Fusion Bonded Epoxy For External Pipeline Coating-MS

Chevron Specification COM-MS-4042-C
FUSION BONDED EPOXY FOR EXTERNAL PIPELINE COATING

Commented Copy - Not for Vendor/Contractor Distribution
SPECIFICATION COM-MS-4042-C
NOTE: This document is the "Commented" version of the Specification COM-EG-

4042-B. The comments, based on Company experience, provide background for the
requirements stated in the Specification. These comments are for Company use only,
not for distribution to Vendors.
Copies of the EG Specification (without comment) are available in both hard copy
(paper) and electronic (MS Word for Windows) format. To order, contact CRTC
Technical Standards at either (510) 242-7232 or -7241. Copies of the MS Specification
are available only electronically. To order, contact CRTC Technical Standards at (510)
242-7241.
January 1996 Page 1 of 26


CONTENTS
1.0 SCOPE .................................................................................................................................3

1.1 General ..................................................................................................................................3
1.2 Conflicting Requirements ........................................................................................................3
1.3 Industry Standards ..................................................................................................................3
2.0 MATERIALS........................................................................................................................3
2.1 Piping ....................................................................................................................................3
2.2 Coating ..................................................................................................................................4
2.3 Batch Information....................................................................................................................4
2.4 Repair Materials .....................................................................................................................5
3.0 APPLICATION....................................................................................................................6
3.1 General ..................................................................................................................................6
3.2 Surface Preparation.................................................................................................................7
3.3 Heating ..................................................................................................................................9
3.4 Coating Application ..............................................................................................................10
4.0 INSPECTION ....................................................................................................................12
4.1 General ................................................................................................................................12
4.2. Surface Preparation...............................................................................................................14
4.3 Preheat Temperatures............................................................................................................14
4.4 Thickness.............................................................................................................................15
4.5 Holiday Detection.................................................................................................................15
5.0 COATING REPAIR ...........................................................................................................17
5.1 Rejected Coatings.................................................................................................................17
5.2 Holiday Repair .....................................................................................................................17
6.0 QUALITY CONTROL TESTS...........................................................................................18
6.1 Sample Frequency ................................................................................................................19
6.2 Bend Test.............................................................................................................................19
6.3 Differential Scanning Calorimeter Analysis.............................................................................20
6.4 Adhesion Test ......................................................................................................................21
6.5 Foam Structure Test..............................................................................................................21
6.6 Cathodic Disbondment Test...................................................................................................21
7.0 HANDLING AND STORAGE PROCEDURES..................................................................22
APPENDIX I ..................................................................................................................................24
APPENDIX II................................................................................................................................. 26
Page 2 of 26 January 1996


1.0 SCOPE
1.1 General
This specification covers the minimum material, application, and handling requirements for
fusion bonded epoxy (FBE) powders used for external pipeline coating.
1.2 Conflicting Requirements
Several testing and surface preparation standards are referenced in this specification. The
latest editions of these standards shall be considered a part of this specification. In case of
conflict, this specification will take precedence over the referenced documents.
1.3 Industry Standards
Fusion bonded epoxy shall conform to the following specifications, except as supplemented in
this Specification. The latest published industry standard shall be used.
1.3.1 Steel Structures Painting Council (SSPC)
SSPC SP1 Surface Preparation

SSPC SP10 Near-White Metal Blast
SSPC VIS-1 Pictorial Surface Preparation Standards for Painting Steel
Surfaces
1.3.2 National Association of Corrosion Engineers (NACE)
RP0490-90 Standard Recommended Practice, Holiday Detection of Fusion Bonded

Epoxy External Pipeline Coating of 10-30 mils (0.25 to 0.76 mm).
Comment 1.3 There are written and visual standards for surface preparation. The SSPC
documents, the industry standard, are a written description of a visual thing. The NACE
visual standard duplicates the SSPC words but also has corresponding samples of blasted
steel encased in plastic. The NACE standard is acceptable if the applicator is not used to
using SSPC VIS-1. The NACE Recommended Practice RP0490-90 provides guidelines on the
proper use of holiday detectors.
2.0 MATERIALS
2.1 Piping
Piping shall be supplied without varnish or mill lacquers.


Comment 2.1 Pipe, whether purchased by the Company or the Applicator, should come
from the mill without varnish or mill lacquers. These are almost impossible to remove well
enough so that they will not affect the adhesion of the FBE. Their removal requires burning
off of the contaminant followed by blasting. Also, varnishes and lacquers will contaminate
the blast abrasive.
2.2 Coating
Shop-applied external coating material shall be a powdered resin for application by the fusion-
bonded process, as specified on the purchase order or contract.
Comment 2.2 The following FBE coatings are recommended on the basis of field
experience and laboratory testing:
Up to 200°F 3M 206N
International Interpon HD3005
NAP-GARD Mark X
Up to 150°F Valspar D1003LD

Lilly Pipeclad
We will revise the temperature limits of the above coatings when we acquire more service
experience with them. Other FBE coatings are available. The Materials and Equipment
Enginering Unit of Chevron Research and Technology Company can help with evaluating
coatings and their temperature limits.
2.3 Batch Information
2.3.1 Each container of powdered coating materials used by the Applicator shall be marked
with the following information:
• The manufacturer's name.

• The material identification number.
• The batch number.
• Date of manufacture.
• The shelf life and storage temperature limits.
Comment 2.3.1 The Applicator generally supplies the material.
2.3.2 The fusion bond epoxy manufacturer shall supply the information listed below for
each batch of powder. Standards for comparison shall also be provided for each
item. This information will be used to check that no changes have been made in the
epoxy formulation.


• Infrared scan of powder and typical powder scans for comparison.

