BREDERO SHAW SX Srancon Conran Popa [Brod Shaw Proj No STANDARD | Quality Plan Three Layer Polyethylene Coating DOCUMENT NUMBER apo7-1EE Document No: GPO7-1 BREDERO SHAW} eee Revision Noo 1 , Three Layer Polyethylene Coating Revision Date: 05105108 Page: 2af 10 Customer Project ‘Bradaro Shaw Projool No STANDARD PROCESS FLOW DIAGRAM © renee tM to ao on Pat ~~ S=aB > oe - neon aa pws © ecmnana bw ET > y = mu snr Bl ut Siston Ohrexitrietegasienn avian, C)sneral = >» > = & > S ce oe don a rae rows Gparimiee (5), © a Oe Oa Oa On a + Ole Oars © seernteton Transporation 0 Stole - . : > Sse key: [_] Process dvectontiow —— @) Aatvity Number \D veaton PitDecimeniNe — OPGTA BREDERO SHAW) fees Revision Nor 1 | Three Layer Polyethylene Coating vision Dae 050508 ise 7 Ee Page 3a10 | | Gasioner Prope ‘Biedero Shaw Projet No | STANDARD 4.0 INTRODUCTION 44 SCOPE ‘This Quality Pian definos the application, Inspection, repair, handling and storage requirements of factory applied external three layer polyethyleno coatings for the anti-corrosion protection of steel line pipe. The coating system can be applied to longitudinal welded, spiral welded and to seamiess pipe for {he construction of buried or submerged pipelines. ‘This procedure is written with the intention of being @ working instruction for Bredero Shaw personnel by detaling the standard of workmanship and acceptance criteria throughout each phase of the process, 4.2 DEFINITIONS Customer ~ Organization issuing P.O. to Bredero Shaw BS = Bredero Shaw Manufacturer = Manufacturer or Supplier of raw materials associated with the coating process. 43 COATING SYSTEM DESCRIPTION ‘The coating system described in this document shall be manufactured using polyethylene as the main coating material, using suitable surface preparation and application techniques to obtain the coating properties required for its intendod instalation and operating consitons. 2.0 REFERENCES ‘The following reterences are relevant to this procedure: 24 Customer's Specifications 2.2. Bredero Shaw Management Procedures 3.0 RESPONSIBILITIES 3.1 The Superintendent shall be responsible for all labour and equipment necessary for the required operation. He shall also ensure that the operations are performed in a safe manner and that the product meets the requirements specified herein, 3.2. The QA/QC Manager is responsible for ensuring that the Customer's agreed quslty requirements are satisfied. He shall also ensure that the Q.C. inspectors inspect and control the quality ofthe product in accordance with this document. 3.3. Project Coordinator shall ensure that all services and coating related materials are evailable for the successful and timely completion of the project. He shall also act as the Customer interface throughout the duration of the Project.40 44 42 43 4a 45 46 Document Ne: GFOTA BREDERO SHAW| ieee Revision Nox 1 Rarer EEE Three Layer Polyethylene Coating Revision Date? OSES Page 4010 Gusiomer Projeal Biedoro Shaw Projecto: | STANDARD | COATING SYSTEM REQUIREMENTS SURFACE PREPARATION (On entering the Plant, pipes shall be placed on incoming racks where they shall be inspected for contamination by oll, grease, etc. Any contamination identified shal be removed by proprietary solvent ‘washing in accordance with SSPC-SP-1. Where excessive contamination is present, pipe shall be Femaved from the system, quarantined and brought to the attention of the Customer's Site Representative for further action. Testing for salt contamination shall be performed using a SCM 400 meter or Bresle kit, Refer to Inspection & Test Plan for criteria. END PLUGS End plugs shall be placed inside both ends of the pipe to prevent the ingress of abrasive during the blast cleaning process. These shall be removed immediately after blasting, at which time any dust or abrasive accumulating inside the bore of the pipe shall be removed by compressed air. PIPE PREHEAT Immediately prior to blasting, pipe is conveyed through an in-line Preheater. Pipes shail be heated to remove any surface moisture and fo ensuro a minimum holding temperature of 3°C above dew point, for the remainder of surface preparation stages. INITIAL BLAST CLEANING (1ST BLASTER) The pipe shail undergo an iniialy blast cleaned process to remove surface rust and to raise any slivets, scabs of other surface defects, allowing adequate steo! inspection. Where pipe have been received with a temporary mill applied coating e.g. Lacquer, and such coatings can not be removed uring normal