P.T.

Bredero Price Indonesia

Customer Project PTBPI Project No

Italian-Thai Development Public Bangkok International Airport

00-0232
Company Limited Development Project

Quality Plan

Three Layer Polyethylene

Coating
DOCUMENT NUMBER
QP07-1

0 18/01/02 Issue for Client Review and Approval Mujianto Ali Mike Nutter D. Conroy
Revision Revision
Comments Raised By Approved By Authorized By Customer
No. Date
 Document No: QP07-1
QUALITY PLAN Revision No: 0
Bredero Price
Three Layer Polyethylene Coating Revision Date: 18/01/02
Page: 2 of 10
Customer Project PTBPI Project No:
Italian-Thai Development Public Bangkok International Airport
00-0232
Company Limited Development Project

PROCESS FLOW DIAGRAM

1 Transportation of Bare Pipe from Stockpile to Coating Plant

Incoming Racks &

2 3 Preheat Oven 4 Blast Cleaning
Foam Plug
Insertion

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 I

FBE Adhesive Polyethylene Water

8 Induction Heating 9 10 11 12 Quench
Application Application Application

Holiday Detection and Cutback Stencil Transportation to

13 14 15 16
Coating inspection Cleaning Application Stockpile

Pipe No
Length
Heat No
I I

KEY: Process Direction of Flow ? Activity Number I Inspection Point

 Document No: QP07-1
QUALITY PLAN Revision No: 0
Bredero Price
Three Layer Polyethylene Coating Revision Date: 18/01/02
Page: 3 of 10
Customer Project PTBPI Project No:
Italian-Thai Development Public Bangkok International Airport
00-0232
Company Limited Development Project

1.0 INTRODUCTION

1.1 SCOPE
This Quality Plan defines the application, inspection, repair, handling and storage requirements of
factory applied external three layer polyethylene coatings for the anti-corrosion protection of steel line
pipe. The coating system can be applied to longitudinal welded, spiral welded and to seamless pipe for
the construction of buried or submerged pipelines.

This procedure is written with the intention of being a working instruction for PTBPI personnel by
detailing the standard of workmanship and acceptance criteria throughout each phase of the process.

1.2 DEFINITIONS
Customer - Italian-Thai Development Public Company Limited
PTBPI - P.T. Bredero Price Indonesia
Manufacturer - Manufacturer or Supplier of raw materials associated
with the coating process.

1.3 COATING SYSTEM DESCRIPTION

The coating system described in this document shall be manufactured using polyethylene as the main
coating material, using suitable surface preparation and application techniques to obtain the coating
properties required for its intended installation and operating conditions.

2.0 REFERENCES

The following references are relevant to this procedure:

2.1 Customer’s Specifications, if any
2.2 PTBPI Management Procedures

3.0 RESPONSIBILITIES

3.1 The Superintendent shall be responsible for all labour and equipment necessary for the required
operation. He shall also ensure that the operations are performed in a safe manner and that the
product meets the requirements specified herein.

3.2 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.

3.3 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 act as the Customer interface throughout
the duration of the Project.

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 the Customer’s Site
Representative for further action.
 Document No: QP07-1
QUALITY PLAN Revision No: 0
Bredero Price
Three Layer Polyethylene Coating Revision Date: 18/01/02
Page: 4 of 10
Customer Project PTBPI Project No:
Italian-Thai Development Public Bangkok International Airport
00-0232
Company Limited Development Project

Testing for salt contamination shall be performed using a SCM 400 meter. Refer to Inspection & Test
Plan for criteria.

4.2 END PLUGS

End plugs shall be placed inside both ends of the pipe to prevent the ingress of abrasive during the
blast cleaning process. These shall be removed immediately after blasting, at which time any dust or
abrasive accumulating inside the bore of the pipe shall be removed by compressed air.

4.3 PIPE PREHEAT

Immediately prior to blasting, pipe is conveyed through an in-line Preheater. Pipes shall be heated to
remove any surface moisture and to ensure a minimum holding temperature of 3°C above dew point,
for the remainder of surface preparation stages.

4.4 INITIAL BLAST CLEANING (1ST BLASTER)

The pipe shall undergo an initially blast cleaned process to remove surface rust and to raise any
slivers, scabs or other surface defects, allowing adequate steel inspection. Where pipe have been
received with a temporary mill applied coating e.g. Lacquer, and such coatings can not be removed
during normal cleaning process, these pipes shall be quarantined and brought to the attention of the
Customer’s Site Representative. The bevel landing shall be protected at all times.

