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ITP No.

: 022-3PE
INSPECTION AND TEST PLAN FOR Revision: 7
EXTERNAL THREE LAYER POLYETHYLENE HIGH DENSITY Issued Date : August 7, 2008
P.O.: -
Technical Dept. STANDARD THICKNESS Buenos Aires – Argentina

ITP prepared in accordance with :

DIN 30-670 -91 Sn External Polyethylene Coating for Pipe

PROCEDURE PRODUCTION PLAN

TERMS & ABBREVIATIONS USED


C - CONTROL, D - TO BE DOCUMENTED, H - HOLD POINT, M - MONITORING, W - WITNESS, R - DOCUMENTS REVIEW, SCA - SOCOTHERM AMERICAS, - Not applicable

7 07.08.2008 Issued for Approval G. Asselborn A. Muller G. Portesan A. Dimascio - -


Rev. Issue Date Description Prepared By Reviewed By Approved By Approved by Approved by Approved by

Document Data Subcontractor / Vendor Contractor Company

Page 1 of 7
ITP No.: 022-3PE
INSPECTION AND TEST PLAN FOR Revision: 7
EXTERNAL THREE LAYER POLYETHYLENE HIGH DENSITY Issued Date : August 7, 2008
P.O.: -
STANDARD RESPONSIBLE FREQUENCY INSPECTION
ITEM DESCRIPTION - STANDARD ACCEPTABILITY CRITERIA RECORD
TEST METHOD PERSON START-UP PRODUCTION SCA CLIENT

1 INCOMING RAW MATERIAL ACCEPTANCE TEST

Manufacturer
1.1 Manufacturer’s certificate control - According Manufacturer’s Data Q.C. Inspector Every batch D Certificate

According Manufacturer’s Data &


Gel time
1.2 SCA-TM-QC-631 within 20% of manufacturer´s Q.C. Lab Every batch C SCA-FO-QC-020
(According CSA Z245.20-06, Clause 12.2)
specified nominal
PRIMER

Moisture content – Mass Loss Method


1.3 SCA-TM-QC-656 0.6 % maximum Q.C. Lab Every batch C SCA-FO-QC-020
(According CSA Z245.20-06, Clause 12.2)

Differential scanning calorimeter of


1.4 epoxy powder (DSC) SCA-TM-QC-616 According Manufacturer’s Data Q.C. Lab Every batch C SCA-FO-QC-020
(According CSA Z245.20-06, Clause 12.7)

Melt Flow Index at 190ºC/2.16 kg


ADHESIVE

1.5 SCA-TM-QC-620 According Manufacturer’s Data Q.C. Lab Every batch C SCA-FO-QC-020
(According ASTM D 1238)

Melting point (DSC)


1.6 (According ASTM D 3418) SCA-TM-QC-644 According Manufacturer’s Data Q.C. Lab Every batch C SCA-FO-QC-020
POLYETHYLENE

Melt Flow Index at 190ºC/2.16 kg


1.7 SCA-TM-QC-620 According Manufacturer’s Data Q.C. Lab Every batch C SCA-FO-QC-020
(According ASTM D 1238)

Melting point (DSC)


1.8 (According ASTM D 3418) SCA-TM-QC-644 According Manufacturer’s Data Q.C. Lab Every batch C SCA-FO-QC-020

2 RECEPTION OF BARE PIPES


Visual inspection of bare pipes at the No bevel damage or pipe body
2.1 incoming rack and pipe identification Visual inspection damage, Every pipe adequately Operator 100% of pipes C Informatic System
control identified

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ITP No.: 022-3PE
INSPECTION AND TEST PLAN FOR Revision: 7
EXTERNAL THREE LAYER POLYETHYLENE HIGH DENSITY Issued Date : August 7, 2008
P.O.: -
STANDARD RESPONSIBLE FREQUENCY INSPECTION
ITEM DESCRIPTION - STANDARD ACCEPTABILITY CRITERIA RECORD
TEST METHOD PERSON START-UP PRODUCTION SCA CLIENT

