PETRONAS TECHNICAL STANDARDS

Fusion Bonded Epoxy Coating for Line Pipe

PTS 11.32.04
July 2015

© 2015 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.
 PTS 11.32.04
FUSION BONDED EPOXY COATING FOR LINE PIPE July 2015
Page 2 of 13

FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplemented by national and international
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.

Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.

Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.

In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.

PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording
or otherwise) or be disclosed by users to any company or person whomsoever, without the prior
written consent of PETRONAS.

The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information
to PETRONAS that this requirement is met.
 PTS 11.32.04
FUSION BONDED EPOXY COATING FOR LINE PIPE July 2015
Page 3 of 13

ANNOUNCEMENT

Please be informed that the entire PTS inventory is currently undergoing transformation exercise
from 2013 - 2015 which includes revision to numbering system, format and content. As part of this
change, the PTS numbering system has been revised to 6-digit numbers and drawings, forms and
requisition to 7-digit numbers. All newly revised PTS will adopt this new numbering system, and
where required make reference to other PTS in its revised numbering to ensure consistency. Users
are requested to refer to PTS 00.01.01 (Index to PTS) for mapping between old and revised PTS
numbers for clarity. For further inquiries, contact PTS administrator at
ptshelpdesk@petronas.com.my
 PTS 11.32.04
FUSION BONDED EPOXY COATING FOR LINE PIPE July 2015
Page 4 of 13

Table of Contents

1.0 INTRODUCTION ................................................................................................... 5

1.1 SCOPE ............................................................................................................................ 5
1.2 GLOSSARY OF TERMS .................................................................................................... 5
1.3 SUMMARY OF CHANGES ............................................................................................... 5
2.0 AMENDMENTS / SUPPLEMENTS TO ISO 21809-2 .................................................. 6
3.0 BIBLIOGRAPHY.................................................................................................... 13
 PTS 11.32.04
FUSION BONDED EPOXY COATING FOR LINE PIPE July 2015
Page 5 of 13

1.0 INTRODUCTION

This PTS provides the minimum technical requirements for the factory-applied single layer
external fusion bonded epoxy (FBE) powder coating of steel pipes, bends and fittings used for
onshore buried or offshore pipelines.

This PTS adopts ISO 21809-2 with additional requirements as an amendment and supplement
based on PETRONAS’ lessons learnt and best practices.

1.1 SCOPE

This PTS covers the following main areas and activities:

i. Coating system requirements, application, quality control and qualification

ii. Applicator qualification

iii. Inspection and test procedures

iv. Coating repair

v. Documentation

vi. Handling, storage and transport of bare and coated pipe

1.2 GLOSSARY OF TERMS

1.2.1 General Definition of Terms & Abbreviations

Refer to PTS Requirements, General Definition of Terms, Abbreviations & Reading Guide PTS
00.01.03 for General Definition of Terms & Abbreviations.

1.2.2 Specific Definition of Terms

None

1.2.3 Specific Abbreviations

None

1.3 SUMMARY OF CHANGES

This PTS 11.32.04 replaces PTS 31.40.30.32 (September, 2012).

 PTS 11.32.04
FUSION BONDED EPOXY COATING FOR LINE PIPE July 2015
Page 6 of 13

2.0 AMENDMENTS / SUPPLEMENTS TO ISO 21809-2

In this section, the reference clauses of ISO 21809-2:2007 are amended or supplemented,
existing clause is deleted or new sections are added as mentioned. Clauses ISO 21809-2:2007
that are not mentioned in this PTS shall apply and remain valid.

3 Terms and definitions

Replace the definition of 3.2 applicator with the following:

“company that undertakes the coating application in accordance with the provisions
of this PTS.”

Replace the definition of 3.15 test report with the following:

“document that provides the quantitative test results for test conducted in
accordance with the requirements of this PTS.”