• Gel time at recommended application temperature.
• Particle size distribution.
Comment 2.3.2 The above information on each batch of powder will ensure that
ingredients have not been left out, changed, or improperly mixed. Infrared scans
characterize the composition or fingerprint of the material. Any changes in
formulation between batches will be detected. Gel time measurements will vary
significantly if ingredients are missing or added in the wrong proportion.
Knowledge of particle size distribution assures the powder was made correctly and
will have the same application properties as previous batches.
The manufacturer knows this information from quality control testing. Invoking
Paragraph 2.3.2 should not cost the Company more money.
2.3.3 Coating powder shall be segregated by batch numbers during shipment, storage, and
handling. Batches shall be used consecutively during coating application and shall
not be mixed except when necessary to keep the coating process continuous.
Comment 2.3.3 Segregation of batches prevents the mixing of a bad batch with a
good batch of powder and ruining the good batch.
2.3.4 No powder stored beyond the manufacturer's recommended shelf life shall be used
for coating pipe.
Comment 2.3.4 Powder epoxies will "age" with time by curing and/or absorbing
water. Both curing and water absorption will affect the application and protection
properties of the coating. Therefore, the use of coatings stored beyond their shelf
life should not be allowed.
2.4 Repair Materials
Comment 2.4 See Section 5.2 for more information on repair materials and their use.
2.4.1 Materials for touch-up or repairs shall be the original powder, the manufacturer's two-
part epoxy repair material, or other compatible material approved by the powder
manufacturer.
2.4.2 Coating and repair materials shall be stored, handled, and applied in strict accordance
with the manufacturer's specifications or as directed by an authorized manufacturer's
representative.


3.0 APPLICATION
3.1 General
3.1.1 The fusion bonded epoxy coating shall be applied in accordance with the coating
manufacturer's application procedures. The Applicator must have a copy of these
procedures at the site where the coating is being applied. Any deviation from the
coating manufacturer's application procedures shall be submitted to the Company
representative for approval.
Comment 3.1.1 Coating manufacturer's application procedures and data sheets

are often the best technical references for a coating. Both the Applicator and the
Company representative should have copies.
The last sentence of 3.1.1 was included because coating applicators often think they
know more about application parameters than the coating manufacturers--and they
frequently do. This requirement allows us to double-check anything that appears
inappropriate.
3.1.2 It shall be the Applicator's responsibility to stop the coating process at any time when
conditions may exist that might adversely affect the coating quality. The Company
inspector may reject any product not proven by the Applicator to be in compliance
with this specification.
3.1.3 Proper equipment for the handling, unloading, and temporary storage of bare pipe
shall be used to avoid any damage to bare pipe and pipe ends, or obliteration of
necessary pipe markings. Each coated length of pipe shall be externally stencilled at
a point approximately 60 cm (24 in) from the end to reproduce the original marking
and to identify the type of coating applied, Purchase Order number, pipe size, pipe
grade and date coated. The Applicator shall also take special care to avoid damage
to any internal coatings during all phases of the external coating process.
3.1.4 The finished coating shall have a cutback at each end of the pipe. The length of the
cutback shall be 1-inch minimum, 2-inches maximum (plus or minus one-half inch)
measured from the end of the pipe. If coating materials accumulate within these
areas, the cutback areas shall be buffed free of coating material.
Comment 3.1.4 A cutback of 2 inches is common practice to allow for welding.

The FBE should be covered with a flame-resistant material during welding to
prevent the formation of holidays due to weld spatter.


3.2 Surface Preparation
Comment 3.2 Surface finish of the pipe is critical to the successful application of FBE.
The presence of rust, mill scale, grease, oils, salts, and chemical contaminants can prevent
FBE from adhering to the steel. Therefore, the following requirements must be strictly
adhered to.
3.2.1 Prior to abrasive cleaning, all oil, grease, salts, and other deleterious materials shall
be removed by solvent cleaning in accordance with SSPC SP1 or by detergent
washing or steam cleaning. No residue that will affect adhesion shall be left on the
surface.
Comment 3.2.1 If we don't chemically clean the surface before abrasive cleaning,
contaminants become worked into the surface during blasting and cause early
coating failures. Chemical cleaning is also done before blasting to prevent
contamination of the abrasive. Mill varnish and lacquers are typically removed by
burning with gas flames followed by blasting. Salts are removed using high
pressure water and/or phosphoric acid-based treatments.
3.2.2 The pipe shall be preheated prior to blast cleaning to a temperature at least 5 degrees
in excess of the dew point or higher if recommended by coating manufacturer or Ap-
plicator. All pipe shall be preheated in a uniform manner to avoid distortion of the
pipe and/or damage to internal coatings.
Comment 3.2.2 Preheating above the dew point dries the pipe and thereby
prevents "flash rusting" of the pipe after blasting. Heating methods are discussed in
Section 3.3.
3.2.3 All external surfaces to be coated shall be cleaned to a near-white metal finish in
accordance with Specification SSPC SP10. Abrasive cleaning on steel pipe surface
shall have a slightly angular pattern. Particle hardness and size distribution of the
shot employed shall be continually controlled by screening to ensure that the surface
profile after cleaning shall have a nominal height of 2.0 mils, with a minimum height
of 1.5 mils, and a maximum height of 2.5 mils as measured by Testex Press-O-Film
replication tape and SSPC-VIS-1. All cleaning shall be done in such a manner that
beveled ends and any internal coating will not be damaged.
Comment 3.2.3 The allowed anchor patterns can usually be met by careful
selection of the abrasive and its mesh distribution. Consider prequalifying the
surface finish obtained from the Applicator's abrasive. Prequalification can save
innumerable arguments later about surface finish. Also note that some coatings
manufacturers specify anchor patterns of up to 3.5 mils. In these cases, follow
Manufacturer's specifications.


