GERENCIA DE PROYECTOS
INGENIERIA DE DETALLES IMPULSIÓN DE AGUA DE MAR TEA, NUEVA VICTORIA.
N° DE PROYECTO 9500010981
INGENIERIA DE DETALLES
ESPECIFICACIÓN TÉCNICA GENERAL
COMPRA DE REVESTIMIENTO INTERIOR Y EXTERIOR
TUBERÍA PIPELINE
DOCUMENTO SQM
Nº I0641-9673-ET-500-004
PÁGINAS
DOCUMENTO INTERNO
1 de 37
N° P289-ESP-PI-004
APROBACIONES
REV.
A
B
FECHA
27/03/23
POR
REV.
JEFE
PROYECTO
H. STACK
F. DONOSO
J. ESTAY
K. OVIEDO
H. STACK
F. DONOSO
J. ESTAY
COORDINACIÓN INTERNA
K. OVIEDO
J. IBAÑEZ
28/03/23
PARA APROBACIÓN
H. STACK
F. DONOSO
0
DESCRIPCIÓN
SQM
18/04/23
F. PARGA
K. OVIEDO
J. IBAÑEZ
PARA CONSTRUCCIÓN
TABLE OF CONTENTS
Page
1.
INTRODUCTION .......................................................................................................4
2.
SCOPE ......................................................................................................................5
2.1
GENERAL ..............................................................................................................5
2.2
DEFINITIONS.........................................................................................................5
2.3
COMMUNICATIONS ..............................................................................................6
3.
CODES AND STANDARDS ......................................................................................6
3.1
CODES...................................................................................................................6
3.2
PROJECT SPECIFICATIONS ................................................................................8
4.
QUALITY SYSTEM ...................................................................................................9
5.
DOCUMENTATION AT THE BID STAGE .................................................................9
5.1
PRE-PRODUCTION DOCUMENTATION ............................................................ 10
5.2
PRODUCTION RECORDS .................................................................................. 11
5.3
RELEASE DOCUMENTATION ............................................................................ 11
6.
COATING ................................................................................................................ 12
6.1
GENERAL ............................................................................................................ 12
6.2
SURFACE PREPARATION.................................................................................. 13
6.3
BLAST CLEANING ............................................................................................... 14
6.4
EXTERNAL COATING THREE LAYER POLYETHYLENE (3LPE) ...................... 16
6.4.1 Application ............................................................................................................ 17
6.4.1.1 Primer Powder Epoxy Layer ............................................................................. 18
6.4.1.2 Adhesive ........................................................................................................... 19
6.4.1.3 Polyethylene (Pe) Layer/Cutback ..................................................................... 20
6.4.2 Properties ............................................................................................................. 20
6.4.2.1 Primer Powder Epoxy ....................................................................................... 20
6.4.2.2 Adhesive ........................................................................................................... 21
6.4.2.3 Polyethylene (PE) ............................................................................................. 21
6.4.3 Thickness ............................................................................................................. 22
6.4.4 Repairs ................................................................................................................. 22
6.4.5 Test and Inspection .............................................................................................. 23
6.5
EXTERNAL COATING POLYURETHANE ........................................................... 30
6.5.1 Application ............................................................................................................ 30
6.5.2 Properties ............................................................................................................. 31
6.5.3 Test and Inspection .............................................................................................. 31
6.6
INTERNAL COATING FBE .................................................................................. 31
6.6.1 Application ............................................................................................................ 31
6.6.2 Properties ............................................................................................................. 32
6.6.3 Thickness ............................................................................................................. 33
6.6.4 Repairs ................................................................................................................. 33
6.6.5 Test and Inspection .............................................................................................. 33
7.
MARKING ................................................................................................................ 34
8.
PACKING, SHIPPING, AND STORAGE ................................................................. 35
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8.1
8.2
8.3
8.4
8.5
GENERAL ............................................................................................................ 35
HANDLING OF COATED PIPE ............................................................................ 35
PIPE STACKING .................................................................................................. 36
DAMAGE TO PIPE, PIPE ENDS AND REPAIR ................................................... 36
SHIPPING ............................................................................................................ 37
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1.
INTRODUCTION
SQM a través de la Gerencia de Proyectos, está en la fase de ejecución del
Proyecto de Impulsión de Agua de Mar TEA, el cual consiste en un sistema de
aducción, tuberías y estaciones de bombeo para levantar un máximo de 900 l/s
desde la playa el sector de Puerto Patillo, ubicada a 62 km al sur de la ciudad de
Iquique, hasta las pozas de recepción ubicadas en la zona de Pampa Hermosa
Oeste a una elevación de 1024 msnm, cercano a la antigua oficina salitrera
Victoria, con un largo total de ductos desde la aducción a la piscina de recepción
de casi 44 km.
La captación de agua de mar ubicada en sector Puerto Patillo se realizará a través
de una torre de captación y un ducto submarino. La tubería de captación,
contrapesos y paso por la rompiente alimentara una sentina con sistema de
compuertas y filtro de rejas en las cual se disponen bombas verticales multietapa
denominada estación bombeo auxiliar (EBA). La EBA alimentará una estación de
bombeo principal (EBP) ubicada aproximadamente a 2 kilómetros de distancia, la
cual recibirá el agua en un estanque de almacenamiento y utilizará un sistema de
bombas centrífugas horizontales multietapa para su impulsión hasta las piscinas
de recepción en el punto de destino, ubicadas en el sector de Pampa Hermosa,
conducción que en total posee una longitud de 40 kilómetros aproximadamente. El
pipeline en su trazado contará con tres piscinas de emergencia, ubicadas en
puntos de acumulación a lo largo de su extensión.
El presente servicio de ingeniería, solicitado por SQM a JRI Ingeniería S.A., se
ampara en el Contrato N°9500010981, denominado “Ingeniería de Detalles
Impulsión de Agua de Mar Tea, Nueva Victoria”.
Este documento corresponde a la especificación técnica de revestimiento interno y
externo de la tubería pipeline, el cual suscriben JRI y SQM.
N° I0641-9673-ET-500-004-0
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2.
SCOPE
2.1
GENERAL
This Specification defines the minimum technical requirements for coating systems
applied in the workshop for pipelines. The external coating system shall comprise a
Three-Layer Polyethylene (3LPE) for underground pipeline and Polyurethane for
aboveground pipelines. The internal coating shall comprise a Fusion Bonded
Epoxy (FBE).
The pipe may be stored outdoors for extended periods. The coatings systems shall
be sufficiently flexible to be compatible with the normal pipe flexing encountered
during pipeline construction and for use with cold field bending of radius as small
as 30-pipe diameter. The finished coating shall have the property of retaining good
flexibility and color integrity when exposed to sunlight and weathering for at least
six months.
All coating materials shall be applied according to the material manufacturer’s
instructions.
It is responsibility of the Bidder and his subcontractors to stop the coating process
at any time when conditions may exist that might adversely affect the coating
quality.
During all phases of the coating application, the beveled pipe ends shall be
protected from damage.
Bidder may propose another type of exterior pipe coating equal to or better than
specified.
2.2
DEFINITIONS
In this document:
"Vendor"
Refers to the party responsible for the supply of the pipe identified
herein.
"Owner"
Refers to Soquimich (SQM).
"Buyer"
Refers to Soquimich (SQM).