5 General requirements

5.1 Rounding

Replace the following:

“Unless otherwise stated in this part of ISO 21809, to determine conformance with the
specified requirements, observed or calculated values shall be rounded to the nearest unit in
the last right-hand place of figures used in expressing the limiting value, in accordance with
ISO 80000-1:2009, Annex B, Rule A.”

with:

“Unless otherwise stated in this PTS, to determine conformance with the specified
requirements, observed or calculated values shall be rounded to the nearest unit in the last
right-hand place of figures used in expressing the limiting value, in accordance with PTS
16.00.01.”

Delete note after last paragraph.

5.2 Compliance to standard

Replace the first paragraph with the following:

“A quality system and an environmental management system should be applied to

assist compliance with the requirements of this PTS.”
 PTS 11.32.04
FUSION BONDED EPOXY COATING FOR LINE PIPE July 2015
Page 7 of 13

Replace the second paragraph with the following:

“The applicator shall be responsible for complying with all of the applicable
requirements of this PTS. It shall be permissible for the purchaser to make any
investigation necessary in order to be assured of compliance by the applicator and to
reject any material and/or coating that does not comply.”

6 Information supplied by the purchaser

Change header to:

“6 Information to be supplied”

6.1 General information

Replace header with:

“6.1 Information supplied by the purchaser”

Replace a) with:

“number of this PTS and year of publication;”

Add the following after h):

“i) project name;

j) type of coating required and preferred brands, if applicable;

k) geographical area (land/sub-sea);

l) expected ambient temperatures during installation and pipeline maximum

operating temperature;

m) soil and backfill conditions for land pipelines;

n) sea bed trenching, laying and burial conditions for sub-sea pipelines;

o) subsequent coatings to be applied (weight coating, insulation);

p) requirement for anti slip-treatment;

q) types of cathodic protection.”

Add the following after 6.2:

“6.3 Information to be submitted by the applicator

Coating Contractor shall submit these information to the purchaser. The information shall
include but not limited to:
 PTS 11.32.04
FUSION BONDED EPOXY COATING FOR LINE PIPE July 2015
Page 8 of 13

• Identification of the coating system;

• Information on the coating from the Coating Manufacturer;

• Qualification of the coating system;

• Procedure on applying the coating system;

• Selected Coating Applicator information and its qualification;

• Applicator's qualification information;

• Specification for coating performance test;

• Applicator’s quality plan; and

• Handling, preservation and storage procedure.

Applicator shall ensure that the selected coating system is applicable to the project’s
specification.”

7.1 Epoxy powder

7.1.1 General

Replace a) with the following:

“certified by the powder manufacturer to be in accordance with the requirements of

9.2, 9.3 and 9.4. Applicator shall submit certified copies of all certificates to the
purchaser if requested.”

Add the following at the bottom of b):

“- HSE information to comply with PTS 18.06.06 and international regulations.”

7.1.2 Properties

Change the following:

“Total volatile/moisture content mass fraction: ≤ 0.6%”

to:

“Total volatile/moisture content mass fraction: ≤ 0.5%”

7.1.3 Packaging

Add the following after the sentence:

“Material that is not traceable to satisfactory test certificates shall not be used.”

9 Application of coating
 PTS 11.32.04
FUSION BONDED EPOXY COATING FOR LINE PIPE July 2015
Page 9 of 13

9.2.2 Abrasive blast cleaning

Add the following after last paragraph:

“As a minimum, surface profile shall be “Medium” in accordance with ISO 8503-2. For
stainless steel pipes, stainless steel of non-ferrous abrasives shall be used for blast cleaning.

Blast cleaning shall not be performed when the relative humidity exceeds 85%. Preheating of
the pipes is required if humidity is higher. The surface temperature shall not exceed 275°C.

Expendable abrasives shall not be recycled.

The maximum residual chloride level on the blast-cleaned surface shall be 20mg/m2 in
accordance with ISO 8502-2.

The dust level on the blast-cleaned surface shall be of Class 1 in accordance with ISO 8502-3.

