Sheet 1 of 22

INDEX

1- INTRODUCTION .
2- DEFINITIONS .
3- REFERENCE STANDARDS AND CODES .
4- GENERAL PROPERTIES OF COATING MATERIALS .
5- PRODUCTION TESTING AND INSPECTION PLAN .
6- COATING APPLICATION AND TESTING PROCEDURE .
7- TEST CERTIFICATES .
8- COATING REPARABILITY AND REPAIR PROCEDURE .
9- PIPE MARKING .
10- MATERIAL RECEIVING AND STORAGE .
11- MATERIAL HANDLING .
12- PIPE TRANSPORTATION .
13- QUALITY CONTROL PLAN .

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 Sheet 2 of 22

1- INTRODUCTION
This specification provides requirements referring to the application, testing and repair of workshop side-
extruded polypropylene coatings ( 3 layer system ) on pipes surfaces .
The coating covered by this specification is suitable for the exterior protection of the steel pipe line which
applied to underground, surface networks designed to convey and distribute oil, gas or any other fluid .
The coating system shall have the following composition :
1) Layer of epoxy-based primer .
2) Layer of propylene-based polymeric adhesive .
3) Layer of polypropylene top coat .
The three system layer offer's the advantage of mechanical, chemical and electrical resistance of the
polypropylene in combination with excellent adhesion of epoxy to metal .

2- DEFINITIONS

• Coating system is the coating technique or process system consisting of the same type of coating material
• Side extrusion is a coating process whereby a hot extruded films of coating materials are wrapped around
the pipe in layers. The pipe is moved past the extrusion head in a spiral motion. The extruded coating films
are fused together to form a continuous adherent sheath around the pipe .
• Three layer system coating system consists of three layers which are primer, adhesive and outer layer
• Primer is the first coating layer ( the anti-corrosion layer ) which applied directly onto the pre-heated pipe
to improve the final adhesion of the final coating to the pipe surface .
• Adhesive the intermediate coating layer to improve the adhesion of between the primer and the outer layer
• Outer layer is the polypropylene layer .
• Coating thickness is understood to be the average thickness of the coating system ( summation of average
thickness for the applied PP, adhesive and primer layers ) .
• Unit of production is a set of pipes have or haven't the same DN and coated with the same coating system
and the same type of primer .
• Coating cycle any production process have the same DN and coated with the same coating system, and not
interrupted more than 12 hours .
• Special requirement is understood to be any requirements needed by the client ( not mentioned in this
procedure ) and require a special agreement between the two parties .

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 Sheet 3 of 22

3- REFERENCE INTERNATIONAL CODES AND STANDARDS .

This specification makes reference to the documents listed below, where relevant, all work shall be carried out
in accordance with the latest editions of these documents, including all revisions and addenda . Where conflict
occurs between the requirements of this procedure and reference codes and standards, the requirements of this
procedure shall apply .

z L’Asaociation Francaise de Normalisation .. ( AFNOR )

NF A 49-711 Steel Tubes - External with Three polypropylene Layers Coating - Application
by Extrusion .

z European Committee for Standardization .. ( CEN )

Pr EN 10286 Steel Tubes and Fittings for On and Off-shore Pipelines – External Three
Layer Extruded Polypropylene Based Coatings .
z Deutsche Institute fur Normung .. ( DIN )
DIN 30 678 Polypropylene Coatings For Steel Pipes .

DIN 53 455 Testing Of Plastics; Tensile Test .

DIN 53 505 Testing Of Rubber, Elastometer And Plastics; Shore Hardness A And D Testing .

z American Society for Testing and Materials .. ( ASTM )

ASTM D 543 Standard Practices For Evaluating The Resistance Of Plastics To Chemical Reagents
.
ASTM D 638 Standard Test Method For Tensile Test Of Plastics .

ASTM D 1238 Standard Test Method For Flow Rates Of Thermoplastics Extrusion Plastometer .

ASTM D 2240 Standard Test Method For Rubber Property- Durometer Hardness .

ASTM G 8 Standard Test Method For Cathodic Disbonding Of Pipe Lines Coatings .

z International Standard .. ( ISO )

ISO 8501-1 ( SIS 05 59 00 ) Pictorial Surface Preparation Standards For Painting Steel Surfaces .

ISO 8502-4 Guidance On The Estimation Of The Probability Of Condensation Prior To

Paint Application

ISO 1133 Plastics - Determination Of The Melt Mass-Flow Rate ( MFR ) And Melt Volume
Flow Rate ( MVR ) Of Thermoplastics .

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 Sheet 4 of 22

4- GENERAL PROPERTIES OF COATING MATERIALS .

