! Procedure 3lpe Msl Rev.00

D.P.
JINDAL GROUP OF INDUSTRIES

MAHARASHTRA SEAMLESS LIMITED,
PIPE NAGAR, COATING PLANT
PROCEDURE FOR PLANT APPLIED

THREE LAYER POLYETHYLENE COATING SYSTEM,
INSPECTION AND TESTING
CUSTOMER /
: M/s CHENNAI PETROLEUM CORPORATION LIMITED (CPCL)
CLIENT
: PIPELINE REROUTING WORKS FOR CAUVERY BASIN REFINERY (CBR) PROJECT AT
PROJECT NAME
Nagapattinam, Tamilnadu.
CONSULTANT : M/s Engineers India Pvt. Limited (EIL) EIL Job No.: B416 INSPECTION CATEGORY: B
CONTRACTOR : Master Engineering Pvt. Limited (MEPL)

WO No/FOA No. : 28235763/ (1046/SC0262/W/111) Dated 13.10.2022
PIPE SIZE & ORDER QUANTITY
OD WT QUANTITY
PO SR. NO.
(MM) (MM) (METERS)
1 219.1 7.92 2163
REFERENCE SPECIFICATION /STANDARD
EIL SPECIFICATION NO.6-71-0041 REV.4, DATED 05.01.2018 & ISO 21809-1:2011
MAHARASHTRA SEAMLESS LIMITED TPI CPCL/EIL
VIJAY PANDEY VED PRAKASH MISHRA RAGHVENDRA SINGH

TPI CPCL/EIL
ENGINEER- QA SR.MANAGER - QA/QC GM - COATING PLANT
PREPARED BY REVIEWED BY APPROVED BY APPROVAL APPROVAL
Doc No.: MSL/PROC/CPCL-CBR/PE/23-18 1|Page

Rev 00, DATE: 14.03.2023
D.P.JINDAL GROUP OF INDUSTRIES
TABLE OF CONTENTS
1.0 INTRODUCTION
2.0 DEFINITIONS
3.0 RESPONSIBILITIES
3.1 Production Manager
3.2 QC Manager
3.3 QC Inspector
4.0 QUALIFICATION OF THE APPLICATION PROCEDURE
5.0 DESCRIPTION OF THE COATING PROCESS
5.1 General
5.2 Incoming Rack
5.3 External Pipe Preheating Station before First Blasting
5.4 Abrasive Blast Cleaning
5.5 Heating Before Epoxy Coating application
5.6 FBE Application Station
5.7 Adhesive Application Station
5.8 Polyethylene Coating Station
5.9 Water Quenching Station
5.10 Inspection Rack after the Water Quenching Station
5.10 Cutback station
5.11 Holiday Inspection Station
5.12 Final activity, Out Going Rack
6.0 3LPE Coating Repair
7.0 PIPE COATING REMOVAL (STRIPPING)

Rev 00, DATE: 14.03.2023
1.0 INTRODUCTION
This procedure describes the process of application of the 3 Layer Polyethylene coating for
line pipes according to the requirement of the Project Specifications provided by the
Customer and as per approved QIP. The bare pipes shall be moved to the Anti-Corrosion
Coating plant where they shall be processed through the cleaning, coating and inspection
working stations. The coating process is performed under covered shed. Externally coated
pipes shall then lifted and transported to the temporary storage area before dispatch to site.
MSL/QIP/CPCL-CBR/PE/23-18, 3Layer Polyethylene Coating of steel Pipes – Quality
Inspection Plan, for all inspection and testing activities to be performed during the coating of steel
pipes with the 3 Layer Polyethylene Coating.
2.0 DEFINITIONS
CUSTOMER/CLIENT : M/s CHENNAI PETROLEUM CORPORATION LIMITED (CPCL)
CONTRACTOR : Maharashtra Seamless Limited
MANUFACTURER : Manufacturer or Supplier of the coating materials for Inspection and testing
Equipment.
3.0 RESPONSIBILITIES
3.1 Production Manager
The Production Manager is responsible for all of the operations performed in the
Coating Plant related to the application of the 3Layer Polyethylene.
3.2 Quality Manager
The QC Manager shall be responsible for all of the quality control inspection and testing during
Surface preparation, coating application and on coated pipe.
3.3 QC Inspector
The QC Inspector shall be responsible for verification that the application of the 3 Layer
Polyethylene coating has been performed in accordance with the approved project documents
and quality of coating meets project approved QIP/specification.
4.0 QUALIFICATION OF THE APPLICATION PROCEDURE
The Procedure Qualification Test shall be performed on 15 pipes and the inspection will be
Conducted as per approved QIP. During PQT coating application parameters shall be established
and recorded to confirm final characteristics of the 3 Layer Polyethylene coating system meet the
agreed Project requirements.

