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DOCT.#MP140-003
REVISION NO.2
REVISION DATE:December 2005
ISSUED BY:QA Dept.
PAGE:1 OF 17
MANUFACTURING PROCEDUREFOR
DUAL POWDER ANTI-ABRASIONEXTERNAL FUSION BOND EPOXYCOATING
MP140-003December 2005
Revision: 2
Reviewed and Approved by
Manager, Performance Coatings: Peter Singh
Quality Assurance Manager, Canada: Brian Elliott
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Quality Plan
for
Fusion Bond Epoxy Coating
QP 140-001
July 2003
Revision: 0
Approved:
Quality Assurance Manager - 7/1/2003
North America T. Whitehurst Date
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Process/Location Description Frequency Acceptance Criteria
* May Be Substituted with Local Facility Forms.
Document: QP140-001. Issued By: Quality Assurance Revision Date: July 2003 Revision: 0
Verify that the pipe received matches the salesorder
Each shipment The pipe diameter, wall size, grade, received match the sales order
Verify that the pipe received is free of damageand/or contamination
Each shipment Document any internal or external das dents, bevel damage, etc. or consuch as oils, salts, grease, etc.
Pipe Receipt
Verify pipe is transferred to designated storageareas
Each shipment According to local Facility Instructionsegregated by order, source, grade,and/or wall thickness
Review powder manufacturers Certificate ofCompliance
Each Lot Meets the requirements of MP 140-0
Test conductivity of blast media in accordancewith TM140-045
Once/Lot 200 Micromhos maximum
Test acid content in accordance with TM140-028
or Manufacturers equivalent
Once/shipment Meets manufacturers specified valu
Test gel time of epoxy powder in accordancewith CSA Z245.20 clause 12.2
Once/Batch Within 20% of manufacturers specif
Test moisture content of Epoxy Powder inaccordance With CSA Z245.20 clause 12.4(procedure A)
Once/shipment Moisture content = 0.6% maximum
Raw MaterialTesting
Test thermal characteristics in accordance withCSA Z245.20 clause 12.7
Once/shipment Meets manufacturers specification
Test pipe for contaminants in accordance withTM140-040 (Potassium Ferricyanide)
Within the first hour ofproduction, one perorder, and ifcontamination is
suspected, whichever ismore frequent
Negative indicationIncoming
Racks
Verify pipe identity All pipes All numbers legible, match to sched
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Process/Location Description Frequency Acceptance Criteria
* May Be Substituted with Local Facility Forms.
Document: QP140-001. Issued By: Quality Assurance Revision Date: July 2003 Revision: 0
Check pipe temperature and dew point Within the first hour ofproduction, and every 4hours after
Pipe temperature 5F (3C) above dminimum
Pipe temperature 302F (150C) maInspect air quality by blotter test Within the first hour of
production, and every 4hours after
Free of oil, grease and moisture afte
Test abrasive working mix for contamination inAccordance with TM-140-045, as required
Within the first hour ofproduction per shift, andonce per hour whenTM140-040 showspositive
60 micromhos maximum
Test blasted surface for contamination inaccordance with TM-140-040, if required(potassium ferricyanide)
Once per hour whenabrasive mix conductivityis greater than 60micromhos
negative
Test blasted surface for contamination in
accordance with TM-140-041, if required(bresle patch)
Once per hour when
blasted surface showspositive to TM-140-040
2 micrograms / square centimeter, m
Inspect blast finish Continually, record withinthe first hour ofproduction per shift, andevery 2 hours after
SSPC SP10 (near white metal finish
Test abrasive working mix for % fines inAccordance with TM-100-002
Within the first hour ofproduction, and every 4hours after
Plant specified
Check surface profile 2 consecutive pipe,within the first hour ofproduction per shift, andevery 2 hours after
Min. 1.5 mils (40 microns)
Max. 3.9 mils (100 microns)
Surface
Preparation
Check pipe for contamination after blast(adhesive tape for particulate contamination)
Within the first hour ofproduction per shift, andevery 4 hours after
30% maximum
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Process/Location Description Frequency Acceptance Criteria
* May Be Substituted with Local Facility Forms.