PRIMER
1- Liquid or powder epoxy primer, applied as anti-corrosion layer for coating of steel pipe line by
polypropylene 3 layer system [Epoxy primer + Adhesive co- polymer + polypropylene ] .
2- Possess good similarity and compatibility with the polymeric adhesive, and react with it, so that the
reciprocal anchorage is increased.
3- Show high capability to minimize cathodic disbondment when steel pipe is subjected to negative
polarization as per ASTM G 8 standard [ the maximum radius of disbonding ≤ 10 mm. ] .

ADHESIVE
1- Propylene co-polymer suitable for 3 layer coating system .
2- Show high affinity and strong bond with polypropylene layer ( top coat layer ), high affinity and stro-
ng bond with primer layer, and assure a strong bond with primer (equal to or higher than that with PP ) .
3- Achieve with other layers, at least, a minimum peel-off resistance as per NF A 49-711 standard .
4- Achieve with other layers a minimum cathodic disbonding when steel pipe is subjected to negative
polarization as per ASTM G 8 standard [ the maximum radius of disbonding ≤ 10 mm. ] .
5- Possess the following properties ...

PROPERTY UNIT TEST METHOD VALUE

Density g / cm3 ASTM D 1505 0.860 - 0.905
Melt Flow Index g / 10 min. ASTM D 1238 . 2 - 10
230 c ° / 2.16 Kg
Tensile Strength at Break kg / cm2 ASTM D 638 > 150
Elongation at Break % ASTM D 638 > 400

POLYPROPYLENE
1- Fully stabilized PP, in granular state, contains additives for stability and resistance to weather
conditions and its combined action of oxygen, sunlight and temperature .
2- Designed for coating of steel pipe, three layer system, where it is side-extruded directly in multiple
wraps to build-up the requested thickness .
3- Compatible with other layers and show with them, at least, a minimum peel-off resistance as per NF A
49-711 standard .
4- Working temperature for coated pipe is ( - 20 c ° to + 110 c ° ) .
5- Possess the following properties ...

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 Sheet 5 of 22

PROPERTY UNIT TEST METHOD VALUE

Density g / cm3 ASTM D 1505 0.895 - 0.905
Melt Flow Index g / 10 min. ASTM D 1238 0.5 – 4.0
230 c ° / 2.16 Kg
Hardness, shore D ASTM D 2240 ≥ 60
Vicat Softening Point c° ASTM D 1525 > 140
Tensile Strength at Break kg / cm2 ASTM D 638 > 190
Elongation at Break % ASTM D 638 > 400

5- PRODUCTION TESTING AND INSPECTION PLAN .

During production application of the coating all quality control activities ( needed to ensure that the coating is
being applied in accordance with the approved specification ) shall be carried out .

5.1 PIPE SURFACE PREPARATION

QC. Supervisor shall perform the following parameters at the frequencies indicated in table ( 1 ) .
! Climatic conditions ( prevailing temperature, humidity, dew point ) .
! Surface cleanliness . ! Surface profile .

5.2 PRE-HEATING TEMPERATURE

QC. Supervisor shall perform the preheating temperature of the coating materials at the frequencies indic-
ated in table ( 1 ) to insure application within the manufacturer recommendation limits .
! Pipe temperature . ! Polypropylene temperature .
! Total temperature . ! Primer temperature .

5.3 COATING SYSTEM THICKNESS

QC. Supervisor shall perform and verify that the total coating thickness meet the requirements mentioned
in 6.4.2, at the frequencies indicated in table ( 1 ) .
! Thickness of primer layer . ! Thickness of adhesive layer .
! Average coating thickness .

5.4 COATING CONTINUITY ( HOLIDAY DETECTION )

QC. Supervisor shall verify that the coating system shall be holiday detected 100 % at voltage set at 10
Kv per millimeter of nominal thickness of coating and not exceeding 25 Kv .

5.5 IMPACT RESISTANCE TEST

QC. Supervisor shall perform the impact resistance of the polypropylene at the frequencies indicated in
table ( 1 ) .

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 Sheet 6 of 22

5.6 ADHESION ( PEEL OFF ) TEST

QC. Supervisor shall perform the peel-off resistance of the coating system at the frequencies indicated in
table ( 1 ) .

5.7 MELT FLOW RATE

QC. Supervisor shall perform the melt flow rate of the polypropylene and adhesive for the new and extru-
ded material at the frequencies indicated in table ( 1 ) .

5.8 INDENTATION RESISTANCE TEST

QC. Supervisor shall perform the indentation resistance of the polypropylene at the frequencies indicated in
table ( 1 ) .

5.9 ULTIMATE ELONGATION

QC. Supervisor shall perform the ultimate elongation of the polypropylene at the frequencies indicated in
table ( 1 ) .

5.10 TENSILE STRENGTH AT YIELD AND AT BREAK

QC. Supervisor shall perform the tensile strength at yield and at break of the polypropylene at the
frequencies indicted in table ( 1 ) .

