pipe during blast cleaning operations. These plugs shall be removed after blast
cleaning. Alternatively the CONTRACTOR may link the pipes suitably together to
prevent the entry of any short/grit into the pipe.
8.6 Chemical Pre-treatment with Phosphoric Acid Solution.
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8.6.1 All pipes shall be provided chemical pre-treatment with phosphoric acid solution. 10%
solution of phosphoric acid, Oakite 31 / 33 or equivalent, shall be used to remove all
soluble salts and other soluble contaminants.
The CONTRACTOR shall provide data sheets and supporting documentation for the
phosphoric acid to be used. The documentation shall verify that the phosphoric acid is
suitable for the treatment of line pipe prior to the application of the specific fusion bonded
epoxy powder being applied and the final coating will meet fully the requirements of this
specification.
8.6.2 The pipe temperature immediately prior to the phosphoric acid treatment shall be in the
range of 45 to 75 °C. Phosphoric acid treatment shall be followed immediately by
washing with de-ionised water. Deionised water used shall conform to the following
requirements:
Sl. Properties Unit Requirement
No.
1. Turbidity NTU 1 max.
2. Conductivity µmho/cm 5 max.
3. Hardness - NIL
4. Total Alkalinity as CaC03 mg/l 2 to 3

5. Chloride as Cl- mg/l 1 max.
6. Sulphate as SO4 mg/l 1 max.
7. PH - 6.5 to 7.5
Tests to determine the above properties shall be carried out in accordance with
“Standard Methods for the Examination of Water and Wastewater” published jointly by
American Public Health Association, American Water Works Association and Water
Pollution Control Federation.
Quality of the deionised water shall be monitored at the start of each shift and at every
four hours interval. Non-compliance of deionised water wrt the above requirements shall
cause for stoppage of the operations.
8.6.3 The pH of the pipe surface shall be determined both before and after the de-ionised
water rinse initially on each pipe and in case of consistent results, the frequency may be
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relaxed to once per hour at the discretion of COMPANY Representative. The measured
pH shall be as follows :
Before de-ionised water wash: 1 to 2
After de-ionised water wash: 6 to 7
8.6.4 After the deionised water wash, the pipe shall be dried with dry air and preheated to a
temperature of 65°C to 85°C.
8.6.5 The salt tests shall be carried out after deionised water rinse. One test shall be carried
out at one end of each pipe. The acceptance criteria shall be 2µg/cm2. An approved salt
meter (SCM 400 or equivalent) shall be used to carry out salt tests and shall be
calibrated in accordance with the equipment manufacturer’s recommendations.
8.7 Abrasive cleaning carried out shall be such that the resultant surface profile is not dished
and rounded when viewed with 30X magnification. The standard of finish for cleaned
pipe shall conform to near white metal finish to Sa 2 ½ of Swedish Standard SIS 055900
latest edition. Surface of pipe after abrasive blast cleaning shall have an anchor pattern
of 50 to 70 microns(RZ). This shall be measured for each pipe by a suitable instrument
such as surface profile depth gauge. In addition the pipe surface after blast cleaning
shall be checked for the degree of cleanliness (Sa 2½), degree of dust and shape of
profile. Degree of dust shall comply the requirements of ISO 8502 – 3. Acceptance limit
shall be either quality rating 2 or Class 2.
8.8 All pipes shall be visually examined for presence of any shot/grit/loose material left
inside the pipe during blast cleaning. Suitable mechanical means (stiff brush) shall be
employed to remove the same before the pipes are processed further. In addition, inside
surface of the pipe shall also be visually inspected for presence of any foreign material
or shots and grit (free or embedded/sticking to pipe inside surface). The pipe inside
surface shall be examined using sharp floodlight focused at the middle of the pipe at one
end while inspection is carried out visually from other end. Any foreign material or
shots/grit present in the pipe shall be completely removed by mechanical brush, high
pressure air jets, by tilting of pipe, etc.
8.9 At no time shall the blast cleaning be performed when the relative humidity exceeds
85%. The CONTRACTOR shall measure the ambient conditions at regular intervals
during blast cleaning and coating operations and keep records of prevailing temperature,
humidity and dew point.
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8.10 The blast cleaned surface shall not be contaminated with dirt, dust, metal particles, oil,
water or any other foreign material, nor shall the surface or its anchor pattern be scarred
or burnished. All blast cleaned pipe surface shall be kept in dust free enclosure prior to
coating. After blast cleaning, all surfaces shall be thoroughly inspected under adequate
lighting to determine anchor pattern, quality of blasting and identify any surface defects
prior to coating application. All surface defects such as slivers, scab, burns, laminations,
welds spatters, gouges, scores, indentations, slugs or any other defects considered
injurious to the coating integrity made visible during blast cleaning shall be reported to
the COMPANY Representative and on permission from COMPANY Representative,
such defects shall be removed by filing or grinding. After any grinding or mechanical
repairs, the remaining wall thickness shall be checked and compared with specified
thickness. Any pipes having thickness less than 95% of specified thickness shall be kept
aside and disposed off as per the instructions of COMPANY Representative. The
method employed to remove surface defects shall not burnish or destroy the anchor
pattern or contaminate the surface. Pneumatic tools shall not be used unless they are
fitted with effective air/oil and water traps. Where burnishing results in destruction of
anchor pattern, the anchor pattern shall be restored by suitable means. Pipes which
have damages repaired by grinding and have ground areas more than 50mm in
diameter shall be re-blasted. Any dust or loose residues that have been accumulated
during blasting and/or during filing/grinding operations shall be removed by vacuum
cleaning.
If contamination of surface occurs, the quality of blast cleaning method and process shall
be examined. If the surface roughness is outside the specified limit, the blast cleaning
material shall be checked and replaced.
8.11 Upon Completion of the blasting operations, the quality control supervisor shall accept
the pipe for further processing or return for re-blasting after removal of
defects/imperfections. In case imperfections are considered detrimental to the coating
quality, the same shall be reported to COMPANY's Representative for final decision on
rejection or re-blasting / removal of defects. Re-blasting / removal of defects or returning
pipe to the yard shall be at the CONTRACTOR's cost.
COMPANY's Representative, in additions, reserves the right to initiate any of the above
actions during periodic inspections for oil, dust, salt, imperfections, surface defects, lack
of white metal finish, etc.
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8.12 In order to ensure that pipe with defects are not processed further, provisions shall be
available to lift the pipes from inspection stand.
8.13 Chemical Pre-treatment with Chromate Solution
8.13.1 Following completion of abrasive blast cleaning, all pipe surface shall be chemically
pretreated with a 10% strength chromate solution.
8.13.2 The CONTRACTOR shall provide data sheets and supporting documentation for the
chemical to be used. The documentation shall verify that the chemical is suitable for the
treatment of line pipe prior to the application of the specific fusion bonded epoxy powder
being applied and the final coating will meet fully the requirements of this specification.
8.13.3 The chemical pre-treatment shall be applied fully in accordance with the chemical
suppliers’ instructions and in a manner that ensures 100% uniform coverage of the pipe
surface without introducing surface contamination.
8.13.4 The CONTRACTOR shall check that the concentration of the chemical pre-treatment
