GP 29-02-13 Fluoropolymer Coating for Fasteners Aug 05

GP 29-02-13 Fluoropolymer Coatings for Fasteners August 2005

Upstream For ExxonMobil Use Only Version 1.1.0

Page 1 of 25 ExxonMobil Development Company

Fluoropolymer Coatings for FastenersGP 29-02-13

Scope Fasteners coated in accordance with this Global Practice (GP) are intended for use in assembly of piping flanges and include studs, bolts, nuts, and washers for systems operating at temperatures below 180qC(350qF). This GP is not intended for use with subsea equipment or for fasteners that may experience operating temperatures in excess of 180qC (350qF).


UPST For ExxonMobil Use Only Version 1.1.0


Table of Contents

Table of Tables .............................................................................................................. 4

1. Required References ............................................................................................ 5

1.1. APIAmerican Petroleum Institute................................................................ 5 1.2. ASMEAmerican Society of Mechanical Engineers ..................................... 5 1.3. ASTMAmerican Society for Testing and Materials ..................................... 5 1.4. SSPCSociety for Protective Coatings......................................................... 6

2. General Description .............................................................................................. 6

3. Base Metal ............................................................................................................. 7

3.1. Studs ............................................................................................................ 7 3.2. Washers ....................................................................................................... 7 3.3. Nuts.............................................................................................................. 7 3.4. Double-End Studs ........................................................................................ 7

4. Testing Objectives ................................................................................................ 7

4.1. Qualification Testing..................................................................................... 8 4.2. Production Testing ....................................................................................... 8

5. Performance Objectives ....................................................................................... 8

6. Coating Applicator Qualification ......................................................................... 8

7. Safety and Environmental .................................................................................... 9

8. Surface Preparation"Cermet" Basecoat............................................................ 9

8.1. Overtap Nuts ................................................................................................ 9 8.2. Bake Out ...................................................................................................... 9 8.3. Degreasing ................................................................................................... 9 8.4. Abrasive Blasting.......................................................................................... 9

9. Surface PreparationOnshore System (Zinc Electro-Plate Basecoat) ........... 10

9.1. Overtap Nuts .............................................................................................. 10 9.2. Pretreatment............................................................................................... 10 9.3. Zinc Plating................................................................................................. 10

10. Coating System Application............................................................................... 11




10.1. General Requirements ............................................................................... 11 10.2. Cermet Basecoat........................................................................................ 11 10.3. Zinc Plating Basecoat................................................................................. 12 10.4. Topcoat ...................................................................................................... 12

11. Quality Control .................................................................................................... 13

11.1. Quality Control Program............................................................................. 13 11.2. Coating Application Procedure ................................................................... 13 11.3. Company Oversight.................................................................................... 13 11.4. Production Testing ..................................................................................... 13 11.5. Sample Size for Testing ............................................................................. 15

12. Packaging ............................................................................................................ 17

12.1. Pre-Assembly ............................................................................................. 17 12.2. Packaging................................................................................................... 17

13. Documentation .................................................................................................... 17

13.1. Documents Submitted With Bids ................................................................ 17 13.2. Documents Required Upon Completion of the Work.................................. 17

Appendix A: Salt Fog Performance Testing for Qualification of Coating Systems for Ferritic Fasteners .......................................................................................... 19

A1. Parts and Materials............................................................................................ 19

A2. Test Flanges....................................................................................................... 19

A3. Nut Tightening ................................................................................................... 20

A4. Salt Fog Exposure ............................................................................................. 20

Appendix B: Summary of Testing Requirements.................................................... 21

Appendix C: Qualified Coating Applicator List........................................................ 23

Record of Change ....................................................................................................... 24

Attachment: Purpose Codes Definitions.................................................................. 25




Table of Tables

Table 1: Summary of Specified Coating Systems ..................................................... 6

Table 2: Cermet Basecoat Cure Schedule ............................................................... 12

Table 3: Fluoropolymer Topcoat Cure Schedule..................................................... 13

Table 4: Basecoat/Topcoat Thickness Requirements............................................. 15

Table 5: Surfaces to be Examined During Testing .................................................. 16

Table A1: Schedule for Examining Specimens Exposed to Salt Fog .................. 20

Table B1: Testing Required with Bids .................................................................... 21

Table B2: Final Testing Required............................................................................ 22

Table B3: Testing Required Within Six Weeks of Job Completion ...................... 22




1. Required References This Section lists Practices and Standards that are generically referenced and assumed to be a part of this document. Unless otherwise specified herein, use the latest edition.

