SCHEDULE 3B

GENERAL SPECIFICATIONS- MECHANICAL

SECTION 32150–FUSION–BONDING EPOXY
LINING
NEOM DESALINATION PLANT TO GAYAL
TRANSMISSION SYSTEM
“00-180000-4700000203-CH2-MEC-SPC-000003” Rev.02.00

August 2021
Document history

Revision code Description of changes Purpose of issue Date

A First Draft Internal Review 11.07.21

02.00 Comment Addressed Issued for Approval 31.08.21

Document approval

Prepared by Reviewed by Approved by

Name Fadi Ezzedine Fadi Sirrieh Conor Carroll

Job Title Mechanical Engineer Senior Mechanical Engineer Project Manager

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 SCH EDULE 3B
GENERAL SPECIFICATIONS - MECHANICAL

1) Section 32010 - Steel Pipes for Mainlines

2) Section 32020 - Factory Made Bends for Mainlines
3) Section 32030 - Main Pumps
4) Section 32040 - Valves for Water Projects
5) Section 32050 - Auxiliary Pumps
6) Section 32060 - Piping Materials for Stations
7) Section 32070 - Surge Vessels
8) Section 32080 - Special Fittings
9) Section 32090 - Cranes and Hoists
10) Section 32100 - Fire Fighting Equipment
11) Section 32110- HVAC Equipment
12) Section 32120 - Air Compressor Plants for Surge Vessels
13) Section 32130 - Handling, Storage and Transportation of Line
Pipe Material
14) Section 32140 - Fabrication and Installation of Station Piping
15) Section 32150 - Bonded Epoxy Lining
16) Section 32160 - Painting of Piping, Equipment and Structural
Steelwork
17) Section 32170 - Fusion-Bonded Epoxy Coating
18) Section 32180 - Chillers
19) Section 32190 - Chlorination Equipment

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Contents
1 SCOPE .................................................................................................................................. 5
2 CODES AND STANDARDS ................................................................................................. 5
3 GENERAL ............................................................................................................................. 5
3.1 Environmental Conditions ..................................................................................................... 5
3.2 Definitions.............................................................................................................................. 5
3.3 Abbreviations ........................................................................................................................ 5
3.4 Conflicting Requirements, Exceptions .................................................................................. 6
4 TECHNICAL REQUIREMENTS ........................................................................................... 6
4.1 Design ................................................................................................................................... 6
4.2 Materials ................................................................................................................................ 6
4.3 Fabrication............................................................................................................................. 7
Lining Application for Pipes ................................................................................................... 7
Lining Special Pipe Connections and Appurtenances .......................................................... 8
Field Procedures ................................................................................................................... 8
Repairs .................................................................................................................................. 9
5 INSPECTION, TESTING AND CERTIFICATION ................................................................. 9
5.1 Inspection .............................................................................................................................. 9
5.2 Testing................................................................................................................................... 9
Calibration of Inspection Equipment ..................................................................................... 9
Coating Materials Tests......................................................................................................... 9
Powder and Coating Systems Tests ..................................................................................... 9
Production coated-pipe tests............................................................................................... 10
Test of lined pipe connections and appurtenances ............................................................. 11
6 HANDLING, STORAGE, PRESERVATION, MARKING AND SHIPPING ........................ 11
7 DOCUMENTATION ............................................................................................................ 11

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1 Scope

The scope of this specification is to define the minimum requirements of material and application for
fusion-bonded epoxy lining for the interior of steel water line pipes, fittings, special sections and welded
joints installed underground or aboveground within stations and the mainline of water transportation
systems.
The minimum pipe diameter for application of an internal lining that can be inspected and repaired by
entering the pipe shall be 24 inch (600 mm). Pipe diameters less than 24 inch that can be electrically
inspected internally should be included, provided all the work complies with applicable provisions of
this specification.
The pipes and fittings which require internal lining are defined as having a flow velocity 3,0 m/s. The
areas where fusion-bonded epoxy lining is required shall be marked on the detail design drawings.

2 Codes and Standards

The Codes and Standards referenced herein shall be used those of the latest edition at the time of
detailed design works. The Contractor shall be familiar with the details of the Standards and other
documents referenced herein.
If there is the same parameter with different values occurring in the Standard and in this Specification,
the one mentioned herein shall prevail.

