Specification for Piping Painting & Coating
CONTENT
1
INTRODUCTION ................................................................................................... 7
1.1
Scope ................................................................................................................................................................ 7
1.2
Definitions ........................................................................................................................................................ 7
1.3
Applicable codes, standards and order of precedence ...................................................................................... 8
1.4
Company Specification .................................................................................................................................. 11
1.5
Acronyms and Abbreviations ......................................................................................................................... 11
2
APPENDIX 1 – PAINTING FOR ABOVE GROUD PIPING ................................. 14
2.1
General ........................................................................................................................................................... 14
2.1.1 Process input data .................................................................................................................................... 14
2.1.2 Surfaces to be painted .............................................................................................................................. 14
2.1.3 Surfaces not to be painted ....................................................................................................................... 14
2.1.4 Painting data ............................................................................................................................................ 15
2.1.5 Painting systems ....................................................................................................................................... 15
2.2
Safety.............................................................................................................................................................. 16
2.2.1 Painting composition ............................................................................................................................... 16
2.2.2 Abrasive material ..................................................................................................................................... 16
2.3
Painting application ........................................................................................................................................ 17
2.3.1 General requirements .............................................................................................................................. 17
2.3.2 Surface preparation and cleaning........................................................................................................... 17
2.4
Preparation and application of painting materials .......................................................................................... 19
2.4.1 General ...................................................................................................................................................... 19
2.4.2 Weather conditions .................................................................................................................................. 20
2.4.3 Storage of materials ................................................................................................................................. 20
2.4.4 Painting preparation ................................................................................................................................ 21
2.4.5 Painting application ................................................................................................................................. 21
2.4.6 Contrasting coatings ................................................................................................................................ 23
2.4.7 Painting before installation ..................................................................................................................... 23
2.4.8 Handling and storage of painted items ................................................................................................... 23
2.5
Inspection and acceptance .............................................................................................................................. 24
2.5.1 Thickness check........................................................................................................................................ 26
2.6
Repair of defects or damages ......................................................................................................................... 26
2.7
Documentation ............................................................................................................................................... 26
2.7.1 Painting records ....................................................................................................................................... 27
2.7.2 Final report ............................................................................................................................................... 27
2.8
Training of personnel ..................................................................................................................................... 27
2.9
Colour and identification ................................................................................................................................ 27
2.9.1 Piping service identification through color ............................................................................................ 28
3
APPENDIX 2 – 3LPE COATING ......................................................................... 30
3.1
General ........................................................................................................................................................... 30
3.2
Process input data ........................................................................................................................................... 30
3.3
Coating raw material characteristics .............................................................................................................. 30
3.3.1 Epoxy powder (FBE) ............................................................................................................................... 30
3.3.2 Polymeric adhesive................................................................................................................................... 31
3.3.3 Polyethylene (PE) compound .................................................................................................................. 32
3.4
Surface preparation ........................................................................................................................................ 32
3.4.1 Limitations ................................................................................................................................................ 33
3.4.2 Pre-cleaning .............................................................................................................................................. 33
3.4.3 Visual inspection ...................................................................................................................................... 33
3.4.4 Pre-heating ............................................................................................................................................... 33
3.4.5 Abrasive blast cleaning ............................................................................................................................ 33
3.4.6 Final cleaning and inspection prior to coating application .................................................................. 34
3.5
3LPE coating application ............................................................................................................................... 35
3.5.1 FBE layer .................................................................................................................................................. 35
3.5.2 Polymeric adhesive layer ......................................................................................................................... 36
3.5.3 PE layer ..................................................................................................................................................... 36
3.5.4 Cutback ..................................................................................................................................................... 36
3.6
Coating repair ................................................................................................................................................. 37
3.7
Inspection and test .......................................................................................................................................... 38
3.7.1 General requirements .............................................................................................................................. 38
3.7.2 Bare pipes preliminary inspection .......................................................................................................... 39
3.7.3 Coating raw material control .................................................................................................................. 39
3.7.4 Coating qualification tests ....................................................................................................................... 40
3.7.5 Coating production test ........................................................................................................................... 42
3.8
Marking of coated pipes ................................................................................................................................. 44
3.9
QA/QC ........................................................................................................................................................... 44
3.9.1 Inspection data sheet (IDS) ..................................................................................................................... 45
3.10
Documentation and reporting ......................................................................................................................... 47
3.11
Storage, handling and transportation management ......................................................................................... 48
4
APPENDIX 3 - COLD TAPE WRAPPING (CTW) COATING FOR APPLICATION
AT SHOP....................................................................................................................... 50
4.1
General ........................................................................................................................................................... 50
4.2
Process input data ........................................................................................................................................... 50
4.3
Coating raw material requirements ................................................................................................................ 50
4.3.1 Liquid adhesive (Primer)......................................................................................................................... 50
4.3.2 Inner-wrap tape ....................................................................................................................................... 51
4.3.3 Outer-wrap tape ....................................................................................................................................... 52
4.4
Handling and storage of coating raw materials .............................................................................................. 52
4.5
Surface preparation ........................................................................................................................................ 53
4.5.1 Limitations ................................................................................................................................................ 53
4.5.2 Pre-cleaning .............................................................................................................................................. 53
4.5.3 Visual inspection ...................................................................................................................................... 53
4.5.4 Pre-heating ............................................................................................................................................... 53
4.5.5 Abrasive blast cleaning ............................................................................................................................ 54
4.5.6 Final cleaning and inspection prior to coating application .................................................................. 54
4.5.7 Surface preparation of Stainless Steel (SS) ............................................................................................ 55
4.6
CTW application ............................................................................................................................................ 55
4.6.1 Liquid adhesive (primer) application ..................................................................................................... 55
4.6.2 Application of inner-wrap ....................................................................................................................... 56
4.6.3 Application of outer-wrap ....................................................................................................................... 56
4.6.4 Cutback ..................................................................................................................................................... 57
4.7
Coating repair ................................................................................................................................................. 57
4.8
Inspection and test .......................................................................................................................................... 58
4.8.1 General requirements .............................................................................................................................. 58
4.8.2 Bare pipes preliminary inspection .......................................................................................................... 59
4.8.3 CTW materials control ............................................................................................................................ 59
4.8.4 CTW coating qualification tests.............................................................................................................. 60
4.8.5 CTW coating production tests ................................................................................................................ 62
4.9
QA/QC ........................................................................................................................................................... 64
4.9.1 Inspection data sheet (IDS) ..................................................................................................................... 65
4.10
Documentation and reporting ......................................................................................................................... 67
4.11
Storage, handling and transportation management ......................................................................................... 68
5
APPENDIX 4 – COLD TAPE WRAPPING (CTW) COATING FOR APPLICATION
AT SITE ......................................................................................................................... 70
5.1
General ........................................................................................................................................................... 70
5.2
Process input data ........................................................................................................................................... 71
5.3
Coating raw material requirements ................................................................................................................ 71
5.3.1 Liquid adhesive (Primer)......................................................................................................................... 71
5.3.2 Inner-wrap tape ....................................................................................................................................... 71
5.3.3 Outer-wrap tape ....................................................................................................................................... 72
5.4
Handling and storage of received materials ................................................................................................... 73
5.5
Surface preparation ........................................................................................................................................ 73
5.5.1
5.5.2
5.5.3
5.5.4
5.5.5
5.5.6
General requirements .............................................................................................................................. 73
Pre-cleaning and visual inspection ......................................................................................................... 74
Pre-heating ............................................................................................................................................... 74
Abrasive blast cleaning ............................................................................................................................ 75
Final cleaning and inspection prior to CTW application ..................................................................... 75
Surface preparation of Stainless Steel (SS) ............................................................................................ 75
5.6
CTW application ............................................................................................................................................ 76
5.6.1 General requirements .............................................................................................................................. 76
5.6.2 Liquid adhesive (primer) application ..................................................................................................... 76
5.6.3 Application of inner-wrap ....................................................................................................................... 77
5.6.4 Application of outer-wrap ....................................................................................................................... 77
5.7
Coating repair ................................................................................................................................................. 77
5.8
Field inspection and test ................................................................................................................................. 78
5.8.1 General requirements .............................................................................................................................. 78
5.8.2 Coated pipe and bare fitting preliminary inspection ............................................................................ 79
5.8.3 CTW materials control ............................................................................................................................ 79
5.8.4 CTW application tests ............................................................................................................................. 80
5.9
QA/QC ........................................................................................................................................................... 82
1
1.1
INTRODUCTION
Scope
This specification covers the minimum requirements for material, application and testing of
painting and coating for the new extension piping lines to be installed for the “EPC for Well Pads
Expansion and Hook-up of Historical Wells, WQ (Phase 2), Iraq” detail design project.
Appendix 1: defines the minimum requirements for material procurement, application and testing
of painting to be applied at site on above ground piping.
Appendix 2: defines the minimum requirements for material procurement, application and testing
of 3 Layer Polyethylene (3LPE) coating to be applied at shop on pipes.
Appendix 3: defines the minimum requirements for material procurement, application and testing
of Cold Tape Wrapping (CTW) coating to be applied at shop on pipes.
Appendix 4: defines the minimum requirements for materials, application, testing and supply of
Cold Tape Wrapping (CTW) coating to be applied at site on buried piping welded field joints, on
buried fittings and on Under Ground/Above Ground (UG/AG) transition zone.
1.2
Definitions
The following definitions will be used in this document and during the execution of the Project
without the need of any further explanation:
Company
LUKOIL Mid-East Limited
Contractor
Consortium Sicim – 77 Insaat who has been awared the Contract for
the “EPC OF WELL PAD EXPANSION AND HOOK-UP OF
HISTORICAL WELLS, WQ (Phase 2), IRAQ.
Subcontractor
ENERECO Spa. The Engineering Firm who has been awarded the
development of the Detail design for the “Well Pads Expansion and
Hook-Up of Historical Wells, WQ (Phase 2), Iraq”.
Contract
Contract
CY-18-8015-0242
for
the
“ENGINEERING,
PROCUREMENT AND CONSTRUCTION OF WELL PAD
EXPANSION AND HOOK-UP OF HISTORICAL WELLS, WQ
(Phase 2), IRAQ –
Project/Job
ENGINEERING, PROCUREMENT AND CONSTRUCTION OF
WELL PAD EXPANSION AND HOOK-UP OF HISTORICAL
WELLS, WQ (Phase 2), IRAQ
Coating Manufacturer/Supplier
Coating Applicator
1.3
Means any third party appointed for supplying or
manufacturing of coating for the Project
Means any third party appointed for application of coating system
at factory and performing relevant tests for the Project
Applicable codes, standards and order of precedence
Unless differently specified, code and standard edition that will be used is latest available revision
at project commencement date and it will not be changed throughout contract period without prior
agreement between Contractor and Company.
In the event of apparent technical conflict, inconsistency or ambiguity occurring in applying this
specification and reference documents, the following order of precedence shall be applied:

national laws and regulations,

purchase requisition,

current specification,

other specifications and standards referenced in this specification.
Exceptions to and deviations from this specification and any other referenced documents shall not
be implemented without written approval by Company.
Here below a list of the main coating codes adopted for this document has been reported:
Ref.
Code
Title
[1]
ISO 306
Plastics – Thermoplastic materials – Determination of Vicat Softening
Temperature (VST)
[2]
ISO 868
Plastics and ebonite – Determination of indentation hardness by means of
a durometer (Shore hardness)
[3]
ISO 1183
[4]
ISO 11357-6
[5]
ISO 15512
[6]
EN ISO 1461
[7]
EN ISO 12944-4
[8]
EN ISO 21809-1
[9]
EN ISO 21809-2
[10]
EN ISO 21809-3
[11]
EN 12068
[12]
ATM D149
[13]
ASTM D257
Standard test methods for DC resistance or conductance of insulating
materials
[14]
ASTM D792
Standard test methods for density and specific gravity (relative density) of
plastics by displacement
[15]
ASTM D1000
[16]
ASTM D1505
[17]
ASTM D1693
[18]
ASTM D4285
[19]
ASTM D4940
[20]
ASTM D4417
[21]
ASTM D6386
Plastics – Methods for determining the density of non-cellular plastics
Plastics – Differential Scanning Calorimetry (DSC) – Part 6:
Determination of oxidation induction time (isothermal OIT) and oxidation
induction temperature (dynamic OIT)
Plastics – Determination of water content
Hot dip galvanized coatings on fabricated iron and steel articles –
Specification and test methods
Paint and varnishes – Corrosion protection of steel structures by protective
paint systems – Part 4: Types of surface and surface preparation
Petroleum and natural gas industries - External coatings for buried and
submerged pipelines used in pipeline transportation systems - Part 1:
Polyolefin coatings (3-layer PE and 3-layer PP)
Petroleum and natural gas industries - External coatings for buried and
submerged pipelines used in pipeline transportation systems - Part 2:
Single layer fusion bonded epoxy coatings
Petroleum and natural gas industries - External coatings for buried and
submerged pipelines used in pipeline transportation systems - Part 3: Field
joint coatings
Cathodic protection – External organic coatings for the corrosion
protection of buried or immersed steel pipelines used in conjunction with
cathodic protection – Tapes and shrinkable materials
Standard test method for dielectric breakdown voltage and dielectric
strength of solid electrical insulating materials at commercial power
frequencies
Standard test methods for pressure-sensitive adhesive-coated tapes used
for electrical and electronic applications
Standard test method for density of plastics by the density-gradient
technique
Standard test method for environmental stress-cracking of ethylene
plastics
Standard test method for indicating oil or water in compressed air
Standard test method for conductimetric analysis of water-soluble ionic
contamination of blast cleaning abrasives
Standard test methods for field measurement of surface profile of blast
cleaned steel
Standard practice for preparation of Zinc (hot-dip galvanized) coated iron
and steel product and hardware surfaces for painting
[22]
ASTM F1249
Standard test method for water vapor transmission rate through plastic film
and sheeting using a modulated infrared sensor
[23]
ASTM G8
Standard test methods for cathodic disbonding of pipeline coatings
[24]
ASTM G14
Standard test method for impact resistance of pipeline coatings (falling
weight test)
[25]
ASTM G17
[26]
ASTM G42
[27]
ISO 527-2
[28]
ISO 4591
[29]
ISO 6964
[30]
EN ISO 2808
[31]
EN ISO 8501-1
[32]
EN ISO 8501-3
[33]
EN ISO 8502-3
[34]
EN ISO 8502-6
[35]
EN ISO 8502-9
[36]
EN ISO 8503-1
[37]
EN ISO 8503-5
[38]
EN ISO 8504-2
[39]
EN ISO 8504-3
[40]
EN ISO 11124
Standard test method for penetration resistance of pipeline coatings (blunt
rod)
Standard test method for cathodic disbanding of pipeline coatings subject
to elevated temperatures
Plastics – Determination of tensile properties – Part 2: Test conditions for
moulding and extrusion plastics
Plastics – Film and sheeting – Determination of average thickness of a
sample and average thickness and yield of a roll by gravimetric techniques
Polyolefin pipes and fittings – Determination of carbon black content by
calcination and pyrolysis – Test method
Paints and varnishes – Determination of film thickness
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 coating
Preparation of steel substrates before application of paints and related
products - Visual assessment of surface cleanliness – Part 3: Preparation
grades of welds, edges and other areas with surface imperfections
Preparation of steel substrates before application of paints and related
products - Tests for the assessment of surface cleanliness - Part 3:
Assessment of dust on steel surfaces prepared for painting (pressuresensitive tape method).
Preparation of steel substrates before application of paints and related
products - Tests for the assessment of surface cleanliness – Part 6:
Extraction of soluble contaminants for analysis - The Bresle method
Preparation of steel substrates before application of paints and related
products - Tests for the assessment of surface cleanliness – Part 9: Field
method for the conductometric determination of water-soluble salts
Preparation of steel substrates before application of paints and related
products - Surface roughness characteristics of blast-cleaned steel
substrates - Part 1: Specifications and definitions for ISO surface profile
comparators for the assessment of abrasive blast-cleaned surfaces.
Preparation of steel substrates before application of paints and related
products - Surface roughness characteristics of blast- cleaned steel
substrates - Part 5: Replica tape method for the determination of the surface
profile
Preparation of steel substrates before application of paints and related
products - Surface preparation methods - Part 2: Abrasive blast cleaning
Preparation of steel substrates before application of paints and related
products - Surface preparation methods - Part 3: Hand and power tool
cleaning
Preparation of steel substrates before application of paints and related
products - Specifications for metallic blast-cleaning abrasives
[41]
EN ISO 11126
Preparation of steel substrates before application of paints and related
products - Specifications for non-metallic blast-cleaning abrasives
[42]
AWWA C 209
Cold-applied tape coatings for the exterior of special sections, connections
and fittings for steel water pipelines
[43]
AWWA C 214
Tape coatings for steel water pipe
[44]
NACE SP 0109
[45]
NACE SP 0169
[46]
NACE SP 0274
[47]
NACE SP 0490
[48]
[49]
[50]
SSPC SP-1
SSPC SP-2
SSPC SP-10
1.4
Field application of bonded tape coatings for external repair, rehabilitation
and weld joints on buried metal pipelines
Control of external corrosion on underground or submerged metallic
piping systems
High-voltage electrical inspection of pipeline coatings
Holiday detection of fusion-bonded epoxy external pipeline coatings of
250 to 760 µm
Solvent cleaning
Hand tool cleaning
Near-white metal blast cleaning
Company Specification
Doc. No
[51]
8015-0151-WGK1-00-000-PI-SP-00002
Specification for External Coating
02
[52]
8015-0151-SECL-00-000-PI-SP-00003
Engineering Design Specification for Painting
02
1.5
Title
Rev.
Ref.
Acronyms and Abbreviations
The following abbreviations are used in this document:
3LPE
3 Layers Polyethylene
UG/AG
Under Ground / Above Ground
ASTM
American Society for Testing and Materials
AWWA
American Water Works Association
BOD
Basic of Process Design
CPF
Central Processing Facilities
CS
Carbon Steel
CTW
Cold Tape Wrapping
DD
Detail Design
DFT
Dry Film Thickness
EPC
Engineering Procurement & Construction
ESCR
Environmental Stress Cracking Resistance
FBE
Fusion Bonded Epoxy
FJC
Field Joint Coating
GS
Galvanized Steel
HT
High Temperature
HSE
Health, Safety and Environment;
ISO
International Standards Organization
IDS
Inspection Data Sheet
ITP
Inspection Test Plan
MRB
Manufacturing Record Book
MSDS
Material Safety Data Sheet
NACE
National Association of Corrosion Engineers
N/A
Not Applicable
PE
Polyethylene
PWT
Produced Water Treatment
QA/QC
Quality Assurance / Quality Control
QCP
Quality Control Plan
SI
International System
SoW
Scope of Work
SSPC
Society for Protective Coating
Tamb
Room temperature (22 °C)
UG
Under Ground
UV
Ultraviolet
VDR
Vendor Document Register
WP
Well Pad
APPENDIX 1 – PAINTING FOR ABOVE GROUD PIPING
2
2.1
General
This specification defines the minimum requirements for the design, application and repairs,
inspection and testing of external painting system to be applied at site on project carbon steel,
galvanized steel and stainless steel piping and fittings.
Painting systems have been defined according to the following parameters:

Type of substrate;

Atmosphere or environment;

Operating temperatures (minimum and maximum values);
2.1.1 Process input data

Service fluid: water injection / crude oil / chemicals / instrument air;

Maximum service temperature: 78 °C;

Design temperature: - 5 / 90 °C;

Application: Above Ground piping and fittings.
2.1.2 Surfaces to be painted

Uninsulated carbon steel surfaces;

Uninsulated galvanized steel (for colour coding / safety / identifications reasons);

Uninsulated stainless steel surfaces.
2.1.3 Surfaces not to be painted

Non-ferrous metal surfaces (i.e. Aluminium and its alloys, Copper and its alloys);

Machined surfaces as flange faces;

Surfaces used for identifications purposes, such as nameplates, serial number plates, valve
identification signs, gauge glasses and guards, gauge faces and light fixtures, valve stems
and flange bolts;

Buried piping and fitting to be wrapped.
Temporary corrosion protection of not-coated items, e.g. shafts or machined surfaces, shall be
easily removable at site. Removal procedure shall be attached to the Painting Procedure.
2.1.4 Painting data
Painting data shall consist as a minimum of the following descriptions:

Surface preparation (method, grade of cleanliness, anchor profile);

Coating products (layer number, product names, thickness, final color, etc.);

Tests and inspections according to this specification.
2.1.5 Painting systems
The purpose of this paragraph is to illustrate the painting systems suitable for the piping.
Substrate
Uninsulated CS
Maximum
service
temperature
78 °C
uninsulated
galvanized steel (Tamb.),
for appearance, safety,
identification
60 °C
Uninsulated SS
78 °C
Painting cycle
Surface
preparation
Primer
Surface cleanliness: EN ISO 8501-1 Sa 2.5
Surface profile: 50 µm ≤ Rz ≤ 75 µm
80 µm of Zinc rich epoxy (organic primer)
Intermediate
100 µm of high build epoxy sealer
Top coat
60 µm of acrylic polyurethane
Surface
preparation
Sweep abrasive blast cleaning
Surface profile: 10 µm ≤ Rz ≤ 15 µm
Primer
75 μm of Zinc-free epoxy
Top coat
Surface
preparation
Primer
Top coat
50 μm of acrylic polyurethane
Sweep abrasive blast cleaning
Surface profile: 10 µm ≤ Rz ≤ 15 µm
75 µm of Zinc-free epoxy
50 µm of acrylic polyurethane
Table 2.1 – Painting cycles.
System
A
B
E
2.2
Safety
Account shall be taken of all relevant technical, health, safety and environmental legislation. Plant
and equipment shall be maintained in good condition and shall comply with applicable health,
safety, and environmental (HSE) requirements.
2.2.1 Painting composition
All painting products used on site shall meet the following requirements:

All painting product formulation shall respect the local legislation of the place of application
(e.g. VOC, isocyanates, etc.) and to some extend they shall comply with the legislation of
the country/ state where the plant is built. Coatings shall comply with federal, state and local
air pollution regulations.

All paintings shall be free from heavy metals such as arsenic, barium, cadmium, lead,
mercury, silver, chromium, selenium. Zinc coatings shall contain less than 100 ppm barium
sulphate or lead. For all other coatings that are not inorganic zinc based, according to ASTM
definition of “lead-free paint” lead content shall be less than 2 ppm.

Finish coats shall be based on acrylic polyurethane media. Where isocyanate cured products
are not allowed, alternative finish products shall be submitted for approval. Finish coat shall
have gloss retention and weather/UV resistance.
Notes:
1. Oil-, alkyd-, vinyl-, or acrylic-based one-component paints, and so-called "enamel",
"varnishes" or "synthetic resin" are not accepted, since not suitable for heavy duty service.
2. Nitrocellulose-based lacquers are not allowed due to high flammability.
2.2.2 Abrasive material
Abrasive media must be free from oil, grease, moisture. Application and disposal shall be as per
Manufacturer’s recommendation and in accordance with material safety datasheet of used
material. The use of silica sand is not permitted.
2.3
Painting application
2.3.1 General requirements

Only paint material classes specified in Table 2.1 paragraph 2.1.5 shall be used.

Mixing products of different painting Manufacturer in the same layer/application for any
given system is not acceptable.

All paint materials shall be delivered to site in the painting Manufacturer unopened original
containers, in good state and correctly labeled. Label shall feature the paint Manufacturer
name, brand name, batch number and date of manufacture.

Contractor shall supply and transfer to site all the equipment and material necessary to carry
out the cleaning, masking, priming and painting work in accordance with this specification
and paint Manufacturer recommendations. Test equipment including wet and dry film
thickness gauges, blast profile testers, pinhole holiday detectors, hydrometers, temperature
measuring devices, shall be provided by the Contractor.
2.3.2 Surface preparation and cleaning
In all cleaning methods the equipment and tools used shall be of suitable design and quality to
properly complete the works to the specification. Where compressed air is used, air lines shall be
provided with effective, well maintained oil and water traps. Efficient well-maintained air filters
shall be provided to control dust.
During cleaning, all weld areas and attachments shall be given special attention to ensure all
welding flux and spatter is removed by the use of solvents, files scrapers, chipping hammers,
power or hand brushes or grinders fitted with flexible grinding discs.
Prior to the commencement of cleaning, the surface to be cleaned shall have all oil, grease or wax
removed by swabbing with a suitable emulsion cleaner. The surface shall then be washed down
with clean fresh water to remove dirt, stains and residues. Where necessary, hand brushing shall
be included to ensure a clean surface.
2.3.2.1 Abrasive blast cleaning
Pressure and volume of the compressed air supply for blast cleaning shall meet the work
requirement and shall be sufficiently free from oil and water contamination to ensure that the
cleaning process is not impaired. Traps, separators and filters shall be emptied and cleaned
regularly.
Millscale, rust and other surface contaminants shall be removed using blast or centrifugally
propelled abrasives. After the specified standard has been achieved, all dust, loose materials and
abrasive residues shall be removed from the cleaned surface and the surface shall be coated before
contamination or flash rusting occurs.
Contaminants such as oil, greases, chemicals or soil shall be removed prior to abrasive cleaning
by the use of a suitable emulsion cleaner.
After blast cleaning and before application of the priming coat, the surface shall cleaned to remove
dust and abrasives and in particular from pockets and corners. This can be done by blowing dry,
oil-free compressed air.
Due care shall be exercised to prevent the abrasive grit entering inside pipe work. On completion
of blasting operations, the inside of piping shall be inspected and cleaned out if the presence of
abrasive grit is detected.
Any surface showing signs of handling contamination after blasting shall be solvent cleaned and
re-blasted.
The use of abrasives containing silica is not permitted. The abrasive must be free from oil, grease,
moisture, etc. Re-used abrasive shall be clean and reasonably sharp. They shall not be rusted or
noticeably worn or dull when compared with fresh material and must be free from contaminants.
Re-used abrasive shall be approved by Field Management and shall meet the requirements as
specified above.
Blast cleaning shall not commence unless a protective coating can be applied before contamination
or flash rusting occur. Blasting shall not be done outside normal daylight work hours unless
authorized by Field Management. Blasting operations shall not be carried out unless surfaces to
be prepared are 3°C above ambient air dew point.
Protect all surfaces not to be coated from damage and from paint products by adequate temporary
coverings during all operations of surface preparations and painting. In particular, stainless steel
and non-ferrous surfaces shall be protected from blasting, overspray and coatings intended for
carbon steel, especially coatings containing zinc.
All weld spatters, sharp edges and surface irregularities shall be contoured and surface
irregularities ground smooth as required by reference standard EN ISO 8501-3.
Surface profile and anchor pattern after blast cleaning shall conform to requirements of paint
Manufacturer, for each painting product. Reference shall be made to Manufacturer’s application
instructions and to paint technical datasheets.
Note for blast cleaning of Stainless Steel (SS):
Surface shall be thoroughly degreased using an appropriate emulsion cleaner and abrasive cleaned
(sweep blasting) to create sufficient anchor profile. Abrasive for blast cleaning of SS surfaces shall
be performed with a suitable non-metallic abrasive such as Aluminium oxide. When hand or power
tool cleaning is required on stainless steel, only SS wire brushes that have not been previously
used on carbon steel surface may be used. All coatings and solvents for use on stainless steel shall
be free from substances such as chlorides and other halides, sulfur, and shall be free from low
melting point metals (Zinc, Aluminium, Tin and Lead).
Note for blast cleaning of Galvanized Steel (GS):
Surface preparation shall consist of thoroughly degreasing, followed by sweep blast cleaning
according to ASTM D6386 / EN ISO 12944-4. Abrasive for blast cleaning of GS surfaces shall be
performed with a suitable non-metallic abrasive such as Aluminium oxide. Dust from blast
cleaning operation shall be removed as previously described. Weathered galvanized surfaces
should be wire brushed first to remove all corrosion products, taking care to avoid removal of
sound galvanized thickness.
2.3.2.2 Mechanical (power tool) cleaning
Dirt, rust, mill scale and/or paint remains are removed and the metal surface prepared by powered
hand tools such as powered wire brushes or needle guns to achieve surface cleanliness of St3.
Manual cleaning shall only be carried out when the use of power tools is prohibited and with the
permission of Company.
On completion of the surface preparation, all dust and other foreign materials shall be removed
and the primer coat applied before any contamination or rusting occur. Should the cleaned surface
be left uncoated for a period showing any contamination, the surface preparation shall be repeated
prior to painting.
2.4
Preparation and application of painting materials
2.4.1 General

Contractor shall adhere strictly to the instructions and recommendations as prescribed by the
painting Manufacturer for the preparation and application of all painting materials.

Successive layers shall have a contrasting colours or tints.
2.4.2 Weather conditions
Contractor shall measure and record local conditions of temperature and humidity during blasting,
painting and curing. Painting shall only be applied when suitable weather conditions prevail.
Painting shall not be applied under the following conditions or when such conditions are likely to
prevail before the painting is cured.