1.1. APIAmerican Petroleum Institute

API SPEC 15LR Specification for Low Pressure Fiberglass Line Pipe and Fittings

1.2. ASMEAmerican Society of Mechanical Engineers

ANSI/ASME B1.1 Unified Inch Screw Threads (UN and UNR Thread Form)

ANSI/ASME B16.5 Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard

ANSI/ASME B16.21 Nonmetallic Flat Gaskets for Pipe Flanges

1.3. ASTMAmerican Society for Testing and Materials

ASTM A 123/A 123M Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A 193/A 193M Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service

ASTM A 194/A 194M Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure or High Temperature Service, or Both

ASTM A 354 Standard Specification for Quenched and Tempered Alloy Steel Bolts, Studs, and Other Externally Threaded Fasteners

ASTM B 117 Standard Practice for Operating Salt Spray (Fog) Apparatus

ASTM B 183 Standard Practice for Preparation of Low-Carbon Steel for Electroplating

ASTM B 322 Standard Guide for Cleaning Metals Prior to Electroplating

ASTM B 633 Standard Specification for Electrodeposited Coatings of Zinc on Iron and Steel

ASTM B 695 Standard Specification for Coatings of Zinc Mechanically Deposited on Iron and Steel

ASTM D 610 Standard Test Method for Evaluating Degree of Rusting on Painted Steel Surfaces (Adjunct to SSPC-VIS 2)

ASTM D 2092 Standard Guide for Preparation of Zinc-Coated (Galvanized) Steel Surfaces for Painting




ASTM D 3363 Standard Test Method for Film Hardness by Pencil Test

ASTM D 3951 Standard Practice for Commercial Packaging

ASTM D 4285 Standard Test Method for Indicating Oil or Water in Compressed Air

ASTM D 5065 Standard Guide for Assessing the Condition of Aged Coatings on Steel Surfaces

ASTM D 5402 Standard Practice for Assessing the Solvent Resistance of Organic Coatings Using Solvent Rubs

ASTM D 6677 Standard Test Method for Evaluating Adhesion by Knife

ASTM F 436 Standard Specification for Hardened Steel Washers

ASTM F 1470 Standard Guide for Fastener Sampling for Specified Mechanical Properties and Performance Inspection

1.4. SSPCSociety for Protective Coatings

SSPC PA 1 Shop, Field, and Maintenance Painting of Steel

SSPC PA GUIDE 3 Guide to Safety in Paint Application

SSPC SP 5 White Metal Blast Cleaning (NACE NO. 1)

2. General Description This GP gives requirements for two coating systems described in Table 1. The coating systems recommended include a Basecoat, which provides the corrosion resistance, and a fluoropolymer Topcoat, which is intended to reduce torque-up friction. The Offshore Marine System includes a cermet Basecoat and a fluoropolymer Topcoat. The Onshore System includes a zinc plating Basecoat and a fluoropolymer Topcoat. The Offshore Marine coating system is inherently more corrosion-resistant. Hot-dip galvanized fasteners, which are not covered in this GP except as stipulated in Section 3.2 below, would likely provide better corrosion resistance than the specified coating systems in most environments. However, galvanized fasteners lack lubricity during assembly and reassembly.

Table 1: Summary of Specified Coating Systems

System Basecoat Topcoat Salt Fog Resistance (ASTM B 117 Rust Grade 5)

Offshore Marine Cermet Fluoropolymer 5,000 hours

Onshore Zinc Plating Fluoropolymer 2,000 hours

The cermet and zinc plating based coating system described in this GP are not appropriate for use as-is on corrosion-resistant alloy (CRA) fastener materials or on carbon steel bolts and externally threaded




fasteners having minimum ultimate tensile strengths (UTSs) in excess of 1000 MPa (145 Ksi). Such materials include ASTM A 354 bolts and studs. Note: This specification is proscriptive. Any deviations from the specified requirements must be identified at the bid stage. Placement of an order will be conditional upon Company approval of defined deviations.

3. Base Metal The specified systems are intended for use on carbon and low alloy steels that are prone to corrode. This fastener coating specification is intended to provide corrosion protection and to reduce friction when tightening and loosening carbon and low alloy steel grades of ASTM A 193/A 193M fasteners.

3.1. Studs Studs are all thread rods machined from the base metal in accordance with referenced ANSI and ASTM specifications. The designated coating systems are intended for use on studs.

3.2. Washers The designated coating systems are intended for use in conjunction with circular hardened steel washers per ASTM F 436 Type 1. Washers shall either be coated with the Basecoat and Topcoat designated in Tables 2 and 3 or, at the discretion of the applicator, zinc-coated. Zinc coating shall be deposited either by the hot-dip process per ASTM A 123/A 123M or mechanically per ASTM B 695, Class 65 or thicker.

3.3. Nuts Nuts shall meet ASTM A 194/A 194M. Over-tapping the nuts is required to accommodate the specified coatings and assure specified nut/stud fit during assembly for delivery and at final assembly. It is the responsibility of the Seller to provide properly fitting nuts on studs at delivery and convey to the nut supplier any over-tapping criteria necessary to ensure effective run-up following the coating process. Guidance in this regard is found in subsection 6.2.4 and Section 7.4 of ANSI/ASME B1.1.

3.4. Double-End Studs Where only all-thread type studs are to be coated, it is the coating applicator's responsibility to furnish double-end studs along with the all-thread studs to facilitate the coating inspection process. (Double-end stud threads are discontinuous, the center portion being unthreaded shank.) The double-end studs shall be at least six (6) diameters in length. Approximately two (2) diameters of the stud shank shall be unthreaded. The number of double-end studs furnished shall be at least one per furnished all-thread stud diameter and 2% of the number of all-thread studs of each diameter to be coated.