Document: QP140-001. Issued By: Quality Assurance Revision Date: July 2003 Revision: 0
Verify acid concentration Within the first hour ofproduction per shift, andevery 2 hours after
4 15%
Verify pipe temperature Within the first hour ofproduction per shift, andevery 1 hour after
77F - 167F (25C - 75C)
Verify acid coverage Within the first hour ofproduction per shift
Full coverage
Verify acid dwell time Within the first hour ofproduction per shift, andevery 1 hour after
Pipe Temp Minimum D
77 93 F 25 sec
(25 - 34C)
94 111 F 15 sec
(35 - 44C)
111F 10 sec
>44C
* Maximum dwell time = Not dry befoVerify rinse water pressure Within the first hour of
production per shift1,200 psi (8,270) kPa minimum
Verify conductivity of rinse water Within the first hour ofproduction per shift
50 mhos (50 S) maximum
Optional Acid
Wash
Verify pH after rinse Within the first hour ofproduction per shift, andevery 4 hours after
1 of rinse water pH
Check pipe preheat temperature Within the first hour ofproduction per shift, andevery 1 hour after
Manufacturers recommendations
Maximum steel temperature = 275CCoating
Application Check time to quench Within the first hour ofproduction per shift, and
every 1 hour after
Manufacturers specifications
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Process/Location Description Frequency Acceptance Criteria
* May Be Substituted with Local Facility Forms.
Document: QP140-001. Issued By: Quality Assurance Revision Date: July 2003 Revision: 0
Check dry film thickness, 3 random locations perpipe
All pipes 12 mils (300 microns) minimum or requirements
Measure coating temperature before holidayinspection and thickness measurements
Twice / shift 100C (212F) maximum
Cooling Racks Holiday detection at 127v/ mil (5v/m) of nominalthickness
All holidays shall be repaired
All pipes 0.064 jeeps/ft2
(.7 jeeps/m2
) of pipefor 14 in. (355.6mm) OD or larger pi
0.30 jeep/ft (1 jeep/m) length of pipesmaller than 355.6mm (14 in.) or cuspecifications
Carry out final visual check on finished coating All pipes Monitor; free from runs, sags, holidapowder drops shall not be means fo
Outgoing
RacksCheck coating cutback length Within the first hour of
production per shift, andevery 1 hour after, and atleast once per order
2 inches +/- 1inch (50.8 mm +/- 25.4
or customer requirements
Markings Mark one end of pipe with OD stencil All pipes Per MP140-001 and Customer requ
Repairs
All coating defects shall be repaired andreinspected for holidays
All pipes Defects 1 inch (25mm) in diameter obe repaired with hot melt stick or two
Defects greater than 1 inch (25mm) 38.75 inch
2(250 cm
2) shall be repa
part epoxy.
Repairs shall have a minimum thickn
12 mils (300 microns) minimum, or cspecifications
Cathodic Disbondment Test (coated pipe ring)per CSA Z245.20 section 12.8
One test per shift, orCustomers requirements
11.5 mm maximum disbondment froholiday
LaboratoryTest Samples
Flexibility test per CSA Z245.20 section 12.11
(4 point bend apparatus shall be an acceptablealternative to mandrel bend apparatus)
One test per shift, or
Customers requirements
No cracking when bent 2.5 / pipe di
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Process/Location Description Frequency Acceptance Criteria
* May Be Substituted with Local Facility Forms.
Document: QP140-001. Issued By: Quality Assurance Revision Date: July 2003 Revision: 0
Adhesion per CSA Z245.20 section12.14 One test per shift, orCustomers requirements
Rating 1 3
Porosity test per CSA Z245.20 section 12.10 One test per shift, orCustomers requirements Cross section porosity rating 1 4
Contamination per CSA Z245.20 section 12.15 One test per shift, orCustomers requirements
Less than 30%
LaboratoryTest Samples
(continued)
Interface porosity per CSA Z245.20 section12.10
One test per shift, orCustomers requirements
Rating 1 4
Issue ShawCor Pipe Protection Certificate ofConformity (Release Notice)
Each order The order meets all test and inspectrequirements of the ShawCor Pipe PQuality program including the customspecification, if applicable.