3.2.4 For consistent surface finish, a stabilized working mix shall be maintained by frequent
small additions of new abrasive commensurate with consumption; infrequent large
additions shall be avoided.
3.2.5 The working abrasive mix shall be maintained clean of contaminants by continuous
effective operations of cleaning machine scalping and air wash separators.
3.2.6 After abrasive cleaning and before coating, the surface to be coated shall be carefully
inspected for metal defects which may affect coating application, i.e., scabs, slivers,
gouges or laminations. The Applicator shall be responsible for the repair of any
defects which can be repaired by filing or grinding of the repair and for restoring the
anchor pattern at the locations of such repairs when the size of the repair exceeds
3 inches in any direction. The tools and manner employed to remove metal defects
shall not contaminate the surface.
3.2.7 If the profile is destroyed over a single area greater than 25 in.2 or over a total area
greater than 0.5% of a pipe joint, the pipe shall be reblasted at no expense to the
Company.
3.2.8 Surface preparation shall not reduce the pipe wall thickness below the minimum
required by the pipe specification.
3.2.9 After surface preparation is complete and before heating the pipe, pressurized air or a
vacuum shall be used to remove all loose abrasive, metal, or other contaminating
particles. Both the exterior and interior of the pipe shall be cleaned. The air shall be
properly filtered to be clean and dry so as not to contaminate the pipe.
Comment 3.2.9 One of the biggest surface preparation problems is blasting dust
that falls back onto the pipe. This dust must be removed before the FBE will adhere
to the pipe. One way to check for dust is by putting adhesive tape on the pipe
surface and then pulling it off to look for particles on the sticky side.
3.2.10 Total elapsed time between cleaning and coating of the cleaned surface shall be kept
to a minimum to avoid the formation of oxides on the surface. Oxidation of the steel
prior to coating, in the form of "blooming" or other apparent oxide formation, is not
acceptable. Visual formation of such oxides shall cause the pipe to be recleaned
prior to coating. Any pipe not coated within three hours after cleaning shall be
completely recleaned before coating at Applicator's expense.
Comment 3.2.10 The three-hour time limit is a variable. It is included to prevent

blasting of the pipe on one day and coating on the next. In most coating plants, the
pipe goes from blasting to inspection to coating in a continuous process, so time
between blasting and coating is minimal.


Note also that various epoxy powders are used with either a phosphoric acid or a
chromate surface pretreatment. These treatments are applied after blasting and
prior to preheating of the pipe for coating. Test data show that these pretreatments
increase the bond strength between the pipe surface and the FBE and reduce the
tendency of FBE to cathodically disbond. Chemical pretreatments should be quick
drying and should leave no salts or other contaminants on the surface of the pipe.
Whether the pretreatment should be applied immediately after blasting and can sit a
few hours before the pipe is coated or whether it should be applied just before the
pipe is preheated in preparation for coating, is a function of the product. Refer to
the pretreatment manufacturer's specifications.
3.3 Heating
3.3.1 Before coating, the pipe shall be heated so that its temperature is within the
application temperature range recommended by the coating manufacturer when it
reaches the coating application area. The temperature shall not exceed 500°F.
Oxidation (bluing) of the steel is not acceptable.
Comment 3.3.1 Two techniques are commonly used to heat the pipe: gas furnaces
or magnetic induction coils. We are not aware of anything in either method that
would affect the quality of the coating.
The coating temperature of the pipe should always be within the range specified by
the coating manufacturer during powder application. A maximum temperature limit
of 500°F is necessary to avoid degradation of the pipe toughness due to strain
aging effects. Strain aging is a metallurgical precipitation reaction occurring
between 500°F and 700°F. Steel chemistry, method of steel manufacture, prior heat
treatment, and percent cold work can affect the susceptibility of the steel to strain
aging.
Another factor to be aware of is the formation of bubbles in the FBE coating. These
bubbles or "foam structure" form when the pipe is too hot and can decrease the
coating's impact resistance. Applying the powder to a pipe which is too cool will
result in a partially cured coating and poor bond strength. See Section 6.5 for more
details.
3.3.2 The furnace atmosphere shall be such that the clean pipe surfaces are not
contaminated.
Comment 3.3.2 Gas-fired ovens must be properly adjusted so that no combustion

products are deposited on the steel surface.


3.3.3 The temperature of the pipe shall be monitored continuously and recorded by means
of thermometers and/or optical pyrometers.
Comment 3.3.3 Pyrometers are often hard to calibrate and keep calibrated, so
Paragraph 3.3.4 is needed.
3.3.4 For accurate control of pipe temperature, the pipe shall be periodically checked with
"Tempilstik" heat-indicating crayons or other suitable devices, provided that the
amount of material deposited and the length of marks will be limited to 1/8 inch wide
by 1/2 inch long. The Tempilstik marks shall be wire brushed from the pipe surface
before application of the coating.
Comment 3.3.4 Although Tempilstiks are a quick and accurate means of measuring
temperature, their use should be minimized. They should only be used to check the
continuous monitor. The reason behind this is that they contaminate the pipe and
affect the adhesion of the FBE.
3.3.5 Pipe heated above 500°F shall be replaced and coated by the Applicator. The actual
Company invoiced cost of scrapped pipe, including pipe, coating, and transportation,
shall be deducted from the amount due the Applicator.
Comment 3.3.5 See Comment 3.3.1 for reasons behind the 500°F temperature
limit.
3.4 Coating Application
Comment 3.4 FBE coatings are usually applied using electrostatic spray guns. It is
important that air in the coating chamber and supporting systems is clean and dry.
Moisture can cause deposition problems as well as craters and holidays in the finished
coating.
3.4.1 The pipe shall be coated while its surface temperature is within the manufacturer's
recommended temperature limits.
3.4.2 The coating shall be applied to produce a uniform coating thickness as specified in
the purchase order. Any coating area measured to be less than the specified minimum
thickness will be cause for rejection of that joint.
Comment 3.4.2 The thickness of FBE to be used depends on the service the coating
will see. In general, consider:
• Subsea or Dry Lines:
≤ 150°F, 14 mils (min.)

> 150°F, 30 mils (min.)


• River crossings, or drilled crossings, or highly irrigated areas, or areas subject to

continuous wetting and drying, or areas where agricultural chemicals are present:
≤ 150°F, 20 mils (min.)