3 BLASTING MATERIAL CONTROL

SSPC-AB2 No indications of oil


3.1 Blasting material control Q.C. Inspector 1 test Once per shift C -
4.4 contamination

Conductivity determination of blasting


3.2 material rinse solution SCA-TM-QC-647 < 80 µS/cm Q.C. Lab 1 test Once per shift C SCA-FO-QC-024
(Ref. ASTM D4940-03)

4 SURFACE PREPARATION WITH FIRST BLASTING MACHINE

Surface inspection and cleaning No oil, grease, dirt or any other


4.1 Visual inspection Operator 100% of pipes C -
before blasting contamination

Determination of relative humidity, Surface pipe temperature:


4.2 dew point and pipe surface SCA-TM-QC-601 > 3°C above dew point Q.C. Inspector First 2 pipes Every 3 hours C SCA-FO-QC-033
temperature and < 80°C
No mill imperfections SCA-FO-QC-056
Control and repair of surface defects Visual Inspection
4.3 and imperfections after first blasting (Such, slivers, scabs, burrs, weld Operator 100% of pipes C (only repaired
API-5L
spatter, etc) pipes)

5 CHEMICAL PRE-TREATMENT WITH PHOSPHORIC ACID (If required)

Pipe surface temperature control SCA-TM-QC-601


5.1 45º C – 65° C Q.C. Inspector 1 pipe Every 3 hours C SCA-FO-QC-016
before phosphoric acid application SCA-TM-QC-606

PH Control of the solution to be


5.2 SCA-TM-QC-664 PH ≤ 1 Q.C. Inspector 1 pipe Every 3 hours C SCA-FO-QC-016
applied, by means of PH paper

Time control from phosphoric


5.3 SCA-TM-QC-605 ≥ 20 sec Q.C. Inspector 1 pipe Every 3 hours C SCA-FO-QC-016
application till pipe rinse

PH control of wetted surface of the


5.4 rinsed pipe SCA-TM-QC-664 Between 6 - 8 Q.C. Inspector 1 pipe Every 3 hours C SCA-FO-QC-016

Page 3 of 7
ITP No.: 022-3PE
INSPECTION AND TEST PLAN FOR Revision: 7
EXTERNAL THREE LAYER POLYETHYLENE HIGH DENSITY Issued Date : August 7, 2008
P.O.: -
STANDARD RESPONSIBLE FREQUENCY INSPECTION
ITEM DESCRIPTION - STANDARD ACCEPTABILITY CRITERIA RECORD
TEST METHOD PERSON START-UP PRODUCTION SCA CLIENT

6 SURFACE PREPARATION WITH SECOND BLASTING MACHINE

Visual control of blasted surface


SCA-TM-QC-602 Minimum
6.1 cleaning grade Q.C. Inspector 100% of pipes C SCA-FO-QC-016
Visual inspection Sa 2 ½
(According ISO 8501-1)

Roughness control of blasted surface SCA-TM-QC-603


6.2 50 - 100 µm Q.C. Inspector First 2 pipes Every 3 hours C SCA-FO-QC-004
with replica tape Press-O-Film Method "A"

Determination of dust contamination Maximum:


6.3 on the blasted surface SCA-TM-QC-604 Rating 2 Q.C. Inspector First 2 pipes Every 3 hours C SCA-FO-QC-005
(According ISO 8502-3) Class 2
Determination of residual salts
contamination with SCM400 salts
6.4 SCA-TM-QC-632 ≤ 2 µg/cm2 Q.C. Inspector First 2 pipes Once per shift C SCA-FO-QC-016
contamination meter
(Perfom on Cut-Back area)
Visual control of pipe surface after
6.5 blasting Visual inspection No mill defects Operator 100% of pipes C -