4. Testing Objectives This GP addresses two distinct types of testing: (1) Qualification Testing and (2) Production Testing.




4.1. Qualification Testing 1) A given potential applicator's ability to demonstrate:

a) Prior experience with the systems specified b) The ability to implement appropriate process controls and QC practices, and c) The ability to apply the specified system in a manner that meets defined performance test

requirements will be the measure Company uses to assign that applicator the status of a "Qualified Applicator."

2) To achieve "Qualified Applicator" status, an applicator must provide test data demonstrating that the coating system satisfies the performance objectives of this specification. The required qualification test is addressed under Section 6, "Coating Applicator Qualification," below

4.2. Production Testing This GP stipulates specific QC testing to be performed on samples taken from each production run of coating work. These will be used to verify that the specified requirements are achieved. The production testing verifies that the intended number and thickness of coats were applied and assesses the adherence and extent of cure of the coating system.

5. Performance Objectives 1) The performance objectives for the coating work are set forth in Appendix A. In overview, the

objective is that specimens coated as prescribed in this specification will not be degraded to a condition inferior to Rust Grade 5 (d 3% rust) per ASTM D 610 when exposed to salt fog in accordance with the objectives indicated in Table 1 and that, after such an exposure, nuts must be capable of being easily loosened.

2) The Topcoat described in this specification is intended to facilitate assemble/disassembly of the coated fasteners due to its friction-reducing properties.

6. Coating Applicator Qualification 1) The coating work shall only be performed by Qualified Applicators. Only those organizations that

have indicated a willingness to perform the coating work described in this specification and that have furnished documentation supporting their claim to be capable of successful application will be designated by Company as Qualified Applicators. The requisite data submittals include the testing indicated in Appendix A (Salt Fog). Qualification testing shall either be performed by a qualified and certified third-party testing laboratory or Company may elect to monitor the panel preparation and portions of the test cycle of applicator or coating manufacturer in-house testing. The Company may elect to consider pre-existing test reports that are comparable to the Appendix A test criteria.

2) A listing of Company-qualified coating applicators is found in Appendix C.




7. Safety and Environmental 1) It is the responsibility of the coating manufacturer to supply the coating applicator with the

appropriate Technical Data Sheets (TDS) and Material Safety Data Sheets (MSDSs) associated with the products to be applied. The precautions outlined in the applicable TDSs and MSDSs pursuant to the use and disposal of those products shall be implemented by the coating applicator.

2) In particular, it shall be recognized that the cermet-type Basecoat materials are toxic and require strict adherence to the worker health and safety and waste disposal stipulations identified by the coating manufacturer as well as the provisions of SSPC PA GUIDE 3.

3) When removing or "burnishing" Basecoat by abrasive blasting, it is imperative that the explosion avoidance precautions addressed in the coating manufacturer's TDSs and MSDSs are observed.

4) The coating applicator shall make such provisions as are necessary to ensure that the coating work is performed in accordance with all applicable worker health and environmental protection regulations of the national and sub-tier governmental units (e.g., state, provincial, local, etc.) wherein the coating work is performed.

8. Surface Preparation"Cermet" Basecoat

8.1. Overtap Nuts 1) Nuts shall be over-tapped to an extent that accommodates the coating system thickness of Table 4,

allowing uninhibited assembly of the coated parts.

2) It is essential for post-coating fit-up that the fastener threads be UNC Class 2A/2B per ANSI/ASME B1.1.

8.2. Bake Out Pre-heat at 750F (399qC) for 30 minutes.

8.3. Degreasing Degrease per Sections 10.1 through 10.4 of ASTM B 322.

8.4. Abrasive Blasting 1) Abrasive blast per SSPC SP 5 using # 60 # 120 mesh aluminum oxide.

2) Prior to using compressed air, test the quality of the air downstream of the separator in accordance with ASTM D 4285.

3) Remove dust, blast abrasives, and other contaminants from the surface after blast cleaning.




9. Surface PreparationOnshore System (Zinc Electro-Plate Basecoat)

9.1. Overtap Nuts 1) Nuts shall be over-tapped to an extent that accommodates the coating system thickness of Table 4,

allowing uninhibited assembly of the coated parts.

2) It is essential for post-coating fit-up that the fastener threads be UNC Class 2A/2B per ASME/ASME B1.1.

9.2. Pretreatment Prepare all bolts, studs, nuts, and washers to be plated according to the following sequence:

1) Pre-Cleaning. Degrease and rinse per Sections 10.1 through 10.4 and 14.6 of ASTM B 322.

2) Anodic electroclean per the practices described in Section 7.2 of ASTM B 183. Cleansers used in electrocleaning shall be selected in accordance with the guidance found in Section 15.4 of ASTM B 322.

3) Rinse. Perform a water rinse consisting of a minimum of two cycles. The water surface in the final stage must be free of sheen.