4.5 BLAST CLEANING (FINAL BLASTING)

Pipe shall then be conveyed to the second mechanical blaster. The abrasive shall be a selection of
steel grit / shot giving a cleanliness (in accordance with ISO 8501-1/BS 7079 or SSPC VIS 1-89, and a
peak to trough profile amplitude according to the requirements detailed in the Inspection and Test Plan
below.
Residual abrasive / dust shall be removed from the pipe surface on exit from the blasting cabinet by
means of an air knife, wire brush or other suitable means. Residue accumulating on the internal
surface shall be blown out using compressed air and removed through the dust collector system.

4.6 GRINDING STATION

Immediately after blast cleaning, the pipe is raised on to an inspection station to visually check for
surface defects, such as slivers, laminations, leafing, scabs, burrs, indentations, slugs or other defects
considered detrimental to the performance or adhesion of the coating.
Any surface defects considered detrimental to the coating shall be removed by manual cosmetic
grinding or filing.
Where extensive grinding is required, or major defects, i.e., out with API 5L and Customer’s
Specification are detected, pipes will be indexed out of the process for further inspection with the
Customer’s Site Representative.

4.7 PIPE COUPLING INSERTION

Pipe couplings shall then be fitted onto one end of the pipe. Prepared surface shall be monitored such
that no oxidation (flash rusting) of the surface occurs which could be detrimental to the adhesion of the
coating. Pipes with flash rusting shall be rejected and reprocessed as per section 4.3 onwards.

4.8 PHOSPHORIC ACID TREATMENT AND WATER RINSE (WHERE NECESSARY)

On exit from the tape station, pipes are conveyed, in-line through the acid wash station where they are
treated with phosphoric acid. Acid is directed at the pipe surface and applied through spray tips,
ensuring full coverage. After a dwell period of minimum 20 seconds, for pipe temperatures between 45
- 65C, high-pressure water is introduced to rinse off any residue and neutralize the acid.
 Document No: QP07-1
QUALITY PLAN Revision No: 0
Bredero Price
Three Layer Polyethylene Coating Revision Date: 18/01/02
Page: 5 of 10
Customer Project PTBPI Project No:
Italian-Thai Development Public Bangkok International Airport
00-0232
Company Limited Development Project

4.9 CHROMATE PRE-TREATMENT

Chromate solution (approx. 10% concentration) shall be applied onto the pipe surface by gravity feed.
A rubber squeegee shall be held against the surface to aid even distribution of the chromate and to
ensure full coverage of pipe surface. Chromate dilution shall be controlled as dictated by the
manufacturer’s data sheet.

4.10 INDUCTION HEATING SYSTEM

Prepared pipe is then conveyed through the induction coil that is pre-set to heat the pipes to the
desired application temperature (within manufacturers recommendations).
Air knife, steel brush and vacuum system (dust removal) shall clean the pipe before entering the
coating booth. After passing through the coil random temperature checks will be carried out using
Tempilstiks to verify the infra red pyrometer reading, which continuously monitors pipe temperature.
Pipe heated in excess of allowed maximum heating temperature of 260C, or as stated in powder
manufacturers data sheet, shall be stripped, and reprocessed.

4.11 POWDER APPLICATION AND RECLAIM SYSTEM

Powder room personnel will check each box of powder before introducing the powder into the system.
Virgin powder will be transferred through a screening system into the application system fluidizing bed.
The powder is then transferred, through a set of magnets to remove any foreign particles, to the
application guns, which are electrostatically charged to facilitate the application of the powder. As
heated pipe enters the spraying booth, guns will be activated and electrostatically charged FBE
powder will be sprayed evenly over the rotating pipe surface.
Over spray powder is continuously extracted into a reclaim system, transferred through a cyclone /
dust collector and a screening system. Screened powder is then transferred into a portioning hopper
then mixed with virgin powder. No more than 20% recycled powder shall be mixed with virgin powder.

4.12 ADHESIVE (INTERMEDIATE COAT) APPLICATION

The intermediate coat will be applied by side extrusion and pressed firmly onto FBE coated surface
using a silicon rubber pressure roller. Where adhesive material to be used is supplied in powder
form, this shall be applied by spray method using fluidizing bed and powder guns. Application of
adhesive will be timed to occur before the powder is cured so that maximum adhesion is achieved
between powder and subsequent intermediate coat. The intermediate coat will be applied with
correct temperature and thickness to firmly adhered to the powder coating layer.

