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DNV RP F106 | Pipe (Fluid Conveyance) | Plastic
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Since issued in print (October 2003), this booklet has been amended, latest in October 2005. See the reference to Amendments and Corrections on the next page.
Comments may be sent by e-mail to rules@dnv.com For subscription orders or information about subscription terms, please use distribution@dnv.com Comprehensive information about DNV services, research and publications can be found at http://www.dnv.com, or can be obtained from DNV, Veritasveien 1, NO-1322 Hvik, Norway; Tel +47 67 57 99 00, Fax +47 67 57 99 11.
Amended October 2005, see note on front cover
Recommended Practice DNV-RP-F106, October 2003 Page 3
1. 1.1 1.2 1.3 1.4 1.5 2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 GENERAL .............................................................. 5 Introduction .............................................................5 Scope .........................................................................5 Objectives and use ...................................................5 Structure of document ............................................6 Relation to DNV-OS-F101 and other DNV documents on pipeline corrosion control ..............6 REFERENCES ....................................................... 7 ASTM (American Society for Testing and Materials) .................................................................7 BS (British Standards) ............................................7 CSA (Canadian Standards Association)................7 DIN (Deutsche Industrie Normen).........................7 DNV (Det Norske Veritas) ......................................7 EN (European Standards) ......................................7 GBE (Gas Business Engineering/British Gas) ......7 ISO (International Organization for Standardization) ......................................................8 NACE (National Association of Corrosion Engineers).................................................................8 2.10 3. 4. 5. 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 6. 7. NF (Normes Francaise)........................................... 8 TERMINOLOGY AND DEFINITIONS ............ 9 ABBREVIATIONS ................................................ 9 COMMON REQUIREMENTS ............................ 9 Manufacturing procedure specification................ 9 Pre-production qualification testing (PQT).......... 9 Quality control of production .............................. 10 Coating and blasting materials ............................ 11 Receipt inspection of pipes and surface preparation ........................................................... 12 Coating application ............................................... 12 Inspection and testing of coated pipes................. 13 Repairs and stripping ........................................... 13 Documentation and marking ............................... 13 Handling and storage of pipes.............................. 14 ANNEX 1 COATING DATA SHEETS ............ 15 ANNEX 2 SPECIFICATION OF AMENDMENTS AND DEVIATIONS .............. 32
Recommended Practice DNV-RP-F106, October 2003 Page 4
Recommended Practice DNV-RP-F106, October 2003 Page 5
1.1.1 The primary objective of external coatings on submarine pipelines is corrosion control. In addition, the coating system can be designed to provide mechanical protection during installation and operation, and/or thermal insulation. A corrosion protective coating may also be combined with a concrete weight coating (for anti-buoyancy and/or mechanical protection during operation). 1.1.2 Coatings for external corrosion control of pipelines are applied to individual pipe lengths at a dedicated coating plant. This coating is referred to as linepipe coating (sometimes also as factory coating). In order to facilitate girth welding, areas at each end of the individual pipe length are left uncoated. These areas are normally coated after welding, by applying a field joint coating system (ref. DNV-RP-F102). Repair of linepipe coating after discharge from the coating factory is referred to as coating field repair (ref. DNV-RP-F102).
Guidance note: In its widest sense, the term pipeline coating includes linepipe coating, field joint coating (FJC) and coating field repair (CFR). FJC and CFR are typically performed under the same contract issued by the installation contractor, whilst linepipe coating is mostly carried out by another coating manufacturer contracted by the pipeline operator, installation contractor or linepipe manufacturer.
5) Glass fibre reinforced asphalt enamel coating*). 6) Glass fibre reinforced coal tar enamel coating*). 7) Polychloroprene (vulcanised rubber) coating (sometimes applied for thermal insulation in addition to corrosion control and mechanical protection). 8) Multi-layer polychloroprene (vulcanised rubber) coating (primarily for heat/thermal insulation).
1.2.3 This RP covers primarily the process of coating of ordinary pipe joints, and pipe joints with a buckle arrestor. It may also be used for coating of pipeline components (e.g. bends, tees and reducers), or for coating of linepipe for onshore pipelines, using the same or similar coating systems. The user shall consider the needs for amendments and deviations for such applications. 1.2.4 The following activities associated with linepipe coating are not covered in the present recommended practice: Requirements for the qualification of supplier specific coating materials for general purposes (i.e. not project specific), see Guidance Note to 5.4.3. Detailed design of linepipe coating systems for project specific purposes (e.g. heat insulation, anti-buoyancy; see also Guidance Note to 5.4.2). Application of concrete weight coating. 1.2.5 Although considerations related to safety and environmental hazards associated with either pipe coating work or properties of the coating in the as applied condition (reflected by national and multi-national regulations) are of great importance, such are never-the-less beyond the scope of this document.
1.1.3 Submarine pipelines are almost invariably designed with a cathodic protection (CP) system, mostly based on galvanic (or sacrificial) anodes. The CP system serves as a back-up for any deficiencies of the pipeline coating, including defects during manufacturing and damage during transportation/installation, in addition to any assumed degradation of coating materials and mechanical damage during operation. Hence, CP design for submarine pipelines is closely related to the design and quality control of pipeline coatings, including FJC and CFR.
1.2.1 This Recommended Practice (RP) has been prepared to facilitate the specification and execution of coating work. While the requirements and recommendations are general, the document contains advice on how amendments can be made to include project specific requirements and requirements/guidelines by a regulating authority, or to reflect the pipeline operators general philosophy on pipeline corrosion control. 1.2.2 This RP covers the process of applying external coating systems for corrosion control of submarine pipelines at the coating plant, and includes the qualification and implementation of this process. The following coating systems are covered: 1) Single or dual layer fusion bonded epoxy*). 2) 3-layer coating based on an inner layer of fusion bonded epoxy (FBE) applied by spraying, an intermediate adhesive layer applied by spraying or extrusion, and an outer jacket of polyethylene (PE) applied by extrusion*). 3) 3-layer coating based on an inner layer of FBE applied by spraying, an intermediate adhesive layer applied by spraying or extrusion, and an outer jacket of polypropylene (PP) applied by extrusion. 4) Multi-layer PP coatings with the 3 innermost layers as for 3) above and a relatively thick layer of foamed or syntactic PP for the purpose of thermal insulation plus an outer jacket in PP.
1.3.1 This Recommended Practice (RP) has two major objectives; it may either be used as a guideline for the preparation of manufacturing specifications for external pipeline coating systems as defined in 1.2.2 above, or it may be used as an attachment to an inquiry or purchase order for such coatings. If Purchaser has chosen to refer to this RP in a purchase document (see definition in Sec. 3, then Contractor shall consider all requirements in this RP as mandatory (see Sec. 3), unless superseded by amendments and deviations in the specific contract (see 1.3.4). 1.3.2 If reference is made to this RP in a purchase document (see definition in Sec. 3), the following additional information and requirements shall always be specified, if applicable and relevant to the specific coating system as defined in the Coating Data Sheet (CDS) of ANNEX 1: Information: Pipe material (reference to selected standard or purchasers specification), nominal inner diameter, wall thickness and length. Seam weld dimensions, including tolerances, if relevant for the specified coating system. Any temporary external coating (e.g. varnish type) or per-
Recommended Practice DNV-RP-F106, October 2003 Page 6
manent internal coating on pipes to be supplied for external coating. Requirements: Coating design; i.e. type of coating system, max./min. thickness of individual coating layers (5.6.5), surface roughness/profile and colour. Coating configuration at pipe ends such as length of cutback and coating chamfer angle (5.6.6). Project specific requirements to the detailed design of coating system (e.g. heat insulation capacity, maximum fluid temperature, maximum water depth), if included in the scope of work. Specific requirements for pre-production qualification testing (PQT) such as number of pipes to be coated, qualification of repairs (type and number) and schedule for notification and supply of documentation (5.2). Methods and acceptance criteria for any testing indicated to be agreed in the applicable CDS of ANNEX 1 (see 5.3.3). Permissible coating repairs, e.g. maximum number per pipe and maximum size (5.8.3). Requirements to pipe tracking (5.5.2) and marking (5.9.1). Requirements to documentation, e.g. schedule for supply of documentation and format (5.9). 1.3.3 The following items, intended as a check list, may be included in purchase documents, as applicable and relevant. (For specification of amendments and deviations in purchase documents, see 1.3.4 below.): Additional testing indicated by agreement in the CDS (see 5.3.3), and any special conditions for testing (e.g. above and/or below ambient temperature). Specific coating materials to be used (e.g. supplier proprietary products, see 5.4.3). Verification of thermal insulation capacity by testing (5.2.6). Qualification of personnel carrying out coating repairs (5.2.7). Specific requirements to the ITP (5.3.2). Facilities needed for the Purchasers quality surveillance. Regulatory-, or Contractors requirements to the control of health and environmental hazards associated with coating work. Contractors management of non-conformities (5.5.12, 5.7.8) and concession requests (5.5.1). Additional pipe receipt inspection, e.g. checking of dimensions or weight (5.5.3). Surface preparation of pipes other than cosmetic grinding (5.5.11). Cleanliness of coated pipe ends and internal surfaces (5.5.7 and 5.6.7). Pipe end protection (e.g. temporary corrosion protective
coating and use of end caps, see 5.10.4). Special requirements to handling and storage of pipes (5.10.1). Special requirements to shipping of coated pipes (5.10.4), including final inspection (5.7.9). Further deviations or amendments to this document. 1.3.4 As far as practical, tentative test methods and acceptance criteria for testing indicated in the CDS as to be agreed (see 1.3.2) or by agreement (see 1.3.3) shall be specified by Purchaser in the inquiry. Purchaser may also specify any preference for a specific test method in case more than one method is specified for mandatory testing (to be included). If alternative methods are given in the CDS and no specific method has been specified by Purchaser, the method to be used is optional to Contractor. 1.3.5 ANNEX 2, Tables 1 and 2 show examples of how deviations and amendments to the common requirements in Sec. 5 and to a specific CDS, respectively, may be specified in a purchase document.
1.4.1 Requirements that are common to all types of external linepipe coating systems are given in Sec. 5 whilst those applicable to a specific system or application are contained in individual Coating Data Sheets (CDS) in ANNEX 1.
1.5.1 DNV-OS-F101 Submarine Pipeline Systems, Sec. 8, gives some guidelines to the selection of pipeline external corrosion protective coatings, field joint coatings and concrete coatings, and general requirements to their manufacturing. This document (DNV-RP-F106) provides detailed requirements for the manufacturing of factory applied external coating of linepipe. 1.5.2 DNV-RP-F102 Pipeline Field Joint Coating and Field Repair of Linepipe External Coating gives detailed requirements to the manufacturing of such coating. 1.5.3 Cathodic protection of coated submarine pipelines is covered in DNV-RP-F103 Cathodic Protection of Submarine Pipelines by Galvanic Anodes.
Guidance note: This document offers CP design parameters that are based on the requirements to pipeline coatings in DNV-RP-F102 and in DNVRP-F106 (i.e. present RP), reducing the need for arbitrary conservatism in CP design due to potential deficiencies associated with pipeline coating design and/or quality control of coating manufacturing..
Recommended Practice DNV-RP-F106, October 2003 Page 7
The following standards are referred to in this document. The latest editions apply.