"Lot"
Refers to a group of pipes of the same diameter and wall thickness,
which have been fabricated from the same heat of steel.
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2.3
COMMUNICATIONS
All formal project communications, including drawings and procedure submittals to
and from the Vendor, shall be routed to the Buyer.
The Buyer representative/inspector will be designated at the discretion of the
Buyer.
Owner will provide Vendor distribution at or near to the time of any order for goods
purchased under this document. Parties may be inspectors, engineers, and
owner's representative or other third parties, at the Owner's discretion.
3.
CODES AND STANDARDS
3.1
CODES
This Specification shall be in accordance with standards and codes included in
Project Standard List of Codes and Standards.
The following document shall be used in conjunction with this Specification:
Nº I0641-9673-ET-500-003, “Especificación Técnica General para Compra de
Tuberías de Acero Pipeline”.
The following industry codes and standards applicable to the coating system and
its application shall also form part of this Specification:
AWWA C213
Fusion-Bonded Epoxy Coating for the Interior and
Exterior of Steel Water Pipelines
ASTM D149
Standard Test Method for Dielectric Breakdown Voltage
and Dielectric Strength of Solid Electrical Insulating
Materials at Commercial Power Frequencies
ASTM D638
Standard Test Method for Tensile Properties of Plastics
ASTM D746
Standard Test Method for Brittleness Temperature of
Plastics and Elastomers by Impact
ASTM D790
Standard Test Methods for Flexural Properties of
Unreinforced and Reinforced Plastics and Electrical
Insulating Materials
ASTM D792
Standard Test Methods for Density and Specific Gravity
(Relative Density) of Plastics by Displacement
ASTM D1238
Standard Test Method for Melt Flow
Thermoplastics by Extrusion Plastometer
N° I0641-9673-ET-500-004-0
Rates
Page 6 of 37
of
ASTM D1505
Standard Test Method for Density of Plastics by the
Density-Gradient Technique
ASTM D1525
Standard Test Method for Vicat Softening Temperature of
Plastics
ASTM D1603
Standard Test Method for Carbon Black Content in Olefin
Plastics
ASTM D1693
Standard Test Method for Environmental Stress-Cracking
of Ethylene Plastics
ASTM D2240
Standard Test Method for Rubber Property—Durometer
Hardness
ASTM D3451
Standard Guide for Testing Coating Powders and Powder
Coatings
ASTM D3895
Standard Test Method for Oxidative-Induction Time of
Polyolefins by Differential Scanning Calorimetry
ASTM D4217
Standard Test Method for Gel Time of Thermosetting
Coating Powder
ASTM E96
Standard Test Methods for Water Vapor Transmission of
Materials
ASTM E203
Standard Test Method for Water Using Volumetric Karl
Fischer Titration
ASTM G6
Standard Test Method for Abrasion Resistance of
Pipeline Coatings
ASTM G8
Standard Test Methods for Cathodic Disbonding of
Pipeline Coatings
ASTM G14
Standard Test Method for Impact Resistance of Pipeline
Coatings (Falling Weight Test)
ASTM G17
Standard Test Method for Penetration Resistance of
Pipeline Coatings (Blunt Rod)
BS 7079
Preparation of steel substrates before application of
paints and related products. Visual assessment of
surface cleanliness.
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BS 7079 – Part A1
Specification for rust grades and preparation grades of
un-coated steel substrates and of steel substrates after
overall removal of previous coatings. (1994).[Identical
with ISO 8501-1 (part 1)].
BS EN ISO 8503-1
Preparation of steel surfaces before application of paints
and related products. Method for the grading of surface
profile of abrasively blast cleaned steel using a
comparator (1995).
DIN 30670
Polyethylene Coatings for Steel Pipe and Fittings
(Requirements and Testing).
DIN 53380
Testing of plastic films; determination of the gas
transmission rate
ISO 21809-1
External coatings for buried or submerged pipelines used
in pipeline transportation systems.
SSPC-SP-1
Solvent Cleaning.
CAN/CSA Z245.20-14
Plant-applied external coatings for steel pipe 2014.
CAN/CSA Z245.21-14
Plant-applied external polyethylene coating for steel pipe
2014
If any conflict exists between this Specification and/or the above-referenced
standards, the most stringent requirement shall prevail. If the Bidder is unsure of
any of the requirements, or any conflicts, he shall submit the query in writing to the
Buyer and Engineer for clarification.
3.2
PROJECT SPECIFICATIONS
I0641-9673-CD-500-002
Criterio de Diseño Cañerías
I0641-9673-CD-300-002
Criterio de Diseño Pipeline
I0641-9673-CD-500-001
Criterio de Diseño Hidráulico
I0641-9673-ET-500-003
Technical Specification for Sea water Mainline
Pipe
I0641-9673-MC-500-013
Memoria de Cálculo Hidráulico
Impulsión EBA Actualización
N° I0641-9673-ET-500-004-0
Sistema
Page 8 of 37
de
I0641-9673-MC-500-014
Memoria de Cálculo Hidráulico
Impulsión EBP Actualización
Sistema
de
In the event of a conflict between the above-referenced codes and standards and
this specification, the most stringent requirements shall apply.
In the event of a conflict between the laws, regulations, standards, and codes
applied to the Project and technical specifications, the Vendor shall bring such
instances to the Buyer's attention for clarification and a ruling. As a general rule,
the most stringent requirement shall be followed to ensure compliance with other
applicable laws, regulations, standards, codes, and specifications.
4.
QUALITY SYSTEM
The Bidder shall operate a Quality Management System in compliance with
ISO 9001 or Project approved equivalent, as appropriate. A Project specific Quality
Plan shall be submitted within 4-weeks from contract or purchase order award, for
acceptance by the Owner/Buyer. This Plan shall ensure compliance with the
requirements of the contract or purchase order and any statutory authority
requirements that may apply, and include all activities to be undertaken by the
Bidder to meet the Scope of Work, and requirements of this Specification.
5.
DOCUMENTATION AT THE BID STAGE
The Bidder shall submit the following documentation to Buyer/Engineer (in English
language) for review at the bid stage:
•
Details of the coating materials including data from the raw material
manufacturers, detailing test results, which demonstrate that the proposed
system conforms to the requirements of this Specification.
•
Details of the Manufacturer’s product specification shall be provided for internal
coat FBE and external coatings systems 3LPE and Polyethylene.
•
Details of coating methods including surface preparation, application
temperature, and required working conditions (humidity, dust and temperature
etc).
•
Confirmation that the specified thickness of the coating system will meet the
requirements of this Specification.
•
An outline QA/QC plan detailing the inspection and testing that will be carried
out to ensure the final product meets or exceeds the requirements of this
Specification.
•
Details of any proposed sub-contractor.
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5.1
•
A copy of the QA accreditation certificate.
•
Draft repair procedure.
PRE-PRODUCTION DOCUMENTATION
The Bidder shall submit the following documentation to Buyer/Engineer for
approval prior to commencing production:
•
The Manufacturer’s trade name and data sheets for all proposed coating
materials. This includes cleaning and abrasive blasting consumables.
•
Method for identifying, or maintaining the identification of each coated item.
•
Handling procedure.
•
Stacking procedure.
•
Materials control and traceability procedure for the batches of coating materials.
•
Materials storage procedure (pipe and coating materials).
•
Method for steel surface preparation including materials, cleaning, inspection,
verification of cleanliness and surface profile.