Rev 00, DATE: 14.03.2023
5.0 DESCRIPTION OF THE COATING PROCESS

5.1 General
During the application of the 3 Layer Polyethylene coating the pipes shall be processed through the
Following stations in the Anti-Corrosion Coating Plant:
 Incoming rack
 External pipe surface preheating station
 Abrasive Blast Cleaning
 Internal cleaning station / blow out
 Heating before epoxy coating
 FBE application station
 Adhesive application station
 Polyethylene application station
 Water quenching station
 Inspection rack after the water quenching station
 Both end cut back station
 Holiday inspection station
 Off-line inspection rack
 Final activity, Outgoing rack
5.2 Incoming Rack
The bare pipes shall bring to the incoming rack using the Fork lift / Hydra from yard.
At this station the pipes shall be visually inspected for presence of surface defects, oil/grease or
similar Contaminant and verify the bare pipe no. with bare packing list.
In case the oil or grease contamination is found, same shall be removed using a suitable solvent or
Chemical (e.g. Xylene, Thinner, Soap water etc.) by swabbing with cloth or similar material.
In case any surface defect is detected on external or internal pipe surface, defected pipe shall be
Segregated and inspected by bare pipe mill team to take further decision.
Any pipe not meeting quality inspection criteria, same shall be segregated and rectify before put in
Coating process.
5.3 External Pipe Preheating Station Before Blasting
At this station external surface of pipes shall be heated by diesel fire oven until the external pipe
Surface temperature is within range specified in approved QIP/Project specification and pipe surface
Temperature at least 3°C above atmosphere dew point temperature. The steel surface temperature
shall be verified using a digital contact thermometer. Following atmospheric condition shall be checked
by using thermo-hygrometer and recorded before blast cleaning:
1. Ambient temperature
2. Relative humidity.
3. Atmospheric Dew point temperature
5.4 Abrasive Blast Cleaning
The internal surface of the pipes shall be closed on both sides of the pipe with the end plugs, to prevent
the ingress of the abrasive into the internal surface of the pipe. Remove end plug at inspection rack
after blast cleaning.
The external pipe surface shall be blast clean using two dry abrasive blast cleaning units attached with
dust collector to achieve surface cleanliness and profile as per approved QIP requirement. For blasting
purpose metallic shot / grit shall be used.
Blasted pipe surface shall be inspected as per QIP requirement for cleanliness, profile, salt level, dust
level and elapsed time after blast cleaning.
Rev 00, DATE: 14.03.2023
a. Cleanliness shall be checked confirming to Sa2½ as per pictorial representation of ISO 8501-1,
b. Surface profile is not dished and rounded when viewed with 30X magnification.
c. Surface roughness profile shall be checked using Digital Roughness Gauge SJ210 or equivalent.
d. Dust level check by using dust level assessment transparent comply to ISO 8502-3 and peeling-off
to assess the degree of Dust.
e. Salt level checking by salt meter (SCM400/130 or Equivalent) as per approved QIP requirements.
If Salt level exceeding the acceptable limits as per approved QIP then pipes shall be either re-
blasted or washed by De - ionized Water.
All pipes shall be visually examined for presence of any shot/grit/loose material left inside the pipe
during blast cleaning. Any foreign material or shots/grit present in the pipe shall be completely removed
by high-pressure air equipped with suction arrangement in the dust collector on the other end of pipe.
After blast cleaning, surface of all pipes shall be checked for defects such as slivers, laminations, welds
spatters, gouges, or any other defects considered injurious to the coating integrity shall be segregate
and inspected by bare pipe mill team to take further decision. Before coating, the pipe surface shall be
cleaned from all dust and foreign matter using clean dry compressed air. The compressed air shall be
free of any trace of oil.
Any pipe not meeting quality requirement, same shall be mark NTC (not to coat), and remove from
Coating line for rectification/re-blast cleaning.
5.5 Heating before epoxy coating application

After chromate treatment, pipe shall be conveyed to an induction heater to maintain blasted bare pipe
Temperature before FBE application as per powder manufacturer recommended (190°C to 250°C).
Required pipe temperature shall be checked before enters to the Epoxy booth. The specified
Temperature shall be carefully monitored and recording non-contact type pyrometer and verified by the
contact type digital thermometers. From this station the pipe shall be conveyed to the FBE application
station.
5.6 FBE Application Station

Fusion Bonded Epoxy Powder shall be applied by electro statically spray gun to the surface of the
heated pipe. The no. of gun, pressure (conveying powder and dosing carrier air) of epoxy spray
system, pipe feeding line speed required to maintain epoxy coating thickness 200 μm minimum, shall
be established during PQT and maintain during production. The Epoxy application Parameter i.e. air
pressure shall be continuously monitored and recording. Air used for Epoxy system shall be dry & free
of oil and moisture, meets approved QIP requirement. The FBE coating thickness shall be 200 μm
minimum, measured on semi/partly coated pipe at thickness Inspection rack.
Minimum 12 measurements shall be taken with 3, 6, 9, 12 O’clock position.
5.7 Adhesive Application Station