At temperatures below 5 °C (or according to painting Manufacturer recommendation) or
when the temperature is likely to fall below this figure before the surface film is dry, or on
surfaces registering low temperatures;

When the relative humidity exceeds 85 % and/or according to paint Manufacturer
recommendation for each specific painting product;

Steel temperature is less than 3 °C above the dew point;

During foggy or misty conditions;

Before dew or moisture has evaporated;

When it is raining or rain is imminent;

In windy conditions or in presence of dust.
Contractor shall remain responsible for scheduling his activities. Painting contaminated during
curing by dust, condensation or rain, shall be removed and redone.
2.4.3 Storage of materials
All products shall be received in sealed containers, clearly marked with product description,
reference number, batch number and date of manufacture. Thinners, solvents, etc. shall be stored
in a well-ventilated fireproof building, separate from other painting consumables. The building
temperature shall be controlled in order that the painting products will not suffer from local
climatic conditions. Recommendations on storage conditions by the painting Manufacturer shall
be strictly followed.
2.4.4 Painting preparation
Painting components shall be power-stirred to obtain a homogenous consistency. No hand stirring
is allowed for quantities greater than 5 litres. Before further use, painting shall be allowed to stand
for a time long enough to remove aeration caused by stirring.
Painting materials shall be mixed in the proportions and under the conditions recommended by the
paint Manufacturer. The mixed painting shall not be used on expiry of its "pot life". Induction
time, where indicated, shall be strictly observed.
The mixed painting shall colour match with other prepared products of the same coat.
Paintings visually showing deterioration such as settling, separation, gelling, skin formation, etc.
shall be discarded. Only the required thinner and quantity (percentage) recommended by the
painting Manufacturer shall be used.
2.4.5 Painting application
Painting shall be done according to the application instructions of the paint Manufacturer and shall
be performed by skilled and experienced staff, aware of health and hazard issues related to painting
activities.
Painting shall be applied by conventional spray or airless spray methods, as approved or specified
by the paint Manufacturer.
The use of roller shall be avoided on blast cleaned surfaces or rough welds; roller can be either
used for successive layers or stripe coats. Brush or rollers used shall be of a suitable size and shape
and shall be kept clean by use of approved solvents. Where rollers are used, the nap shall be of
sufficient length to work the coating well into the surface.
When using spray or airless spray methods, all the equipment shall have adequate, well-maintained
pressure regulating devices, effective strainers, traps, and separators, suitable size hoses and clean,
well-maintained guns. Pressure and volume of the compressed air used for spray application shall
meet the work requirement and be free from oil and water contamination. Traps, separators and
filters shall be emptied and cleaned regularly. The traps and separators for removing oil and water
maintained from the compressed air shall be such that air atomizing guns will not deposit oil or
water when directed on to a clean surface for 15 seconds. Nozzles shall be of the correct size and
provide the most suitable spray shape for the most effective and economical application of the
coating without excessive overspray.
The specified painting thickness shall be achieved at all protrusions, corners and crevices. Edges,
borders, bolt heads, etc. may require the application of a stripe coat by brush to achieve the
complete coverage.
All painting materials shall be applied evenly in a normal full layer, free from mud cracking,
wrinkling, sagging, curtaining, fish eyes, orange peeling, pinholes, brush and roller marks and
other defects.
Dry film thickness shall be measured from the peaks of the grit blast profile and suitable pieces of
grit blasted steel shall be prepared to enable the thickness meters to be calibrated in accordance
with the indications from the equipment Manufacturers.
Due care shall be exercised whilst spraying to prevent overspray and contamination of other
surfaces by the use of shields, etc.
Under no circumstances Zinc or Aluminum in the form of coating pigments or metal spray shall
be allowed to come into contact with stainless steels.
2.4.5.1 Priming
Priming shall be applied as soon as possible after the surface preparation has been carried out and
before any contamination, deterioration or flash rusting of the cleaned surface.
The primer shall not be applied before any possible Post Welding Heat Treatment (PWHT).
Angles, corners, sharp edges, bolt or rivet heads shall be stripe-coated by brush. This coat shall be
the same product as the primer, but should be of a different color for identification purpose.
2.4.5.2 Intermediate layer
Intermediate paint shall be applied when primer has properly dried in accordance with the
recoating times indicated in the relevant product datasheet, its correct application and thickness
has been confirmed, and the primed surface has, if necessary, been cleaned to remove
dust/moisture.
The use of paints made from different paint Manufacturers in a same painting cycle is not allowed.
Wet film thickness shall be checked when each coat is applied, to ensure that the full painting
thickness will be achieved in the specified number of coats. Total system dry film thickness shall
be in accordance with this specification.
2.4.5.3 Top layer
Final coat shall be applied in accordance with the undercoat overcoating time recommended by
the paint Manufacturer. The final coat shall provide a smooth, even finished coating surface.
Where gloss finish coats are applied, the surface shall be a smooth gloss finish with no breaks in
the surface. The multi-coat system shall be free from all the defects previously mentioned.
Each coat shall be allowed to dry thoroughly in accordance with the paint Manufacturer
instructions for overcoating, before the next coat is applied. Drying and curing times are highly
dependent on local conditions.
2.4.6 Contrasting coatings
Where it is necessary to apply more than one coat of a particular product to obtain a specified DFT,
then the first coat shall be selected sufficiently different in color, in order to distinguish from the
subsequent coats.
2.4.7 Painting before installation
All surfaces that will be inaccessible after assembly or installation shall be cleaned and painted
before installation.
When painting is carried out before installation, all reasonable steps shall be taken by the
Contractor to reduce to a minimum damage to the painting cycle before and during installation.
Metal contact surfaces -i.e. bolted joints in structures- should be coated with one full layer of the
specified primer on both surfaces immediately before bolting up. Fretting surfaces where friction
grip is required shall not be coated.
2.4.8 Handling and storage of painted items
Painted items shall not be handled or moved until proper drying or cure as required in the paint
Manufacturer's instructions.
Painted items shall be handled with equipment such as wide belt slings, web belts, and wide padded
skids selected to prevent damage to the painting. Handling equipment likely to cause damage to
the painting shall not be used. Items such as chains, cables, hooks, tongs, metal bars, and narrow
skids shall not be permitted to come in contact with the painting. Dragging or skidding painted
items shall not be permitted.
Painted items shall be loaded, padded and secured for transport in such a manner that the painting
will not be damaged in transit.
Painted items shall be separated so that the items do not bear against each other and shall be stacked
off the ground using suitable means (e.g. parallel height ridges of rock-free sand, wooden timbers
placed under the uncoated pipe ends) to avoid damages of the coating.
2.5
Inspection and acceptance
Contractor shall guarantee that painting system is applied in compliance with present specification
and with the prescriptions of paint Manufacturer to meet the project quality requirements.
During painting works, Contractor shall perform as a minimum the checks and testing listed in
Table 2.2.
Company reserves the right to monitor the Contractor inspection activities and tests and carry out
checks as deemed appropriate.
Item
Test method /
Acceptance criteria
Reference code
Surface preparation
Property
1
Environment conditions
1.1.1 Relative humidity
Dew point meter
≤ 85%
Frequency
1.1.2
Ambient temperature
Thermometer
> 5 °C
Before start of each
shift. + min twice
per shift
1.1.3
Steel temperature
Digital contact
thermometer
≥ 3 °C above air dew point
Each component
1.2
Surface condition before blasting
Visual inspection
Free from contamination,
defects, weld spatter, etc.
Each component
1.3
Abrasive materials quality
EN ISO 8504-2
Free from oil, grease, moisture
1.4
Compressed air cleanliness
ASTM D4285
Dry and free from oil, grease
Each component or
once per 10 m2
Each component
1.1
Every new batch
and spot checks
Before start of each
shift or change in
compressor
operation
Abrasive blast cleaning
1.5
1.5.1
Anchor profile
EN ISO 8503-5
1.5.2
Surface cleanliness grade
EN ISO 8501-1
As per painting cycle
specification,
Table 2.1
1.6
Cleaning of blasted surface
Compressed air
Removal of residual debris
Each component
1.7
Dust contamination test
EN ISO 8502-3
Max rating: 2
Spot check
1.8
≤ 30 mg/m
Free from contamination, flash
Surface condition prior to
Visual inspection rust, dent, oxides, scales,
painting
laminations, gouges
Inspection and tests of applied painting cycle
Uniform, homogeneous, film.
No visual defects (pinholes,
External appearance of painting
Visual inspection
run sags, flacking, orange peel
and excessive overspray)
As per painting cycle
SSPC-PA2 / EN
Dry film thickness
specification,
ISO 2808
Table 2.1
No holiday @ 90 V
Holiday detection
EN ISO 29601
(Low voltage pinhole
detection)
1.9
2
2.1
2.2
2.3
2.4
Salt contamination test
Adhesion test
EN ISO 8502-9
EN ISO 2409 /
ASTM D3359
2
Class 0 / Class 5A
Table 2.2 – Inspection and tests of painting works.
4 samples/2000 m2
Each component
100% of surface
after each coat
Each component or
once per 10 m2
100% of surface,
each component
Spot checks
(between first coat
and substrate;
between coats)
2.5.1 Thickness check
Dry film thickness shall be measured with a magnetic or ultrasonic probe. The equipment shall be
calibrated at least twice daily in accordance with the paint Manufacturer recommendations. It is
suggested that, in order to achieve the specified dry-film thickness, wet-film thickness be checked
during the painting application with wet film thickness gauges.
If the dry film thickness does not meet the specified value, additional coats shall be applied.
2.6
Repair of defects or damages
Any defect or damage that may occur shall be repaired before the application of further coats.
Areas which are to be overcoated shall be thoroughly cleaned free from grease, oil and other
contaminants and shall be dry.
The surfaces shall then be prepared to the standard as specified. Edges of sound coating around
the repair area shall be feathered back approximately 50 mm for a smooth transition. If necessary,
vacuum blasting equipment shall be used for surface preparation.
Subsequently additional compatible coats shall be applied, until they meet the specification. Those
additional coats shall be blend in with final coating on adjoining area. Damaged areas of
uninsulated surfaces shall after cleaning be touched up with one or two coats of surface tolerant
high solids epoxy (compatible with previously applied coats of different nature). The repair coat
shall overlap sound coating.
Galvanized steel presenting damages exposing the steel substrate shall be repaired. Prior touch up,
the damaged surface shall be cleaned by mechanical wire brushing to St 3. Touch up shall be with
Zinc rich epoxy and shall match original grey color of galvanized steel. Minimum dry film
thickness of Zinc rich epoxy repair coat shall be 80 µm.
2.7
Documentation
Based on the requirements of this specification, Contractor shall prepare a detailed "working
procedure" including production procedures, test, check and inspection program and any other
requirements necessary to achieve the job. These procedures shall be approved by Company before
start any painting works.
Contractor shall prepare a detailed quality control plan reporting all details necessary to achieve
proper works, including: description of test, procedure check and methods, acceptability criteria,
frequency of the check, person required to be present during the inspections, final inspection.
Daily reports and documentation, including test results, shall be submitted to the Company.
2.7.1 Painting records
Contractor shall operate a comprehensive recording/ reporting system on all aspects of the
painting:

Including aspects covered above;

Details of environmental conditions;

Details of repair work and reasons necessary.
2.7.2 Final report
On completion of the work, a report is required giving full details of surface preparation and system
used together with Manufacturer data sheets and records of all measurements.
2.8
Training of personnel
If necessary, painting Supplier shall train the Contractor operators before the work commences.
Company representative supervisor/inspector can witness all the painting activities carried out by
Contractor.
2.9
Colour and identification
ITEM DESCRIPTION
COLOUR
DESIGNATION
STD COLOUR
No.
Structural steel
Silver Gray
RAL 7001
Railings of ladders and platforms
Yellow
RAL 1018
Platforms and ladder’s supports (if not galvanized)
Silver Gray
RAL 7001
Buildings, walls, fences
Optic White
RAL 9003
Window frames, profiles
Telegrey 4
RAL 7047
Piping and supports
Telegrey 4
RAL 7047
Tanks, Vessels, Columns
Optic White
RAL 9003
Equipment (heat exchanger, reactor)
Telegrey 4
RAL 7047
ITEM DESCRIPTION
COLOUR
DESIGNATION
STD COLOUR
No.
Combustion Equipment (burner, furnace, boiler, stack, ducts)
Telegrey 4
RAL 7047
Dynamic Equipment (motor, power generator, pump, compressor)
Ultramarine Blue
RAL 5002
Packaged Equipment on skid (including skid)
Telegrey 4
RAL 7047
Control panels
Grey
RAL 7035
Electrical equipment (panel, power transformer, cable duct,
junction box, switchgear)
Telegrey 4
RAL 7047
Instruments
Mfr’s Standard
Mfr’s Standard
Fire fighting equipment and piping
Flame Red
RAL 3000
Davits, monorails
Yellow
RAL 1018
Table 2.3 - Colour of topcoat for item identification.
2.9.1 Piping service identification through color
Selected process and utility piping may require additional color identification to be placed directly
on the painted piping.
Such coding can be realized with the finish base color of the pipe or through the mean of bands.
Service or content of piping not already finished with proper identifying color shall be identified
by identification bands.
Coloured bands can be realized by paint or tape bands, stencils, decals, or metal tags, provided
that they withstand atmospheric conditions and process temperatures.
Piping service
Process lines and utility lines
(Toperative ≤ 120 °C)
Instrument Air
Fire water piping
Cooling water
Drinking water
Demi water
Nitrogen
H2S Gas
Steam
Dangerous/toxic fluids
Band identification colour
Light Grey
Light blue
Red
Black
Green
White
Orange
Yellow ochre
Aluminum
Yellow ochre
Table 2.4 - List of piping service and related identification colours.
The width of the identification colour band depends on the pipe nominal diameter:

Up to 4": 100 mm

Above 4": pipe diameter x 2
Unless otherwise agreed, bands shall be located only at significant points for plant operation (e.g.
where pipe starts and ends, at valves (on one side), at branches etc.); approximately, a 25 feet
interval along piping can be observed.
Symbols (Arrows) shall be used to indicate the flow direction of commodities contained in piping.
The arrows shall be white or black in colour to contrast with the basic colour of the pipe. Tape
bands, paint, stencils or decals can be used as labeling, provided that they withstand atmospheric
conditions and process temperatures.
The following sizes are recommended:

Pipe diameter 2" ÷ 6": arrow to fit in a 25 mm x 100 mm rectangle;

Pipe diameter ≥ 8": arrow to fit in a 50 mm x 150 mm rectangle.
Arrows shall be placed (preferably near the colour bands) at each section of pipe adjacent to
fittings, valves, tees, and at both sides of elbows, tee-type connection to a utility station, at both
sides of stanchion, and both sides of wall or ceiling penetration. Where flow of the commodity is
possible in either direction, two arrows shall be indicated pointing in opposite directions.
APPENDIX 2 – 3LPE COATING
3
3.1
General
This specification defines the minimum requirements for the design, materials, application and
repairs, inspection, testing, and supply of 3LPE external coating system to be applied at Coating
Applicator factory/shop on carbon steel pipes.
3LPE coating shall consist of:

FBE (Fusion Bonded Epoxy) primer (powdered),

Layer of polymeric adhesive,

Multiple top layer of PE compound.
3LPE coating shall be:

capable of protecting the piping for at least 25 years;

suitable to show excellent properties at maximum service temperature.
3.2
Process input data

Service fluid: water injection;

Maximum service temperature: 60 °C;

Design temperature: - 5 / 85 °C;