5.11 HARDNESS - SHORE D

QC. Supervisor shall perform the hardness shore D of the polypropylene at the frequencies indicated in
table ( 1 ) .

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 Sheet 7 of 22

TABLE ( 1 ) THE MINIMUM QUALITY CONTROL TESTS FREQUENCY

FREQUENCY

TEST At Production At Regular Production

Start
1) Ambient temperature 1 test test / 4 hrs .
2) Relative humidity 1 test test / 4 hrs .
3) Dew point 1 test test / 4 hrs .
4) Surface cleanliness first 3 pipes test / 25 pipes
5) Surface profile first 3 pipes test / 25 pipes
6) Pipe temperature first 5 pipes test / 4 hrs.
7) Polypropylene temperature 1 test test / 4 hrs .
8) Adhesive temperature 1 test test / 4 hrs .
9) Primer temperature 1 test test / 4 hr .
10) Thickness of primer layer 1 test XXXX
11) Thickness of adhesive layer 1 test XXXX
12) Total coating thickness. first 3 pipes test / 25 pipes
13) Continuity-holiday- control 100 %
14) Peel-off test first 3 pipes test / 25 pipes
15) Impact test first 3 pipes test / 50 tons of PP or at new batch No.
16) Melt flow rate ( for PP. &
Adhesive )
- New
material test / day or at new batch No.
- Processe
d
material
17) Tensile strength at Yield and Break 1 test test / 50 tons of PP or at new batch No.
18) Ultimate elongation 1 test test / 50 tons of PP or at new batch No.
19) Hardness, Shore D 1 test test / 50 tons of PP or at new batch No.

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 Sheet 8 of 22
20) Indentation Resistance 1 test test / 50 tons of PP or at new batch No.

6- COATING APPLICATION AND TESTING PROCEDURE .

6.1 COATING SYSTEM

The coating of polypropylene three layer system is performed as shown in figure 1 …
1- Pipe pre-heating and surface preparation ( blast cleaning ) .
2- Once the blasted pipe is accepted, it conveyed to the coating line where it’s induction
heated .
3- Application of the epoxy layer .
4- A bond breaker material is applied over length as defined in 6.3 to facilitate the cut back removal .
5- Application of the polymeric adhesive material ( copolymer ) by side-extrusion .
6- Application of the polypropylene layers by side-extrusion , then a hydraulically operated silicon
pressure roller is engaged to smooth the coat surface and improve the adhesion performance .
7- The coated pipe enters cooling tunnel to be cooled down .

( fig. 1 )
6.2 PIPE SURFACE PREPARATION
• Before blast cleaning and application of the coating system, the pipe surface shall be free of all surf-
ace contaminants . Oil, grease, and other contaminants shall be removed wiping the contaminated
area by suitable solvent, detergent or potable water .
• All pipes should be visually checked for moisture, if the pipe looks damp, the pipe must be preheated
to at least 45 c° to eliminate the moisture , the pipe surface should be at least 3 c° above the dew point
temperature prior to coating .
• The pipe surface shall be cleaned by shot/grit blast cleaning technique to achieve the requirements of
SA 2 ½ Very thorough blast cleaning , SIS 05 59 00 ( ISO 8501-1 ) , and surface profile has a peak-
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 Sheet 9 of 22
to-valley 40 - 90 µm .

• Prior to coating, the pipe surface shall be cleaned from all dust and abrasives which still remain on the
exterior surface of the pipe by using mechanical nylon brush .
• Blast cleaned pipes shall be coated within the following maximum times and any pipe delayed beyond
this period shall be re-blasted and re-inspected .

% RH TIME
> 80 2 hrs.
70 < RH ≤ 80 3 hrs.
≤ 70 4 hrs.

< Q.C TEST >

1- QC supervisor shall verify that the pipe surface cleanliness meets the requirements of SA 2 ½ ( Very
thorough blast cleaning), by visual comparison with photographs in SIS 05 59 00 standard ( allowance
must be made for the fact that differences in color can occur due to the type of grit used, spherical grit,
for example, results in a slightly darker surface than that in the photographs in SIS 05 59 00 )
2-QC supervisor shall verify the pipe Surface profile has a peak-to-valley 40 - 90 µm, using Testex tape
( or equivalent ) in accordance with the following procedure :
- Zero the dial micrometer ensuring the flat contact points are clean .
- Remove paper backing from Testex tape and stick Testex tape to the surface to be measured .
- Rub the Testex tape paste into the troughs using a blunt instrument, until the peaks can be seen
butting up to the transparent plastic .
- Remove the Testex tape from the surface and measure the overall thickness with the dial micro-
meter .
- Deduct 50 µm for the plastic from the reading to obtain the amplitude ( surface profile ) .
3-Production personnel shall be inspect the blasted pipes for all surface defects ( silvers, scabs, dents,
..etc ) which shall be marked .
- All marked defects shall be brought to the attention of client representative to approve the action
shall be taken by Petrojet or to provide the corrective action .
- Grinding or repair in the area thus treated shall not reduce the pipe wall thickness below the specif-
fication requirements or the API 5L standard .
- For repaired area more than 100 cm2 the pipe shall be re-blasted and re-inspected .