cleaning process, these pipes shall be quarantined and brought to the attention of the Customer's Site Representative. The bevel landing shall be protected at ail times. BLAST CLEANING (FINAL BLASTING) Pipe shall then be conveyed to the second mechanical blaster, The abrasive shall be a selection of steel git / shot giving a cleanliness (in accordance with ISO 8501-1/8S 7079 or SSPC VIS 1-89, and a peak fo trough profile amplitude according to the requirements detailed in the Inspection and Test Plan bolow. Residual abrasive / dust shall be removed from the pipe surface on exit from the blasting cabinet by means of an air knife, wire brush or other suitable means. Residue accumulating on the internal surface shall be blown out using compressed air and removed through the dust collector system. GRINDING STATION Immediately after blast cleaning, the pipe is raised on to an inspection station to visually check for surface defects, such as slivers, laminations, leafing, scabs, burrs, indentations, slugs or other defects, considered detrimental to the performance or adhesion of the coating, Any surface defects considered detrimental to the coating shall be removed by manual cosmetic ‘grinding or filing‘ozument Noo OFOT-T BREDERO SHAW) eee Raviion No: 1 * Three Layer Polyethylene Coating Revision Cate” 05150 o : Page Sot Gastar ; Project edere Shaw Pet No STANDARD. ar 48 49 4.10 ant Where extensive grinding Is required, or major defects, Le., out with API SL and Customer's Specification are detected, pipes will be indexed out of the process for further inspection with the Customer's Site Representative. PIPE COUPLING INSERTION Pipe couplings shall then be fitted onto one end of the pipe. Prepared surface shall be monitored such that no oxidation (flash rusting) of the surface occurs which could be detrimental to the adhesion of the coating, Pipes with flash rusting shall be rejected and reprocessed as per section 4.3 onwards. PHOSPHORIC ACID TREATMENT AND WATER RINSE (WHERE NECESSARY) (On exit from the grinding station, pipes are conveyed. in-line through the acid wash station where they are treated with phosphoric acid, Acid Is directed at the pipe surface and applied through spray tips, ‘ensuring full coverage. After a dwell period of minimum 20 seconds, for pipe temperatures between 45 = 85°C, high-pressure water Is introduced to rinse off any residue and neutralize the acid. Dwell time may be extended 1 second for each degree below 45°C, or reduced by 1 second for each degree above 65°C, This process is normally utilized where seit contamination has been detected at levels in excess of 4ugicm®. Levels below this should not require acid wash. CHROMATE PRE-TREATMENT (IF REQUESTED) Chromate solution (approx. 10% concentration) shall be applied onio the pipe surface by gravity feed. ‘A rubber equeegee shall be held against the surface to aid even distribution of the chromate and to ensure full coverage of pipe surface, Chromate dilution shall be controlled as dictated by the manufacturer's data sheet INDUCTION HEATING SYSTEM Prepared pipe is then conveyed through the induction coll that is pre-set to heat the pipes to the desired application temperature (within manufacturers recommendations). Air knife, steel brush and vacuum system (dust removal) shail clean the pipe before entering the coating booth, After passing through the coll random tamporature checks will be carried out using Tempilstks to verify the infra ted pyrometer reading, which continuously monitors pipe temperature. Pipe heated in excess of allowed maximum coating temperature of 269°C, or as stated in powder manufacturers data sheet, shall be stripped, and reprocessed, POWDER APPLICATION AND RECLAIM SYSTEM Powder room personnel will check each box of powder before introducing the powder into the system. Virgin powder will be transferred through a screening system into the application systern fluidizing bed. The powder is then transferred, through a set of magnels to remove any foreign particles, to the application guns, which are electrostaticaly charged {0 facilitate the application of the powder. As heated pipe entors the spraying booth, guns wil be activated and electrosiatically charged FRE powder will be sprayed evenly over the rotating pipe surface. ‘Over spray powder is continuously extracted into a reclaim system, transferred through a cyclone / dust collector and a screening system, Screened powder is then transferred into a portioning hopper