MPS No:TJXY-MPS-Z21-0105-2

TIANJIN XINYUE INDUSTRIAL AND TRADE CO.,LTD.

Coated with three layers of polyethylene (PE)

Manufacturing process specification

Implementation Standard:DIN30670

Coating Implementation Standard DIN30670

3LPE Coating thickness Min 2.7mm
Pipe Implementation Standard API 5L PSL1 X52

Pipe Size 273.1*15.09*11000~12000 (SMLS)

Complied Approved
Edition Date Description Checked by Verified by
by by
01 2021-01-05 Gao Liang Xiao Yang Li Jiaxian Liu Fuming
This manufacturing process specification is made according to the DIN30670 standard and the
quality management system of Tianjin Xinyue Industrial and Trade Co.,Ltd.
The content of this manufacturing process specification accords with the requirements of the
DIN30670 standard and the quality management system of Tianjin Xinyue Industrial and Trade
Co.,Ltd.
This manufacturing process specification contains appendix A, B, and C.
1 Introduction

1.1 Scope
The manufacturing process of the rules and regulations of the project with three layer
polyethylene coating related manufacturing technology requirements, and the definition of the
steel pipe anti-corrosion protection with three layer polyethylene coating, inspection, repair,
handling and storage requirements.

1.2 Definition
Project The 3LPE project
Coating party Tianjin Xinyue Industrial and Trade Co.,Ltd.
Customer
TPI The third party inspector who represents the customer
3LPE Three layers of polyethylene coating,
FBE Fusion bonded epoxy coating
Heating Gas heating
Inspector Representatives of the quality control department, whose function is to witness, verify
and record one or more aspects of the processes, and ensure the processes conform to the
specified minimum requirements. In this paper, the QC inspector should be understood as "quality
control inspector".

1.3 Coating system introduction

The coating system described in this paper should use polyethylene (high temperature type) as the
main coating material; the three-layer polyethylene layer is composed of epoxy powder, adhesive
and polyethylene, can work in the 80℃environment for a long time. T

2. Normative references
The following standards referenced in this specification become the standards of this
specification. For dated references, all the subsequent amendments (not including content
correction) or revised editions are not suitable for this specification. However, it is encouraged that
all parties who have reached an agreement according to this specification discuss whether can use
the latest version of these standards.

ISO 9001
DIN30670
API
ASTM
3. External polyethylene coating manufacturing process specification

3.1 Manufacturing, inspection and test flow chart of the three-layer polyethylene coating
(Appendix A)

3.2 Product identification and traceability

3.2.1 Raw material identification and traceability

The unique identification of the raw materials should be manufacturer, model and batch number,
please see the suggested content in appendix B.

b. Raw material conveying operator is responsible for conveying the qualified internal lining
material to production field, and storing the materials respectively according to the manufacturers,
types and batch numbers. Raw material feeding operator should classify the materials according to
the manufacturers, types and batch numbers, then use them in turns. Do not mix the materials with
different manufacturers, types and / or batch numbers.

c. In the production process, raw material feeding operator should record the manufacturer, type
and batch number of the coating material which has been consumed in order to achieve the
purpose of traceability.

3.2.2 Product identification and traceability

a. Pipe number will be the only product identification. The product traceability should be achieved
by checking the pipe numbers and production inspection record.
b. In receiving inspection, quality controller should check all kinds of information carefully, such
as the type of steel, pipe diameter, pipe number, batch number, pipe length and so on, and compare
the information with the information on the receiving note. The pipes with the same number, no
number or vague number should be rejected.
c. In the production process, no one is allowed to change the pipe number. The pipes with the
same number, no number or vague number should not be used for further processing.
d. Manufacturing workers and quality controllers should keep product record in each production
stage to ensure the traceability.
e. When all the inspection and testing conforms to the requirements of the project specification,
markings should be sprayed on the lining surfaces.
f. When stripping the unqualified lining, the operators should record the relevant pipe
identification information. This information will be copied to the inner surface of pipes after
relining.
3.2.3 Identification verification or process state
a. Quality controller should classify the raw materials on the basis of the inspection results, then
mark the inspection or testing state.
b. For unqualified sandblasting pipes, use stone chalk to mark the defect location, and indicate the
reason for rejection in the quality control report.
c. For the coated pipes needing repairing, mark the defective location with masking tape. Mark the
unqualified coated pipes with white circles, and indicate the reason for rejection in the quality
control report.
d. Rejected and pending pipes should be isolated and clearly marked. Quality controllers should
indicate the reasons in the quality control report.