During blasting, the bevelled ends of the pipes shall be protected from blast cleaning and
impact damage by using caps when requested by Owner.”

9.3 Coating application and curing temperature

9.3.1 General

Add the following after last paragraph:

“Blast-cleaned pipes shall be coated within 4 hours. Pipes delayed beyond this period, or
pipes showing any visible rust stains, shall be blast cleaned again.

Any pipe heated above 275°C shall be replaced at manufacturer’s expense. Heating
equipment shall be controlled to maintain uniform temperatures throughout the coating
process.

The sequence of use of the batches of epoxy powder shall be in the order in which they were
manufactured.

Different brands of powders shall not be mixed.

During coating, the bevelled ends of the pipes and the pipe bore shall be protected against
mechanical damage and from contamination with coating material.

Each pipe end shall be left uncoated over a length of 80mm ± 15mm unless otherwise
specified.

Uncoated pipe ends shall receive a temporary protective coating for transit.

The post application temperature and the time interval between application and quenching
of the pipe shall be measured, recorded and controlled to ensure the coating is being
adequately cured.

If the Manufacturer requires the post-curing of the coating on the bends and fittings, this
shall be done in an oven for a maximum time of 15 minutes at a maximum temperature of
 PTS 11.32.04
FUSION BONDED EPOXY COATING FOR LINE PIPE July 2015
Page 10 of 13

250°C. Following such a curing process, the bend or fitting may be allowed to cool to ambient
temperatures in air as an alternative to water quenching.”

12 Markings

12.2 Required markings

Replace second bullet item with:

“number of this PTS and year of publication;”

13 Handling and storage in the coating area

Replace Clause 13 with the following:

“13 Handling, storage and transport of bare and coated pipe

13.1 General

The Coating Contractor shall take receipt of the pipes, delivered by the Linepipe
Manufacturer and shall keep a record of the serial numbers of the delivered pipes. Upon
receipt, the pipes shall be inspected for transport damage or other defects. Damaged pipes
shall be separately stored and reported to the Owner. Repairs shall only be carried out after
approval by the Owner.

During the various stages of the complete coating process, the Coating Contractor shall
ensure that all pipes shall be handled, stored and transported in such a manner that no
damage is caused to the pipes and the applied coating. Instructions by the Linepipe
Manufacturer and/or the Coating Manufacturer shall be followed. Instructions below shall
also apply.

13.2 Handling of pipes

Bevel protectors and/or end caps as installed by the Linepipe Manufacturer shall be re-
installed after coating and before handling of the pipes.

Lifting of pipes shall only be carried out using slings, lifting hooks or vacuum lifters, fitted with
suitable spreader bars. Chains shall not be used to lift pipes. Wire ropes shall not be used to
lift coated pipes. Hooks shall be padded with soft material to prevent damage to the bevelled
ends.

Lifting trucks or front-end loaders shall have soft padded forks or grips to prevent damage to
pipes or pipe coating.

Coated pipes shall not be rolled or dragged over the ground.

Pipes shall not be lifted in bundles without prior approval by the Owner. When more than
one pipe is lifted, separate slings or hooks shall be used for each pipe and coated pipes shall
be provided with soft padding between the pipes.

For handling of stainless steel pipes, handling and transport equipment and conveyors shall
be padded to prevent contact with carbon steel.
 PTS 11.32.04
FUSION BONDED EPOXY COATING FOR LINE PIPE July 2015
Page 11 of 13

Pipe that is damaged during processing and coating that is damaged after holiday inspection
shall be repaired according to clause 11.

13.3 Storage and stockpiling of pipes

Pipes shall be stored in designated areas. Pipes shall not be stored with other consignments
or pipes for other contracts.

Pipes shall be stacked only to such height that damage or deformation to the pipes due to
the weight of other pipes shall not occur. Coated pipes shall be stacked only to such height
that no damage to the coating occurs.