> 150°F, 30 mils (min.)
The thickness of FBE should be carefully considered. Increasing the thickness

increases cost and decreases flexibility. It also makes the coating harder to apply
because there has to be enough heat in the pipe to cure the outer layers of the
coating, but not so much heat that the coating is filled with bubbles from escaping
volatiles. However, increasing the thickness improves the cathodic disbondment
and penetration resistance, decreases the chance of having holidays, and hinders
water permeation.
When using coatings over 20 mils thick, keep a careful watch on the quality control
test results from Section 6.0. Be sure to check the coating for internal bubbles and
layering. Layering will show up as flaking of the outer layers during the bend test.
If the thickness required for corrosion protection does not allow bending of elbows
to a sharp enough radius, consider having FBE hand-spray-applied to pre-bent
elbows, applying two-part liquid epoxies or tape wraps. Tape wraps are the least
favorable of coatings for bend protection (refer to this manual's section on External
Pipeline Coatings).
Consult with coatings manufacturers and the Materials and Equipment Engineering
Unit of Chevron Research and Technology Company on thickness for various
applications.
3.4.3 Powder batches shall not be mixed together except as necessary to keep the coating
process continuous. The Applicator shall record all batch numbers used along with
other information necessary for the Company to relate the powder batches to the
joints of pipe on which it was applied. No batch of powder shall be applied prior to
the Company having in its possession all of the required batch information and having
accepted the powder.
Comment 3.4.3 When batches are mixed together only as needed, fewer joints are
coated with a bad batch of powder and the amount of good powder contaminated by
the bad powder is reduced.
3.4.4 The use of recycled powder is permitted, provided that it has not been contaminated,
has not been heat affected, and is continuously recovered and reprocessed through
magnetic separators. It shall be uniformly mixed with new virgin powder.


Comment 3.4.4 Paragraphs 3.4.3 and 3.4.4 are included to help keep the
properties of the coating uniform. Paragraph 3.4.4 is intended to prevent the
Applicator from sweeping the powder up off the floor and mixing it with new
powder, before it is separated from contaminants which may be on the floor.
Old specifications required that the amount of reclaimed powder be no more than
10-20%, depending on the specification. This is hard to measure. A better way to
watch for problems is to look for poor results from the tests listed in Section 6.0
and to watch for excessive holidays and craters in the coating. Applicators
generally try to minimize the overspray anyway because it costs them money to
rehandle and clean the powder.
3.4.5 Manufacturer's recommendations for full curing shall be followed. The curing reaction
of the coating must be completed prior to any forced cooling. Forced cooling of the
pipe to facilitate inspection and repair may be conducted after the coating has
completely cured.
Comment 3.4.5 The Applicator must allow the coating to cure completely before
cooling the pipe to a temperature at which it can be handled. Incompletely cured
coatings can have poor impact, adhesion, and bending properties.
3.4.6 The cured coating shall be of uniform color and gloss and shall be free of blisters,
pinholes, fish eyes, sags or runs, and any other irregularities.
3.4.7 Any coating which, in Company representative's judgment, has not been applied in
conformance with these specifications shall be rejected.
4.0 INSPECTION
4.1 General
4.1.1 The Applicator shall perform all inspection necessary to assure surface preparation
and coating application comply with the requirements of this specification. All work
shall be subject to Company inspection.
4.1.2 The Applicator shall notify the Company representative not less than five days in
advance of the start of each production run and shall provide him with a detailed time
schedule to permit him to witness all processing and testing phases.
Comment 4.1.2 The time limit required for notification of action by the Applicator
should be based on the time required by the Company inspector to get to the job
site. Last-minute notice or "we don't know exactly when we'll start" answers from


the Applicator do not need to be accepted. Some Applicator flexibility needs to be

allowed, but the Chevron inspector has the right to be notified of inspection
opportunities.
4.1.3 The Company's inspector shall be the final authority on the acceptability of surface
preparation and coating application.
4.1.4 The Company's inspector shall have access to each part of the process and shall have
the right and opportunity to witness any of the quality control tests and/or to perform
such tests himself on a random sampling basis.
4.1.5 The Company's representative shall have the right to halt the coating of pipe pending
alterations or corrections to the process to correct all faults found in the work that
result in failure of the work to conform to these specifications.
4.1.6 The coating Applicator shall keep the records indicated in Table I below and submit
these records to the Company daily for verification to the Company's satisfaction.
Table I
Required Records
Coating/Inspection Step Required Frequency
1. Surface Profile Check three locations per joint:

a. At beginning of each eight-hour shift and every
two hours throughout the shift.
b. Whenever any change in abrasive type or blast
pressure is made (see Section 4.2).
2. Thickness Five measurements per joint of pipe (see Section 4.4).
3. Repaired Holidays 100% inspected. Record number of repaired holidays

per joint (see Section 4.5.6).
Comment 4.1.6 Requiring regular recordkeeping and submittal is the most

effective way of getting compliance with the specification. Without this, there is too
much to observe and compliance quickly falls off. Also, noticeable changes in data
could indicate something has gone wrong with the coating process.
Chevron inspectors need to review the work and the record submittals in a timely
way in order to correct errors.


4.2. Surface Preparation
4.2.1 Surface cleanliness shall be judged against both written (NACE No. 2, SSPC-SP10)
and visual (NACE TM-01, SSPC VIS-1) standards. Surface cleanliness must be
inspected constantly.
Comment 4.2.1 Steel cleanliness is the most important inspection item in a

coatings job. Without the specified cleanliness, the best coating will not achieve its
design life. However, cleanliness is very subjective. All parties should use the
same standard. Use of the standard should quickly become unnecessary as all
inspectors reach a common agreement on what will be accepted.
Blasted surfaces should be viewed without magnification. A slight blotchy

appearance is normal.
In cases of disagreement, the written word should prevail over the visual standards.
4.2.2 The surface profile shall be checked at the beginning of every eight-hour shift and
every two hours throughout the shift (see Paragraph 3.2.3). The anchor pattern shall
be determined at three different places on the pipe joint. The readings shall be
recorded. Anchor patterns shall also be checked if abrasive material or blast pressure
is changed and after grinding of slivers.
Comment 4.2.2 There are many acceptable anchor pattern measurement tools.
Their results will differ. It is important that all parties use the same tool. Do this to
avoid arguments over whose tool is right.
"Press-O-Film" tape is preferred because it is not subjective and gives a permanent

record. Another common type is called a comparator. It is acceptable but is
subjective and frequently leads to disagreements.
The Coatings Manual lists addresses for ordering inspection tools.
Anchor pattern measurements are statistical and should not be enforced with
absolute rigidity.
4.3 Preheat Temperatures
Optical pyrometers and/or thermometers shall be used to assure correct pipe temperature (see
Section 3.3). Tempilstiks may be used to check accuracy of the pyrometers and/or
thermometers, but their use must be minimized (see Section 3.3.3).
Comment 4.3 Although tempilstiks are a good way to measure temperature, they
contaminate the pipe surface and their use should be minimized. (Refer to Section 3.3.4.)