4) HCl pickle per the practices described in Section 7.4 of ASTM B 183 or H2SO4 pickle per 8.2 and 6.4 of ASTM B 183. Alternately, use of proprietary aqueous acid salt solutions, with or without current, is acceptable. If proprietary acids are used, the process, including concentration and replenishment, shall conform with the supplier's recommendations.

5) Rinse per Item (3) above.

9.3. Zinc Plating 1) Immediately following the final rinse, fasteners shall be electroplated per ASTM B 633, Class Fe/Zn

12, Type IV (i.e., zinc phosphate conversion coating post-treatment, per ASTM D 2092, Method A +12 Pm zinc).

2) The objective with respect to the concentration of the zinc phosphate conversion coating atop the zinc plating is for it to be in the range of 25 g/m2. Visual examination of the conversion coated parts, unaided or with magnification d 5X, shall show a uniform appearance free from spots, uncoated areas powder, and white residues. Differences in color or shade in different areas or from piece to piece will not be considered cause for rejection.

3) Following application of the zinc plating, rinse all treated parts in clean water using a multi-stage process consisting of a minimum of two cycles. The water surface in the final stage must be free of sheen. The parts must be visibly dry prior to Topcoating and free of visible cracking or flaking. Fasteners manifesting plating flaws shall be reworked or scraped prior to Topcoating.




10. Coating System Application

10.1. General Requirements 1) Coating work must be performed by a qualified coating applicator designated in Appendix C.

2) Coating material shall be shipped, stored, mixed, and applied in accordance with SSPC PA 1, which references the printed instructions indicated on the applicable coating manufacturer's product data sheets (PDS). In the event of conflict, the requirements indicated on the PDS apply.

3) Prior to performing the coating system application process, the coating applicator is responsible for obtaining the applicable job code from the fastener supplier. The job code shall be an alpha-and/or-numeric code unique to the lots of fasteners to be coated. It shall be incorporated into the coating applicators job code.

4) Each coating container shall bear a batch number. If the expiration date is not evident on the container but is encoded in the Batch #, then the coating applicator shall obtain this information from the coating manufacturer, transcribing the expiration date onto the container. Coating material shall be applied before its expiration date. The batch number, expiration date, and label must be fully legible when the coating is mixed.

5) Coatings shall be applied when the surface of the parts being coated is t 5qF (3qC) warmer than the ambient dew point and the ambient air temperature is between 55qF (13qC) and 90qF (32qC) unless documented approval of less strict criteria has been promulgated by the coating manufacturer and approved by Company. The parts must be visibly dry and at a surface temperature of d 125qF (52qC)prior to coating.

10.2. Cermet Basecoat 1) The cermet Basecoat shall consist of one or more individual layers of a product combining pigments

that include aluminum and/or metal oxide pigments in an inorganic binder. Once the Basecoat is applied, it is oven cured and burnished prior to Topcoating. Acceptable Basecoat materials include:

2) Xylar 2 as manufactured by Whitford Corp. of West Chester, PA

3) SermaGard 1105 as manufactured by SermaTech International of Limerick, PA

4) The Basecoat shall be mixed and applied by conventional spray per the coating material manufacturer's product data sheet to sufficient wet film thickness (WFT) to produce the post-Basecoat cure dry film thickness (DFT) tabulated in Table 4 below.

5) Bake Basecoat(s) in accordance with Table 2.




Table 2: Cermet Basecoat Cure Schedule

Basecoat Coating Manufacturer

DFT (Pm) Pre-Cure (qF) Bake (Minutes @ qF)

Xylar 2 See Table 4 Room-to-150 until uniformly gray

510 @ 700 r 50 or

1822 @ 650 r 25

SermaGard 1105 See Table 4 15 minutes @ 150175 30 @ 650 r 25

6) The temperatures tabulated above shall be understood to be the surface temperature of the parts being coated (i.e., the "part metal temperature"). Ramp-up and down to/from the stipulated temperature plateau shall not exceed 3qF/min. Following the bake, the parts shall be allowed to cool to < 100qFprior to further processing.

7) Following the Basecoat(s) final cure, examine the coating to ensure it is free of mudcracking. To the extent that mudcracking exists, the affected surfaces must be reworked by removal and reapplication. When removing the Basecoat(s) by abrasive blasting, it is imperative that the explosion avoidance precautions addressed in the coating manufacturer's published application instructions/MSDSs are observed.

8) The applied Basecoat(s) shall be burnished by a method that produces a uniform metallic aluminum appearance without significantly reducing the DFT. The minimum post-burnishing Basecoat DFT shall be as indicated in Table 4. Abrasive blasting with fresh, clean alumina using reduced nozzle pressure (25 r 5 psi) is a suitable means for burnishing. Alternately, soft mineral abrasives having a hardness of d 5 mho in conjunction with abrasive blast nozzle pressure of < 60 psi may be used. Satisfactory burnishing is manifested by the surface having an electrical resistance of not less than 1 ohm when ohmmeter contacts are placed within 2 mm of each other on the Basecoated surface.

10.3. Zinc Plating Basecoat The requirements governing the zinc plating are addressed above under "Surface PreparationOnshore System" (Section 9).