solution remains within the range recommended by the chemical manufacturer for the
pipe coating process. The concentration shall be checked at the make up of each fresh
solution and once per hour, using a method approved by the chemical manufacturer.
The CONTRACTOR shall also ensure that the chemical pre-treatment solution remains
free from contamination at all times. Recycling of chemical pre-treatment solution is not
permitted.
8.13.5 The CONTRACTOR shall ensure that the temperature of the substrate is maintained
between 40°C and 80°C and the chromate solution temperature does not exceed 60° or
as recommended by the manufacturer.
8.13.6 The chromate coating shall be smooth, even, free from runs, drips or excessive
application and lightly adherent with no flaking of the coating. The chromate coated steel
must be thoroughly dried immediately after application and shall be achieved by boiling
off any residual solution on the surface.
8.14 The total allowable elapsed time between completion of the blasting operations and
commencement of the pre-coating and heating operations shall be such that no
detectable oxidation of the surface occurs. Relative humidity readings shall be recorded
every half an hour during the blasting operations in the immediate vicinity of the
operations. The maximum elapsed time shall not exceed the duration given below:
Relative Humidity % Maximum elapsed time
> 80 2 hours
70 to 80 3 hours
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< 70 4 hours
Any pipe not processed within the above time-humidity requirement shall be completely
reblasted. Any pipe showing flash rusting shall be re-blasted even if the above
conditions have not been exceeded.
8.15 Pipe handling between abrasive blasting and pipe coating shall not damage the surface
profile achieved during blasting. Any pipe affected by the damage to the surface
exceeding 200mm² in area and/or having contamination of steel surface shall be
rejected and sent for re-blasting.
9.0 COATING APPLICATION
The external surface of the cleaned pipe conforming to clause 8.0 of this specification
shall be immediately coated with 3-layer polypropylene coating in accordance with the
procedures approved by COMPANY, relevant standards and this specification. In
general the procedure shall be as follows:
9.1 Pipe Heating
9.1.1 Immediately prior to heating of pipe, all dust and grit shall be removed from inside of the
pipe by a combination of air blast, brushing and vacuum cleaning. Suitable arrangement
shall be made to protect the bevel ends from getting damaged during the coating
operation.
9.1.2 Induction heater or gas fired heating shall be used for heating the pipe. The method shall
be capable of maintaining uniform temperature along the total length of the pipe, and
shall be such that it shall not contaminate the surface to be coated. In case of induction
heating, appropriate frequency shall be used to ensure ‘deep heating’ and intense skin
heating is avoided. Gas fired heating system shall be well adjusted so that no
combustion products are deposited on the steel surface. This shall be demonstrated on
bare pipes prior to start of PQT. Oxidation of the cleaned pipe surfaces prior to coating
(in the form of blueing or other apparent oxide formation) is not acceptable.
9.1.3 The pipe shall be uniformly preheated to a temperature of 220°C to 235°C (425 to
450°F) as per MANUFACTURER’s recommendation. The pipe metal temperature shall
not exceed 275°C (575°F).
9.1.4 Temperature of the pipe surface shall be continuously monitored & recorded by using
suitable instruments such as infrared sensors, contact thermometers, thermocouples
etc. The recording method shall allow to correlate each linepipe. The monitoring
instrument shall be able to raise an alarm / activate audio system (hooter) in the event of
tripping of induction heater / gas fired heater or in the event of pipe temperature being
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outside the range recommended by the manufacturer. Any deviation from the application
temperature range recommended by manufacturer shall be rectified. If immediate
rectification is not feasible, the production shall be stopped until cause of deviation has
been removed. Any pipe coated during the duration of temperature deviation shall be
identified by marking and rejected. Such rejected pipes shall be stripped, re-cleaned and
recoated.
9.1.5 Temperature measuring & monitoring equipment shall be calibrated twice every shift
and/or as per COMPANY Representative’s instruction.
9.1.6 CONTRACTOR shall ensure that pipe surface emissivity variations are minimised during
pipe heating. To avoid significant variance, more than once blasted pipes should be
coated at the same time and not mixed with pipes blasted only once.
9.2 FBE Layer Coating
9.2.1 Thickness of FBE layer shall be between 350 and 450 microns.
9.2.2 Oxidation of the steel prior to coating in the form of ‘blueing’ or other apparent oxide
formation is not acceptable. If such oxidation occurs, the pipe shall be set aside and
recleaned.
9.2.3 Prior to starting the fusion bonded epoxy powder application, the recovery systems shall
be thoroughly cleaned to remove any unused powder.
9.2.4 The use of recycled powder shall not be permitted.
9.2.5 Epoxy powder is sprayed using electrostatic spray guns. Pipe must be well grounded
during the entire process of coating application. Proper charge on the powder must be
maintained. Guns should be positioned to make optimum use of electrostatic properties
and to minimize overspray.
9.3 Adhesive Layer Coating
9.3.1 Thickness of adhesive shall be between 250 and 350 microns.
The CONTRACTOR shall ensure that the rollers push adhesive film to eliminate any air
entrapment or voids. The adhesive layer shall be applied before gel time of the FBE has
expired by using either the cross-head or lateral extrusion technique. Application of the
adhesive shall not be permitted after the FBE has fully cured. The CONTRACTOR shall
establish to the satisfaction of COMPANY’s representative that the adhesive is applied
within the gel time window of the FBE and at the temperature recommended by the
adhesive MANUFACTURER. The CONTRACTOR shall state the proposed minimum
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and maximum time interval between FBE and adhesive applications at the pipe
temperature range and overlap.
9.3 Polypropylene Layer Coating
9.3.1 The number of wrap and overlapping shall be such that they polypropylene thickness
achieved meets the overall specified thickness requirement.
9.3.2 Polypropylene may be applied by either the cross-head or lateral extrusion technique.
The polypropylene shall be applied over the adhesive within the time limits established
during pre-production testing.
9.3.3 As the concrete weight coating will be applied on the three layer polypropylene system,
the coating surface shall be worked in a way to improve friction coefficient and enhance
the bonding of concrete to the extruded polypropylene surface. Granules of
polypropylene shall be spray applied to the hot extruded polypropylene surface before
quenching. Such granules shall not be totally melted to provide a rough surface.
9.3.4 The coating shall be cooled to below 80°C before handling.
9.3.5 Coating and/or adhesive shall terminate 120 mm (+) 20 / (-) 0 mm from pipe ends. The
adhesive shall seal the end of applied coating. CONTRACTOR shall adopt mechanical
brushing for termination of the coating at pipe ends. Edge of the coating shall be shaped
to form a bevel angle of 30° to 45°.The cut back length shall be 150 (+) 20/(-) 0 mm
width, bevel 30° to 45° if specified by purchaser (in case of Automatic UT and Automatic
Welding).
9.3.6 Immediately after the coating is fully cured, pipe identification marks shall be reapplied to
the coated pipe using a method approved by the COMPANY’s representative. Additional
identification shall be made in order to monitor the coating and test batches. All such
markings shall be within 2 meters of the pipe end.
9.3.7 Failure to comply with any of the above applicable requirement and of the approved
procedure shall be cause for the rejection of the coating and such coating shall be
removed in a manner approved by COMPANY at CONTRACTOR's expense.
10.0 INSPECTION AND TESTING