•
Coating application procedures, including fusion bonded epoxy (FBE), adhesive
and polyethylene layers.
•
The results of the batch tests for batches to be used for pre-qualification tests.
•
Details of testing methods including instrument types and copies of current
calibration certificates.
•
Details of inspection methods for bare and coated pipe in the form of an
Inspection and test plan (ITP) for both production and PQT.
•
Full test results from the coating Procedure Qualification Test (PQT).
•
Repair procedure and results of tests on demonstration of repairs.
•
Project specific Quality Plan.
Work shall not begin until these procedures have been reviewed and approved by
Buyer/Engineer.
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5.2
PRODUCTION RECORDS
A daily log containing the following data shall be maintained and be available for
inspection by Buyer, or Owners designated representative during and/or after
production. The following data shall be recorded against the pipe unique
identification number:
•
Bare pipe inspection data.
•
Ambient temperature (every 4 hours).
•
Humidity (every 4 hours).
•
Coating progress (number of items coated, including item serial numbers).
•
Blast pipe surface amplitude.
•
Tests for cleanliness of blast surface.
•
Tests for cleanliness of blast medium.
•
Film thickness measurements.
•
Average, maximum and minimum coating thickness during each shift.
•
Details of any coating defects recorded and defect density on respective pipe
length.
•
Details of any coating repairs.
•
The unique identification number of all items that are stripped for recoating.
•
Pipe coating test results.
•
Numerical values shall be recorded. Phrases such as ‘acceptable’ or ‘within
Manufacturer’s stated limits’ are not acceptable.
The log shall be available to Owner/Buyer, or Owner’s designated representative
throughout all coating operations.
5.3
RELEASE DOCUMENTATION
The Bidder shall submit to Buyer the following documentation in hard copy and
Microsoft Excel compatible electronic format with each batch of pipes released:
•
Production listing for each batch.
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•
Unique pipe identification numbers.
•
Unique coating identification number (if different).
•
Pipe length.
•
Reductions in lengths due to use in tests, damage or repairs, recorded against
pipe unique identification number.
•
Date of coating.
•
Batch numbers of coating materials used.
•
Listing of pipe repairs.
•
This shall be followed within two weeks by the following:
•
Manufacturer’s certificates for each batch of coating materials.
•
Certification/calibration certificates for all testing and coating equipment.
•
Inspection and test records, results and other documentation of all materials
and coating tests.
All reports shall be signed by the Bidder to signify compliance with the
requirements of this Specification.
6.
COATING
6.1
GENERAL
The Bidder shall provide coating materials to effect a high quality, external pipe
coating system fully compliant with this Specification. The Bidder shall submit to
Buyer for approval, names of suppliers and specifications for all materials.
The Bidder shall submit certificates of material conformity and test results to the
Buyer, for all coating materials. All materials used for pipe coating shall be
appropriately cross-referenced to relevant test results. All material packages shall
be labelled with the batch number. Bidder quality control (QC) shall crossreference batch number with Certificate of Material detailing the following minimum
information:
•
Name of manufacturer.
•
Complete material identification, i.e. trade name, chemical name and type of
product details.
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•
Batch number.
•
Date of manufacture.
•
Place of manufacturer.
•
Shelf life/expiry date (if applicable).
•
Relevant specification/manufacturing standard or product identification.
•
Health and safety, and environmental instructions.
•
Hazard warnings.
•
Storage instructions.
•
Quantity.
All materials not suitably labelled shall be deemed unacceptable by Buyer and be
rejected.
All materials shall be used at least one month prior to product expiration date. All
materials less than one month from expiration date shall be rejected by Buyer.
Bidder shall remove and replace all rejected material solely at Bidder’s expense.
6.2
SURFACE PREPARATION
All surface contaminants such as oil, grease, tar, or other contaminants on the pipe
shall be removed by solvent cleaning (xylol-mineral spirits or similar), in
accordance with SSPC-SP1 or alternative Buyer/Engineer approved procedure.
Prepare bare metal exterior surfaces for coating abrasive blast cleaning to a
minimum Near White Metal degree of cleaning per SSPC-SP10 unless a higher
degree of cleanliness is required by the coating material manufactured.
Salt contamination shall be removed by rinsing the complete surface of the pipe
with fresh clean water prior to blast cleaning.
All water used for rinsing or cleaning purposes shall be potable with less than
200 ppm total dissolved solids and 50 ppm chlorides.
Following cleaning, the pipe shall be tested for salt and oil contamination.
A Buyer/Engineer approved salt meter shall be used to carry out salt tests; one test
shall be carried out at each end and one at the center of the pipe. The salt test
N° I0641-9673-ET-500-004-0
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meter shall be calibrated and used in accordance with the manufacturer’s
recommendation. The acceptance criteria shall not exceed 2 µg/cm2.
The removal of hydrocarbon contamination shall be confirmed by a water spray
break test, where a fine spray is applied to the surface and uniform wetting
confirms the removal. This check shall be carried out on start-up pipe and pipe
which will not be production coated.
Items found to be contaminated shall be cleaned as above and re-blasted if testing
after blasting establishes that salt or hydrocarbon contamination is still present.
The remainder of the batch concerned shall all be checked individually.
6.3
BLAST CLEANING
Blasting and other dust producing areas shall be separate from coating application
areas.
After water rinsing and cleaning and prior to abrasive blasting the pipe lengths shall
be uniformly heated to at least 60°C to remove all moisture, and preclude any
condensation of moisture on the pipe after blast cleaning.
The ends of the pipe shall be fitted with plugs to prevent entry of abrasive into the
pipe during the blast cleaning operations. Pipes with machined weld bevels shall
not be linked together at any stage of production such that there is contact
between the prepared weld faces.
Weld joints, sharp-edge projections, weld spatter and slag etc. shall be dressed
prior to blast cleaning.
Using dry blasting techniques only, the exterior surface of the pipe joints shall be
abrasively cleaned to remove all mill scale, and other impurities from the surface.
The abrasive shall be iron or steel grit to provide the specified anchor pattern. The
use of round shot or sand is not permitted.
Blasting abrasive shall be kept dry, clean and free from contamination. When
recovered metallic grit systems are used, a stablished working mix of blast
cleaning material shall be established and maintained by frequent small additions
from fresh or cleaned stock at a rate sufficient to replenish consumption. Large
additions of new material shall be avoided.
No blast cleaning shall take place when the prevailing relative humidity is greater
than 85 percent unless pipe is preheated to at least 3°C above the dew point.
N° I0641-9673-ET-500-004-0
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Twice per shift, samples of the abrasive mixture shall be removed from the hopper
and checked for hydrocarbon contamination. The sample shall be placed in a
beaker to which de-ionised water is added. The beaker shall then be sealed and
shaken vigorously. Once the grit has settled the surface of the water shall be
examined for signs of hydrocarbon contamination. If any signs are found all the
abrasive in the hopper shall be rejected and not re-used.
Additionally, abrasive materials shall be checked at least once per shift to ensure
that only uncontaminated angular grit with an acceptable size distribution is used.
As a minimum the following shall be carried out:
Correct abrasive size distribution shall be carried out by sieve analysis.
Placing a sample of abrasive on a clean, dry sheet of absorbent paper to
determine water contamination.