ASTM G21 ASTM G22
2.1 ASTM (American Society for Testing and Materials)
ASTM C518 Test Method for Steady-State Heat Flux Measurements and Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus Test Method for Dielectric Breakdown Voltage and Dielectric Strength of Solid Electric Insulating Materials at Commercial Power Frequencies Test Method for determining the Izod Pendulum Impact Resistance of Notched Specimens of Plastics Test Method for D-C Resistance or Conductance of Insulating Materials Test Method for Water Absorption of Plastics Test Method for Tensile Properties of Plastics Test Method for Brittleness Temperature of Plastics and Elastomers by Impact Test Method for Rockwell Hardness of Plastics and Electrical Insulating Materials Test Method for Flexural Properties of Unreinforced and Reinforced Plastics and Electrically Insulating Materials Practice for Testing Water Resistance of Coatings Using Water Immersion Test Method for Rubber Deterioration Surface Ozone Cracking in a Chamber Test Method for Flow Rates of Thermoplastics by Extrusion Plastometer Test Method for Vicat Softening Temperature of Plastics Test Method for Particle Size (Sieve Analysis) of Plastic Materials Standard Test Method for Rubber Property Vulcanization Using Oscillating Disc Cure Meter Test Method for Rubber Property-Durometer Hardness Test Method for Oxidative-Induction Time of Polyolefins by Differential Scanning Calorimetry Test Method for Abrasion Resistance of Organic Coatings by the Taber Abrader Test Method for Indicating Oil or Water in Compressed Air Test Methods for Water Vapour Transmission of Materials Practice for Measuring Thickness by Manual Ultrasonic Pulse-Echo Contact Method Test Method for Cathodic Disbonding of Pipeline Coating Test Method for Impact Resistance of Pipeline Coatings (Falling Weight Test) Test Method for Penetration Resistance of Pipeline Coatings
Practice for Determining Resistance of Synthetic Polymeric Materials to Fungi Practice for Determining Resistance of Plastics to Bacteria
2.2 BS (British Standards)
Test Sieves Technical Requirements and Testing. Test Sieves of Metal Wire Cloth BS410 Part 2 Test Sieves. Technical Requirements and Testing. Test Sieves of Perforated Metal Plate BS903 PartA1 Physical Testing of Rubber. Determination of Density BS3900 Part F4 Methods of Tests for Paint; Resistance to Continuous Salt Spray BS4147 Specification for Bitumen-Based Hot-Applied Coating Materials for Protecting Iron And Steel, Including Suitable Primers Where Required BS4164 Specification for Coal-Tar-Based Hot-Applied Coating Materials for Protecting Iron And Steel, Including a Suitable Primer BS6374 Part 5 Lining of Equipment with Polymeric Materials for the Process Industries Part 5. Specification for Lining with Rubbers BS410 Part 1
ASTM D256 ASTM D257 ASTM D570 ASTM D638 ASTM D746 ASTM D785 ASTM D790 ASTM D870 ASTM D1149 ASTM D1238 ASTM D1525 ASTM D1921 ASTM D2084 ASTM D2240 ASTM D3895 ASTM D4060 ASTM D4285 ASTM E96 ASTM E797 ASTM G8 ASTM G14 ASTM G17
2.3 CSA (Canadian Standards Association)
CAN/CSAZ245.20/21 External Fusion Bond Epoxy Coating for Steel Pipe-External Polyethylene Coating for Pipe
DIN 30670 DIN 30671 DIN 30678 DIN 53516 Polyethylene Coatings of Steel Pipes and Fittings; Requirements and Testing Thermoses Plastic Coatings for Buried Steel Pipes Polypropylene Coatings for Steel Pipes Testing of Rubber and Elastomers; Determination of Abrasion Resistance
DNV-OS-F101 Submarine Pipeline Systems DNV-RP-F102 Pipeline Field Joint Coating and Field Repair of Linepipe External Coating DNV-RP-F103 Cathodic Protection of Submarine Pipeline by Galvanic Anodes
EN 1426 EN 10204 Methods for Determination of Softening Point of Bitumen (Ring and Ball) Metallic Products Types of Inspection Documents
2.7 GBE (Gas Business Engineering/British Gas)
GBE/CW6 Technical Specification for the External Protection of Steel Linepipe and Fittings Using Fusion Bonded Powder and Associated Coating Systems
Recommended Practice DNV-RP-F106, October 2003 Page 8
2.8 ISO (International Organization for Standardization)
ISO 34 ISO 37 ISO 178 ISO 188 ISO 306 ISO 527 ISO 719 ISO 813 ISO 815 ISO 845 ISO 868 ISO 1133 ISO 1183 ISO 1306 ISO 1431-3 ISO 1515 ISO 1817 ISO 2187 ISO 2409 ISO 2431 ISO 2655 ISO 2781 ISO 2808 ISO 2811 ISO 2815 ISO 3001 Rubber, Vulcanised or Thermoplastic. Determination of Tear Strength Rubber, Vulcanised or Thermoplastic Determination of Tensile Stress- Strain Properties Plastics, Determination of Flexural Properties Rubber, Vulcanised or Thermoplastic Accelerated Ageing and Heat-Resistance Tests Plastics-Thermoplastic Materials Determining of Vicat Softening Temperature Plastics Determination of Tensile Properties. Part 1 and 2. Testing of Glass; Determination of Water Resistance (Grain Titration Method) and Classification of Glass in Hydrolytic Classes Rubber, Vulcanised or ThermoplasticDetermination of Adhesion to Rigid Substrate- 90 Degree Peel Method Physical Testing of Rubber. Method for Determination of Compression Set at Ambient, Elevated and Low Temperatures Cellular Plastics and Rubbers Determination of Apparent (Bulk) Density Plastics and Ebonite Determination of Indentation Hardness by Means of a Durometer (Shore Hardness) Plastics Determination of the Melt MassFlow Rate (MFR) and the Melt VolumeFlow-Rate (MVR) of Thermoplastics Plastics Methods for Determining the Density and Relative Density of Non-Cellular Plastics Rubber Compounding Ingredients-Carbon Black (Pelletized)-Determination of Pour Density Rubber, Vulcanised or ThermoplasticResistance to Ozone Cracking- Part 1: Static Strain Test Paints and Varnishes Determination of Volatile and Non-Volatile Matter Vulcanised Rubber. Determination of the Effects of Liquids Non-Magnetic Coatings on Magnetic Substrates Measurements of Coating Thickness-Magnetic Method Paints and Varnishes Cross-Cut Test Paints and Varnishes Determination of Flow Time by Use of Flow Cups Plastics Resins in the Liquid State or as Emulsions or Dispersions Determining of Apparent Viscosity by the Brookfield Test Rubber Vulcanised Determination of Density Paints and Varnishes Determination of Film Thickness Paints and Varnishes Determination of Density Paint and Varnishes Buchholz Indentation Test Plastics-Epoxy Compounds-Determination of Epoxy Equivalent
ISO 3251 ISO 4624 ISO 4892-2 ISO 7253 ISO 8130-6 ISO 8501-1
ISO 8502-2 ISO 8502-3 ISO 8502-6 ISO 8503-2
ISO 10005 ISO 10474 ISO 13736
Plastics- Determination of Melting Behaviour (Melting Temperature) of Semi-Crystalline Polymers by Capillary Tube and Polarizing-Microscope Methods Plastics- Unsaturated Polyesters and Epoxy Resins-Determination of Overall Volume Shrinkage Paints and Varnishes Pull-Off Test for Adhesion Plastics Methods of Exposure to Laboratory; Light Sources Paints and Varnishes-Determination of Resistance to Neutral Salt Spray Determination of Gel Time of Thermosetting Coating Powders at a Given Temperature Preparation of Steel Substrate Before Application of Paint and Related Products Visual Assessment of Surface Cleanliness. Part 1: Rust Grades and Preparation Grades of Uncoated Steel Substrates and of Steel Substrates After Overall Removal of Previous Coatings. Part 2: Laboratory Determination of Chloride on Cleaned Surfaces Part 3: Assessment of Dust on Steel Surfaces Prepared for Painting (Pressure Sensitive Tape Method) Part 6: Sampling of Soluble Impurities on Surfaces to be Painted the Bresle Method. Preparation of Steel Substrates Before Application of Paints and Related Products Surface Roughness Characteristics of BlastCleaned Substrates. Part 2: Method for the Grading of Surface Profile of Abrasive Blast-Cleaned Steel Comparator Procedure Part 4: Method for the Calibration of ISO Surface Profile Comparators and for the Determination of Surface Profile Stylus Instrument Procedure Quality Management- Guidelines for Quality Plans Steel and Steel Products Inspection Documents Methods for Determination of the Flash Point by the Abeles Apparatus
2.9 NACE (National Association of Corrosion Engineers)
2.10 NF (Normes Francaise)
NF A 49-710 NF A 49-711 External 3- Layer Polyethylene Based Coating. Application by Extrusion External 3- Layer Polypropylene Based Coating. Application by Extrusion
Recommended Practice DNV-RP-F106, October 2003 Page 9
party (pipeline operator or main contractor) issuing inquiry or contract for coating work, or nominated representative Contractor party to whom the coating work has been contracted manufacture manufacture/manufacturing relates to the manufacturing processes associated with the qualification of linepipe coating (PQT), and the subsequent production of such coatings. The producer of coating materials is referred to as coating material supplier or supplier shall indicates a mandatory requirement should indicates a preferred course of action may indicates a permissible course of action agreed refers to a written arrangement between agreement Purchaser and Contractor (e.g. as stated in a contract) report and refers to an action by Contractor in writing notify accepted refers to a confirmation by Purchaser in acceptance writing certificate refers to the confirmation of specified propcertified erties issued by Contractor or supplier of coating materials according to EN 10204:3.1.B, ISO 10475:5.1-B or equivalent purchase refers to an inquiry/tender, or to purchase/ document(s) contract specification, as relevant For definition of coating terms associated with submarine pipeline systems, reference is made to 1.1.2 above. Purchaser
5.1.2 The MPS shall as a minimum include the following data sheets, procedures and other information: coating material properties, including suppliers product data sheets (PDS) and/or certificates (5.4.3 - 5.4.9) receipt, handling and storage of materials for surface preparation and coating (5.4.10 - 5.4.12) coating plant lay-out sketch or flow diagram surface preparation (5.5) data sheets for chemical pre-treatment products (5.5.14) and masking tape (5.6.4), if applicable coating application (including control of essential process parameters, see 5.6.6) inspection and testing (5.5, 5.7) coating repairs and stripping of unrepairable coating (5.8) preparation of pipe ends after coating (5.6.6, 5.6.7 and 5.7.5) pipe tracking (5.5.2, 5.9.1) marking and documentation (5.5.2 and 5.9) handling and storage of coated and uncoated pipes (5.10). Procedures for the last five items are subject to acceptance by Purchaser. Some detailed requirements for items to be included in the coating manufacturing specification are given in 5.4 5.10.
Guidance note: For accepted/acceptance, and agreed/agreement, see definitions in Sec .3
5.1.3 Purchaser may specify (see 1.3.3) that other additional detailed information is included in the MPS, e.g. procedures for testing and inspection, Contractors management of nonconformities and concession requests (see 1.3.3).
5.2 Pre-production qualification testing (PQT)
CDS CP CR FBE ITP LE MIP MPS NC PDS PE PP PQT RP Coating Data Sheet Cathodic Protection Concession Request Fusion Bonded Epoxy Inspection and Testing Plan (see 5.3.2) Liquid Epoxy (two-pack type) Manufacturing and Inspection Plan (see 5.3.3) (Coating) Manufacturing Procedure Specification (see 5.1) Non-Conformance (Coating material) Product Data Sheet (see 5.4.4) Polyethylene (polyethene) Polypropylene (polypropene) (Coating) Pre-Production Qualification Testing (see 5.2) Recommended Practice
5.2.1 The primary objective of the pre-production qualification testing (PQT) is to verify that the MPS is adequate to achieve the specified as-applied coating properties. Of particular interest are those aspects that require destructive testing and hence cannot be frequently verified during regular production. The PQT shall use the specific coating materials, equipment and key personnel to be used during ordinary production. Furthermore, it shall establish that specified dimensions/tolerances for cut-back preparation and surface roughening of the coating (if applicable) can be met. The PQT shall also include any receipt testing of the actual coating materials supplied for the specific assignment. Coating of pipe joints with buckle arrestor and pipeline components, if applicable, shall be included in the PQT. 5.2.2 Coating manufacturing procedures (including repairs) and equipment for coating shall be qualified prior to production, or alternatively (if contractually agreed) during the manufacturing start-up phase of the plant (normally referred to as first day production test).