The grafted co-polymer adhesive shall be applied using side extrusion method within the gel time/ inter
coat time of the epoxy application as per epoxy powder manufacturer recommendation. It shall be
ensured that applied powder layer is tacky prior to application of adhesive layer. The adhesive film
Temperature shall be within range as per manufacturer’s recommendation (200°C to 240°C).
The grafted co-polymer adhesive thickness shall be 200 μm minimum, measured on semi/partly
Coated pipe coated with epoxy + adhesive at thickness inspection rack. To measure the adhesive
Coating thickness, Minimum12 measurements shall be taken with 3, 6, 9, 12 O-Clock position and
Subtract average reading of 12 measurements from FBE thickness Minimum 12 measurements taken
over Adhesive + FBE coating to ensure the adhesive thickness is maintained i.e. 200 μm minimum.
Adhesive temperature shall be continuously monitored and recording by non-contact type pyrometer.
5.8 Polyethylene Coating Station

The Polyethylene layer shall be applied by using side extrusion, just after the Adhesive layer.
Polyethylene film temperature shall be maintain within range as per manufacturer’s recommendation
(200°C to 240°C). Polyethylene temperature shall be continuously monitored and recording by non-
contact type pyrometer.
From this station the pipe shall be conveyed to the water quenching station.
Rev 00, DATE: 14.03.2023
5.9 Water Quenching Station
3LPE coated pipes shall be cooled down to approximately ≤ 80ºC using water, before kick out from
Coating line to thickness inspection rack. The quenching time must be established and recorded during
PQT to ensure FBE layer is enough cured to achieve DSC result (Delta Tg / % Cure) specified in
Approved QIP and maintain during production.
The 3LPE coated pipe temperature shall be continuously monitored by non-contact type pyrometer and
Verified by the portable IR thermometer / contact type digital thermometers.
From this station the pipe shall be conveyed to the coating inspection rack.
5.10 Coating Inspection Rack after the Water Quenching Station
At this station coated pipes shall be inspected for:

 FBE thickness (Only on partly/semi coated pipe, frequency as per proved QIP).
 Adhesive thickness (Only on partly/semi coated pipe, frequency as per proved QIP).
 Total 3LPE coating thickness measurement.
 Visual inspection
The coated pipe thickness will be measured using calibrated digital coating thickness gauge and must
meet the thickness and visual requirements as mentioned in approved QIP/Project specification.
From this station the pipes shall be conveyed to the cutback preparation or test pipes shall be move to
Peel testing rack, if applicable frequency as per approved QIP requirement.
5.11 Cutback Station
At this station, the external 3LPE coating shall be removed from both pipe ends to the required
Cutback length (120 to140 mm), by using the tool with an angle / rotating wire brushes.
Edge of the Coating shall be shaped to form a bevel angle of 30° to 45°.
Cutback length shall be checked using steel scale / measuring tape and bevel angle checked by bevel
Angle protector.
From this station the pipes shall be conveyed to the holiday inspection rack .
5.12 Holiday Inspection Station
To ensure coating is free from discontinuity, all 3LPE coated pipes shall be inspected by using holiday
Detector equipped with an audible and visual alarm and set at test voltage specified in approved QIP
(25KV). During holiday inspection, following pointes will be maintained:
1. Make sure the earthling wire connected with pipe.

2. Travel speed of pipe maximum 300mm/s.
3. Holiday electrode is properly in touch with coating surface to ensure 100% contact with entire
coating surface.
4. Holiday detector is calibration using Jeep Meter as per approved QIP.
From this station the pipes shall be conveyed either to the final inspection station.
5.13 Final activity and Outgoing Rack
At this station following final activity will be conducted and ensure 3LPE coated pipe meeting quality
Requirement:
1. Pipe bevel grinding by flap disk to remove any coating residue at both pipe ends.
2. Cutback inspection, ensure QIP requirement.
3. Check Residual magnetism as per approved QIP requirement.
Marking for pipe OD will be conducted as per approved QIP.

Rev 00, DATE: 14.03.2023
6.0 3LPE Coating Repair
Any 3LPE coating damage observed, same shall be repaired as per approved repair procedure.
7.0 Pipe Coating Removal (Stripping)

The 3LPE coated pipes not meeting acceptance criteria as specified in approved QIP, same shall be
marked coating rejected. Such pipes shall be move to coating stripping area to remove PE & adhesive
Layer coating by mechanical tool and FBE layer by blast cleaning.

