Bsibv-Itp-07-2 Pe Itp For 3lpe Coating Dpe Rev. 0

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Site Project Quality Document
INSPECTION AND TEST PLAN - 3LPE COATING
BREDERO SHAW INTERNATIONAL B.V, RAK
Customer Project PO Number
TechnipFMC AQAM Development EPCI 077607C004-230-PO-5530-012-7010
C: Record & Raise Documents H: Hold Point N: Non-Destructive Testing V: Visual 1: 100%
Legend D: Dimensional Inspection I: Random Inspection R/A: Review/APPROVAL W: Witness 2: 10%
E: Examine/Endorse Documents M: Monitor T: Destructive Testing WFO: Witness First Off S: Surveillance
Approval Inspection
BSIBV-
DP-PL-4 Production Test
No. Activity Description QP-07-2 Method / Acceptance Criteria Verifying doc
Rev. 01 Frequency BSIBV TP FMC DPE / TPI
(PP)
1 Raw Material certificates 2.1 / 4.1 Manufacturer test certificate shall be submitted to the Customer. RF 033 Every Batch H R R
a Moisture Content
b Gel Time
c DSC- Thermal Analysis of Powder
Laboratory testing of FBE
4.2 / d Density RF 013E / RF
2 powder (Valspar Pipeclad 5.0 Every Batch H W1 R
Table 1 033
2000) e Sieve Analysis
The acceptance criteria and test method shall be in accordance with
Material manufacturer’s Certificate of Analysis (CoA) for the
laboratory tests.
a Melt Flow Index
Laboratory testing of b Density
4.3 / RF 013F / RF
3 adhesive material (Borealis - 5.0 Every Batch H W1 R
Table 2 The acceptance criteria shall be in accordance Material 033
Borcoat ME0433)
manufacturer’s Certificate of Analysis (CoA) for the laboratory tests.
a Melt Flow Index

Laboratory testing of PE b Density
4.4 / RF 013B / RF
4 material (Borealis - Borcoat 5.0 Every Batch H W1 R
Table 4 The acceptance criteria shall be in accordance Material 033
HE3450)
manufacturer’s Certificate of Analysis (CoA) for the laboratory tests.
Certificate
The criteria shall be less than 100-ppm sulphates and chlorides and from
5 Abrasive Material 2.1 100 ppm chlorides. The material manufacture’s certificate shall be Manufacturer Every Batch H W1 R
submitted. / RF 033 / QF
01-3
Verify pipe's identification number in accordance with packing list or
6 Verify pipe identity 2.3 TF-001 All Pipes H W1 R
tally sheet.
Removal of End Caps or The end caps and bevel protectors shall be removed from each end
7 5.1.1 - All Pipes H M R
Bevel Protector of pipes.
Doc. No.: BSIBV-ITP-07-2 (PE), Rev. 0 Page 2 of 10

Revision Date: 08-Oct-18
Approval Inspection
BSIBV-
(PP)
Verify pipes are free from major mechanical damages, oil, grease
and surface contamination. Check pipe identification. If oil grease QF-001 /
8 Visual Inspection of Pipes 5.1.1 2.3 contamination observed on pipe will be cleaned in accordance with GloQ-410 / All Pipes H W1 R
SSPC SP-1 Solvent Cleaning. Defective pipes shall be removed RF 002
from the coating line for resolution of defects.
The pipe shall be externally hot water washed prior to Blast cleaning
and each pipe evenly pre-heated to a minimum of 40°C but in no All Pipes, Record in
9 Hot water wash 5.1.1 2.4 QF-001 H V R
case above 180°C, to ensure the steel surface is free from every 30 minutes
moisture.
Abrasive Material No oil/water in accordance with ASTM 4940. The abrasive material QF 07-1 / QF
10 3.1 Once per Shift H W1 R
Contamination Test shall be dry, clean, and free from contamination. 01-3
Check Pipe Temperature,
Steel temperature shall be simultaneously higher than 5°C and Start of Shift / Every 2
11 Relative Humidity and Dew 5.1.1 2.7 / 3.1 QF 07-2b H W1 R
more than 3°C above dew point. Hours
point
The end plugs (Sponges) shall be installed inside both ends of the
pipe after hot water bath to prevent the ingress of abrasive material
during the blast cleaning process. Ensure the end plugs shall be
Protection of pipes during capable to protect the hard stamp (pipe identity punched on bevel)
2.4.1 /
12 Abrasive Blasting and from blasting. - All Pipes H M R
2.6
Coating.
After abrasive blasting, the coupling shall be installed into one end
of the pipe, ensuring that it is free of abrasive particles, clean and
free of oils and lubricants. Open couplings shall be used.
13 Compressed Air Supply 2.5 / 3.1 No trace of oil or water in accordance with ASTM D 4285-83. QF 021 Twice per Shift H W1 R
Cleaning of Blast Cleaned Using clean dry compressed air an operator shall blow out residue
14 2.5 - All Pipes H M R
Pipe Internal Surface which has accumulated on the internal surface.
Abrasive Blast Cleaned Pipe 5.1.2 / Pipe surfaces shall be cleaned to a degree corresponding as a
15 2.5 / 3.1 QF 07-1 All Pipes H W1 R
Surface Visual Standard 8.3.1 minimum to Sa 2 1/2 in accordance with ISO 8501-1.