4.13 POLYETHYLENE (TOP COAT) APPLICATION

Top coat shall be extruded in such a way that it is applied immediately following the adhesive
coating. The top coat will be applied with the correct width, temperature and thickness, to ensure
that parameters used in the production yield satisfactory results and overall quality is met.

NOTE: In the event where deemed to be necessary, one test pipe may be coated prior to production
with a small portion of coating 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. Thus
ensuring that overall quality of coating is met prior to full production run.

4.14 SINTER COAT - ROUGH COAT (FOR SUBSEQUENT CONCRETE COATING ONLY)
Additional ‘sinter powder coat’ shall be spray applied on to coated surface as soon as pipe leaves the
coating booth. Such sinter coatings shall be applied to produce a rough coating surface onto which
concrete coating can be applied. This system is intended to improve anti-slip properties.

4.15 QUENCH STATION

Coated pipe shall then conveyed to quenching station where pipe is cooled by a drenching flood of
cooling water to allow further handling. Pipe temperature on exit from quench shall not exceed 90C.
The pipe is then lifted onto inspection racks.
 Document No: QP07-1
QUALITY PLAN Revision No: 0
Bredero Price
Three Layer Polyethylene Coating Revision Date: 18/01/02
Page: 6 of 10
Customer Project PTBPI Project No:
Italian-Thai Development Public Bangkok International Airport
00-0232
Company Limited Development Project

4.15 COOLING AND INSPECTION RACKS

As coated pipe is rolled and set on cooling racks, cutback ends will be cleaned of all tape and excess
coating material. Electrical test (holiday detection) will be carried out at a travel speed of no more than
0.3 m/sec and inspection voltage shall be as set/calibrated at a frequency as dictated by the
Inspection and Test plan below. All detected holidays shall be clearly marked and the number of
holidays detected on each pipe shall be written at the end of the pipe.

Immediately after holiday detection, pipes shall be inspected for dry film thickness, uniform finish,
adhesion...etc., as required in the Inspection and Test plan. At the same time stencil marking shall be
applied in accordance to the contractual requirement.

4.16 CUTBACK BRUSHING

Pipe ends shall be finished using powered wire brushes to clean all remaining powder or tape from the
ends on the pipe. Finishing shall produce clean bare steel over the required distance from the pipe
ends.

4.17 REPAIRS USING TWO PACK PATCHING COMPOUND

All holidays or spots with coating defects shall be appropriately marked so that the damage/holiday
is at the centre of the repaired area. Defective coating shall be removed by knife or chisel and the
surrounding area roughened by using sandpaper or a grinder.

If the damage extends to the steel, apply a layer of two-pack epoxy (e.g., Valspar 46F640). If
necessary, a hot air blower may be used to accelerate curing process. The surface of cured epoxy
compound shall be roughened and cleaned prior to repair application of adhesive layer.

For large repairs, the adhesive and topcoat layer may be repaired using the following method:
A thin layer of adhesive (e.g., Fusabond MD 158), shall be melted, applied onto repaired epoxy
surface and smoothed out using a spatula to provide an even smooth ‘waxy’ film. Continuously
adding more adhesive (mixed with topcoat material if desired) and melted evenly to prevent
excessive deposits of material at anytime, which may end up with incomplete melting of material.
The application shall start approximately 25 mm from the edge of the prepared section to ensure
overlap on parent coating and side overlap shall be approximately 25 mm.

For small repairs, PE melt sticks may be used to fill the cavity.

Once cool, the repair shall be fused with the parent coating and any excess material shall be
removed by knife or file, such that a smooth transition is obtained. Completed repair areas shall be
holiday detected.

Minor indentation or scores on topcoat do not require repair.

4.18 RETEST PROCEDURE

In the event that test pipes/samples fail to meet acceptance criteria, two additional samples shall be
tested for compliance. Both tests must pass in order to accept the represented batch of pipe. Should
one or both tests fail the preceding pipes coated after the last acceptable test pipe/sample and the
pipe coated following the failed pipe shall be quarantined for further testing.