Guidance note: For more complex coating systems, it is recommended that the PQT is carried out in due time prior to start-up of production.
5. Common Requirements
5.1 Manufacturing procedure specification
5.1.1 All work associated with coating manufacturing (including its qualification; PQT, see 5.2) shall be described in procedures which shall be compiled in a manufacturing procedure specification (MPS). This MPS shall be submitted to the Purchaser prior to the PQT and/or start of production.
5.2.3 Purchaser may choose to accept results from a previous qualification using identical coating materials and process parameters, and similar pipe dimensions (to be confirmed in contract). However, significant changes of essential process parameters (e.g. application temperature for pipe material and coating materials, line speed, etc.), coating material formulation or pipe dimension require re-qualification.
Guidance note: In case of any doubt whether changes of process parameters are
Recommended Practice DNV-RP-F106, October 2003 Page 10
significant, a new PQT should always be carried out. For certain coating systems, in particular those that are dependant on curing of an innermost epoxy layer by induction heating, the quality of the coating is dependant on a combination of parameters, including coil arrangement and applied power, line speed and pipe wall thickness that are unique for each specific project. The PQT shall demonstrate proper application temperature by direct temperature recordings at the location where FBE shall be applied. Furthermore, it is essential for coating configuration at pipe ends i.e. length of cut-back and coating chamfer angle, that the capability of the equipment to apply a uniform thickness of the individual layers is verified prior to start of production. It is recommended that a previous PQT of such coating systems is not accepted, and that the PQT is witnessed by a competent person representing Purchaser.
adhesion to steel surface and/or parent coating. It shall further be demonstrated that the repair does not deteriorate the properties of the adjacent parent coating (e.g. adhesion to steel substrate). 5.2.13 Results from all inspection, testing and calibrations during qualification, recordings of essential operational parameters for coating (including e.g. line speed and parameters relevant to temperature control for linepipe and coating materials ), and coating material certificates shall be compiled in a PQT report. Unless otherwise agreed, the report shall be accepted by Purchaser prior to start of production.
5.3 Quality control of production
5.3.1 Prior to start-up of regular production, Contractor shall submit the following documents to Purchaser for acceptance: a project specific MPS updated to reflect the process parameters used during the completed and accepted PQT a project specific inspection and testing plan (ITP) updated to reflect the process parameters used during the completed and accepted PQT (see 5.3.2) a daily log format (see 5.7.10) a description of responsibilities of personnel involved in quality control. 5.3.2 The ITP shall meet the general requirements of ISO 10005, Sec. 5.10. It shall be in tabular form, defining all quality control activities associated with receipt of coating materials, inspection and marking of incoming pipe, surface preparation, coating application and inspection/testing of the applied coating. The activities shall be listed in consecutive order, with each activity assigned a unique number and with reference to the applicable code(s), standard(s) and Contractors procedure(s) or work instruction(s) that shall apply for the specific project. Furthermore, frequency / extent of inspection and testing, acceptance criteria and actions in the case of non-conformances shall be defined in the plan. The ITP shall further contain a column for inspection codes, (e.g. inspection, witnessing and hold points) indicating the involvement of Contractor, Purchaser and any 3rd party. It is good practice to include a reference to the applicable reporting form/document and to refer to the specific equipment or tools to be used for verification.
Guidance note: It is recommended that the ITP also reflects the relevant manufacturing steps, in addition to the inspection and testing activities, all in the consecutive order they occur during production. Such a document is sometimes referred to as a manufacturing and inspection plan (MIP).
5.2.4 Specific requirements for pre-production qualification testing, including e.g. number of pipes to be coated and repaired, schedule for notification and reporting, shall be specified in the purchase document (see 1.3.2 -1.3.4 and definition of purchase document in Sec. 3). 5.2.5 For pipes with internal coating, the PQT shall confirm no detrimental effects of the external coating process.
5.2.6 For linepipe coating intended for thermal insulation, Purchaser may require verification of insulating capacity by testing (to be specified in the purchase document). 5.2.7 Purchaser may require that the PQT shall include qualification of individual coating applicators to carry out more complex repairs of coating. 5.2.8 An MPS and an inspection and test plan (ITP, see 5.3.2) specific for the PQT, together with a detailed schedule for coating application, inspection/testing and reporting shall be submitted to Purchaser in a timely manner (as per purchase document) prior to start-up of the qualification activities. 5.2.9 Coating application temperature, drying or curing conditions, shall be according to coating material suppliers recommendations. Data sheets and calibration certificates for instruments essential to quality control (e.g. temperature sensors) shall be available for Purchasers review during the PQT. 5.2.10 If practical, the pipes to be coated for PQT should be of the same supply as that used for production. As a minimum, 3 pipes shall be coated with a full coating system. For 3- and multi-layer systems with an innermost layer of FBE, minimum one pipe shall be coated without adhesive to allow easy stripping of the outer PE/PP layer for verification of FBE thickness, curing of FBE and PE/PP as-applied tensile properties. The number of personnel involved in coating application during the PQT, including any supervisor, should be the same as that used for normal production. 5.2.11 Purchaser shall have the right to select or accept pipe(s) for inspection and testing during the PQT. Unless otherwise agreed, test methods and acceptance criteria shall be in accordance with the applicable CDS in ANNEX 1 of this document. The frequency and extent of testing for properties with a frequency/extent of testing noted as by agreement in the CDS shall be specified in purchase document (1.3.3). 5.2.12 Qualification of coating repairs shall be performed to verify the properties of maximum allowable repair size as specified in purchase document. Minimum 3 repairs shall be carried out for each repair procedure to be used for repairs. Testing shall as a minimum include holiday detection and
5.3.3 Unless otherwise agreed (see 1.3.3), methods and frequency of inspection and testing, as well as acceptance criteria shall be in accordance with the applicable CDS in ANNEX 1 of this document. The following notes apply to all CDSs: according to MPS / ITP means that testing method and/ or acceptance criteria are optional to Contractor but shall be defined in the MPS / ITP to be included under frequency / qualification means that testing shall be included during PQT to be agreed means that testing shall be carried out, and that test method and/or acceptance criteria (as applicable) are subject to agreement. (A tentative test method and acceptance criterion is preferably to be specified by Purchaser in inquiry and the agreed method / criterion shall be included in the contract) by agreement and agreed testing method or acceptance criterion means that Purchaser may require testing, and/or that methods and acceptance criteria are subject to agreement (to be specified by Purchaser in inquiry and
Recommended Practice DNV-RP-F106, October 2003 Page 11
confirmed in contract). For specification of amendments and deviations to the data sheets, see 1.3.5. 5.3.4 The MPS, ITP, and daily log shall be in English, unless otherwise agreed. 5.3.5 Procedures and work instructions referenced in the ITP, and applicable acceptance criteria, shall be available to all persons concerned with the associated work and in their normal language. 5.3.6 Purchaser shall have the right to inspect any activity associated with coating work throughout production and to carry out audits of Contractors QA / QC system. Purchaser shall identify any hold points for witnessing (see 5.7.1) in the ITP and inform Contractor accordingly.
Guidance note: In the case of continuous production, batches will not apply and a lot is defined based on e.g. hours or weight/volume of production.
5.4 Coating and blasting materials
5.4.1 In this sub-section, coating materials cover materials for coating repairs as well as for linepipe coating. 5.4.2 The selection of coating materials for a particular project, and the specification of properties to be verified during PQT and production, shall take into account the maximum and minimum operating temperature of the pipelines, and any special conditions during installation and operation.
Guidance note: Unless included in Contractors scope of work, the selection of generic types of coating materials (e.g. high density PE or PP) shall be specified by Purchaser. (This selection is typically carried out during conceptual design).
5.4.7 For properties of processed (as-applied) coating materials, and in particular those related to long-term environmental degradation resistance, data for a representative product specification (i.e. not batch/lot specific) will normally apply and a test report based on non-specific testing is issued (EN 10204, type 2.2 or ISO 10474, type 4.2). For certain coating systems, mandatory requirements for certification of such processed properties apply as indicated by to be included or to be agreed in section 2 of the CDS, column Coating Material Qualification (see 1.3.2). Contractor may specify further properties for certification as indicated by agreement in the CDS (see 1.3.3).
Guidance note: Data on as-applied coating properties that are much dependent on surface preparation and/or coating application (e.g. adhesion and resistance to bending, blistering and cathodic disbonding) should be considered as indicative only and cannot replace any PQT data as specified in sub-section 3.2 of the applicable CDS.
5.4.8 Properties of blasting materials shall be documented (e.g. in a product data sheet for inclusion in the MPS). Abrasives for stainless steel linepipe shall be based on fused aluminium oxide, stainless steel shot or non-ferrous garnet according to an appropriate standard. 5.4.9 Contractor shall verify that all coating materials and abrasives received are in accordance with the specified requirements in the MPS. The verification may include testing - by Contractor himself (or by a third party) -, and/or review of suppliers certificates. Review of certificates and any verification testing to be performed by Contractor shall be included in the ITP. 5.4.10 Until compliance with specified requirements has been confirmed, the coating and blasting materials received by Contractor shall be kept physically separated from checked materials. Any materials checked and found non-conforming shall be marked and quarantined. 5.4.11 All materials to be used for surface preparation and coating of pipes shall be contained in their original packing until use and shall be adequately marked, including: manufacturers name and place of manufacture material type and product designation batch/lot number weight (for materials in drums, bags or similar) size (for materials in rolls or similar) date of manufacturing (and shelf life, if applicable) manufacturing standard (if applicable) short instruction for storage and handling (including health and safety notes).
5.4.3 Supplier specific coating materials shall be specified by Contractor in the MPS (see 5.1.2). Purchaser may specify in inquiry any preferences for supplier specific coating materials.
Guidance note: Prior to the issue of a specific purchase order, Purchaser or Contractor may choose to qualify specific coating material formulations according to their own requirements for linepipe coating (which need not be project specific). Such coating qualification should be specific to a production facility, and a defined range of production process parameters. Purchaser and/or Contractor may require witnessing of the coating material qualification testing, either by himself or by a third party, or that the qualification testing shall be performed by a third party.
5.4.4 Coating materials shall be described by supplier in specific product data sheets (PDS), including relevant properties of raw materials and processed (as-applied) materials, recommendations for surface preparation, application temperature range, conditions for curing/drying, detailed instruction for storage and handling. The PDSs (including those to be used for repairs) shall be contained in the MPS. 5.4.5 Testing and certification of coating material properties may relate to properties of either raw materials (as-delivered) or processed (as-applied) materials. In the latter case, test panels with applied coating, or specially prepared coating layers (i.e. without substrate) are used. 5.4.6 Certain properties related to raw materials (as-delivered) for coating shall be certified per batch / lot (i.e. by an inspection certificate type 3.1.B according to EN 10204, or type 5.1.B according to ISO 10474), in accordance with section 2, column Production, of the relevant coating data sheet (CDS) in ANNEX 1. Contractor may specify further properties for batch wise certification as indicated by agreement in the CDS.
5.4.12 Contractor shall ensure that all materials for coating and surface preparation are stored and handled so as to avoid damage by environment or other effects. The suppliers recommendations for storage and use shall be readily available for Purchasers review. 5.4.13 Any mixing of coating material batches/lots to be used for production shall be described in the MPS. 5.4.14 Recycled coating materials may be used if detailed in the MPS, stating e.g. requirements to cleaning and maximum addition to virgin coating material. Purchaser may require documentation that such use does not affect the specified proper-
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ties. For FBE powder, the maximum amount of recycled material shall not exceed 15%. 5.4.15 All coated pipes shall be traceable to individual batches/lots of coating materials.