10.4. Topcoat 1) The Topcoat shall be a product containing a polytetrafluoroethylene (PTFE) resin bound within a

polymeric organic matrix. Acceptable Topcoat materials include:

a) Xylan #1424 manufactured by Whitford Corp. of West Chester, PA

b) SermaGard #1280 manufactured by SermaTech International of Limerick, PA

2) Mix and apply by conventional spray per the coating material manufacturer's Product Data Sheet to sufficient wet film thickness (WFT) to produce the post-Topcoat bake dry film thickness (DFT) indicated in Table 4.

3) Bake the Topcoat in accordance with Table 3.




Table 3: Fluoropolymer Topcoat Cure Schedule

Topcoat Coating Manufacturer

DFT (Pm) Pre-Cure (qF) Bake (Minutes @ qF)

Xylan 1424 See Table 4 46 minutes @ 175-200 15 @ 400 -0/+ 25

SermaGard 1280 See Table 4 510 minutes @ ambient 15 @ 400 -0/+ 25

4) The temperatures tabulated above shall be understood to be the surface temperature of the parts being coated (i.e., the "part metal temperature"). Ramp-up and down to/from the stipulated temperature plateau shall not exceed 3qF/min. Following the bake, the parts shall be allowed to cool to < 100F prior to handling.

11. Quality Control

11.1. Quality Control Program The coating applicator shall document and maintain a quality control program (QCP) approved by the coating manufacturer within 12 months of the coating system application. The QCP shall capture the array of coating material batches applied under a given job code.

11.2. Coating Application Procedure The QCP shall include or reference a coating application procedure (CAP) expressly addressing each of the process steps entailed in the performance of the coating work. The CAP shall include the step-wise QC records to be established and maintained throughout the coating work process. The results of the four tests described below shall be made part of the QC records. All QC records pertaining to the coating work shall indicate both the fastener supplier's job code and that of coating applicator.

11.3. Company Oversight Surface preparation and other critical process processes steps such as mixing, thinning, baking, and Basecoat burnishing are subject to being witnessed by Company.

11.4. Production Testing The following describe the required quality testing that shall be completed prior to shipping. Failure to comply with the acceptance criteria of any test shall be cause for rejection of the lot. Testing of washer coatings is not required.

11.4.1. #1Coating Cure Determine the adequacy of the Topcoat's cure per ASTM D 5402 (MEK Rub Test). The procedure will need to be modified because the available rubbing surface is very limited. Color photographs furnished by the coating manufacturer depicting various extents of color transfer onto the white rubbing medium shall serve as the acceptance standards. Manufacturer's standard photographs are to be labeled "Acceptable Discoloration/Cure" and "Unacceptable Discoloration/Cure." To be considered adequately




cured, the color transfer shall replicate the "Acceptable Discoloration/Cure" photos and the Basecoat shall not be revealed.

11.4.2. #2Coating Adhesion Assess coating adhesion per ASTM D 6677. The adhesion shall evaluate both the Basecoat-to-substrate and Topcoat-to-Basecoat adhesion. The acceptance criterion for coating adhesion is that the coatings shall have a rating of not less than 8.

11.4.3. #3Hardness Testing of Cured Coatings Perform Hardness Testing per ASTM D 3363. The acceptance criteria shall be as follows:

1) Xylan 1424: 4H minimum

2) SermaGard 1280: 2H minimum

11.4.4. #4Coating Thickness Determine the dry film thickness (DFT) of each coat and the overall DFT. DFT assessment shall be made visually by means of examination of the sectioned and polished fasteners using a 50X magnifier. Externally-threaded fasteners (studs and bolts) shall be ground or milled as necessary to achieve longitudinal sectioning over a length of at least 2 cm. Do not exceed 350qF during the sectioning process. Sectioning shall confirm that the thickness of each of the two coatings comprising the system and the combined two coat system falls within the range indicated in Table 4 for the various possible combinations of Basecoat and Topcoat. Due to the difficulty in coating nut threads, the thickness criteria for nuts apply only for the first thread in from each face.




Table 4: Basecoat/Topcoat Thickness Requirements

Coat Basecoat(Pm)

Topcoat (Pm)

BC (Pm)(minmax)

TC (Pm) (minmax)

Total (Pm)(minmax)

Xylar 2 + Xylan 1424 50 r 12 25 r 5 38 62 20 30 58 92

Xylar 2 + SermaGard 1280 50 r 12 25 r 5 38 62 20 30 58 92

SermaGard 1105 + Xylan 1424 36 r 6 25 r 5 30 42 20 30 50 72

SermaGard 1105 + SermaGard 1280

36 r 6 25 r 5 30 42 20 30 50 72

Zinc Plating + Xylan 1424 12 min 25 r 5 12 min 20 30 32 (Zn + 30)

Zinc Plating + SermaGard 1280 12 min 25 r 5 12 min 20 30 32 (Zn + 30)

Note: It is required that the Basecoat application be performed in full compliance with the Coating Manufacturer's TDS/MSDS instructions. To achieve the specified Basecoat DFT, more than one layer maybe required. The process needed to achieve the stipulated Basecoat DFTs differs and depends on the particular Basecoat material to be applied.