10.1 General
In addition to the tests required on the material batches, the CONTRACTOR shall
perform the tests detailed below on finished production coatings to demonstrate
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compliance with this specification. Details of all inspections and testing shall be fully
documented in accordance with Section 15.
10.2 Production Testing
10.2.1 Production testing shall be performed at the frequency shown in Appendix 2.
10.2.2 The frequency of tests shown in Appendix 2 will be for normal production operations.
This frequency of tests will also be required after a change in normal operations as a
result of material change or quality acceptance.
10.3 Visual Inspection
The following external surfaces of the coated pipe shall be carefully inspected:
- Adjacent to the cut-back at each end of pipe.
- Adjacent to the longitudinal weld
- Within the body of the pipe.
The coating shall be of natural colour, smooth & uniform and shall be blemish free with
no dust or other particulate inclusions. The coating shall not show any defects such as
blisters, pinholes, wrinkles, scratches, engravings, cuts, swellings, excess material
thickness, dis-bonded zones, air inclusions, tears, voids, etc. In addition, inside surface
of the pipe shall also be visually inspected for presence of any foreign material or shots
and grit (free or embedded/sticking to pipe inside surface). The pipe inside surface shall
be examined using sharp floodlight focused at the middle of the pipe at one end while
inspection is carried out visually from other end.
10.4 Coating Thickness

10.4.1 The thickness of the cooled polypropylene coating system shall be checked using an
approved magnetic or electro-magnetic thickness gauge.
10.4.2 Measurements shall be made at 12 points uniformly spaced over the length and
circumference of pipe. In case of welded pipes, five of the above readings shall be made
at the apex of the weld seam, uniformly distributed over the length of the coated pipe.
10.4.3 The minimum coating thickness on pipe surface shall be as per the table below.
However, localized coating thickness of less than the permissible minimum thickness
can be tolerated on the condition that it does not attain a total extent of more than 5 cm2
per meter length of coated pipe, and the actual coating thickness does not drop more
than 10% below the permissible minimum coating thickness at these locations.
Pipe OD (Inch) Coating Thickness (mm)
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≤6.625
2.5
>6.625 and ≤12.75

3.0
>12.75 and ≤16”