The extent of defect shall be determined by lot narrowing and all pipes that failed project requirement
shall be rejected.
 Document No: QP07-1
QUALITY PLAN Revision No: 0
Bredero Price
Three Layer Polyethylene Coating Revision Date: 18/01/02
Page: 7 of 10
Customer Project PTBPI Project No:
Italian-Thai Development Public Bangkok International Airport
00-0232
Company Limited Development Project

4.19 STRIPPING AND RE-COATING

All rejected pipes shall be stripped by means of induction heating to the application temperature. At
which point a scraper blade is then held against the pipe to remove the coating. The temperature
during stripping operation shall not exceed 260°C. Following this, the pipe shall be blast cleaned to
remove any trace of the FBE material in the steel profile.

5.0 HANDLING, TRANSPORTATION & STORAGE

5.1 HANDLING
After coating, pipes shall be rolled on bearing racks for inspection/repair. Pipe shall be transferred
from outgoing racks to trucks by means of overhead crane or loader fitted with suitable padding.

Where no further processing of the pipe is required, unless otherwise stated in the Inspection and Test
plan below, bevel protectors shall be refitted to the pipe ends (where provided) to further aid in
preventing 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 re-coating work.
Quarantine pipes including test pipes shall be marked with temporary marking tapes. Such
tape/marking shall be removed cancelled by QC/Tally personnel upon acceptance of repair work,
rectification or customer agreed action, as applicable.

5.2 TRANSPORTATION
Coated pipes shall be transported by flat bed trucks or pole trailers with suitably 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
Coated pipe shall be stored on sand berms comprising of two bulks of sand, 50 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 colour-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 of 4
meters high.
 Document No: QP07-1
QUALITY PLAN Revision No: 0
Bredero Price
Three Layer Polyethylene Coating Revision Date: 18/01/02
Page: 8 of 10
Customer Project PTBPI Project No:
Italian-Thai Development Public Bangkok International Airport
00-0232
Company Limited Development Project

INSPECTION & TEST PLAN

Acceptance Criteria Approval Inspection
Process/ Report
Description Frequency (As per Customer’s Specification –
Location Where applicable)
Forms
PTBPI Customer

DSC, Moisture Content and Gel Time

Material FBE Powder Every Batch shall be within Manufacturer’s stated IRF 033 VNC ME
Receipt values and
Batch Test
Copolymer Adhesive Every Batch Packaging Secure, Marking Legible Certificate VC ME
from
Manuf.
Polyethylene Every Batch Packaging Secure, Marking Legible VC ME

Phosphoric Acid Every Batch Packaging Secure, Marking Legible IRF 033 VC ME

Chromate Every Batch Packaging Secure, Marking Legible IRF 033 VC ME

Abrasive Every Batch Packaging Secure, Marking Legible IRF 033 VC ME

Incoming Visual Inspection All pipes Contamination & defect Free --- V M
Racks
Confirm Pipe No., Heat No., &
Verify pipe identity All pipes Length is still legible. Reinstate --- V M
where necessary.
Twice per
Salt Contamination test 40 mg/m2 Maximum (4 g/cm2) QF 040 NC ME
shift

Startup and
Surface Check pipe temperature 3C above dew point minimum.
every 2 QF 024 HC ME
Preparation and relative humidity. Record humidity reading.
hours
All pipes.
Inspected blast finish Sa 2 ½ (near white metal finish). Re-
Record QF 024 HVC ME
and for steel defects. blast if grinding exceeds 0.5ft 2
every 2 hrs.
Check surface profile
Two per
one location per test 40 - 100m. QF 024 DC ME
shift
pipe
Phosphoric Acid
Treatment (applied pH 6 to 8 after rinse. Dwell time and
4 times per
when salt contamination concentration as per manufacturer’s QF 024 NC ME
shift
exceeds requirement recommendations.
value)

Chromate Treatment Monitor Full and even coverage --- V M

FBE = 180–220C, Adhesive = 200-

Coating Application Temperature
Continuous 230C, PE = 220-250C nominal
(using pyrometer and
Application Record temperature QF 031 VHC ME
Tempilstiks)
every hour No pipe shall exceed 260oC for
(Jotun EP-F 2001)
coating application.
Every start as per manufacturer’s
Check time to quench QF 031 VNC ME
up recommendation.

