H10M401-I1-JRI-MMH-ESPCA002-6300-006_E.doc

TECHNICAL SPECIFICATIONPURCHASE OF STEEL PIPES COATED WITH A THREE LAYER COATINGH10M401-I1-JRI-MMH-ESPCA002-6300-0069. EXTERNAL COATING This chapter specifies the minimum technical requirements for the preparation of the surface coating per pipe section of pipe line for a coating service with a three layer HDPE extruded coating. This coating is applicable for 16” and 20” diameter pipe requirements.Finish coating shall have the property of retain color flexibility or integrity when exposed to sunlight and climate conditions for at least for 2 years. Coatings shall be flexible enough to be compatible with the normal pipe deflection found during construction and assembly of pipelines and to be used with cold forming bend in the field within a radius of at least 15 diameters of the piping involved. Three layer of high density polymer shall consist of: One layer of fusion-bonded epoxy material on the steel. One layer of extruded adhesive coating. One layer of High Density Polymer (HDPE) extruded coating. The mark required to conform to the specification API 5L or other main marks on the pipe shall not be destroyed or darkened after the coating procedure is performed.The vendor shall be responsible for the subcontractors with regard to these specification requirements as well as the requirements for codes and standards mentioned herein. Materials9.1.1GeneralEvery batch or delivery of material received shall be tested to verify that the properties thereof are in accordance with the manufacturer literature and with the requirements of this specification.Vendor shall have the appropriate equipment, properly calibrated at his premises for testing and assessing the coating materials.Before using them, materials shall be stored in accordance with the manufacturers instructions. Materials shall be stored and used in clean conditions and in dry areas. All materials of each type of coating shall come from the same manufacturer, (eg., all epoxy powder shall come from the same manufacturer). The manufacturer or type of material may be changed only if a quality problem is found during the coating procedure resulting in a change and only after the buyers approval.All materials shall be used before the expiry date marked on the material or that indicated by the material manufacturer. Each container or tank of material to be used during coating works shall be clearly indicated by the manufacturer with at least the following information. Manufacturers name Name of the product Delivery or container number Manufacture date Expiry dateThe purchaser reserves the right to reject any coating material which has not been approved by the vendor or by his subcontractor with regard to compliance with the standards of the manufacturer or with the requirements of this specification which establishes that the coating material shall not have any of the following problems: Inadequately stored material Materials with past sell-by date Damaged or not marked material9.1.2 Epoxy PowderAll epoxy powders shall comply with the material properties and testing standards indicated in the following table:PROPERTYUNITACCEPTANCE CRITERIUMTESTING METHODParticle size % Screen 100 Screen 10% Retained% RetainedMaximum 10Maximum 90ASTM D3451ASTM D3451Gel time (at 200C)SecondAccording to manufacturers instructionsDIN 55990Densitygr/cm3According to manufacturers instructionsASTM D792Moisture content%0.5% MaximumASTM E203Epoxy powder manufacturers shall provide the information listed below for each powder delivery. Likewise, standards of comparison shall be provided. This information shall be used to verify that no change has been made to epoxy material formulation. Powder infrared scanning and powder typical scanning for comparison. Gel time at the recommended application temperature Particle size distribution Moisture content9.1.3 Adhesive MaterialAll adhesives shall comply with the material properties indicated in the following table:PROPERTYUNITACCEPTANCE CRITERIUMTESTING METHODMelt rategr/10 min3 to 8ASTM D1238Densitygr/cm30.91 to 0.95ASTM D1505Yield strengthMPaMinimum 11ASTM D638Elongation%Minimum 500ASTM D638Flexural modulusMPaMinimum 60ASTM D790HardnessShore DMinimum 30ASTM D2240Melting pointCMinimum 95ASTM D15259.1.4 High Density Polyethylene (HDPE virgin resin)All high density polyethylene resins to be used shall comply with the material properties and the standardized tests indicated in the following table:PROPERTYUNITACCEPTANCE CRITERIUMTESTING METHODColorManufacturers standardYield strengthpsiMinimum 2700 psi ASTM D638Elongation%Minimum 700% at rupture.(CSA Z245 21: Min 600%) for Virgin resin and 300% for coating test.ASTM D638Densitygr/cm30.94 to 0.96ASTM D1505Coal content%2% to 2.5%ASTM D1603Dielectric ConstantVolts/milMinimum 800ASTM D149Environmental stress-cracking resistanceMinimum F 50: 10% Igepal CO-630, Value of 150 hours 100%Igepal CO 630, value of 1000 hoursMini. 300 hours as CSA Z245.21ASTM D1693Abrasion resistanceWithout changes in appearance or electric resistanceASTM G6-69Impact resistance.