Coating Procedure: Etor ET

DOCUMENT DESCRIPTION COATING PROCEDURE
DOCUMENT CODE PTJ-COAT-PE-01
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The Petroleum Projects and Technical Consultation Co.

PETORJET
PIPE COATING SECTOR
COATING PROCEDURE
FOR EXTERNAL PROTECTION OF STEEL PIPELINES USING
SIDE-EXTRUSION POLYETHYLENE THREE LAYER SYSTEM
Rev Date Description BY CH'D APPR.
THIS DOCUMENT IS CONFIDENTIAL AND THE SOLE PROPERTY OF PETROJET
PDF created with pdfFactory trial version www.pdffactory.com

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INDEX
1- INTRODUCTION .
2- DEFINITIONS AND ABBREVIATIONS .
3- REFERENCE STANDARDS AND CODES .
4- GENERAL PROPERTIES OF COATING MATERIALS.
5- PRODUCTION TESTING AND INSPECTION PLAN.
6- COATING APPLICATION AND TESTING PROCEDURE.
7- TEST CERTIFICATES.
8- REPAIR OF COATING.
9- PIPE MARKING.
10- PIPE RECEIVING, STORAGE, HANDLING AND TRANSPORTATION.

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1- INTRODUCTION
This procedure is designed to comply the requirements of NF A 49-710 and DIN 30 670 standards
The procedure provides the requirements of the application, testing and repair of workshop side-
extruded Polyethylene coatings ( 3 layer system ) on pipes surfaces .
The coating covered by this procedure is suitable for the exterior protection of the steel pipe line
which applied to On-shore and Off-shore pipelines designed to convey and distribute oil, gas or
any other fluid .
The coating system shall have the following composition :
1) Layer of epoxy primer .
2) Layer of polymeric adhesive .
3) Layer of Polyethylene top coat .

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2- DEFINITIONS AND ABBREVIATIONS

Within the application od this procedure the following definitions and abbreviations shall be apply:
2.1 DEFINITIONS
• Coating system The coating technique or process system consisting of the same type of
coating material .
• Side extrusion Coating process whereby a hot extruded films of coating materials are wrapped
around the pipe in layers. The pipe is moved past the extrusion head in a spiral motion. The
extruded coating films are fused together to form a continuous adherent sheath around the pipe .
• Three layer system Coating system consists of three layers which are epoxy primer, adhesive
and outer layer .
• Epoxy primer The first coating layer ( the anti-corrosion layer ) which applied directly onto the
preheated pipe to improve the final adhesion of the final coating to the pipe surface .
• Adhesive The intermediate coating layer to improve the adhesion between the primer and the
outer layer .
• Outer layer The polyethylene ( PE ) layer .
• Coating thickness Understood to be the average thickness of the coating system ( summation of
average thickness for the applied top coat, adhesive and primer layers ) .
• Unit of production Set of pipes have the same DN and coated with the same coating system
and the same type of material .
• Coating cycle Any production process have the same DN and coated with the same coating
system, and not interrupted more than 3 days .
• Test ring Test sample from a coated pipe.
• Day Production run and shall not more than 24 hrs.
• Shift Production run and shall not more than 12 hrs.
• Batch No. Quantity of PE material not more than 50 tons.

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2.2 ABREVIATIONS
• DN Pipe nominal diameter
• FBE Fusion Bonded Epoxy ( epoxy primer )
• PE Polyethylene
• RH Relative humidity %
• Tg Glass transition temperature, expressed in °C .
• ΔTg Variation of the glass transition temperature ( Tg2 – Tg1 ), expressed in °C .
• J Impact energy in joules .
• UV Ultra Violet .
• DSC Differential Scanning Calorimetry
• MEK Methayl Ethyel Ketone

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3- REFERENCE INTERNATIONAL CODES AND STANDARDS .

This specification makes reference to the documents listed below, where relevant, all work shall
be carried out in accordance with the latest editions of these documents, including all revisions and
addenda . Where conflict occurs between the requirements of this procedure and reference codes
and standards, the requirements of this procedure shall apply .
z European Committee for Standardization .. ( CEN )

PrEN 10285 Steel Tubes and Fittings for On and Off-shore Pipelines – External Three Layer
Extruded Polyethylene Based Coatings.
z L’Asaociation Francaise de Normalisation .. ( AFNOR )

NF A 49-710 Steel Tubes External Triple-Layer Polyethylene Based Coatings Application By
Extrusion.
z Deutsche Institute fur Normung .. ( DIN )

DIN 53 505 Testing of Rubber, Elastometer and Plastics;Shore Hardness A and D Testing.
DIN 53 455 Testing Of Plastics; Tensile Test .
DIN 30 670 Polyethylene Coatings For Steel Pipes and Fittings, Requirements and Testing
z American Society for Testing and Materials .. ( ASTM )

Standard Practices for Evaluating The Resistance of Plastics to Chemical
ASTM D 543
Reagents .
ASTM D 638 Standard Test Method For Tensile Test Of Plastics .
ASTM D 1238 Standard Test Method For Flow Rates Of Thermoplastics Extrusion Plastometer
ASTM D 1248 Standard Test Method For Polyethylene Plastics Molding and Extrusion Materials.
ASTM D 2240 Standard Test Method For Rubber Property- Durometer Hardness .
ASTM D 3359 Standard Test Method For Measuring Adhesion By Tabe Test
Standard Test Method For Measuring MEK Resistance of Ethyl Silicate ( Inorg-
ASTM D 4752
anic) Zinc-Rich Primers by Solvent Rub .
Standard Test Method For Assessing the Resistance of Organic Coatings
ASTM D 5402 Using Solvent Rubs .
ASTM G 8 Standard Test Method For Cathodic Disbonding Of Pipe Lines Coatings .
z National American Of Corrosion Engineering .. ( NACE )

Standard Recommended Practice - Application,Performance, and Quality Control
NACE RP 0394 Of Plant-Applied, Fusion Bonded Epoxy External Pipe Coating .