5.5.9 After the blast cleaning, the pipes shall be thoroughly checked, e.g. by survey alongside a rotating pipe so that the entire pipe surface is covered. 5.5.10 Marking of defects (if applicable) shall be carried out using French chalk only. 5.5.11 Slivers, swabs, burns, laminations or gouges shall be removed by cosmetic grinding. (Any needs for, and specific requirements to, more excessive grinding required by Purchaser shall be specified in purchase documents). The remaining wall thickness shall comply with the applicable linepipe specification. (Checking of remaining wall thickness by ultrasonic testing shall be according to ASTM E797 or equivalent). Pipes with any dressed area larger than 10 cm2 shall be completely re-blasted. Unrepairable pipes shall be quarantined and Purchaser notified accordingly. 5.5.12 Dust or abrasive remains shall be removed from the pipe surface using dry clean air, vacuum cleaning, brushing or an equivalent technique. Compressed air quality shall be controlled (to be specified in MPS / ITP). Surface cleanliness and roughness shall be verified as detailed in the applicable CDS in ANNEX 1. Measurements of residual salt contamination may be performed using special proprietary equipment if specified in the ITP, and provided that compliance with the referenced standard can be demonstrated. Pipes not meeting specified requirements shall be subject to new blast cleaning or rejection. In the case of repeated failures, surface preparation shall be discontinued and Contractor shall issue a non-conformance report suggesting measures to improve the efficiency of the associated process. 5.5.13 Precautions shall be taken to avoid contamination or other damage to the pipe surface after completed surface preparation (e.g. by conveyor rollers) and/or superficial rusting. Requirements for maximum duration (in hours) between blasting and coating, and/or maximum relative humidity shall be specified in the MPS / ITP. 5.5.14 Mechanical surface preparation may be followed by a chemical treatment (to be stated in the MPS / ITP) if accepted by Purchaser. Any associated pre-heating of pipes, checking of chemicals and control of application shall be specified in MPS / ITP.
5.5 Receipt inspection of pipes and surface preparation
5.5.1 All surface preparation and associated inspection and monitoring activities shall be carried out according to the qualified MPS and ITP (5.3.2). Methods, acceptance criteria and frequency or extent of inspection and testing shall comply with requirements given in the relevant CDS in ANNEX 1, and/or amendments in purchase documents (see 1.3.2 and 1.3.3) as applicable. Once qualified, any changes from the MPS / ITP shall be formally accepted by Purchaser through a concession request (CR). 5.5.2 On receipt, every pipe shall be identified by a unique number (i.e. as applied by pipe manufacturer) and any additional marking made by Contractor to maintain identity shall be performed as specified or accepted by Purchaser (5.9.1). Intermediate storage of pipes shall be according to 5.10. 5.5.3 Each pipe shall be subject to an initial visual examination. Particular emphasis shall be paid to examination of pipe ends. Pipes with severe damage such as dents, ovality, cuts and other defects that cannot be corrected by surface dressing shall be removed and Purchaser notified accordingly. Any requirements to additional checking of pipe dimensions and/or weight shall be specified in purchase document. 5.5.4 Salts, soils and other loose contamination shall be removed from the pipe surface using a suitable water-based cleaning method (e.g. high-pressure fresh water or brushing). Organic contaminants like oil and grease shall be removed by using suitable hydrocarbon solvents or detergents (type to be specified in MPS). Purchaser shall be notified promptly if the surface condition of the received pipes is deemed to affect the quality of the coating. 5.5.5 Pipe surfaces shall be prepared for coating using blast cleaning to provide a surface cleanliness and surface roughness (anchor pattern) to meet the requirements in the applicable CDS of ANNEX 1. Any relaxation of these requirements based on coating suppliers recommendations shall be accepted by Purchaser. Materials and equipment to be used shall be described in the MPS. 5.5.6 Relevant properties of blasting materials shall be documented (e.g. in a product data sheet). Receipt, storage and marking of purchased products shall be as defined in 5.4.9 5.4.13. The blasting material and pressurised air system shall be kept dry and free from injurious contaminants, including salts, oil and grease. Recycled blasting material shall be checked for cleanliness at regular intervals (to be specified in the ITP and recorded in the daily log). Checking of oil contamination shall be carried out according to ASTM D4285. Conditioning of grit during production shall be described in the MPS. Special precautions shall be taken to avoid contamination of blasting materials for stainless steel linepipe (to be described in MPS). 5.5.7 Special protection of machined bevels and/or internal surfaces, e.g. by use of end caps during cleaning, may apply (to be specified in purchase documents). Precautions shall be taken to avoid contamination of stainless steel linepipe by C-steel particles, C-steel tools and handling equipment. 5.5.8 During blast cleaning, the pipe surface shall be at least 3C above the dew point temperature and the ambient relative humidity should not exceed 85%. Pre-heating of pipes is required if humidity is higher.
5.6 Coating application
5.6.1 All coating work shall be carried out according to the qualified MPS. Once the MPS has been qualified, any changes of materials, equipment and essential process parameters (including e.g. change in line speed) shall be formally accepted by Purchaser through a CR. 5.6.2 If pre-heating is applied, temperature control shall ensure that no pipe is heated above 270C. Powder application on linepipe shall be by automatic electrostatic spraying with control of compressed air quality. For use of re-cycled coating materials, see 5.4.14. 5.6.3 Throughout coating application, essential parameters affecting the quality of the coating (e.g. application temperature of linepipe and coating materials, line speed, relative humidity, etc) shall be monitored on-line and recordings noted in the daily log (5.7.10). For certain coating systems, the application temperature shall be continuously monitored and recorded on-line as specified in the applicable pipeline coating data sheet in ANNEX 1. Equipment for monitoring shall be calibrated at scheduled intervals as specified in the ITP (5.3.2). 5.6.4 Any use of temporary coatings or tapes to mask coating application at pipe ends shall be described in the MPS (material data sheets to be included). 5.6.5 Coating thickness (nominal and minimum values of
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individual layers, maximum value if applicable) shall be defined in purchase document (i.e. unless thicknesses stated in the CDS shall apply).
Guidance note: Thickness measurements during production are made on a spot check basis and are primarily intended to verify nominal coating thickness (or minimum/maximum average thickness), not an absolute minimum thickness for individual pipes. The capability to produce uniform coating thickness for individual pipes is to be verified during the PQT.
coating layer (or indication by holiday detector).
5.7.5 Inspection shall verify specified dimensions for coating cut-backs and any requirements for cleanliness of pipe ends. 5.7.6 Failures during testing which are obviously due to defective sampling or operational errors of testing equipment may be disregarded and testing repeated on the same pipe. 5.7.7 Individual pipes not meeting specified criteria shall be re-coated, or if possible (see 5.8), repaired. In case of failure of a pipe coating during fractional testing (e.g. each 20th pipe or twice per shift), the preceding and following pipes shall be tested individually until at least 3 successively coated pipes show adequate properties. In the case of repeated failures to meet specified acceptance criteria, Purchaser shall have the right to require testing frequency to be increased. Similarly, subject to acceptance by Purchaser, testing frequency may be reduced as a result of repeated successful testing. 5.7.8 In case of repeated failures to meet specified requirements, production shall be discontinued. Contractor shall then carry out an examination of the cause(s) of the failure and issue a non-conformance report. Non-conforming pipes (individual or lots) shall be marked and quarantined. 5.7.9 Purchaser may specify a final inspection of the pipe coating prior to discharge. 5.7.10 All data from inspection and testing of coated pipes, essential operating parameters (e.g. application temperature, line speed, etc.) and calibration of testing and monitoring equipment, shall be noted in the daily log. For pipe specific data, reference shall be made to the unique pipe number 5.5.2). The log shall be up-dated on a daily basis and is to be available for Purchasers review at any time during manufacturing.
5.6.6 The length and surface condition of pipe ends to be left uncoated (or cut-back), and any chamfering of edges, shall be performed in accordance with the requirements in purchase documents and in the MPS. Any use of temporary protective coating on pipe ends shall be specified or accepted by Purchaser. 5.6.7 Any remainders of coating or blasting materials on the internal pipe surface shall be removed by an appropriate method. Special requirements to cleanliness of internal surfaces may apply as specified in purchase documents. Unless otherwise accepted by Purchaser, any end caps supplied with the pipes shall be refitted soon after coating has been completed.
5.7 Inspection and testing of coated pipes
5.7.1 Coated pipes shall be inspected and tested according to the ITP (5.3.2). Any changes shall be formally accepted by Purchaser through a concession request. Purchaser shall be allowed to witness all inspection and testing. Contractor shall give adequate notice for Purchaser to arrange for witnessing of special hold points indicated in the ITP (see 5.3.6).
Guidance note: Purchaser should consider the needs and benefits of carrying out quality surveillance during production, either as an audit or by continuous presence by trained and qualified inspectors.
5.8 Repairs and stripping
5.8.1 Coating repair may apply to coating holidays associated with production or damage to the coating during handling and storage at Contractors facilities. (For repairs of linepipe coating in the field, reference is made to DNV-RP-F102) 5.8.2 Coating repairs shall also be carried out and inspected according to a qualified procedure (see 5.2). Requirements to coating repair materials in 5.4 apply. 5.8.3 Maximum permissible repairs (e.g. maximum surface area of individual repair, maximum repairs per pipe and maximum number of pipes with repairs) shall be specified in purchase documents (1.3.2 and 1.3.3) and in MPS. Inspection of repairs shall as a minimum include visual examination, checking of thickness and holiday detection. 5.8.4 All major repairs (e.g. coating damage down to pipe surface) shall be noted in the daily log and shall be traceable to individual batches of coating material. 5.8.5 Stripping of unrepairable coating for re-coating of pipe shall be carried out according to a procedure accepted by Purchaser. Temperature control shall ensure that no pipe is heated above 270C. Multiple stripping of coating (i.e. for the same pipe) shall be subject to a CR. 5.8.6 Any cutting of pipes shall be carried out according to a procedure accepted by Purchaser. Cutting of individual pipes shall be subject to a CR.
5.7.2 Inspection and testing of coated pipes during qualification and production shall be carried out according to the applicable methods, acceptance criteria and frequencies specified in the applicable CDS and any amendments made in purchase documents (see 1.3.2 and .3.3). If alternative test methods are given in the CDS and Purchaser has not specified any preference in purchase document (see 1.3.4), then the selection of method is optional to Contractor. 5.7.3 Purchaser may specify testing of specified coating properties during production requiring cutting of pipe wall (e.g. cathodic disbondment testing and hot water soak test). Such testing may then be carried out on a special (dummy) test pipe if all other conditions are the same as for regular production. 5.7.4 Visual inspection of completed coating shall ensure that the entire pipe surface is covered, e.g. by survey alongside a rotating pipe.
Guidance note: Acceptance criteria for visual coating defects should be quantitative as far as practical. Photographs of non-acceptable defects may be helpful. Characterisation of damage to the linepipe coating should distinguish between, e.g. a) b) superficial defects that can be repaired by light surface dressing, defects with major reduction in coating thickness but without exposure of bare metal (or no indication by holiday detector), and damage that extends down to the pipe material or an inner
5.9 Documentation and marking
5.9.1 Specific requirements to pipe tracking (e.g. electronic format), marking and documentation format shall be specified
Recommended Practice DNV-RP-F106, October 2003 Page 14
in purchase documents (1.3.2). Contractors marking and pipe tracking shall be described in the MPS and included as a specific activity in the ITP. 5.9.2 All results from inspection and testing during qualification and production shall be documented and be traceable to a unique pipe number and individual coating material batches / lots. Recordings of essential process parameters and inspection of repairs (other than surface dressing) shall be included. For specific requirements to a daily log, see 5.7.10. 5.9.3 Documentation, including coating material certificates, shall be retained by Contractor for minimum 5 years, or as agreed upon. 5.9.4 Contractor shall issue an inspection document corresponding to the requirements given in EN 10204 or ISO 10474, inspection certificate 3.1.B.
