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CP06 - Procedure For Fusion Bonded Epoxy Coating (CP Powder Coating Atau Surface Preparation)
CP06 - Procedure For Fusion Bonded Epoxy Coating (CP Powder Coating Atau Surface Preparation)
Quality Plan
I I I
Inspection Racks & Phosphoric Acid Wash & High Pressure Chromate
6 7
5 Internal Blow-Out Water Rinse (when necessary) Application
Station
I I I
FBE Water
8 Induction Heating 9 10
Application Quench
Pipe No
Length
Heat No
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1.0 INTRODUCTION
1.1 SCOPE
This technical procedure defines the application, inspection, repair, handling and storage
requirements of factory applied external fusion bonded epoxy powder-based coatings for the anti-
corrosion protection of steel line pipe. The coating system can be applied to longitudinally or spirally
welded and to seamless pipe for the construction of buried or submerged pipelines.
1.2 DEFINITIONS
Customer - Italian – Thai Development Public Company Ltd.
PTBPI - PT. Bredero Price Indonesia
Manufacturer - Manufacturer or Supplier of raw materials associated
with the coating process.
FBE - Fusion Bonded Epoxy
Chemical pre- treatment - Phosphate and/or Chromate used on blast cleaned
pipe surface to improve the steel cleanliness and
adhesion of the coating to the substrate.
Shift - Normal working day under constant production
conditions approximately 12 hours or non-stop shift
where production runs on single shift.
Holiday - A coating defect penetrating through the coating to
the steel pipe surface, of such dimensions that it is
detectable using a high voltage search electrode.
2.0 REFERENCES
The following references are relevant to this procedure:
2.01 Customer’s Specifications - PTT SP-Q-000-09 Rev.0
2.02 ASTM D4285 Test for Indicating Oil or Water in Compressed Air
2.03 ASTM D4417 Field Measurement of Surface Profile of Blasted Cleaned Surface
2.04 NACE RP-02-74 High Voltage Electrical Inspection of Pipeline Coatings.
2.05 SSPC-SP1 Solvent Cleaning
2.06 SSPC-SP10 Near White Blast Cleaning
2.07 SSPC PA-2 Measurement of Dry Film Thickness with Magnetic Thickness Gauge
2.08 Swedish Std SIS Surface Preparation Standard for Painting 05-59-00 Steel Surface
2.09 Inspection and Test Plan - Document Nº ITP05-1
2.10 PTBPI Management Procedures
3.0 RESPONSIBILITIES
3.1 Plant Superintendent shall be responsible for all labor and equipment necessary for the required
operation. He shall also be responsible for ensuring that the manufactured product meets the
requirements specified herein and that all plant foremen/charge hands are aware of their individual
responsibilities.
3.3 The QA/QC Manager is responsible for ensuring that the Customer’s agreed quality requirements are
satisfied. He shall also ensure that the Q.C. inspectors inspect and control the quality of the product in
accordance with this document.
Document No: QP05-1
QUALITY PLAN Revision No: 0
Bredero Price
Fusion Bonded Epoxy Coating Revision Date: 30/07/01
Page: 4 of 10
Customer Project PTBPI Project No:
ITALIAN-THAI
TLP INTERCONNECTING NUTURAL GAS
DEVELOPMENT PUBLIC
PIPELINE PROJECT
COMPANY LIMITED
3.4 Project Coordinator shall ensure that all services and coating related materials are available for the
successful and timely completion of the project. He shall also ensure pipe-tracking system, which
recorded the identity, status and disposition of all pipes.
3.5 The Quality Control Coordinators and inspectors, inspect and control the quality of the product in
accordance with this document and the relevant Inspection and Test Plan.
Commented [DC1]:
4.0 COATING SYSTEM REQUIREMENTS
Commented [DC2]:
4.1 PIPE RECEIPT AND SURFACE CLEANING
On entering the Plant, pipes shall be placed on incoming racks where they shall be inspected for
contamination by oil, grease, etc. Contamination, if any shall be removed by proprietary solvent
washing e.g. xylene, in compliance with SSPC-SP-1. Where excessive contamination is present, pipe
shall be removed from the system, quarantined and brought to the attention of Customer’s Site
Representative.
NOTE: In the event where deemed to be necessary, one test pipe may be coated prior to production
with a small portion of FBE to enable thickness, adhesion and degree of cure to be checked to
ensure that parameters intended to be used in the production can yield satisfactory results, ensuring
that overall quality of coating is met prior to full production run.
Immediately after holiday detection, pipes shall be inspected for dry film thickness, uniforms finish,
adhesion...etc., as required in ITP05-1. In the same time marking shall be applied in accordance to
the contractual requirement.
The extents of defect shall be determined and all pipes that failed project requirement shall be
rejected.
Document No: QP05-1
QUALITY PLAN Revision No: 0
Bredero Price
Fusion Bonded Epoxy Coating Revision Date: 30/07/01
Page: 7 of 10
Customer Project PTBPI Project No:
ITALIAN-THAI
TLP INTERCONNECTING NUTURAL GAS
DEVELOPMENT PUBLIC
PIPELINE PROJECT
COMPANY LIMITED
5.1 HANDLING
After coating, pipes shall be rolled on bearing racks for inspection/repair. Accepted pipe shall be fitted
with rope separators, to prevent coatings contacting one another during storage. Pipe shall be
transferred from outgoing racks to trucks by means of crane or loader fitted with suitably padding.
Loose separators shall be tightened and missing separators shall be replaced.
Where no further processing of the pipe is required, unless otherwise stated in ITP05-1 bevel
protectors shall be fitted to the pipe ends to prevent the possibility of bevel damage.
Rejected pipes shall be marked with single red circumferential bend for identification and traceability.
Such rejected pipes shall be stored separately for further process; e.g. re-blasting and recoating
work.
Quarantine pipes including test pipes shall be marked with temporary marking tapes. Such
tapes/marking shall be removed cancelled by QC/Tally personnel upon acceptance of repair work,
rectification or customer agreed action, as applicable.
5.2 TRANSPORTATION
Where required, FBE pipes shall be transported by flat bed trucks with suitable padded supports to
prevent damage to the coating. Front-end fork loaders may also be used providing the lifting cradle is
lined with soft rubber or foam
5.3 STORAGE
Where required, FBE coated pipe shall be stored on sand berms comprising of two baulks of sand,
30 cm high with a bearing surface 1m wide, each 6m apart, approximately. Sand berms shall be
inspected for suitability prior to use. Sand berms shall be covered with polythene sheeting, to ensure
no contact with the berm.
All pipes shall be stored in stacks segregating the pipe by source, grade, diameter, and wall
thickness, coating type and color-codes. Pipes shall be positioned clear of the ground and at an angle
sufficient to ensure adequate water drainage through the bore of each pipe. Pipe interiors shall be
kept clean and free from mud splashing or dirt deposits during storage.
Pipe will be stacked with due consideration to impact effects, nested together up to a maximum safe
working height of 4 m.
Sand berms shall be reinstated prior to each new batch of pipes being stored.
Document No: QP05-1
QUALITY PLAN Revision No: 0
Bredero Price
Fusion Bonded Epoxy Coating Revision Date: 30/07/01
Page: 8 of 10
Customer Project PTBPI Project No:
ITALIAN-THAI
TLP INTERCONNECTING NUTURAL GAS
DEVELOPMENT PUBLIC
PIPELINE PROJECT
COMPANY LIMITED
Note: Attached latest from FBE manufacture clarification on holiday testing voltage.