DEP SPECIFICATION

COATING OF FASTENERS
Copyright Shell Group of Companies. No reproduction or networking permitted without license from Shell. Not for resale

DEP 30.48.00.32-Gen.

February 2012
ECCN EAR99

DESIGN AND ENGINEERING PRACTICE

© 2012 Shell Group of companies

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior
written permission of the copyright owner or Shell Global Solutions International BV.

This document contains information that is classified as EAR99 and, as a consequence, can neither be exported nor re-exported to any country which is under an
embargo of the U.S. government pursuant to Part 746 of the Export Administration Regulations (15 C.F.R. Parts 746) nor can be made available to any national of such
country. In addition, the information in this document cannot be exported nor re-exported to an end-user or for an end-use that is prohibited by Part 744 of the Export
Administration Regulations (15 C.F.R. Parts 744).

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PREFACE

DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions
International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and
maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international,
regional, national and industry standards.
The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and
gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help
achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each
locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the
quality of their work and the attainment of the required design and engineering standards. In particular, for those
requirements not specifically covered, the Principal will typically expect them to follow those design and engineering
practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or
Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal.
The right to obtain and to use DEPs is restricted, and is granted by Shell GSI (and in some cases by other Shell
Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and
other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three
categories of users of DEPs can be distinguished:
1) Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these
Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2) Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of
a Service Agreement or otherwise).
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2)
which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said
users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims
any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person
whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs
or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The
benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these
companies, that may issue DEPs or advise or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall
not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the
DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after
use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The
copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell
GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.

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TABLE OF CONTENTS
1. INTRODUCTION ........................................................................................................4
1.1 SCOPE........................................................................................................................4
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS .........4
1.3 DEFINITIONS .............................................................................................................4
1.4 SAFETY ......................................................................................................................5
1.5 CROSS-REFERENCES .............................................................................................5
1.6 COMMENTS ON THIS DEP .......................................................................................5
1.7 DUAL UNITS...............................................................................................................5
2. GENERAL...................................................................................................................6
2.1 WARRANTY ...............................................................................................................6
2.2 MANUFACTURER/SUPPLIER’S RESPONSIBILITY.................................................6
3. PROTECTIVE COATINGS FOR BOLTS AND FASTENERS ...................................7
3.1. GENERAL ...................................................................................................................7
3.2 COATING PERFORMANCE.......................................................................................8
3.3 PHOSPHATING..........................................................................................................8
3.4 ZINC BASED COATINGS...........................................................................................8
3.5 ALUMINIUM AND ALUMINIUM-CERAMIC TYPE COATINGS..................................9
3.6 ELECTROPLATED ZINC-NICKEL ALLOY COATING .............................................10
3.7 FLUOROPOLYMER/PTFE COATING......................................................................10
3.8 WAX BASED SYSTEMS ..........................................................................................11
3.9 THREAD LUBRICANT SYSTEM ..............................................................................11
3.10 PROTECTION OF NUTS..........................................................................................11
4. PROTECTION WITH CATHODIC PROTECTION ...................................................12
5. QUALITY CONTROL REQUIREMENTS .................................................................12
5.1 GENERAL .................................................................................................................12
5.2 APPEARANCE .........................................................................................................12
5.3 THICKNESS .............................................................................................................12
5.4 ADHESION ...............................................................................................................12
5.5 CHROMATE CONVERSION TREATMENT .............................................................12
5.6 WEAR RESISTANCE ...............................................................................................13
5.7 FRICTION COEFFICIENT ........................................................................................13
5.8 HEAT TREATMENT AFTER PROCESSING ...........................................................13
6. QUALITY ASSURANCE TEST METHODS .............................................................14
6.1 MEASUREMENT OF THICKNESS ON PROCESSED PARTS ...............................14
6.2 MEASUREMENT OF ADHESION ............................................................................14
6.3 TESTING OF CORROSION RESISTANCE .............................................................15
6.4 TESTING FOR EFFECTIVENESS OF STRESS RELIEF AND HYDROGEN
EMBRITTLEMENT BAKING .....................................................................................15
6.5 THREAD FRICTION .................................................................................................15
7. REFERENCES .........................................................................................................16