5.10 Handling and storage of pipes
5.10.1 Pipes shall be handled and stored such that damage to coated and uncoated surfaces is avoided and in accordance with any special requirements in purchase documents. A procedure shall be contained in the MPS and is subject to acceptance by Purchaser. 5.10.2 Materials to be used on e.g. conveyors, rollers, pipe racks, fork padding and hooks contacting the external/internal pipe surface shall be specified in MPS. Stainless steel pipes require special considerations to avoid surface contamination (e.g. from use of C-steel tools and handling equipment). Purchaser may require documentation (e.g. by calculations) that a specified maximum stack height cannot cause any damage to large diameter pipes. 5.10.3 Damage to coatings during handling or storage shall be repaired according to 5.8, whilst any damage to linepipe material shall be reported to Purchaser. (Pipes with damage to linepipe material shall be separated and quarantined). 5.10.4 Any specific requirements for packaging or other means of protection of coated pipes for shipping (including use of end-caps) shall be defined in the purchase documents (1.3.3).
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6. ANNEX 1 Coating Data Sheets
Coating Data Sheet No.1: Single or Dual Layer Fusion Bonded Epoxy Coating 1 Coating Configuration Epoxy layer FBE: Typical nominal value 400 m to 600 m (min/max value and test method/frequency to be agreed for inclusion in ITP) 2 Coating Materials Item/Property Test method Acceptance criteria Frequency Coating Material Production Qualification and PQT 2.1.1 FBE material, raw material property Density ISO 2811 according to PDS not applicable every batch/lot Particle size according to PDS according to PDS not applicable every batch/lot Max. moisture content according to PDS according to PDS not applicable every batch/lot Gel time ISO 8130-6 according to PDS not applicable every batch/lot Thermal analysis NF A 49-711 or according to PDS not applicable by agreement GBE/CW6 part 1, App. A Infrared scan by agreement by agreement by agreement by agreement 2.1.2 FBE material, processed (as-applied) property Glass transition tempera- by agreement min. 95C and min. 5C to be included not applicable ture above pipeline max. operating temperature Water resistance ASTM D870, no blistering, to be included not applicable 3000 hrs at 85C or loss of hardness <10% Flexibility (bending) test Impact resistance Salt spray test Cathodic disbonding GBE/CW6 part 1, App. E GBE-CW6 Part 1 or CAN/CSA 245.20 ASTM G14 or GBE/CW6 part 1, App. D ISO 7253, 4000 hrs or BS 3900, Part F4 ASTM G8 or GBE/CW6, part 1, App. F or or other agreed procedure ASTM D4060 according to standard according to standard or by agreement >13 Joules acc. to standard no rusting, no blistering by agreement to be included by agreement by agreement by agreement not applicable not applicable not applicable not applicable
Abrasion resistance <0.050 g/1000 cycles 2.2.1 LE material, raw material property (for coating repairs) Epoxy equivalent in the ISO 3001 base Volume solids of the base ISO 3251 according to PDS and hardener Viscosity of base and hard- ISO 2655 according to PDS ener 2.2.2 LE material, processed material property (for coating repairs) not applicable 3 Surface Preparation, Coating Application and Final Inspection/Testing 3.1 Surface Preparation Item/Property Test method Acceptance criteria Initial surface condition visual examination
every batch every batch
Frequency Production every pipe minimum once per hour first 5, then 1/30 both pipe ends
Pipe temperature and rela- according to ITP tive humidity Salt contamination after ISO 8501-2 and blast cleaning ISO 8502 -6 or agreed method
PQT dry and free from contam- to be included ination (oil, grease, etc.) and surface defects pipe temperature min. to be included 3C above dew point max. 10 mg NaCl/m2 to be included
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Coating Data Sheet No.1: Initial/ intermediate washing by water or phosphoric acid Surface cleanliness Surface cleanliness Surface roughness
Single or Dual Layer Fusion Bonded Epoxy Coating (Continued) according to MPS/ITP not applicable by agreement ISO 8501-1 ISO 8502-3 ISO 8503-4 A/B Sa 2 . rating max. 2 RZ min. 40 m; max. 100 m free from surface defects according to ITP to be included to be included to be included to be included to be included
by agreement every pipe first 5, then 1/30 both pipe ends first 5, then 1/30 both pipe ends every pipe continuous monitoring
Final surface condition visual examination Pipe temperature prior to according to ITP chemical treatment (if specified in MPS) 3.2 Coating Application and Final Inspection/Testing Item/Property Test method Pipe temperature Coating material and pipe temperatures Pipe feed rate Water quenching Appearance of coating Pipe end configuration Holiday detection according to ITP according to ITP according to ITP according to ITP visual according to ITP
Acceptance criteria according to ITP according to ITP according to ITP according to ITP according to ITP according to ITP PQT to be included to be included to be included to be included to be included, 100% surface area to be included to be included, 100% surface area to be included
Frequency Production continuous monitoring continuous monitoring continuous monitoring continuous monitoring every pipe, 100% surface area every pipe, both pipe ends every pipe, 100% surface area (visual/acoustic alarm function) first pipe and start/lead pipe 1), then one pipe every shift 4 recordings (90) at both pipe ends and mid section first pipe, start/lead pipe1) then one pipe every shift by agreement
GBE/CW6 part 1, App. C no holidays or by agreement ISO 2808 or by agreement FBE: differential thermal analysis according to GBE/CW6 or by agreement ISO 2409 or ISO 4624 or DIN 30671 or by agreement according to ITP
FBE: TG = max. 5C
Impact resistance Hardness Porosity Bending resistance (specimen) at room temperature Cathodic disbonding
classification: 0 (ISO 2409) min. 34 MPa (ISO 4624) no detachment (DIN 30671) GBE/CW6 part 1, App. D according to standard or ASTM G14 ISO 2815 by agreement CAN/CSA-Z245.20 by agreement GBE/CW6, Appendix B no cracking or disbond(min. 2% strain) ment
to be included by agreement by agreement to be included
not applicable by agreement by agreement by agreement by agreement by agreement by agreement
ASTM G8 or max. 7 mm disbonding, 48 to be included GBE/CW6, part 1, App. E hrs at 65C, or 28 days at or other agreed procedure room temperature Hot water soak test GBE/CW6 according to standard to be included Part 1, App. E or agreed procedure Residual magnetism by agreement by agreement by agreement 1) start/lead pipe refers to first pipe after interrupted coating according to ITP, to be included, to be agreed and by agreement are explained in 5.3.3
END OF CDS 1
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Coating Data Sheet No.2: 3-Layer Polyethylene Coating 1 Coating Configuration Fusion bonded epoxy Typical nominal value 200 m to 400 m (min/max value and test method/frequency to be agreed for inclusion in ITP) Polyethylene adhesive According to ITP Polyethylene outer sheath According to ITP Total thickness Min. 2.0 mm (to be agreed for inclusion in ITP) 2 Coating Materials Item/Property Test method Acceptance criteria Frequency Coating Material Production Qualification and PQT 2.1.1 FBE material, raw material property as for CDS 1, 2.1.1 as for CDS 1, 2.1.1 as for CDS 1, 2.1.1 as for CDS 1, 2.1.1 2.1.2 FBE material, processed (as-applied) property as for CDS 1, 2.1.2 as for CDS 1, 2.1.2 as for CDS 1, 2.1.2 as for CDS 1, 2.1.2 2.1.3 LE material, raw material property (for coating repairs) as for CDS 1, 2.2.1 as for CDS 1, 2.2.1 as for CDS 1, 2.2.1 as for CDS 1, 2.2.1 2.1.4 LE material, processed material property (for coating repairs) as for CDS 1, 2.2.2 as for CDS 1, 2.2.2 as for CDS 1, 2.2.2 as for CDS 1, 2.2.2 2.2.1 PE adhesive material, raw material property Density ISO 1183 according to PDS not applicable every batch Particle size (for spraying) According to PDS according to PDS not applicable every batch Melt flow index/rate ISO 1133 or according to PDS not applicable every batch ASTM D1238 Softening point (Vicat) ISO 1306 or ASTM D1525 according to PDS not applicable every batch 2.3.1 PE material, raw material property Density ISO 1183 >0.94 kg/dm3 not applicable every batch/lot Melt flow index/rate ISO 1133 or ASTM D1238 according to PDS not applicable every batch/lot Softening point (Vicat) ISO 306 or ASTM D1525 110C not applicable every batch/lot Melting point ISO 3146 120C not applicable by agreement Thermo stabilisation ASTM D3895 by agreement by agreement by agreement 2.3.2 PE material, processed (as-applied) property Hardness ISO 868 or 50 Shore D to be included by agreement ASTM D785 Impact resistance NF A 49-710 according to standard to be included not applicable Izod impact, ASTM D256 by agreement by agreement by agreement room temperature Tensile properties, ISO 527 or tensile strength at yield to be included by agreement room temperature ASTM D638 20 MPa elongation at break 400% Indentation NF A 49-710 max. 0.1 mm at 20C to be included not applicable max. 0.3 mm at 80C Thermal degradation resist- NF A 49-710 100 days to be included not applicable ance Flexural modulus ASTM D790 or ISO 178 700MPa by agreement not applicable Brittleness temperature ASTM D746 <-40C by agreement not applicable UV resistance ISO 4892-2 or by agreement (ISO) or by agreement not applicable DIN 30670 or according to standard (NF) NF A 49-710 Abrasion resistance ASTM D4060 or by agreement by agreement not applicable DIN 53516 Fungi resistance ASTM G21 no growth by agreement not applicable Bacteria resistance ASTM G22 no growth by agreement not applicable
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Coating Data Sheet No.2: 3-Layer Polyethylene Coating (Continued) Water absorption ASTM D570 <0.5% per 24 hours Water vapour permeability ASTM E 96 <0.1g/m2 per 24 hours Thermal conductivity ASTM C518 by agreement Volume resistivity ASTM D 257 1013 ohm cm Electrical insulation capaci- NF A 49 710 108 ohm cm2 ty Dielectric strength ASTM D 149 25 kV/mm 3 Surface Preparation, Coating Application and Final Inspection/Testing 3.1 Surface Preparation Item/Property Test method Acceptance criteria as for CDS 1, 3.1 as for CDS 1, 3.1 as for CDS 1, 3.1 3.2 Coating Application and Final Inspection/Testing Item/Property: Test method Acceptance criteria 3.2.1 Epoxy layer 3.2.2 PE Adhesive Layer Thickness 3.2.3 PE layer and full layer Coating material and pipe temperatures Pipe feed rate Water quenching Appearance of coating Pipe end configuration Holiday detection
by agreement by agreement by agreement by agreement by agreement by agreement
Frequency PQT as for CDS 1, 3.1 Production as for CDS 1, 3.1 Frequency PQT Production
according to MPS/ITP
according to MPS/ITP according to MPS/ ITP according to ITP visual according to MPS/ ITP
according to ITP according to ITP according to ITP according to ITP according to ITP
to be included to be included to be included to be included, 100% surface area to be included to be included, 100% surface area
Thickness Adhesion (peel strength), at 20C 5C at 80C 5C Hardness Impact resistance, at room temperature at max. operating temperature, Indentation resistance, at room temperature and at 110C at max. operating temperature, if higher than 110C Tensile properties, at room temperature at room temperature at max. operating temperature Cathodic disbonding, at room temperature or at 65C at max. operating temperature, if higher than 65C
no holidays NACE RP0274, 10 kV/mm nominal thickness, max. 25 kV, 200-300 mm/s or NF A 49-711 according to MPS/ ITP according to purchase order (method to be agreed) and ITP NF A 49-711, E3 or DIN 30670/30678