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z Gas Business Engineering .. ( GBE )

GBE/CW6 : part 1 Technical Specification For The External Protection Of Steel Line Pipe and
Fittings Using Fusion Bonded Powder and Associated Coating Systems
( Part 1 : Requirementes For Coat materials and Methods Of Test .
z International Standard .. ( ISO )

ISO 8501-1 Pictorial Surface Preparation Standards For Painting Steel Surfaces .
( SIS 05 59 00 )
ISO 8502-1 Field Test for Soluble Iron Corrosion Products .
ISO 8502-3 Field Test for The Determination Of Dust Contamination
ISO 8502-4 Guidance on the Estimation of the Probability of Condensation Prior to Paint
Application .
ISO 1133 Plastics - Determination of the Melt Mass-Flow Rate ( MFR ) and Melt Volume-
Flow Rate ( MVR ) of Thermoplastics .

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4- GENERAL PROPERTIES OF COATING MATERIALS .
The coating materials used in this project shall be have the following general properties:
EPOXY PRIMER
1- Powder or liquid epoxy primer, applied as anti-corrosion layer for coating of steel pipe line by
polyolefin 3 layer system .
2- Possess good similarity and compatibility with the polymeric adhesive, and react with it, so that
the reciprocal anchorage is increased.
3- Show high capability to minimize cathodic disbondment when steel pipe is subjected to negative
polarization as per ASTM G 8 standard [ the maximum radius of disbonding ≤ 7.5 mm. ] .
ADHESIVE : GENERAL PROPERTIES

1- Ethylene co-polymer suitable for 3 layer coating system .
2- Be suitably stabilized against aging at its maximum application temperature and free from volatile
or other unstable substances at maximum application temperature ( application temperature
indicated by the manufacturer ) .
3- Show high affinity and strong bond with polyethylene layer (top coat layer), high affinity and
strong bond with primer layer, and assure a strong bond with primer (equal to or higher than that
with PE).
4- Achieve with other layers, at least, a minimum peel-off resistance as per DIN 30 670 standard .
5-Possess the following properties ...
PROPERTY UNIT TEST METHOD VALUE

Density g / cm3 ASTM D 1505 0.910 - 0.950
g / 10 min.
Melt Flow Index ASTM D 1238 max. 10
190 °c / 2.16 Kg
Tensile Strength at Break kg / cm2 ASTM D 638 ≥ 110
Elongation at Break % ASTM D 638 ≥ 350

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POLYETHYLENE GENERAL PROPERTIES
1- Fully stabilized PE, in granular state, contains additives for stability and resistance to weather
conditions and its combined action of oxygen, sunlight and temperature .
2- Designed for coating of steel pipe, three layer system, where it is side-extruded directly in
multiple wraps to build-up the requested thickness .
3- Compatible with other layers and show with them, at least, a minimum peel-off resistance as
per NF A 49-710 and DIN 30 670 standards .
4- Possess the following properties ...
PROPERTY UNIT TEST METHOD VALUE

Density, compound g / cm3 ASTM D 1505 0.930 - 0.955
g / 10 min.
Melt Flow Index ASTM D 1238 0.2 – 1.0
190 °c / 2.16 Kg
Carbon Black % ASTM D 1603 2-3
Durometer Hardness shore D ASTM D 2240 ≥ 50
Brittleness Point °c ASTM D 746 < - 60
ESCR h ASTM D 1693 > 1000
Vicat Softening Point °c ASTM D 1525 > 105
Tensile Strength at Break kg / cm2 ASTM D 638 > 126
Elongation at Break % ASTM D 638 > 400

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5- PRODUCTION TESTING AND INSPECTION PLAN .

During production application of the coating all quality control activities ( needed to ensure that the
coating is being applied in accordance with the approved specification ) shall be carried out .
5.1 PIPE SURFACE PREPARATION

QC. Supervisor shall perform the following parameters at the frequencies indicated in table ( 1 ) .
- Climatic conditions ( prevailing temperature, humidity, dew point ) .
- Surface cleanliness . - Surface profile .
- Surface salt contamination . - Dust control .
5.2 PRE-HEATING TEMPERATURE

QC. Supervisor shall perform the preheating temperature of the coating materials at the frequencies
indicated in table ( 1 ) to insure application within the manufacturer recommendation limits .
- Pipe temperature . - Epoxy primer ( liquide epoxy only )
- PE temperature . - Adhesive temperature .
5.3 COATING SYSTEM THICKNESS

QC. Supervisor shall verify that the coating thickness meet the requirements mentioned in 6.6, at the
frequencies indicated in table ( 1 ) .
- Thickness of primer layer - Thickness of adhesive layer - Total coating thickness
5.4 COATING CONTINUITY ( HOLIDAY DETECTION )

QC. Supervisor shall verify that all coated surface is holiday detected 100 % at voltage set at 10 Kv
per millimeter of nominal thickness of coating and not exceeding 25 Kv.
5.5 IMPACT RESISTANCE TEST

QC. Supervisor shall perform the impact resistance of the coating system at the frequencies
indicated in table (1) .
5.6 ADHESION ( PEEL OFF ) TEST

QC. Supervisor shall perform the peel-off resistance of the coating system at the frequencies
indicated in table ( 1 ) .
5.7 MELT FLOW RATE

QC. Supervisor shall perform the melt flow rate of the PE and adhesive for the new and extruded
material at the frequencies indicated in table ( 1 ) .
5.8 INDENTATION RESISTANCE TEST

QC. Supervisor shall perform the indentation resistance of the PE at the frequencies indicated in
table ( 1 ) .