(CSA Z245.20 page 25 is for FBE not for HDPE)in-lbMinimum 160 in-lb at 77F (25C) and 108 in-lb at -40F (Acceptance criteria is not same as CSA)ASTM G14Blunt rod penetration%Maximum 13%ASTM G17Cathodic disbondmentInMaximum 30 days:0.015 in2 77F (25C),0.50 in2 140F (60C)(1.5v 20C 28days, and 3.5V 65C 24 hours. as CSA Z 245.21 for HDPE coating test but not for HDPE resin)ASTM G8Flow0.15-0.80 ASTM D1238HardnessShore DMinimum 60 Shore DASTM D2240Oxidative induction timeMinimum 10 minutes in oxygen at 428F (220C).ASTM D3895Permeability Water vaporGm/m2/24 hMaximum 0.3 at 230C, 0.1 mmDIN 53122Permeability OxygenCm3/m2/24 h/barMaximum 650 at 230 C, 01 mmDIN 53380Water absorptionWt % / 24 hrMaximum 0.01 wt %ASTM D746Brittleness temperatureMaximum -94F (-70C) (for F20)ASTM D746UV ray resistanceCapable of withstanding 2 years outdoors without loosing properties.High density polyethylene to be used shall be virgin material (i.e., not recycled material) 9.2 Pipe preparation9.2.1 GeneralAll coating material shall be applied in accordance with the instructions of the material manufacturer.It is the responsibility of the vendor or subcontractor to stop the coating procedure under conditions that may adversely affect the coating quality.The buyer reserves the right to reject any coating product which has not been tested by the vendor or his subcontractor with regard to the compliance with this specification.During all stages of coating application, pipe beveled ends shall be protected against damage. The pipe ends shall be left uncovered according to the following detail:The pipe end to be tapered with a mini. 100 maxi .200mm uncoated length from pipe end.This area shall be appropriately protected during the coating procedure.9.2.2 Surface PreparationSurfaces to be cleaned shall be free from any foreign materials. All grease and oil shall be removed by means of a cleaning solvent as per standard SSPS-SP1. Only safe residue-free solvents may be used. Gasoline and kerosene are unacceptable. Any type of salt or dust shall be removed with a high pressure water jet. The water to be used shall be clean and appropriately filtered in order to avoid pipe surface contamination.In case of severe corrosion o any other surface contamination, the surface shall be washed with an aqueous acid solution. The vendor and his subcontractor shall provide the space, equipment and materials to perform this washing procedure. Before cleaning or blasting, pipes shall be at least 30C(3C) above the dew point. If required, preheat shall be used. Pipes shall be evenly and gradually heated. Pre-heat temperature shall not exceed 150C. Pipes may also be pre-heated to remove grease, oil, or solvents (Refer to CSA Z245.21 -)Pipes surfaces to be coated shall be abrasive blasted until reaching white metal, as per SSPS-SP10 (SSPC-SP10) requirements. Abrasive level shall be maintained by frequently adding small amounts of abrasive material. Large or irregular additions shall not be used.Abrasives shall be appropriately filtered to ensure they are free from pollutants. For a continuous and effective operation, the abrasive work-mix for blasting machines shall be maintained free from pollutants. Abrasive wheel equipment shall provide an appropriate mixture of shot and grit. After blasting, pipes shall be carefully inspected for chips and other surface defects. These defects shall be adequately removed, grinded and/or polished. The blasting profile shall be checked for these repaired areas. If the profile is not between 1.5 and 2.5 mils over a single area larger then 25 inch2, the pipe shall be blasted again at the expense of the vendor. Pipe shall be blasted again at the expense of the vendor if any joint profile is destroyed over an area grater than 0.5% of the joint outer surface. Slight shadows, streaks, or discoloration shall be accepted. However, at least 95% of each square foot of surface shall have the uniform grey appearance of the surface of white blasted metal. The profile shall be verified by using an appropriate quantitative testing method.Surface preparations or repairs shall not reduce the pipe thickness below the minimum required to comply with the specifications. The wall thickness of each pipe shall be verified by using a properly calibrated ultrasonic gauge. After surface preparation and before heating pipes for the epoxy material to be applied, pressurized air or vacuum shall be used to remove every loose abrasive, metal or other polluting particle. Pipes shall be coated as soon as possible after each blasting cleaning. Rust traces of pipes will be unacceptable. 9.2.3 HeatingBefore coating, pipes shall be heated to the temperature of application specified by the manufacturer of the epoxy material. Maximum temperature shall not exceed 275C or the maximum temperature recommended by the manufacturer, whichever is lower. Temperatures that cause pipe steel oxidation shall not be acceptable.Pipes shall be heated in a furnace( by induction heating method ) through electric heaters or natural gas in order to protect pipe surfaces from contamination. Pipe temperature shall be monitored by using “tempilstik” type temperature gauges or properly calibrated optical pyrometers. “Tempilstik” type rod marks may affect coating bonding and thus shall be reduced to the minimum. 9.3 Application9.3.1 GeneralEpoxy powder application shall commence as soon as possible after pipes are taken off the furnace. ( heated by induction heating)Coating thickness shall correspond at least to the following table (Z 245.20-02 )( Z245.20 -02 is for FBE standard)6.2.4 Coating ThicknessThe nominal thickness of the coating and the maximum permissible thickness of the coating shall be asspecified in the purchase order. Except as allowed by Clause .2, the minimum permissiblethickness of the coating shall be 300 um. This is CSA Z245.20 FBE coating thickness, for 3 layer HDPE thickness refer to CSA Z245.21 table 1 page 61.Pipe Nominal Diameter (inch)Dry Total Minimum Thickness (mm)16” and 20”2,75 For LDPE the mini thickness is : FBE 0.12mm+ Adhsive 0.10mm+2.5mm LDPE)but for HDPE is the mini thickness is : FBE 0.12mm+ Adhsive 0.10mm+1.0mm HDPE(CSA Z245.21 Table 6 indicated 9.3.2 Epoxy PowderWhen commencing the application of epoxy powder, pipes shall be within the