The surfaces of the pipes shall be blasted until a finish of Sa 2.5 to BS 7079:
Part 1A (steel condition A or B) is attained. The surface profile (anchor pattern)
shall be between 60 and 100 microns, measured in accordance with BS EN ISO
8503-2. Profile measurements shall be made with a Keane-Tator Profile
Comparator, Testex Press-O-Film or other Buyer/Engineer approved method
suitable for the abrasive being used.
Following abrasive blasting, the surface shall not be contaminated with residual mill
scale, dirt, dust, metal particles, hydrocarbons, water, chlorides, sulphates or any
other foreign matter, which would be detrimental to the coating. If pipe was
delivered with a temporary coating such as varnish, the pipe surface shall be
checked at a magnification of x30 to confirm no residues of varnish remain in the
anchor pattern valleys.
Prior to the coating application, the exterior surface shall be thoroughly inspected
under adequate lighting. Any damage such as distortion, buckling, denting,
flattening, surface imperfections, slivers, scabs, burrs, gouges, or sharp edged
defects, shall be repaired in accordance with this Specification, and ASME B31.4
version 2016 and API 5L 46th ed. at Bidder’s cost. Pipes that have damage
repaired by grinding and have ground areas greater than 50 mm diameter shall be
re-blasted to meet the requirements of the clauses above.
Any dust or loose residue that has accumulated during blasting and/or grinding
operations shall be removed by the use of clean compressed air or by vacuum
extraction. Alternative methods for removing dust and lint shall require approval of
Buyer/Engineer.
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The total elapsed time between the start of blasting of any pipe and the heating of
that pipe to the specified temperature shall not exceed 2 hours as long as the pipe
is held at 3°C above the dew point. However, any flash rusting regardless of
elapsed time shall be cause for rejection of the pipe.
Any pipe surface not processed within the period stated above or any pipe that is
rejected due to flash rusting shall be completely re-cleaned and re-blasted before
coating.
6.4
EXTERNAL COATING THREE LAYER POLYETHYLENE (3LPE)
The FBE powder selected shall be suitable for use at the design temperatures in
the proposed environment and be designed only for use as an integral constituent
of a three-layer polyethylene coating system. The FBE shall be endorsed by the
manufacturer of the adhesive and polyethylene as being compatible with these
products under the specified service conditions.
Each FBE batch shall be accompanied by a certificate (BS EN 10204: 1991 or
Project approved equivalent) stating the following tests have been carried out on
every batch, and results are in accordance with the manufacturer’s product
specifications:
•
Gel time.
•
Moisture content.
•
Particle size distribution.
•
Density.
•
Infrared scan.
•
Thermal analysis.
For the primer, the minimum acceptable material shall be 3M Scotchkote 226N or
its equivalent.
The adhesive shall be manufactured by the manufacturer of the polyethylene and
shall be completely suitable for use at the design temperatures in the proposed
environment, and be suitable for the proposed three-layer polyethylene coating
system.
Each adhesive batch shall be accompanied by a certificate (BS EN 10204: 1991 or
Project approved equivalent) stating the following tests have been carried out on
N° I0641-9673-ET-500-004-0
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every batch, and results are in accordance with the manufacturer’s product
specifications:
•
Melt flow index.
•
Density.
•
Adhesion.
The minimum acceptable material for the adhesive shall be DuPont Fusabond A
EMB206D, Borealis Borcoat ME0420 or its equivalent.
The polyethylene selected shall be of high density and shall contain additives as
required to provide ultra-violet protection for a minimum exposed storage period of
12 months. The polyethylene shall be suitable for the proposed three-layer
polyethylene coating system.
Each polyethylene batch shall be accompanied by a certificate (BS EN 10204:
1991 or equivalent) stating the following tests have been carried out on every
batch, and results are in accordance with the manufacturer’s product specification:
•
Density.
•
Melt flow index.
•
Melting point.
The minimum acceptable material for the Polyethylene shall be Borcoat HE3450 or
its equivalent.
6.4.1 Application
Under no circumstances shall production commence until all coating procedures
have been reviewed and approved by the Buyer. The Bidder shall also perform
coating procedure qualification testing (PQT).
All coating materials shall be applied according to the material manufacturer’s
instructions, and the requirements of this Specification.
It is responsibility of Bidder and his subcontractors to stop the coating process at
any time when conditions may exist that might adversely affect the coating quality.
During all phases of the coating application, the beveled pipe ends shall be
protected from damage.
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Prior to application of the fusion epoxy powder, the powder application and
recovery systems shall be thoroughly cleaned. During coating application no
container/hopper shall contain powder/pellets from more than one batch of material
unless it is required to keep the coating process continuous. In addition, the spray
booth shall be cleaned of excess powder at the end of each shift.
The external surface of the cleaned pipe shall be immediately coated with a threelayer polyethylene coating as summarized below. While applying the coating,
Bidder shall ensure that there is no entrapment of air or void formation. The
resultant coating shall be free of air bubbles, wrinkles, holidays, irregularities,
discontinuities, etc.
A polyethylene layer cut back of 225 mm (± 10 mm) shall be provided at pipe ends
as follows: Pipe ends shall be supplied as bare steel, free of all coating, for a
distance of 200 mm (± 10mm) from the pipe end. In addition, each pipe end shall
be left without polyethylene/adhesive coating so that a 25 mm undamaged FBE toe
protrudes on the steel beyond the cutback polyethylene coating layer. The
adhesive shall seal the end of the applied coating to prevent peeling, cracking, or
other coating damage from occurring at the terminations
Figure 6.1: Detail of Pipe Ends and Coating Cutback
6.4.1.1 Primer Powder Epoxy Layer
The FBE primer layer shall be applied to a minimum thickness of 200 microns and
a maximum of 300 microns; however the average thickness shall not be less than
250 microns.
The pipe shall be uniformly preheated in accordance with the FBE manufacturer’s
instructions. It is essential that the steel temperature is sufficient to ensure total
wetting of the surface by the FBE. This temperature shall have been confirmed
during PQT. The surface temperature shall not exceed 275°C. The heating shall be
conducted such that a uniform temperature is maintained along the total length of
N° I0641-9673-ET-500-004-0
Page 18 of 37
the pipe joint with particular attention being given to the pipe ends where cooling
could result from the use of pipe couplers, which could result in premature
adhesion failure in service. The heating method shall not contaminate the surface
to be coated.
The coating shall be applied by electrostatic spray with the pipe at earth potential
and the epoxy powder charged to high potential.
Pipe temperature shall be checked periodically using a recording pyrometer. The
pyrometer shall be checked for error not less than every four hours against a
calibrated temperature-measuring instrument according to the procedural
requirements of ISO 9001, or Project approved equivalent.
Oxidation of the steel prior to coating in the form of ‘blueing’ or other apparent
oxide formation is not acceptable. If such oxidation occurs, the pipe shall be set
aside, re-cleaned and re-blasted.
The use of recycled FBE powder shall not be permitted.
During application, the beveled ends and pipe bore shall be protected against
mechanical damage and from contamination with coating material.
6.4.1.2 Adhesive
The adhesive shall be applied by using either the crossheads, by lateral extrusion
or powder spray techniques, immediately after the primer powder epoxy (i.e. before
the gel time of the FBE has expired). Application of the adhesive shall not be
permitted after the FBE has fully cured.
Where adhesive is applied by spray instead of extruded means the recovered
comingled FBE powder and adhesive shall be reused through dedicated guns only.