then mixed with virgin powder. No more than 20% recycled powder shall be mixed with virgin powder.Docanent Ne! OPaTA BREDERO SHAW/| Sauedlige Revson Nee 1 Ba | Three Layer Polyethylene Coating Revsion Date 050809 Ef Page: Bat 10 492 443 an 445 4.16 ‘Guster Project ‘Biedero Shaw Prject No: ‘STANDARD ADHESIVE (INTERMEDIATE COAT) APPLICATION ‘The intermediate coat will be applied by side extrusion and prossed firmly onto FBE coated surface using a silicon rubber pressure roller. Where adhesive material o be used is supplied in powder form, this shall be applied by spray method using fluidizing bed and powder guns. Application of adhesive will be timed to occur before the powder is cured so that maximum adhesion is achieved between powder and subsequent intermediate coat, The intermediste coat will be applied with correct temperature and thickness to firmly adhered to the powder coating layer. POLYETHYLENE (TOP-COAT) APPLICATION ‘Top-coat shall be extruded in euch a way that it's applied immediately following the adhesive coating. The top-coat will be applied with the correct width, temperature and thickness, to ensure that parameters used in the production yield satisfactory results and overall quality is met. NOTE: In the event where deomed to be necessary, one test pipe may be coated prior to production wih a small portion of coating to enable thickness, adhesion and dagree of cure to be checked to ensure that parameters intended to be used in the production can yield satisfactory results. Thus ensuring that overall quality of coating is met prior to full production run. SINTER COAT - ROUGH COAT (FOR SUBSEQUENT CONCRETE COATING ONLY) ‘Additional ‘sinter powder coat’ shall be spray applied on to coated surface as soon as pipe leaves the Coating booth. Such sinter coatings shall be applied to produce a rough coating surface onto which ‘concrete coating can be applied. This system Is intended to improve anti-slip properties. QUENCH STATION Coated pipe shall then conveyed to quenching station where pipe is cooled by a drenching flood of cooling water to allow further handling. Pipe temperature on exit from quench shall not exceed 90°C. The pipe is then lifted onto inspection racks. COOLING AND INSPECTION RACKS ‘As coated pipe is rolled and set on cooling racks, cutback ends will be cleaned of all tape and excess coating material, Electrical test (holiday detection) will be carvied out at a travel speed of no more than 0.3 misec and inspection voltage shall be as selcalibrated al a frequency as dictated by the Inepection and Test pian below, All detected holidays shall be clearly marked and the number of holidays detected on each pipe shall be writen at the end of the pipe. Immediately after holiday detection, pipes shall be inspected for dry fm thickness, uniform finish adhesion...ete., a3 required in the Inspection and Test plan, At the same time stencii marking shall be applied in accordance to the contractual requirement. CUTBACK BRUSHING Pipe ends shall be finished using powered wire brushes to clean all remaining powder from the ends of the pipe, Finishing shall produce clean bare steel over the required distance from the pipe ends, REPAIRS USING TWO PACK PATCHING COMPOUND Al holidays of spots with coating defecte shall be appropriately marked so that the damagetholiday is al the centre of the repaired area. Defective coating shall be removed by knife or chisel and the ‘surrounding area roughened by using sandpaper or a grinder.| STANDARD 4.16 4.19 50 Document Wo. Gor BREDERO SHAW) Kaeweliied RevsonNo 7 | Three Layer Polyethylene Coating Revision Ble) 051058 Bate it Page! To 10 Castor Propet ‘Bredero Shaw Peja No If the damage extends to the steel, apply a layer of two-pack epoxy (e.g., Valspar 46F640). If necessary, a hot air blower may be Used to accelerate curing process. The surface of cured epoxy ‘compound shall be roughened and cleaned prior to repair application of adhesive layer. For large ropairs, the adhesive and topcoat layer may be repaired using the following methos: ‘A thin layer of adhesive shall be melted, applied onto repaired epoxy surface and smoothed out using a spatula to provide an even smooth ‘waxy’ film. Continuously adding more adhesive (mixed with topcoat material if desired) and melted evenly to provent excessive deposits of material at anytime, which may end up with incomplete melting of material. The application shail start epproximately 25 mmm from the edge of the prepared section fo