6.3 CUT BACK

The coating, at pipe ends shall be cut back over length defined in the table below ( unless otherwise is
Specified ) , at cut backs the PP and Adhesive layers shall be removed , the epoxy primer layer will
left as temporary protective layer .

Pipe diameter D Cut Back ( mm )

D up to 10" 110 ± 20
> 10" up to 20" 130 ± 20
> 20" up to 32" 150 ± 20

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 Sheet 10 of 22
> 32" 170 ± 20

6.4 VISUAL INSPECTION

Production personnel shall be inspect the coated pipes 100 % to insure that …
1- The coating free from blisters .
2- Pipe temperature after cooling shall be ≤ 100 c° .

6.5 PRE-HEATING TEMPERATURE

QC. Supervisor shall perform the pre-heating temperature of the coating materials as following ..
1- Pipe temperature

! QC supervisor shall verify the pipe surface temperature is between 120 c° - 220 c° ( or as
the primer manufacturer recommendations ) using the TEMPIL STICK temperature ind-
icating crayons as follows ..
6 Stroke heated surface with the crayon, a liquid smear will show at the specified tempe-
rature .

2- Polypropylene / Adhesive temperature

! QC supervisor shall verify the temperature of both extruded polypropylene and adhesive
material is in the recommended application temperature using one of the following methods
6 METHOD Ι ( Destructive test )
While the material is being extruded prior to coating application using probe type thermo-
meter .
6 METHOD II ( Non-Destructive test )
While the material is being extruded prior to / or during coating application using portable
pyrometer .

3- Primer temperature

! QC supervisor shall verify the primer material is in the recommended application tempe-
rature .

6.6 COATING THICKNESS

6.6.1 Epoxy primer thickness : the thickness shall be 50 ± 20 µm. .

6.6.2 Adhesive thickness : the thickness shall be 150 ± 25 µm .
6.6.3 Coating thickness :
The total coating thickness is the summation of the thickness of individual layers .
The coating thickness is relevant to the pipe diameter as specified in the following table

Pipe Diameter Total Coating Thk.

( in ) ( mm )
up to 4" 1.2
> 4" up to 10" 1.5
> 10" up to 20" 1.8
> 20" up to 30" 2.0
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 Sheet 11 of 22
≥ 32" 2.5
1) The thickness given in this table can be relaxed by 15 %For welded
pipes ( longitudinal or spiral weld ), at the weld reinforcement .

Note 1 : For concrete coating over PP ( special requirement ) , the PP surface shall be undulated to ob-
tain a reliable cohesion with the outside concrete cladding . The difference in thickness between
bottoms and crests of undulations shall be has an average ≥ 0.4 mm .
< Q.C TEST >

The thickness of the coating system shall be measured using thickness meter gauge calibrated at least
once per shift . Calibration shall be carried out as following ..
1- Choose a plastic shim of a thickness close to the thickness you expect to fined .
2- Place the shim on an non-coated blasted pipe surface .
3- Measure the thickness of the shim, if any deviation is detected adjust the thickness
meter gauge to the thickness of the shim .

Primer / Adhesive Layers Thickness

At the start of each coating cycle, production personnel shall run one test pipe to verify the
DFT of the primer and adhesive layers as following ..
1. A series of 12 individual measurements shall be carried out on painted panel .
2. The maximum and minimum readings shall not be considered, the
arithmetical mean is
calculated for the remaining 10 measurements to satisfy the thickness given in 6.6.

Coating Thickness
For quality control purposes the thickness of the coating system shall be measured as following
! A series of 12 individual measurements shall be carried out on each pipe to be inspected,
the measurements shall be regularly distributed along 3 transverse sections of the tested pipe .
! At each section the thickness shall be measured at 4 positions, equally spaced around the
circumference of the pipe .
! When a weld seam is visible, one measurement per section shall be added and executed on
the top of the weld seam .
! The maximum and minimum readings shall not be considered, the arithmetical mean is calc-
ulated for the remaining 10 measurements to satisfy the thickness given in 6.6.3 .

6.7 COATING CONTINUITY ( holiday detection )

The coating system shall be holiday detected 100 % , the test voltage shall be set at 10 Kv per mill-
imeter of nominal thickness of coating and not exceeding 25 Kv, The maximum no. of allowed
holidays is 5 localized or scattered holidays per coated pipe .
The holiday test shall be carried out using an adjustable high voltage tester having an audible and
visual alarm, the scanning electrode shall consist of a metal brush or coil spring or coil brush,
fitting the diameter of the coated pipe .
The test voltage shall be set at 10 Kv per millimeter of nominal thickness of coating , The detector
shall be calibrated at start of each coating cycle as follows :
At least 5 holes of around 1 mm diameter must be made in the coating, down to the
pipe metal, with a needle; these holes must be spaced by about 10 cm .