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1. INTRODUCTION

1.1 SCOPE
This new DEP specifies requirements and gives recommendations for corrosion resistant
coatings applied to bolts for both offshore and onshore facilities.
It is applicable to new bolts and nuts. It may also be applied to existing bolts when removed
during shutdown.
This DEP covers a number of different types of metallic and non-metallic corrosion
protection coatings suitable for the exposure conditions in offshore and onshore
environments.
For offshore topside equipment, coating systems typically used on carbon steel and low
alloy steel bolting include:
• hot dip galvanised zinc (with or without an organic topcoat),
• zinc/nickel electroplated,
• zinc electroplated,
• PTFE,
• aluminium or aluminium-ceramic.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated
by them. Any authorised access to DEPs does not for that reason constitute an
authorization to any documents, data or information to which the DEPs may refer.
This DEP is intended for use in offshore/onshore exploration and production facilities, oil
refineries, chemical plants, gas plants, and supply/marketing installations. This DEP may
also be applied in other similar facilities.
When DEPs are applied, a Management of Change (MOC) process shall be implemented;
this is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements could be more
stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable with regards to safety, environmental, economic and legal aspects. In all cases,
the Contractor shall inform the Principal of any deviation from the requirements of this DEP
which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the Authorities concerned, the objective
being to obtain agreement to follow this DEP as closely as possible.

1.3 DEFINITIONS
1.3.1 General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of
a facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party that manufactures or supplies equipment,
components of equipment and services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The word should indicates a recommendation.

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1.3.2 Specific definitions and abbreviations

Term Definition
Bolting Bolting is a mechanism for creating and maintaining a clamping force
between joint members.
Coating System Details of coating, priming and other intermediate layer materials,
together with production procedures pertaining to the pre-treatment
and coating work or test pieces.
CRA Corrosion Resistant Alloy.
Cracking The splitting of a dry paint film.
DFT Dry Film Thickness; the thickness of the dried or cured paint or coating
film.
Duplex System Hot dip galvanised steel plus coating.
Fastener A fastener is any male component with threads (bolts, studs or screw).
In this DEP the word bolt and fastener will be used as synonyms.
Holiday/Pinhole Pinhole or very small size defect in a coating system, penetrating the
entire thickness of the coating.
Hot Dip Formation of a coating of zinc and/or zinc-iron alloys produced by
Galvanizing dipping prepared steel in molten metallic zinc.
HSSE Health, Safety, Security and Environment.
Inspection Lot An inspection lot shall be defined as a collection of processed parts
that are of the same kind, that have been processed to the same
specifications, that have been processed by a single
Manufacturer/Supplier at one time, or at approximately the same time,
under essentially identical conditions, and that are submitted for
acceptance or rejection as a group.
MSDS Material Safety Data Sheet.
NDFT Nominal (specified) Dry Film Thickness.
PTFE Polytetrafluoroethylene

1.4 SAFETY
This Standard may call for the use of hazardous substances and procedures. Attention is
drawn to the need to comply with statutory and all other legal obligations relating to
environment, health and safety at any stage.

1.5 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section
number is shown in brackets ( ). Other documents referenced by this DEP are listed in (7).

1.6 COMMENTS ON THIS DEP

Comments on this DEP may be sent to the Administrator at standards@shell.com, using
the DEP Feedback Form. The DEP Feedback Form can be found on the main page of
“DEPs on the Web”, available through the Global Technical Standards web portal
http://sww.shell.com/standards and on the main page of the DEPs DVD-ROM.

1.7 DUAL UNITS

This DEP contains both the International System (SI) units, as well as the corresponding
US Customary (USC) units, which are given following the SI units in brackets. When
agreed by the Principal, the indicated USC values/units may be used.