continuous monitoring (pipe temperature before FBE application) continuous monitoring continuous monitoring every pipe, 100% surface area every pipe, both pipe ends every pipe, 100% surface area (visual/acoustic alarm function) according to ITP (frequency and location to be agreed) first pipe and start/lead pipe 1),then one per shift, both pipe ends not applicable not applicable first pipe and start/lead pipe 1), or by agreement not applicable first pipe for each PP batch by agreement first pipe for each PP batch not applicable by agreement by agreement
to be included, coverage to be defined for PQT min. 150 N/cm, no peeling of to be included FBE layer min. 40 N/cm, no peeling of FBE layer to be included to be included to be included by agreement to be included to be included to be included by agreement
ISO 868 NF A 49-711 or DIN 30670/30678
50 Shore D according to standard by agreement
NF A 49-711 or DIN 30670/30678
max. 0.10 mm, 20C max. 0.3 mm, 80C to be agreed
ASTM D638 or ISO 527 or NF A 49-711
UTS 20 MPa, elongation 400% by agreement
ASTM G8 or GBE/CW6 or other agreed procedure
max. 7 mm disbonding, 48 to be included hrs at 65C or 28 days at room temperature by agreement by agreement
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Coating Data Sheet No.2: 3-Layer Polyethylene Coating (Continued) Hot water soak test GBE/CW6 max. 2 mm disbonding, 7 to be included Part 1, App. E days at 80C (modified, cut edges freely exposed) or agreed procedure Bending resistance by agreement by agreement; by agreement (full scale testing), (e.g. no cracking or disbondat room temperature ing at strain exceeding max. strain during installation by 30%) at min. installation by agreement by agreement by agreement temperature (e.g. no cracking or disbonding at strain exceeding max. strain during installation by 30% and at 5C below min. installation temperature) Residual magnetism by agreement by agreement by agreement 1) start/lead pipe refers to first pipe after interrupted coating according to ITP, to be included, to be agreed and by agreement are explained in 5.3.3
END OF CDS 2
Recommended Practice DNV-RP-F106, October 2003 Page 20
Coating Data Sheet No.3: 3-Layer Polypropylene Coating 1 Coating Configuration Fusion bonded epoxy Typical nominal value 200 m to 400 m (min/max value and test method/frequency to be agreed for inclusion in ITP) Polypropylene adhesive According to ITP Polypropylene outer sheath According to ITP Total thickness min. 2.5 mm (to be agreed for inclusion in ITP) 2 Coating Materials Item/Property Test method Acceptance criteria Frequency Coating Material Production Qualification and PQT 2.1.1 FBE material, raw material property as for CDS 1, 2.1.1 as for CDS 1, 2.1.1 as for CDS 1, 2.1.1 as for CDS 1, 2.1.1 2.1.2 FBE material, processed (as-applied) property as for CDS 1, 2.1.2 as for CDS 1, 2.1.2 as for CDS 1, 2.1.2 as for CDS 1, 2.1.2 2.1.4 LE material, raw material property (for coating repairs) as for CDS 1, 2.2.1 as for CDS 1, 2.2.1 as for CDS 1, 2.2.1 as for CDS 1, 2.2.1 2.1.3 LE material, processed material property (for coating repairs) as for CDS 1, 2.2.2 as for CDS 1, 2.2.2 as for CDS 1, 2.2.2 as for CDS 1, 2.2.2 2.2.1 PP adhesive material, raw material property Density ISO 1183 according to PDS not applicable every batch Particle size (for spraying) According to PDS according to PDS not applicable every batch Melt flow index/rate ISO 1133 or according to PDS not applicable every batch ASTM D1238 Softening point (Vicat) ISO 1306 or according to PDS not applicable every batch ASTM D1525 2.2.2 PP adhesive material, processed (as-applied) property Tensile properties, ISO 527 Tensile strength 12 MPa by agreement not applicable room temperature ASTM D638 elongation at break 500% Flexural modulus ASTM D790 450 MPa by agreement not applicable 2.3.1 PP material, raw material property Density ISO 1183 >0.89 kg/dm3 not applicable every batch/lot Melt flow index/rate ISO 1133 or according to PDS not applicable every batch/lot ASTM D1238 Softening point (Vicat) ISO 306 or ASTM D1525 120C not applicable every batch/lot Melting point ISO 3146 150C not applicable by agreement Thermo stabilisation ASTM D3895 by agreement by agreement by agreement 2.3.2 PP material, processed (as-applied) property Hardness ASTM D785 or 60 Shore D to be included by agreement ISO 868 Impact resistance NF A 49-711 according to standard to be included not applicable Izod impact, ASTM D256 by agreement by agreement by agreement room temperature Tensile properties, ASTM D638 tensile strength at yield to be included by agreement room temperature 20 MPa elongation at break 400% Indentation NF A 49-711 max. 0.3 mm at 20C to be included not applicable max. 0.5 mm at 110C Flexural modulus ASTM D790 or ISO 178 700MPa by agreement not applicable Brittleness temperature ASTM D746 <-20C by agreement not applicable
Recommended Practice DNV-RP-F106, October 2003 Page 21
Coating Data Sheet No.3: 3-Layer Polypropylene Coating (Continued) Thermal degradation reNF A 49-711 100 days sistance UV resistance ISO 4892-2 or by agreement (ISO) or NF A 49-711 according to standard (NF) Abrasion resistance ASTM D4060 or by agreement DIN 53516 Fungi resistance ASTM G21 no growth Bacteria resistance ASTM G22 no growth Water absorption ASTM D570 <0.5% per 24 hours Water vapour permeability ASTM E96 <0.1g/m2 per 24 hours Thermal conductivity ASTM C518 by agreement Volume resistivity ASTM D257 1013 ohm cm Electrical insulation caNF A 49 711 108 ohm cm2 pacity Dielectric strength ASTM D149 25 kV/mm 3 Coating Application and Final Inspection/Testing 3.1 Surface Preparation Item/Property Test method Acceptance criteria as for CDS 1, 3.1 as for CDS 1, 3.1 as for CDS 1, 3.1 3.2 Coating Application and Final Inspection/Testing Item/Property: Test method Acceptance criteria 3.2.1 Epoxy layer as for CDS 1, 3.2 as for CDS 1, 3.2 3.2.2 PP Adhesive Layer Thickness according to MPS/ITP 3.2.3 PP layer and full layer Coating material and pipe according to MPS/ITP temperatures
to be included by agreement by agreement by agreement by agreement by agreement by agreement by agreement by agreement by agreement by agreement
Frequency PQT as for CDS 1, 3.1 Frequency PQT as for CDS 1, 3.2 to be included Production as for CDS 1, 3.1
Production as for CDS 1, 3.2 by agreement
as for CDS 1, 3.2 according to ITP
continuous monitoring (pipe temperature before FBE application) Pipe feed rate according to MPS/ ITP according to ITP to be included continuous monitoring Water quenching according to ITP according to ITP to be included continuous monitoring Appearance of coating visual according to ITP to be included, every pipe, 100% surface area 100% surface area Pipe end configuration according to MPS/ ITP according to ITP to be included every pipe, both pipe ends Holiday detection NACE RP0274, no holidays to be included, every pipe, 10 kV/mm nominal thick100% surface area 100% surface area ness, max. 25 kV, 200-300 (visual/acoustic alarm mm/s or NF A 49-711 function) Thickness according to MPS/ ITP according to purchase order to be included, cover- according to ITP (method to be agreed) and ITP age to be defined for (frequency and location PQT to be agreed) Adhesion NF A 49-711, E3 min. 50 N/cm, no peeling of FBE to be included first pipe and start/lead (peel strength), or DIN 30670/30678 layer pipe 1),then one per shift, at 100C 5C both pipe ends at max. operating temperato be agreed to be included not applicable ture, if higher than 100C Hardness ISO 868 60 Shore D to be included not applicable Impact resistance, NF A 49-711 or according to standard to be included first pipe and start/lead at room temperature DIN 30670/30678 pipe 1), or by agreement at max. operating temperaby agreement by agreement not applicable ture, Indentation resistance, NF A 49-711 or max. 0.10 mm, 20C to be included first pipe for each PP at room temperature and at DIN 30670/30678 max. 0.3 mm, 110C batch 110C at max. operating temperato be agreed to be included by agreement ture, if higher than 110C Tensile properties, ASTM D638 tensile strength at yield to be included first pipe for each PP at room temperature or ISO 527 or 20 MPa batch NF A 49-711 elongation at break 400% at max. operating temperaby agreement by agreement not applicable ture
Recommended Practice DNV-RP-F106, October 2003 Page 22
Coating Data Sheet No.3: Cathodic disbonding, at room temperature or at 65C at max. operating temperature, if higher than 65C Hot water soak test
3-Layer Polypropylene Coating (Continued) ASTM G8 or max. 7 mm disbonding, 48 hrs at to be included GBE/CW6 or 65C or 28 days at room temperother agreed procedure ature by agreement by agreement
by agreement by agreement by agreement
GBE/CW6 max. 2 mm disbonding, 7 days at to be included Part 1, App. E 80C (modified, cut edges freely exposed) or agreed procedure Bending resistance by agreement by agreement by agreement (full scale test), (e.g. no cracking or disbonding, at room temperature no loss of adhesion strength after bending at strain exceeding max. strain during installation by 30%) at min. installation by agreement by agreement by agreement temperature (e.g. no cracking or disbonding, no loss of adhesion strength after bending at strain exceeding max. strain during installation by 30% and at 5C below min. installation temperature) Residual magnetism by agreement by agreement by agreement 1) start/lead pipe refers to first pipe after interrupted coating according to ITP, to be included, to be agreed and by agreement are explained in 5.3.3
END OF CDS 3
Recommended Practice DNV-RP-F106, October 2003 Page 23
Coating Data Sheet No. 4: Multi-Layer Polypropylene Coating 1 Coating Configuration (typical) Fusion bonded epoxy (FBE) Typical nominal value 200 m to 400 m (min/max value and test method/frequency to be agreed for inclusion in ITP) Polypropylene adhesive According to ITP Polypropylene intermediate layer According to ITP Polypropylene foam or syntactic layer To be agreed for inclusion in ITP Polypropylene outer layer According to ITP Total thickness To be agreed for inclusion in ITP 2 Coating Materials Item/Property to be tested Test method Acceptance criteria Frequency of testing Coating Material Production Qualification and PQT 2.1.1 FBE material, raw material property as for CDS 1, 2.1.1 as for CDS 1, 2.1.1 as for CDS 1, 2.1.1 as for CDS 1, 2.1.1 2.1.2 FBE material, processed (as-applied) property as for CDS 1, 2.1.2 as for CDS 1, 2.1.2 as for CDS 1, 2.1.2 as for CDS 1, 2.1.2 2.2.1 LE material, raw material property (for coating repairs) as for CDS 1, 2.2.1 as for CDS 1, 2.2.1 as for CDS 1, 2.2.1 as for CDS 1, 2.2.1 2.2.2 LE material, (as-applied) material property (for coating repairs) as for CDS 1, 2.2.2 as for CDS 1, 2.2.2 as for CDS 1, 2.2.2 as for CDS 1, 2.2.2 2.3 PP foam material, raw material and processed (as-applied) properties Density according to PDS according to PDS to be included every batch/lot Melt index ISO 1133 according to PDS not applicable every batch/lot Softening point ISO 306 according to PDS not applicable every batch/lot Tensile properties ISO 527-2 by agreement by agreement not applicable Flexural modulus ISO 178 by agreement by agreement not applicable 2.4 PP Sheathing Material raw material and processed (as-applied) properties as for CDS 3, 2.3.1 and as for CDS 3, 2.3.1 and 2.3.2 2.3.2 3. Surface Preparation, Coating Application and Final Inspection/Testing 3.1 Surface Preparation Properties Test method Acceptance criteria as for CDS 1, 3.1 as for CDS 1, 3.1 as for CDS 1, 3.1 3.2 Coating Application and Final Inspection/Testing 3.2.1 FBE layer as for CDS 1, 3.2 as for CDS 1, 3.2 3.2.2 Adhesive layer as for CDS 1, 3.2.2 as for CDS 1, 3.2.2 3.2.3 First 3 layers PP temperature according to MPS/ITP according to ITP Pipe feed rate according to MPS/ITP according to ITP Water quenching according to ITP according to ITP Appearance of coating visual according to ITP Thickness Adhesion (peel strength), at 100C 5C at max. operating temperature, if higher than 100C according to MPS/ITP (method to be agreed) NF A 49-711, E3 as for CDS 3, 2.3.1 and 2.3.2 as for CDS 3, 2.3.1 and 2.3.2