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 Sheet 12 of 22
The detector is switched on ,the voltage shall be set at 10 Kv per millimeter of nominal
thickness of coating and the electrode is set to pass the test holes .
A spark discharge must be correspondence with every hole .

6.8 ADHESION ( PEEL-OFF ) TEST

The adhesion of the coating shall be determined by measuring the peel-off resistance, the minimum
force required to lift the coating shall be as indicated in the table below …

Force at 50 C° ± 2 C° Force at 90 C° ± 2 C° Force at 110 C° ± 2 C°

10 N / mm 8 N / mm 4 N / mm

< Q.C TEST >

The adhesion of the coating shall be carried out by one of the following methods …
METHOD I Using Suspended weights ( fig. 2 ) , in which a strip of coating with width of 5 cm.
shall be manually peeled off at an angle of 45 ° to the pipe surface where a weight of
10 N/mm width is suspended .
The time ( in minutes ) required to peel of the coating with a pulling rate of 10 mm
per minute ≥ 0.4 x D ( D is the pipe diameter in mm ) .
METHOD II Using a Tensile machine ( fig. 3 ) , in which a strip of coating with width of 5 cm. shall
be peeled off at an angle of 90 ° to the pipe surface with a pulling rate of 10 mm per
minute .
6.8.1 Any pipe that exhibits a peel off below the required value shall receive 2 additional peel tests
to verify the accuracy of the first test .
6.8.1.1 If the 2 additional peel tests meet the required value, the pipe is
accepted .
6.8.1.2 If the 1 out of the 2 additional peel tests is below the required value, the pipe is rejec-
ted then 5 previously coated pipes and 5 new coated pipes shall be tested, if below the
required value is detected, the production line shall stopped until the defect is determ-
ined .
6.8.2 To minimize repair areas, it is preferred to do the test at the cut back area .
6.8.3 The continuity of the coating must be restored by repairing the tested areas applying repair
spot patch .

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 Sheet 13 of 22

FIG. 2 FIG. 3

6.9 IMPACT RESISTANCE TEST

The impact resistance of the polypropylene coating system shall be tested at temperature ( 25 ± 5 C° )
The coating shall have a minimum impact resistance value , E = ( 10 x ϕ ) J / mm coating .

< Q.C TEST >

- QC supervisor shall perform the impact test according to NF A 49-711 standard and carried out as
following …
1- A minimum of 30 points shall be selected on the surface of the tested pipe, the distance between
two impact points shall be at least 30 mm .
2- An impact body with hemispherical steel head with diameter of 25 mm shall
be dropped onto the pipe surface from approximately 1 meter height .
3- This described body shall produce an impact energy, E, equal to ( 10 x ϕ ) J
per mm of coating thickness, with tolerance of 5 % .

DN ( mm ) ϕ
Up to 76.1 0.70
76.1 to 219.1 0.85
D ≥ 219.1 1.0
• The factor ϕ accounts for the
curvature of the pipe .

4- The coating is accepted if the impact energy has not cause any perforation
inspected with holiday detector .

6.10 INDENTATION RESISTANCE TEST

The indentation resistance of the polypropylene material shall be tested according to NF A 49-711
standard , The maximum indentation resistance shall be as following …

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 Sheet 14 of 22
at 20 C° ± 2 C° at 110 C° ± 2 C°

0.1 mm 0.4 mm

< Q.C TEST >

- QC supervisor shall perform the indentation test according to NF A 49-711 standard and shall be carried
out as following …
1- A sample of PP of thickness ≥ 2 mm shall be taken from a pipe where neither
the primer nor the adhesive have been applied .
2- The sample shall be subjected to an indentor with flat face and 1.8 mm
diameter , The total mass of the indentor assembly shall be 2.5 kg .
3- The indentor shall be slowly and carefully lowered on the test sample , the Zero
( T0 ) reading set at penetometer within 5 sec. then after 24 h, the final reading
( T ) of the penetometer is recorded .
The indentation depth is given by the following equation :-
Indentation ( mm ) = T - T0

6.11 TENSILE STRENGTH AND ULTIMATE ELONGATION TEST

The tensile strength and ultimate elongation ( elongation at break ) of the polypropylene material
shall be as following :
- TENSILE STRENGTH AT YIELD ≥ 150 Kg/cm2
- TENSILE STRENGTH AT BREAK ≥ 190 Kg/cm2
- ULTIMATE ELONGATION ( elongation at break ) ≥ 400 % .