7 COATING APPLICATION

Control of Raw material batch to be


7.1 - All batch to be recorded Q.C. Inspector All raw material batch C SLB-FO-QC-100
applied

According epoxy manufacturer’s Continuously monitored and recorded


Control of pipe surface temperature
7.2 SCA-TM-QC-606 recommendation and process Operator with optical pyrometer and checked with C SCA-FO-QC-016
after heating and before coating Tempilstick every 1 hour
instructions

Visual inspection at coating Continuous and uniform


7.3 Visual inspection Operator 100% of pipes C -
application point application

Surface temperature of coated pipe


7.4 after cooling SCA-TM-QC-601 ≤ 70°C Q.C. Inspector First 2 pipes Every 3 hours C SCA-FO-QC-033

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ITP No.: 022-3PE
INSPECTION AND TEST PLAN FOR Revision: 7
EXTERNAL THREE LAYER POLYETHYLENE HIGH DENSITY Issued Date : August 7, 2008
P.O.: -
STANDARD RESPONSIBLE FREQUENCY INSPECTION
ITEM DESCRIPTION - STANDARD ACCEPTABILITY CRITERIA RECORD
TEST METHOD PERSON START-UP PRODUCTION SCA CLIENT

8 ON LINE TEST

SCA-TM-QC-640 Primer ≥ 100 µm One on the first 10 First pipe after each
8.1 Control of each layer thickness SCA-TM-QC-607 Adhesive
Q.C. Inspector C SCA-FO-QC-045
≥ 250 µm pipe re-start

Nominal size of pipe Minimum thickness


First pipe Every 10 pipes
(mm) (mm)

Total coating Thickness ≤ DN 100 1.8


8.2 (The tickness gauge shall be SCA-TM-QC-607 > DN 100 ≤ 250 2.0 Q.C. Inspector C SCA-FO-QC-016
on five equidistant points along the length
calibrated at least once per shift) > DN 250 < 500 2.2
of pipe
≥ DN 500 < 800 2.5
≥ DN 800 3.0

Holiday detection
Set of supply voltage to 25Kv and pipe 100% of full coated pipes
No more than 3 holidays per pipe
8.3 travel speed ≤ 0.3 m/sec. SCA-TM-QC-626 Operator (Holiday and minor damage pipes shall be C SCA-FO-QC-016
allowable to repair repaired) and retested with Holiday
(Holiday detector shall be calibrated at
least once every working shift)

8.4 Control of coating repair 03-EXT No defects Q.C. Inspector Every repaired pipe C SCA-FO-QC-028

One of the first 10


8.5 Residual magnetism control SCA-TM-QC-630 ≤ 20 Gauss Q.C. Inspector pipes
Every 1 hour C -

Adhesion Test dynamic method at


≥ 88 N at 20 ± 5°C One of the first 10
8.6 constant speed SCA-TM-QC-621 Q.C. Inspector Every 3 hour C SCA-FO-QC-003
≥ 39 N at 50 ± 5°C pipes
(According DIN 30670-91)
E: (5xΦ) J/mm Factor Φ
Impact Test at 23 ± 2°C Up tp 65 0.7 One of the first 10
8.7 SCA-TM-QC-610 Q.C. Inspector 1 per shift C SCA-FO-QC-014
(According DIN 30670-91) 80 to 150 0.85 pipes
200 or more 1.0
Uniform aspect and colour, free
of any surface defects. No
8.8 Visual inspection of coated pipes Visual inspection
blisters, bubbles, voids, wrinkles
Operator 100% of pipes C SCA-FO-QC-016
or other discontinuities

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ITP No.: 022-3PE
INSPECTION AND TEST PLAN FOR Revision: 7
EXTERNAL THREE LAYER POLYETHYLENE HIGH DENSITY Issued Date : August 7, 2008
P.O.: -
STANDARD RESPONSIBLE FREQUENCY INSPECTION
ITEM DESCRIPTION - STANDARD ACCEPTABILITY CRITERIA RECORD
TEST METHOD PERSON START-UP PRODUCTION SCA CLIENT