Application: buried pipes.
3.3
Coating raw material characteristics
3.3.1 Epoxy powder (FBE)
Raw material for FBE primer shall be epoxy powder, characterized by the minimum requirements
listed in Table 3.1:
Property
Moisture content
Minimum glass transition
temperature, Tg2
(DSC analysis)
Particle size
Test method /
Reference code
EN ISO 21809-1
Annex K
EN ISO 21809-1
Annex D
EN ISO 21809-2
Gel time @ 205 °C
Density
EN ISO 21809-1
Annex J
EN ISO 21809-1
Annex M
Minimum requirements
≤ 0.6 %
≥ 95 °C and within epoxy Manufacturer
specification
3% retained on 150 µm sieve
≤ 0.2 % retained on 250 µm sieve
and as within epoxy Manufacturer
specification
Within 20% of the value specified by
epoxy Manufacturer
Within ± 0.05 of the epoxy Manufacturer
specified value
Table 3.1 – Minimum requirements for epoxy powder material.
Epoxy powder shall be of the same coating Supplier of adhesive and PE materials. Coating
Supplier shall ensure that FBE primer is completely compatible with the adhesive and that FBE
maintains perfect adhesion to the metal and to the adhesive at maximum service temperature.
3.3.2 Polymeric adhesive
The adhesive (PE compatible copolymeric type) shall be characterized by the minimum
requirements listed in Table 3.2:
Property
Density, g/cm3
Test method /
Reference code
ISO 1183
Melt Flow Rate (MFR), g/10 min
ISO 1133-1
Strain at break @ 25 °C
Stress at yield @ 25 °C
Vicat softening temperature A/50
Water content
ISO 527-2
ISO 527-2
ISO 306
ISO 15512
Minimum requirements
Within adhesive Manufacturer
specification
Within adhesive Manufacturer
specification
≥ 600 %
≥ 8 MPa
≥ 85 °C
≤ 0.05
Table 3.2 – Minimum requirements for polymeric adhesive material.
Coating Supplier shall ensure that polymeric adhesive is designed to provide high adhesion,
chemical/physical, both to the FBE primer and to the PE layer at maximum service temperature.
Moreover, adhesive shall be resistant to microbiological attack and it shall contain no solvents or
unstable substances.
3.3.3 Polyethylene (PE) compound
PE compound shall be characterized by the properties listed in Table 3.3:
Property
Density of black compound
Carbon black content
Melt Flow Rate (MFR), g/10 min
Strain at break @ 25 °C
Stress at yield @ 25 °C
Vicat softening temperature A/50
Water content
Hardness Shore D
ESCR (50 °C, F50)
Test method / Reference code
ISO 1183 / ASTM D792 /
ASTM D1505
ISO 6964
ISO 1133-1
ISO 527-2
ISO 527-2
ISO 306
ISO 15512
ISO 868
ASTM D1693
Oxidation induction time
UV resistance and thermal ageing
ISO 11357-6
EN ISO 21809-1
Annex G
Minimum requirements
≥ 0.940 g/cm3
2÷3%
Within Manufacturer specification
≥ 600 %
≥ 15 MPa
≥ 110 °C
≤ 0.05
≥ 55
≥ 1000 h Cond. B, 10% Igepal CO630
≥ 300 Cond. B, 100% Igepal CO630,
if black compound density > 0.955 g/cm3
≥ 30 min @ 210 °C
∆MFR ≤ 35%
Table 3.3 – Minimum requirements for PE material.
Coating Supplier shall ensure that PE compound is designed to provide high mechanical resistance,
electrical isolation, microbiological and chemical attack, at maximum service temperature.
3.4
Surface preparation
Coating Applicator shall perform surface preparation in accordance with the requirements of this
specification and the coating Supplier recommendations. The sequence of minimum surface
preparation activities has been below specified:
3.4.1 Limitations
Coating work shall not take place if the following plant conditions occur:

when the ambient temperature is below 5 °C;

when the relative humidity is above 85%;

when steel surface temperature is less than 3 °C above the ambient dew point.
It is coating Applicator responsibility to check and record the above-mentioned conditions and
ensure that coating activities are performed when these parameters are in the specified range of
values.
3.4.2 Pre-cleaning
The bare pipe surface shall be free from mud, mill scale, mill lacquer, coal tar, asphalt, oil, wax,
grease or any foreign material (e.g. temporary protective paint or markings). These contaminants
shall be removed by using appropriate detergent, water rinsing and, for heavy contamination, wire
brush or power water cleaning (< 130 bar). The water used shall be potable quality. If solvent
cleaning (SSPC-SP 1) is necessary, only solvents meeting health and safety regulations and that
do not leave an oily residue shall be used.
3.4.3 Visual inspection
Any limited imperfections on pipe surface such as scabs, slivers, burrs and weld spatter shall be
identified and removed where possible by slight filing or grinding.
3.4.4 Pre-heating
Pipe surface shall be uniformly heated up to max 60 °C with suitable tools (i.e. propane torches)
to remove moisture and prevent its condensation on pipe after blast cleaning.
3.4.5 Abrasive blast cleaning
Prior to blast cleaning, the pipe ends shall be fitted with plugs so as to prevent entry of abrasive
into the pipe during the cleaning operation.
Blast cleaning shall be performed according to EN ISO 8504-2. Pipe surface shall be abrasive grit
blast cleaned to grade Sa 2.5 EN ISO 8501-1 corresponding to near-white metal finish SSPC SP10. The surface anchor profile shall be in the range of 50 ÷ 100 µm from peak to valley. Surface
profile shall be measured in accordance with EN ISO 8503-5.
Blasting and other dust producing areas shall be kept separate from coating application areas.
Abrasive grit and compressed air of blasting machine shall be dry, free from oil, grease and any
other contaminants. Sand and silica abrasive are not permitted. Particle hardness and size
distribution of the blasting medium shall be continually controlled by screening and shall be such
to obtain the required surface profile of 50 ÷ 100 µm. When recovered/recycled metallic grit
systems are used, a stabilised working mix of blast cleaning material shall be established and
maintained throughout the entire course of the production by frequent small additions from fresh
clean stock at a rate sufficient to replenish consumption. Coating Applicator shall regularly sample
recycled grit to ensure the absence of contamination.
Abrasives shall be stored in dry conditions and shall remain dry during usage. Maximum abrasive
conductivity shall be 150 µS/cm, measured according to ASTM D 4940. If required, coating
Applicator shall provide a chemical analysis report to the Contractor for every batch of utilized
abrasive, to verify the compliance with the conductivity requirement.
3.4.6 Final cleaning and inspection prior to coating application
After blast cleaning and before FBE application, coating Applicator shall carry out the following
tests/controls:

Any traces of foreign contaminants on the blast cleaned surface (e.g. dirt, dust, metal
particles, hydrocarbons, water, sulphates) shall be removed using dry and clean compressed
air;

Dust contamination test (EN ISO 8502-3): maximum residual dust rating shall be class 2;

Salt contamination test (EN ISO 8502-6): maximum residual chloride content, measured
according to EN ISO 8502-9, shall be less than 20 mg/m2;

Check of flash rusting on steel: if flash rusting occurs, steel surfaces must be blasted again
as per paragraph 3.4.5;

Check of “critical” defects: oxides, scales, laminations, gouges, sharp edges, dents, drops,
flame cuts or any other foreign material made visible by blast cleaning are considered as
“defective steel” and shall be marked using French chalk. Coating Applicator shall promptly
advice the Contractor who shall determine whether the defects can be removed by
mechanical techniques, i.e. filing or grinding according to the requirement of EN ISO 85013 grade P3. Coating Applicator shall be responsible for grinding operation. No steel surface
“critical” defects shall be grinded without the approval of the Contractor. After grinding, any
area larger than 50 mm in diameter shall be re-blasted for restoring the required anchor
pattern. Grinding shall not reduce the wall thickness below the required thickness. Item with
wall thickness below the required shall be rejected;

3.5
Time span between the blast cleaning and the coating operation shall be kept to a minimum.
Any pipes that cannot be coated within 3 hours after cleaning or showing any deterioration
to the required surface cleanliness Sa 2½ shall be completely re-blasted before applying the
coating.
3LPE coating application
Coating materials shall be applied strictly in accordance with this specification and the applicable
guidelines of the coating Supplier. Any deviation from the approved procedure shall be submitted
by coating Applicator for Contractor approval.
The application of the coating at any point of the pipe shall not be interrupted. Should this occur,
it would not be allowed to restart the application until the pipe subjected to the interruption is
removed from the coating line and the pipe subject again to surface preparation (paragraph 3.4).
3.5.1 FBE layer
Before the application of FBE, all surfaces shall be dry and free from rust, grease, oil, dust and
dirtiness, soluble salts, oxides and any other foreign material. Cleaned steel surfaces shall be
uniformly preheated to a minimum temperature of 235 °C or to the FBE manufacturer
recommended temperature. The pipe temperature shall not exceed 260 °C. Oxidation (bluing) of
the steel is not acceptable. The furnace atmosphere shall be such that the steel surfaces are not
contaminated. Pipe temperature shall be checked periodically and recorded by an optical
pyrometer. Recorded temperature shall be highlighted on a continuous chart. Optical pyrometer
shall be checked for error not less than every 4 hours against a calibrated temperature measuring
instrument.
Epoxy powder shall be applied by electrostatic spray, with the pipe at earth potential, while the
epoxy powder charged to high potential. On the preheated pipe surface, the epoxy powder melts
and a continuous FBE layer is formed. The process shall be such as to guarantee a uniform color,
gloss and thickness end to end, without any sag, floods, runs, blisters, orange peel, pin holes, bare
spots or over spray. The FBE coating will terminate at the end of the pipe as specified in paragraph
3.5.4. During application, the bevelled ends shall be protected against mechanical damages and
from contamination with epoxy powder.
FBE thickness shall be from a minimum of 0.125 mm to a maximum of 0.150 mm.
The use of recycled powder shall not be permitted. Moreover, only one brand of epoxy powder
shall be used at a given time. Coating Applicator shall record all used batch numbers along with
other information necessary for the Contractor in order to relate the powder batches to the items
on which the coating is applied.
3.5.2 Polymeric adhesive layer
Polymeric adhesive shall be applied to a thickness of 0.150 to 0.250 mm. Coating Applicator shall
ensure that the rollers push adhesive into the base of weld, in order to eliminate any air entrapment
or voids immediately adjacent to the longitudinal weld. Adhesive application shall be continuous:
under no circumstances can the PE layer be in contact with FBE layer.
The adhesive layer shall be applied before the expiration of FBE gel time by using either the
crosshead or lateral extrusion technique. Application of the adhesive shall not be permitted after
the FBE has fully cured.
Coating Applicator shall establish to the satisfaction of Contractor that the adhesive is applied
within the gel time window of the FBE and at the temperature recommended by the adhesive
coating Supplier.
Coating Applicator shall state the proposed minimum and maximum time internal between FBE
and adhesive applications at the pipe temperature range and overlap.
3.5.3 PE layer
PE top layer may be applied by either the crosshead or lateral extrusion technique. PE shall be
applied over the adhesive within the time limits as per coating Supplier installation guidelines.
After application and prior to handling, the coating shall be water cooled to below 60 °C, to ensure
proper shrinkage at the PE sheath and good adhesion.
3.5.4 Cutback
Coating cutback shall be nominally 150 mm and a 10 mm long FBE ‘toe’ shall be visible
protruding from the chamfered ends of the polymeric adhesive / PE interface.
The ends of the PE shall be bevelled at maximum 30°, measured in the direction of the pipe axis.
Pipe bare bevel ends shall be properly clean, free from fabrication residues and shop primed to
prevent rusting during storage or field installation.
150 mm
10 mm
max 30° chamfer
Uncoated
FBE
3 LPE
Fig. 3.1 – Scheme of cutback requirement.
3.6
Coating repair
Coating repairs shall be performed during qualification phase, using the repair material
recommended by the coating Supplier.
Coating Applicator shall issue a detailed coating repair procedure for Contractor approval. The
procedure shall include as minimum:

Cleaning of the faulty area by mechanical brush and/ or abrasive blasting;

The edges of the sound coating shall be bevelled to 45°, to accept the repair material;

Application of approved repair materials to achieve the appropriate thickness and to overlap
the defect edges by at least 25 mm;

Visual inspection;

Holiday detection of the repaired area.
All inspection following repairs shall be documented and shall include the repair and re-test details.
Manual repair of the coating is allowed for the following defects:

Scratches, cuts, indentations and similar local defects of indeterminate dimension and
quantity, providing they do not penetrate to the metal surface.

The same defects mentioned above but penetrating to the metal surface providing they do
not exceed 200 mm in axial length or more than 30% of the circumference of the pipe. The
exposed area of metal surface shall be less than 10000 mm2.
Should the coating defects exceed the above mentioned limits the coating shall be rejected, the
coating stripped, the pipe re-prepared (paragraph 3.4) and recoated (paragraph 3.5).
The coating repair procedure proposed by the coating Applicator shall be verified during
qualification tests, through visual inspection and the use of holiday detection on the repairs of
artificial defects made on the coating.
3.7
Inspection and test
Inspection and test activities shall be performed during the following phases:
1. At every receipt of bare pipes and coating raw materials (paragraphs 3.7.2, 3.7.3);
2. During coating qualification (paragraph 3.7.4);
3. During coating production (paragraph 3.7.5).
3.7.1 General requirements

Coating Applicator shall provide documentation by recording on daily work sheets the tests
performed and the relevant results.

Coating Applicator shall ensure that controls, inspections and tests are efficiently carried out
and that the application of the coating meets the requirements of this specification. All main
coating application parameters set up by coating Applicator shall be recorded and shall not
be modified unless otherwise approved in writing by Contractor.

At his discretion, coating Applicator can give the Contractor the list of additional tests he
intends to carry out at his cost on coating materials. Contractor reserves the right to approve
the execution of the proposed additional tests.

All the instruments used for checks and tests during the coating process shall be calibrated
regularly and whenever doubts arise on their reliability. As a general rule, the instruments
that are more frequently used should be calibrated at the start of each shift while other
instruments should be calibrated just before they are used. Coating Applicator shall submit
the calibration procedures for all instruments utilized for tests and checks. The said
procedures shall be put at the personnel and Contractor disposal.

Contractor reserves the right to inspect, at all times, any materials, equipment, instruments
or test during coating work. Authorized representative inspection designated by the
Contractor may be assigned to the coating Applicator mill during qualification and
production activities.
3.7.2 Bare pipes preliminary inspection
At the reception, coating Applicator shall ascertain that:

All bare pipes shall be accompanied by the specific documentation (e.g. material certificates,
packing list, delivery notes, etc.);

All bare pipes are correctly identified. Coating Applicator shall record the pipe number, the
heat number and any other identification marking for each pipe and check that it tallies with
the packing list and delivery notes;

All received bare pipes have no critical damages that cannot be immediately repaired. These
defects shall be marked “defective steel” and coating Applicator shall promptly advice
Contractor for his disposition.