4.4 Thickness
4.4.1 The dry coating thickness of each joint shall be measured using a nondestructive
magnetic or electronic thickness gage. The gage shall be calibrated twice per eight-
hour shift using U.S. Department of Commerce Certified Coating Thickness
Calibration Standards for Nonmagnetic Coating of Steel.
4.4.2 A minimum of five (5) measurements randomly distributed along the length of each
joint of pipe shall be made and recorded, with notation of the minimum, maximum,
and predominant thickness measured.
4.4.3 Any joint of pipe with a measured thickness less than that specified in this
specification shall be rejected. Refer to Section 5.0 for procedures to recoat rejected
pipe.
Comment 4.4.3 Having a minimum thickness limit protects the coating from having
holidays and provides us with the minimum protection we require. Coatings with a
thickness greater than the minimum required are to our advantage, unless the pipe
must be bent. Consult with the coating manufacturer on coating thickness versus
bend radius for pipe with coatings thicker than specified. These joints may have to
be marked "Do Not Bend."
Coating thickness should be enforced in an even-handed, reasonable way.

Occasional minor deviations are normal and should be accepted. Pipes coated with
too thin a layer of FBE have to be sent through the coating system for reapplication
of the coating. Applying FBE over FBE is not recommended unless there is a
significant number of undermillage pipe. Normally, the FBE should be completely
removed and the pipe recoated. The main concern is adhesion between the two
layers of FBE. Conducting bend tests will verify adhesion. Some type of cleaning
and/or roughening of the FBE coating may be required.
All parties should use the same thickness gage. Watch out for miscalibrated gages.
Dropping a gage can cause miscalibration.
Standards for calibration are not always available. They can be ordered from the
address listed in the Coatings Manual.
4.5 Holiday Detection
4.5.1 All coated pipe shall be 100% inspected for holidays. Either a pulsating or a
nonpulsating spiral coil or wet sponge detector is acceptable, provided it meets and is
operated according to the requirements in NACE Standard Recommended Practice
RP0490-90. Use 100-125 volts/mil, or as recommended by the coating manufacturer.
The holiday detector shall have an audible alarm.


Comment 4.5.1 The goal is to specify a holiday detector without making the
Applicator have to purchase new equipment. However, they must use a detector
that will find holidays.
Use of too high a voltage can break down FBE and cause pinhole defects.
4.5.2 The holiday detector voltage shall be measured and recorded twice per shift with an
accurate DC voltmeter. The holiday detector shall be recalibrated after recording its
voltage or during noticeable changes in handling.
4.5.3 The detector electrode shall be in direct contact with the entire surface of the coating
being inspected. There shall be no gaps in the electrode or separations between the
electrode and the surface of the coating, including the surfaces on either side of the
longitudinal seam of the pipe.
4.5.4 The travel rate of the detector's electrode shall not exceed 1 foot/second and shall not
be allowed to remain stationary while the power is on. Refer to NACE RP0490-90 to
determine rate of travel.
4.5.5 All holidays and other coating defects, including without limitation primer blister,
crazed coating, lifted and unfilled pipe scabs, etc., shall be marked with a nongrease
marker and the number and nature of holidays and coating defects in each joint of
pipe recorded, as per Section 4.1.6.
Pipe joints not meeting the requirements below shall be rejected:
• The numbers of pinholes (defects less than 1 mm in diameter) shall be limited to

one per 25 ft.2 for any given joint.
• The number of larger holidays (to a maximum size of 3 in.2) shall be limited to
three per joint. Any holiday greater than 3 in.2 is unacceptable.
Rejected pipe shall be handled as described in Paragraph 5.1. Non-rejected pipe

joints that have defects shall be repaired as described in Paragraph 5.2.
Comment 4.5.5 The limit of one pinhole per 25 ft.2 of coated area is probably best
expressed in linear feet of pipe when the pipe diameter is known. Good records of
holidays and other defects are important for the detection of problems in the coating
process. A sudden increase in holidays or repeated thin spots in the coating are
indications that something has gone wrong.


5.0 COATING REPAIR
Each length of coated pipe leaving the Applicator's premises shall be free of holidays and visual
coating defects.
5.1 Rejected Coatings
All rejected coatings (those coated joints that fail to pass the criteria listed in Sections 4.0 and
6.0) shall be completely removed from the entire joint of pipe and the pipe surface reprepared
and recoated in conformance with the foregoing sections at no additional expense to the
Company.
Comment 5.1 Undercured coatings have been finish cured by reheating for predetermined
times and temperature. If a large number of pipes have been undercured, it may be worth
trying to finish curing a couple of joints to determine if a good quality coating can still be
obtained. As described in the next paragraph, removing an FBE coating is costly and time-
consuming.
FBE is typically stripped by heating the coating with open flame burners. This causes the
coating to break down so that it can be blasted off. Blasting alone will not remove FBE.
The burning procedures can typically be done without heating the pipe over 500°F.
However, the temperature of the steel should be carefully monitored.
5.2 Holiday Repair
All coating defects disclosed by visual or holiday detector inspection shall be repaired at no
additional expense to Company. For all holiday repairs where repairs are approved by
Company, the following procedure shall be followed:
5.2.1 Pinholes (defects less than 1 mm in diameter) need no more surface preparation. The
pipe to be repaired shall be cleaned to remove all dirt and damaged or disbonded
coating using approved means. The edges of the original coating shall be abraded
around the area to be coated 1/2-1 inch out from the pinhole and all dust wiped off
before applying the patch coating. Files shall not be used.
Comment 5.2.1 It is important to abrade the existing coating to remove the surface
"skin" along with accumulated contaminants. Generally, 80-100 grit sand paper or
a flexible sander are used. It is also important to avoid using files or grinders
because they will turn a pinhole into a large gap.
5.2.2 Large holidays require surface preparation of the steel. Any exposed metal must be
treated to remove contaminants such as corrosion products, salts, dirt, etc. using
abrasive blast or other means approved by the Company. The FBE must also be
abraded around the areas to be coated 1/2-1 inch from the edge of the coating and all