*Note: No product shall be shippedcompletion of all inspections and tesCustomer initiated release form has
by the Customer.Verify Customers Pipe Release Each shipment The appropriate size, grade, and am
released product is shipped
Pipe Shipment
Verify Pipe shipment Each Shipment The appropriate size, grade, and amreleased product is shipped
Legend: C Raise Document H Hold Point N Non-Destructive Test
D Dimensional Inspection I Identification R Review
E Examine / Endorse Documents T Destructive Testing
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* May Be Substituted with Local Facility Forms.
Document: QP140-001. Issued By: Quality Assurance Revision Date: July 2003 Revision: 0
Process/
Location Equipment Calibration Process Calibration Method
Thermometers Comparison to certified temperature
device
CP2-015
Ovens Temperature verification Comparison to certifiedthermometer
Balances Mass verification CP2-001, CP2-016
Coating Thickness Gauge Film calibration standards CP2-002
Calipers and Micrometers Measurement verification CP2-003
Contact Pyrometer withThermocouple
Measured temperature verification CP2-007
Psychrometer Temperature CP2-006
Holiday Detector Voltage CP2-012
Voltage Meter Comparison to certified unit CP2-004
Stop Watch Time CP2-008
DSC Thermograph Temperature and cell constant CP2-010
Temperature Controller Temperature CP2-007
Calibrations
Conductivity Meter Conductivity CP2-026
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DOCT.#MP140-003
REVISION NO.2
REVISION DATE:December 2005
ISSUED BY:QA Dept.
PAGE:2 OF 17
DOCUMENT REVISION LIST
REVISION
NUMBERREVISION
DATESECTION(S)
REVISED REVISION DESCRIPTION, COMMENTSRev 2 December
2005 4.2.7,4.2.8,4.4.2.3,
5.1
Revisions to the sections listed were made tocorrespond with the 2005 edition of the StandardProduct Specification 140-003.
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DOCT.#MP140-003
REVISION NO.2
REVISION DATE:December 2005
ISSUED BY:QA Dept.
PAGE:3 OF 17
1.0 GENERAL
1.1 Scope
This Manufacturing Procedure details the application, inspection and testingprocedures required to ensure acceptable product quality for Dual Powder ExternalFusion Bond Epoxy coating (FBE) for Anti Abrasion Service.This Manufacturing Procedure relates to the application of the coating only, and isnot intended as a recommendation for the use of a particular coating. Whendesigning the pipeline and selecting a coating, the customer should consider thespecific conditions under which the pipeline will be constructed and operated.
1.2 References
References made to other publications shall be considered to refer to the latest
edition and relevant amendments.
CSA - Z 245.20 (External Fusion Bond Epoxy Coating for Steel Pipe.) SSPC - SP 10 Near white blast cleaning
ASTM Standards
TM - Bredero-Shaw Test Methods
Quality Manual
Management Procedures Manual
Approved Materials List Approved Vendors List
Calibration Procedures Manual
Quality Plan QP 140-003
Customer Specification where required Standard Product Specification SPS 140-003
1.3 Definitions
Shipment: Based on raw material manufacturer's definition. Could include oneor more lots.
Lot: Quantity of material produced using similar procedures which couldinclude on or more batches.
Batch: Quantity of epoxy powder produced in a continuous production run ofnot more than 8 hrs.
Shift: Continuous production of maximum 12 hrs.
Start-up: The first production after a shutdown exceeding 2 hours duration or achange in pipe diameter or wall thickness or coating material.
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DOCT.#MP140-003
REVISION NO.2
REVISION DATE:December 2005
ISSUED BY:QA Dept.
PAGE:4 OF 17
2.0 PRODUCT DESCRIPTION
Dual Powder Anti Abrasion External FBE coating is produced from two powder epoxy basedthermosetting resins. They are applied sequentially directly to the steel pipe surface as an
anti-corrosion bottom FBE coat and anti-abrasion top FBE coat.
3.0 RAW MATERIALS
3.1 Materials
3.1.1 Acid
The acid shall have properties as specified in 3.3.1.
3.1.2 Blast Media
The blast media shall have properties as specified in 3.3.2.
3.1.3 Chromate
The chromate concentrate shall have properties as specified in 3.3.3.