AWWA Manual M 11 Steel Pipe – A Guide for Design and Installation

AWWA C 213 Fusion-bonded Epoxy Coating for the Interior and Exterior of Steel

Water Pipelines

ASTM D4585 Standard Practice for Testing Water Resistance of Coatings Using
Controlled Condensation

NACE TM 0186 Holiday Detection of Internal Tubular Coatings of 250 to 760 μ m (10 to
30 mils) Dry-Film Thickness

SSPC-SP-COM Surface Preparation Specifications

3 General
3.1 Environmental Conditions

The environmental conditions, operating conditions and the quality of conveyedwater shall be
those defined in the general specification.

3.2 Definitions

The terms “ Contractor”,” Engineer”,” Final Acceptance”, etc. shall have themeaning as defined in
the General and Special Conditions of Contract.

3.3 Abbreviations

ASTM American Society for Testing and Materials

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AWWA American Water Works Association
DFT Dry Film Thickness

DSC Differential Scanning Calorimeter

DWI Drinking Water Institute
FBE Fusion Bonded Epoxy
NACE National Association of Corrosion Engineers

NPS Nominal Pipe Size

Sec. Section
SSPC The Society for Protective Coatings

WRC / WRI Water Research Commission

3.4 Conflicting Requirements, Exceptions

The Contractor shall notify the Engineer of any conflict between this specification, the Codes and
Standards and any other specifications included as part of the Contract Documents which may be
applicable for the FBE lining.
Any exceptions to this specification and referenced documentation shall be raisedby the Contractor
and approved by the Engineer in writing.

4 Technical Requirements

4.1 Design

The Design Standard AWWA C213 is defined to be the prevailing standard for fusion-bonded epoxy
applications.
For special applications and parts not covered by the above-mentioned code, the AWWA Manual M11
shall be used.
Other requirements and special requirements are amended and supplemented herein.

4.2 Materials

The epoxy powder must be suitable for use in the transport of drinking water and shall not affect
adversely the water intended for human consumption. A relevant certification from an approved
laboratory, such as DWI, DVGW, WRC / WRI shall be submitted. Materials provided shall be products
of one (1) manufacturer.
The materials used in the lining systems shall have the following properties:

 excellent resistance to water and disinfectants

 assured performance due to many years track record and third-party testing

 material shall have passed the “Cleveland Test” (as described in ASTMD
4585) or equivalent qualification
 the epoxy material must be suitable to resist flow velocity defined

 high mechanical strength, with good abrasion and impact resistance

 good adhesion to steel

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  easy to apply
Lining materials (and materials used for touch-up and repairs) supplied on site shall be marked as a
minimum with the following information:

 the manufacturer’s name

 the material identification number

 the batch number

 date of manufacture

 the shelf life (or expire date)

The Contractor shall retain samples of each epoxy resin batch for a period of one
(1) year. The sample shall be of sufficient size for the tests mentioned in Table 1and2 of AWWA
C213.
Touch-up or repairs shall be made with epoxy resin or other approved materials tested in accordance
with 5.2.

4.3 Fabrication

Lining Application for Pipes

The requirements shall be the same as in Sec. 4.4 of AWWA C213 supplementedand/or amended by
the following requirements.

4.3.1.1 Surface Preparation

The requirements shall be the same as in Sec. 4.4.2 of AWWA C213 supplemented and/or amended
by the following requirements.
Pre-cleaning shall be done according to SSPC SP 1. Only solvents that do not leave residue shall be
used.
The surface to be coated shall be blast-cleaned to achieve a near-white metal surface according to
SSPC-SP10 / NACE No.2. A visual reference SSPC-VIS 1 shall be used to supplement the cleaning
criteria.
As an aid in selecting the proper surface preparation method and materials the SSPC-SP-COM shall
be used.
After abrasive cleaning and before lining, the surface to be lined shall be carefullyinspected for metal
defects. The Contractor shall be responsible for the repair of any defects which can be repaired by filing
or grinding, and for re-storing the anchor pattern at the locations of such repairs when the size exceeds
75 mm in any direction. The tools and manner employed to remove metal defects shall not contaminate
the surface.
Any pipes or fittings containing surface defects that are so serious or extensive that they cannot be
readily repaired shall be rejected.
Dew Point readings shall be recorded at the start and every two (2) hours during the blasting operation
in the immediate vicinity of the operation. Blasting and coating operations shall be suspended if the
substrate temperature is less than three (3) °C above the dew point.
The elapsed time between the start of blasting and the heating of pipes shall be indicated in the
application procedure submitted by the Contractor and shall be reflected on his plant scheme.
The total elapsed time between the start of blasting of any pipe and the heating ofthat pipe to the
specified temperature.