3.5
10.4.4 The frequency of thickness measurement as stated above shall be initially on every pipe
upto at least 100 pipes but may be reduced depending upon the consistency of result to
one pipe in every fifty (50) instead of every pipes, at the sole discretion of the
COMPANY Representative. Results of all measurements shall be recorded.
10.4.5 Thickness of epoxy and adhesive shall be measured at the beginning of each shift and
whenever the plant re-starts after any stoppage for compliance. Coating of epoxy and
adhesive on portion of pipe required for this purpose, stripping and recoating of such
partly coated pipes shall be at CONTRACTOR’s expense.
10.4.6 Coated pipes not meeting the above requirements shall be rejected. Rejected coated
pipes shall be stripped and re-coated in accordance with approved procedure, at
CONTRACTOR's expense.
10.5 Holiday Detection
10.5.1 Each coated pipe length shall be checked over 100% of coated surface by means of a
"holiday detector" of a type approved by COMPANY for detecting holidays in the finished
coating.
10.5.2 The holiday detector shall be a low pulse D.C. full circle electronic detector with audible
alarm and precise voltage control complying with DIN VDE 0433 Part 2. The set voltage
for inspection shall be minimum 25 KV. The operating voltage between electrode and
pipe shall be checked at least twice per working shift, and shall be maintained at 25
kilovolts.
10.5.3 CONTRACTOR shall demonstrate to the COMPANY that setting of the detector is
satisfactory for detecting pin holes. CONTRACTOR shall calibrate the holiday detector at
least once every 4 hours of production. CONTRACTOR shall have necessary
instruments or devices for calibrating the holiday detector. The correct travel speed shall
be determined by consistent detection of an artificial pinhole made in a good coating
sample but shall not exceed 300 mm/s.
10.5.4 Any pipe coating shall be rejected if more than 1(one) holiday & area more than 100 cm²
in size are detected in its length attributable to coating process.
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10.5.5 Holidays which are lesser in size than those mentioned in para 10.5.4 above, shall be
repaired in accordance with a approved procedure and shall be at CONTRACTOR's
expense.
10.5.6 If there is an excess occurrence of holidays on successive pipes, the CONTRACTOR
shall immediately stop the coating operation to determine the cause and remedy it.
10.6 Adhesion Test
10.6.1 The coating adhesion shall be determined in accordance with either of the methods
described in DIN 30678. The test shall be performed at 90ºC, 110ºC and 120ºC in
accordance with NF A 49-711.
10.6.2 Minimum adhesion strength shall be in accordance with DIN 30678, 80 newtons per
centimeter width of strip peeled at 90°C and 40 newtons or 30 newtons per centimeter
width of strip peeled at 110°C or 120°C respectively in accordance with NF A 49-711.
10.6.3 The frequency of test for cut back portions shall be one pipe in every fifteen (15) pipes
coated and for middle of pipe shall be one pipe in every sixty (60) pipes coated or one
pipe per shift whichever is higher. On each selected pipe, adhesion test shall be
performed for each specified temperature. Test shall be performed at each cut back
portion and one in the middle of pipe. The system shall disbond/separate cohesively
either in adhesive layer or in polypropylene layer. Majority of the peeled off area on the
pipe shall show presence of adhesive. Disbondment/separation at epoxy to steel
interface or epoxy / adhesive interface or adhesive / polypropylene interface shall not be
permitted. The failure mode shall be recorded for each test.
10.6.4 The frequency of adhesion test as per para 10.6.3 for cut back portion may be reduced
depending upon the consistency of result to one pipe in every twenty five (25) instead of
every fifteen pipes, at the sole discretion of the COMPANY Representative.
10.6.5 During adhesion testing, samples of coating shall be examined using 30X microscope
for air entrapment on the body of the pipe as per para 10.10.
10.7 Penetration Indentation Test
10.7.1 Three samples shall be cut from each of three pipes and tested for resistance to
indentations in accordance with the method stated in NF A 49-711. The test shall be
performed at a temperature of 110°C.
10.7.2 Maximum penetration depth exhibited after testing shall not exceed 0.45 mm.
10.7.3 The frequency of test shall be initially 2 (two) coated pipes per shift which shall be further
reduced to one test each on 2 coated pipes per week at random after 1 week of
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consistently acceptable results. Two samples for each temperature shall be taken from
the cut back portion of coated pipe and one in the middle of the pipe for this test.
10.8 Impact Test
10.8.1 A sample of coated pipe shall be impact tested in accordance with the procedures
specified in both DIN 30678. Tests shall be performed at temperatures of 0°C, 50°C.
10.8.2 Acceptance criteria for the number of blows per coating breakdown shall be as detailed
in both DIN 30678.
10.8.3 Impact test shall also be carried out at 110°C and the results shall be recorded for
COMPANY’s representative evaluation.
10.8.4 Initially the frequency of test shall be two (2) coated pipes per shift that may be further
reduced to one coated pipe per 2 weeks depending upon consistently acceptable results
at the sole discretion of COMPANY's Representative.
10.9 Cathodic Disbondment Test
Cathodic disbondment testing shall be performed for 48 hours at an electrolyte
temperature of 95°C. The acceptance criteria shall be 7 mm maximum disbondment
from the edge of the pre-drilled hole. The test shall be performed in accordance with NF
A 49-711. The frequency of this test shall be once in every two weeks or one test
representing each batch of epoxy powder used, whichever is more frequent.
In case the test fails to conform to the specified requirement, at the option of the
CONTRACTOR, all pipes coated after the previous acceptable test and prior to next
acceptable test shall be rejected or the test shall be repeated using two additional
samples taken from the same end of the affected pipe. When both retests conform to the
specified requirement, the lot of pipes shall be accepted. When one or both the retests
fail to conform to the specified requirement, all coated pipes after previous acceptable
test and prior to next acceptable shall be rejected. All rejected pipes shall be stripped,
re-cleaned and re-coated. COMPANY may consider a further retest program to
determine whether any of the affected pipe meet the criteria for acceptance upon written
request by the CONTRACTOR.
10.10 Air Entrapment Assessment
10.10.1 No more than 10% of the observed area shall be taken with air entrapment (porosity or
bubbles). Bubble size in the polypropylene layer shall be limited to less than half the
thickness of polypropylene layer in height or circumference. Bubbles shall not link
together to provide a moisture path to the adhesive/FBE layers.
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10.10.2 Air entrapment or porosity shall be similarly rated for the adhesive and FBE layers of
coating.
10.10.3 The strips of coating from the adhesion test should be studied to determine the level of
air entrapment at the failure interface. This same area can be used to determine the air
entrapment by cutting the coating at 45° angle along the edge of the remaining coating
on the pipe at the test area.
10.10.4 See Appendix 3 for Air Entrapment Assessment.
10.11 Degree of Cure
A thermal analysis shall be carried out using a Differential Scanning Calorimeter (DSC).
Epoxy film samples shall be removed from the coated pipe using hammer and cold
chisel. This produces furled coating flakes. Care shall be taken to remove samples of full
film thickness but at the same time avoid the inclusion of steel debris and contamination
with adhesive or polypropylene. The sample shall be tested for cure using DSC
procedure. The glass transition temperature differential (∆Tg) and % cure (∆H) shall be
the test used to verify cure along with a visual examination to ensure no residual cure in
the portion of the graph beyond the glass transition temperature.
The required cure characteristics are:
∆Tg = -2°C to + 3°C (∆Tg = ∆Tg final - ∆Tg initial)
Only a 95% minimum cured coating shall be acceptable.
% Cure = (∆H - ∆H residual) x 100
∆H
(∆H = exothermic heat of reaction)
Frequency of this test shall be once per shift. Pipe shall be selected randomly by
COMPANY Representative during the middle of a shift. Suitable provisions/
arrangements as per the instructions of COMPANY Representative shall be made by the
CONTRACTOR for this purpose.
In case of test failure, production carried out during the entire shift shall be rejected,
unless the CONTRACTOR proposes a method to establish the compliance with the
degree of cure requirements of all pipes coated during that shift.
10.12 Destructive Tests
10.12.1 For coating destructive tests listed in Appendices 1 and 2, a sufficient length of
production pipe shall be cold cut to provide the required number of samples for testing.
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10.12.2 The coating on the cut end of the pipe length shall be cut back to comply with para. 9.3.4
of this specification.
10.13 Test Failure
10.13.1 In the event that a production coated pipe fails to meet the acceptance criteria for a
specified test, the CONTRACTOR shall test the preceding and succeeding coated pipe.
If both pipes pass the test, then the remainder of the pipe lengths in that shift shall be
deemed satisfactory. If either pipe fails to meet the specified requirements, all pipes
coated during that shift shall be tested until the coating is proved acceptable. Rejected
coated pipes shall be stripped and re-coated in accordance with approved procedure, at
CONTRACTOR's expense.
10.13.2 COMPANY reserves the right to perform inspection and witness tests on all activities
concerning the pipe coating operations starting from bare pipe to finished coated pipe
ready for despatch and also testing of raw materials. CONTRACTOR shall give
reasonable notice of time and shall provide without charge reasonable access and
facilities required for inspection to the COMPANY's representative. Inspection and tests
performed or witnessed by COMPANY's representative shall in no way relieve the
contractors obligation to perform the required inspection and tests.
10.13.3 In case rate of defective or rejected pipes and/or samples tests are 10% or more for a
single shift (typically 8 hours), CONTRACTOR shall be required to stop production and
carry out a full and detailed investigation and shall submit findings to COMPANY for
approval. CONTRACTOR shall recommence the production only after getting the written
permission from COMPANY.
Under no circumstances any action or omission of the COMPANY's Representative shall
relieve the CONTRACTOR of his responsibility for material and quality of coating
produced. No pipes shall be transported from the coating plant unless authorised by
COMPANY in writing.
11.0 HANDLING, TRANSPORTATION AND STORAGE OF MATERIALS
11.1 Contractor shall develop the method of stock piling and loading out bare and coated
pipes and shall receive approval from Company’s Representative prior to handling
coated pipes.
11.2 The Contractor shall unload, load, stockpile and transport the bare pipes using suitable
means and in a manner to avoid damages to pipes. Pipe shall not be allowed to drop
or strike objects which will damage the pipe but shall be lifted or lowered from one
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level to another by suitable equipment, preferably by vacuum lifting equipments.