Such guns shall be located between those spraying FBE powder and those used to
apply the co-polymer spray adhesive.
The Bidder shall establish to the satisfaction of Buyer that the adhesive is applied
within the gel time window of the FBE and at the temperature recommended by the
adhesive manufacturer. The Bidder shall state the proposed minimum and
maximum time interval between FBE and adhesive applications at the proposed
pre-heat temperature.
The thickness of the adhesive coat shall be 200 and 300 microns.
N° I0641-9673-ET-500-004-0
Page 19 of 37
6.4.1.3 Polyethylene (Pe) Layer/Cutback
The polyethylene may be applied by either the crosshead or lateral extrusion
technique. The polyethylene shall be applied over the adhesive within the time and
temperature limits established during pre-production testing.
The polyethylene coating shall be applied on single or multiple layers such that the
total thickness of the coating is as specified below:
Table 6-1: Minimum Total Finished Coating Thickness
Minimum Total
Nominal Pipe
(Powder) Epoxy
Adhesive
Finished Coating
Diameter (inches)
Thickness (mm)
20 and above
8 mils to 12 mils
9 mils to 16 mils
3.5 (137.8 mils)
The polyethylene shall be extruded such that there is a minimum of 12.7 mm (1/2
inch) and a maximum of 25.4 mm (1 inch) overlap with the lapped surfaces
completely fused together.
During the entire coating operation, the pipe and coating components shall be
maintained at the optimum temperature recommended by the coating manufacturer
for maximum adhesion at the contact surfaces. When the friction from the extrusion
process does not raise the coating materials to the specified temperature an
external heat source shall be used.
Upon completion of the coating application, the pipe shall be cooled by quenching
in water (to below 60°C), before handling.
The ends of the coating shall be beveled between 30° and 45° from the pipe
surface.
Immediately after the coating is fully cured, pipe identification marks shall be
reapplied to the coated pipe using a method approved by the Buyer.
6.4.2 Properties
The following materials supplied by the Bidder shall be certified as complying with
the required standards.
6.4.2.1 Primer Powder Epoxy
All epoxy powder used shall comply with the material properties listed below when
tested in accordance with the standards indicated:
N° I0641-9673-ET-500-004-0
Page 20 of 37
Table 6-2: Primer Epoxy Properties
Property
Unit
Acceptance Criteria
-Sieve opening of 100µm
%retained
maximum 10
-Sieve opening of 100µm
%retained
minimum 90
Test
Method
Particle size
Gel Time (at 200°C)
second
Density
gr/cm3
Moisture
%
Meet Supplier’s
Specification
Meet Supplier’s
Specification
maximum 0.5
ASTM
D3451
ASTM
D4217
ASTM D792
ASTM E203
6.4.2.2 Adhesive
All adhesives used shall comply with the material properties listed below when
tested in accordance with the standards indicated:
Table 6-3: Adhesive Properties
Property
Test
Method
ASTM
D1238
Unit
Acceptance Criteria
Melt Flow Index
gr/10
min
3 to 8
Density
gr/cm3
0.91 to 0.95
ASTM
D1505
MPa
minimum: 11
ASTM D638
%
minimum: 500
ASTM D638
MPa
minimum 60
ASTM D790
Shore D
minimum 30
ASTM
D2240
°C
minimum 95
ASTM
D1525
Tensile Strength
Elongation
Flexural Modulus
Hardness
Melting Point
6.4.2.3 Polyethylene (PE)
All high-density polyethylene resin used shall comply with the material properties
listed below when tested in accordance with the standards indicated:
Table 6-4: Polyethylene Properties
Property
Unit
Acceptance Criteria
Test Method
-
Manufacturer’s Standard
-
Tensile strength
psi
Minimum 2700
ASTM D638
Elongation
%
Minimum 700% at break
ASTM D638
gr/cm3
0.94–0.96
ASTM D1505
Color
Density
N° I0641-9673-ET-500-004-0
Page 21 of 37
Property
Carbon Black
Content
Dielectric Strength
Environmental
Stress
Unit
Acceptance Criteria
Test Method
%
2% to 2.5%
ASTM D1603
V/mil
Minimum 800
Minimum of F 50:
10% Igepal CO-630. Value of
150 hours.
ASTM D149
Crack Resistance
Abrasion
Resistance
Impact Resistance
In-lb
100% Igepal CO 630. Value of
1000 hours.
No change in electrical
resistance or appearance.
Minimum 160 in - lb at 77°F
(25°C) and 108 in-lb at -40°F (40°C)
ASTM D1693
ASTM G6
ASTM G14
Blunt Rod
Penetration
Melt Flow Rate
%
Maximum 13%
ASTM G17
g/10min
0.15 to 0.80
ASTM D1238
Hardness
shore D
ASTM D2240
cm3/m2/24hr /
bar
Minimum 60 shore D
Minimum 10 minutes in Oxygen
at 428°F (220°C)
Aluminum pan, no screen
Maximum 0.3 at 230°C,
0.1mm
Maximum 650 at 230C,
0.1 mm
Wt %
Maximum 0.01 wt %
ASTM D746
Maximum -94° F
(-70°C) for F20
ASTM D 746
Oxidative Induction
Time
Permeability- Water
Vapour
Permeability Oxygen
Water Absorption
(24 hours + 25°C)
Brittleness
Temperature
Gm/m2/24Hr
ASTM D3895
ASTM E96
DIN 53380
6.4.3 Thickness
The total coating system shall be applied to the following minimum thickness
requirements.
Table 6-5: Minimum Total Finished Coating Thickness
Nominal Pipe
Minimum Total Finished
Diameter (inches)
Coating Thickness (mm)
32
2.5
The thickness of the cooled polyethylene coating system shall be checked using
Buyer approved equipment in accordance with the requirements of DIN30670.
6.4.4 Repairs
Bidder shall submit detailed coating repair procedures for approval by
Owner/Buyer. These shall include procedures for repair of ‘pin-hole’, ‘small area’
N° I0641-9673-ET-500-004-0
Page 22 of 37
and ‘large area’ defects. The minimum and maximum areas for which each type of
repair is applicable shall be stated.
The maximum number of coating defects allowable, before a joint of pipe shall be
classed as reject and recoated, shall not exceed 1 per 1 square meter (peel
adhesion testing shall be carried out at the pipe ends in the areas that will
ultimately be subject to cutback and not in the main body of the coated pipe).
No single defect shall exceed an area of 625 mm 2. Pipes with a coating defect
exceeding 625 mm2 shall be cause for rejection.
Repair shall be limited to a total damaged surface area no greater than 6” x 6”
(150 mm x 150) mm on a single pipe.
Pipes with damage to the external 3LPE coating greater than 6” x 6” (150 mm x
150 mm) in total surface area shall be rejected and replaced by the Vendor.
Repairs shall provide a finished coating equal in effectiveness to that of the parent
coating.
The use of heat-shrink sleeves is not considered an acceptable repair method.
Bidder shall submit coating stripping procedure for pipes rejected for coating
quality. The rejected coating may be stripped by heating in an oven. Under these
circumstances, the temperature of the pipe joint shall not be allowed to rise above
400ºC.
Repairs to the 3LPE coating system applied to the pipe exterior shall be made
using the 3LPE heat activated repair patch, Canusa-CPS CRP-65 or its
equivalents.