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4.3.1.2 Lining / Coating Application

The requirements shall be the same as in Sec. 4.4.3 of AWWA C213 supplemented and/or amended
by the following requirements.

The minimum DFT provided shall be at least 505 mm and shall be applied in one layer only.

Any line pipe and associated fittings having less than the specified minimum dry film thickness shall be
re-blasted and re-lined.
Cutback and bevels shall be temporarily protected against corrosion during storage and shipment with
weldable primer coat.
The cured lining shall be of uniform colour and gloss, and shall be free of blisters, and fisheyes.
Cosmetic sags, runs, and other non-injurious irregularities are acceptable as long as the area affected
is less than 0.5 % of the coated area.
The following lining performance testing shall be done according to Sec. 4.4.3.7of AWWA C213:

 Thermal analysis (DSC)

 Permanent train (bendability)

 Water Soak

 Impact

4.3.1.3 Field Welded Joints

The requirements shall be the same as in Sec. 4.4.5 of AWWA C213 supplemented and/or amended
by the following requirements.
When fusion-bonded epoxy is used on field-welded joints a surface preparationas described above
shall be applied. The minimum pipe diameter for the application of an internal coating that can be
repaired by entering the pipe, shall be 24 inch (600 mm).
The adjacent fusion-bonded coating shall be roughened by sanding or grindingfor a distance of 25 mm
(1 inch) back from the edge of cutback.
Fusion-bonded epoxy shall be field-applied in the internal field joints using induction heat. The epoxy
used on the joint shall be fully compatible with the material used on the pipe. The minimum
temperature of epoxy application shallbe as per manufacturer’s requirements.
The weld area shall be heated to a temperature not exceeding 260 °C using a circumferential induction
heating coil of sufficient size, width and power to providethe required heat in the weld zone and in 2
inch (50 mm) back under the fusion- bonded pipe coating.

Lining Special Pipe Connections and Appurtenances

The requirements shall be the same as in Sec. 4.5 of AWWA C213 supplementedand/or amended by
the following requirements.
Flange faces shall not be coated.
Transition rings for making the transfer from cement mortar lining to FBE-lining shall be prepared and
lined according to procedures described above.

Field Procedures

The requirements shall be the same as in Sec. 4.6 of AWWA C213.

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 Repairs

Each length of lined pipe leaving the application premises shall be free of holidays and visual coating
defects.
Defects shall be repaired in accordance with the criteria and methods specified in Sec. 4.4.4 of AWWA
C213.

5 Inspection, Testing and Certification

The requirements and the standards of acceptability for inspection and testing shall be the same as in
Sec. 5 of AWWA C213 supplemented and/or amended bythe following requirements.

5.1 Inspection

The Contractor shall notify the Engineer not less than thirty (30) days in advance of the start of each
production run. The Contractor shall provide the Engineer witha detailed time schedule to permit him
to witness or monitor all processing and testing phases.
The Contractor shall be responsible for all quality control checking including visual inspection,
thickness measurements, and holiday testing, and shall keep records on the results of all such
inspections in a form suitable to the Purchaser's appointed Inspector.
The Purchaser's appointed Inspector shall have access to each part of the process and shall have the
right and opportunity to witness or monitor any of the quality control tests and/or perform such tests
himself on a random sampling basis.
The Purchaser's appointed Inspector shall have the right to stop this work pending alterations or
corrections to the process to correct all faults found in the work that result in failure to conform to this
specification.

5.2 Testing

Calibration of Inspection Equipment

The lining thickness gauge shall be calibrated at the start of production and every three (3) hours during
production, at approximately the mid-range of the lining thickness against a certified or known standard.
The holiday detector shall be calibrated at least twice per eight (8) hour shift against a suitable
calibrated voltmeter and adjusted to ensure that voltage is sufficiently high to detect an intentional
pinhole holiday through the lining on the pipe.