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2. GENERAL

2.1 WARRANTY
Contractors undertaking the application and supply of coated bolts shall follow the
requirements of corrosion protection coating in accordance with this DEP and warranty the
quality of their coating work. The corrosion protection system shall be selected from the
coating systems listed in Table 1, depending upon the Principal’s requirements and service
conditions.
Before supply of any coated bolts, the warranty period and associated corrosion protection
coating condition shall be agreed by the Contractor with the Principal. A minimum warranty
period of five (5) years shall be provided for the coating applied. However, the design life of
coating should be as much as the design life of bolt.
The coating systems to be used in accordance with this DEP shall be suitable for the highly
corrosive coastal and marine environment, C5-M as specified in ISO 12944-2.
Only surfaces that have mechanical damage or chemical spillage as a result of operational
activities may fall outside this warranty.
In case of a dispute over the condition of the coated bolts that has been inspected, an
agreed independent and qualified body shall conduct an inspection at the Contractor’s cost.
Both the Principal and the Contractor shall accept the findings of the inspection by this
independent consultant.

2.2 MANUFACTURER/SUPPLIER’S RESPONSIBILITY

2.2.1 General
The Manufacturer/Supplier, in addition to his responsibilities under the general conditions of
the contract, shall be responsible for the quality of the coated bolts supplied, which shall be
in strict accordance with this DEP and all other relevant documents, such as site
regulations, safety rules and requirements, product data sheets, referenced standards and
codes.
The Manufacturer/Supplier shall be fully responsible for all Quality Assurance and Control
activities.
2.2.2 Safety and environment
The Contractor shall be responsible for all aspects of safety and personal protection related
to the corrosion protection coating work to be done on metallic bolts and fasteners. All
environmental regulations and rules shall be met.
All personnel shall be provided with personal protection, e.g., protective clothing, safety
glasses, safety shoes, hard hats, goggles, respirators, earplugs, fresh air-fed hood and all
other necessary safety equipment. Protective clothing for abrasive blasters shall comply
with ISO 14877. All safety equipment shall be maintained in a good working condition.

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3. PROTECTIVE COATINGS FOR BOLTS AND FASTENERS

3.1. GENERAL
The selection of coatings shall be based on the following considerations:
a) Corrosion resistance
b) Appearance
c) Shape and size
d) Embrittlement
e) Conductivity
f) Lubricity
g) Application limitations
h) Design life
i) Operating pressure
j) Operating temperature
k) Maximum design temperature
l) External environment (submerged/topside offshore/ splash zone/ coastal
area/onshore away from the sea coast)
Candidate coatings for bolts and fasteners are listed in Table 1. A suitable corrosion
protection coating system shall be selected based on the exposure and service conditions
and considerations listed below as per the Principal’s requirements.

Table 1: Coatings for bolts and fasteners

Type of coating Application method Comment

Dip galvanised Galvanising bath For large size bolts
Zinc thickness :10 to 200 microns
Dip-spin galvanised Special equipment Uniform coating thickness
Zinc thickness: About 40 microns
Sherardizing Special equipment Uniform coating thickness.
Zinc thickness : 10 to 100 microns
Electrodeposited (Zn, Electrolytic Low zinc thickness
Cd) Zinc thickness : 2 to 25 microns
Zinc/Nickel alloy coating Electroplated Thickness : 10 microns
Phosphate Dipping As pre-treatment to additional coating
application.
Al-based coating Spraying techniques Low coating thickness.
Zinc- silicate Spraying technique Surface preparation by abrasive blast
cleaning is required.
Fluoropolymer Spraying technique surface preparation by abrasive blast
cleaning is required.
Thermoplastic Spraying technique With inhibitor. Can also be used for
maintenance.
Wax system Spraying equipment Also for maintenance use.
Nickel -electroless Special equipment Suitable in crude oil sour service

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The following coating systems are recommended for bolts on flanges or other pressure
containing connections in subsea and atmospheric marine environment:
®
• Ceramic-Aluminium filled coatings (e.g., SermaGard 1105/1280) or Principal
approved equivalent,
• Zinc electroplated as per ISO 2081 or equivalent ASTM standard,
• Hot dip or mechanically galvanized.
The fluorocarbon coating (PTFE) is recommended for atmospheric marine environment but
not acceptable for use in subsea applications.