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5.9 ULTIMATE ELONGATION

QC. Supervisor shall perform the ultimate elongation of the PE at the frequencies indicated in table (1) .
5.10 TENSILE STRENGTH AT YIELD AND AT BREAK

QC. Supervisor shall perform the tensile strength at yield and at break of the PE at the frequencies
indicted in table ( 1 ) .
5.11 DUROMETER HARDNESS - SHORE D

QC. Supervisor shall perform the hardness shore D of the PE at the frequencies indicated in
table(1)
5.12 DEGREE OF CURE

QC. Supervisor shall check the degree of cure of the F.B.E layer at the frequencies indicated in table ( 1 ).
5.13 FLEXIBILITY
QC. Supervisor shall perform the flexibility of the coating at the frequencies indicated in table ( 1 )
5.14 CATHODIC DISBONDING TEST

QC. Supervisor shall perform the cathodic disbonding test for the coating at the frequencies indicated in
table ( 1 ) .
5.15 ENTRAPMENT ASSESSMENT

QC. Supervisor shall check the air entrapment in the coating at the frequencies indicated in table ( 1 ) .

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TABLE ( 1 ) THE MINIMUM QUALITY CONTROL TESTS FREQUENCY
Frequency At Regular
Test Acceptance Criteria
Production
1) Ambient temperature test / hr .
2) Relative humidity ≤ 90٪ test / hr .
3) Dew point test / hr .
4) Surface cleanliness min SA 2 ½ test / hr.
5) Surface profile 50 - 100 µm test / hr.
6) Surface salt contamination 20 mg/ m2 test / Shift

≥ 3°c
7) Pipe Temperature After Blasting test / hr .
above dew point
8) Cleanliness Of Blast Cleaned Surface For
≤ Rating 2 test / hr .
Dust
9) Abrasive Check For Contamination Free test / shift
10) Pipe temperature 190 °c - 230 °c test / hr.
11) Epoxy primer temperature ( liq. Epoxy ) Material D. S. test / hr .
12) PE temperature Material D. S. test / hr .
13) Adhesive temperature Material D. S. test / hr .
14) Thickness of primer layer 100 ± 25 µm. test / day
15) Thickness of adhesive layer 200 ± 50 µm. test / day

On pipe body:
Relvant to pipe diameter
16) Total coating thickness. test / hr .
On weld: ± 15%
17) Visual Inspection Free from blisters Each pipe.
18) Continuity-holiday- control 25 Kv 100 %
at 23 °C ≥ 35 N/ mm test / hr.
19) Peel-off test
at 50 °C ≥ 25 N/ mm test / shift.
20) Impact test ≥ 5 J/mm test / batch No.

New: ± 15 % of the
test / day
Material D.S
21) Melt Flow rate
Prec.: ± 20 % of the New
test / day
MFR

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Frequency At Regular
Production Test Acceptance Criteria
Production
22) Hardness, Shore D ≥ 50 test / day
MEK, Slight softening test / shift

23) Degree of Cure DSC ,
test / week
- 2°C ≤ ΔTg ≤ + 3 °C
Yield ≥ 126 Kg/cm2
24) Tensile strength at Yield and Break test / day
Break ≥ 170 Kg/cm2
25) Ultimate elongation ≥ 400 % test / day
≤ 0.2 mm at 23 °C
26) Indentation Resistance test / batch No.
≤ 0.3 mm at 50 °C
27) Entrapment Assessment ≤ 20% air entrapment test / shift.

st
28) Flexibility, 3º PD at -10 °c No cracks 1 . pipe / 3 Randoum
29) Cathodic disbonding test Max. Increase in Radial st
( at 48 hrs, 65 °c ) Defect 7.5 mm 1 . pipe / 3 Randoum

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6- COATING APPLICATION AND TEST PROCEDURE .
6.1 COATING SYSTEM

The coating of PE three layer system is performed as following …
1- Pipe pre-heating and surface preparation ( blast cleaning ) .
2- Once the blasted pipe is accepted, it conveyed to the coating line where it’s induction heated .
3- Application of the epoxy layer .
4- A bond breaker material may be applied to facilitate the cut back removal .
5- Application of the polymeric adhesive material ( copolymer ) by side-extrusion .
6- Application of the PE layers by side-extrusion , then a hydraulically operated silicon pressure roller
is engaged to smooth the coat surface and improve the adhesion performance .
7- The coated pipe enters cooling tunnel to be cooled down .
6.2 PIPE SURFACE PREPARATION