Coating Materials Tests

Shall be done according to Sec. 5.3.1 of AWWA C213.

Powder and Coating Systems Tests

Shall be done according to Sec. 5.3.2 of AWWA C213 and shall comprise the following tests:

 Specific gravity

 Sieve analysis

 Gel time – hot steel plate

 Appearance

 Impact

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  Bendability

 Shear adhesion

 Penetration

 Abrasion resistance

 Water soak

Production coated-pipe tests

Shall be done according to Sec. 5.3.3 of AWWA C213 and shall comprise the following tests:

5.2.4.1 Electrical inspection for continuity

The holiday detection test shall be carried out according to NACE Standard RP0188 and supplemented
by NACE Standard TM0186 and the following requirements.
l00% of the lined pipe or fittings surface area shall be holiday detected with a hot spark pulse-type DC
detector employing an audible signaling device. The electrode used for locating holidays shall be
designed to ensure direct contact with the lining, (with no visible gaps). Holiday detection shall not be
conducted if the surface temperature of the pipe is above 88 °C.
The travel rate of the detectors electrode shall not exceed 75 cm/s and shall not be allowed to remain
stationary while the power is on.
Holidays shall be clearly marked for repair.

5.2.4.2 Adhesion Test

The adhesion of the lining shall be determined at one location on a pipe for each of the following cases:
- the first production joint,
- the first joint after any interruption in production and
- once every hour or twenty pipe lengths, whichever is more frequent.
If three (3) tests have been successful, the frequency may be reduced to once every two (2) hours or
fifty (50) pipe lengths, whichever is sooner. Failure of the test shall require lot narrowing by testing the
pipes until three (3) in a row (coated both before and after the piece that failed) show satisfactory
adhesion. A lot is defined as one shift's production.
With a sharp narrow bladed knife, two incisions (approximately 13 mm long) shall be made, in the form
of an X, through to the metal substrate. At the intersection ofthe X, an attempt shall be made to force
the lining from the steel substrate with the knife point. The point of the knife shall be inserted
horizontally i.e., the flat of the blade under the lining at the point of intersection of the X such that the
blade point is on the metal surface. Using a levering action, the flat point shall be forcedaway from the
steel in an attempt to pry off the coating. Refusal of the lining to disbond from the substrate shall be
recorded as a pass. A pass shall also be recorded where the lining fails cohesively. Partial or complete
adhesive failure between the lining and the substrate shall be recorded as a failure. Disbondment at
the point of the intersection is common due to the action of marking the 'X' cut. Therefore, for 1 mm
away from the tip of the intersection any disbondment shall be ignored.

5.2.4.3 Thickness Test

Every pipe shall be checked at least at five (5) equidistant places and fittings shallbe checked in at least
five (5) locations. All coating thickness measurements shallbe made using a non-destructive type of
thickness gauge, which shall be calibrated as required in section 5.3.1 “Calibration of Inspection
Equipment”.

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5.2.4.4 Cure Test

Twice per shift the lining on production pipes shall be tested by Differential Scanning Calorimeter (DSC)
analysis. Failure of the test shall require each piece lined on that day to be subjected to the test until a
total of three (3) tests in a row (three (3) done both before and after the piece which failed) are
satisfactory.

5.2.4.5 “Cleveland Test” shall be done according to ASTM D4585.

In addition, the following tests shall be performed as proof that the “Cleveland Test” did not damage
the lining:
- Corrosion creep
- Impact resistance
- Adhesion (pull off test)

Test of lined pipe connections and appurtenances

Shall be done according to Sec. 5.3.4 of AWWA C213 and shall comprise the following tests:

 Electrical inspection for continuity

 Thickness

6 Handling, Storage, Preservation, Marking and Shipping

The requirements shall be the same as in Sec. 6 of AWWA C213.
Specification “Handling, Storage and Transportation of Line Pipe Material” shall be observed.

7 Documentation
The Contractor shall provide the following proven Qualification Procedures for approval by the
Engineer. The approval of the said procedures is required prior commencement of work.

 Lining Application Procedure

 Inspection and Test Plan
 Procedure for handling, loading, unloading, storage and preparation for
shipping

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