< Q.C TEST >

- QC supervisor shall perform one tensile and elongation test according to the standards ASTM D
638 and DIN 53 455 and shall be carried out as following …
1- A sample of PP of thickness ≈ 2 mm shall be taken from a pipe where neither
the primer nor the adhesive have been applied .
2- The sample shall be Dumbbell shape No. 4 .
3- Determine the cross-section of the test sample ( cm2 ) .
4- The sample shall be hold between the tensile grips .
5- The grips shall be moved away at constant speed = 50 mm / min.
6- Record the tensile force at the yield point, tensile force at the break point and
the extension at break point .
7- Calculation and expression of results
Tensile strength at yield ( kg / cm2 ) = F0 /A
Tensile strength at break ( kg / cm2 ) = F/A
Elongation at break ( % ) = ∆L / L . 100
where
F0 = is the tensile force at yield point ( kgf ) .
F = is the tensile force at break point ( kgf ) .
A = is the cross-section of the test sample ( cm2 ) .
L = is the initial gauge length of the test sample ( mm )
∆L = is the increase in the sample length between gauge marks ( mm ) .
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 Sheet 15 of 22

6.12 DUROMETER HARDNESS - SHORE D

The hardness shore D of the polypropylene material shall be ≥ 60 shore D .
< Q.C TEST >

QC supervisor shall perform one hardness test according to the standards ASTM D 2240 and DIN
53 505 and shall be carried as following …
1- A sample of PP of thickness ≈ 4 mm shall be taken from a pipe where
neither the primer nor the adhesive have been applied .
2- Place the sample on the steel plate of the tester .
3- The sample shall be subjected to a durometer to which an additional weight
of 4 kg is attached so, the total mass of the assembly shall be 5.0 kg .
4- The durometer shall be placed, without shock, on the sample making a firm
contact with it .
5- The hardness shore D shall be read-off 3 sec. after the presser foot of the
durometer has made complete contact with the sample .

6.13 MELT FLOW RATE

QC supervisor shall perform the melt flow test ( M.F.R ) on the new and extruded polypropylene
and adhesive materials .
< Q.C TEST >

QC supervisor shall perform the melt flow rate test according to ASTM D 1238 and ISO 1133 stan-
dard and shall be carried as following …
1- A sample of new or processed material shall be taken .
2- Heat the sample on extrusion plastometer tester according to test condition specified in
material data sheet ( 230 c°/ 2.16 Kg )
3- The melt flow rate ( MFR ), expressed in grams per 10 minutes and is given by the following
equation :-
MFR ( θ, mnom ) = tref . m / t
where
θ = is the test temperature, C° .
mnom = is the nominal load, Kg .
tref = is the reference time ( 10 minutes ), 600 sec.
m = is the average mass of the cut-offs, gr. .
t = is the cut-off time interval, sec.
6.13.1 New MFR = shall be within ± 15 % of the material certificate of analysis or material data sheet .
6.13.2 Extruded MFR = shall be within ± 20 % of the New MFR .

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 Sheet 16 of 22
7- test certificates

Test certificate shall be submitted to certify the following properties of the coating, Test certificate is a
fact test reports of tests performed annually at PETROJET, Quality control laboratories .

7.1 CATHODIC DISBONDING RESISTANCE TEST

The coating shall show good resistance to cathodic disbondment when subjected to a potential of – 1.5 V,
in a 3% NaCl electrolyte solution as per ASTM G 8 and NF A 49-711 standards at the following test
conditions …

at 25 C° ± 3 C° at 40 C° ± 3 C° at 65 C° ± 3 C°

28 days 7 days 2 days

Max. Disbonding Radius ≤ 10 mm

7.2 STABILITY TO THERMAL AGING

The PP material shall withstand thermal aging without deterioration, The stability shall be determined
from the change that the material subjected to temperature of 150 c° shows from the unexposed material
in respect to MFR . The MFR of the subjected material for duration 2000 hrs must remain within ± 50 %
( as per NF A 49-711 standard ) .

7.3 CHEMICAL RESISTANCE

The PP material shall withstand alteration when immersed in chemical reagents ( as per ASTM D 543
standard ) , The stability shall be determined from the change that the material immersed to chemical
reagents shows from the non immersed material in respect to tensile strength at break , elongation at
break and MFR . The figures of the immersed material must remain within ± 25 % from original
figures after 60 and 90 days immersion period in the following chemical reagents of the test are :
- 5 % and 10 % in volume of Sodium Hydroxide .
- 5 % and 10 % in volume of Sodium Chloride .
- 1 % and 10 % in volume of Nitric Acid .