3.2 COATING PERFORMANCE

A salt fog chamber shall be used to establish the performance of coatings. Testing shall be
in accordance with ASTM B117.
Traditional salt fog testing of organic coatings testing time may be based on coatings on
structural steel:

ASTM B117 (salt fog) 3000 hours with acceptance:

Equivalent to 30 years marine service

ASTM B117 (salt fog) 720 hours with acceptance:

Equivalent to 15 years service industrial

It should be noted that the conventional salt fog chamber is not included as a separate part
of the qualification of organic coatings in the NORSOK Document, “Surface preparation and
protective coating”. The NORSOK qualification test for organic coatings includes a cyclic
testing (25 cycles of a testing which include salt fog, a drying sequence and
UV-A weatherometer to give a total exposure period of 4200 hours).
The bolt shall be exposed in service with a preloading for performance testing of coatings
on bolts. The preloading will also influence the stress in the coating and may lead to
cracking or ageing effects in combination with the given external environmental impact.

3.3 PHOSPHATING
Phosphating has been a traditional primer for achieving a good bonding for the subsequent
corrosion protection coating (e.g., fluoropolymer). In cases where corrosion protection is not
an issue the phosphating may be used as remedial to reduce friction in the threaded
connection. Additionally, a suitable lubricant is used on the phosphate coating.
A phosphate coating shall not be used in marine or coastal service.

3.4 ZINC BASED COATINGS

The hot dip galvanising process provides a thicker coating than electrodeposited zinc, but
may not be compatible with the thread tolerances. Hot dip galvanising should not be used
for bolts with a diameter less than about 10 mm (3/8 in).
Hot dip galvanizing bolts last longer than electroplated zinc bolts but the thicker coating
means that it is more difficult to get the right torque level and the nuts have the be
manufactured accordingly.
To achieve a uniform coating thickness, the dip-spin procedure may be applied. The dip-
spin galvanizing method can give a uniform zinc thickness of around 40 microns and may
be used for the small bolting dimensions [< 10 mm (3/8 in)].
Coating by electro-deposition shall not be used for in the marine offshore service.

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3.5 ALUMINIUM AND ALUMINIUM-CERAMIC TYPE COATINGS

Aluminium and aluminium oxide type coatings are also recommended coating systems for
corrosion protection of bolts in submerged service and marine atmosphere application.
Aluminium provides excellent corrosion resistance and temperature resistance.
Aluminium based coatings are often applied by anodizing or spraying. This results in
porosity in coating. To avoid ingress of water and subsequent subsurface corrosion, it is
important to apply a sealer. These coatings will have a good adhesion and will have
minimal deterioration (corrosion) in the pH range 4 to 8.5.
Aluminium coatings are also applied as flakes in an organic binder. Such coatings can be
mixtures of zinc and aluminium flakes in an organic binder Aluminium coatings shall have
®
a sealer applied. The SermaGard aluminium basecoat plus organic topcoat systems are
suitable for use on bolting materials submerged in sea water or exposed to marine
atmosphere for structural components or marine equipment where corrosion protection, low
friction and resistance to bearing stress are desirable qualities.
The surface preparation shall be abrasive blast-cleaning to ISO 8501-1 Sa3 or
SSPC-SP5/NACE No.1 and an anchor profile of 0.3-1.0 mils (7.6-25.4 microns).
Immediately prior to blast cleaning, surfaces to be coated shall be heated to 343°C-371°C
(650°F-700°F) for a minimum time period of 90 minutes in order to decompose any
remaining contaminants. (This step is not required if parts are subject to thermal cleaning at
similar time and temperature parameters).
®
The SermaGard coating system shall be applied by conventional spray techniques.
Conductivity testing shall be performed to ensure that electrical resistance is no more than
5 ohms per 25.4 mm (1 in), as measured at the surface of the coating.
®
The following is the recommended typical SermaGard system for bolting materials:

Base Coat ®
SermaGard 1105 with dry film thickness (DFT) 1 mil
(25.4 microns) to 2 mils (50.8 microns)

Curing time 30 minutes (minimum) to 480 minutes (maximum)

Cure test Wet rag cure test

The wet cure test is carried out by using a wet clean cloth with water and placed on coated
surface. If there is any transfer of yellow colour to the cloth, the coating is not cured.
A presence of gray or silver coloured areas is not cause for rejection.
®
Burnishing of SermaGard 1105 primer is required, together with conductivity testing prior
to overcoating.