ensure overlap on parent coating and side overlap shall be approximately 25 mm. For small repairs, PE melt sticks may be used to fil the cavity. ‘Once cool, the repeir shall be fused with the parent coating and any excess material shall be removed by knife or fle, such that a smooth transition is obtained. Completed repair areas shall be holiday detected, ‘Minor indentation or scores on topcoat do not require repair, RETEST PROCEDURE In the event that tast pipes/samples fall to meet acceptance criteria, two additional samples shall be tested for compliance, Both tests must pass in order to accept the represented batch of pipe. Should ‘one of both tests fail the proceding pipes coated after the last acceptable test pipe/sample and the pipe coated following the failed pipe shall be quarantined for further testing, The extent of defect shall be determined by lot narrowing and all pipes that failed project requirement shal be rejected. STRIPPING AND RE-COATING Al rejected pipes shall be stripped by means of induction heating to the application temperature. At ‘which point @ scraper blade is then held against the pipe to remove the coating. The temperature during stripping operation shall not exceed 275°C. Following this, the pipe shall be biast cleaned to remove any trace of the FBE material in the steel profi. HANDLING, TRANSPORTATION & STORAGE HANDLING After coating, pipes shall be rolled on bearing racks for inspection/repair. Pipe shall be transferred from outgoing racks to trucks by means of overhead crane or loader filled with suitable padding, Where no further processing of the pipe is required, unless otherwise stated in the Inspection and Test plan below, bevel protectors shall be refilled to the pipe ends (where provided) to further aid in preventing the possibilly of bovol damage. Rejected pipes shall be marked with single red circumferential bend for identification and traceability ‘Such rejacted pipes shall be stored soparately for further process; e.g. re-blasting and re-coating work Quarantine pipes including test pipes shall be marked with temporary marking tapes. Such tapelmarking shall be removed cancelled by QCiTally personnel upon acceptance of repair work, rectification or customer agreed action, as applicableGastomer Project STANDARD 62 53 ‘Document No” OPOTT BREDERO SHAW ea RevisionNes 1 pe Three Layer Polyethylene Coating Fevision ate: 0515008 TRANSPORTATION Coated pipes shall be transported by flat bed trucks or pole trailers with suitably padded supports to prevent damage to the coating, Front-end fork loaders may also be used providing the lifting cradle is lined with soft ruber or foam. STORAGE Coated pipe shall be stored on sand berms comprising of two baulks of sand, 50 cm high with a bearing surface 1m wide, each 6m apart, approximately. Sand berms shall be inspected for suitability prior to use. Sand berms shail be covered with polythene sheeting, to ensure no contact with the berm. ‘All pipes shall be stored in stacks segregating the pipe by source, grade, diameter, and wall thickness, coating type and colour-codes. Pipes shall be positioned clear of the ground and at an angle sufficient tw ensure adequate water drainage through the bore of each pipe. Pipe interiors shall be kept clean and free from mud splashing or ditt deposits during storage. Pipe will be stacked with due consideration to impact effects, nosted together up to a maximum of 4 metres high.Document Nal __GPOT-L BREDERO SHAW) ee . ‘Revision No: 4 Three Layer Polyethylene Coating Revision Date: 05/05/03, Page 0110 ‘Camiomer Propet rere Saw reject N= STANDARD INSPECTION & TEST PLAN eee ‘Aceolones Ciera Topan [Azeovat inspection Presa 5p roquensy | (ep Sactomers Spceaton- | Roper } ERAT | ‘ere Rooke) Bed | cnr aaa a O80, Nose Gove ana Gttene | at | Foe Power Every atch | shal'be ihn Monafacturors sated ne | me Receipt P values and Sich Test CopmerAthosio | Every Ban | Packaging Secu, Mating Leptie | Cereae | vc | ME tom Poiyethylene Every Batch | Packoging Secure, Marking Lege | MEM ve Me Phosphor ek Every ote | Pockeding Secure, Marking Leghie | eros | vo | Me Crome every Bach | Packecing Secure, Manna toate | F033 | vo | ME ‘ease Every Baten | Packasing Secure, Manna togtie | w@ross | ve | Me tocoming | Visual nepocon Axpives | Contamination & cfet Fee - v ™ Race enema Wo eat Verity ip erty Axpipes | Longin sn ie Renin - v ” sire neces ssatcontaninaiontest | ™E5PE | 40min? 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