7.4 STABILITY TO AGING BY ULTRAVIOLET RAYS

The PP material shall withstand UV radiation without deterioration, The stability shall be determined
from the change that the material exposed to the Xenon lamp shows from the unexposed material in
respect to elongation at break or MFR .
The elongation at break of the exposed material for duration 800 hrs, must not less than 75 % from the
original figures (as per NF A 49-711 standard ) , The MFR of the exposed material for duration 800 hrs,

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 Sheet 17 of 22
must remain within ± 25% (as per NF A 49-711 standard ) .

8- COATING REPAIRABILITY AND REPAIR PROCEDURE

8.1 COATING REPAIRABILITY

In theory, no coating defect or damage should ever be found during approval testing of the coating, but
at practical level it can not however be excluded, so .. some defects may occasionally show up in pipe
coating . Taking the above into consideration , the following repair methods are applied for
polypropylene coated pipe damaged during storage, transportation and/or field construction of the
pipe line .
8.1.1 For local defects ( scratches, cuts, dents, … etc. ) of any dimension and any quantity where the
defect not reach the metal surface, no repair is required .
8.1.2 For same defect mentioned above, having a linear dimension greater than 50 mm and not greater
than 100 mm where the defect reach the metal surface, these defects could be repaired using
repair spot patch .
8.1.3 For defects , having a linear dimension greater than 100 mm and not greater than 150 mm
where the defect reach the metal surface , these defects could be repaired using heat shrink
sleeve .
8.1.4 The maximum level for repair of coating ( exclude repair due to QC tests ) is 5 spot
patches + 1 heat shrink sleeves .
8.1.5 The quality of the repair shall be examined and tested for appearance and holidays. Each repair
shall be visually inspected for …
- The surface of repaired coating shall be smooth, and free of folds or bubbles .
- Holiday detection shall be performed on each repair using a maximum voltage of 10 Kv / mm .

8.2 REPAIR PROCEDURE

8.2.1 APPLICATION OF REPAIR MATERIAL BY SPOT PATCH METHOD

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 Sheet 18 of 22
1- Remove rust or other contaminants, if any, with a hand brush .
2- Preheat the steel surface of the damaged part .
3- Apply a piece of sealant material smaller than the size of the damage on the steel surface .
4- Heat the sealant then extending the hot sealant with trowel and Apply a piece of sealant material more
and more to mold the damaged part with a sealant more or less thicker than the polypropylene coating
5- Cut a piece of the patch sheet larger by 5 to 10 cm than the damaged part .
6- Cut the corner of the patch piece .
7- Apply the patch piece centering in the damaged part .
8- Heat from the center to each edge .
9- Tapping from the center to the edge to drive away the trapped air .
10- Heat again and tapping again .
11- Immediately after heating the repair patch, press all the edges by finger to get an adequate adhesive
strength .

8.2.2 APPLICATION OF REPAIR MATERIAL BY SHRINKABLE SLEEVE METHOD

1. Wrap the JOINT COVER around the pipe keeping the clearance between the JOINT COVER and the
pipe surface about 1 inch and make an overlap to the JOINT COVER about 4 inches .
2. Preheat the overlapped area of the JOINT COVER then cover it with heat seal tape.

3. Heat the heat seal tape and tapping from the center to the edge to drive away the trapped air .
4. Heat and shrink the JOINT COVER from the center toward the edges of the JOINT by moving the
torch up and down along the circumferential direction .
5. Apply a profile roller from the center to the side edge to drive away the trapped air .
6. Re-Heat and shrink the JOINT COVER from the center toward the edges of the JOINT by moving
the torch up and down along the circumferential direction .
7. Heat shrinking process is completed when the adhesive flows out of all the edge of the JOINT
COVER .

9- PIPE MARKING

- All identification data ( heat number, pipe number and pipe length ), if available, shall
recorded before surface preparation .
- After coating process pipe number, pipe length and Petrojet serial number shall be recorded
on the external surface of the pipe .
- All identification data ( heat number, pipe number, pipe length and Petrojet serial number )
shall be recorded on the daily pipe tally sheet .
- For pipes have the same DN but differ in wall thickness, each wall thickness shall marked
with special code color .

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 Sheet 19 of 22

10- MATERIAL RECEIVING AND STORAGE

10.1 RECEIVING
10.1.1 COATING MATERIAL

10.1.1.1 All received material is inspected for the following :

correct material type ( as per Petrojet order or client Rep. )
correct components ( as per material data sheet )
correct labeling on each package, unit or container ( as per material data sheet )
10.1.1.2 All accepted material shall be entered onto the material inventory and stored in the proper
warehouse.
10.1.1.3 All unacceptable material shall be segregated from acceptable materials .