Top coat ®
SermaGard 1280 with dry film thickness 0.5 to 1 mil
(12.7 to 25.4 microns)

Curing time 15 minutes (minimum) to 60 minutes (maximum)

Cure test ASTM D5402-93

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3.6 ELECTROPLATED ZINC-NICKEL ALLOY COATING

The zinc-nickel alloy coating deposited from an alkaline, cyanide free, electrolyte shall have
6-8% Ni with yellow iridescent passivate or 12 to 18% nickel and the balance being zinc.
The normal coating thickness of this system is 10 microns. The coating thickness shall be
5 to 10 microns on parts with external threads and 8 to 18 microns on parts without threads.
The maximum coating thickness from an alkaline cyanide free electrolyte should be
25 microns.
The method of applying the coating shall ensure that damage through delayed
embrittlement (hydrogen embrittlement) is avoided. This is particularly important in the case
of high tensile steels of Grades B, C and D with tensile strength > 1000 N/mm²
The application should be carried out in accordance with ASTM B841 and associated
standards The surface shall be treated with chromate conversion treatment according to
ASTM B841 Section 4.
The surface of bolts shall be free from soils, such as soap, drawing compounds, oil, grease
etc., discolouration oxide, scale or other foreign matter. All parts shall be cleaned and pre-
treated in accordance with Clauses 4 and 5 of BS 7371-1. Any scale or oxide film shall be
removed by inhibitor and or preferably by mechanical means. Before processing, steel
parts shall be stress relieved if required.
The coating shall be capable of passing the adhesion test specified in ASTM B571;
Section 10 latest edition and the test procedure shall be in accordance with Section 3 of
ASTM B571.

3.7 FLUOROPOLYMER/PTFE COATING

The fluoropolymer resin can provide coating thickness from 8 to 30 microns layer of
Fluoropolymer (PFTE). This type of coating may provide several advantages properties on
bolts:
• Corrosion protection;
• Lubricant –low friction surface;
• To avoid galling;
• Heat resistance properties.
A PTFE coating is often applied on a zinc-nickel electroplated surface.
The fluorocarbon coating (PTFE) is recommended for atmospheric marine environment.
Bolts coated with a fluorocarbon coating are not recommended for use in subsea
applications.
The coating shall be applied by spraying and cured at about 150°C to 350⁰C (300°F to
660°F) (a few minutes up to about half an hour). The surface preparation shall be abrasive
blast-cleaning to ISO-8501-1 Sa3 or SSPC-SP5/NACE No.1 and an anchor profile of
0.3-1.0 mils (7.6-25.4 microns).
Surfaces shall be pre-treated after blast cleaning by immersion in phosphate conversion
coating solution (e.g., Aerocote # 4).
The following is a typical recommended fluorocarbon coating system for bolts exposed to
marine atmosphere on top side facilities with bearing stress < 30,000 psi:

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Primer coat Xylan 4090 with a dry film thickness of 0.6 to 1 mil (15 to
25.4 microns),
Intermediate cure at 138⁰C (280.4°F) for 15 minutes

Second coat Xylan 1070 with a dry film thickness of 0.6 to 1 mil (15 to
25.4 microns)
Intermediate cure at 138⁰C (280.4°F) for 15 minutes

Third coat Xylan 1070/870 with a dry film thickness of 0.6 to 1 mil
(15 to 25.4 microns),
Final cure at 205⁰C (401°F) for 20 minutes

The fluorocarbon coating system (PTFE) shall be tested in an ASTM B117 salt fog chamber
for 3000 hours.