9 PIPE ENDS & IDENTIFICATION

9.1 Control of cut-back length SCA-TM-QC-711 100 - 150 mm Operator 100% of pipes C -

SCA-SP-PRO-
9.2 Coated pipe identification marking 003
One label per pipe Operator 100% of pipes C Informatic System

10 OFF LINE TEST

Differential scanning calorimeter on


One of the first 10
10.1 epoxy layer (DSC) SCA-TM-QC-616 ∆Tg - 3˚C to + 3˚C Q.C. Lab pipes
1 test per shift C SCA-FO-QC-060
(According ASTM D3418)

Hardness
10.2 SCA-TM-QC-611 ≥ 60 shore D Q.C. Lab 1 per Batch of PE C SCA-FO-QC-013
(According ASTM D 2240)

Identation Test ≤ 0.2 mm at 23 ± 2°C


10.3 SCA-TM-QC-615 Q.C. Lab 1 per Batch of PE C SCA-FO-QC-025
(According DIN 30670-91) ≤ 0.3 mm at 50 ± 2°C

Cathodic Disbondment test at Disbondment


65°C ± 3°C radius One of the first 10
10.4 (24 hours / -3.5V/ 3% NaCl) SCA-TM-QC-613 Q.C. Lab 1 test per day C SCA-FO-QC-021
≤ 4 mm pipes
(According CSA Z245.21-06, Clause 12.3) (from the edge of the hole)

SCA-TM-QC-619
Elongation at Break ASTM D 638;
10.6 (According ASTM D638) Type IV sample; ≥ 400 % Q.C. Lab 1 sample per batch of extruded PE sheet C SCA-FO-QC-048
crosshead speed
50 mm/min

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ITP No.: 022-3PE
INSPECTION AND TEST PLAN FOR Revision: 7
EXTERNAL THREE LAYER POLYETHYLENE HIGH DENSITY Issued Date : August 7, 2008
P.O.: -
STANDARD RESPONSIBLE FREQUENCY INSPECTION
ITEM DESCRIPTION - STANDARD ACCEPTABILITY CRITERIA RECORD
TEST METHOD PERSON START-UP PRODUCTION SCA CLIENT

11 LONG TERM TEST (Previous certificate - Historical Data)

Coating resistivity test Resistivity at 100 days ≥ 108Ωm2 Previous preformed test or Mfgr. Data SCA-FO-QC-046
11.1 SCA-TM-QC-639 Q.C. Lab C
(According DIN 30670-91) Ratio 100/70 days ≥ 0.8 (no older than 1 year) or Mfgr. Data

Thermal Ageing Melt flow index variation: ± 35 % Previous preformed test or Mfgr. Data SCA-FO-QC-050
11.2 SCA-TM-QC-643 Q.C. Lab C
(According DIN 30670-91) from original value (no older than 1 year) or Mfgr. Data

Ligth Ageing Q.C. Lab


Melt flow index variation: ± 35 %
11.3 (According DIN 53387, Condition 1-A-X) -
from original value
(Tested by Manufacturer's data R Mfgr. Data
mfgr.)
12 DOCUMENTATION CONTROL
According to project
12.1 Verify the daily production report - Q.C. Mgr. Every day R -
requirements
According to project
12.2 Verify the test report - Q.C. Mgr. Every day R -
requirements

Certificates will include:


- Detail quantity of coated
products
- Size, thickness of coated
Final inspection and issue of Approved products certificates will be
12.3 SCA-SP-QC-006 products Q.C. Mgr. D SCA-FO-QC-038
certificate of conformity issued at production end
- Material descriptions of system
- Specification
- Quality plan
- P/O No.

Final documentation report


12.4 (Data Book) SCA-SP-QC-006 - Q.C. Mgr. Once per project R -

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