dust removed before applying the patch coating. The patch coating shall be applied
in accordance to Manufacturer's recommendations to a minimum thickness of 25 mils
and shall overlap the existing sound coating by a minimum of 1 inch.
Comment 5.2.2 The surface must be made just as clean now as it was before the
original FBE coating was applied. Again, avoid the use of files and grinding
wheels, which can enlarge the defect.
5.2.3 The material for patching repairs in the mill shall be those listed in Section 2.4 of this
specification. No thermoplastic patchsticks shall be used.
Comment 5.2.3 Thermoplastic patchsticks will provide an acceptable coating for

ambient (less than about 100°F) lines if they are applied properly. Applicators like
them because they are a quick way to repair a coating. However, they are often
improperly applied and, therefore, not recommended. Patchsticks should never be
used to repair "large" defects.
The reason for the 100°F temperature limit (which we believe is conservative) is
that patchsticks are made of thermoplastics; that is, they can be repeatedly softened
with heat. Catalytically cured two-part epoxies are thermosets, meaning they do not
soften when heated but will chemically decompose if heated above a certain
threshold temperature. The threshold temperature is far above the temperature
limits of FBE (200-225°F on pipelines). In addition, the two-part epoxy repair will
have properties closer to that of the original coating.
5.2.4 The freshly patch-coated areas shall be allowed to cure fully according to the coating
manufacturer's specifications prior to handling those areas.
5.2.5 After curing, all patches shall be visually inspected and jeeped with a wand electrode
of fine brass whiskers at a voltage of not less than 100 volts/mil and tested for
adhesion by knife lifting. The use of a wet sponge detector set at the manufacturer's
recommended parameters is also acceptable. The patch shall be holiday-free and
shall not disbond when lifted with a knife.
Comment 5.2.5 A knife is a good adhesion tester. If the repair has been done
improperly, picking at it with a knife will cause the repair to flake off the pipe in big
patches.
6.0 QUALITY CONTROL TESTS
The Applicator shall perform the tests listed in this section. The Company representative may be
present during the tests. Test results must be made available within 72 hours of taking the sample.
No pipe lot shall be accepted before the test results from the representative samples are known. If
any test results do not meet the specification, the Company will specify additional samples to be


tested at Applicator's expense. Also, the Company reserves the right to test additional samples at
Company's expense.
Comment 6.0 The following tests are included to ensure that Chevron gets a good quality
coating. Failure of these tests indicate that things have gone wrong somewhere in the coating
process.
6.1 Sample Frequency
From the joints listed below, the Applicator shall cut an 18-inch long strap from the pipe for
coating tests. The cut pipe ends shall be rebevelled and all burnt coating removed.
Sample No. From Joint No.
1 1
2 75
3 200
4 500
Etc. Every 500
joints thereafter.
Last The last joint.
Comment 6.1 The frequency of the following tests can be increased or decreased from that
recommended above depending on job size, work experience of the contractor, and results
of the tests. For small jobs (less than 500 joints), specimens should be taken at closer
intervals. Require enough specimens to satisfy the Company that the Applicator is doing a
good job. The first pipe is the most important because it tells whether or not the coating
parameters are set properly. Repeat the tests until the coating parameters have been fine
tuned. Expect to have to coat a number of joints until the process is refined.
If the job requires one batch of powder only, samples should be taken from the first joint,
the last joint, and a number of other joints.
6.2 Bend Test
The Applicator shall perform bend tests per Appendix I on each sample listed in Section 6.1.
Comment 6.2 The bend test is one of the best quality control tests available because it can
be done quickly and in the plant. The results of the bend test provide information on degree
of cure and adhesion. If the coating cracks and splits during bending, it has not been cured
properly. However, if the coating pops off the metal while bending, adhesion is poor.
Examine the back of the coating. The presence of dirt or dust, etc., means the pipe surface
was not properly cleaned. The presence of bubbles indicates that the pipe was overheated.


The results of this test should be used in conjunction with differential scanning calorimeter
results. (See Section 6.3.)
The test criteria listed in Paragraph 5 of Appendix I are fair values for coatings. If the pipe
being coated for the project must be bent more than is tested for by the 2.9-degree pipe
diameter criterion, consider increasing the criterion. Also, consult with the coatings
manufacturer on the bending limits of his coating.
Bend tests run at 32°F or 0°F are also becoming common. These tests are more severe than
room temperature tests and should be considered if the pipe will be used for cold
applications.
More information on the bending of small diameter pipe and bend tests, in general, can be
obtained from the Materials and Equipment Engineering Unit of Chevron Research and
Technology Company.
6.3 Differential Scanning Calorimeter Analysis
The Applicator shall perform a differential scanning calorimeter (DSC) analysis on each
coating sample listed in 6.1. Delta Tg shall be less than 5°C for the coating to be considered
fully cured.
If analysis shows any sample to be partially cured, it must be determined which pipes of the
lot were not properly cured. Those joints not properly cured will be rejected and repaired per
Paragraph 5.2.
Comment 6.3 The DSC test is good for determining the degree of cure of a coating.
However, it does have problems and does not always provide the correct answer.
Therefore, use both this test and the bend test. If the bend test results are good and the DSC
scan only slightly off, the coating is okay.
The DSC criterion of delta Tg = 5°C is common for most FBE's. However, some FBE's
have larger or smaller delta Tg values that indicate complete cure. Contact coating
manufacturers for their recommended delta Tg. Also, for coatings thicker than about
25 mils, get the DSC sample by scraping off the outer layer of coating. This area sees less
heat and may not be cured as well.
The DSC test is fairly expensive and must be run by trained personnel. Often the DSC
equipment and personnel are not available at the Applicator's shop. For "small" jobs, the
bend test and adhesion tests may be sufficient.
We do not recommend the MIBK (methylisobutylketone) solvent swab test for checking the
cure of FBE. A coating must be significantly undercured to fail the test, and some pigments
are soluble in MIBK. (The test method consists of holding an MIBK-soaked swab on the