Lifting hooks when used, shall be equipped with a plate curved to fit the curvature of
the pipe. In loading pipe on trucks each length shall be lowered to position without
dropping and each succeeding length shall rest on special supports on the truck and
shall be separated from the adjacent pipes. After loading, suitable chains and padding
shall be used to tie the load securely to each bolster. Pipe, when stock piled, shall be
placed on suitable skid to keep it clear of the ground and flood water. Care shall be
exercised in handling or stock-piling pipes in order to avoid distortion, flattening,
denting or other damages. The Contractor shall provide all necessary timber or other
materials required for the stock-piling. While stacking, the number of allowable layers
of bare pipes shall be calculated as per API RP 5L 1 and shall be agreed with the
Company. The stacks must be properly secured against sliding and shall consist of
pipes of the same diameter and wall thickness. Adjacent stacks of pipes having
different dimensional characteristics shall be clearly separated. Bare / coated pipes at
all times shall be stacked completely clear from the ground, at least 300 mm, so that
the bottom row of pipes remains free from any surface water. The pipes shall be
stacked at a slope so that driving rain does not collect inside the pipe. Bare / coated
pipes may be stacked by placing them on ridges of sand free from stones and covered
with a plastic film or on wooden supports provided with suitable cover. This cover can
be of dry, germ free straw covered with plastic film, otherwise foam rubber may be
used. The supports shall be spaced in such a manner as to avoid permanent bending
of the pipes.
11.3 Contractor shall load out the coated pipes onto rail-car or trucks and barges and shall
furnish special loading spacers, bolsters and the like, approved by the Company’s
Representative, to protect the pipe during transport.
11.4 Coated pipe shall be handled at times with wide non-abrasive or leather belts or other
equipment designed to prevent damage to the coating. All such equipment shall be
kept in proper working order so as to prevent injury to the coating. The use of tongs,
bare pinch bars, chain slings, protruding rivets, pipe hooks without proper padding, or
any other handling equipment that may be injurious to the coating shall not be
permitted.
11.5 Yard coated pipe shall be raised or lowered to or from stock pile, ground, barge, rail
car or truck by means of brass lined or padded pipe end hooks engaging the ends of
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the pipe and carried by wire rope on chain slings with “spreader bars” between lifting
lines. The bolster of the trailer or barge shall have a bearing surface not less than 300
mm wide to give necessary support to the padding which protects the coating.
Sacks partly filled with sand or saw dust shall be placed on the bolster and between
the outside bottom pipes and bolster stacks. All chains, cables or other equipment
used for fastening shall be padded.
11.6 The maximum stack height for various types of coated pipes shall be limited to such
heights as will not cause damage to the pipe and coating. The stacking shall conform
to the requirements of API RP 5L 1 and API RP 5L 5. Only coated pipes of same
outside diameter and wall thickness shall be nested together.
11.7 All pipes shall be tightly nested (laid parallel with full length in contact). Corrosion
coated pipes shall not be loaded, piled or nested with the concrete coated pipes.
11.8 In case of any marine transportation of bare/coated line pipes involved, the same shall
be carried out in compliance with API RP 5LW. CONTRACTOR shall furnish all details
pertaining to marine transportation including drawings of cargo barges,
storing/stacking, sea fastening of pipes on the barges/marine vessels to the company
for approval prior to undertaking such transportation works. In addition contractor shall
also carry out requisite analyses considering the proposed transportation scheme and
establish the same is safe and stable. On-deck overseas shipment shall not be
allowed.
11.9 Material Control Records
11.9.1 CONTRACTOR shall record the receipt, issue return or disposal of all materials supplied
by COMPANY and shall permit inspection of those records by COMPANY at all
reasonable times. In particular, the records shall reference the pipe number of each
pipe.
11.9.2 CONTRACTOR shall submit details of material control recording procedure to
COMPANY for review prior to commencement of the works.
11.9.3 CONTRACTOR shall submit details of his traceability procedure for COMPANY’s review
and approval. The complete mill markings on the bare pipe along with the pipe number
and project specific description shall be stencilled with indelible markings on both ends
on outside surface of the pipe within 200 mm of the ends.
11.9.4 A detailed procedure for marking and transferring the full traceability of the pipe from the
bare pipe to the external surface of the coated line pipes after coating shall be submitted
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to the COMPANY for review and approval. Material Test Certificates and
MANUFACTURER Test Reports shall be traceable to each pipe within the
APPLICATOR’s Coating Book, which shall be part of the QC Data Book.
11.9.5 All coated line pipes shall be provided with full traceability details stenciled on the
external surfaces of the coated pipes as per para 11.9.3 above.
12.0 REPAIR OF COATING
CONTRACTOR shall submit to COMPANY, its methods and materials proposed to be
used for executing a coating repair and shall receive approval from COMPANY prior to
use. In open storage the repair coating materials must be able to withstand a
temperature of at least (+) 80°C without impairing its serviceability and properties.
CONTRACTOR shall furnish manufacturer’s test certificates for the repair materials
clearly establishing the compliance of the repair materials with the applicable coating
requirements indicated in this specification.
All pipe leaving coating plant, shall have sound external coating with no holiday or
porosity on 100% of the surface.
Defects, repairs and acceptability criteria shall be as follows:
- Pipes showing porosities or very small damage not picked up during holiday test
and having a surface less than 0.5 cm2 or linear damage (cut) of less than 3 cm
shall be repaired by stick using material of same quality.
- Damages caused to coating by handling such as scratches, cuts, dents, gouges,
not picked up during holiday test, having a total reduced thickness on damaged