3.8 WAX BASED SYSTEMS

Wax systems are used as maintenance systems. Wax based systems shall be pre-qualified
and approved by the Principal to ensure fitness for purpose.
Wax systems are used above water and have a prime application to prevent corrosion on
mechanical components that form crevices or grooves. Wax systems are applied on a bare
and clean surface of the installed bolted connection and shall not be used above 45ºC
(113°F) of operating temperature.

3.9 THREAD LUBRICANT SYSTEM

Thread lubricant system can provide some corrosion protection to the threaded parts.
However these products cannot be expected to provide protection in the marine
environment and shall not be used.
For bolts which are broken up occasionally the reapplication of the lubricant systems may
provide protection. Bolted systems which are to remain unbroken in corrosive service shall
require other corrosion protection measures.
For lubricate systems in general the following properties should be considered:
a) A thin film which will not cause interference in thread fits;
b) A reproducible surface finish which offers good conformance during installation;
c) No breakdown or spall off under high surface pressures encountered during use;
d) Reproducible application methods;
e) A consistent coefficient of friction over a wide range of surface pressures;
f) A low coefficient of friction for ease of installation and break-out.
It should be noted that molybdenum sulphide may cause stress corrosion cracking at higher
temperatures [> 180⁰C (356°F)] with CRA bolts and advised not to use the same.

3.10 PROTECTION OF NUTS

Nuts shall also be coated when fasteners are coated.
For zinc based coating, the threads in the nut will be protected by the zinc on the bolt
threads. In the case of PTFE coating the friction reduction effect will be achieved by the
smearing of the PTFE coating from the bolt threads.
Oversized nuts shall be required if thicker coatings (e.g., galvanised zinc) are applied to
nuts. Nuts should be galvanized as blanks and tapped as oversize nuts in relation to the
coating thickness and thread type.

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4. PROTECTION WITH CATHODIC PROTECTION

For submerged service where cathodic protection is applied to the bolts, if bolt end caps or
flange protectors are used, the design shall prevent shielding of bolts from the cathodic
protection. The flange mating surfaces shall be bare to ensure electrical continuity.
An electrical contact between the bolt and the flange connector shall be designed to
achieve protection by the remote sacrificial anodes (electrical contact can be established
strapping or by using a serrated washer).
For low alloy bolts on a bare flange of a high alloy material (e.g., duplex stainless steel) the
current demand will increase and may reduce the ability to adequately polarise the bolt in
crevices.

5. QUALITY CONTROL REQUIREMENTS

5.1 GENERAL
The following quality control requirements shall apply for coating on bolts and fasteners.

5.2 APPEARANCE
The appearance of the significant surfaces in the as-processed condition shall be dull/bright
(or as specified by the Principal). The surface shall be uniform and free from such defects
as pits, cracks, blisters, exfoliation or growths.
Surface defects visible in the base metal before processing, and as reported to the
Principal following examination, shall not be cause for rejection of the processing. Also,
stains and discoloration as a result of any post-process heat treatments shall not be cause
for rejection of the processing. Also, stains and discoloration as a result of any post-process
heat treatments shall not be cause for rejection.

5.3 THICKNESS
The thickness of the coating or treatment at all points on the significant surface shall
conform to the requirements of the specified Class, as defined in BS 7371-1 or as defined
by the Principal. The number of parts requiring a thickness test shall be determined by the
sampling plan as given in Table 7. Thickness measurement shall be taken directly from the
production parts.
Table 7: Sampling plan

Number of Parts in the Plating Batch Number of Parts Sampled

0 - 19 All
20 - 199 20
200 and over 50

5.4 ADHESION
The coating or treatment shall be adherent to the base metal. The coating shall be capable
of passing the adhesion test specified in ASTM B571; Section 10 - latest edition. When
separate samples are to be tested for adhesion, the test procedure shall be in accordance
with Section 3 of ASTM B571.

5.5 CHROMATE CONVERSION TREATMENT

Electroplated coatings shall be treated with a specified chromate conversion treatment
(passivation), such as Clear(A), Bleached(B), Black(Bk), Incandescent(C) and Opaque(D).
The chromate conversion treatment type shall be according to ASTM B841 Section 4.