Rev 00, DATE: 14.03.2023
Raw material & Coating Inspection and Testing

TABLE OF CONTENTS
1) Reviewed Raw Material test certificates

2) In house Raw Materials testing (Epoxy Powder, Adhesive & Polyethylene)
3) Inspection And Testing Coated Pipes.
4) Calibration/ Verification of measuring instruments
5) List Of Formats & Records
Reviewed Raw Material test certificates as EN 10204 3.1 ( Epoxy Powder, Adhesive & HDPE):
1.1) Fusion Bonded Epoxy (FBE) Powder

Epoxy powder properties reviewed as per Approved QIP Clause No.: 1.1.
1.2) Adhesive (Grafted)

Co-polymer adhesive used shall be grafted type and the adhesive properties reviewed as per
Approved QIP Clause No.: 1.2.
1.3) High Density Polyethylene
High density Polyethylene properties reviewed as per Approved QIP Clause No.:1.3.
1.4) Abrasive Materials
Abrasive materials requirements as per Approved QIP Clause No.: 1.0A.
2) In house Raw material testing:

 Epoxy Powder
1) Gel Time:-
Testing equipment: Hot plate, stop watch & spatula.
Test Procedure:
Gel time shall be determined by placing coating material in a hot plate stabilized at temperature of
205°C ± 3°C or as per manufacturer’s recommendation. Use a spatula to coat out a Uniform thickness.
Start the timing device as soon as the coating material is applied to the hot plate Surface. Stir/Scribe the
coating with a spatula and stop the watch when the coating becomes as Un-steerable /comes over epoxy
layer and no longer contact with metal plate. The elapsed time is the Gel time. Test performs three times
and takes the average value for result.
Acceptance criteria depending on the FBE powder manufacture recommendation.
2) Thermal analysis (Virgin Epoxy Powder):-
Test equipment: DSC equipment connected to a data analyzer and printer, laboratory balance with
scales accurate to the nearest 0.1 mg, DSC Pans & laboratory tools.
Test procedure:
Heating cycle as per standard condition and raw material manufacturer recommendation
DSC pans shall have a volume such to contain the sample to be tested. Weight 10 mg ± 3 mg of the
Epoxy powder coating. Record the weight of the sample with an accuracy of 0.1 mg. After having
Placed the sample on the bottom of the pan, with a suitable and perfectly clean cylindrical rod, push
Gently the sample close to the bottom of the pan in order to increase as much as possible the contact
Surface of the sample with the pan. After this operation, Pierce the top of the pan cover with a
Clean needle. Close the pan with its pan cover by the specific device. An inert gas (N2) shall be used
To purge the cell. The scan program shall be prepared depending on the instrument used DSC
Machine with fast cooling device.
Heating cycle as per standard condition and raw material manufacturer recommendation.

Rev 00, DATE: 14.03.2023
3) Moisture Content:-
 Procedure A (Mass loss methods)
The test shall be performed in the laboratory.
Test equipments: Hot Air Oven, Balance (Accurate to 0.001gm), Desiccators.
Sample container.
Test procedure:
Weigh the sample container. Transfer approx. 10 g of epoxy powder into the sample container. Weigh
the sample container and epoxy powder. Place the sample container with the epoxy powder into the
oven for a minimum of 2 hours at 105 ± 3°C. Remove the container from the oven and place it in the
desiccators to cool. Weigh the sample container when it has cooled to 20 ± 3°C and then return it to the
Desiccators repeat at intervals of 1 Hrs ± 10 min until two consecutive mass determinations.
Calculate the Percentage of Moisture by using the formula
Where,
M = Percentage of Moisture
B = Initial mass of sample container and epoxy powder, g
C = Final mass of sample container and epoxy powder, g
A = Mass of sample container, g
 Procedure B (automatic procedure)
The moisture content of the epoxy powder shall be determined using a machine that automatically
Determines moisture content by mass loss.
4) Cure time
Test procedure:
DSC pans shall have a volume such to contain the sample to be tested. Weight 10 mg ± 3 mg of the
Cured FBE sample which are prepared by Hot plate temp. @ 232±3°C, after 120 seconds or as per
Raw Material manufacturer recommendation. After having placed the sample on the bottom of the
Pan, with a suitable and perfectly clean cylindrical rod, push gently the sample close to the bottom of
The Pan in order to increase as much as possible the contact Surface of the sample with the pan.
After This Operation, Pierce the top of the pan cover with a clean needle. Close the pan with its pan
Cover by the specific device. The scan program shall be prepared depending on the instrument used
DSC Machine with fast cooling device. An inert gas (N2) shall be used to purge the cell.

Rev 00, DATE: 14.03.2023
 Adhesive (Grafted) & High Density Polyethylene (HDPE)

1) Melt Flow Index - HDPE & Adhesive
Test equipment: Melt flow Index assembly, Die Plug, Cutting Tool, Stopwatch & Analytical balance.
Test Procedure:
For the adhesive and topcoat HDPE material, the melt index shall be determined at a temperature of
190°C±3°C with a load of 2.16 kgs, Preheat the apparatus to test temperature for at least 15 minutes.
Remove the piston and place it on the insulated surface. Charge the cylinder within 1 minute with a
weighed portion of the sample, 4 to 6 grams. Place the weighed piston into position. Start timing for a
6 to 8 minute pre-heat period. As the lower scribe mark reaches the top of the cylinder (or index), reset
the stopwatch and cut off the extruded material simultaneously. Cut off the extruded material 3 times
after each interval of 20 seconds (Adhesive) & 40 seconds (HDPE). Discharge the remainder of the
specimen and push the die out through the top of the cylinder. Swab out the cylinder with cloth
patches while hot, like a gun barrel. It is not necessary to clean the die so long when similar materials
are being tested. When the Extruded material has cooled to the room temperature weigh it to the
nearest mg and record the melt Flow rate in g/10minutes.
Acceptance criteria as per Approved QIP & material manufacture recommendation
2) Vicat Softening Point - HDPE & Adhesive
Test equipment: Vicat softening assembly.
Test Procedure:
The test shall be performed in the laboratory. This method consists of temperature at which a flat
Ended needle penetrates 1mm under a specified load (10N) and uniform rise rate of temperature.
For testing purpose approximately 10mm X 10mm sample shall be cut from sheet prepared from
Granules of materials (HDPE/ADHESIVE). Sample shall be place under needle and apply a 10N
Load and set indent meter on “zero”. Start the heater @ 50±5°C/hrs. Record the temperature of the
Bath when the needle has penetrated 1± 0.01 mm into the test specimen.
Acceptance criteria as per Approved QIP & material manufacture recommendation.
3) Density- HDPE & Adhesive