6.4.5 Test and Inspection
All stages of the surface preparation, coating and testing shall be subject to 100%
inspection by the Bidder. Owner/Buyer or Owner’s designated representative shall
be informed at least two weeks prior to the start of surface preparation to allow
scheduling of inspection supervision work
Buyer may witness the 3LPE Procedure Qualification. Buyer shall be notified 15
days prior to Procedure Qualification date, to allow Engineer sufficient time for
travel arrangements.
Pipes selected for testing shall pass all the criteria contained in this specification
before production commences. Any change in the coating material or coating
procedure shall require re-qualification. If any of the tests fail to meet the minimum
N° I0641-9673-ET-500-004-0
Page 23 of 37
acceptance criteria defined in this Specification, then the pre-qualification pipes
shall be rejected. Further pipes may be prepared and coated using revised
procedures and further tests performed. Once acceptable results are obtained and
approved by Buyer, the Bidder’s quality plan and procedures shall be revised, and
submitted to the Buyer for approval. All items coated using the rejected procedures
shall be stripped and recoated to the revised procedures.
As part of the PQT phase of the contract, the Bidder shall submit a ‘Procedure
Qualification Report’ for review and approval by the Buyer, in triplicate, within two
weeks of completing the PQT. Production shall not commence until the Bidder has
received (in writing) full and complete approval from the Buyer. As a minimum the
report shall include the following:
•
Coating materials specifications.
•
Details of coating equipment, materials and consumables.
•
Detailed surface preparation and coating procedures.
•
Detailed procedures for each type of inspection and testing carried out (as
detailed in Appendix A of this Specification).
•
Detailed results from all inspection and testing activities carried out.
An exception could be done for the cathodic disbondment test of 28 days, as long
as the 48-hour test results reach the requirements stated in the test method and
the 28 days-test is in process. In case of test of 28 days result in fail, Bidder shall
remove (own cost) the whole coat from the pipes already coated and shall restart
the process with a new MPS and PQT.
Table 6-6: Production Testing Frequency
Property
On Arrival
Pipe Damage
Before Cleaning
Pipe condition
After Cleaning
Chloride
Oil
N° I0641-9673-ET-500-004-0
Acceptable Values
Minimum
Frequency
Minor damage/grinding <3 per
pipe
Each Pipe
Conditions A&B of BS
7079 Part 1A
Each Pipe
2 mg/cm2
No contamination
1 per 100 pipe
1 per 100 pipe
Page 24 of 37
Property
After Abrasive
Blasting
Cleanliness
Profile
Dust
Contamination
Pipe Damage
Acid Washing
(where necessary)
Chromate
Pretreatment
Temperature of
solution Concentration
Coating Thickness
(minimum)
Hollydays
Visual Inspection
Coating
Bare steel at pipe
ends
FBE toe/PE cutbacks
Acceptable Values
Minimum
Frequency
ISO-Sa 2.5
60-100 µm
No contamination
Each pipe
1 pipe per 50
1 pipe per 50
Each pipe
Surface Ph of 6.0 minimum
Once per shift
Per Bidder’s procedure
Once per shift
Clause 6.4.3
No holidays
Each pipe
Each pipe
No surface defects
125 +25/-0 mm width
25 mm (±10mm) width,
bevel 30-45°
Each pipe
Each pipe
Each pipe
Clause 10.15 and Appendix B
1 pipe per 100
>35 N/cm at ambient
temperature as per DIN 30670
1 pipe per 100
≤0.2 mm
Once per shift
(and
when FBE or PE
batch is changed)
Air Entrapment
Adhesion
Peel Test
Resistance to
Indentation
PE coating
(20°C ±5°C)
PE coating
(70°C± 2°C)
Impact Testing
FBE
PE
N° I0641-9673-ET-500-004-0
≤0.3 mm
CAN/CSA Z245-20-M92
(Clause 12.12)
DIN 30670
On test at start of
production for
each
pipe dia. and in
case of any
change in
procedure.
Page 25 of 37
Property
Transverse
Electrical
Res. PE
UV Resistance PE
Degree of Cure FBE
coating
(separated from
Adhesive and PE).
Cathodic
Disbondment at Room
Temperature
Acceptable Values
Clause 10.10
Manufacturers certificate
Acceptable
-2°C ≤ΔTg ≤+ 3°C
48 hours @ 65°C @ -1.5V,
8mm radius maximum
Minimum
Frequency
One test at start
of
production for
information only
2 per Shift
First pipe, last
pipe
and at intervals of
every 350 pipes
Holiday Detector
The Bidder shall furnish, operate, and maintain a minimum of two holiday
detectors. The holiday detectors shall be of the full encirclement ring type with
adjustable output, which maintains complete contact with the coating. It may be
either constant or pulsed voltage type. If constant voltage type, holiday detection
shall be carried out on a dry coating. A suitable ‘kilovoltmeter’ or similar voltage
testing equipment shall be supplied and the operating voltage, between electrode
and pipe shall be checked not less than twice per working shift.
The operating voltage between electrode and pipe shall be maintained at 8
kilovolts/mm of coating thickness, to a maximum of 25 kilovolts. For testing FBE
only during the PQT, the voltage shall be set at 8 volts per micron thickness.
The Bidder shall demonstrate to Buyer that the setting of the detector is
satisfactory for detecting pinhole defects. This setting shall be checked once every
two hours. The correct travel speed shall be determined by consistent detection of
an artificial pinhole made in a good coating sample, but shall not exceed 300
mm/s.
The acceptance shall be no holiday indications with the holiday detector set at the
voltage stated above.
All holidays and other defects shall be marked for subsequent repair and re-testing.
On re-testing, no holidays shall be permitted in the final coating. The number of
holidays for each pipe length shall be recorded. Coated pipe having holidays in
N° I0641-9673-ET-500-004-0
Page 26 of 37
excess of 1 per 1 square meter shall be stripped and re-coated at no additional
cost to Owner/Buyer.
If there is an excess occurrence of holidays on successive pipes (as specified by
the Owner/Buyer or Owner’s designated representative), the Bidder shall
immediately stop the coating operation to determine the cause and remedy it.
The Bidder shall also ensure that spare holiday detectors are available at all times
as well as spare fully charged batteries and spare detector spring rings, in order to
allow dirty and clogged rings to be changed and cleaned, without adversely
affecting the production schedule. In the event that Bidder is unable to holiday
detect the coating satisfactorily due to a faulty detector or otherwise, the coating
operation shall be shut down forthwith until a satisfactory detector is provided.
The coating adhesions of the FBE layer shall be tested using the St Andrews cross
method.
Adhesion
For the 3LPE coating, the adhesion shall be determined in accordance with the
requirements for bond strength in DIN 30670.
The failure mode shall be recorded. The failure should occur at the
adhesive/polyethylene interface or adhesive/FBE interface or cohesively in the
polyethylene layer. If failure should occur at the FBE/steel interface, this will be
considered a total failure of the system.
During adhesion testing, samples of coating shall be examined, using x30
magnification, for air entrapment.
Resistance to Indentation
Once per shift (and when the FBE or polyethylene batch is changed), the
indentation hardness of two coated samples shall be measured (at 20°C ± 5°C and
70°C ± 2°C) in accordance with DIN 30670 (Section 5.3.5).
Indentation depth shall not exceed 0.2mm at 20°C ± 5°C nor 0.3 mm at 70°C ±
2°C.