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5.6 WEAR RESISTANCE

If the wear resistance of the coating or treatment is important, it shall be specified by the
Principal, together with the methods of testing and evaluation.

5.7 FRICTION COEFFICIENT

If the friction coefficient of the coating or treatment is important, it shall be specified by the
Principal, together with methods of testing and evaluation. Testing to BS 7371-2 shall be
the preferred method for fasteners.

5.8 HEAT TREATMENT AFTER PROCESSING

5.7.1 General
When required by the Principal, heat treatment after plating shall be performed as
described here and can be carried out in order to give relief from hydrogen embrittlement.
Heat treatment after processing shall be carried out before any conversion treatment or
mechanical finishing.
5.7.2 Heat treatment for relief of hydrogen embrittlement
Heat treatment for the relief of hydrogen embrittlement shall be carried out within 4 hours of
electroplating and for the minimum amount of time specified in BS 7371-1, Appendix B.

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6. QUALITY ASSURANCE TEST METHODS

6.1 MEASUREMENT OF THICKNESS ON PROCESSED PARTS

6.1.1. General
The thickness shall be measured at any place on the significant surface designated on the
engineering drawing and the measurement shall be made with a measurement uncertainty
of less than 10 percent, by one of the methods shown below. If there is a dispute in the
thickness measured, then metallographic sectioning shall be used to verify thickness.
6.1.2 Measurements before and after processing
Measurement, in accordance with ISO 4527 Annex A.4 - latest edition, of the part or test
specimen shall be in a specific spot before and after processing using a suitable instrument
(e.g., micrometer). The part or test coupon shall be at the same temperature for each
measurement. The surface measured shall be even surface.
6.1.3 Coating thickness determination from coating mass (batch average thickness)
The mass of the coating shall be measured in accordance with BS IBS EN ISO 4042.
6.1.4 Local thickness
The local thickness shall be measured by one of the methods contained in BS 5411-2, 4,
5 and 8. The thickness shall only be measured on the significant surface.
6.1.5 Metallographic sectioning
The method specified in ASTM B487 shall be used.

6.2 MEASUREMENT OF ADHESION

6.2.1 General
The adhesion shall be measured at any place on the significant surface designated on the
engineering drawing by one of the methods shown below. If there is a dispute in the
adhesion measured, then the Tape Test shall be used to verify adhesion.
6.2.2 Tape test
Tape test shall be carried out in accordance with BS 7371-2 Annex A.
6.2.3 Burnishing test
The processed part shall be tested and evaluated for adhesion in accordance with
ASTM B571, Section 4.
6.2.4 Bend test
The sample specimen shall be bent once through an angle of 180° in accordance with
ASTM B571, Section 3. It shall then be impossible to detach any appreciable areas of the
plating with a sharp instrument on the outside radius of the bend test specimen. The
specimens shall be examined at the magnification 4x, after the plated surface has been
bent and tested with a sharp instrument, to determine whether or not the coating is
adherent to the base metal.
Three 4.8 mm (3/16 in) diameter by 127 mm (5 in) long rods of equivalent base metal as
the parts being processed shall be used for all bend test samples, when separate
specimens are used.
Punch Test Procedure The Manufacturer/Suppler shall perform either a Punch Test or an
Impact Test (e.g., ISO 4527 Annex B3 - latest edition or ASTM B571 Section 10 - latest
edition). The punch or impact test shall be performed on a non-critical location which does
not require corrosion resistance and is not on or adjacent to a wear or seal surface. The
indentations and surrounding area shall be visually examined at a minimum magnification
of 10x for blistering, flaking or disbonding.

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The part shall fail if blistering, flaking or disbonding occurs on or around the indentations.
The results (i.e., pass/fail) of the adhesion test shall be reported on the Certified Test
Report.

6.3 TESTING OF CORROSION RESISTANCE

When required by the Principal, parts or separate specimens shall be selected for corrosion
resistance in accordance with Clause 7 of BS 7371-1 and shall be tested for resistance to
neutral salt spray in accordance with ISO 9227.