Frequency as for CDS 1, 3.1 as for CDS 1, 3.2 as for CDS 1, 3.2.2 as for CDS 1, 3.2 as for CDS 1, 3.2.2 continuous monitoring continuous monitoring continuous monitoring every pipe, 100% surface area according to ITP first pipe and start/lead pipe, then one per shift, both pipe ends not applicable
to be included to be included to be included to be included, 100% surface area according to ITP to be included, coverage to be defined in PQT min. 50 N/cm, no peeling of to be included FBE layer to be agreed to be included
Recommended Practice DNV-RP-F106, October 2003 Page 24
Coating Data Sheet No. 4: Multi-Layer Polypropylene Coating (Continued) Cathodic disbonding, ASTM G8 or max. 7 mm disbonding, at room temperature or 65C GBE/CW6 or 48 hrs at 65C or 28 days at other agreed procedure room temperature at max. operating temperaby agreement ture, if higher than 65C Hot water soak test GBE/CW6 max. 2 mm disbonding, Part 1, App. E 7 days at 80C (modified, cut edges freely exposed) or agreed procedure 3.2.4 Full layer (Inner 3-layer + foam layer + outer PP layer) Condition of 3-layer coating visual according to ITP Pre-heating according to MPS/ITP according to ITP temperature Pipe feed rate according to MPS/ITP according to ITP Water quenching according to ITP according to ITP Appearance of coating visual according to ITP Overall thickness Foam specific density Adhesion of foam layer to inner 3-layer, shear test Verification of heat insulation Full scale bending test, at room temperature according to MPS/ITP (method to be agreed) according to MPS/ITP according to MPS/ITP according to MPS/ITP (e.g. by weighing of applied coating) by agreement
to be included by agreement to be included
by agreement not applicable by agreement
every pipe continuous monitoring continuous monitoring continuous monitoring every pipe, 100% surface area according to ITP, (frequency and location to be agreed) according to ITP first pipe and start/lead pipe, then one per shift, every pipe not applicable
to be included to be included to be included, 100% surface area according to purchase order to be included, coverage and ITP to be defined for PQT according to ITP according to ITP to be included to be included to be included
by agreement by agreement (e.g. no cracking or disbonding, no loss of adhesion strength after bending at strain exceeding max. strain during installation by 30%) at installation temperature by agreement by agreement by agreement (e.g. no cracking or disbonding, no loss of adhesion strength after bending at strain exceeding max. strain during installation by 30% and at 5C below min. installation temperature) according to ITP, to be included, to be agreed and by agreement are explained in 5.3.3
END OF CDS 4
Recommended Practice DNV-RP-F106, October 2003 Page 25
Coating Data Sheet No. 5: Asphalt Enamel (or Bitumen) Coating 1 Coating Configuration Primer Dry Film Thickness: min. 15 m (20 5 m) Type: BS 4147, Type B Asphalt Enamel Thickness: 5-9 mm Type: BS 4147, Type 2 Grade b Inner wrapping Thickness: min. 0.3 mm Type: Non woven fibre tissue consisting of uniformly porous mat of glass; Phenolic resin binder Outer wrapping Thickness: min. 0.6 mm Type: Glass fibre, e.g. regular weaving of continuous glass filaments in the wrap and of glass filament or of single or double staple glass fibres in the wool, with small amounts of phenolic resin binder 2 Coating Materials Item/Property Test method Acceptance criteria Frequency (applicable to PQT and production) 2.1 Primer material Volatile matter BS 4147Appendix A according to BS 4147 Table 3 every batch/lot Viscosity ISO 2431 according to BS 4147 Table 3 every batch/lot 2.2 Filler material Filler fineness BS 410 99% passing 250 m sieve every batch/lot 90% passing 250 m sieve 2.3 Asphalt enamel material Flash point ISO 13736 min. 260C every batch/lot Filler content BS 4147 Appendix B according to BS 4147 Table 6 every batch/lot Density BS 4147 Appendix C according to BS 4147 Table 6 every batch/lot Softening point EN 1426 according to BS 4147 Table 6 every batch/lot Penetration BS 4147 Appendix D according to BS 4147 Table 6 every batch/lot, twice per shift Sag test BS 4147 Appendix E according to BS 4147 Table 7 first batch/lot, then every 10th Impact test BS 4147 Appendix G according to BS 4147 Table 7 first batch/lot, then every 10th Bend test BS 4147 Appendix F according to BS 4147 Table 7 first batch/lot, then every 10th Peel test BS 4147 Appendix H according to BS4 147 Table 7 first batch/lot, then every 10th 2.4 Inner wrapping material Hydrolytic class ISO 719 min. Class 3 every batch/lot Weight according to ITP min. 42 g/m2 every batch/lot Glass content According to ITP min. 40 g/ m2 every batch/lot Binder content according to ITP max. 15% of total weight every batch/lot Thickness according to ITP min. 0.3 mm every batch/lot Tensile strength according to ITP longitudinal: min. 100 N / 5 every batch/lot cm strip lateral: min. 25 N / 5 cm strip 2.5 Outer wrapping material Hydrolytic class same as for inner wrapping every batch/lot Weight according to ITP min. 250 g/m2 every batch/lot Glass content according to ITP min. 170 g/m every batch/lot Thickness according to ITP min. 0.6 mm every batch/lot Tensile strength according to ITP longitudinal and lateral: every batch/lot min. 800 N/ 5 cm strip 3. Surface Preparation, Coating Application and Final Testing 3.1 Surface Preparation Properties Test method Acceptance criteria Frequency PQT Production Initial surface condition visual examination free from surface contamina- to be included every pipe, tion, temporary corrosion pro100% surface area tection and defects Pipe temperature and relative according to ITP pipe temperature min. to be included minimum once per hour humidity 3C above dew point Salt contamination after blast ISO 8502-2, -6 or agreed max. 30 mg NaCl/m2 to be included one per shift, both ends cleaning method Surface cleanliness ISO 8501-1 A/B Sa 2 . to be included every pipe 100% surface area Roughness ISO 8503-2 grade Medium (G) to be included one per shift, both ends Final surface condition visual examination free from surface defects to be included every pipe 100% surface area
Recommended Practice DNV-RP-F106, October 2003 Page 26
Coating Data Sheet No. 5: Asphalt Enamel (or Bitumen) Coating (Continued) 3.2 Coating Application and Final Testing(Inspection Item/Property Test method Acceptance criteria PQT 3.2.1 Primer layer Application temperature Coating layer thickness 3.2.2 Full layer Time duration from priming Enamel temperature Pipe temperature Wrap and enamel configuration Appearance of finished coating Total thickness Holiday detection according to ITP (max. 50C) according to ITP according to ITP according to ITP to be included to be included
Frequency Production every pipe first 10 pipes then every 10th pipe, 3x4 locations (90 apart) every pipe continuous monitoring every pipe according to ITP every pipe, 100% surface area first 10 pipes then every 10th pipe, 3x4 locations (90 apart) every pipe, 100% surface area first 10 pipes then every 10th pipe, 100% surface area first 5 pipes (one pipe end), then first pipe per shift first 5 pipes (one pipe end), then first pipe per shift
according to ITP according to ITP according to ITP according to ITP visual examination according to ITP
according to ITP according to ITP according to ITP according to ITP according to ITP 5.0 mm minimum (incl. seam weld) 9.0 mm maximum no defects acceptable
to be included to be included to be included to be included to be included to be included
NACE RP0274 to be included min. 15 kV Rate: 150-250 mm/s Adhesion tapping by wooden stick according to ITP to be included (Tapping/sounding test) (According to ITP) Adhesion cutting by knife through coating shall be difficult to re- to be included (Peeling test) coating (e.g. 30x100 mm move, causing cohesive failstrip) and peeling by force ure of the coating. (According to ITP) Compactness test examination of strip reaccording to ITP to be included moved from coating for homogeneity and thickness of individual layers (acc. to ITP) Pipe end configuration according to ITP according to ITP to be included according to ITP, to be included, to be agreed and by agreement are explained in 5.3.3
every pipe, both pipe ends
END OF CDS 5
Recommended Practice DNV-RP-F106, October 2003 Page 27
Coating Data Sheet No. 6: Coal Tar Enamel Coating 1. Coating Configuration Primer Dry Film Thickness: min. 15 m (20 5 m) Type: BS 4164, grade B Coal Tar Enamel Thickness: 5-9 mm Type: BS 4164, grade 120/5 Inner wrapping Thickness: min. 0.3 mm Type: 1 wrap of glass mat, non-woven glass fibre Outer wrapping Thickness: min. 0.6 mm (when impregnated) Type: 1 wrap of saturated woven glass fibre 2. Coating Materials Item/Property Test method Acceptance criteria Frequency (applicable to PQT and production) 2.1 Primer material Viscosity ISO 2431 according to BS 4164 Table 1 every batch/lot Flash point ISO 13736 according to BS 4164 Table 1 every batch/lot Volatile matter BS 4164 Appendix A according to BS 4164 Table 1 every batch/lot 2.2 Filler material Filler fineness BS 410 99% passing 250 m sieve every batch/lot 90% passing 250 m sieve 2.3 Coal tar enamel material Filler content BS 4164 Appendix B according to BS 4164 Table 2 every batch/lot, once per shift Density BS 4164 Appendix C according to BS 4164 Table 2 every batch/lot, once per shift Softening point BS 4164 Appendix D according to BS 4164 Table 2 every batch/lot, once per shift Penetration BS 4164 Appendix E according to BS 4164 Table 2 every batch/lot, once per shift Viscosity BS 4164 Appendix F according to BS 4164 Table 2 every batch/lot, once per shift Sag test BS 4164 Appendix G according to BS 4164 Table 3 first batch/lot, then every 10th Impact test BS 4164, Appendix K according to BS 4164 Table 3 first batch/lot, then every 10th Bend test BS 4164, Appendix J according to BS 4164 Table 3 first batch/lot, then every 10th Low temperature test for BS 4164, Appendix H according to BS 4164 Table 3 first batch/lot, then every 10th cracking and disbonding Peel test BS 4164, Appendix L according to BS 4164 Table 3 first batch/lot, then every 10th Cathodic disbonding test BS 4164, Appendix M according to BS 4164 Table 3 by agreement 2.4 Inner wrapping material Hydrolytic Class ISO 719 class 3 or better every batch/lot Weight according to ITP min. 42 g/m2 every batch/lot Binder content according to ITP 10-18% every batch/lot Thickness according to ITP according to ITP every batch/lot Tensile strength according to ITP min. 306 N/150 mm wide strip every batch/lot measured in the longitudinal direction 2.5 Outer wrapping material Hydrolytic class ISO 719 Class 3 or better every batch/lot Weight according to ITP min. 250 g/m2 every batch/lot Binder content according to ITP according to ITP every batch/lot Tensile strength according to ITP min. 535 N/150 mm wide strip every batch/lot 3. Surface Preparation, Coating Application and Final Testing/Inspection 3.1 Surface Preparation Item/Property Test method Acceptance criteria Frequency PQT Production Initial surface condition visual examination free from surface contamina- to be included every pipe tion, temporary corrosion pro100% surface area tection and defects Pipe temperature and relative according to ITP pipe temperature min. to be included minimum once per hour humidity 3C above dew point Salt contamination after blast ISO 8502-2, -6 or agreed max. 30 mg NaCl/m2 to be included one per shift, both ends cleaning method Surface cleanliness ISO 8501-1 A/B Sa 2 . to be included every pipe 100% surface area Roughness ISO 8503-2 grade Medium (G) to be included one per shift, both ends Final surface condition visual examination free from surface defects to be included every pipe 100% surface area