Approval Inspection
BSIBV-
(PP)
The Dust level shall be checked by adhesive tape method in

5.1.2 / QF 07-1 / First 25 pipes and 4
16 Surface dust level 2.5 / 3.1 accordance with ISO 8502-3. The maximum dust level shall be H W1 R
8.3.2 QF07-7 pipes per shift thereafter
class 2 or less after abrasive blasting.
Surface Profile shall be 50-75 Microns, measurement by testex

5.1.2 / First 25 pipes and 4
17 Surface Profile 2.5 / 3.1 (replica) tape. The test shall be performed in accordance with ISO QF 07-2b H W1 R
8.3.3 pipes per shift thereafter
8503-4.
If the defect or repair size greater than 10 cm² of the pipe surface
area shall be reblasted. And also the pipe shall be reblasted if any
Surface Preparation QF 07-1 /
18 5.1.2 3.1 pipe does not achieve the following requirements, If required H W1 R
Rejection QF 07-2b
- Visual Standard,
- Surface Profile.
After blast cleaning the pipes shall be thoroughly inspected for

surface defects such as raised slivers, laminations, or hackles of GloQ-410 /
steel visible on the surface. The defects shall be removed by RF 002 / QF
19 Metal Defects 3.1 If required H W1 R
grinding and/or filing. The acceptance criteria for wall thickness shall 01-3 / QF 07-
be in accordance with API 5L. If not in the above range pipe shall be 1
quarantined for Non-Conformance.
Surface chlorides shall be measured with the use of an Elcometer

130 SCM 400 salt meter in accordance with ISO 8502. The
Residual External Surface Chlorides shall be <2microgram/cm² (<20
Surface Chlorides on mg/m²).
Start of Shift & Every 4
20 Abrasive Blast Cleaned 5.1.2 3.1 QF 07-1 H W1 R
hour
Pipes Note: The Residual surface chloride test shall be conducted on
random pipes during receipt; If any pipe with surface chloride level
more than 2μg/cm² (≥20 mg/m²) shall be quarantined and Customer
informed.

Approval Inspection
BSIBV-
(PP)
RH(%) Max. Elapsed time (Hours)

85 0.5
80 1.0
70 1.5
60 1.75
Elapsed time from Abrasive Start of Shift & Every 2
21 2.7 50 2.0 QF 07-2b H W1 R
blast to Acid Application Hours
Note: The total allowable elapsed time between completion of the
blast cleaning operation and commencement of the coating
operation shall be such that no detectable oxidation of the pipe
surface occurs.
Following abrasive blast cleaning, the pipe surface shall be pre- • All production pipes
treated 100% coverage with Phosphoric Acid. Acid Contact time shall be acid treated.
shall be minimum 20 Seconds at a pipe temperature of 43-65°C.
For every °C below 43°C the acid contact time shall be increased by • Acid contact time and
QF 023 / QF temperature shall be
22 Phosphoric Acid Treatment 2.7 / 3.2 1 second. H W1 R
01-3 recorded for first 3 pipes
The pH of acid shall be ≤ 1. The pH of Phosphoric acid shall be and in every 1 hour.
checked in the laboratory at once per hour. The test shall be • pH of acid shall be
recorded on report form QF 01-3. checked once per hour.
The acid treated pipe shall be passing through high-pressure All production pipes
(Minimum 1200 psi) fresh water wash rinse prior to pipe preheating. shall be water washed /
QF 023 / QF pH and conductivity of
23 Water Wash 2.7 / 3.2 H W1 R
The conductivity of water used for water wash shall be less than 30 01-3 water shall be checked
µS. The pH of Water shall be >6 to <8. The pH of water shall be Once per shift from the
checked in the laboratory at once per shift. laboratory
24 Pipe Drying 2.7 Maximum drying effect by use of clean dry compressed air. N/A All Pipes H M R