3.3 Pipe handling and storage

a. When the coated pipes are handled, please do not collide.
b. When the polyethylene anticorrosive pipes are lifted, adopt the slings and hooks filled with
nylon slings or soft material, so as to avoid damage to the lining and pipe end groove.
c. When the coated pipes are stored, please fill in storage record carefully.
d. The coated pipes should be should be stacked in strict accordance with the storage requirements.
When stacking, use more than two flexible supports as underlay; the support spacing is 4-8 meters;
the minimum width of the support is 200mm; the distance between anti-corrosive pipes and ground
should not be less than150mm.
e. When the coated pipes are transported, the pipes should be fixed with nylon straps, try to avoid
any collision damage in the loading process.
3.4 Inspection and test instrument list
(Appendix B)
3.5 Inspection and test instrument calibration
Quality controller should use standard thickness foil to calibrate the coating thickness gauge at
least once every 4 hours according to the coating thickness gauge instruction manual. Quality
controller should calibrate the holiday detector at least once every 4 hours, in order to maintain the
required detection voltage.

3.6 Production equipment list

(Appendix C)

3.7 Quality inspection table sample

3.8 Health, safety, environment (HSE)

3.8.1 Material: polyethylene, adhesive and epoxy powder
3.8.2 Health, safety, environmental requirements on raw material storage
3.8.2.1 Storage facilities and conditions
a) Special storage warehouse for anti-corrosion materials, should be constructed in a place where
is well ventilated and has appropriate moisture-proof measures; the indoor temperature and
humidity should be consistent with the storage requirements of the coating material;
b) The warehouse should be equipped with explosion-proof lights and explosion-proof switch, and
make sure there are enough fire extinguishers.

3.8.2.2 Raw material safekeeping and storage

a) Material supply center is responsible for receiving inspection. The outer packing should have no
damage or moisture, quality certificate and other related information should be complete. Written
acceptance certificate shall be sent to the quality inspection center for retesting.
b) The raw materials should be classified strictly in accordance with manufacturer, model and
batch number, stored stably and orderly, identifiable. Bagged materials shall be stacked more than
the 20 layers, while box packed material no more than 5 layers. There should be safe passages
between the stacked materials and the walls or between the stack materials themselves.
c) After retesting, the unqualified outer packing and/or unqualified materials should be isolated,
and clearly marked as unqualified raw materials.
d) keep the inspection certificate and the quality certificate fully in accordance with the technical
requirements; establish the temperature and humidity record.
e) Carry out moisture content test to the polyethylene stored for more than 2 months; when
supplying the materials for use, follow the first-in-first-out principle.
f) In order to strengthen the warehouse safety check and inspection, fire or smoke should be
banned in the warehouse .
3.8.3 Health, safety, environmental requirements on coating
3.8.3.1 Main HSE hazard factors and environmental impact factors in the coating process
a) The dust discharge in the processes of pipe derusting, powder coating and pipe end cleaning;
b) The noise pollution in the processes of pipe derusting, pipe end cleaning and intermediate frequency
preheating;
c) The solid waste discharge waste polyethylene and empty packaging materials;
d) The potential fire hazards caused by flammable materials;
e) Personnel casualties in the production and storage process.