3.1.4 Fusion Bond Epoxy Powder
The fusion bond epoxy powders shall have properties as specified in 3.3.4.
3.2 Ordering and Accepting
3.2.1 Purchase Documents
All purchase orders for raw materials shall include the following items:
a) productb) formc) amountd) specificationse) request for test results of delivered lot(s) to be sent with shipmentf) proper labelling as per WHMIS regulationsg) MSDS to be provided as per WHMIS regulationsh) title number and issue of the quality standard to be applied where
applicablei) packaging specification where applicable
3.2.2 Approved Sources
Only approved raw materials from approved sources shall be ordered andused. All alternate sources and materials must be approved as specified inManagement Procedure MP-8.
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DOCT.#MP140-003
REVISION NO.2
REVISION DATE:December 2005
ISSUED BY:QA Dept.
PAGE:5 OF 17
3.2.3 Receiving Materials
All raw material shall comply with Sections 3.1 and 3.2.1 above beforeapproval. Alternative test methods can be used to those specified in 3.3 and
3.4, subject to T & D approval. All raw material shipments shall be tested asdetailed in Clause 3.4 prior to using.
3.3 Specifications
All materials shall be assessed for their ability to meet the properties listed in section3.3 at the time of qualification. The values listed in section 3.3 shall also serve asthe acceptance criteria for all routine tests specified in section 3.4.
3.3.1 Acid
PROPERTY UNIT TEST METHOD VALUE
Acid Content % TM 140-028 orManufacturer'sequivalent
ManufacturersSpecification
3.3.2 Blast Media
PROPERTY UNIT TEST METHOD VALUE
Conductivity mhos(S) TM 140-045 200 (200) max
3.3.3 Chromate
PROPERTY UNIT TEST METHOD VALUE
Density g/ml (lbs/ft3) Pycnometer Manufacturers
Specification
Acidity pH pH meter or paper ManufacturersSpecification
Active ChromateContent
--- Manufacturers method ManufacturersSpecification
3.3.4 Epoxy Powders
3.3.4.1 Anti-Corrosion FBE Powder
PROPERTY UNIT TEST METHOD VALUE
Cure Time seconds CSA Z245.20 (12.1) Manufacturer'sSpecification
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DOCT.#MP140-003
REVISION NO.2
REVISION DATE:December 2005
ISSUED BY:QA Dept.
PAGE:6 OF 17
PROPERTY UNIT TEST METHOD VALUE
Gel Time seconds CSA Z245.20 (12.2) Manufacturer'snominalSpecification 20%
% CSA Z245.20 (12.3)- Titration
0.5 maxMoisture Content (by either ofthe following methods at theManufacturer's option)
% CSA Z245.20 (12.4)- Mass Loss
0.6 max
Particle Size (Mesh Size)
Retain on 150 m (100)Retain on 250 m (60)
%%
CSA Z245.20 (12.5)
3.0 max0.2 max
Density g/L
(lb/ft
3
)
CSA Z245.20 (12.6) Manufacturer's
Specification 50(3.12)
Thermal Characteristics ---- CSA Z245.20 (12.7) Manufacturer'sSpecification
Cathodic Disbondment:
28 days 1.5V, 20C (68F)
24 hr, 3.5V, 65C (149F)
mm (in.)
mm (in.)
CSA Z245.20 (12.8)
(a)
(b)
8.5 ( 0.335) max
6.5 (0.256) max
Porosity:
Cross SectionInterface
RatingRating
CSA Z245.20 (12.10)
1 41 4
Flexibility deg/pipediameter
CSA Z245.20 (12.11) 3 min @ - 30C(-22F)
Impact Resistance J (Ft/lbf) CSA Z245.20 (12.12) 1.5 (1.106) min
Strained Coating, 28dCathodic Disbondment
---- CSA Z245.20 (12.13) no cracking
Adhesion Rating CSA Z245.20 (12.14) 1 3
3.3.4.2 Anti-Abrasion FBE Powder
PROPERTY UNIT TEST METHOD VALUE
Cure Time seconds CAN/CSA Z245.20 (12.1) ManufacturersSpecification
Gel Time seconds CAN/CSA Z245.20 (12.2) Manufacturer'snominalSpecification 20%
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DOCT.#MP140-003
REVISION NO.2
REVISION DATE:December 2005
ISSUED BY:QA Dept.