Test equipment: Density setup & & Analytical balance.
Test Procedure:
Approximately 25mm X 25mm (Weight at least 1 g) sample shall be cut from sheet prepared from
Granules of raw materials (HDPE/ADHESIVE). Precisely weigh the sample up to 0.1mg in air.
Place the sample in sample holder immersed in distilled or de- ionized water/Immersion bath.
Note the submerged weight of Sample up to 0.1mg. Calculate the specific gravity as per following
Formula:
Specific gravity = Wt. in air / (Wt. in air - Submerged Wt.) X Density of immersion liquid
4) Water Content - HDPE & Adhesive
Test equipment: Water content testing apparatus (Coulometer) & Analytical balance
Test Procedure:
Weigh the graduals sample with sample vials with locked cap (crimping). Weigh the empty sample vial
and then reset the weighing balance. After then put graduals into the vial and then weigh the
Graduals sample approx.1 gram (Without sample vial weight). After conditioning the Apparatus
Sample vial put in apparatus Assembly and start the test. After completion of test the Apparatus
Shows the result directly on Screen. Record the test result.
5) Oxidative Induction time – Only HDPE
Doc No.: MSL/PROC/CPCL-CBR/PE/23-18 10 | P a g e

Rev 00, DATE: 14.03.2023
Test Procedure:
DSC pans shall have a volume such to contain the sample to be tested. Weight 5 mg to10 mg of the
HDPE sample. After weighing the sample with DSC pan and pin, locked the DSC pan with press
assembly. After then put sample in DSC machine and start it. When the temperature of sample reached
at 220°C, then An inert gas (N2) shall be used to purge the cell after then Oxygen (O2) will be start
automatically. After completion of test machine show the result on Graph for print.
Coating Procedure Qualification
15 pipes to be coated, out of these 1 partly coated with epoxy and partly with both epoxy & adhesive
Layer + 5 pipes 3LPE coated shall be selected for testing.
Testing
One partially coated and 5 No’s 3LPE coated test pipes shall be selected out of 15 coated pipes by
Owner Representative / TPI for coating procedure approval tests and shall be subjected to procedure
Qualification testing as described here in after.
 INSPECTION AND TESTING COATED PIPES
 FBE COATED PIPE (DURING PROCEDURE QUALIFICATION)

 TESTING ON 3LPE COATED PIPES (DURING PROCEDURE QUALIFICATION & REGULAR
PRODUCTION)
3.1) Degree of Cure (Sample from Partly Coated &3LPE Coated pipes)-
The test shall be performed in the laboratory during PQT & Regular Production.
Equipments: DSC equipment connected to a data analyzer and printer, laboratory balance with scales
Accurate to the nearest 0.1 mg, DSC Pans & laboratory tools.
Procedure:
Epoxy film samples shall be scrapped from one coated pipe. Weigh the cured FBE samples in pan, then
after put the hole by pin on cap, put cap on pan the locked the cap with pan by press machine. After then
samples shall be taken for cure test using Differential Scanning Calorimetric (DSC) Procedure. Glass
transition temperature differential (Tg) and % cure (ΔTg) shall comply with the specified requirements as
per Approved QIP. The scan program shall be prepared depending on the instrument used
DSC Machine with fast cooling device. An inert gas (N2) shall be used to purge the cell.
3.2) Dry Adhesion Test

The test shall be performed during PQT & Regular Production
Equipments: Utility Knife
Procedure:
Adhesion of epoxy layer shall be determined at ambient temperature by the “V - Cross” method.
Rev 00, DATE: 14.03.2023
Inscribe a V-cut with two 20 mm lines intersecting at approximately 5 mm from their ends at 30° to 45°.
Insert the blade of the knife at the point of the V-cut, 45° to the surface, then with an upward flicking action
Attempt To dislodge the coating within the V. If little or no coating is removed, repeat this action within the
V at Least four Times to confirm the integrity of the coating. Examine the appearance of the disbonded
Surface and compare the rating / Test Acceptance criteria as per Approved QIP.
3.3) Adhesion Test (24 Hours)