3.8.3.2 Control and prevention of the main HSE hazard factors and environmental impact factors in the
coating process

a) Ensure the operation of the HSE facilities is normal and effective. Use all kinds of advanced dust
removal systems, circulating water systems, strengthened ventilation systems, vibration reduction systems
and noise elimination systems to reduce or eliminate the dust, noise, solid wastes which may cause
negative effect to the environment.

b) Establish the talent training programs, to improve the HSE risk awareness and risk prevention capacity
of the staffs. Make sure all new employees 100% accept HSE training, in addition, special operation
personnel must 100% hold relevant certificates.

c) Make sure all employees abide by the "safe technology operating rules", and wear a complete and
effective set of labor protective equipment. The company should supervise and urge all the staffs to
correctly wear personal protective equipment and monitor dangerous workplace. The company should
also provide regular physical examination for the staffs working in the poisonous and harmful
environment.

d) Raw materials should be used and stored according to the corresponding standard. Formulate strict
regulations to manage the fire source of the facilities, and equip with sufficient fire extinguishing
equipment. No smoking in workplace.

e) All of the solid wastes should be disposed according to the laws, regulations and the company systems.
All of the waste management should be kept in record.

f) Continuously improve the HSE management system to ensure its efficiency. Comply with HSE
standards, and eliminate any possible accidents.

g) Strengthen HSE supervision and inspection, and cancel any inappropriate HSE specifications.
Appendix A
Manufacturing, inspection and test flow chart of the three-layer polyethylene coating

1. Before coating the 3PE anticorrosive layer, please clear the grease and dirt and other contaminants on the steel pipe surface, and carry out the surface pretreatment
of the steel pipe after preheating, the steel pipe surface pretreatment quality should meet the Sa2.5 level requirements in ISO 8501-1 Rust Grades and Preparation
Grades of Steel Surfaces Before Application of Paints and Related Products, the anchor pattern depth reaches 40μm to 90μm.
2. After the steel pipe surface pretreatment, clean the adherent dust on the steel pipe surface, and prevent the steel pipe surface from moisture, rust or secondary
pollution before coating the polyethylene anticorrosive layer.
3. When the anticorrosion production starts, first use test section in the production line to respectively regulate the anticorrosive preheating temperature and the
thickness of each anticorrosive layer in turns. Only when all the parameters meet the requirements, can the production be started.
4. Use pollution-free heat source to heat the steel pipe to the appropriate 3PE anticorrosive temperature.
5. Epoxy powder coating (FBE) should be evenly applied to the steel pipe surface, the epoxy powder coating (FBE) thickness should be more than or equal to (≥) 60
μm.
6. The adhesive must be coated in the epoxy powder gel process, adhesive coating thickness should be more than or equal to (≥) 140μm.
7. The coating of the polyethylene anticorrosive layer can use vertical extrusion process or winding process. When use lateral winding process, make sure the
overlapping part of the polyethylene and the polyethylene on both sides of the steel pipe weld seam are completely rolled compactly; when use the vertical extrusion
process, there should not no holes on both sides of weld seam.
8. After coating the three-layer PE anticorrosive layer, use water to cool the temperature of the steel pipe to be not higher than 60 degrees celsius. Coating the epoxy
powder in the interval before the polyethylene anticorrosive layer starts cooling, make sure the epoxy coating is solidified completely.
9. When the anticorrosive layer coating is completed, use mechanical polishing to remove the polyethylene layer on the pipe ends. For the steel pipes with nominal
diameter less than 500mm, the pipe end reserved length should be: 100mm-110mm; for the steel pipes with nominal diameter greater than or equal to 500mm, the
pipe end reserved length should be: 140mm-150mm; the end face of the polyethylene layer should form a chamfer angle which is less than or equal to 30 degree, and
retain no more than 20mm of epoxy coating.
Process inspection level distribution

□ 钢管检验★★ 抛丸除锈 管内吹扫 加热

Pipe inspection Blast cleaning Pipe blowing Heating

★★★ ★★

粉末喷涂
水冷却 聚乙烯、胶缠绕 Powder spraying
Water cooling Polyethylene, rubber winding

★★★
电火花检漏 喷标识、防护 成品检验
Electric spark leak detector Identification, protection Product inspection

★ 一般过程控制点 ★★ 特殊过程控制点 ★★★重点过程控制点□ 停检点

★ General process control point ★★ Special process control point ★★★ Key process control point hold
Appendix B
Inspection and test instrument list