PAGE:7 OF 17
PROPERTY UNIT TEST METHOD VALUE
% CAN/CSA Z245.20 (12.3) -Titration
0.5 maxMoisture Content (by either ofthe following methods at theManufacturer's option)
% CAN/CSA Z245.20 (12.4) -Mass Loss
0.6 max
Particle Size (Mesh Size)
Retain on 150 m (100)
Retain on 250 m (60)
%%
CAN/CSA Z245.20 (12.5)
3.0 max0.2 max
Density g/L(lb/ft
3)
CAN/CSA Z245.20 (12.6) Manufacturer'sSpecification 50(3.12)
Thermal Characteristics ---- CAN/CSA Z245.20 (12.7) Manufacturer'sSpecification
3.3.4.3 Dual Powder FBE System
PROPERTY UNIT TEST METHOD VALUE
Cathodic Disbondment:
28 days 1.5V, 20C (68F)
24 hr, 3.5V, 65C (149F)
mm (in.)
mm (in.)
CSA Z245.20 (12.8)
(a)
(b)
8.5 ( 0.335) max
6.5 (0.256) max
Porosity:
Cross SectionInterface
RatingRating
CAN/CSA Z245.20 (12.10)
1 41 4
Flexibility deg/pipediameter
CAN/CSA Z245.20 (12.11) 1.5 min @ -30C
(-22F), nodelamination,cracking is not afailure
Impact Resistance J (Ft/lbf) CAN/CSA Z245.20 (12.12) 3 (2.2) min
Cathodic Disbondment ofStrained Coating
---- CAN/CSA Z245.20 (12.13) no cracking
Adhesion Rating CAN/CSA Z245.20 (12.14) 1 3
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DOCT.#MP140-003
REVISION NO.2
REVISION DATE:December 2005
ISSUED BY:QA Dept.
PAGE:8 OF 17
3.4 Inspection & Testing
Raw Materials shall be tested at the frequencies of section 3.4.1, using the valuesspecified in section 3.3 as the acceptance criteria. Reporting and documentation
procedures shall be as specified in Management Procedures MP-7, MP-8, MP-10.
3.4.1 Acid
PROPERTY TEST METHOD MANUFACTURERTEST FREQUENCY
PLANT TESTFREQUENCY
Acid Content TM 140-028 orManufacturers equivalent
1 / lot 1 / shipment
3.4.2 Blast Media
PROPERTY TEST METHOD MANUFACTURER
TEST FREQUENCY
PLANT TEST
FREQUENCY
Soluble Contaminants ConductivityTM 140-045
--- 1 / lot
3.4.3 Chromate
PROPERTY TEST METHOD MANUFACTURERTEST FREQUENCY
PLANT TESTFREQUENCY
Density Pycnometer ---- 1 / lot
Acidity pH 1 / lot 1 / yr
Active Chromate Content Manufacturers method 1 / lot 1 / yr
3.4.4 Epoxy Powders
3.4.4.1 Anti-Corrosion FBE Powder
PROPERTY TEST METHOD MANUFACTURERTEST FREQUENCY
PLANT TESTFREQUENCY
Gel Time* CSA Z245.20 (12.2) CSA Z245.20 (5.2) 1 / batch
Moisture Content* CSA Z45.20 (12.3) or (12.4) CSA Z245.20 (5.2) 1 / shipment
Adhesion CSA Z245.20 (12.14) --- 1 / shipment
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DOCT.#MP140-003
REVISION NO.2
REVISION DATE:December 2005
ISSUED BY:QA Dept.