1- Before blast cleaning and application of the coating system, the pipe surface shall be free of all
surface contaminants . Oil, grease, and other contaminants shall be removed wiping the
contaminated area by suitable solvent, detergent or potable water .
2- All pipes should be visually checked for moisture, if the pipe looks damp, the pipe must be preheated
to at least 45 °c to eliminate the moisture, the pipe surface should be at least 3 °c above the dew
point temperature prior to coating .
3- The pipe surface shall be cleaned by shot/grit blast cleaning technique to achieve the requirements of
SA 2 ½ Very thorough blast cleaning , SIS 05 59 00 ( ISO 8501-1 ) , and surface profile has a peak-
to-valley 50 - 100 µm .
4- Production personnel shall be inspect the blasted pipes for all surface imperfections ( silvers, scabs,
dents, ..etc ) which shall be marked .
- All marked defects shall be brought to the attention of client representative to approve the action
shall be taken by Petrojet or to provide the corrective action .
- Grinding or repair in the area thus treated shall not reduce the pipe wall thickness below the client
requirements or API 5L standard .
- For repaired area more than 100 cm2 the pipe shall be re-blasted and re-inspected .
5- Production personnel shall make sure that the abrasive material in the blasting machine is free from oil
and greas contamination ( by mixing a sample of abrasive material with fresh water or with solvent
[ thiner] ) .
6- Prior to coating, the pipe surface shall be cleaned from all dust and abrasives which still remain on the
exterior surface of the pipe by using mechanical nylon brush .
7- Blasted pipes shall be coated within the following maximum times and any pipe delayed beyond this
period shall be re-blasted and re-inspected .
% RH TIME
85 > RH ≤ 90 1/2 hr.
80 > RH < 85 1 hrs.
70 < RH ≤ 80 2 hrs.
60 < RH ≤ 70 3 hrs.
50 < RH ≤ 60 4 hrs.

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< Q.C TEST >
1- QC supervisor shall verify that the pipe surface cleanliness meets the requirements of SA 2 ½ (Very
thorough blast cleaning), by visual comparison with photographs in SIS 05 59 00 standard ( allowance
must be made for the fact that differences in color can occur due to the type of grit used, spherical
grit, for example, results in a slightly darker surface than that in the photographs in SIS 05 59 00
standard ) .
2- QC supervisor shall verify that the pipe Surface profile has a peak-to-valley 50 - 100 µm, using
testex tape ( or equivalent ) in accordance with the following procedure :
- Zero the dial micrometer ensuring the flat contact points are clean .
- Remove paper backing from Testex tape and stick Testex tape to the surface to be measured .
- Rub the Testex tape paste into the troughs using a blunt instrument, until the peaks can be seen
butting up to the transparent plastic .
- Remove the Testex tape from the surface and measure the overall thickness with the dial
micrometer .
- Deduct 50 µm for the plastic from the reading to obtain the amplitude ( surface profile ) .
3- QC supervisor shall verify that the salt contamination for the blasted pipe surface is within the rang of
20 mg/m2.
4- QC supervisor shall verify that the dust contamination level for the blasted pipe surface is withing the
quality ≤ rating 2 .
6.3 CUT BACK

The coating, at pipe ends shall be cut back over length of 100 + 0/- 20 and beveld at 45 °, at cut backs
the PE and Adhesive layers shall be removed, the epoxy primer layer will left as temporary protective
layer .
6.4 VISUAL INSPECTION

Production personnel shall be inspect the coated pipes 100 % to insure that …
1- The coating free from blisters .
2- Pipe temperature after cooling shall be ≤ 65 °c.
6.5 PRE-HEATING TEMPERATURE

QC. Supervisor shall perform the pre-heating temperature of the coating materials as following ..
1- Pipe temperature
QC supervisor shall verify the pipe surface temperature is between 190 °c - 230 °c ( in any case the
pipe temperature shall not exceed 275 °c ) using the TEMPIL STICK temperature indicating crayons
as follows..
F Stroke heated surface with the crayon, a liquid smear will show at the specified temperature .

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2- Epoxy Primer temperature ( liquide epoxy only )

QC supervisor shall verify the temperature of epoxy primer is in the recommended application
temperature using one of the following methods ….
3- POLYETHYLENE & Adhesive temperature

QC supervisor shall verify the temperature of both extruded PE and adhesive material is in the
recommended application temperature using one of the following methods ….
F METHOD Ι ( Destructive test )

While the material is being extruded prior to coating application using probe type thermometer .
F METHOD ΙΙ ( Non-Destructive test )

While the material is being extruded prior to / or during coating application using portable pyrometer.
6.6 COATING THICKNESS

6.6.1 Epoxy Primer Thickness : The thickness shall be 100 ± 25 µm.
6.6.2 Adhesive Thickness : The thickness shall be 200 ± 50 µm.
6.6.3 Total Coating Thickness
The average total thickness is the summation of the thickness of individual layers, The coating
thickness is relevant to the pipe diameter as specified in the following table
Pipe Diameter ( in ) Total Coating Thk. ( mm )

up to 4" 1.8
> 4" up to 10" 2.0
> 10" up to 20" 2.2
> 20" up to 30" 2.5
≥ 32" 3.0
The thickness given in this table is relaxed by 15 % For welded pipes
( longitudinal or spiral weld ), at the weld reinforcement .
< Q.C TEST >
The thickness of the coating system shall be measured using thickness meter gauge calibrated at
least once per shift . Calibration shall be carried out as following ..
1- Choose a plastic shim of a thickness close to the thickness you expect to fined .
2- Place the shim on an non-coated blasted pipe surface .
3- Measure the thickness of the shim, if any deviation is detected adjust the thickness meter
gauge to the thickness of the shim .