Marking of 20” line pipe reference for the qualification tests (paragraph 3.7.4) shall clearly
indicate “FOR COATING QUALIFICATION TESTS”, to permit coating Applicator a right
and prompt identification of the reference pipe.
Any discrepancies which cannot be resolved immediately, shall be brought to the attention of the
Contractor for his decision.
3.7.3 Coating raw material control
Coating raw material dispatched to the coating Applicator shall be verified. Each material lot shall
be provided with test certificates and coating Applicator shall check that the raw materials meet
the minimum requirements of this specification (paragraphs 3.3.1, 3.3.2, 3.3.3).
Materials that do not meet the requirements of this specification shall be rejected.
Item
Property
1
1.1
Bare pipe condition
1.2
Pipe traceability control
2
2.1
Delivered packing condition
2.2
Epoxy powder properties
2.3
Polymeric adhesive properties
2.4
PE properties
2.5
Abrasive properties (shape, size)
including conductivity
Test method /
Acceptance criteria
Reference code
Pipe receipt inspection
No bevel damage, dents,
gouges, contaminants, flat
Visual check
ends. Presence of pipe
marking (*)
According to received
Visual check
packing list
Coating raw material inspection
Visual examination
No visible damage
Batch certificate /
Manufacturer
Table 3.1
historical data
Batch certificate /
Manufacturer certified
Table 3.2
test report
Batch certificate /
Manufacturer certified
Table 3.3
test report
Batch certificate / EN
Max conductivity
ISO 11124/
150 µS/cm
ASTM D4940
Frequency
Each pipe
Each pipe
Each delivery
Every batch
Every batch
Every batch
Each batch
NOTE
(*) Marking of 20” line pipe reference for qualification tests shall also indicate “FOR COATING QUALIFICATION
TESTS”.
Table 3.4 – Inspection activities at receipt of bare pipes and coating raw materials.
3.7.4 Coating qualification tests
Before coating production, the coating application procedures shall be qualified by coating
Applicator and approved by Contractor by means of dedicated tests and inspections listed in Table
3.5.
Item
Property
3
3.1
Test method /
Reference code
Applied coating qualification test
Degree of cure of cured epoxy film
EN ISO 21809-1,
Annex D
Acceptance criteria
-3 ≤ ∆Tg ≤ + 3
and as per Manufacturer
specification
Peel strength test
3.2.1
@ 25 °C
3.2
EN ISO 21809-1,
Annex C
3.2.2
@ 60 °C (Top,max)
3.3
Impact strength test @ 25 °C
3.4
Indentation test @ 25 °C
3.5
Cathodic disbondment @ 60 °C, 24 h,
-3.5 V
3.6
Flexibility test
EN ISO 21809-1,
Annex E
EN ISO 21809-1,
Annex F
EN ISO 21809-1,
Annex H
EN ISO 21809-1,
Annex I
≥ 18 N/mm
No disbonding between
steel and FBE
≥ 5 N/mm
No disbonding between
steel and FBE
> 7 J/mm
No holidays @ max 25 kV
≤ 0.20 mm
Radius ≤ 4 mm
No cracking at angle of 2°
per diameter length
Table 3.5 – Qualification tests for 3LPE coating.
20” pipe (thickness 44.45 mm) has been selected as the representative pipe for the coating
qualification tests. Since all the coated pipes shall be used for the field installation, Contractor
shall consider to provide coating Applicator with appropriate 20” line pipe spare length to be used
for the qualification tests. Prior to the delivery of bare pipes at coating Applicator mill, Contractor
shall take care that the marking of the 20” reference line pipe is completed with “FOR
QUALIFICATION TESTS” sentence.
Coating Applicator, after completion of surface preparation (paragraph 3.4) and coating
application (paragraph 3.5), shall cold cut a length of 20” pipe to provide:

sufficient space for the proper execution of peel test, impact test and coating repairs,

the required number of samples (minimum 3) for cathodic disbondment test and indentation
test.
Cutback of the remain 20” line pipe shall be properly restored to comply with the requirements of
paragraph 3.5.4.
Coating Applicator shall sustain all costs associated with the coating qualification. Coating
Applicator shall submit to Contractor the qualification documentation.
3.7.5 Coating production test
Coating Applicator shall perform during coating production the inspection and test specified in
Table 3.6.
Item
Property
4
Environment conditions
4.1.1
Relative humidity
4.1
4.1.2
Ambient temperature
4.1.3
Steel temperature
Test method /
Acceptance criteria
Reference code
Surface preparation
Dew point meter
≤ 85%
Thermometer
> 5 °C
Once every
shift and
every 2 hours
Digital contact
thermometer
Visual
inspection
≥ 3 °C above air dew point
Each pipe
4.2
Surface condition before blasting
4.3
Pipe pre-heating before blasting
Propane torches
4.4
Compressed air cleanliness
Abrasive blast cleaning
4.5.1
Anchor profile
4.5.2
Surface cleanliness grade
ASTM D4285
EN ISO 8504-2
EN ISO 8503-5
EN ISO 8501-1
Cleaning of blasted surface
Compressed air
4.5
4.6
Free from contamination and
defects
Surface temperature
up to max 50 °C
No residual moisture
Dry and free from oil, grease
Each pipe
Max rating: 2
4.8
Salt contamination test
EN ISO 8502-9
≤ 20 mg/m2
4.9
Surface condition prior to
introduction to coating line
Free from contamination, flash
rust, dent, oxides, scales,
laminations, gouges
235°C ÷ 260 °C or
Pre-heating pipe temperature before
Optical
within Manufacturer specification.
coating
pyrometer
No steel oxidation
Inspection and tests of applied 3LPE coating
Black, uniform, homogeneous.
External appearance of coating,
Visual
No wrinkle, cut, air blister,
after water cooling
inspection
swelling, thickening, air blister and
tear
Thickness measurement
5.2.1
FBE
5.2.2
Adhesive
5.2.3
Total coating
Visual
inspection
125 ÷ 150 µm
EN ISO 2808
5.2
150 ÷ 250 µm
Ultrasonic
thickness
Every start up
Removal of residual debris
EN ISO 8502-3
5.1
Each pipe
Each pipe
Dust contamination test
5
Each pipe
50 µm ≤ Rz ≤ 100 µm
Grade Sa 2.5
4.7
4.10
Frequency
Min. 2.9 mm
12 single readings
EN ISO 21809-1, Annex A
Once every 3
pipes, at least
once every
pipe diameter
Once every 3
pipes, at least
once every
pipe diameter
Each pipe
Each pipe
Each pipe
Once every
pipe diameter
Once every
pipe diameter
Once every
pipe diameter
Item
Property
5.3
Check of coated pipe temperature
5.4
Cutback control
5.5
Test method /
Reference code
Digital contact
thermometer
Tape reading
100% coating continuity
EN ISO 21809-1,
Annex B
Acceptance criteria
Frequency
≤ 60 °C
Each pipe
150 mm
paragraph 3.5.4
Each pipe
No holidays @ max. 25 kV
Once every 3
pipes, at least
once every pipe
diameter
Table 3.6 – Production tests for 3LPE coating.
3.8
Marking of coated pipes
Coating Applicator shall maintain complete traceability of pipe identification markings throughout
the coating process. Immediately after the applied coating is fully shrunk, Coating Applicator shall
restore the identification markings previously removed. Pipe identification markings shall be
applied to the coated pipe using a method approved by Contractor.
3.9
QA/QC
Coating Applicator shall submit for Contractor approval Inspection Test Plan (ITP) based on the
minimum requirements of this specification.
ITP shall cover minimum verifications, checks and tests required to ensure compliance with codes,
specifications and/or contractual requirements and specify all phases witnessed by coating
Applicator and Contractor relevant certification to be provided.
Contractor reserves the right to increase the level or frequency of quality control activities or
request the coating Applicator to revise his working practices, as necessary. The extent of Factory
Acceptance Test shall be agreed prior to the award of any order.
Coating Applicator shall obtain from coating Supplier all material, quality control documentation
and material test certificates for each batch consignment, confirming compliance with this
specification and coating Supplier procedure. Coating Applicator shall be responsible for verifying
the certificates against batch delivered at its goods inward inspection site and of recording batch
number of all materials.
Coating Supplier shall advice its proposed material traceability system (EN 10204 type 2.2) by
which materials are assured to be fit-for-purpose and identified throughout the coating process.
Only original certificates or copies verified by the Contractor representative, a recognized
independent third party or QA department representative of Supplier operating an accredited ISO
9001 Management System shall be accepted.
3.9.1 Inspection data sheet (IDS)
Coating Applicator shall prepare and provide Inspection and Test Plan (ITP) according to the
following Inspection Data Sheet (IDS):
INVOLVED PARTIES
CA Coating Applicator
C Contractor
P
Company/Principal
TPA Third Party Inspection
Agency
CODES OF INTERVENTION
H -100% WITNESSED (HOLD POINT).
Coating Applicator cannot proceed without the presence of
designed Inspector. Advance notification is mandatory.
W - WITNESSING NOT MANDATORY
Coating Applicator may proceed even if designed Inspector
did not witness the test. Advance notification is mandatory
R - REVIEW OF DOCUMENTS / CERTIFICATES
C - ACTIVITY / TEST EXECUTED AND CERTIFICATES ISSUED
D - DOCUMENT ONLY
M - MONITORING
GENERAL NOTES:
1.
2.
This Inspection Data sheet shall be used as a basis for the coating Applicator Inspection and Test Plan document (ITP) that shall
be defined and agreed by all parties during the post-order phase. The ITP shall contain also a column for “Applicable Specification
/ Code” and one for “Acceptance Criteria” for all inspection activities.
Inspection activities will be performed according to approved ITP.
Point N°
DESCRIPTION OF INSPECTIONS AND TESTS
PARTIES
CA
C
3LPE COATING
ACTIVITIES TO BE PERFORMED BEFORE THE
INSPECTION AND TEST STAGE
1
Review and approval of ITP
D
H
2
Review and approval of coating application procedures
D
R
RAW MATERIALS AND BARE PIPES – PRELIMINARY
INSPECTION
3
Check of the received bare pipes conditions and traceability
(as per Table 3.4 of the specification)
D
R
4
Check of the chemical, physical and mechanical properties of the coating raw
materials (as per Tables 3.1, 3.2, 3.3 of the specification)
D
R
5
Check of abrasive size, cleanliness, conductivity
C
R
LINE PIPE COATING – QUALIFICATION TESTS
6
Check of surface preparation (as per Items from 4.1 to 4.10 of Table 3.6 of the
specification)
C
R
7
3LPE qualification tests (as per Table 3.5 of the specification)
C
W
8
Coating repair (as per paragraph 3.6 of the specification)
C
W
LINE PIPE COATING - PRODUCTION TESTS
9
Check of surface preparation (as per Items from 4.1 to 4.10 of Table 3.6 of the
specification)
C
R
10
3LPE production tests
(as per Items from 5.1 to 5.5 of Table 3.6 of the specification)
C
W
P
NOTES
TPA
Point N°
DESCRIPTION OF INSPECTIONS AND TESTS
PARTIES
CA
C
P
NOTES
TPA
FINAL INSPECTION CERTIFICATION
11
Non conformity list / Certificates check
D
R
12
Certification of compliance with specification, data sheets and code
requirements
C
R
13
Preparation of the Manufacturing Record Book (MRB)
D
R
14
Packing inspection, marking and packing list check
C
H
3.10 Documentation and reporting
Coating Applicator shall submit to Contractor the documentation listed below. The documentation
shall be made available for review upon request by Contractor.
COATING APPLICATOR DOCUMENTATION
WITH BID
Item
DESCRIPTION
POST ORDER
For review/approval
Copies no.
Copies no.
Weeks no. after
order date
1D
1
1D
1
1D
1D
Final
Copies no.
Weeks no. before
delivery
1
3P + 1D
(Note 3)
2
2
3P + 1D
(Note 3)
2
1
Production Schedule
1D
2
Deviation List
1D
3
Vendor Document Register (VDR)
4
Inspection Test Plan
5
Coating application procedure
6
Coating material certificates (including
applicable material safety data sheet)
3P + 1D
(Note 3)
2
7
Inspection and Test Reports
3P + 1D
(Note 3)
2
8
Manufacturing Record Book (MRB)
3P + 1D
(Note 3)
2 (Note 1)
1D (Note 2)
1D
3
TYPE OF SUPPORT
P - Paper print D – PDF file or CD Rom
NOTE
1)
2)
3)
One copy shall be delivered with the material package.
To be supplied a preliminary ITP during BID.
Included in the MRB
3.11 Storage, handling and transportation management
During and after coating activities, coating Applicator shall handle and store all coated pipes using
procedures that prevent damage to the coating and pipe ends. All coating damage shall be inspected
and repaired according to approved procedure.
Coated pipes shall be carefully lifted using pipe end hooks or sufficiently wide straps such as nonabrasive canvas or leather belts. All skids used to support coated pipe shall be padded. The use of
tongs, bare pinchers, chain slings, rope slings without canvas or composition belt-slings with
protruding rivets, pipe hooks without proper padding or any other handling equipment likely to be
injurious to the coating shall not be permitted.
Coated pipes shall be carefully stacked using sufficient spacers and padding to prevent damage.
For pipe with diameter larger than 12”, staking during storage should be limited to a maximum of
3 tiers. Walking on the pipe shall not be allowed.
Coating Applicator shall provide proper shipment/transportation procedure specification with the
minimum requirement for safety operation and to avoid damages to the coated pipes.
4
APPENDIX 3 - COLD TAPE WRAPPING (CTW) COATING FOR APPLICATION
AT SHOP
4.1
General
Appendix 3 covers minimum requirements for the materials, application, testing and supply of
Cold Tape Wrapping (CTW) system to be applied at coating Applicator factory/shop on pipes.
CTW system shall be multicoat tape consisted of liquid adhesive (primer), inner-wrap tape and
outer-wrap tape. CTW materials shall be:

compatible each other and provided from the same coating Supplier;

suitable to show excellent properties at maximum operative temperature;

capable of protecting the piping for at least 25 years.
4.2
Process input data

Service fluid: crude oil / water injection / chemicals;

Maximum operative temperature: 78°C;

Design temperature: - 5 / 90 °C;

Application: buried pipes.
4.3
Coating raw material requirements
4.3.1 Liquid adhesive (Primer)
Liquid adhesive shall fulfill the following minimum requirements:

Applicable without heat;

It shall produce an effective, continuous and stable bond between the steel surface and the
subsequently inner-wrap tape;

It shall comply with pollution-control requirements applicable for the area of use;

In case of settling in the container, liquid adhesive shall not form a cake that cannot be mixed
easily by hand stirring or agitation;

Suitable for spray or brush application;

Minimum tendency to produce bubbles during application.
4.3.2 Inner-wrap tape
Inner-wrap tape shall satisfy the following minimum requirements:

It shall be a two-layered composition consisting of Polyethylene (PE) backing layer and a
butyl-based adhesive layer;

Proven Ultraviolet (UV) resistance;

High electrical resistivity, resistance to corrosive environments, low moisture absorption and
permeability;

Able to ensure an effective bond to the primed steel surface;

Sufficiently pliable so as to conform to the surface to be coated;

Able to withstand, without tearing, the tensile force necessary to obtain a tightly wrapped
coating;

It shall be provided in a standard widths and standard lengths.
Property
Elongation
Tensile strength
Water vapor
transmission rate
Dielectric strength
Volume resistivity
Test method /
Reference code
ASTM D1000
ASTM D1000
min. 150 %
min. 45 N/10 mm width
ASTM F1249
max. 0.03 g/ 24 h / 100 cm2
ASTM D149
ASTM D257
min. 20 kV
min 1015 Ω∙cm
Requirements
Table 4.1 – Minimum requirements for inner-wrap tape @ 25 °C.
4.3.3 Outer-wrap tape
Outer-wrap tape shall satisfy the following minimum requirements:

It shall be a two-layer composition consisting of a PE backing layer and a butyl-based
adhesive layer;

Good mechanical and storage protection to the inner-wrap tape,

It shall contribute to the overall long-term corrosion protection properties of the total coating
system;