PAGE:9 OF 17
PROPERTY TEST METHOD MANUFACTURERTEST FREQUENCY
PLANT TESTFREQUENCY
Cathodic Disbondment24 Hours, 3.5V,
65C (149F)
CSA Z245.20 (12.8) --- 1 / shipment
Cure Time CSA Z245.20 (12.1) CSA Z245.20 (5.2) ---
Density CSA Z245.20 (12.6) CSA Z245.20 (5.2) ---
Flexibility CSA Z245.20 (12.11) --- 1 / shipment
Impact Resistance CSA Z245.20 (12.12) --- 1 / shipment
Particle Size CSA Z245.20 (12.5) CSA Z245.20 (5.2) ---
Porosity CSA Z245.20 (12.10) --- 1 / shipment
Thermal Characteristic CSA Z245.20 (12.7) CSA Z245.20 (5.2) 1 / shipment
3.4.4.2 Anti-Abrasion FBE Powder
PROPERTY TEST METHOD MANUFACTURERTEST FREQUENCY
PLANT TESTFREQUENCY
Gel Time* CSA Z245.20 (12.2) 1 / batch 1 / batch
Moisture Content* CSA Z45.20 (12.3) or(12.4)
1 / batch 1 / shipment
Cure Time CSA Z245.20 (12.1) 1 / batch ---
PROPERTY TEST METHOD MANUFACTURERTEST FREQUENCY
PLANT TESTFREQUENCY
Density CSA Z245.20 (12.6) 1 / batch ---
Particle Size CSA Z245.20 (12.5) 1 / batch ---
* approved powder transported to other facilities must be re-tested for at leastthese properties prior to approval at receiving facility
3.5 Raw Materials Handling and Storage
All raw materials must be handled and stored according to the manufacturersrecommendations.
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DOCT.#MP140-003
REVISION NO.2
REVISION DATE:December 2005
ISSUED BY:QA Dept.
PAGE:10 OF 17
Figure 1Process Description
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DOCT.#MP140-003
REVISION NO.2
REVISION DATE:December 2005
ISSUED BY:QA Dept.
PAGE:11 OF 17
4.0 COATING
4.1 Surface Preparation
4.1.1 The pipe external surfaces shall be free of oil, grease, or other injuriouscontaminants prior to the application of the coating.
4.1.2 The pipe shall be preheated prior to blast cleaning so that the pipe surfacetemperature shall be at least 3C (5.4F) above the ambient plant dew point.
4.1.3 The external pipe surface shall be blast cleaned at least to SSPC SP10, witha surface roughness profile of 40-100 micrometers (1.57 3.94 mil)
4.1.4 The blast-cleaned surface shall be visually inspected for defects that wouldimpair proper coating application. Defects shall be removed by grinding or
hand filing. If defect removal is not possible, the joint shall be set aside forinspection by the customer or customers representative.
4.1.5 Residual blast media or loose debris on the interior of the pipe shall beremoved.
4.1.6 Additional Surface Treatments
At the applicators option, the pipe surface may be subjected to an additionalsurface treatment.
4.1.6.1 Acid Wash
The rotating pipe passes through the acid treatment station, whichconsists of an acid application booth and a water rinse booth. Theacid is applied evenly, and the rinse removes the acid solution andthe by-products. The remaining rinse water is then removed withan air knife.
4.1.6.2 Chromate Treatment
The rotating pipe passes through an enclosed exhaustedchromate application booth where chromate solution is appliedevenly by a saturated wiping device. The solution must be dryprior to contacting the spiral conveyor.
4.2 Coating Application
4.2.1 Application Temperature
The surface temperature of the pipe immediately prior to epoxy powderapplication shall be monitored and controlled in accordance with the
Manufacturers recommendations, and shall not exceed 275C (527F).
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DOCT.#MP140-003
REVISION NO.2
REVISION DATE:December 2005
ISSUED BY:QA Dept.
PAGE:12 OF 17
4.2.2 Epoxy Powder Application
Epoxy powder shall be applied to the heated pipe in a manner whichproduces a uniform coating. The two epoxy powders shall be appliedsequentially in a manner which produces two distinct layers. Bottom coatepoxy powder reclaim, as an option, shall be immediately reapplied in theapplication process as part of the top coat in amounts within manufacturersrecommended levels. Top coat epoxy powder reclaim, as an option, shall beimmediately reapplied in the application process in amounts within themanufacturer's recommended levels and not exceeding 25% of the powderflow at any time.
4.2.5 Quench
The coated pipe shall be cooled using air and/or water quench. A surface-active agent may be used to promote wetting during water quench.
4.2.6 Thickness
4.2.6.1 Coating thicknesses shall be according to Customersspecification. Measurements shall be made using a thicknessgauge that has been calibrated at least once per shift.