Maximum of 20%, blended

Reclaim Monitor --- M M
continuously with virgin powder.
 Document No: QP07-1
QUALITY PLAN Revision No: 0
Bredero Price
Three Layer Polyethylene Coating Revision Date: 18/01/02
Page: 9 of 10
Customer Project PTBPI Project No:
Italian-Thai Development Public Bangkok International Airport
00-0232
Company Limited Development Project

Acceptance Criteria Approval Inspection

Process/ Report
Description Frequency (As per Customer’s Specification –
Location Where Applicable)
Forms
PTBPI Customer

FBE minimum 100m

Final Adhesive minimum 200m
Inspection Total Coating Thickness Minimum
Total coating thickness
All pipes = 1.27mm QF 033 DVHC ME
4 locations per shift
(On pipe body not over weld seam
area).

Holiday detection Maximum 15 allowable holidays. All

All pipes QF 033 NVHC ME
Minimum 16 kV holidays to be repaired.

Free from runs, sags, blisters and

Visual Inspection All pipes -- V M
uniformity of colour

Cutback All Pipe 75 ± 20 mm -- D M

Production Once Per Min. 15 N per cm at 50°C.

Adhesion Peel Strength QF 033 VTHC ME
Tests Shift Record mode of failure
(On Cut Ring
Sample)
Once Per 3 joules per mm of thickness
Impact Test QF 033 THC ME
Shift minimum without causing a holiday.

On external surface at Pipe No, Length, Heat No, Customer

Markings All pipes -- V M
one end Name, PTBPI

Coating Defects & Smooth and even repair patch.

Repairs All repairs QF 046 VNC ME
Mechanical Damage Holiday Free.

Cathodic disbondement
The maximum radius of disbondment
Laboratory 6 mm  holiday, -1.5 V, Once Per
from the edge of holiday shall not QF 085 TDHC WE
Testing 3% NaCl electrolyte, 48 400 pipes
exceed 15 mm.
hours at 60±5°C
(On Cut Ring
Sample) Once Tensile at 10kg/cm and elongation at
Tensile/Elongation QF 085 DHC ME
Production Failure, 5 samples/test
Testing in
accordance
with Once Per Shall not exceed 0.3 mm at 50  2oC,
DIN 30670 & Indentation Test QF 085 DHC ME
400 pipes 3 samples/test
Canadian Std
CSA-Z245.21

Startup and In-House calibrate against traceablity Adjustable to ± 5% of

Calibration Profile Gauge QF 024
Every 4hrs Coating Thickness Standard (Ferrous) Target Value

Coating Thickness Startup and In-House calibrate against traceablity Adjustable to ± 5% of

QF 033
Gauge Every 4hrs Coating Thickness Standard (Ferrous) Target Value

Impact Test Falling In-House calibrate against traceability Adjustable to ± 5% of

Every Year CF 028
Mass Weight Balance Target Value

Indentation Test In-House calibrate against traceablity Adjustable to ± 5% of

Every Year CF 014
Digimatic Micrometer Coating Thickness Standard Target Value

Peel/Adhesion Testing In-House calibrate against traceability Adjustable to ± 5% of

Every Year CF 038
Machine Standard Weight Target Value
 Document No: QP07-1
QUALITY PLAN Revision No: 0
Bredero Price
Three Layer Polyethylene Coating Revision Date: 18/01/02
Page: 10 of 10
Customer Project PTBPI Project No:
Italian-Thai Development Public Bangkok International Airport
00-0232
Company Limited Development Project

(It’s Factory Calibrated)

Salt Contamination Adjustable to ± 1.7% /
Every Year In House calibrate as per manufacture CF 033
(SCM 400) °C of Target Value
recommendation
Cathodic Disbonding
Calibration Apparatur In House calibrate against traceability Adjustable to ± 5% of
Every Year CF 038
Hot-Plate and calibrated Pyrometer Target Value
Temperature Indicator
Instron
Elongation/Tension Manufacture calibrate against S/N :
Every Year External Calibration
and Compression traceability to NATA Standard UK1130
Machine
In House calibrate against Tempilstik Adjustable to ± 5% of
Pyrometer (Laser) Every Year CF 021
(Temperature Indicator) Target Value

Startup and Calibrate against traceability Calibrated Adjustable to –0%, +

Holiday Detector QF 033
Every 4hrs Voltmeter 5% of Target Value

C Record & Raise Documents H Hold Point N Non-Destructive Testing V Visual Inspection
Legend D Dimensional Inspection I Random Inspection R Review W Witness
E Examine / Endorse Documents M Monitor T Destructive Testing WFO Witness First Of