pipe for one minute followed by 15 seconds of vigorous rubbing. No softening or color
removal should occur.)
6.4 Adhesion Test
At production start up, after production interruptions, at the start of using a new batch of
powder, and once every hour or 20 pipe lengths (whichever is more frequent), the adhesion of
the coating will be determined at one location on the pipe. If three tests have been successful,
the frequency may be reduced to once every two hours or 50 pipe lengths, whichever is
sooner.
Comment 6.4 This test is quick and simple and allows for frequent spot checks of the
adhesion of the coating and its cure. It is much less severe than cutting 18 inches of coated
steel from a pipe.
6.4.1 With a sharp knife of narrow width blade, two approximately 0.5-in. long incisions
shall be made through to the metal substrate to form an X.
6.4.2 At the intersection of the X, an attempt shall be made to force the coating from the
steel substrate with the knife point. Refusal of the coating to peel constitutes a pass.
Partial or complete adhesion failure between the coating and the metal substrate
constitutes a failure.
6.5 Foam Structure Test
The Applicator shall ensure excessive foaming does not take place. A cross-section
examination of the coating under a 40-power magnification shall be made and shall fall within
the 2-5 grade range per the attached Appendix II. The test shall be performed on coating
chipped from the first joint coated each day and once per shift thereafter and on chips from the
bend test specimens.
Comment 6.5 A lack of porosity, as shown in Grades 1 and 2 of Appendix II, could indicate
that the coating was applied to a too cool pipe and, therefore, may be undercured. Porosity
greater than Grade 5 indicates the coating was applied to a too hot pipe. Excessive porosity
(bubbles, foam) is not acceptable because it can decrease the impact resistance of the
coating and the distance water has to diffuse to get to the steel. Bubbles are caused by air,
moisture, and volatiles from the coating being trapped in the coating because it cured
before they reached the surface.
6.6 Cathodic Disbondment Test
The following cathodic disbondment test shall be conducted on the samples listed in Section
6.1.


A 4 inch x 4 inch plate is cut from the production coated ring sample. A 1/8 inch holiday is
drilled through the coating to the steel. A 3-inch diameter PVC cell is centered over the
intentional holiday and fixed to the coated surface with silicone. The cell is filled with 3%
NaC1 electrolyte and a platinum wire anode is inserted below the electrolyte level. A 3.5 DC
voltage (reference saturated calomel) is impressed and the entire test plate and apparatus are
maintained at 150°F for 24 hours.
At test completion a 30 degree "V" cut is made through the coating originating at the
intentional holiday. The amount of coating removed in the "V" is evaluated and expressed in
millimeters radius (mmr), as measured from the holiday edge to the area where well bonded
coating exists.
The maximum disbondment allowed is 8 mmr.
Comment 6.6 This test is optional for small jobs where time does not warrant conducting
it.
The cathode disbondment test is a good quality control test for detecting Applicator
mistakes, undercuring, a too thin film and chemical contamination. The millimeters of
radius that disbonds is a function of coating thickness, temperature and test duration. Eight
millimeters radius is a common limit for the above test conditions. Generally, results will
be less than 8 mmr. The key thing to watch for is sudden changes in disbonded radius. For
example, if you normally measure 4 to 5 mmr and suddenly get 8 mmr, you know you have
an application problem, even though the 8 mmr is within the limit.
The above test is up for acceptance in a specification on FBE application being proposed by
NACE. Because the spec had input from coating manufacturers, applicators and end users,
some end users and third party inspectors feel that 8 mmr is too high. This limit may be
tightened. Consult with the coating manufacturer and third party inspector for typical
disbondment radii values for a given coating. Again, the key is sudden increases in
disbondment radii.
For small diameter pipe on which the above test cannot be conducted, consider coating a
steel test panel of equal thickness to the pipe, or deleting this test. If test panels are used,
the coating procedure of the test panel must exactly duplicate that of the pipe.
7.0 HANDLING AND STORAGE PROCEDURES
7.1 The Applicator shall be solely responsible for the condition of the pipe from the time it is
received until after it has been loaded for shipment.
7.2 All booms, hooks, clamps, forks, supports, and skids used in handling or storing coated pipe
shall be designed and maintained in such a manner as to prevent any damage to the pipe or to
the coating and shall be approved by Company's representative.


Comment 7.2 Padded forks, canvas slings, and rubber-coated hooks are commonly used
methods for handling FBE-coated pipe. Whatever method is used, the goal is to prevent
damage to the FBE because a repaired coating will not have the continuity of the newly
applied coating.
7.3 All pipes shall be stored on padded elevated racks or polyethylene-sheathed sand berms until
time for delivery. Noncompressible rubber pads 0.5 inch thick, or hoops of 5/8-inch nylon
rope, three per 40-foot length, shall be used to separate the pipe for yard transportation and
storage.
Comment 7.3 Padding separates the coated pipe and prevents abrasion of the coating
against other pipe and the separators. Rubber pads are best for large, heavy pipe. The
rope is best for small diameter, thin wall pipe because the pipe is not heavy enough to
compress the rubber, and stacking instability problems can occur. Wood separators are not
recommended.
The coated pipe should be separated in a similar manner when shipped to allow road gravel
to fall through the pipe stack and prevent abrading. Also, consider use of tarpaulins to
protect the pipe.
7.4 The Company's representative will have authority to stop any storage procedure or means of
transport from the yard, if in his opinion there is a possibility of damage to the coating
because of improper procedures.
7.5 Any pipe damaged by Applicator shall be repaired in accordance with Company's pipe
specifications and applicable API Standards at Applicator's expense. Pipe damaged beyond
permissible repair shall become the property of Applicator. The actual Company invoiced
cost of scrapped pipe, including pipe, coating, and transportation, shall be deducted from the
amount due the Applicator.