4.2.6.2 Where an individual measurement of the total value is less thanspecified, the affected pipes shall be measured at intervals alongthe pipe not exceeding 1m (3.28 ft.). The average of total coatingthickness value shall be at least minimum specified.
4.2.6.3 Coating not meeting the requirements of Section 4.2.6.2 shall bestripped and recoated in accordance with the requirements ofSection 4.4.3.
4.2.6.4 The bottom coat fusion bond epoxy coating thickness shall bemeasured by the following procedure or approved alternative. Thetop coat fusion bond epoxy coating shall be ground or buffed off inan area within 2 cm (0.79 inch) of the cutback. The bottom coatfusion bond epoxy coating thickness shall be measured using athickness gauge that has been calibrated at least once per shift.The ground area shall be repaired according to 4.4. These
readings shall be recorded at start-up and once per hourthereafter. If there is a significant change in the total coatingthickness, the thickness of the bottom coat of fusion bond epoxycoating shall be checked.
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DOCT.#MP140-003
REVISION NO.2
REVISION DATE:December 2005
ISSUED BY:QA Dept.
PAGE:13 OF 17
4.2.7 Holiday Inspection
4.2.7.1 All coated surface shall be tested for holidays using a D.C. high
voltage holiday detector set to 5.0V/micrometer (127V/mil) ofnominal coating thickness to a maximum of 5000V. The entirecoated surface shall be inspected with the holiday detector.
4.2.7.2 Holiday inspection shall be performed when the temperature of
the coating is 100C (212F) or less.
4.2.8 End Finish
The cutback length for both ends of pipe shall be per the Customer'sspecification. The cutback area shall be free of coating.Typical ranges = 40-75mm manual weld, 90-125mm automatic weld
4.3 Product Identification
Pipe number where applicable and sequence number shall be recorded. Sequencenumbers shall be restarted by Sales Order item or by date. The pipe exterior shallbe marked with all information as required on the production schedule/stencil report.
4.4 Repairs
4.4.1 All holidays shall be repaired by patching or stripping and recoating in
accordance with 4.4.2 or 4.4.3 whichever is applicable.
4.4.2 Patching
4.4.2.1 Holidays shall be cleaned by removing all rust, scale, dirt or otherforeign material and loose coating.
4.4.2.2 The areas shall be suitably roughened and all dust shall beremoved.
4.4.2.3 Areas less than 250 cm2 (38.75 in.2) shall be patched with thepowder supplier's recommended two-part epoxy or equivalent.Conventional patch sticks may be used as a repair material incases where the coating is not to be used for abrasive service,and the powder supplier recommends their use.
4.4.2.4 The patching material shall be applied in accordance with thesuppliers recommendations.
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DOCT.#MP140-003
REVISION NO.2
REVISION DATE:December 2005
ISSUED BY:QA Dept.
PAGE:14 OF 17
4.4.3 Stripping and Recoat
Pipe shall be heated to a temperature not exceeding 275C (527F) to soften
the coating to permit removal by scraping and/or blasting. Recoating shall beperformed in accordance with Section 4.0. Recoated pipes shall meet therequirements of 5.1.
4.5 Production Test Rings
4.5.1 Test rings shall be approximately 600mm (24 inch) long and shall beobtained from locations at least 300 mm (12 inch) from a pipe end unlessotherwise specified by the customer. Care should be taken to protect thecoating from damage by the cutting process including excessive heat. Allsamples shall be promptly delivered to the lab free from burrs, sharp edges,corners and coating damage.
4.5.2 Pipe coating shall be tested and shall meet the requirements in 5.1.
4.6 Pipe Cleanliness
The interior of each coated joint of pipe shall be visually inspected to ensure theabsence of blast media or other loose debris. Any such material, if present, shall beremoved prior to pipe storage.
4.7 Handling and Storage
Coated pipe shall be handled and stored in such a manner as to avoid damage toboth the pipe and the coating. When requested by the Customer, Bredero-Shawshall submit details of the Handling and Storage procedures.
4.8 Shipping
All accepted coated pipe shall be shipped as per the Customers requirements.
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DOCT.#MP140-003
REVISION NO.2
REVISION DATE:December 2005
ISSUED BY:QA Dept.