Compatible with the inner-wrap tape.
Property
Elongation
Tensile strength
Water vapor
transmission rate
Dielectric strength
Volume resistivity
Test method /
Reference code
ASTM D1000
ASTM D1000
min. 350 %
min. 70 N/10 mm width
ASTM F1249
max. 0.03 g/ 24 h / 100 cm2
ASTM D149
ASTM D257
min. 22 kV
min. 1015 Ω∙cm
Requirements
Table 4.2 – Minimum requirements for outer-wrap tape @ 25 °C.
4.4
Handling and storage of coating raw materials
Coating Applicator shall properly store CTW materials to prevent damage and deterioration, in a
clean, dry and covered warehouse whose temperature does not exceed 50 °C. Stacking, shelving
and storage procedures for all containing materials shall be as recommended by the coating
Supplier.
Containers, tape rolls or individual repair rolls removed from the storage pallets shall not be
dropped, rolled or thrown in any manner so as to prevent any damage to the coating materials.
Cartons or tape rolls shall not be handled with hooks, ropes, cables or any other mechanical devices
that could cause damage to the coating materials.
4.5
Surface preparation
Coating Applicator shall perform surface preparation in accordance with the requirements of this
specification and the coating Supplier recommendations. The sequence of minimum surface
preparation activities has been below specified:
4.5.1 Limitations
Coating work shall not take place if the following plant conditions occur:

when the ambient temperature is below 5 °C;

when the relative humidity is above 85%;

when steel surface temperature is less than 3 °C above the ambient dew point.
It is coating Applicator responsibility to check and record the above-mentioned conditions and
ensure that coating activities are performed when the parameters are in the specified range of
values.
4.5.2 Pre-cleaning
The bare pipe surface shall be free from mud, mill scale, mill lacquer, coal tar, asphalt, oil, wax,
grease or any foreign material (e.g. temporary protective paint or markings). These contaminants
shall be removed by using appropriate detergent, water rinsing and, for heavy contamination, wire
brush or power water cleaning (< 130 bar). The water used shall be potable quality. If solvent
cleaning (SSPC-SP 1) is necessary, only solvents meeting health and safety regulations and that
do not leave an oily residue shall be used.
4.5.3 Visual inspection
Any limited imperfections on pipe surface such as scabs, slivers, burrs and weld spatter shall be
identified and removed where possible by slight filing or grinding.
4.5.4 Pre-heating
Pipe surface shall be uniformly heated with suitable tools (i.e. propane torches) to remove moisture
and prevent its condensation on pipe after blast cleaning.
4.5.5 Abrasive blast cleaning
Prior to blast cleaning, the pipe ends shall be fitted with plugs so as to prevent entry of abrasive
into the pipe during the cleaning operation.
Blast cleaning shall be performed according to EN ISO 8504-2. Pipe surface shall be abrasive grit
blast cleaned to grade Sa 2.5 EN ISO 8501-1 corresponding to near-white metal finish SSPC SP10. The surface anchor profile shall be in the range of 50 ÷ 76 µm from peak to valley. Surface
profile shall be measured in accordance with EN ISO 8503-5.
Blasting and other dust producing areas shall be kept separate from coating application areas.
Abrasive grit and compressed air of blasting machine shall be dry, free from oil, grease and any
other contaminants. Sand and silica abrasive are not permitted. Particle hardness and size
distribution of the blasting medium shall be continually controlled by screening and shall be such
to obtain the required surface profile of 50 ÷ 76 µm. When recovered/recycled metallic grit systems
are used, a stabilised working mix of blast cleaning material shall be established and maintained
throughout the entire course of the production by frequent small additions from fresh clean stock
at a rate sufficient to replenish consumption. Coating Applicator shall regularly sample recycled
grit to ensure the absence of contamination.
Abrasives shall be stored in dry conditions and shall remain dry during usage. Maximum abrasive
conductivity shall be 150 µS/cm, measured according to ASTM D 4940. If required, coating
Applicator shall provide a chemical analysis report to the Contractor for every batch of utilized
abrasive, to verify the compliance with the conductivity requirement.
4.5.6 Final cleaning and inspection prior to coating application
After blast cleaning and before CTW application, coating Applicator shall carry out the following
tests/controls:

Any traces of foreign contaminants on the blast cleaned surface (e.g. dirt, dust, metal
particles, hydrocarbons, water, sulphates) shall be removed using dry and clean compressed
air;

Dust contamination test (EN ISO 8502-3): maximum residual dust rating shall be class 2;

Salt contamination test (EN ISO 8502-6): maximum residual chloride content, measured
according to EN ISO 8502-9, shall be less than 20 mg/m2;

Check of flash rusting on steel: if flash rusting occurs, steel surfaces must be blasted again
as per paragraph 4.5.5;

Check of “critical” defects: oxides, scales, laminations, gouges, sharp edges, dents, drops,
flame cuts or any other foreign material made visible by blast cleaning are considered as
“defective steel” and shall be marked using French chalk. Coating Applicator shall promptly
advice the Contractor who shall determine whether the defects can be removed by
mechanical techniques, i.e. filing or grinding according to the requirement of EN ISO 85013 grade P3. Coating Applicator shall be responsible for grinding operation. No steel surface
“critical” defects shall be grinded without the approval of the Contractor. After grinding, any
area larger than 50 mm in diameter shall be re-blasted for restoring the required anchor
pattern. Grinding shall not reduce the wall thickness below the required thickness. Item with
wall thickness below the required shall be rejected;

Time span between the blast cleaning and the coating operation shall be kept to a minimum.
Any pipes that cannot be coated within 3 hours after cleaning or showing any deterioration
to the required surface cleanliness Sa 2½ shall be completely re-blasted before applying the
coating.
4.5.7 Surface preparation of Stainless Steel (SS)
Coating Supplier guidelines and recommendations shall be followed for the surface preparation of
Stainless Steel (SS) pipes.
As a minimum, SS surface shall be thoroughly degreased using an appropriate emulsion cleaner
and abrasive cleaned (sweep blasting) to create sufficient anchor profile (50 ≤ Rz ≤ 76 µm, as per
standard ref [44], or as recommended by coating Supplier). Abrasive for blast cleaning of SS
surfaces shall be performed with a suitable non-metallic abrasive such as Aluminium oxide. When
hand or power tool cleaning is required on stainless steel, only SS wire brushes that have not been
previously used on carbon steel surface may be used. All coatings and solvents for use on SS shall
be free from substances such as chlorides and other halides, sulfur, and shall be free from low
melting point metals (Zinc, Aluminium, Tin and Lead).
4.6
CTW application
CTW materials shall be applied strictly in accordance with this specification and the applicable
guidelines of the coating Supplier. Hand application of tape is not permitted. Any deviation from
the approved procedure shall be submitted by coating Applicator for Contractor approval.
4.6.1 Liquid adhesive (primer) application
Liquid adhesive shall be applied with spray in a uniform and continuous film.
The liquid adhesive coverage and curing/drying time shall be sufficient to ensure an effective bond
between the steel substrate and the subsequent tape layer.
The measured dry film thickness (DFT) shall be 60 ÷ 80 µm. Continuous mixing of the liquid
adhesive shall be kept during the application in order to prevent any settling. The liquid adhesive
shall dry in accordance with the coating Supplier guideline.
Liquid adhesive application shall be limited to the amount of surface area that can be wrapped
during the same workday; otherwise, the steel must be re-blasted and primed.
Before the inner-layer application, liquid adhesive coat shall be “dry-to-touch” and free from runs,
sags, drips, bare spots or any foreign substances such as sand, grease, oil, grit, rust particles or dirt.
4.6.2 Application of inner-wrap
The inner-layer tape shall be spirally applied at a minimum temperature of 21 °C, onto the liquid
adhesive coated surface by means of mechanical constant-tension coating equipment. Tape
wrapping machine and application tensions shall be as recommended by the coating Supplier.
Moreover, the following minimum requirements shall be fulfilled during the application:
1. The minimum spiral overlap width shall be 25 mm and maximum 50% of roll width,
2. The end of the spiral wrap shall be cut on the downside at 3 or 9 o’clock position on the pipe,
3. When a new roll of tape is started, the ends shall be overlapped at least 150 mm (measured
circumferentially). The overlap shall be smooth and it shall be positioned to ensure the
continuity of the inner-layer coating.
Maximum contact of the tape with the primed surface shall be ensured: hard-rubber roller, wider
than the width of the tape, or similar tool can be used for this purpose.
4.6.3 Application of outer-wrap
The outer-layer tape shall be applied at a minimum temperature of 21 °C, over the inner-layer tape
with the same type of mechanical equipment used for the inner-layer tape. The overlap of the
outer-layer tape shall not coincide with the overlap of the inner-layer tape.
The same requirements of paragraph 4.6.2 points 1, 2 and 3shall be satisfied during the outer-wrap
tape application.
4.6.4 Cutback
CTW application shall stop 150 mm from the ends of the pipe. The bare pipe shall be cleaned and
shop primed to the end of the pipe to prevent rusting during storage or field installation. If it is not
possible to stop at 150 mm from the ends of the pipe, then the pipe shall be totally covered with
tape. The tape shall be removed from both ends before joining. Cutback length shall be 150 mm
from the ends of pipe.
4.7
Coating repair
Coating Applicator shall issue a detailed coating repair procedure for Contractor approval. Coating
repairs shall be performed in accordance with coating Supplier guidelines and using coating
Supplier recommended repair materials. Coating repair procedure shall include as minimum the
following actions:

Peeling back and removal of the tape layers from the affected area;

Cleaning the faulty area by clean and dry compressed air and by brush;

Brush application of approved liquid adhesive;

Wrapping around the pipe of approved patch of tape covering a minimum of 100 mm around
the affected area or application of a patch of tape as specified by coating Supplier repair
guidelines;

Holiday detection of the repaired area.
All inspection following repairs shall be documented and shall include the repair and re-test details.
The coating repair procedure proposed by the coating Applicator and approved by Contractor shall
be verified during qualification tests, through visual inspection and the use of holiday detection on
the repairs of artificial defects made on the coating.
4.8
Inspection and test
Inspection and test activities shall be performed during the following phases:
1. At every receipt of bare pipes and coating raw materials (paragraphs 4.8.2, 4.8.3);
2. During CTW system qualification (paragraph 4.8.4);
3. During CTW system application (paragraph 4.8.5).
4.8.1 General requirements

Coating Applicator shall provide documentation by recording on daily work sheets the tests
performed and the relevant results.

Application, inspection and tests of CTW system shall be efficiently carried out by coating
Applicator in accordance with the requirements of this specification. All main coating
application parameters set up by coating Applicator shall be recorded and shall not be
modified unless otherwise approved in writing by Contractor.

At his discretion, coating Applicator can propose the Contractor a list of the additional tests
he considers necessary to be performed on coating materials. Contractor reserves the right to
approve the execution of the proposed additional tests.

All the instruments used for checks and tests during the coating process shall be calibrated
regularly and whenever doubts arise on their reliability. As a general rule, the instruments
that are more frequently used should be calibrated at the start of each shift while other
instruments should be calibrated just before they are used. Coating Applicator shall submit
the calibration procedures for all instruments utilized for tests and checks. The said
procedures shall be put at the personnel and Contractor disposal.

Contractor reserves the right to inspect, at all times, any materials, equipment, instruments
or test during coating work. Authorized representative inspection designated by the
Contractor shall be assigned to the coating Applicator mill during qualification and
production activities.

When an inspection is required, coating Applicator shall give Contractor representative
inspector reasonable notice of the time at which the application or tests are to be made. All
coating work not done in presence of the inspector shall be subject to rejection. If any time
it is found that procedure of applying the CTW system is not according to this specification
and approved procedure, all the coating work shall be rejected.
4.8.2 Bare pipes preliminary inspection
At the reception, coating Applicator shall ascertain that:

All bare pipes shall be accompanied by the specific documentation (e.g. material certificates,
packing list, delivery notes, etc.);

All bare pipes are correctly identified. Coating Applicator shall record the pipe number, the
heat number and any other identification marking for each pipe and check that it tallies with
the packing list and delivery notes;

All received bare pipes have no critical damages that cannot be immediately repaired. These
defects shall be marked “defective steel” and coating Applicator shall promptly advice
Contractor for his disposition.

Marking of 2” and 6” pipe reference for the qualification tests (paragraph 4.8.4 and 4.8.4.1)
shall clearly indicate “FOR COATING QUALIFICATION TESTS”, to permit coating
Applicator a right and prompt identification of the reference line pipe.
Any discrepancies which cannot be resolved immediately, shall be brought to the attention of the
Contractor for his decision.
4.8.3 CTW materials control
CTW materials shall be provided with relevant product data sheets and/or coating Supplier
certified test reports. Properties of CTW materials listed in paragraph 4.3.2 and paragraph 4.3.3
shall be verified with relevant product data sheets/certificates.
Materials that do not meet the requirements of this specification shall be rejected.
Item
Property
1
1.1
Bare pipe condition
1.2
Pipe traceability control
2
2.1
Delivered packing condition
2.2
Inner-wrap properties
2.3
Outer-wrap properties
2.4
Abrasive properties (shape,
size) including conductivity
Test method / Reference
Acceptance criteria
code
Pipe receipt inspection
No bevel damage, dents,
gouges, contaminants,
Visual check
flat ends. Presence of
pipe marking (*)
According to received
Visual check
packing list
Coating raw materials inspection
Visual examination
No visible damage
Coating Supplier certified test
paragraph 4.3.2
report / product data sheet
Coating Supplier certified test
paragraph 4.3.3
report / product data sheet
Batch certificate / EN ISO
11124 (metallic abrasive) / EN
Max conductivity
ISO 11126 (non-metallic
150 µS/cm
abrasive) /
ASTM D4940
Frequency
Each pipe
Each pipe
Each delivery
Every batch
Every batch
Each batch
NOTE
(*) Marking of 6” line pipe reference for qualification tests shall also indicate “FOR COATING QUALIFICATION
TESTS”.
Table 4.3 – Inspection activities at receipt of bare pipes and coating raw materials.
4.8.4 CTW coating qualification tests
Before coating production, coating application procedures shall be qualified by coating Applicator
and approved by Contractor by means of dedicated tests and inspections listed in Table 4.4.
Item
3
3.1
3.2
3.3
3.4
Property
Peel strength test to pipe surface
3.1.1
@ 25 °C
3.1.2
@ 80 °C
Peel strength test inner to inner +
outer to inner
3.2.1
@ 25 °C
3.2.2
@ 80 °C
Peel strength test outer to outer
3.3.1
@ 25 °C
3.3.1
@ 80 °C
Impact resistance test @ 25 °C
Test method / Reference code
Applied coating qualification test
Acceptance criteria
EN 12068, Annex C
≥ 10 N/10 mm width
≥ 1 N/10 mm width
EN 12068, Annex B
≥ 15 N/10 mm width
≥ 2 N/10 mm width
EN 12068, Annex B
EN 12068, Annex H / ASTM
G14
≥ 2 N/10 mm width
≥ 2 N/10 mm width
≥ 15 J
No holidays @ max 12 kV
Indentation test
3.5
3.6
3.5.1
@ 25 °C
3.5.2
@ 80 °C
Cathodic disbondment @ 80 °C,
48 h
4
4.1
EN 12068, Annex G /
ASTM G17
Coating repair
EN 12068, Annex K /
ASTM G42
Coating Repairs
As per coating Applicator
approved procedure /
paragraph 4.7
Res. thickness ≥ 0.6 mm
No holidays
Res. thickness ≥ 0.6 mm
No holidays
≤ 15 mm
No holidays @ max 12 kV
Table 4.4 – Qualification tests for CTW coating.
6” pipe (thickness 18.26 mm) has been selected as the representative pipe for the CTW coating
qualification tests. Moreover, Coating Applicator shall specify the necessary pipe length for the
execution of these tests (Ref. Table 4.4).
Since all the coated pipes shall be used for the field installation, Contractor shall provide coating
Applicator with specified 6” length of bare pipe to be used for the qualification tests. Prior to the
delivery of bare pipes at coating Applicator factory, Contractor shall take care that the marking of
the 6” reference pipe is completed with “FOR QUALIFICATION TESTS” sentence.
Coating Applicator, after completion of surface preparation (paragraph 4.5) and coating
application (paragraph 4.6), shall cold cut a length of 6” pipe to provide:

sufficient space for the proper execution of qualification tests listed in Table 4.4,