10.1.2 BARE PIPE

10.1.2.1 All received pipes are inspected for the following :

- Dents, Pitting and Damaged bevels .
- Contamination or residue on pipe that would result in additional pre-cleaning materials/man-
hours and time delay prior to surface preparation .
- Pipe interior and exterior “ Rust grade “ in accordance with SIS 09 59 00 .
- Manufacturers identification marks ( heat number, pipe number and pipe length ) .
- Pipe diameter and wall thickness .
- Quantity of pipes .
10.1.2.2 Rejected pipe, or that dose not comply with the shipping documents shall be segregated from
acceptable pipes and reviewed by customer Rep.
10.1.2.3 Pipe that comply with the shipping documents but is damaged or contaminated shall be segr-
egated until reviewed and approved by customer Rep.
10.1.2.4 Approved pipe shall be coated in accordance to the approved procedure .

10.2 STORAGE
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 Sheet 20 of 22

10.2.1 COATING MATERIAL

10.2.1.1 Coating material shall be stored out of direct sun light, kept dry indoors .
10.2.1.2 A system of material rotation shall be employed to assure that material received first are used
first and the correct batch number is withdrawn. No material shall be used if the manufactu-
rers shelf life has expired .
10.2.2 PIPES STACKING ARRANGEMENT
The following table shows the maximum number of layers for storing bare and coated pipes, the table
applies to all types of steel pipes and wall thickness, for safety reasons for pipes of any diameter the
maximum height for stacking pipes ( excluding beam height ) shall be less than 4.0 meters .
The pipes shall be stacked off ground on sandy prepared beams .

DN Permissible No. of Layers

Up to 8" 15
10" to 14" 10
16" to 20" 7
22" to 28" 5
30" to 36" 4
≥ 36" 3

11- MATERIAL HANDLING

11.1 COATING MATERIAL
Coating material shall be handled in a way that minimize damage to the container or package prior to use

11.2 BARE PIPE

11.2.1 Bare pipe shall be carefully removed from the truck using a crane and stacked on sand beams.
11.2.2 Fork lift shall carefully remove the pipe from the storage yard and with equal care place the pipe
on the shot/grit blast machine incoming rack .

11.3 COATED PIPE

11.3.1 A properly prepared fork lift shall be used to transport the coated pipe to the storage area provided
they have padded forks. Fork lift shall not be used to load coated pipe onto trucks .
11.3.2 The coated pipe may be handled using crane. The pipe can be directly loaded from the outgoing
rack onto the trucks or to the storage area .

12- TRANSPORTATION
12.1 COATED PIPE
- Only approved pipes shall be loaded onto trucks ( may directly after coating from the outgoing rack )
or from the storage area using a crane.
- When available, wooden beams with covered with padding shall be used to separate the pipes from
the truck base .
- Pipes shall not be stacked onto the truck any higher than 2.0 meters or any higher than the law perm-
its or is safe .

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 Sheet 21 of 22
- The loaded pipes shall not exceed the maximum allowable weight for the truck or by law or is safe .
- The loaded pipes shall be tied down using Nylon straps or other means to avoid damage to the coa-
ting during transportation .

13 - QUALITY CONTROL PLAN

The scope of this plane is to list all activities relevant to coating process and to define the level of
intervention at such activities by client or his representative .

13.1 ABBREVIATIONS
C = CLIENT
TP = CLIENT REPRESENTATIVE OR INSPECTOR .
P = PETROJET .
H = COMPULSORY PRESENCE, the production cycle is tied to this presence .
R = REVIEW AND CHECK of the certificate / or documents relevant to the activity .
W = NOT COMPULSORY PRESENCE , in the event of the absence of ( C and / or TP )
PETROJET is authorized to continue all activities .

13.2 QUALITY PLAN

ITEM ACTIVITY PARTIES

P C TP

1 Review And Approval of The

Coating Procedures ( PTJ-PP-WP-04
) H H R

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 Sheet 22 of 22

2 Review / Approval of Coating

Materials . H H R

3 Checks During Production

1- Climatic conditions
Prevailing temperature .
Relative humidity H R W
Dew point

2- SURFACE PREPARATION
Cleanliness control .
H R W
Surface profile .

3- COATING MATERIAL TEMPERATURE

Pipe pre-heating temperature .
Epoxy primer application
temperature .
Adhesive application temperature H R W
.
Polypropylene application
temperature .

ITEM ACTIVITY PARTIES

P C TP

4-QUALITY CONTROL TESTS

Thickness check of the single
layer .
Total thickness check .
Peel-off test .
Continuity ( Holiday Detection )
of coating H R W
M.F.R
Resistance to impact .
Resistance to penetration .
Hardness test .
Tensile strength test .
Elongation test .

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 Sheet 23 of 22

4 Test Certificates
Cathodic Disbonding Resistance
Test .
Stability to Aging by Ultraviolet
H R R
Rays
Stability to Thermal Aging .
Chemical Resistance .

5 Repair of Defected Pipe . H R W

Transportation of Coated Pipes

6 H R W
.

All ( W ) points consider hold points at project start up.

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