11.5. Sample Size for Testing 1) The testing shall be performed per the guidance presented in Sections 6 through 8 of ASTM F 1470

for Sample Level "C" using the "Detection Process," except as otherwise allowed in Section 6 of ASTM F 1470. If a vendor has an ISO 9001 quality program, Company will consider an alternative sampling process for approval. The sample size shall be differentiated according to: a) The type of fastener, i.e.:

i) Studs and Double-End Studs (Combined) ii) Nuts

b) The diameter of the fastener

2) With respect to double-end studs and washers, the sample shall include all of those furnished in accordance with Section 3.4 ("Base Metal: Double-End Studs") of this GP.

3) The surface of each sample item to be tested shall be as follows:




Table 5: Surfaces to be Examined During Testing

Test Fastener Surface Examined

Studs End #1 (Note 1)

Double-End Studs Unthreaded Shank

#1Cure

Hex Nuts Flute Face "X" (Note 2)

Studs End #2

Double-End Studs Unthreaded Shank (Portion Opposite Site of Test #1 above)

#2Adhesion

Hex Nuts Flute Face "Y"

Studs End #1 (Allow at least 24 hrs at room temperature following Test #1.)

Double-End Studs Ends #1 and #2 and, as needed, undisturbed shank

#3Hardness

Hex Nuts Remaining Flute Faces as needed

Studs Longitudinal Cross-Section

Double-End Studs Longitudinal Cross-Section @ No Thread Portion

#4Thickness

Hex Nuts Simple Cross-Section

Notes:

(1) The length of the rub stroke will need to be reduced from the 6 in. x 1 in. area indicated in ASTMD 5402. On end-sections and nut flutes, the rub will need to be modified to a 90-degree rotation rather than a linear stroke.

(2) A flute face is the flat or outer face.

4) The tests described are destructive. Each item tested (stud/double-end stud/nut) shall be set apart and retained by the coating applicator for a period of not less than thirty-six (36) months following coating application. These retains shall be made available upon the request of Company at any time during this interval.

5) Company or its agent reserves the right to use the previously described inspection process for receipt inspection. Rejected lots will be identified by Company or its agent and returned to the Coating Applicator. The Coating Applicator will be required to replace rejected lots within 10 calendar days of notification at no expense to Company.




12. Packaging

12.1. Pre-Assembly All externally threaded fasteners are to be prepared for shipping by assembly with matching pairs of coated nuts. Washers may be packaged separately. Nuts shall be run-up onto the exterior threaded part to the extent that a minimum of two threads project.

12.2. Packaging 1) Each assembly shall be encased within plastic netting or a zip-lock type poly bag. Netting stock and

film shall be 2 mil (0.002 in.) medium density polyethylene. An acceptable alternative to plastic encasement is to use crating dividers that ensure flute-to-flute contact of nuts during shipment.

2) Encased assemblies shall be packaged in boxes or drums having a combined weight of 65 pounds. Boxes shall be wood crates of fiberboard. Fiberboard boxes shall have stitch-lock stapled joints throughout and shall be externally secured with crimp joined steel straps. Drums shall be steel with ratchet-clamp or threaded perimeter band closure hardware.

3) Assemblies shall be cushioned and stabilized against motion within the box by means of plastic bubble wrap or cellular plastic packing.

4) Only fastener assemblies of a given nominal diameter shall be packed in a given container.

5) Each box shall be marked per the requirements of ASTM D 3951. The box marking shall indicate the nominal diameter of the fasteners contained therein.

13. Documentation The Coating Applicator shall furnish the following to Company.

13.1. Documents Submitted With Bids 1) Accelerated weathering test data that the bidder considers comparable to if not identical to the salt fog

testing criteria of Appendix A.

2) The coating applicator's Quality Control Procedure (QCP), including the Coating Application Procedure (CAP) and including annotation or documentation of the coating manufacturer's approval of the version of the QCP/CAP submitted to Company.

13.2. Documents Required Upon Completion of the Work NOTE: The following document is required within six (6) weeks of job completion in order for a coating applicator to be designated as qualified by Company. Any such qualification will be limited to the particular system(s) tested.

1) Copies of the reports summarizing the results of the Coating Applicator Qualification Test per Appendix A hereto.




2) All quality control and inspection test records associated with the testing designated in the Coating Applicators QCP, including the test stipulated in Section 11.4 ("Production Testing") above. Records shall note the batch numbers of the applied coating.

3) Certification from the packaging supplier that the packaging conforms to the criteria stipulated above under Section 12.2 ("Packaging").




Appendix A: Salt Fog Performance Testing for Qualification of Coating Systems for Ferritic Fasteners The fastener coating process for use on low alloy ferritic steel bolting shall be qualified by salt spray testing per ASTM B 117.

A1. Parts and Materials 1) The coating applicator shall prepare fastener test specimens that represent the coating system(s) that

is (are) to be applied.