Approval Inspection
BSIBV-
(PP)
The pipe shall be heated by Induction Heating System to a

temperature of in accordance with manufacturer recommendation
Monitor Continuously.
(204°C to 240°C for Valspar Pipeclad 2000). The pipe temperature
25 Preheating of pipes 2.8 / 3.3 QF 028 Record in every 30 H W1 R
shall not exceed 274 °C at any stage of the process. The
minutes
temperature shall be monitored using Calibrated surface pyrometers
and/or infra red guns.
Pre-coating Inspection of The coating booth and extruders shall be inspected to ensure that
26 Coating Booth and there is no accumulation of coating material and that the extruders - Start of each shift H M R
Extruders are working effectively.
The fluidized powder shall be applied by electro-static spray guns on
27 Powder application 5.2.1 2.9 / 3.4 the entire pipe surface at a temperature recommended by the - All Pipes H M R
powder manufacturer.
Minimum thickness of FBE

FBE thickness shall be minimum 200 microns and maximum 300 Every day at the
28 layer on partially coated pipe 5.2.1 3.4 / 3.8 QF 07-3 H W1 R
microns. beginning of the shift
section
The fluidized Adhesive Powder shall be applied by powder spray
guns on the entire FBE coated pipe. Application of adhesive will be
29 Adhesive Application 5.2.2 2.10 / 3.5 - All Pipes H M R
timed to occur before the FBE powder has cured. Smooth even
coating.
Minimum thickness of
Smooth even coating. The thickness shall be minimum 150 Every day at the
30 Adhesive layer partially 5.2.2 3.5 / 3.8 QF 07-3 H W1 R
microns and maximum 250 microns. beginning of the shift
coated pipe section
Polyethylene Application Virgin Polyethylene extruded sheet is spirally wound in multiple

31 5.2.3 2.11 / 3.6 - All Pipes H M R
(Top Coat) layers so that a homogeneous layer of Polyethylene is formed.
Rough coat Application Additional ‘coat’ shall be spray applied to produce a rough coating
All Pipes (Concrete
32 (Borealis Borcoat HE 7405 - 5.2.4 2.11.1 surface and to improve anti-slip properties on the pipe used for - H M R
coating pipes)
Sinter Coat) concrete coating.

Approval Inspection
BSIBV-
(PP)
On completion of the coating process, the coating shall be

quenched with potable water for cooling and the method of
All pipes / Record in
33 Water Quenching 5.3 2.12 / 3.7 quenching shall be such that the coating will not sustain mechanical QF 07-3 H W1 R
every hour
damage as the pipe travels along the conveyor. The coating shall be
cooled to below 60°C.
Coating thickness shall be inspected and recorded in accordance
with Annex A of ISO 21809-1 with following procedure,
-On each pipe to be tested, a total of 12 single readings shall be

carried out in accordance with ISO 2808. If any of these 12 readings
is below the minimum coating thickness, an additional 4 readings
shall be taken around this area. The average of the additional 4
readings and the initial reading shall be higher than the minimum
7.2 / thickness. The measurements shall be taken at points distributed QF 07-3 /
34 Full system Thickness 3.8 All Pipes H W1 R
8.4.2 along 4 equally space longitudinal lines at the pipe length with three TF 007
equally circumferential lines on the middle of the pipe . The coating
thickness shall be as per below table,
The cut back shall be 130 +20/-0 mm both pipe ends, bevel angle
(chamfer) shall be ≤30°. The FBE Toe shall be15 mm (-
5mm/+15mm).
7.3 / QF 07-3 /
35 Cut Back 2.14 / 3.8 All Pipes (Both ends) H W1 R
8.4.3 QF 01-3
Note: Any damage on the FBE toe without exposing steel and/ or
adhesive residue on the FBE toe shall be accepted as it is, no repair
required.