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Primer / Adhesive Layers Thickness

At the start of each coating cycle, production personnel shall run one test pipe to verify the DFT of the
primer layer as following ..
1. A series of 12 individual measurements shall be carried out on painted panel .
2. The maximum and minimum readings shall not be considered, the arithmetical mean for the rem-
aining 10 measurements is calculated to satisfy the thickness given in 6.6.1 & 6.6.2 .
Total Coating Thickness

For quality control purposes the thickness of the coating system shall be measured as following ..
1- A series of 12 individual measurements shall be carried out on each pipe to be inspected, the
measurements shall be regularly distributed along 3 transverse sections of the tested pipe .
2- At each section the thickness shall be measured at 4 positions, equally spaced around the
circuference of the pipe, when a weld seam is visible, one measurement per section shall be
executed on the the top of the weld seam .
3- The maximum and minimum readings shall not be considered, the arithmetical mean for the
remaining 10 measurements is calcullated to satisfy the thickness given in 6.6.3 .
6.7 COATING CONTINUITY ( holiday detection )

The coating system shall be holiday detected 100 % , the test voltage shall be set at 10 Kv per
millimeter of nominal thickness of coating and not exceeding 25 Kv,The maximum no. of allowed
holidays is 5 localized or scattered holidays per coated pipe .
The holiday test shall be carried out using an adjustable high voltage tester having an audible and
visual alarm, the scanning electrode shall consist of a metal brush or coil spring or coil brush, fitting
the diameter of the coated pipe .
The test voltage shall be set at 10 Kv per millimeter of nominal thickness of coating and not
exceeding 25 Kv The detector shall be calibrated at start of each coating cycle as follows :
At least 5 holes of around 1 mm diameter must be made in the coating, down to the pipe
metal, with a needle; these holes must be spaced by about 10 cm .
The detector is switched on ,the voltage shall be set at 10 Kv per millimeter of nominal
thickness of coating and the electrode is set to pass the test holes .
A spark discharge must be correspondence with every hole .

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6.8 ADHESION ( PEEL-OFF ) TEST

The adhesion of the coating shall be determined by measuring the peel-off resistance, the minimum
force required to lift the coating shall be as indicated in the table below …
Force at 23 °C ± 3 °C Force at 50 °C ± 3 °C
35 N / mm 25 N / mm
< Q.C TEST >
The adhesion of the coating shall be carried out using habging weights, in which a strip of coating 5 cm
width shall be manually peeled off at an angle of 45 ° to the pipe surface where the peel strength requi-
red to peel off the coating with a pulling rate of 10 mm/min.
The required peel strength shall be calculated as:
Peel strength ( N/mm ) = M x 9.81 / W
Whrer M = the mass of the wieght in Kg.
W = the width of the strip in mm
6.8.1 Any pipe that exhibits a peel off value below the required value, the pipe shall receive 2 additional
peel tests to verify the accuracy of the first test .
6.8.1.1 If the 2 additional peel tests meet the required value, the pipe is accepted .
6.8.1.2 If the 1 out of the 2 additional peel tests is below the required value, the pipe is rejected
then 3 previously coated pipes and 3 new coated pipes shall be tested, if below the requi-
red value is detected, the production line shall stopped until the defect is determined .
6.8.2 The adhesion test shall be preferred only at the cut back area .
6.9 IMPACT RESISTANCE TEST

The impact resistance of the PE coating system shall be tested accordance To DIN 30 670 and NF A
49-710 standards at temperature ( 23 ± 3 °C ) the coating shall have a minimum impact resistance
value equal to E = ( 5 x ϕ ) J / mm coating .
< Q.C TEST >
QC supervisor shall perform the impact test as following …

1- A minimum of 30 points shall be selected on the surface of the tested pipe, the distance between two
impact points shall be at least 30 mm .
2- Drop the impact wieght with hemispherical steel head with diameter of 25 mm from 1 meter height, the
weight required to produce the specified energy to the coating is calculated using the following formula :

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H = J / 9.81 * W
Whrer H = impactor height, m.
W = impactor mass, Kg.
J = Impact energy, joules.
3-This described body shall produce an impact energy, E, equal to ( 5 x ϕ ) J per mm of coating thick-
ness, with tolerance of 5 % .
DN ( mm ) ϕ
≥ 200 1.0
65 < 200 0.85
< 65 0.70
• The factor ϕ accounts for the curvature of the pipe .
4- The coating is accepted if the impact energy has not cause any perforation inspected with holiday
detector .
6.10 INDENTATION RESISTANCE TEST

The indentation resistance of the PE material shall be tested in accordance to DIN 30 670 and NF A
49-710 standards The maximum indentation resistance shall be as following …
at 23 °C ± 3 °C at 50 °C ± 3 °C
0.2 mm 0.3 mm
< Q.C TEST >
QC supervisor shall perform the indentation test as following …

1- A sample of PE of thickness ≤ 4 mm shall be taken from a pipe where neither the primer nor
the adhesive have been applied .
2- The sample shall be subjected to an indentor with flat face and 1.8 mm diameter , The total
mass of the indentor assembly shall be 2.5 kg .
3- The indentor shall be slowly and carefully lowered on the test sample , the Zero ( T0 ) reading
set at penetometer within 5 sec. then after 24 h, the final reading ( T1 ) of the penetometer is
recorded The indentation depth is given by the following equation :-
Indentation ( mm ) = T1 - T0

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6.11 TENSILE STRENGTH AND ULTIMATE ELONGATION TEST

The tensile strength and ultimate elongation ( elongation at break ) of the PE material shall be as
following :
Tensile Strength Tensile Strength