temperature range recommended by the manufacturer.Each delivery of epoxy powder shall not be mixed with other delivery, except when the process continuity needs to be maintained. Remaining powder from other processes may be used only if it has not been contaminated or affected by heat. Only a maximum of 10% of the remaining powder in the final material will be accepted. The vendor shall keep a record of the ratio between the amount of remaining material and the amount of virgin powder. Such record shall be updated at least every eight (8) hours.The epoxy coating shall be completely cured prior to hardening according to the manufacturers instructions.After fully cured, pipes shall be cooled at a temperature below 94C for the following handling and inspection.This portion is applied with FBE coating as CSA Z 245.20 but it is not suitable to CSA Z 245.21 3 layer HDPE application. We follow CSA Z245.21 section .3 AdhesiveAdhesive shall be applied by lateral extrusion immediately after completion of the epoxy coating in a continuous and linear process.The temperature shall conform to the temperature recommended by the material manufacturer.HDPE shall be applied by lateral extrusion at a die temperature from 200C to 240C, immediately after the adhesive application in a continuous and linear process. HDPE shall be extruded in such a way to allow a minimum of 2,5 mm and a maximum of 2,75 mm overlapping with the other surfaces melted as a whole.(not applicable, We follow CSA Z245.21 section )During coating operation, pipes and coating shall be maintained at the optimum temperature recommended by the manufacturer to provide a maximum of adhesion to contact surfaces. When material temperature is not risen by the extrusion process friction to the specified temperature, an external heat source shall then be used. After completion of the coating application, pipes shall be cooled and hardened through immersion in clean water. 10. PIPE DAMAGES, PIPE ENDS REPAIRRepair works shall not be performed until a procedure is prepared by the vendor. This procedure shall be approved by the buyer. Pipe and pipe ends minor damages which are identified upon receipt or after blasting shall be repaired by grinding or polishing. The number of such damages may not exceed 3 per pipe. Pipe end and bevel grinding repair shall not reduce the wall thickness to values below those required in accordance with the dimensions established by the standard API 5L for such pipe nominal diameter. All other pipe, pipe end, and bevel damages shall be informed to the buyer for checking. These defects may be repaired provided that the buyer has agreed to do so. These defects might be repaired by removing the pipe damaged material and by making a new bevel. No welding on pipe surfaces shall be accepted. The pipe ID number shall be maintained during repair. The pipe record to be sent to the buyer shall include pipe lengths. Any pipe length reduction shall be indicated on the record. If pipes or coating are damaged under the Vendors control, he shall reimburse to the buyer the cost of repairs or pipe replacement, together with the inspection and further transportation costs. 11.STEEL PIPE INSPECTIONThe inspection agency, designated by the buyer, shall have at all times, free access to the working areas involved in the pipe manufacture. The manufacturer shall provide, at no cost, all reasonable facilities to verify that pipes being manufactured comply with this specification, as well as with specification API 5L.The manufacturer shall submit an inspection certificate indicating that the material has been manufactured, tested and inspected in accordance with this technical specification and with the specification API 5L.12.STEEL PIPE EXTERNAL COATING INSPECTIONThe supplier shall be responsible for the inspection and testing of every element used for external coating, for the surface preparation and for coating application works. However, the client may be present during all work procedures in order to confirm full compliance with the standards and specifications. All records and control documents shall be sent to the client in writing.The client shall have, at all times, free access to working areas involved in the coating procedure performed under this specification.The suppliers Technical Inspection shall perform the control he may deem necessary in order to verify work for compliance with standards and specifications with regard to either surface preparation or coating application works.The coating may be rejected by the inspection if the application procedure is deemed not to meet the specification.12.1 RecordsSupplier Inspection and Contractor shall maintain a written control of the following: ID number of the coated pipe Pipe temperature (work commencement and completion) Roughness Dry coating thickness Dimensions of pipe uncoated end Material yield Environmental conditions (work commencement and completion).13.INFORMATION REQUESTED FROM SUPPLIERS13.1 Quotation StageAlong with the offer, the supplier shall provide a specification describing the pipe manufacturing procedure. The information provided with the offer shall include at least the information indicated in document H10M401-I1-JRI-MMH-SOLCA002-6300-005, section 3, and steel pipe requisition.13.2 Transportation StagePrior to shipment, the supplier shall send a detailed list of components (the format shall be an excel spreadsheet), according to the information in document H10M401-I1-JRI-MMH-SOLCA002-6300-005, section 3, steel pipe requisition.The client shall check the documents “For Approval” sent by the supplier and shall send back a copy with one of the following grades: ApprovedManu