序号 型号/大小
仪器描述 Instrument description 状态 state
No. model / size

涂层测厚仪(厚)
1 Mikro 643-0002 test OK
Coating thickness gauge (thick)
涂层测厚仪(薄)
2 Mikro 643-0003 test OK
Coating thickness gauge (thin)
（ 0 ～ 30 ）
3 不锈钢板直尺 Stainless steel ruler OK
cm/0.5mm
4 游标卡尺 Vernier caliper （0～500）mm OK

5 红外测温仪 Infrared thermometer AR842A OK

6 厚度千分尺 Thickness micrometer 0～1mm OK
7 露点湿度计 Dew point hygrometer HT-6850 OK
数字温度湿度仪
8 HTC-1 OK
Digital temperature humidity meter
9 弹簧秤 Spring balance LTZ-50/0-500N OK
移动式漏涂检测仪
10 SL-50A OK
Mobile holiday detector
在线移动式漏涂检测仪
11 BSD-208A OK
On-line mobile holiday detector
12 厘米计米器 cm meter counter (0～10)mm OK

13 厘米计米器 cm meter counter (0～10)mm OK

14 厘米计米器 cm meter counter (0～10)mm OK

15 落 锤 冲 击 试 验 机 falling impact testing machine QCJ/2kg/1.2m OK

在线移动式漏涂检测仪
16 AC25KV OK
On-line mobile holiday detector
测厚仪使用
17 标 准 厚 度 薄 膜 Standard thickness thin film used for OK
thickness gauge
18 差 示 扫 描 量 热 仪 differential scanning calorimeter / OK

19 老化试验机 aging tester 401-A OK

20 硬 度 试 验 机 Hardness testing machine 2.59kg/1.8mm OK

Appendix C
Production equipment list
序号 No. 设备名称 device name 型号 model 数量 qty 状态 state
外表面防腐喷砂清理传送机
1st
Outside surface anti-corrosion sand blasting transfer machine
1 进管架 Inlet pipe rack 12M 4 OK
喷砂传送机
2 46M 4 OK
sandblast transfer machine
3 预热机组 Preheating unit KGPS-350KW/2500Hz OK
喷砂清理机
4 HZQGW1420 4 OK
Sand blasting machine
5 除尘器 deduster 2 OK
室内除尘系统
OK
6 Indoor dust removal system
7 输送架 transmission rack 12M 4 OK
2st 外表面防腐涂料传送机 Outside surface anticorrosive paint transfer machine
8 感 应 加 热 器 Induction heater 燃气 gas 3 OK
FBE 喷涂控制柜
OK
9 FBE spraying control cabinet 2078-70LR 4
10 粘合剂挤出机 Adhesive extruder JHS-90/30 4 OK
聚乙烯挤出机
11 JHS-200/33 4 OK
Polyethylene extruder
12 冷却塔 Cooling tower YLT-CD-300-15 3 OK
13 冷却塔 Cooling tower YLT-CD-100-15 1 OK
14 集尘器 Dust collector LSH-2000 4 OK
15 管 口 支 架 nozzle bracket 12M 4 OK
管端清理机
16 4 OK
Pipe cleaning machine
空气过滤干燥器
17 LD650 3 OK
Air filtering dryer
18 漏 涂 检 测 仪 holiday detector SL-58B 4 OK
天然气加热炉
19 RQ-400-1 3 OK
natural gas heating furnace
3rd 外表面防腐辅助设备 Outside surface anticorrosion auxiliary equipment
20 配 电 柜 power distribution cabinet 5 OK
变压器和真空断路器
21 OK
Transformer and vacuum circuit breaker SCB9-1250/10 2
22 变压器 Transformer 2 OK

23 空 气 压 缩 机 Air compressor M65 8 OK

24 液 压 设 备 Hydraulic equipment 4 OK

25 管 道 装 载 机 Pipeline loader ZL50G 2 OK

管道表面除尘设备
26 OK
Pipeline surface dust removal equipment USFU-2000 4
27 振 动 干 燥 机 Vibrating drier HGZZ 4 OK