2) For each different coating system to be tested, the salt spray test shall be carried out on two sets of four coated, ASTM A 193/A 193M Grade B7 test studs, each with a coated pair of ASTM A 194/A 194M Grade B7 nuts and Basecoat + Topcoat coated or zinc-coated (hot-dip galvanized or mechanically galvanized) ASTM F 436 washers.

3) Except where zinc-coated washers are supplied per Section 3.2, all parts of each set of fasteners shall be coated per the requirements of this specification except as otherwise approved by the Company.

4) It is the responsibility of the coating applicator to notify the cognizant Company representative of the schedule date for applying the coating systems to the fastener test specimens. This will enable a representative of Company to witness application of the coating systems to the test fasteners.

5) The test studs shall be any diameter from 1/2 in. diameter but no larger than 1 1/2 in. diameter. Stud length shall be as required to satisfy the flange size/geometry described in A2 below. The thread projection must not be so great as to interfere with the tightening socket described in A3, Item (3) below.

6) The particular coated fasteners to be tested shall be selected by the test facility and shall have a range of fits as judged by the ability to turn the nuts by hand.

7) "X" scribe opposite faces of both nuts on a given stud per Section 6.4 of ASTM B 117.

A2. Test Flanges 1) Each of the two groups of test studs, nuts, and washers shall be fitted to separate assemblies

comprised of a pair of raised-faced FRP piping flanges, ASME B16.5 Class 150#. Fasteners shall be arrayed symmetrically around the bolt circle.

2) FRP flanges shall be fabricated from material complying with API SPEC 15LR. Each flange pair shall bear a unique, indelible ID. Provide a gasket conforming to the requirements of ASME B16.21.The gasket material shall not contain metallic fillers.

3) The flange thickness shall be selected to ensure that when snug, and accounting for the gap due to the raised faces and gasket, nuts are threaded onto the stud at least one nut width (across the flats), i.e., so that the thread stick-out is a least one nut width.




A3. Nut Tightening 1) The nuts for one of the two flange pairs shall be tightened such that the net stud elongation is as

required to produce a stress equal to 105 Ksi, the 0.2% Offset Yield per Table 2 of ASTM A 193/A 193M for Grade 7.

2) The nuts for the second flange pair shall be finger-tight only.

3) Stud tensioning shall be by means of a manual socket wrench rather than by pneumatic impact.

A4. Salt Fog Exposure 1) Place the pair of flanges within the salt spray cabinet. One shall be oriented vertically and the other

horizontally. The test report shall note, by reference to the flange ID, how a particular flange assembly was oriented. Remove the flange assemblies for examination in accordance with the following schedule:

Table A1: Schedule for Examining Specimens Exposed to Salt Fog

Cumulative Exposure

Cermet Basecoat Zinc-Plated Basecoat

3,000 r 36 hours 1,200 r 24 hours

4,200 r 36 hours 1,800 r 24 hours

4,800 r 36 hours @ 168 hour intervals thereafter

@ 264 hour intervals thereafter

2) Terminate the salt fog exposure when the evaluation shows that the extent of rust on two or more coated nuts or studs is at or inferior to Rust Grade 5 per ASTM D 610 or at 5,500 hours (cermet Basecoat) or 2,200 hours (zinc plate Basecoat), whichever occurs first.

3) It shall then be verified that the nuts can be removed from the studs with hand torque. Manual loosening using a crescent wrench not longer than eight (8) times the nut width (across the flats) may be used for the first one complete turn.

4) Clean the flanges/fasteners per Section 13 of ASTM B 117 and dry prior to examination. Assess the condition of the coating and document the results in accordance with ASTM D 5065 except that, with respect to adhesion assessment referenced in Section 5.5, use the "X" scribe assessment described in ASTM D 6677.

5) The test facility shall package all salt fog exposure pieces in the manner defined in this GP under Section 12.2, "Packaging," and return these to the Company.




Appendix B: Summary of Testing Requirements

Table B1: Testing Required with Bids

Type of Test System Tested

Performed By

TestMethod

Number of Tests Acceptance Criteria

Salt Fog Proposed coating system

Similar to ASTM B 117

Provide data on one such test for a

given Basecoat/Topcoat

system

Approximating that of Appendix A but 1750 hours

Onshore 4400 hours

Offshore with 5% red rust

DFT Each coat of proposed

coating system

Magnetic or destructive

examination

Per established sampling plan

Approximating that of Table 4.

Report results

Surface Preparation

Cleaning

Coating manufacturer,

coating applicator, or subcontractor

test lab

Visual/ photographic

Per established sampling plan

Report




Table B2: Final Testing Required


Performed By

Test Method Sample Size Acceptance Criteria

Topcoat Cure (MEK rub)

* ASTM D 5402 Level of coloration transferred to rub

cloth d depicted on coating

manufacturer's pictorial standard

Coating Adhesion ("X" cut")

* ASTM D 6677 Rating t 8(max 1/8 in. sq.

chips)

Coating Hardness (Pencil)

* ASTM D 3363 t 4H Xylan #1424

t 2H

SermaGard #1280

Coating Thickness (Visual)

*

Coating applicator or subcontractor

test lab

Sectioning, polishing, and 50X optical examination

A function of # of each type fastener (studs/double-end

studs/nuts) of a given diameter per

ASTM F 1470, Table 3

75 Pm r 17 PmXylar 2 Basecoat

61Pm r 11 PmSermaGard #1280

Basecoat

32 Pm Min. (Zn + 30) Pm Max.Zinc Plate Basecoat

* Indicate the specific system represented by the test (e.g., basecoat/topcoat product), surface preparation, and thickness of each coat and how measured.