The test shall be performed during PQT.
Equipments: Hot temperature water bath, Tap water or De- ionized or reverse osmosis water & Utility
Knife
Procedure:
This test shall be performed at the time of procedure qualification. Test shall be performed on FBE coating
Sample. Prepare the Sample of size approximately 100 X 100 mm, put in Hot water bath for 24 ± 0.5 hours.
After 24 hours pick out the sample from hot water bath, 30 mm x 15 mm rectangle through the coating to
the substrate, then air cool the test specimen to 20 ± 3°C within 1 h of removal from heat, insert the tip of
the utility knife under the coating at a corner of the scribed rectangle. Use the levering action to remove the
coating. Examine the appearance of the disbonded surface and compare the rating / Test Acceptance
Criteria as per Approved QIP.
3.4) 2° Flexibility Test (FBE coated)
Equipments: Flexibility test assembly (Hydraulic Press) with mandrel, Deep freezer.
Procedure:
This test shall be performed at the time of procedure qualification. 2° Flexibility test shall be carried out at
a test temperature of 0±2°C of FBE coating. Take the test specimen of measure approx. 25 mm x 200
mm x pipe wall thickness dimension parallel to the axis of the pipe. Smooth the coating on the edge of the
Sample to remove any potential stress risers. Place the test specimen in the freezer, flexibility test
Temperature of 0±2°C & hold it within that temperature range for a minimum of 1 hour. Calculate the radius
of mandrel as required. If available radius mandrel match with calculations, the will can used nearest lowest
radius mandrel of calculated mandrel. Bend the test specimen over a mandrel whose radius is not larger
than that determined in accordance with the applicable requirements. Bend the specimen such that the
operation lasts not longer than 10 s and is Completed with 30 s of the test specimen having been removed
from the freezer. Warm the bent test Specimen to 20 ± 5°C and hold it in within 2 hours this temperature.
Calculation of mandrel
Required deflection, degrees Application formula
2.0 R = 28.15 t
Legend: R = mandrel radius, mm
t = sample thickness, mm
Number of test specimen and acceptance criteria shall as per Approved QIP.
3.5) Cross-section & Interface Porosity Test

Equipments: Flexibility test assembly (Hydraulic Press, Deep freezer, 40X Magnification (Microscope)
&Utility Knife
Procedure:
Take a test specimen of dimensions approximately 25 mm x 200 mm x wall thickness. Use the Utility knife
to remove an piece of coating from the test specimen, bend to piece of coating from the bend test
Specimen. Examine the metal cross section side & interface side of the coating with the 40 X Magnifying
Glasses (Microscope). Estimate the of contamination (porosity) rating and Number of test specimen as per
acceptance criteria shall as per Approved QIP.
3.6) Tensile Strength

The test shall be performed during PQT
Equipments: Tensile testing machine, Hydraulic press machine with Dumble cutting setup.
Procedure:
This test shall be performed at the time of procedure qualification .Test shall be carried out on
3LPE Coated pipe sample during PQT. Tensile strength test shall be performed on Sample taken from
Rev 00, DATE: 14.03.2023
3LPE coated pipe, prepared in lab hydraulic press. Sample shall be subjected for Tensile strength test as
per ISO 21809-1 & ISO 527.
3.7) Air Entrapment Test
Equipments: Utility knife & 30 X magnification (handheld).
Procedure:
Strips from the bond strength tests may be used to help determine the Air entrapment of the finished
Coating. The strips shall be viewed from the side and the interface of the coating. The examination
shall be down with the help 30X-magnification hand held microscope. The polyethylene and Adhesive
layer shall have no more than 10 % of the observed area & thickness taken up with air entrapment as
per Approved QIP.
3.8) Bond Strength Test

Equipments: Bond Strength (Peel) test assembly Utility knife & thermometer.
Procedure:
Peel strength test shall be performed as per ISO 21809-1. A strip coating with a width of 20 to 50 mm
shall be peeled off in circumferential direction. Cut a strip with width of 20 to 50 mm, tight the strip in
peeling direction. Using knife make a cut mark at root of PE test strip on FBE layer up to steel. After tighten
the strip, test will get start, the force applied for peeling is determined by peeling strip from surface of
coated pipe. The observation shall be made on the force applied to peel the test strip. The coating shall be
peeled at an angle of 90° to the pipe surface with constant peeling rate of 10 mm/min. A minimum of 140
mm length shall be peeled as per ISO 21809-1. During test first and last 20mm shall not be Consider.
Result will be considering only average value of 100 mm peeing estimated from 20mm interval band. For
middle position testing At feasible distance (Approx.: 600mm from pipe end) the tests shall be conducted &
Acceptance criteria (for both temperatures i.e. old & Hot) as per Approved QIP.
3.9) Impact Strength Test