Recommended Practice DNV-RP-F106, October 2003 Page 28
Coating Data Sheet No. 6: Coal Tar Enamel Coating (Continued) 3.2 Coating Application and Final Testing/Inspection Item/Property Test method Acceptance criteria PQT 3.2.1 Primer layer Application temperature Coating layer thickness 3.2.2 Full layer Time duration from priming Enamel temperature Pipe temperature Wrap and enamel configuration Appearance of finished coating Total thickness Holiday detection Adhesion (Tapping/sounding test) Adhesion (Peeling test) according to ITP according to ITP according to ITP according to ITP to be included to be included
Frequency Production every pipe 10 first pipe, then every 10th pipe, 3x4 locations (90 apart) every pipe continuous monitoring every pipe according to ITP every pipe, 100% surface area first 10 pipes then every 10th pipe, 3x4 locations (90 apart) every pipe, 100% surface area first 10 pipes then every 10th pipe, 100% surface area. first 5 pipes (one pipe end), then first per shift
according to ITP according to ITP according to ITP according to ITP visual examination according to ITP NACE RP0274 min. 15 kV rate: 150-250 mm/s tapping by wooden stick (According to ITP) cutting by knife through coating (e.g. 30x100 mm strip) and peeling by force (according to ITP)
according to ITP according to ITP according to ITP according to ITP according to ITP 5.0 mm minimum (incl. seam weld) 9.0 mm maximum no defects acceptable according to ITP
to be included to be included to be included to be included to be included to be included to be included to be included
Compactness test
examination of strip removed from coating for homogeneity and thickness of individual layers (acc. to ITP) according to ITP, to be included, to be agreed and by agreement are explained in 5.3.3
coating shall be difficult to re- to be included move, causing cohesive failure of the coating. Clean peeling from primer or the pipe surface is not acceptable according to ITP to be included
first 5 pipes (one pipe end), then first per shift
END OF CDS 6
Recommended Practice DNV-RP-F106, October 2003 Page 29
Coating Data Sheet No.7: Polychloroprene (or Vulcanised Rubber) Coating (max. operating temperature 90C for ordinary grades) 1 Coating Configuration Primer (bonding agent) Type and thickness according to ITP Polychloroprene Thickness to be agreed 2 Coating Materials Item/Property Test method Acceptance criteria Frequency 2.1 Primer material Coating Material Quali- Production fication According to ITP according to ITP according to ITP to be included every batch/lot 2.2 Polychloroprene material, raw material and as-applied (processed) properties Rheometer curve ASTM D2084 according to ITP to be included every batch/lot Hardness ISO 7619 or 56-68 Shore A to be included every batch/lot ASTM D2240 Density ISO 2781 or 1.401.70 kg/dm3 to be included every batch/lot BS 903 Part A1 Tensile strength ISO 37 min. 11 MPa to be included 1/20 batch/lot or by agreement Elongation at break ISO 37 min. 350% to be included 1/20 batch/lot or by agreement Compression set ISO 815 max. 20% at 60C or to be included 1/20 batch/lot or by max. 30% at 70C agreement Tear strength ISO 34 -1 min. 20 N/mm to be included 1/20 batch/lot or by agreement Accelerated ageing ISO 188 according to ITP/MPS to be included not applicable Ozone resistance ISO 1431-1 or by agreement by agreement not applicable ASTM D1149 Seawater absorption ISO 1817 by agreement by agreement not applicable Abrasion resistance DIN 53516 by agreement by agreement not applicable Volume resistivity ASTM D257 by agreement by agreement not applicable Thermal conductivity by agreement by agreement by agreement not applicable Penetration ASTM G17 by agreement by agreement not applicable 3 Surface Preparation, Coating Application and Final Testing 3.1 Surface preparation Properties Test method Acceptance criteria Frequency PQT Production Initial surface condition visual examination free from visual surface to be included every pipe, contamination, tempo100% surface area rary corrosion protection and defects Pipe temperature and relative hu- according to ITP pipe temperature min. to be included minimum once per hour midity 3C above dew point Salt contamination after blast ISO 8502-6 max. 20 mg NaCl/m2 to be included first pipe and every 10th cleaning pipe Surface cleanliness ISO 8501-1 A/B Sa 2 . to be included every pipe Roughness ISO 8503-2 grade Medium (G) to be included every pipe Final surface condition visual examination free from surface defects to be included every pipe 100% surface area 3.2 Coating Application and Final Testing Primer and Polychloroprene layer Max. duration from surface prepaccording to ITP to be included every pipe aration to application of primer Ambient temperature and humidi- according to ITP min. 15C and to be included every hour ty max. 75% rel. humidity Pipe temperature according to ITP min. 3C above dew to be included every hour point Surface appearance prior to prim- according to ITP according to ITP to be included every pipe er application Primer drying time according to ITP according to ITP to be included every pipe Primer appearance visual inspection according to ITP to be included every pipe Primer thickness ISO 2187 according to ITP to be included every pipe Wrapping appearance visual inspection according to ITP to be included every pipe (prior to vulcanising)
Recommended Practice DNV-RP-F106, October 2003 Page 30
Coating Data Sheet No.7: Polychloroprene (or Vulcanised Rubber) Coating (max. operating temperature 90C for ordinary grades) (Continued) Vulcanising temperature and according to ITP according to ITP to be included every batch, continuous pressure monitoring and recording Vulcanised coating appearance visual inspection according to ITP to be included every pipe, 100% surface area Coating layer thickness ISO 2187 according to ITP to be included every pipe, 3x4 locations (90 apart) Holiday detection BS 6374 according to ITP to be included every pipe, 100% surface area Adhesion (peel strength) ISO 813 or by agreement to be included every pipe (at cutback or at room temperature BS 6374 on test plate) at max. operating temperature by agreement by agreement by agreement Hardness ISO 7619 or according to ITP to be included every pipe ASTM D2240 Pipe end configuration according to ITP according to ITP to be included every pipe, both pipe ends Bending resistance by agreement by agreement by agreement not applicable (full scale test), at room temperature at min. installation by agreement by agreement by agreement not applicable temperature Cathodic disbonding, ASTM G8 or max. 10 mm disbonding, to be included by agreement at room temperature or at 65C GBE/CW6 or 48 hrs at 65C or 28 days other agreed procedure at room temperature at max. operating temperature, if by agreement by agreement not applicable higher than 65C according to ITP, to be included, to be agreed and by agreement are explained in 5.3.3
END OF CDS 7
Recommended Practice DNV-RP-F106, October 2003 Page 31
Coating Data Sheet No.8: Multi-Layer Polychloroprene (Vulcanised Rubber) Coating (primarily for heat insulation) 1 Coating Configuration Primer (bonding agent) Type and thickness according to ITP Inner layer High temperature rubber grade (polychloroprene applicable up to 90C), thickness to be agreed Mid layer Insulation rubber grade, thickness to be agreed Outer layer Polychloroprene, thickness to be agreed 2 Coating Materials Item/Property Test method Acceptance criteria Frequency 2.1 Primer material Coating Material Quali- Production fication as for CDS 7, 2.1 as for CDS 7, 2.1 as for CDS 7, 2.1 as for CDS 7, 2.1 as for CDS 7, 2.1 2.2 Rubber materials, raw material and as-applied (processed) properties 2.2.1 Inner layer as for CDS 7, 2.2 as for CDS 7, 2.2 as for CDS 7, 2.2 as for CDS 7, 2.2 as for CDS 7, 2.2 2.2.2 Mid layer Rheometer curve Hardness Density Tensile strength Elongation at break Compression set Tear strength Accelerated ageing Seawater absorption Abrasion resistance Thermal conductivity 2.2.3 Outer layer as for CDS 7, 2.2
according to ITP ASTM D2240 ISO 2781 ISO 37 ISO 37 ISO 815 ISO 34 ISO 188 ISO 1817 DIN 53516 by agreement as for CDS 7, 2.2
according to ITP according to ITP according to ITP according to ITP according to ITP according to ITP according to ITP by agreement by agreement by agreement by agreement
to be included to be included to be included to be included to be included to be included to be included by agreement by agreement by agreement by agreement as for CDS 7, 2.2
every batch/lot every batch/lot every batch/lot 1/20 batch/lot 1/20 batch/lot 1/20 batch/lot 1/20 batch/lot not applicable not applicable not applicable not applicable as for CDS 7, 2.2
as for CDS 7, 2.2 or by agreement 3 Surface Preparation, Coating Application and Final Testing 3.1 Surface preparation Properties Test method Acceptance criteria
Frequency PQT as for CDS 7, 3.1 Production as for CDS 7, 3.1
as for CDS 7, 3.1 as for CDS 7, 3.1 as for CDS 7, 3.1 3.2 Coating Application and Final Testing Primer and full layer as for CDS 7, 3.2 as for CDS 7, 3.2 as for CDS 7, 3.2 as for CDS 7, 3.2 according to ITP, to be included, to be agreed and by agreement are explained in 5.3.3
as for CDS 7, 3.2
END OF CDS 8
7. ANNEX 2 Specification of Amendments and Deviations
Table 1: Example of a Purchaser specification of amendments and/or deviations to Common Requirements in Sec.5 of this RP, see 1.3.5. Sec. 5 ref. Item/Property Amendment Description or Deviation 1.3.2 FBE layer thickness Amendment Min. thickness 250 m, max. thickness 450 m. 1.3.2 Full layer thickness Amendment Min. thickness 3.0 mm (2.7 mm allowed on seam weld), max. thickness 5.0 mm. 1.3.2 Cut-back design Amendment Cut-back to be prepared by brushing. Length: 120 10 mm, chamfer angle 20 2 5.1.2 MPS Amendment Specification of management of non-conformities and concession requests to be included in MPS. 5.2.1 PQT Amendment Minimum 3 pipes shall be coated and tested successfully.
Recommended Practice DNV-RP-F106, October 2003 Page 32
5.4.2 5.7.7 5.8 5.9.3
Coating materials Final inspection Repairs Documentation
Amendment Amendment Amendment Deviation
Purchaser list of approved products shall apply. All pipes shall be subject to final visual inspection prior to discharge from stock. Only one damage affecting FBE layer per pipe and max. 10 cm2 repair area is allowed. (Pipes with more damage to be stripped and re-coated). Documentation shall be retained for 3 years.
Table 2: Example of a Purchaser specification of amendments and/or deviations to coating data sheet (CDS) in ANNEX 1 of this RP, see 1.3.5. Coating Data Sheet No. 3 CDS Property or Test ref. 2.1.1 Thermal analysis 2.1.2 2.3.2 3.1 3.2.3 3.2.3 3.2.3 3.2.3 Property/Test related to: Coating material, quality control Amendment or Deviation Amendment Description Testing of each lot/batch (EN 10204, 3.1.B) according to GBE/CW6 part 1, App. A to be included Each lot max. 10 tonnes. Compliance with GBE-CW6 Part 1, App. A to be certified (EN 10204, 2.2). Testing of each batch/lot (EN 10204, 3.1.B) to be included. ISO 868; 60 Shore D One pipe per shift, both ends to be tested. One coated joint to be tested according to Purchaser procedure. First pipe per shift and each 10th pipe to be tested according to NF A 49-711 addendum B. Every 20th pipe, one end to be tested acc. to NF A 49-711, min. 100 N/cm to be met. Test method: ISO 527.
Water resistance (FBE) Coating material, qualifica- Amendment tion Tensile properties Coating material Amendment (PP) quality control Salt contamination Bending test (full layer) Full layer thickness Adhesion at 100C (full layer) Tensile properties Production PQT Production Production PQT and production Deviation Amendment Amendment Deviation and Amendment Amendment
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