Table B3: Testing Required Within Six Weeks of Job Completion


Performed By Test Method

Number of Tests Acceptance Criteria or Deliverable

Salt Fog * Coating manufacturer,

coating applicator, or subcontractor

test lab

ASTM B 117 as modified

perAppendix A of this GP

Provide test report for each

Basecoat/Topcoat system furnished

d 3%red rust @ 2,000 hrs

for Zinc Plate Basecoat

5,000 hrs for cermet Basecoat Report Results

* Indicate the specific system represented by the test (e.g., basecoat/topcoat product), surface preparation, and thickness of each coat and how measured.




Appendix C: Qualified Coating Applicator List * indicates approval pending

* Custom Coating Applicators, Inc. Houston, TX (SermaGard 1105/1280)

* Fluid Sealing Products Houston, TX (Zinc Plate + Xylan only. No cermet.)

* Lone Star Fasteners, LP Spring, TX (SermaGard 1105 + SermaGard 1280 or Xylan 1424)

* Southwest Impreglon Humble, TX (SermaGard 1105/1280. Zinc Plate not offered)

* Southwest Plating Co. Houston, TX (Zinc Plate + Xylan. No cermet.)

* Allegheny Coatings Freemont, IN (SermaGard 1105/Xylan 1424)

* International Polymer Canada, Ltd. Edmonton, Alberta, Canada (Xylar 2/Xylan 1424)

* E/M Coating Services Worcester, UK (SermaGard 1105/1280)

* Praxair/Smaltirivia, S.p.A. Monte Marenzo (LC), Italy (SermaGard 1105 + SermaGard 1280 or Xylan 1424)

* Asemco Co., Ltd. Busan, Korea (SermaGard 1105/1280)

* High Technology Coating Co., Ltd. Busan, Korea (Xylar 2/Xylan 1424)

* Seng Heng Engineering PTE, Ltd. Singapore (SermaGard 1105/1280)




Record of Change

Version 1.0.0 Date: 08/05

Location Action Description

Initial Publish.

Version 1.1.0 Date: 08/05

Title Modification Title was changed from "Corrosion Resistant Coating System for Ferritic Steel Fasteners."

Section A-1, Item (2)

Modification The identifier M was deleted from the "Grade B7M." The phrase now reads, "...ASTM A 193/A 193M Grade B7 test studs, each with a coated pair of ASTM A 194/A 194M Grade B7 nuts..."

Section A-3, Item (1)

Modification The following phrase was added at the end of the sentence, "for Grade 7."




Attachment: Purpose Codes Definitions

Code Description

C Assigned to paragraphs containing specifications whose primary purpose is reduced costs. Reduced cost in this context refers to initial investment cost and does not include Life-Cycle cost considerations. Life-Cycle cost considerations are captured under reliability, maintainability, or operability purpose codes.

E Assigned to paragraphs containing specifications whose primary purpose is driven by environmental considerations. Environmental considerations typically include specifications intended to protect against emissions/leakage to the air, water, and/or soil. Deviations from the specifications contained in such paragraphs require formal review and approval according to local environmental policy.

I Assigned to paragraphs that provide only clarifying information such as Scope statements, definitions of terms, etc.

M Assigned to paragraphs containing specifications whose primary purpose is to provide for maintainability of equipment or systems. Maintainability provisions are those that facilitate the performance of maintenance on equipment/systems either during downtimes or during on-stream operations.

O Assigned to paragraphs containing specifications whose primary purpose is to assure operability of equipment or systems. Operability is the ability of the equipment/system to perform satisfactorily even though conditions are off-design, such as during startups, process swings, subcomponent malfunction, etc.

R Assigned to paragraphs containing specifications whose primary purpose is to improve or assure the reliability of equipment or systems. Reliability is a measure of the ability of equipment/systems to operate without malfunction or failure between planned maintenance interventions.

S Assigned to paragraphs containing specifications whose primary purpose is avoidance of personnel or operational safety incidents. Any deviation from the specifications contained in such designated paragraphs requires formal review and approval according to local safety policy.

Personnel Safety: Refers to the avoidance of recordable personnel injuries; i.e., burns, cuts, abrasions, inhalation, or exposure to dangerous substances, etc., that could result in medical treatment, restricted work, lost-time incidents, or fatalities.

Operational Safety:

Refers to the prevention and control of process releases, fires, explosions, etc.

GP 29-02-13 Fluoropolymer Coating for Fasteners Aug 05

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Transcript of GP 29-02-13 Fluoropolymer Coating for Fasteners Aug 05