Equipments: Impact test assembly & Holiday Detector.
Procedure:
Before impact test the pipe shall be tested for absence of holiday. Calculate the height of impact as per
required Impact energy Height of the impact and weight can be adjusted The impact tester kept vertically
on the pipe and impact weight shall be released from calculated height Test shall be conducted at 30
impacts after interval of minimum 50mm along the length of the pipe and then impact area shall be
checked at high voltage i.e., 25 kV Holiday test should not show a holiday of coating at impact areas.
3.9) Indentation Hardness Test

Equipments: Indentation test assembly with weight & test temp. Monitoring system.
Procedure:
Sample which has been removed from the pipe and free of adhesive. It may be necessary to abrade the
reverse side of the sample to obtain the required thickness. The indenter shall be a metal rod to which an
additional weight can be added. Under this test, the resistance of the polyethylene to penetration of an
indenter under 2.5 Kgs load shall be determined as per specified temperatures. A metal pin with a flat
surface of shall be fitted correctly at the lower end of the rod. After 24 ±0.5 hrs. The depth of penetration
shall be read from the dial gauge Testing shall be carried out at temperatures and the penetration allowed
as per Approved QIP.
3.10) Elongation test

Equipments: Tensile testing machine, Hydraulic press machine with Dumble cutting setup.
Procedure:
Test shall be carried out on 3LPE Coated pipe sample during PQT & during Regular production if HDPE
Batch change. Tensile strength test shall be performed on Sample taken from 3LPE coated pipe, prepared
in lab hydraulic press. Sample shall be subjected for test as per ISO 21809-1 & ISO 527.
Elongation shall be calculated as:
% Elongation at break = Final length – Initial length x 100
Initial length
Acceptance criteria as per Approved QIP.

Rev 00, DATE: 14.03.2023
3.12) Cathodic Disbondment Test

The test shall be performed during PQT & Regular Production.
Equipment: Cathodic disbondment test assembly (DC power supply), Sand Bath with temperature
Monitoring system, Utility Knife, Caliper, Platinum & Calomel reference electrode
Procedure:
Test shall be carried out on 3LPE Coated pipe samples. The Cathodic disbondment test shall be carried
out for 24 hrs(Testing during PQT & Regular Production) & 28 days in accordance with the ISO 21809-1
Standard. Prepare the 3LPE coated pipe Sample of size approximately 100 mm × 100 mm. after cutting
the sample, the sample by using transparent vessel assemble with sealant and make electrolyte solution of
3% NaCl. After drying the sealant put the sample in sand bath and maintaining test temperature with filling
Electrolyte solution and connected electrodes to Cathodic disbondment tester apparatus and start the test.
Monitoring the parameter of test at least once in a day.
During test following parameter shall be maintained:-
A) Testing during PQT Only – Once whole project)
Test temperature
Test Potential (sample Temp.) Test duration Electrolyte solution
- 1.5 (Min.) 23°C ± 3°C 28 Days 3% NaCl
- 1.5 (Min.) 80°C ± 3°C 28 Days 3% NaCl
B) Testing during PQT & Regular Production - Once per day)
- 3.5 (Min.) 65°C± 3°C 24 Hours 3% NaCl
Acceptance Criteria as per Approved QIP.
3.13) Hot Water Immersion 3LPE coated

The test shall be performed during PQT & Regular Production
Equipments: Hot temperature water bath, Tap water or De- ionized or reverse osmosis water & Utility
Knife
Procedure:
Test shall be performed on 3LPE coating sample. Prepare the Sample of size approximately 150 mm × 100
mm with the shorter side transverse to the pipe axis, put in Hot water bath for 48 ± 0.5 hours. After 48
hours pick out the sample from hot water bath, then air cool the test specimen to room temperature
removal from heat, insert the tip of the utility knife under the coating at a corner of the scribed rectangle.
Use the levering action to remove the coating. After the conditioning period extract the samples from the
bath, dry them with paper or tissue and examine them cooled to room temperature. Acceptance criteria
shall be as per Approved QIP.
3.14) Flexibility test 3LPE coated

This test shall be performed at the time of PQT.
Equipments: Flexibility test assembly (Hydraulic Press) with mandrel, Deep freezer.
Procedure:
This test shall be performed at the time of procedure qualification. 2° Flexibility test shall be carried out at
a test temperature of 0 ± 2°C of 3LPE coated pipe sample. Take the test specimen of measure approx. 25
mm x 200 mm x pipe wall thickness dimension parallel to the axis of the pipe. Smooth the coating on the
edge of the sample to remove any potential stress risers. Place the test specimen in the freezer, flexibility
test temperature of 0±2°C & hold it within that temperature range for a minimum of 1 hour. Calculate the
radius of mandrel as required. If available radius mandrel match with calculations, the will can used nearest
lowest radius mandrel of calculated mandrel. Bend the test specimen over a mandrel whose radius is not
larger than that determined in accordance with the applicable requirements. Bend the specimen such that
the operation lasts not longer than 10 s and is Completed with 30 s of the test specimen having been
removed from the freezer. Warm the bent test Specimen to 20 ± 5°C and hold it in within 2 hours this
temperature. Number of test specimen and acceptance criteria shall as per Approved QIP.