Ultimat Elongation
( Yield ) ( Break)
≥ 126 Kg/cm2 ≥ 170 Kg/cm2 ≥ 400 %
< Q.C TEST >
QC supervisor shall perform one tensile and elongation test according to the standards ASTM D 638
and DIN 53 455 standards and shall be carried out as following …
2- The sample shall be Dumbbell shape No. 4 .
3- Determine the cross-section of the test sample ( cm2 ) .
4- The sample shall be hold between the tensile grips .
5- The grips shall be moved away at constant speed = 50 mm / min.
6- Record the tensile force at the yield point, tensile force at the break point and the extension at
break point .
7- Calculation and expression of results
Tensile strength at yield ( kg / cm2 ) = F0 /A
Tensile strength at break ( kg / cm2 ) = F/A
Elongation at break ( % ) = ∆L / L . 100
where
F0 = is the tensile force at yield point ( kgf ) .
F = is the tensile force at break point ( kgf ) .
A = is the cross-section of the test sample ( cm2 ) .
L = is the initial gauge length of the test sample ( mm )
∆L = is the increase in the sample length between gauge marks ( mm ) .
6.12 DUROMETER HARDNESS – SHORE D

The hardness shore D of the PE material shall be ≥ 50 shore D .
< Q.C TEST >
QC supervisor shall perform one hardness test according to the standards ASTM D 2240 and DIN
53 505 standards and shall be carried as following …

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2- Place the sample on the steel plate of the tester .
3- The sample shall be subjected to a durometer to which an additional weight of 4 kg is attached
so, the total mass of the assembly shall be 5.0 kg .
4- The durometer shall be placed, without shock, on the sample making a firm contact with it .
5- The hardness shore D shall be read-off 3 sec. after the presser foot of the durometer has
made complete contact with the sample .
6.13 MELT FLOW RATE

QC supervisor shall perform the melt flow test ( M.F.R ) on the new and extruded PE and
adhesive materials .
< Q.C TEST >
QC supervisor shall perform the melt flow rate test according to ASTM D 1238 and ISO 1133
standards and shall be carried as following …
1- A sample of new or processed material shall be taken .
2- Heat the sample on extrusion plastometer tester to the test condition specified in material data
sheet (2.16 Kg or 5.0 Kg. / 190 °c )
3- Use the test weight pressure specified in material data sheet.
4- The melt flow rate ( MFR ), expressed in grams per 10 minutes and is given by the following
equation :-
MFR ( θ, mnom ) = tref . m / t
Where :
θ = is the test temperature, °C .
mnom = is the nominal load, Kg .
tref = is the reference time ( 10 minutes ), 600 sec.
m = is the average mass of the cut-offs, gr. .
t = is the cut-off time interval, sec.
6.13.1 New MFR = shall be within ± 15 % of the material certificate of analysis or material
data sheet .
6.13.2 Extruded MFR = shall be within ± 20 % of the New MFR .

REV. DATE SHEET

A June 2004 22 of 28
6.14 ENTRAPMENT ASSESSMENT

The strips of coating from the adhesion test shall be used to determine the level of air entrapmet on
the body of the pipe or in the saw weld, the coating shall be examined using 30X microscope.
The coating should show not more than 20% of the observed area contains air entrapment, bubble
size in the PE layer shall be limited to less than 1/2 the thickness of the PE layer in hieght or
circumference and not linked together.
6.15 DEGREE OF CURE

The degree of cure of the F.B.E layer shall be tested by one of the following methods …
6.15.1 MEK Rub method
The degree of cure of the F.B.E is tested once per shift using MEK ( Methyl-Ethyl Ketone ) double rubs
according with ASTM D 5402 standard, The curing of the coating shall be ≤ rating 2 .
Rating Criteria
0 No change of gloss, No softening ( no scratch by fingernail )

1 Slight loss of gloss, No softening ( no scratch by fingernail )
2 Slight loss of gloss, Slight softening ( can be scratched by fingernail )
3 Strong reduction in gloss, Complet softening ( easily scratched by fingernail )
4 Strong reduction in gloss, Complet softening ( coating partiallly removed )
5 Removal of coating
6.15.2 Differential Scanning Calorimetry ( DSC ) method
The degree of cure of the F.B.E is tested once per week by determination of the glass transition
temperatures, Epoxy sample of the full film thickness shall be taken from a test ring .
The test shall be performed according with NACE RP 0394 standard, the curing of the coating is accept-
able when variation of the glass transition temperature ΔTg ( Tg2 – Tg1 ) shall be between -2 oC and +3 oC.

REV. DATE SHEET

A June 2004 23 of 28
6.16 FLEXIBILITY TEST

The degree of flexibility of the coating shall be tested when a test ring is bent over a mandrel at -10 °c,
The coating shall satisfay the requirements when no visible cracks is shown in the coating system
when bending performed to 3º PD .
6.17 CATHODIC DISBONDING RESISTANCE TEST
The coating shall show good resistance to cathodic disbondment when subjected to a potential of – 1.5
V, in a 3% NaCl electrolyte solution as per ASTM G 8 and PrEn 10285 standards at the following test
conditions …
PQT Regular production

Test Conditions 65 ± 2 °c 65 ± 2 °c or 23 ± 2 °c
Test Duration 2 days 2 days or 28 days
Max. Disbonding Radius 7.5 mm 7.5 mm
6. 17.1 After Test period the degree of disbonding is evaluated as following ….

- Make radial 45° through the coating intersecting at the center of the intentional holiday with a
sharp knife.
- Attempt to lift the coatingfrom the pipe starting from the test defect .
-The distance over which the coating is detached and the metel is exposed is measured from the
edge of the original test defect.
- recored the measurments for all four directions, the redius of disbonding shall be the arithmetic
mean of the four measurments.