portion not less than 2 mm and an area not exceeding 20 cm2 shall be rebuild by
heat shrink patch only and without exposing to bare metal.
- Defects of size exceeding above mentioned area or holidays of width less than
300 mm shall be repaired with heat shrink repair patch by exposing the bare
metal surface.
- Defects exceeding the above and in number not exceeding 2 per pipe and linear
length not exceeding 500 mm shall be repaired using heat shrinkable sleeves.
- Pipes with bigger damage shall be stripped and recoated.
- In case of coating defect close to coating cut back, CONTRACTOR shall remove
the coating throughout the entire circumference of the pipe down to the steel
surface and increase the coating cut back length. Now if the coating cut back
exceeds 140 mm of linear length of pipe then the coating shall be repaired by the
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use of heat shrink sleeves thereby making up the coating cut back length of 120
mm.
Not withstanding the above, if any defect exceeds 70 mm from the original coating cut
back length, the entire coating shall be removed and the pipe shall be recycled through
the entire coating procedure.
Irrespective of type of repair, the maximum numbers of repair of coating shall be as
follows:
- Holiday repair of size ≤ 100 cm2 attributable to process of coating application
shall be maximum one number per pipe.
- In addition to the above, defects to be repaired by heat shrink patch/sleeve shall
be maximum 2 (two) per pipe.
Defects exceeding the above limits shall cause pipe coating rejection, stripping and
recoating. The above is exclusive of the repairs warranted due to testing as per this
specification.
All repairs carried out to coating for whatever reason shall be to the account of
CONTRACTOR.
Cosmetic damages occurring in the polypropylene layer only need not be repaired by
exposing up to steel surface, as deemed fit by the COMPANY Representative. In any
case the CONTRACTOR shall establish his material, methods and procedure of repair
that result in an acceptable quality of product by testing and shall receive approval from
COMPANY prior to use.
Testing of repairs shall be in the same form as testing of coating. All repairs shall result
in a coating thickness no less than the parent coating thickness. CONTRACTOR shall
test repairs to coating as and when required by COMPANY.
13.0 MARKING
CONTRACTOR shall place marking on the outside surface of the coating at one end of
the coated pipe, and marking shall indicate, but not limited to the following information:
a. Pipe number, Heat number
b. Diameter & Wall thickness
c. Coated pipe number
d. Colour band
e. Any other information considered relevant by COMPANY.
f. Pipe Manufacturer Name
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g Inspection Mark/Punch
CONTRACTOR shall obtain prior approval on marking procedure to be adopted from the
COMPANY.
14.0 QUALITY ASSURANCE
14.1 The CONTRACTOR shall have established within his organisation and, shall operate for
the contract, a documented Quality System that ensures that the requirements of this
specification are met in all aspects. The Quality System shall be based upon ISO 9001/2
or equivalent.
14.2 The CONTRACTOR shall have established a Quality Assurance Group within its
organisation that shall be responsible for reviewing the Quality System and ensuring that
it is implemented.
14.3 The CONTRACTOR shall submit the procedures that comprise the Quality System to
the COMPANY for agreement.
14.4 The CONTRACTOR’s Quality System shall pay particular attention to the control of
Suppliers and Sub-contractors and shall ensure that the requirements of this
specification are satisfied by the Suppliers and Sub-contractors operating Quality system
in their organisation.
14.5 The CONTRACTOR shall, prior to the commencement of work, prepare and issue a
Quality Plan for all of the activities required to satisfy the requirements of this
specification. The plan shall include any sub-contracted work, for which the sub-
contractors Quality Plans shall be submitted. The plan shall be sufficiently detailed to
indicate sequentially for each discipline the requisite quality control, inspection, testing
and certification activities with reference to the relevant procedures and the acceptance
standards.
14.6 The CONTRACTOR’s Quality system and associated procedures may, with due notice,
be subject to formal audits. The application of quality control by the CONTRACTOR will
be monitored by the COMPANY Representatives who will witness and accept the
inspection, testing and associated work required by this specification.
15.0 DOCUMENTATION
APPLICATOR shall submit the type and quantity of details and documentation for
CONTRACTOR’s authorization or information as listed in the individual Material
Requisitions and Purchase Orders.
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Reports shall be kept of all relevant data for each item coated. This shall include, but not
be limited to the following:
- Material batch numbers and certificates detailing all the information required for
each batch as defined in this specification
- Details of blasting abrasive, measurement of surface profiles, surface preparation
standard and recording of environment conditions prevailing during blasting
- Recording of steel surface defects and repairs
- Surface temperature of items prior to coating
- Results of all tests as defined in this specification
- Details of repairs to coating defects exposed during testing and the repair
techniques used
- Details of rejected items, with reasons for failure
- Information on items which, after rejection, require complete recycling
Such information shall be submitted daily by the APPLICATOR to the CONTRACTOR.
Absence of documentation shall be considered a just cause for rejection of coating
system.
The following documentation, written in the English Language, shall be submitted to
COMPANY for review.
Prior to the start of Production Operations, CONTRACTOR shall submit the following
documentation to the COMPANY:
- Quality Plan
- Production Schedule
- Coating and Testing Procedures
- Detailed Description of Coating Equipment and Materials
- Pipe Handling Equipment Description and Procedures
- Pipe Stacking Arrangements
- Material Control Recording Procedure
- Inspection Quality Plan
- Inspection and Testing Plan
- Repair Procedure
- Procedures for all PQT and Production Tests
CONTRACTOR shall submit to COMPANY the following documentation prior to the
return of coated pipe to COMPANY:
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- Mill Certificates for Line Pipe Received