6.4 TESTING FOR EFFECTIVENESS OF STRESS RELIEF AND HYDROGEN

EMBRITTLEMENT BAKING
When required by the Principal, testing for relief of stress and/or hydrogen embattlement
shall be performed in accordance with the following:
a) Four separate specimens or actual parts that will be subjected to a sustained tensile
load equal to 75 percent of the yield strength of the base metal.
b) The separate specimens or parts shall be held under load for at least 200 hours and
then examined under 10x magnification at an illumination of 1,100 Lux for cracks.
c) If any processed part or separate specimen develops cracks the lot shall be
rejected.
d) For steels having a minimum yield strength of 1655 Mpa (240,000 psi) or higher,
four cylindrical specimens, in accordance with ASTM E8 with a 0.51 mm (1/16 in)
notch in the centre of the gauge length, shall be used for testing. The area at the
base of the notch shall be one-half that of the full diameter of the specimen. The
notch shall be 0.254 mm by 0.013 mm for standard 12.8 mm (1/2 in) diameter
specimens and proportional to this for smaller specimens. These parts shall be
subjected to a sustained tensible load equal to 75 percent of the ultimate notch
tensile strength of the material. Specimens shall be tested and examined in
accordance with the procedure set out above.
e) All processed parts (processed with any separate specimens) which do not meet the
minimum requirement for stress and hydrogen embrittlement relief shall be heat
treated for a total length of time equal to that of the total heat treatment time of the
production parts, before retesting the separate specimens for stress or hydrogen
embattlement relief.

6.5 THREAD FRICTION

If required by the Principal, processed parts or separate specimens shall be tested to
determine the friction constant for threaded components in accordance with BS 7371-2.

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7. REFERENCES
In this DEP, reference is made to the following publications:
NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards/.

AMERICAN STANDARDS
Standard Practice for Operating Salt Spray (Fog) Apparatus ASTM B117
Standard Test Method for Measurement of Metal and Oxide ASTM B487
Coating Thickness by Microscopical Examination of Cross Section
Standard Practice for Qualitative Adhesion Testing of Metallic ASTM B571
Coatings
Standard Specification for Electrodeposited Coatings of Zinc Nickel ASTM B841
Alloy Deposits
Standard Practice for Assessing the Solvent Resistance of Organic ASTM D5402
Coatings Using Solvent Rubs
Standard Test Methods for Tension Testing of Metallic Materials ASTM E8
Joint Surface Preparation Standard White Metal Blast Cleaning - NACE No.1
Item No. 21065
White Metal Blast Cleaning SSPC-SP5/NACE No. 1

BRITISH STANDARDS
Methods of Test for Metallic and Related Coatings BS 5411
Coatings on Metal Fasteners – Part 1: Specification for General BS 7371-1
Requirements and Selection Guidelines
Coatings on Metal Fasteners — Part 2: Specification for BS 7371-2
Torque/Clamping Force Relationship
Coatings on Metal Fasteners-Part 4: Specifications for BS 7371-4
electroplated Nickel, Nickel/Chromium and
Copper/Nickel/Chromium Coatings

INTERNATIONAL STANDARDS
Metallic and Other Inorganic Coatings — Electroplated Coatings of ISO 2081
Zinc with Supplementary Treatments on Iron or Steel
Fasteners- Electroplated Coatings ISO 4042
Metallic Coatings Autocatalytic (Electroless) Nickel-Phosphorus ISO 4527
Alloy Coatings Specification and Test Methods
Preparation of Steel Substrates before Application of Paints and ISO 8501-1
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
Corrosion Tests in Artificial Atmospheres - Salt Spray Tests ISO 9227
Paints and Varnishes - Corrosion Protection of Steel Structures by ISO 12944-2
Protective Paint Systems - Part 2: Classification of Environments

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Protective Clothing for Abrasive Blasting Operations Using ISO 14877

Granular Abrasives

OTHER
Coating requirements for bolts and nuts MESC 81/007
(amendments / supplements to ASTM B 841/B633)

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