Impact Resistance
A sample of coated pipe shall be impact tested in accordance with the procedures
and acceptance criteria of DIN 30670.
N° I0641-9673-ET-500-004-0
Page 27 of 37
Impact resistance of the procedure pipe with FBE coating alone shall be assessed
in accordance with the procedure described in clause 12.12 of CAN/CSA
Z245-20-14.
Testing shall be at 30 equally spaced points along each pipe followed by holiday
testing.
For determination of impact resistance to pre-qualification testing, 58 or more
series of impact shall be made using a range of impact energy setting above and
below the expected value. At least two series of tests with the higher impact energy
shall show no defects. A graph shall be plotted of the number of impacts versus the
impact energy.
For the purpose of Production testing, one series of 10 impacts shall be made with
impact energy set at the specified minimum requirement.
Elongation Failure
This test shall be conducted on each of the full system pre-qualification pipes, 2
samples per pipe to the requirements of DIN 30670.
Cathodic Disbondment Testing
Cathodic disbondment testing shall be conducted, as follows:
•
As a pre-qualification test - 48 hours duration, maximum disbondment radius of
8mm.
•
As a pre-qualification test - 28 days duration at 20° C.
•
As a production test - 48 hours duration, at the frequency of one test per 350
coated pipes.
The 28-day test at time of pre-qualification shall be carried out for information only
if the results of 48 hours test were satisfactory. The criteria for rejection or
acceptance shall be based on the 48-hour test for both pre-qualification and
production and shall be carried out at 65°C. In case of rejection, Bidder shall
remove the entire coat from the tubes and shall start a new coating process with a
new MPS and PQT.
The test requirements shall be in accordance with CAN/CSA Z245.21-14, except
as modified below.
Every 24 hours the applied voltage and current flow shall be recorded. Any drift
from the specified voltage setting shall be corrected.
N° I0641-9673-ET-500-004-0
Page 28 of 37
The Bidder may propose alternative cathodic disbondment test standards provided
the essential requirements of this Specification be retained. Any such alternatives
shall be submitted to Buyer/Engineer for review and approval.
Transverse Electrical Resistivity Testing (Coating Resistivity)
Testing shall consist of measuring at regular intervals the insulation strength of the
coating of a pipe immersed in a salt solution. This test shall only be performed
once for information only.
The following equipment is required:
•
Basin filled with a decinormal NaCl solution.
•
Copper backplate electrode.
•
D.C. source, minimum voltage 50 V.
•
Suitable ammeter and voltmeter.
A test piece of the coated pipe shall be used and closed at one end to prevent the
salt solution from coming into contact with the pipe metal.
Prior to immersing the sleeve into the solution, it must be tested with a holiday
detector (at 25 kV). Connect the pipe to the negative pole of the DC source.
The transverse electric Resistivity Rs shall be calculated using the values U, A and
I as follows:
Rs =
Where:
•
U = Voltage of DC – source in volts
•
A = immersed pipe surface in m2 (minimum 0.03 m2)
•
I = current intensity in amps
The transverse resistivity of the coating after 100 days of immersion shall be at
least 108 [Ωm2].
The result are only reliable if the creep current is not greater than the measured
current I.
Creep current shunt as per DIN 53482 may be used.
N° I0641-9673-ET-500-004-0
Page 29 of 37
Alternatively, the manufacturer´s certificate for Transverse electrical Resistivity is
acceptable.
6.5
EXTERNAL COATING POLYURETHANE
6.5.1 Application
The polyurethane system shall be applied on clean and dry surfaces and in
accordance with the requirements stated of this specification.
Personnel in coat application works shall be qualified to apply the specified coating
system in accordance with the Vendor procedure.
All coatings shall be applied with tools defined in the data sheet of the product
(guns, brushes, airless, as indicated).
The coating shall be applied on a properly prepared, clean and dry surface, under
favorable environmental conditions and according to the instructions of the
polyurethane manufacturer. The coating shall not be applied over a surface with
moisture or dust.
The minimum and maximum drying time between the application of a layer and the
next one shall be in accordance with the instructions of the polyurethane
manufacturer.
Each layer of polyurethane shall be applied to the dry thickness (DTF) as specified.
The finished dry thickness shall be measured with a Mikrotest FIM/102 or another
equivalent, according to SSPC-PA 2.
Metallic surfaces shall be painted only if the surface temperature is before 38°C.
All Paints parts shall be mixed, thickened, applied, and cured in total accordance to
the manufacturer's latest published instructions.
The painted surface must be free of defects, such as overspray, porosity, bubbles,
craters, roughness or inadequate drying.
Vendor shall ensure that the maximum thickness is correctly applied over critical
areas such as edges and welds, because are critical points of failures in the
protective systems.
All the polyurethane layers of the protection system shall be applied in the
specified thicknesses and it must look homogeneous in terms of gloss, texture,
color and continuity.
N° I0641-9673-ET-500-004-0
Page 30 of 37
Coating works shall not be allowed if there is no environmental thermometer and
hygrometer at the work site.
The colors in the finishing layers will be in accordance with the indications given in
this specification.
6.5.2 Properties
The minimum requirements shall be:
•
Product:
Polyurethane
•
Solid content:
100%
•
Heat resistance:
100°C
•
Pull-off Strength ASTM D4541:
70 kg/cm2 minimum
•
Flexibility ASTM D522 (bending 180°):
Pass
•
Water Resistance ASTM D4585:
Pass
•
Hardness Shore ASTM A2240:
D 70
•
Sea Sat fog ASTM B117:
1000 hours min, without softening
•
Thickness DFT:
1250 µm
•
Color RAL:
7040
•
Cut back:
200 ± 20 mm
6.5.3 Test and Inspection
The test frequency and control for the polyurethane coating will be in accordance
with the requirements indicated in Table 5 of EN 10290 standard. The Vendor shall
provide all tests certificates done.
6.6
INTERNAL COATING FBE
6.6.1 Application
Once the pipe has been blast cleaned, it shall be preheated according to the
coating manufacturer's recommendations, but it must be taken into account that it
cannot exceed 275ºC.
N° I0641-9673-ET-500-004-0
Page 31 of 37
Coated pipes shall have an uncoated area at their ends of 6.4 cm +/- 1.0 cm.
The extreme environmental conditions for the application of the product; they
should be the following:
•
Temperature: 10º C minimum, 43º C maximum (at least 3º C above dew point)
•
Relative Humidity: 85% maximum
6.6.2 Properties
Fusion-bonded epoxy (FBE) lining shall meet the requirements outlined in Tables 1
and Table 2 of AWWA C213.
The limit values of epoxy powder are detailed in Table 6.1 of this specification.
The FBE coating must be of a quality “3M™ Scotchkote™ Fusion Bonded Epoxy
Coating 206N XTRA LG” or equivalent.
Table 6-7 – FBE Properties
Property
Unit
Acceptance Criteria
-Sieve opening of 100µm
%retained
maximum 10
-Sieve opening of 100µm
%retained
minimum 90
Test
Method
Particle size
Gel Time (at 200°C)
second
Density
gr/cm3
Moisture
%
Meet Supplier’s
Specification
Meet Supplier’s
Specification
maximum 0.5
ASTM
D3451
ASTM
D4217
ASTM D792
ASTM E203
Liquid paint with a high solid content or high body is characterized by being selfpriming, with high chemical resistance, high resistance to abrasion and high
resistance to corrosion, thus the paint to be used must have at least the properties
indicated
Table 6-8 – Paint properties
Properties
Termination
Solids (volume)
Solids (weight)
Mixed ratio
N° I0641-9673-ET-500-004-0
Description
Bright
98% +/- 2%, mixed.