- MANUFACTURER’s Certificates for Each Batch of Coating Materials
- Certification/Calibration Certificates for all Testing and Coating Equipment
- Inspection and Test, Records, Results, and other Documentation of all Material
and Coating Tests
- Certificate of conformance and dimensional check report
- Verification certificates for standard compliance
- All concession requests
All reports shall be signed by CONTRACTOR to signify compliance with the
requirements of this specification.
16.0 PREPARATION FOR SHIPMENT
The CONTRACTOR shall submit shipping and handling procedures to the COMPANY
for approval. The procedures should adequately address storage, shipping and handling
in view of the long voyage from manufacturing locations and climatic extremes at the job
site.
An appropriate design of end cap shall be fitted to each opening to protect the butt weld
ends and prevent ingress of foreign material. Handling shipping and storage procedure
shall incorporate requirements given in Section 7 of NACE 0185.
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ANNEXURE-I
LIST OF ACCEPTABLE COMBINATIONS OF COATING MATERIALS

The following combinations of coating materials’ manufacturers are considered
acceptable.
In case any of the combinations listed below are offered, details regarding the offered
materials and its properties need not be furnished with bid. However, In the event of
award of contract, manufacturer’s trade name and data sheets/ properties for each
coating material proposed by the CONTRACTOR and compatibility certificate for the
proposed combination (s) from the raw materials Manufacturers, shall be submitted for
COMPANY’s approval prior to the placing of any order for coating work.
Although the above combinations would be acceptable to COMPANY, the responsibility

of suitability for application, performance and compliance to the coating system
requirements shall unconditionally lie with the CONTRACTOR.
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APPENDIX 1: INSPECTION SUMMARY FOR PROCEDURE QUALIFICATION TEST ON