Approval Inspection
BSIBV-
(PP)
Freshly coated pipe shall be visually inspected as soon as it leaves

the cooling racks. The coating shall be smooth, of uniform color and
Visual Inspection (3-Layer 7.1 / QF 07-3 /
36 3.8 gloss, and free of blisters, pinholes, scratches, lumps, heavy surface All Pipes H W1 R
system) 8.4.1 TF 007
marks, or any irregularities. Cosmetic water marks on the surface
are acceptable.
Holiday detection shall be carried out at a travel speed of
approximately 30cm/second. The holiday detector shall be set to 10
37 Holiday Detection 6.3 / 7.4 2.13 / 3.8 kV per mm (1 kV for 0.1 mm) of coating thickness (25 kV maximum QF 07-3 All Pipes H W1 R
in accordance with Annex B of ISO 21809-1). 100% of the coating
surface shall be holiday detected.
End caps shall be reinstalled on each end of pipes after completion
38 Reinstallation of End Caps 9.5 - All Pipes H M R
of all the process, before leaving from the plant.
The DSC analysis shall be performed in accordance with Annex D
of ISO 21809-1. The acceptable value is, Δ Tg = -2°C to +3°C.
39 DSC Test (FBE) 3.8 QF-024 Once per day H W1 R
DSC Heating cycles are as per the FBE manufacturer specification
or test method.
The test shall be performed in accordance with ISO 21809-1 Annex

7.5 / C. The acceptable values are below,
QF-07-5 & QF-
40 Peel Test (3LPE) Table 6 / 3.8 ≥750 N/50mm at 23°C ± 3°C and Once in every 4 hours H W1 R
07-5-1
8.5.5 ≥150 N/50mm at 65°C ± 3°C.
Note: The test will be performed at cut back area of coated pipes.
The Cathodic Disbondment test shall be carried out in accordance

7.5 / with Annex H of ISO 21809-1. The test requirement shall be as
41 Cathodic Disbondment Table 6 / 3.8 follows, QF 07-6 Once per day H W1 R
8.5.8 24 Hrs, -3.5 volts @ 23°C ± 3°C. The average disbondment shall
be ≤7mm.
7.5 / Elongation at break shall be tested in accordance with ISO 527.
Elongation at Break & Tensile Table 6 /
41 3.8 Elongation at break shall be ≥500% @ 23°C ± 3°C. The Tensile QF 07-6 Once per PE batch H W1 R
yield strength 8.5.1 /
8.5.2 yield strength shall be minimum 15 MPa.

Approval Inspection
BSIBV-
(PP)
The ‘bending’ method shall use samples 25 mm wide by 200 mm

long. These shall be bent over an appropriately sized mandrel at a
7.5 / test temperature of 0°C.The arc length of the mandrel shall be 225
Flexibility test of 3LPE coated
42 Table 6 / 3.8 mm ±5 mm. After bending, the coating shall not exhibit visible signs QF 07-6 Once per day H W1 R
pipes
8.5.7 of cracks, disbondment, or pinholes and shall pass a holiday
detection tested. Limit of strain shall be 2% at 0°C. The test shall be
carried out as per ISO 21809-1 Annex I.
The Indentation Test shall be carried out in accordance with Annex

7.5 /
F of ISO 21809-1. The test requirement shall be as follows,
43 Indentation Test Table 6 / 3.8 QF 07-6 Once per PE batch H W1 R
: 23°C ± 3°C, Maximum indentation shall be < 0.2 mm for 24 hrs.
8.5.6
: 65°C ± 2°C, Maximum indentation shall be < 0.4mm for 24 hrs.
The Impact Test shall be carried out in accordance with Annex E of

ISO 21809-1. The test requirement shall be as follows,
7.5 / The test shall be carried out at 23 ºC ± 3 ºC. The impact energy
Impact resistance (Full 3LPE
44 Table 6 / 3.8 shall be >7 J/mm. No holidays when tested. The coated pipe QF 07-6 Once per PE batch H W1 R
system)
8.5.3 sample shall be cut for testing.
Note: The holiday detector shall be set to 10 kV per mm of coating
thickness (25 kV maximum in accordance with NACE RP0274).
7.5 /
The Shore D Hardness Test shall be performed in accordance with
45 Shore D Hardness Table 6 / 3.8 QF 07-6 Once per shift H W1 R
ISO 868. The acceptable value shall be ≥ 55.
8.5.4
The defect area shall not exceed 100 cm² and the total number of
defects being repaired shall not exceed three (3) defecta per pipe
joint unless otherwise specified. The above repair criteria is not QF 07-3 /QF
46 Repairs 6.2 2.16 If required H W1 R
applicable for handling damages and repair of test pipes. If the 07-9
damaged areas requiring repair on any single pipe exceed above
values, the pipe shall be stripped and re-coated.