98% +/- 2%, mixed
4:1 by volume
Page 32 of 37
6.6.3 Thickness
To prevent cracking of the coating due to the bending of the pipes, the thickness
must be a minimum of 20 mils (508 µm).
6.6.4 Repairs
Two-part, 100% solids, liquid epoxy type patches compatible with the initially
applied FBE coating should be used for coating repair.
Repair materials must be of the following quality:
•
Two part epoxy liquid coating (3M Scotchkote 323-Brush or similar)
Repaired areas shall be overlapped base siding by a minimum of 13 mm. The
surface to be repaired shall be adequately prepared to ensure adhesion of the
repair material. The minimum thickness of the repaired coating must be in
accordance with section 6.6.3.
The maximum number of admissible defects in each pipe such that it can be
classified as "rejected and repaired" may not exceed 1 per 2 square meters.
No defect may exceed an area of 625 mm2. Pipes with coating defects greater than
625 mm2 shall be rejected.
Repairs must provide a coating that is as effective as the main coating on the
pipeline.
To take off the existing coat, the pipe shall be heated to a temperature not to
exceed 275°C in order to soften the coating to allow removal by scraping, followed
by abrasive blasting. All coating must be removed before recoating. The
identification of each stripped and relined pipe must be recorded.
The repaired areas must be inspected by Holyday Detector, according to section
5.3.3.1 of AWWA C213.
Pipes with major FBE defects, such as non-adhered coating or poor thickness,
must be reprocessed.
6.6.5 Test and Inspection
If the pipe thicknesses inspected at the factory do not meet the minimum
requirements indicated in this specification, the pipe must be shot-blasted again
and the entire cleaning and coating process must be carried out as indicated in the
previous points of this specification.
N° I0641-9673-ET-500-004-0
Page 33 of 37
Inspection of the coating shall be done in accordance with the requirements listed
in section 5.3.3 of AWWA C213.
The inspection procedure must be in accordance with the NACE TM0186-202
standard. “Holiday detection of Internal Tubular Coating of 250 to 760 µm (10 to 30
mils) Dry Film Thickness”.
7.
MARKING
Marking shall conform to the requirements of document N° I0641-9673-ET-500-003
“Technical Specification for Sea water Mainline Pipe”.
Pipe markings as prescribed in API Specification 5L 46th edition (including weight
of each pipe and heat number) and CAN/CSA Z245.20-14, shall be paint stenciled
on the inside of the pipe and transferred to the outside of the finished coating. If
this identification is missing or obliterated, the pipe section shall be rejected.
The following should be stenciled internally at both end of the pipe:
•
Project Name.
•
Purchase order item number.
•
Pipe diameter and wall thickness.
•
Steel Grade
•
Heat or cast number.
•
Manufacturer’s unique pipe number.
•
Coating identification number.
•
Pipe length.
•
Pipe weight.
There may be a combination of numbers necessary for unique identification. The
combination of numbers required shall be proposed by Bidder and approved at the
time of order.
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8.
PACKING, SHIPPING, AND STORAGE
8.1
GENERAL
The pipe may store outdoors for extended periods. The coating shall be sufficiently
flexible to be compatible with the normal pipe flexing encountered during pipeline
construction and for use with cold field bending of radius as small as 30-pipe
diameter.
The finished coating shall have the property of retaining good flexibility and color
integrity when exposed to sunlight and weathering for at least six months.
The kit of product, which travels on board ships, shall be stowed below deck with
hatch covers closed to prevent the contact of seawater to pipe metal.
The elements shall be handled in a way such that the chance of damage will be
kept to a minimum during shipping.
8.2
HANDLING OF COATED PIPE
Pipe shall be handled in such a manner as to protect the pipe, coating and beveled
ends from damage. Boomers or equivalent load bearing members shall always be
used for transport cross-country, on rough roads, and during boat loading. Only
padded fixing hooks shall be used for handling the pipe. A spreader bar shall be
used between lifting lines. During handling, the pipe shall be protected from
impacts or jars. Buyer shall be advised of any pipe suffering impact or jars. Lifting
equipment shall be Buyer approved.
A detailed Pipe Handling/Shipping Procedure shall be submitted to Buyer for
approval 60 days before any pipe handling/shipping is schedule to be shipped.
End caps (bevel protectors) shall be used to protect all prepared pipe ends, the
bevel protector shall be of such design, material and mechanical strength to avoid
damages during handling, shipping and transportation.
If Owner/Buyer or Owner’s designated representative observes coating or pipe
damage due to handling or stacking, the Bidder will be required to take immediate
corrective action.
The use of metal chains, wire ropes or cables is unacceptable. The pipe bevels
shall be inspected, and the interior of the pipe inspected for cleanliness, by the
Buyer's Inspector prior to replacement of the metal end protectors
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8.3
PIPE STACKING
Pipe shall be stacked in such a manner to prevent damage to the pipe or coating.
Prior to use, the Bidder shall submit proposed stacking arrangements, including
stacking heights, to Buyer for review.
Stacked pipes shall be separated from each other to prevent damage in according
to API RP 5LW.
All pipes shall be stacked on level ground free from foreign materials, stones and
vegetation and on supports of a proven load bearing capacity. Pipes shall be
suitably spaced from the soil (minimum 150 mm) to prevent any contact with the
ground and to prevent surface water from entering during the entire storage period.
Pipe shall be prevented from exposure to salt spray.
Separation between coated pipe joints shall be provided by use of strips of soft
rubber, rope or other material, which will prevent damage to the coating. Pipe
stacks shall be of the same diameter, wall thickness and grade of pipe and shall be
clearly marked.
Slings or non-metallic straps shall be used for securing loads during transportation.
They shall be suitably padded at contact points with the pipe.
8.4
DAMAGE TO PIPE, PIPE ENDS AND REPAIR
No repair work shall proceed until a written procedure has been prepared by the
Vendor and approved by Buyer.
Minor damage to pipe and pipe ends/bevels, identified either at time of receipt or
after abrasive blasting shall be repaired by grinding. The number of such damages
shall be not more than 3 per pipe. Repair by grinding on the pipe or pipe
ends/bevels outside diameter shall not reduce the wall thickness to less than the
minimum requirements of the line pipe specification, when measured using
ultrasonic thickness measurement equipment.
All other damage to pipe ends/bevels shall be advised to Owner/Buyer for review.
Subject to Owner/Buyer approval, these defects may be repaired by removal of
damaged pipe material and re-beveling. No welding on the pipe surface shall be
allowed.
Pipe identification numbers shall be preserved during repair. The pipe tally to be
submitted to Owner/Buyer shall record all pipe lengths. Any reduction in pipe
lengths shall be input as a separate entry in the tally.
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If pipe or coatings are damaged whilst under the control of the Bidder, the Bidder
shall reimburse Owner/Buyer for the cost of the repairs or replacement of all such
pipe, and the cost of additional inspection and transport.
8.5
SHIPPING
The Bidder's bid shall include shipping and all packing for shipping costs involved
for delivery as stated in the material requisition.
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