MANUFACTURING PROCEDURE SPECIFICATION

of
INTERNAL EPOXY PAINTING

Coating Type : Internal Epoxy Painting 400 µm

Title Introduction

3.1. Scope

This document covers “MANUFACTURING PROCEDURE SPECIFICATION” including

Testing and Inspection procedure specification of application of paint epoxy on pipe internal
surface.

This procedure is written with the intention of being a working instruction for shop floor
personnel by detailing the standard of workmanship and acceptance criteria throughout
each phase of the process.
Pipe epoxy coating activities will be conducted at PT. Krakatau Pipe Industries Cigading
Factory.

3.2. Definition

Coater : PT. Krakatau Pipe Industries - Cilegon Banten (KPI)

PDS : Product Data Sheet

MSDS : Material Safety Data Sheet

WFT : Wet Film Thickness

DFT : Dry Film Thickness

ITP : Inspection Test Plan

Title Code, Specification, Standard & References

The following code, specifications, standards and reference are relevant to this document:

Preparation of steel substrates before application

of paints and related products - Visual assessment of surface
a ISO 8501 – 1 cleanliness – Part 1: Rust grades and preparation grades of
uncoated steel substrates and of steel substrates after overall
removal of previous coatings
Preparation of steel substrates before application
of paints and related products - Surface roughness
b ISO 8503 – 2 characteristics of blast-cleaned steel substrates – Part 2 :
Method for the grading of surface profile of abrasive blast-
cleaned steel – Comparator procedure
c SSPC PA2 Measurement of dry coating thickness with Magnetic Gages

Standard test method for Pull-Off strength of coatings using

d ASTM D4541
portable adhesion tester

e SSPC SP2 Hand Tool Cleaning

f SSPC SP3 Power Tool Cleaning

Remarks:
Title Flow Process Diagram

Material Receiving

Separate
Material Manufacturer

Check for Not Good

Material Certificate
P DS & MSDS

Coating Aplicator

Good

Pipe Receiving

Separate

Check for Not Good

Visual inspection
Traceability record

Good

INTERNAL BLASTING

Check for
Dew Point & RH Not Good
Surface appearance
Roughness
Salt contamination

Good

Continue

Remarks:
Title Flow Process Diagram

Continue

Internal Coating Application

Check for
Visual Inspection Not Good
WFT / DFT Repair/Recoating
Adhesion Test (1st
Production)

Good

MARKING

STORAGE

DELIVERED

Remarks:
Title Receiving Inspection

6.1 Pipe Receiving Inspection

All pipes shall be visually examined for defect such as slag, arc strike, weld spatter,
porosity, sharp edge, pit, lamination, slivers, crevice and internal ridges or welds that
have not been properly scarfed.
Pipes containing these defects shall be segregated if the defects are to the extent they
would reduce the coating quality.
If pipes are received from other pipe manufacturer the marking shall be recorded and
kept for identification and the bevel end protector shall be kept and installed later after
coating application has finished.

6.2 Coating Material Receiving Inspection

a. Receiving coating material shall be checked as per delivery sheet.
b. Check, verify and reported every batch of coating with the following items:
Coating Manufacturer’s name address
 Product Type
 Batch No
 Quantity
 Certificate
 Date of Manufacture / expire date
 Packing Condition
 Product Data Sheet (PDS)
 Material Safety Data Sheet (MSDS)
c. Keep the coating material as per manufacturer specification.
d. Only the coating materials which have been approved shall be used for coating
process.
e. Coating material as per Customer Purchase Order.
Title Internal Blasting & Coating Application

7.1 Internal Blasting

Before blasting the pipe surface shall be cleaned to remove dirt or grease. All
traces of oil and grease shall be brushed and wiped off using detergent/water
cleaning (Aqueous solutions of household detergent) and a clean cloth. All
moisture, if any shall be removed by heating using a gas burner or a hot air blower.
Weld spatter, scale, sliver, lamination and surface defect which are not remove
during blasting shall be edges smoothed or rendered flush or removed by grinding
and re-blast.
Any pipe which has been blasted but not primed and then wet by rain moisture
shall be re-blasted. All moisture, if any shall be removed by heating using a gas
burner or a hot air blower.
Every pipe is blasted to meet Sa 2 1/2 standard by grit blasting, sand blasting or
abrasive blasting.
Blasting shall not be commenced when humidity is greater than 85% or surface
temperature shall not less 3°C above dew point, work in outside when it rain, any
visible moisture is on the surface, the abrasive is wet, when painting is being done
or coating is drying and curing in adjacent areas, and the lighting is poor and
equipment is in improper working condition, at night.
Th e finishing surface of blasting shall be Sa 2 1/2 according by ISO 8501-1
It is compared to the pictorialstandard.
The roughness value shall be 30 - 85 microns as per ISO 8503-2 or as per Product
Data Sheet (PDS). The roughness profile depth shall be checked using a
calibrated Elcometer roughness gauge or Keane-Tator profile comparator or press
O film tape.