REV. DATE SHEET

A June 2004 24 of 28
7- TEST CERTIFICATES
Test certificate shall be submitted to certify the following properties of the coating, Test certificate is a
may be from test reports of tests performed at PETROJET Quality Control Laboratories ( code 1),
material manufacturer ( code 2 ).
7.1 STABILITY TO AGING BY ULTRAVIOLET RAYS ( code 1 )
The PE material shall be tested for measuring UV aging resistance as per DIN 30 670 standard, The
stability of the PE must remain within ± 35% from the original figures of the MFR after the material
exposed to the Xenon lamp for duration 2400 hrs.
7.2 STABILITY TO THERMAL AGING ( code 1 )
The PE material shall be tested for measuring UV aging resistance as per DIN 30 670 standard, The
stability of the PE must remain within ± 35% from the original figures of the MFR after the material
subjected to temperature of 100 °c for duration 4800 hrs.
7.3 CHEMICAL RESISTANCE ( code 1 )
The PE material shall withstand alteration when immersed in chemical reagents for 60 days ( as per
ASTM D 543 standard ) , The stability shall be determined from the change that the material immersed
to chemical reagents shows from the non immersed material in respect to tensile strength at break ,
elongation at break and MFR .
The figures of the immersed material must remain within ±50% from original figures after 60 days and 90
days immersion period in the following chemical reagents of the test are :
- 5 % and 10 % in volume of Sodium Hydroxide .
- 5 % and 10 % in volume of Sodium Chloride .
- 1 % and 10 % in volume of Nitric Acid .

REV. DATE SHEET

A June 2004 25 of 28
8- REPAIR OF COATING
8.1 COATING REPAIRABILITY
In theory, no coating defect or damage should ever be found during the coating process, but at
practical level it can not however be excluded, so .. some defects may occasionally show up in
pipe coating . Taking the above into consideration , the following repair methods are applied for in
plant damaged coated pipe .
8.1.1 For local defects ( scratches, cuts, dents, … etc. ) of any dimension and any quantity where
the defect not reach the metal surface ( the remaining coating thickness is not less
than 80% of the specified thichness ), no repair is required .
8.1.2 For same defect mentioned above, having damaged area aprox. 625 mm2 where the defect
reach the metal surface or the remaining coating thickness is less than 80% of the
specified thichness , these defects could be repaired using spot patch .
8.1.3 For defects , having damaged area greater than 625 mm2 and less than 750 cm2, these
defects could be repaired using heat shrink sleeve .
8.1.4 The maximum level for repair of coating ( exclude repair due to QC tests ) is 5 spot patches
or 3 spot patches + 1 heat shrink sleeves .
8.1.5 The quality of the repair shall be examined and tested for appearance and holidays. Each
repair shall be visually inspected for …
- The surface of repaired coating shall be smooth, and free of folds or bubbles .
- Holiday detection shall be performed on each repair using a maximum voltage of 25 Kv.
8.2 REPAIR PROCEDURE
8.2.1 APPLICATION OF REPAIR MATERIAL BY SPOT PATCH METHOD
1- Remove rust or other contaminants, if any, with a hand brush .

2- Preheat the steel surface of the damaged part .
3- Apply a piece of sealant material smaller than the size of the damage on the steel surface .
4- Heat the sealant then extending the hot sealant with trowel and Apply a piece of sealant
material ore and more to mold the damaged part with a sealant more or less thicker than
the POLYETHYLENE coating .
5- Cut a piece of the patch sheet larger by 5 cm than the damaged part .
6- Cut the corner of the patch piece .
7- Apply the patch piece centering in the damaged part .
8- Heat from the center to each edge .
9- Tapping from the center to the edge to drive away the trapped air .
10- Heat again and tapping again .
11- Immediately after heating the repair patch, press all the edges by finger to get an adequate
adhesive strength .

REV. DATE SHEET

A June 2004 26 of 28
8.2.2 APPLICATION OF REPAIR MATERIAL BY SHRINKABLE SLEEVE METHOD
1. Wrap the JOINT COVER around the pipe keeping the clearance between the JOINT COVER
and the pipe surface about 1 inch and make an overlap to the JOINT COVER about 4 inches .
2. Preheat the overlapped area of the JOINT COVER then cover it with heat seal tape.
3. Heat the heat seal tape and tapping from the center to the edge to drive away the trapped air .
4. Heat and shrink the JOINT COVER from the center toward the edges of the JOINT by moving
the torch up and down along the circumferential direction .
5. Apply a profile roller from the center to the side edge to drive away the trapped air .
6. Re-Heat and shrink the JOINT COVER from the center toward the edges of the JOINT by
moving the torch up and down along the circumferential direction .
7. Heat shrinking process is completed when the adhesive flows out of all the edge of the JOINT
COVER .
9- PIPE MARKING
- All identification data ( heat number, pipe number and pipe length ), if available, shall recorded
before surface preparation .
- After coating process pipe number, pipe length and Petrojet serial number shall be recorded on
the external surface of the pipe .
- All identification data ( heat number, pipe number, pipe length and Petrojet serial number ) shall
be recorded on the daily pipe tally sheet .
- For pipes have the same DN but differ in wall thickness, each wall thickness shall marked with
special code color .