Rev 00, DATE: 14.03.2023
4) Calibration/ Verification of measuring instruments

Lab In charge shall be responsible for calibration of equipment according to the following schedule: -
Instrument Name Frequency of Calibration

Stylus type roughness Gauge Once per shift
Thickness Gauge Once per shift
Temperature Gauge Twice per shift
Holiday Detector Once per 4.0 Hours
5) LIST OF FORMATS & RECORDS
The following minimum records shall be maintained as hard copies:-
FORMAT NAME FORMAT NO.

REPAIR REPORT F: QC/COAT:001 Rev.00
FIRST PIPE REPORT (SHIFT WISE) F: QC/COAT:002 Rev.00
FIELD TEST REPORT F: QC/COAT:003 Rev.00
RAW MATERIAL TEST REPORT F: QC/COAT:004 Rev.00
CALIBRATION REPORT OF MEASURING & TESTING INSTRUMENTS F: QC/COAT:005 Rev.00
FINAL INSPECTION REPORT F: QC/COAT:006 Rev.00
PIPE COATING DATA SHEET - 3LPE / 3LPP /FBE F: QC/COAT:007-‘A’ Rev.00
INDENTATION TEST REPORT F: QC/COAT:009 Rev.01
DUST LEVEL FORMAT AS PER ISO 8502-3 F: QC/COAT:011 Rev.00

Rev 00, DATE: 14.03.2023

! Procedure 3lpe Msl Rev.00

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D.P.

JINDAL GROUP OF INDUSTRIES

PROCEDURE FOR PLANT APPLIED

CONTRACTOR : Master Engineering Pvt. Limited (MEPL)

PIPE SIZE & ORDER QUANTITY

REFERENCE SPECIFICATION /STANDARD

EIL SPECIFICATION NO.6-71-0041 REV.4, DATED 05.01.2018 & ISO 21809-1:2011

MAHARASHTRA SEAMLESS LIMITED TPI CPCL/EIL

VIJAY PANDEY VED PRAKASH MISHRA RAGHVENDRA SINGH

Doc No.: MSL/PROC/CPCL-CBR/PE/23-18 1|Page

Doc No.: MSL/PROC/CPCL-CBR/PE/23-18 2|Page

4.0 QUALIFICATION OF THE APPLICATION PROCEDURE

Doc No.: MSL/PROC/CPCL-CBR/PE/23-18 3|Page

5.0 DESCRIPTION OF THE COATING PROCESS

5.4 Abrasive Blast Cleaning

5.5 Heating before epoxy coating application

5.6 FBE Application Station

5.7 Adhesive Application Station

5.8 Polyethylene Coating Station

5.9 Water Quenching Station

5.10 Coating Inspection Rack after the Water Quenching Station

At this station coated pipes shall be inspected for:

1. Make sure the earthling wire connected with pipe.

5.13 Final activity and Outgoing Rack

Doc No.: MSL/PROC/CPCL-CBR/PE/23-18 6|Page

6.0 3LPE Coating Repair

7.0 Pipe Coating Removal (Stripping)

Doc No.: MSL/PROC/CPCL-CBR/PE/23-18 7|Page

Raw material & Coating Inspection and Testing

1) Reviewed Raw Material test certificates

1.1) Fusion Bonded Epoxy (FBE) Powder

1.2) Adhesive (Grafted)

1.4) Abrasive Materials

Abrasive materials requirements as per Approved QIP Clause No.: 1.0A.

2) In house Raw material testing:

Doc No.: MSL/PROC/CPCL-CBR/PE/23-18 8|Page

Calculate the Percentage of Moisture by using the formula

Acceptance criteria depending on the FBE powder manufacture recommendation.

Doc No.: MSL/PROC/CPCL-CBR/PE/23-18 9|Page

 Adhesive (Grafted) & High Density Polyethylene (HDPE)

Acceptance criteria as per Approved QIP & material manufacture recommendation.

3) Density- HDPE & Adhesive

Doc No.: MSL/PROC/CPCL-CBR/PE/23-18 10 | P a g e

Coating Procedure Qualification

 INSPECTION AND TESTING COATED PIPES

 FBE COATED PIPE (DURING PROCEDURE QUALIFICATION)

3.2) Dry Adhesion Test

3.3) Adhesion Test (24 Hours)

3.5) Cross-section & Interface Porosity Test

3.6) Tensile Strength

3.8) Bond Strength Test

3.9) Impact Strength Test

3.9) Indentation Hardness Test

3.10) Elongation test

Doc No.: MSL/PROC/CPCL-CBR/PE/23-18 13 | P a g e

3.12) Cathodic Disbondment Test

3.13) Hot Water Immersion 3LPE coated

3.14) Flexibility test 3LPE coated

Doc No.: MSL/PROC/CPCL-CBR/PE/23-18 14 | P a g e

4) Calibration/ Verification of measuring instruments

Instrument Name Frequency of Calibration

5) LIST OF FORMATS & RECORDS

The following minimum records shall be maintained as hard copies:-

FORMAT NAME FORMAT NO.