APPENDIX I
BEND TEST PROCEDURE
Scope
This procedure checks degree of cure and adhesion of FBE-coated pipe.
Equipment
Four-point bend apparatus
Procedure
1. Cut a minimum of four 8-in. (longitudinal) x 1-in. (circumferential) x thickness (pipe + coating)
straps out of the coated pipe. File all edges smooth.
2. Using a four-point bend apparatus, bend each strap until failure, which is the point where cracks
begin to be visible in the coating when viewed with no magnification.
3. Measure the strap thickness (pipe + coating), t, and the deflected angle, A, as shown in Figure 1.
Figure 1
4. Calculate the amount of bend in degrees/pipe diameter.
degrees/pipe diameter = (A.t)/d (Eq. 1)
where A = deflection angle in degrees

d = distance between two center points in bend test rig (where strain is
constant), usually 2 inches.
t = pipe wall + coating thickness.


5. To pass, the average of the values from Equation 1 for the four (or more) samples must be greater
than 2.9 degrees/pipe diameter. Any single value must be at least 2.3 degrees/pipe diameters.
Also, the coating shall show full adhesion to the steel in the bend, with no splitting, cracking, or
flaking occurring before a bend of 2.9 degrees/pipe diameter is obtained.
Comment Appendix I Information on other types of bend tests and procedures for small diameter pipe
are available from the Materials and Equipment Engineering Unit of Chevron Research and Technology
Company.


APPENDIX II
FOAM STRUCTURE TEST PROCEDURE
Scope
This procedure covers the test method to determine the degree of foaming experienced by the coating
during application.
Equipment
Sharp knife.
40-power magnifier (or microscope).
Procedure
Use the knife to "snap" off coating from surface and examine cross-sections under magnification. Rate the
presence of voids according to the examples in Figure 2.
Figure 2
Comment Appendix II The coating must be "snapped" off because "saw" cutting with a knife can distort
the edge of the coating.

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Chevron Specification COM-MS-4042-C

FUSION BONDED EPOXY FOR EXTERNAL PIPELINE COATING

NOTE: This document is the "Commented" version of the Specification COM-EG-

January 1996 Page 1 of 26

FUSION BONDED EPOXY FOR EXTERNAL PIPELINE COATING

1.0 SCOPE .................................................................................................................................3

Page 2 of 26 January 1996

FUSION BONDED EPOXY FOR EXTERNAL PIPELINE COATING

1.2 Conflicting Requirements

1.3 Industry Standards

1.3.1 Steel Structures Painting Council (SSPC)

SSPC SP1 Surface Preparation

1.3.2 National Association of Corrosion Engineers (NACE)

RP0490-90 Standard Recommended Practice, Holiday Detection of Fusion Bonded

Piping shall be supplied without varnish or mill lacquers.

January 1996 Page 3 of 26

FUSION BONDED EPOXY FOR EXTERNAL PIPELINE COATING

Up to 150°F Valspar D1003LD

2.3 Batch Information

• The manufacturer's name.

Comment 2.3.1 The Applicator generally supplies the material.

Page 4 of 26 January 1996

FUSION BONDED EPOXY FOR EXTERNAL PIPELINE COATING

• Infrared scan of powder and typical powder scans for comparison.

2.4 Repair Materials

January 1996 Page 5 of 26

FUSION BONDED EPOXY FOR EXTERNAL PIPELINE COATING

Comment 3.1.1 Coating manufacturer's application procedures and data sheets

Comment 3.1.4 A cutback of 2 inches is common practice to allow for welding.

Page 6 of 26 January 1996

FUSION BONDED EPOXY FOR EXTERNAL PIPELINE COATING

3.2 Surface Preparation

January 1996 Page 7 of 26

FUSION BONDED EPOXY FOR EXTERNAL PIPELINE COATING

Comment 3.2.10 The three-hour time limit is a variable. It is included to prevent

Page 8 of 26 January 1996

FUSION BONDED EPOXY FOR EXTERNAL PIPELINE COATING

Comment 3.3.2 Gas-fired ovens must be properly adjusted so that no combustion

January 1996 Page 9 of 26

FUSION BONDED EPOXY FOR EXTERNAL PIPELINE COATING

3.4 Coating Application

• Subsea or Dry Lines:

≤ 150°F, 14 mils (min.)

Page 10 of 26 January 1996

FUSION BONDED EPOXY FOR EXTERNAL PIPELINE COATING

• River crossings, or drilled crossings, or highly irrigated areas, or areas subject to

≤ 150°F, 20 mils (min.)

The thickness of FBE should be carefully considered. Increasing the thickness

January 1996 Page 11 of 26

FUSION BONDED EPOXY FOR EXTERNAL PIPELINE COATING

Page 12 of 26 January 1996

FUSION BONDED EPOXY FOR EXTERNAL PIPELINE COATING

the Applicator do not need to be accepted. Some Applicator flexibility needs to be

Coating/Inspection Step Required Frequency

1. Surface Profile Check three locations per joint:

2. Thickness Five measurements per joint of pipe (see Section 4.4).

3. Repaired Holidays 100% inspected. Record number of repaired holidays

Comment 4.1.6 Requiring regular recordkeeping and submittal is the most

January 1996 Page 13 of 26

FUSION BONDED EPOXY FOR EXTERNAL PIPELINE COATING

4.2. Surface Preparation

Comment 4.2.1 Steel cleanliness is the most important inspection item in a

Blasted surfaces should be viewed without magnification. A slight blotchy