Approval Inspection
BSIBV-
(PP)
Stripped to bare metal and re-processed. The rejected 3LPE coated

47 Stripping of reject pipes 2.17 pipe shall be heated internally up to maximum 230°C using an QF 026 If required H R1 R
internal gas torch lance fed along the internal length of the pipe.
Profile Gauge shall calibrated against a calibrated shim. QF 500-1 Once per Shift
Coating Thickness Gauge shall calibrated against a calibrated
QF 500-1 Once per Shift
thickness shim/ plate at the nominal coating thickness.
48 Calibration 2.2 Digital Contact Thermometer shall calibrate with calibrated H R1 R
QF 500-1 Once per Shift
Equipment.
Holiday detector shall be calibrated with calibrated voltmeter, the
test voltage shall be 10kV per mm of coating thickness with a QF 500-1 Once per Shift
maximum of 25 kV in accordance with NACE RP0274.
After completion of PE coating, the pipe identification shall be clearly
applied at one end of the coating. The stencil marking is not
required, if the pipes are undergoing for concrete coating.
All anticorrosion coated

49 Marking of coated pipes 9.6 2.15 - H W1 R
pipes
Note: The stencil marking may burnished / rubbed off while transporting or
handling the coating pipe, the coater shall not be responsible for such issues. The
appropriate identification number shall be marked on the internal surface of the
pipe.
Partial / complete release After completion of all the production tests, Inspection release notes
for load-out of coated pipes shall be submitted to BSIBV from Customer Representative, when
50 3.8 QF 032 Accepted pipes H H H
/ Issue of Inspection all QC documents are approved. Partial / complete release shall be
Release Note issued for load-out of coated pipes.
Final documentation shall be submitted to Client/TPI, by BSIBV
51 Final documentation 3.8 once entire documentations are completed. Th final documentation MRB All coated pipes H H R
shall be prepared in accordance with approved MRB Index.


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Epandi@t

a Melt Flow Index

Doc. No.: BSIBV-ITP-07-2 (PE), Rev. 0 Page 2 of 10

Doc. No.: BSIBV-ITP-07-2 (PE), Rev. 0 Page 3 of 10

The Dust level shall be checked by adhesive tape method in

Surface Profile shall be 50-75 Microns, measurement by testex

After blast cleaning the pipes shall be thoroughly inspected for

Surface chlorides shall be measured with the use of an Elcometer

Doc. No.: BSIBV-ITP-07-2 (PE), Rev. 0 Page 4 of 10

RH(%) Max. Elapsed time (Hours)

Doc. No.: BSIBV-ITP-07-2 (PE), Rev. 0 Page 5 of 10

The pipe shall be heated by Induction Heating System to a

Minimum thickness of FBE

Polyethylene Application Virgin Polyethylene extruded sheet is spirally wound in multiple

Doc. No.: BSIBV-ITP-07-2 (PE), Rev. 0 Page 6 of 10

On completion of the coating process, the coating shall be

-On each pipe to be tested, a total of 12 single readings shall be

Doc. No.: BSIBV-ITP-07-2 (PE), Rev. 0 Page 7 of 10

Freshly coated pipe shall be visually inspected as soon as it leaves

The test shall be performed in accordance with ISO 21809-1 Annex

The Cathodic Disbondment test shall be carried out in accordance

Doc. No.: BSIBV-ITP-07-2 (PE), Rev. 0 Page 8 of 10

The ‘bending’ method shall use samples 25 mm wide by 200 mm

The Indentation Test shall be carried out in accordance with Annex

The Impact Test shall be carried out in accordance with Annex E of

Doc. No.: BSIBV-ITP-07-2 (PE), Rev. 0 Page 9 of 10

Stripped to bare metal and re-processed. The rejected 3LPE coated

All anticorrosion coated

Doc. No.: BSIBV-ITP-07-2 (PE), Rev. 0 Page 10 of 10

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