7.2 Internal Coating Application

Internal Coating will be applied by airless spray

Total coating thickness is 400 microns.
The pipe surface temperature s hall always be minimum of 3°C above dew point.
Each coat shall be free from sags, runs, mud cracking, wringkling, fat edges, blisters,
pinhole, and heavy brush marks.
Title Inspection and Repair Coating

8.1 Inspection Procedure

 Report the ambient condition (Humidity, Dew Point) when the blasting and coating process
is performed.
 Testing Certificate of the abrasive material shall be provided.
 Visual surface cleanliness shall be checked as per ISO 8501-1 and spot checks for dust
level as per ISO 8502-3.
 Testing for salt contamination shall be performed using a SCM 400 meter. Refer to
Inspection & Test Plan (ITP) for acceptance criteria.
 The surface preparation and surface profile shall be evaluate and reported at the beginning
of each production shift.
 DFT measurement shall be performed on every coat and reported.
 DFT shall be checked as per SSPC-PA2 Standard Level 5.
 Visual Inspection of finish every coat shall be performed and reported.
 Specified Nominal Coating Thickness is 400 microns.
Adhesion test shall be conducted at first day application as per ASTM D 4541

8.2 Cut Back

Every pipe shall have the cut-back area prepared at both ends of the pipe. Any material that
has adhered to the pipe surface shall be removed by using an electrical wire brush. The
dimensions of the cut backs shall be as specified in the Inspection and Test Plan.

8.3 Repair of Coating

 Damage area caused by transportation and handling shall be repaired

 Degrease if necessary.
 Cleaning for spot damaged can be used SSPC SP-2 (Hand Tool Cleaning) and SSPC SP-3
(Power Tool Cleaning)
 Spot blast and clean the damage area back to with SA 2 1/2 and sweep blast the others if
over coating time has exceeded.
 Feather back the adjacent coating to minimum 25 mm and firm edge by sanding disc.
 Clean and apply at least 2 touch up coats with appropriate epoxy coating.
Title Marking

9.1 Marking

Coated Epoxy 400 µm [WO Coating]

Title Storage and Handling

10.1 Pipe Storage :

The pipe shall be stored under which do not have any effect detrimentally to its performance
characteristic.

1. Pipes with difference wall thickness shall be stacked at separate locations.

2. Storage area shall be well drained and free from any materials which may damage the
d pipe.
3. Pipes shall be stockpiled on a horizontal surface. They may be stockpiled in a
pyramidal shape.
Wood or other soft dunnage shall be used to support the bottom layer and to
eliminate contact of the pipe with any metallic surface.
4. The pipes shall be stached at maximum tiers as per manufacture recommendation
depand on the Diameter and thickness of pipes.

10.2 Handling :

Pipe shall be handled in a manner to prevent damage to pipe walls beveled ends and coatings.

1. Padding shall be provided when loading for transfer to any location.

2. Pipes shall be raised or lowered to or from stock pile, ground, barge or truck by end
hooks inserted in the ends of the pipe and carried by a wire rope with spreader bar
between the lines.
As alternative for coated pipe, sufficient strength of nylon sling can also be used.
3. Pipes shall not be dropped
4. Pipes shall not be rolled on a surface that can damage the pipe.
5. Pipes shall be picked up clear of the ground on deck of the barge and moved bodily,
and not dragged over the ground of the barge deck.
6. Pipe shall not be subjected to jars or impact.

Remarks:
 INSPECTION AND TEST PLAN
of
INTERNAL EPOXY PAINTING

Coating Type : Internal Epoxy Painting 400 µm

 COATING TYPE Doc. No. PAGE NO.:
INSPECTION AND TEST PLAN
INTERNAL EPOXY PAINTING 005/KPI/ITP/INC/III/2023 3 OF 3

NO PROCESS DESCRIPTION INSPECTION AND INSPECTED BY ACCEPTANCE REMARKS

(QC ACTIVITY) TESTING ITEM REFERENCE FREQUENCY CRITERIA
KPI CUST

1 Receiving Bare pipe / - Visual 005/KPI/MPS/INC/III/2023 Mill Certificate issued

Bare pipe condition
2 Material Certificates
Free from oil contaminant and surface
- check for trace oil & grease Sec. 6 Every Pipe M R by Pipe Manufacturer
defect
- Surface pipe check
Coating Material 005/KPI/MPS/INC/III/2023 Every Batch Certificate issued by
M R Standard Manufacturer
Abrasive Material Sec. 6 - Manufacturer

3 Surface Preparation, Each shift before start 0

Environmental conditions Max.85% RH; Min 3 C above dew point
production

Surface apperance check 005/KPI/MPS/INC/III/2023 Every Pipe ISO Sa 2 1/2

Sec. 7 M R
2
Salt Contamination Check One per day 2 microgram/cm

Roughness check One per day 30 - 85 microns

4 Coating Application
5 Inspection
Wet Film Thickness 005/KPI/MPS/INC/III/2023
Sec. 7
Humidity, Dew point & Pipe Temp. Min. 2 times a day
005/KPI/MPS/INC/III/2023
Visual Inspection & DFT Sec. 7 & 8
SSPC PA 2 Lv.5
Every Pipe As per material data sheet
M R
o
3 above dew point
- No sags, runs, mud cracking,
wringkling, fat edges, blisters, pinhole,
Every Pipe M R heavy brush marks and damage Report Inspection Issued
by KPI
- Thickness as perrequirement

Adhesion Test ASTM D 4541 First day application M R Min. 3 Mpa

005/KPI/MPS/INC/III/2023
End Cleaning (Cut Back Removal) Sec 8 Every Pipe M - Minimum 100 ± 10 mm from bevel end

005/KPI/MPS/INC/III/2023
Marking Sec 9 Every Pipe M - Clearly visible

005/KPI/MPS/INC/III/2023
Pipe Handling Every Pipe M - No Damage
Sec. 10
005/KPI/MPS/INC/III/2023
Storage Every Pipe M - Neat and Safe
Sec. 10

6 Mill Certificate Full Content - All pipe M R Certificate issued by KPI

Note :
M: Perform Inspection/test
R : Inspection/test record to be submitted for Review
I : Inspection/test record to be submitted for Inspection/Monitoring/ Randon Check
W: Witness of inspection test
H: Hold Point