Pipe supports shall be spaced so that no bending of pipes occurs. Pipe supports shall be made
of soft padded wooden bolsters or sand rows, free of stones, covered with plastic sheets. The
pipe surface shall be at least 150mm above the ground.

Piles of pipe shall be secured by wooden wedges or ground pins, provided with adequate
padding to prevent coating damage, and of sufficient size to prevent collapse of the piles.

Coated pipes shall be stacked using soft separators such as rubber pads or tyre tread.

When stored outdoors, pipes shall be placed at a small angle to allow drainage of any rain
water from the inside of the pipes.

Rope separators, or similar, shall be used to prevent adjoining pipes rubbing together.
Minimum rope separator diameter is 16mm.

13.4 Transport of coated pipe

Coated pipes shall be prepared for transport or shipment in accordance with API RP 5L1, API
RP 5LW, Owner’s specification for land transportation or whichever is applicable. During
transportation, pipes shall be stacked and secured such as to prevent movement, abrasion
and/or peening.”

14 Test reports and certificate of compliance

Replace the paragraph with the following:

“Unless specified otherwise in the purchase order, an Inspection certificate of type

3.1.B according to ISO 10474:1991 (or type 3.1 according to EN 10204:2004) shall be
issued by the applicator, which provides the results from the inspection and testing
of the coated pipes in accordance with the requirements of this PTS and any other
requirements specified in the purchase order. If, however, in the purchase order, the
purchaser does waive the requirement for an Inspection certificate, then the
applicator should provide a certificate of compliance.”

Add the following after Clause 14:

“15 Documentation

The Contractor shall keep accurate records of all relevant data of the coating process which
include:
 PTS 11.32.04
FUSION BONDED EPOXY COATING FOR LINE PIPE July 2015
Page 12 of 13

• Coating system information as required in clause 6;

• Qualification information as required in clause 8;

• Copies of, or reference to, all procedures for coating of the pipes;

• Serial numbers of all pipes as given by the Linepipe Manufacturer (e.g. by copies
of the pipe mill data sheets);

• Serial numbers as given by the coating Applicator (if applicable) related to the
Manufacturer's serial numbers;

• The order of coating, the day and shift of coating of each pipe;

• The batch numbers of the coating materials, the day and time of loading of each
batch;

• Serial numbers of rejected pipes and the reason for rejection;

• Records of any repairs;

• The results of all quality control testing;

• Records of temperatures during the coating process for each pipe, with the
processing time of every tenth pipe, shall be marked on the temperature chart
with the pipe number;

• Names and signatures of the responsible persons for the coating process and
quality control.

This document shall be submitted to the Owner after completion of the coating works
together with the testing and inspection instruments calibration certificates.”
 PTS 11.32.04
FUSION BONDED EPOXY COATING FOR LINE PIPE July 2015
Page 13 of 13

3.0 BIBLIOGRAPHY

In this PTS, reference is made to the following Standards/Publications. Unless specifically

designated by date, the latest edition of each publication shall be used, together with any
supplements / revisions thereto:

PETRONAS STANDARDS
Index to PTS PTS 00.01.01
PTS Requirements, General Definition of Terms & Reading PTS 00.01.03
Guide

INTERNATIONAL STANDARDS

Petroleum and natural gas industries - External coatings for ISO 21809-2
buried or submerged pipelines used in pipeline transportation
systems - Part 2: Single layer fusion-bonded epoxy coatings
Preparation of steel substrates before application of paints and ISO 8503-2
related products - Surface roughness characteristics of blast-
cleaned steel substrates –
Part 2: Method for the grading of surface profile of
abrasive blast-cleaned steel - Comparator procedure
Preparation of steel substrates before application of paints and ISO 8503-3
related products - Surface roughness characteristics of blast-
cleaned steel substrates –
Part 3: Method for the calibration of ISO surface profile
comparators and for the determination of surface profile -
Focusing microscope procedure
Issued by:
International Organization for Standardization
Case Postale 56
CH-1211 Geneva
Switzerland
Copies can also be obtained from national standards organizations.