PPCOATING SYSTEM FOR ONE PIPE DIAMETER
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Number of Tests can be increased at the sole discretion of COMPANY.
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APPENDIX 2: INSPECTION SUMMARY FOR PRODUCTION TESTING ON FULL PP-

COATINGSYSTEM FOR ONE PIPE DIAMETER
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Note:
1. The cut back length shall be 150 (+)20/ (-)0 mm width, bevel 30º to 45º if specified by
purchaser (in case of Automatic Welding and AUT)
*COMPANY reserves the rights to increase inspection and testing frequency if warranted by the
circumstances.
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APPENDIX 3
AIR ENTRAPMENT ASSESSMENT
1.0 Scope
To determine the amount of cross section and interface air entrapment (porosity or
bubbles in the plant applied coating.
2.0 Equipment
2.1 Microscope - Hand Held 30 X.
2.2 Utility knife.
3.0 Test Specimen
Strips from Adhesive Tests, coating disbondment (CD) test samples, and coated pipe
may all be used to help determine the rating.
4.0 Procedure
4.1 Adhesion strip shall be viewed from the side ant the failure interface.
4.2 Cathodic disbondment samples shall be viewed from the side before tests begins.
Scraping with a sharp knife to remove cutting damage on the edge of the coating may be
necessary to provide a smooth surface for viewing.
4.3 At the pipe adhesion test site use a utility knife to cut the edge of the coating to a 45°
angle and view with a microscope.
4.4 Perform a similar test in the cut back area. This should be used for information to
determine if further testing is needed.
5.0 Reporting and Grading
5.1 Report pipe joint number, date pipe was coated, coating batch number, and date of test.
5.2 Report rating of cross-section and interface entrapment.
5.3 A rating of 1 or 2 is passing.
Rating will be on a scale of 1 to 5 as follows:
Rating
1. Very Good - Passing
2. Good - Passing
3. Fair - Failing
4. Poor – Failing
5. Very Poor - Failing
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Rating for each area of concern:
No. 1 Rating – Passing Less than 10% of area with bubbles.
No. 2 Rating –Passing Less than 20% / more than 10%
No. 3 Rating – Failing Less than 30% / more than 20%
No. 4 Rating – Failing Less than 40% / more than 30%
No. 5 Rating – Failing Over 50% of area taken by air entrapment (bubbles)
By looking at the top (outside) surfaces the same type rating system can be used.
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APPENDIX 4
FOR FBE LAYER COATING PQT
1. Test Method
The flexibility of the coating shall be determined once on the first day of production of
only FBE layer coated pipes (2 Nos.) by the following method:
Coated samples (300 mm x 50 mm x thickness of pipe wall) taken form a FBE coated
pipe joint shall be subjected to a bend test at a temperature of 0°C and 20°C to induce a
2% and 3% strain respectively in the sample.
At each temperature the test shall be carried out twofold.
The deflection loading rate during bend testing shall be 25 ± 2 mm/min.
The mandrel sizes shall be selected according to the following formula:
D = t (1-s)/s
D = mandrel diameter (mm)
t = specimen wall thickness (mm)
s = 0.02 at 0°C
0.03 at 20°C
2. Acceptance Criteria
The coating shall not exhibit any signs of cracking, disbondment or pinholes.
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2012A Functional Spec For 3LPP (3 Layer Poly Propelene) Corrosion Coating For Linepipes) (Rev. 0)

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Spec. No.

3LPP (3 LAYER POLY PROPELENE)

CORROSION COATING FOR LINE PIPES

RP KPV SBS 46 24.05.11 0

ANNEXURE – I COATING SYSTEM/ MATERIAL PRE-QUALIFICATION

1. Specific Gravity 0.89 – 9.2 ASTM D 1505

7. Brittle Point -20°C ASTM D 746

5.2.3 Properties of Polypropylene Compound

Sl. Properties Requirement Applied Standard

1. Specific Gravity 0.89 ASTM D 1505

5.2.4 Properties of Coating System

Sl. Properties Requirement Applied Standard

6.0 MEASUREMENT AND LOGGING

c. Pipe heating, temperatures and control prior to epoxy application.

temperature monitoring and recording system including alarm/hooter shall be

b. visual inspection of finished coating, cut back dimension, internal/external cleanliness,

4. Total Alkalinity as CaC03 mg/l 2 to 3

6. Sulphate as SO4 mg/l 1 max.

10.0 INSPECTION AND TESTING

10.4 Coating Thickness

>6.625 and ≤12.75

>12.75 and ≤16”

level to another by suitable equipment, preferably by vacuum lifting equipments.

- Mill Certificates for Line Pipe Received

LIST OF ACCEPTABLE COMBINATIONS OF COATING MATERIALS

Although the above combinations would be acceptable to COMPANY, the responsibility

APPENDIX 1: INSPECTION SUMMARY FOR PROCEDURE QUALIFICATION TEST ON

Number of Tests can be increased at the sole discretion of COMPANY.

APPENDIX 2: INSPECTION SUMMARY FOR PRODUCTION TESTING ON FULL PP-

Rating for each area of concern:

No. 1 Rating – Passing Less than 10% of area with bubbles.

No. 2 Rating –Passing Less than 20% / more than 10%

No. 3 Rating – Failing Less than 30% / more than 20%

No. 4 Rating – Failing Less than 40% / more than 30%

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