the required number of samples (minimum 3) for cathodic disbondment test and indentation
test.
Coating Applicator shall sustain all costs associated with the coating qualification. Coating
Applicator shall submit to Contractor the qualification documentation.
4.8.4.1 CTW coating qualification on stainless steel pipes
Coating Applicator to submit a proposal for qualification of CTW application on SS pipes
specifying the necessary pipe length for execution of these tests. Table 4.4 can be used as reference.
To be considered that cathodic disbondment Test shall not be performed on SS pipes.
Contractor shall provide coating Applicator with appropriate 2” pipe spare length to be used for
the qualification tests on SS pipes. Prior to the delivery of bare pipes at coating Applicator factory,
Contractor shall take care that the marking of the 2” reference pipe is completed with “FOR
QUALIFICATION TESTS” sentence.
4.8.5 CTW coating production tests
Coating Applicator shall perform, during CTW system application, the inspection and test
specified in Table 4.5.
If an unacceptable number of defects of the same kind on one pipe are recorded, coating Applicator
shall investigate the cause of the defect. If the Contractor deems that the number of defects is
excessive, then the whole production of that day shall be placed aside and shall be carefully
checked by the coating Applicator.
Item
Property
5
Environment conditions
5.1.1
Relative humidity
5.1
5.1.2
Ambient temperature
5.1.3
Steel temperature
Test method /
Acceptance criteria
Reference code
Surface preparation
Frequency
Dew point meter
≤ 85%
Thermometer
> 5 °C
Once every
shift and
every 3 hours
Digital contact
thermometer
Visual
inspection
≥ 3 °C above air dew point
Each pipe
Free from contamination and
defects
Each pipe
5.2
Surface condition before blasting
5.3
Pipe pre-heating before blasting
Propane torches
No residual moisture
Each pipe
5.4
Compressed air cleanliness
Abrasive blast cleaning
5.5.1
Anchor profile
5.5.2
Surface cleanliness grade
ASTM D4285
EN ISO 8504-2
EN ISO 8503-5
EN ISO 8501-1
Dry and free from oil, grease
Every start up
50 µm ≤ Rz ≤ 76 µm
Grade Sa 2.5
Each pipe
Cleaning of blasted surface
Compressed air
Removal of residual debris
Each pipe
5.5
5.6
5.7
Dust contamination test
EN ISO 8502-3
Max rating: 2
5.8
Salt contamination test
EN ISO 8502-9
≤ 20 mg/m2
5.9
Surface condition prior to
introduction to coating line
6
6.1
Free from contamination, flash
rust, dent, oxides, scales,
laminations, gouges
Inspection and tests of applied CTW coating
Visual
Solid, free from wrinkles, buckles,
External appearance of coating
inspection
tears, air blisters
Thickness measurement
6.2.1
Liquid adhesive
6.2.2
Inner-wrap
6.2.3
Outer-wrap
6.2.4
Total
Visual
inspection
ISO 2808
60 ÷ 80 µm (DFT)
min. 600 µm
6.2
ASTM D1000
min. 760 µm
min. 2 mm
Once every 4
pipes, at least
once every
pipe diameter
Once every 4
pipes, at least
once every
pipe diameter
Each pipe
Each pipe
Once every 4
pipes, at least
once every
pipe diameter
Once every 4
pipes, at least
once every
pipe diameter
Once every 4
pipes, at least
once every
pipe diameter
Once every 4
pipes, at least
once every
pipe diameter
Item
6.3
6.4
Property
Cutback control
100% coating continuity
Test method /
Reference code
Acceptance criteria
Frequency
Tape reading
150 mm
paragraph 4.6.4
Each pipe
No holidays @ max 12 kV
Once every 3
pipes, at least
once every pipe
diameter
NACE SP0274
Table 4.5 – Production tests for CTW coating.
4.8.5.1 Coating thickness
The coating thickness shall be measured at five equidistant locations along the length and four at
each quadrant around each coated pipe section of 12 m. Suitable coating thickness gauge shall be
used and it shall be calibrated at least once during each shift. All thickness measurements shall be
recorded.
4.9
QA/QC
Coating Applicator shall submit for Contractor approval Inspection Test Plan (ITP) based on the
minimum requirements of this specification.
ITP shall cover minimum verifications, checks and tests required to ensure compliance with codes,
specifications and/or contractual requirements and specify all phases witnessed by coating
Applicator and Contractor relevant certification to be provided.
Contractor reserves the right to increase the level or frequency of quality control activities or
request the coating Applicator to revise his working practices, as necessary. The extent of Factory
Acceptance Test shall be agreed prior to the award of any order.
Coating Applicator shall obtain from coating Supplier all material, quality control documentation
and material test certificates for each batch consignment, confirming compliance with this
specification and coating Supplier procedure. Coating Applicator shall be responsible for verifying
the certificates against batch delivered at its goods inward inspection site and of recording batch
number of all materials.
Coating Supplier shall advice its proposed material traceability system (EN 10204 type 2.2) by
which materials are assured to be fit-for-purpose and identified throughout the coating process.
Only original certificates or copies verified by the Contractor representative, a recognized
independent third party or QA department representative of Supplier operating an accredited ISO
9001 Management System shall be accepted.
4.9.1 Inspection data sheet (IDS)
Coating Applicator shall prepare and provide Inspection and Test Plan (ITP) according to the
following Inspection Data Sheet (IDS):
INVOLVED PARTIES
CA Coating Applicator
C Contractor
P
Company/Principal
TPA Third Party Inspection
Agency
CODES OF INTERVENTION
H -100% WITNESSED (HOLD POINT).
Coating Applicator cannot proceed without the presence of
designed Inspector. Advance notification is mandatory.
W - WITNESSING NOT MANDATORY
Coating Applicator may proceed even if designed Inspector
did not witness the test. Advance notification is mandatory
R - REVIEW OF DOCUMENTS / CERTIFICATES
C - ACTIVITY / TEST EXECUTED AND CERTIFICATES ISSUED
D - DOCUMENT ONLY
M - MONITORING
GENERAL NOTES:
1.
2.
This Inspection Data sheet shall be used as a basis for the coating Applicator Inspection and Test Plan document (ITP) that shall
be defined and agreed by all parties during the post-order phase. The ITP shall contain also a column for “Applicable
Specification / Code” and one for “Acceptance Criteria” for all inspection activities.
Inspection activities will be performed according to approved ITP.
Point N°
DESCRIPTION OF INSPECTIONS AND TESTS
PARTIES
CA
C
CTW COATING
ACTIVITIES TO BE PERFORMED BEFORE THE
INSPECTION AND TEST STAGE
1
Review and approval of ITP
D
H
2
Review and approval of coating application procedures
D
R
RAW MATERIALS AND BARE PIPES – PRELIMINARY
INSPECTION
3
Check of the received bare pipes conditions and traceability
(as per Table 4.3 of the specification)
D
R
4
Check of the chemical, physical and mechanical properties of the coating raw
materials (as per Tables 4.1, 4.2 of the specification)
D
R
5
Check of abrasive size, cleanliness, conductivity
C
R
LINE PIPE COATING – QUALIFICATION TESTS
6
Check of surface preparation (as per Items from 5.1 to 5.9 of Table 4.5 of the
specification)
C
R
7
CTW coating qualification tests (as per Table 4.4 of the specification)
C
W
8
Coating repair (as per paragraph 4.7 of the specification)
C
W
LINE PIPE COATING - PRODUCTION TESTS
9
Check of surface preparation (as per Items from 5.1 to 5.9 of Table 4.5 of the
specification)
C
R
10
CTW coating production tests
(as per Items from 6.1 to 6.4 of Table 4.5 of the specification)
C
W
P
NOTES
TPA
Point N°
DESCRIPTION OF INSPECTIONS AND TESTS
PARTIES
CA
C
P
NOTES
TPA
FINAL INSPECTION CERTIFICATION
11
Non conformity list / Certificates check
D
R
12
Certification of compliance with specification, data sheets and code
requirements
C
R
13
Preparation of the Manufacturing Record Book (MRB)
D
R
14
Packing inspection, marking and packing list check
C
H
4.10 Documentation and reporting
Coating Applicator shall submit to Contractor the documentation listed below. The documentation
shall be made available for review upon request by Contractor.
COATING APPLICATOR DOCUMENTATION
POST ORDER
WITH BID
Item
For review/approval
DESCRIPTION
Copies no.
Copies no.
Weeks no. after
order date
1D
1
1D
1
1D
1D
Final
Copies no.
Weeks no. before
delivery
1
3P + 1D
(Note 3)
2
2
3P + 1D
(Note 3)
2
1
Production Schedule
1D
2
Deviation List
1D
3
Vendor Document Register (VDR)
4
Inspection Test Plan
5
Coating application procedure
6
Coating material certificates (including
applicable material safety data sheet)
3P + 1D
(Note 3)
2
7
Inspection and Test Reports
3P + 1D
(Note 3)
2
8
Manufacturing Record Book (MRB)
3P + 1D
(Note 3)
2 (Note 1)
1D (Note 2)
1D
3
TYPE OF SUPPORT
P - Paper print D – PDF file or CD Rom
NOTE
1)
2)
3)
One copy shall be delivered with the material package.
To be supplied a preliminary ITP during BID.
Included in the MRB
4.11 Storage, handling and transportation management
During and after coating activities, coating Applicator shall handle and store all coated pipes using
procedures that prevent damage to the coating and pipe ends. All coating damage shall be inspected
and repaired according to approved procedure.
Coated pipes shall be carefully lifted using pipe end hooks or sufficiently wide straps such as nonabrasive canvas or leather belts. All skids used to support coated pipe shall be padded. The use of
tongs, bare pinchers, chain slings, rope slings without canvas or composition belt-slings with
protruding rivets, pipe hooks without proper padding or any other handling equipment likely to be
injurious to the coating shall not be permitted.
Coated pipes shall be carefully stacked using sufficient spacers and padding to prevent damage.
For pipe with diameter larger than 12”, staking during storage should be limited to a maximum of
3 tiers. Walking on the pipe shall not be allowed.
Coating Applicator shall provide proper shipment/transportation procedure specification with the
minimum requirement for safety operation and to avoid damages to the coated pipes.
APPENDIX 4 – COLD TAPE WRAPPING (CTW) COATING FOR APPLICATION
AT SITE
5
5.1
General
Appendix 4 covers minimum requirements for the materials, application, testing and supply of
Cold Tape Wrapping (CTW) system to be applied at site on buried piping welded field joints
(FJC), on buried fittings and on piping Under Ground/Above Ground (UG/AG) transition zone.
CTW system shall be multicoat tape consisted of liquid adhesive (primer), inner-wrap tape and
outer-wrap tape.
CTW materials shall be:

compatible each other and provided from the same coating Supplier;

suitable to show excellent properties at maximum operative temperature of 80 °C;

capable of protecting the component to be wrapped for at least 25 years.
FJC CTW shall be compatible with and provide effective bond to the coating systems already
applied at shop on piping to be buried, in particular:

3LPE parent coating;

CTW parent coating.
For UG/AG transition piping, CTW shall be compatible with and provide effective bond to the
painting system applied on the external surface of AG piping. Painting systems to be taken into
account are described below:
Substrate
Uninsulated
CS
Uninsulated
SS
Maximum service
temperature
80 °C
80 °C
Painting cycle
Primer
80 µm of Zinc rich epoxy
Intermediate
100 µm of high build epoxy
Top coat
Total DFT
Primer
Top coat
Total DFT
60 µm of acrylic polyurethane
240 µm
75 µm of Zinc-free epoxy
50 µm of acrylic polyurethane
125 µm
5.2
Process input data

Service fluid: crude oil / water injection / chemicals;

Maximum service operative temperature: 78 °C;

Design temperature: - 5 / 90 °C;

Application: buried fittings, welding joints on buried pipes/fitting, AG/UG transition zone.
5.3
Coating raw material requirements
5.3.1 Liquid adhesive (Primer)
Liquid adhesive shall fulfill the following minimum requirements:

Applicable without heat;

It shall produce an effective, continuous and stable bond between the steel surface and the
subsequently inner-wrap tape;

It shall comply with pollution-control requirements applicable for the area of use;

In case of settling in the container, liquid adhesive shall not form a cake that cannot be mixed
easily by hand stirring or agitation;

Suitable for spray or brush application;

Minimum tendency to produce bubbles during application.
5.3.2 Inner-wrap tape
Inner-wrap tape shall satisfy the following minimum requirements:

It shall be a two-layered composition consisting of Polyethylene (PE) backing layer and a
butyl-based adhesive layer;

Proven Ultraviolet (UV) resistance;

High electrical resistivity, resistance to corrosive environments, low moisture absorption and
permeability;

Able to ensure an effective bond to the primed steel surface;

Sufficiently pliable so as to conform to the surface to be coated;

Able to withstand, without tearing, the tensile force necessary to obtain a tightly wrapped
coating;

It shall be provided in a standard widths and standard lengths.
Property
Elongation
Tensile strength
Water vapor
transmission rate
Dielectric strength
Volume resistivity
Test method / Reference code
ASTM D1000
ASTM D1000
Requirements
min. 150 %
min. 45 N/10 mm width
ASTM F1249
max. 0.03 g/ 24 h / 100 cm2
ASTM D149
ASTM D257
min. 20 kV
min 1015 Ω∙cm
Table 5.1 – Minimum requirements for inner-wrap tape @ 25 °C.
5.3.3 Outer-wrap tape
Outer-wrap tape shall satisfy the following minimum requirements:

It shall be a two-layer composition consisting of a PE backing layer and a butyl-based
adhesive layer;

Good mechanical and storage protection to the inner-wrap tape,

It shall contribute to the overall long-term corrosion protection properties of the total coating
system;

High UV resistance;

Compatible with the inner-wrap tape.
Property
Elongation
Tensile strength
Water vapor
transmission rate
Dielectric strength
Volume resistivity
Test method / Reference code
ASTM D1000
ASTM D1000
Requirements
min. 350 %
min. 70 N/10 mm width
ASTM F1249
max. 0.03 g/ 24 h / 100 cm2
ASTM D149
ASTM D257
min. 22 kV
min. 1015 Ω∙cm
Table 5.2 – Minimum requirements for outer-wrap tape @ 25 °C.
5.4
Handling and storage of received materials
As arrived on field, all coated pipe shall be handled with care and stored off the ground to avoid
coating damage. Coated items shall be hoisted using wide belt slings. Metal chains, cables, tongs,
or other equipment likely to cause damage to the coating shall not be permitted, nor will dragging
or skidding be permitted.
Inspection of the coating on the undersides of the coated pipes shall be allowed while they are
suspended from the slings. Any coating damage shall be repaired according to paragraph 5.7.
Contractor shall properly store the received coating materials to prevent damage and deterioration,
in a clean, dry and covered warehouse whose temperature does not exceed 50 °C. Stacking,
shelving and storage procedures for all containing materials shall be as recommended by the
coating Supplier. Containers, tape rolls or individual repair rolls removed from the storage pallets
shall not be dropped, rolled or thrown in any manner so as to prevent any damage to the coating
materials.
5.5
Surface preparation
Contractor shall perform surface preparation in accordance with the requirements of this
specification and the coating Supplier recommendations. The sequence of minimum surface
preparation activities has been specified below:
5.5.1 General requirements

If the received CTW coated pipes are totally covered with tape, 150 mm length of tape shall
be properly removed from both ends before field welding.

During field welding activities, 450 mm wide strip of heat resistance material shall be draped
over the top half of the coated pipes on each side of the weld area, to avoid damage to the
coating by hot weld spatter.