REV. DATE SHEET

A June 2004 27 of 28
10- PIPE RECEIVING, STORAGE, HANDLING AND TRANSPORTATION
10.1 PIPE RECEIVING
10.1.1 Received pipes shall be percentally checked ( 3% ) for the following :

- Dents .
- Damaged bevels .
-Contamination on pipe that would result in additional pre-cleaning materials/man hours and
time delay prior to surface preparation .
- Pipe interior and exterior “ Rust grade “ in accordance with SIS 09 59 00 .
- Manufacturers identification marks ( heat and pipe number ) .
- Pipe diameter and wall thickness .
- Quantity of pipes .
10.1.2 Rejected pipe, or that dose not comply with the shipping documents shall be
segregated from acceptable pipes and reviewed by client Rep.
10.1.3 Pipe that comply with the shipping documents but is damaged or contaminated shall be
segregated until reviewed and approved by client Rep.
10.1.4 Approved pipe shall be coated in accordance to the approved procedure .
10.2 PIPE STORAGE ( STACKING ARRANGEMENT )
10.2.1 The pipes shall be stacked off ground on well prepared beams.
10.2.2 For safety reasons for pipes of any diameter the maximum height for stacking pipes shall not
exceeds the maximum number of layers shown in the following table, the table applies to all
types of steel pipes and wall thickness …
Permissible No. of
Pipe Dia.
Layers
Up to 10" 12
12" to 16" 8
18" to 22" 7
24" to 28" 5
≥ 30" ≤4
10.3 PIPE HANDLING

10.3.1 BARE PIPE
10.3.1.1 Bare pipe shall be carefully removed from the truck using a crane and stacked on beams at
maximum hight indicated in 10.2.2.

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A June 2004 28 of 28
10.3.1.2 Fork lift shall carefully remove the pipe from the storage yard and with equal care place the
pipe on the shot/grit blast machine incoming rack .
10.3.2 COATED PIPE
10.3.2.1 A properly prepared fork lift shall be used to transport the coated pipe to the storage
area provided they have padded forks. Fork lift shall not be used to load coated pipe
onto trucks.
10.3.2.2 The coated pipe may be handled using crane .The pipe can be directly loaded from the
outgoing rack onto the trucks or to the storage area .
10.4 TRANSPORTATION OF PIPES
- Only approved pipes shall be loaded onto trucks ( may directly after coating from the outgoing
rack ) or from the storage area using a crane.
- When available, wooden beams with covered with padding shall be used to separate the pipes
from the truck base .
- Pipes shall not be stacked onto the truck any higher than 2.5 meters or any higher than the law
permits or is safe .
- The loaded pipes shall not exceed the maximum allowable weight for the truck or by law or is
safe .
- The loaded pipes shall be tied down using Nylon straps or other means to avoid damage to the
coating during transportation .

Coating Procedure: Etor ET

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DOCUMENT DESCRIPTION COATING PROCEDURE

DOCUMENT CODE PTJ-COAT-PE-01

REV. DATE SHEET

The Petroleum Projects and Technical Consultation Co.

Rev Date Description BY CH'D APPR.

THIS DOCUMENT IS CONFIDENTIAL AND THE SOLE PROPERTY OF PETROJET

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DOCUMENT CODE PTJ-COAT-PE-01

REV. DATE SHEET

THIS DOCUMENT IS CONFIDENTIAL AND THE SOLE PROPERTY OF PETROJET

PDF created with pdfFactory trial version www.pdffactory.com

DOCUMENT CODE PTJ-COAT-PE-01

REV. DATE SHEET

THIS DOCUMENT IS CONFIDENTIAL AND THE SOLE PROPERTY OF PETROJET

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2- DEFINITIONS AND ABBREVIATIONS

• Test ring Test sample from a coated pipe.

• Day Production run and shall not more than 24 hrs.

• Shift Production run and shall not more than 12 hrs.

• Batch No. Quantity of PE material not more than 50 tons.

THIS DOCUMENT IS CONFIDENTIAL AND THE SOLE PROPERTY OF PETROJET

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DOCUMENT CODE PTJ-COAT-PE-01

REV. DATE SHEET

THIS DOCUMENT IS CONFIDENTIAL AND THE SOLE PROPERTY OF PETROJET

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3- REFERENCE INTERNATIONAL CODES AND STANDARDS .

z European Committee for Standardization .. ( CEN )

z L’Asaociation Francaise de Normalisation .. ( AFNOR )

z Deutsche Institute fur Normung .. ( DIN )

DIN 53 455 Testing Of Plastics; Tensile Test .

z American Society for Testing and Materials .. ( ASTM )

z National American Of Corrosion Engineering .. ( NACE )

THIS DOCUMENT IS CONFIDENTIAL AND THE SOLE PROPERTY OF PETROJET

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REV. DATE SHEET

z Gas Business Engineering .. ( GBE )

z International Standard .. ( ISO )

ISO 8502-3 Field Test for The Determination Of Dust Contamination

THIS DOCUMENT IS CONFIDENTIAL AND THE SOLE PROPERTY OF PETROJET

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REV. DATE SHEET

4- GENERAL PROPERTIES OF COATING MATERIALS .

ADHESIVE : GENERAL PROPERTIES

PROPERTY UNIT TEST METHOD VALUE

THIS DOCUMENT IS CONFIDENTIAL AND THE SOLE PROPERTY OF PETROJET

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REV. DATE SHEET

POLYETHYLENE GENERAL PROPERTIES

PROPERTY UNIT TEST METHOD VALUE

THIS DOCUMENT IS CONFIDENTIAL AND THE SOLE PROPERTY OF PETROJET

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REV. DATE SHEET

5- PRODUCTION TESTING AND INSPECTION PLAN .