Field coating work shall not take place if the following conditions occur:
-
when the ambient temperature is below 5 °C;
-
when the relative humidity is above 85%;
-
when steel surface temperature is less than 3 °C above the ambient dew point;
-
when steel surface is exposed to rain, fog, wind.
It is Contractor responsibility to check and record the above-mentioned conditions and ensure that
coating activities are performed when environmental parameters and steel surface temperature are
in the specified range of values.
5.5.2 Pre-cleaning and visual inspection
On completion of welding and hydrostatic testing, the exposed steel bare areas shall be thoroughly
cleaned, free from all loose mill scale, metal burrs, weld spatter, dust, debris, oil, grease, wax and
other foreign materials. These contaminants shall be removed by using appropriate detergent,
water rinsing and, for heavy contamination, slight wire brushing. If solvent cleaning (SSPC-SP 1)
is necessary, only solvents meeting health and safety regulations and that do not leave an oily
residue shall be used.
Any disbonded portions of the plant coating shall be removed and properly trimmed. Portions
where parent coating is removed shall be thoroughly cleaned.
Parent coating edge shall be verified and, if necessary, it shall be bevelled to 30° or less, to provide
smooth transition for the new cold tape coating.
5.5.3 Pre-heating
Steel surface shall be uniformly heated with suitable tools (i.e. propane torches) to remove
moisture and prevent its condensation on item after blast cleaning.
5.5.4 Abrasive blast cleaning
Abrasive blast cleaning shall be performed according to EN ISO 8504-2. Steel surface shall be
abrasive grit blast cleaned to grade Sa 2.5 EN ISO 8501-1 corresponding to near-white metal finish
SSPC SP-10. The surface anchor profile shall be in the range of 50 ÷ 76 µm from peak to valley.
Surface profile shall be measured in accordance with EN ISO 8503-5.
Abrasive grit and compressed air of blasting machine shall be dry, free from oil, grease and any
other contaminants. Sand and silica abrasive are not permitted. Particle hardness and size
distribution of the blasting medium shall be such to obtain the required surface profile of 50 ÷ 76
µm. Abrasives shall remain dry during usage.
Minimum 100 mm of adjacent parent coating/painting shall be slightly blasted or abraded, to
obtain a rough surface of coating useful for mechanical adhesion of liquid adhesive.
5.5.5 Final cleaning and inspection prior to CTW application
After blast cleaning and before CTW application, Contractor shall carry out the following
tests/controls:

Any traces of foreign contaminants on the blast cleaned surface (e.g. dirt, dust, metal
particles, hydrocarbons, water, sulphates) shall be removed using dry and clean compressed
air;

Dust contamination test (EN ISO 8502-3): maximum residual dust rating shall be class 2;

Salt contamination test (EN ISO 8502-6): maximum residual chloride content, measured
according to EN ISO 8502-9, shall be less than 20 mg/m2;

Check of flash rusting on steel: if flash rusting occurs, steel surfaces must be blasted again
as per paragraph 5.5.4;

Time span between the blast cleaning and the coating operation shall be kept to a minimum.
Steel areas showing any deterioration to the required surface cleanliness Sa 2½ shall be
completely re-blasted before applying the CTW.
5.5.6 Surface preparation of Stainless Steel (SS)
Coating Supplier guidelines and recommendations shall be followed for the surface preparation of
Stainless Steel (SS) field welded joints and fittings.
As a minimum, SS surface shall be thoroughly degreased using an appropriate emulsion cleaner
and abrasive cleaned (sweep blasting) to create sufficient anchor profile (50 ≤ Rz ≤ 76 µm, as per
standard ref [44], or as recommended by coating Supplier). Abrasive for blast cleaning of SS
surfaces shall be performed with a suitable non-metallic abrasive such as Aluminium oxide. When
hand or power tool cleaning is required on stainless steel, only SS wire brushes that have not been
previously used on carbon steel surface may be used. All coatings and solvents for use on SS shall
be free from substances such as chlorides and other halides, sulfur, and shall be free from low
melting point metals (Zinc, Aluminium, Tin and Lead).
Minimum 100 mm of adjacent parent coating/painting shall be slightly blasted or abraded, to
obtain a rough surface of coating useful for mechanical adhesion of liquid adhesive.
5.6
CTW application
5.6.1 General requirements

Contractor field personnel shall be properly trained by the coating Supplier before CTW
application activity.

CTW materials shall be applied strictly in accordance with this specification and the
applicable guidelines of the coating Supplier. Hand application of tape is permitted only
when the use of tape wrapping machine is difficult to perform. Any deviation from the
approved procedure shall be submitted by Contractor for Company approval.

CTW application shall start and finish giving a minimum 75 mm wide overlap onto the
adjoining coating and painting.

Where deemed required, the weld seam area shall be smoothed by applying approved mastic
on both side of the weld, to prevent tenting of the applied tape.
5.6.2 Liquid adhesive (primer) application
Liquid adhesive shall be applied with spray or brush, on steel and on the parent coating/painting
75 mm wide overlap, in a uniform and continuous film. Care shall be taken to ensure that primer
coverage is complete, especially at welds.
The liquid adhesive coverage and curing/drying time shall be sufficient to ensure an effective bond
between the substrate and the subsequent tape layer.
The measured dry film thickness (DFT) shall be 60 ÷ 80 µm. During application, any action useful
to prevent liquid adhesive settling shall be done. The liquid adhesive shall dry in accordance with
the coating Supplier recommendations.
Liquid adhesive application shall be limited to the amount of surface area that can be wrapped
during the same workday; otherwise, the area must be re-prepared.
Before the inner-layer application, liquid adhesive coat shall be “dry-to-touch” and free from runs,
sags, drips, bare spots or any foreign substances such as sand, grease, oil, grit, rust particles or dirt.
5.6.3 Application of inner-wrap
The inner-layer tape shall be spirally applied onto the liquid adhesive coated surface by means of
mechanical constant-tension coating equipment. Tape wrapping machine and application tensions
shall be as recommended by the coating Supplier. Moreover, the following minimum requirements
shall be fulfilled during the application:
1. The minimum spiral overlap width shall be 25 mm and maximum 50% of roll width,
2. The end of the spiral wrap shall be cut on the downside at 3 or 9 o’clock position on the
component,
3. When a new roll of tape is started, the ends shall be overlapped at least 150 mm (measured
circumferentially). The overlap shall be smooth and it shall be positioned to ensure the
continuity of the inner-layer coating.
Maximum contact of the tape with the primed surface shall be ensured: hard-rubber roller, wider
than the width of the tape, or similar tool can be used for this purpose.
5.6.4 Application of outer-wrap
The outer-layer tape shall be applied over the inner-layer tape with the same type of mechanical
equipment used for the inner-layer tape. The overlap of the outer-layer tape shall not coincide with
the overlap of the inner-layer tape.
The same requirements of paragraph 5.6.3 points 1, 2 and 3 shall be satisfied during the outerwrap tape application.
5.7
Coating repair
Coating repairs shall be performed in accordance with the coating Supplier guidelines and using
coating Supplier recommended repair materials. Coating repair activity shall include as minimum
the following actions:

Peeling back and removal of the tape layers from the affected area;

Cleaning the faulty area by clean and dry compressed air and by brush;

Brush application of approved liquid adhesive;

Wrapping around the component of approved patch of tape covering a minimum of 100 mm
around the affected area or application of a patch of tape as specified by coating Supplier
repair guidelines;

Visual inspection and holiday detection of the repaired area.
All inspection following repairs shall be documented and shall include the repair and re-test details.
5.8
Field inspection and test
Field inspection and test activities shall be performed during the following phases:
1. At every receipt of coated pipes, bare fittings and coating raw materials (paragraphs 5.8.2,
5.8.3);
2. During CTW application (paragraph 5.8.4).
5.8.1 General requirements

The applied CTW shall be solid, free of wrinkles, buckles and tears and bonded to the
component surface. The finished product shall be inspected by the Contractor by means of
holiday detector as per ISO 21809-3 Annex C, to locate any defects not detectable by visual
inspection.

Contractor shall provide documentation by recording on weekly work sheets the tests
performed and the relevant results.

Inspection and tests of CTW shall be efficiently carried out by Contractor in accordance with
the requirements of this specification.

All the instruments used for checks and tests during the coating application shall be calibrated
regularly and whenever doubts arise on their reliability. As a general rule, the instruments
that are more frequently used should be calibrated at the start of each shift while other
instruments should be calibrated just before they are used.

Company reserves the right to inspect, at all times, any materials, equipment, instruments or
test during coating activities. Authorized representative inspection designated by the
Company may be assigned to the site during coating application.

When an inspection is required, Contractor shall give Company representative inspector
reasonable notice of the time at which the application or tests are to be made. All coating
work not done in presence of the inspector shall be subject to rejection. If any time it is found
that procedure of applying the CTW materials is not according to this specification, all the
coating work shall be rejected.

During construction, every precaution shall be taken to prevent damage to the applied
coating. No metal tools or heavy objects shall be permitted to come in contact with the
finished coating. Damage from any cause during installation to the coating shall be repaired
in accordance with paragraph 5.7 before final acceptance. Contractor personnel shall take
care when it is necessary to walk on the coating, in which case only shoes with rubber or
composition soles and heels shall be worn.
5.8.2 Coated pipe and bare fitting preliminary inspection
At the reception on field, Contractor shall ascertain that:

All received coated pipes and bare fittings shall be accompanied by the specific
documentation (e.g. material certificates, packing list, delivery notes, etc.);

All received coated pipes and bare fittings are correctly identified. Contractor shall record
the component number and any other identification marking and check that it tallies with the
packing list and delivery notes;

All received coated pipes and bare fittings have no critical damages that cannot be
immediately repaired.
5.8.3 CTW materials control
CTW materials shall be provided with relevant product data sheets and/or coating Supplier
certified test reports. Properties of CTW materials specified in paragraph 5.3.2 and paragraph 5.3.3
shall be verified with relevant product data sheets/certificates.
Materials that do not meet the requirements of this specification shall be rejected.
Item
1
1.1
1.2
1.3
2
2.1
2.2
2.3
Test method /
Acceptance criteria
Reference code
Coated pipe/bare fitting receipt inspection
No bevel damage, dents,
gouges, contaminants, flat
Coated pipe condition
Visual check
ends, plant coating damage.
Presence of 150 mm cutback
No bevel damage, dents,
Bare fitting condition
Visual check
gouges, contaminants, flat
ends
According to received
Component traceability control
Visual check
packing list
Coating raw materials inspection
Delivered packing condition
Visual examination
No visible damage
Coating Supplier
Inner-wrap properties
certified test report /
paragraph 5.3.2
product data sheet
Coating Supplier
Outer-wrap properties
certified test report /
paragraph 5.3.3
product data sheet
Property
Frequency
Each
component
Each
component
Each
component
Each delivery
Every batch
Every batch
Table 5.3 – Inspection activities at receipt of coated pipes / bare fittings and coating raw materials.
5.8.4 CTW application tests
During CTW application activities, Contractor shall perform the tests and inspections listed in
Table 5.4.
Item
Property
3
3.1
Environment conditions
3.1.1
Relative humidity
3.1.2
Ambient temperature
3.1.3
Steel temperature
Test method /
Acceptance criteria
Reference code
Surface preparation
Dew point meter
Thermometer
Digital contact
thermometer
Frequency
≤ 85%
> 5 °C
Start of shift, every
2 hours
≥ 3 °C above air dew point
Each component
3.2
Surface condition before blasting
Visual inspection
Free from contamination,
defects, moisture
Each component
3.3
Parent coating (3LPE, CTW) edge
Visual inspection
≤ 30°
Each component
3.4
Preparation of adjacent coating /
painting
Coating Supplier
recommendations
Slight blasting / abrading of
minimum 100 mm of plant
coating
Each component
3.5
Steel pre-heating before blasting
Propane torches
No residual moisture
Each component
3.6
Compressed air cleanliness
ASTM D4285
Dry and free from oil, grease
Start of shift
3.7
Abrasive blast cleaning
3.7.1
Anchor profile
3.7.2
Surface cleanliness grade
EN ISO 8504-2
EN ISO 8503-5
EN ISO 8501-1
50 µm ≤ Rz ≤ 76 µm
Grade Sa 2.5
Each component
3.8
Cleaning of blasted surface
Compressed air
Removal of residual debris
Each component
3.9
Dust contamination test
EN ISO 8502-3
Max rating: 2
3.10
Salt contamination test
EN ISO 8502-9
≤ 20 mg/m2
3.11
Surface condition prior to CTW
application
4
4.1
4.2
Check overlap width on parent
coating/painting
External appearance of applied
CTW
Thickness measurement
4.3.1
Liquid adhesive
4.3.2
Inner-wrap
4.3.3
Outer-wrap
4.3.4
Total
Free from contamination, flash
rust, dent, oxides, scales,
laminations, gouges
Inspection and test of applied CTW
Visual inspection
Start of shift, every
4 hours, once per
type of fitting
Start of shift, once
per type of fitting
Each component
Visual inspection
min. 75 mm
Each component
Visual inspection
Solid, free from wrinkles,
buckles, tears, air blisters
Each component
ISO 2808
DFT: 60 ÷ 80 µm
min. 600 µm
4.3
ASTM D1000
min. 760 µm
min. 2 mm
Start of shift, every
4 hours, once per
type of fitting
Start of shift, every
4 hours, once per
type of fitting
Start of shift, every
4 hours, once per
type of fitting
Start of shift, every
4 hours, once per
type of fitting
Item
Property
4.4
100% coating continuity
4.5
Peel strength test between tape
layers @ 25 °C
4.5.1
to inner/inner
4.6
4.5.2
to outer/inner
4.5.3
to outer/outer
Peel strength test @ 25 °C
4.6.1
to pipe surface
4.6.2
to plant coating
4.6.3
to painting (UG/AG
transition piping)
5
5.1
Applied CTW repair
Test method /
Reference code
EN ISO 21809-3,
Annex C
Acceptance criteria
Frequency
No holidays @ max 15 kV
Each component
≥ 1.5 N/mm
EN ISO 21809-3,
Annex L
≥ 1.5 N/mm
≥ 0.2 N/mm
Start of shift, once
per type of fitting
EN ISO 21809-3,
Annex H
≥ 1 N/ mm
≥ 0.4 N/ mm
≥ 0.2 N/ mm and as per
coating Supplier minimum
requirement
Start of shift, once
per type of fitting
Once every 3
UG/AG transition
piping
Coating Supplier
guidelines
CTW repairs
Coating Supplier
guidelines /
No holidays @ max 15 kV
paragraph 5.7
Every detected
damage
Table 5.4 – Inspection and tests during CTW field application.
Contractor shall submit to Company the inspection and test documentation.
5.9
QA/QC
Contractor shall submit for Company approval a Quality Control Plan (QCP) based on the
minimum requirements of this specification.
QCP shall cover minimum verifications, checks and tests required to ensure compliance with
codes, specifications and/or contractual requirements and specify all phases witnessed by
Company relevant certification to be provided.
Company reserves the right to increase the level or frequency of quality control activities or request
the Contractor to revise his working practices, as necessary. The extent of production acceptance
Test shall be agreed prior to the award of any order.
Contractor shall obtain from coating Supplier all material, quality control documentation and
material test certificates for each batch consignment, confirming compliance with this
specification and coating Supplier procedure. Contractor shall be responsible for verifying the
certificates against batch delivered at site and of recording batch number of all materials.
Coating Supplier shall advice its proposed material traceability system (EN 10204 type 2.2) by
which materials are assured to be fit-for-purpose and identified throughout the coating process.
Only original certificates or copies verified by the Company or a recognized independent third
party operating an accredited ISO 9001 Management System shall be accepted.