PAGE:15 OF 17
5.0 QUALITY ASSURANCE
5.1 Finished Product Inspection and Testing
PROPERTY TEST METHOD SPECIFICATION TEST FREQUENCY
5.1.1Adhesion CSA Z245.20 (12.14) Rating of 1-3
inclusiveBased on CSA Z245.20(7.3.3.3), as defined below*
5.1.2Cathodic Disbondment CSA Z245.20 (12.8)
24 Hrs @ 35 V11.5 mm (0.45 inch)maximum radius
Based on CSA Z245.20(7.3.3.3), as defined below*
5.1.3Cross-section Porosity CSA Z245.20 (12.10) Rating of 1-4
inclusiveBased on CSA Z245.20(7.3.3.3), as defined below*
5.1.4Flexibility CSA Z245.20 (12.11)
at temperature specifiedby Customer
Dual Powder system:No cracking at 1.5deg/pipe diameter
FBE Anti-Corrosionlayer:No cracking at2.5 deg/pipe diameter
Based on CSA Z245.20(7.3.3.3), as defined below*
5.1.5Impact Resistance CSA Z245.20 (12.12) Dual Powder system:
3.0J (2.2 ft/lbs f) min
FBE Anti-Corrosionlayer:1.5J (1.1ft/lbs f)min
Based on CSA Z245.20(7.3.3.3), as defined below*
5.1.6Interface Contamination CSA Z245.20 (12.15) 30% maximum Based on CSA Z245.20
(7.3.3.3), as defined below*
5.1.7Interface Porosity CSA Z245.20 (12.10) Rating of 1-4
inclusiveBased on CSA Z245.20(7.3.3.3), as defined below*
* Tests on specimens coated with both layers of the coating system shall be conducted, for all properties,at the frequency defined in CSA Z245.20 clause 7.3.3.3.
Tests on specimens coated with Corrosion Barrier only shall be conducted, for all properties, as follows:
Once in the first shift of each order,
at least once per every 5 shifts thereafter,
after any change in pipe diameter, or wall, or material type, or other significant parameter.
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DOCT.#MP140-003
REVISION NO.2
REVISION DATE:December 2005
ISSUED BY:QA Dept.
PAGE:16 OF 17
5.2 Inspection, Measuring and Test Equipment Calibration
All measuring and testing equipment used in tests performed on raw materials, in-
process and finished product shall be calibrated as described in the Quality Plan.
5.3 Rejection & Retest Procedures
Finished product that does not conform to the product specification as detailed in4.0 and 5.1 will not be shipped unless there is Customer concession.
Rejection and/or retesting to confirm or refute test results shall be carried out asin 5.3.1 or as agreed upon between Bredero Shaw and Customer.
5.3.1 Retesting
When the test results for adhesion, cathodic disbondment, flexibility andimpact (5.1.1, 5.1.2, 5.1.4, and 5.1.5) are out of specification, a FinishedProduct Nonconformance report shall be initiated as per ManagementProcedure MP-10, and the following procedures will be followed:
5.3.1.1 The test procedures shall be checked to ensure proper testing isperformed. All test apparatus shall be checked for properoperation and calibration.
5.3.1.2 The pipe in question shall be retested for the property out ofspecification. Two tests of the property shall be conducted. If bothof these retests pass, no further testing will be required, and thepipe shall be accepted.
5.3.1.3 If either of the retests fails, the pipe in question shall not beaccepted. Further testing shall be conducted to isolate theunacceptable condition. This shall be done by sampling twoadditional pipes; one coated prior to, and one coated after the pipein question. These additional pipes shall be tested only for theproperty out of specification.
5.3.1.4 If the results of the tests on the two additional pipes are inspecification, the pipe produced in the 12-hour shift, excluding the
pipe coated between the retest pipes, will be accepted withoutfurther testing.
5.3.1.5 If the results of the retest are out of specification, the pipeproduced in the 12-hour shift in question will be put on holdpending further testing as outlined in 5.3.1.6.
5.3.1.6 Using the sequential testing technique outlined in 5.3.1.3,continue testing until the defective production is isolated.
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When the test results for cross section porosity, interface contamination andinterface porosity. (5.1.3, 5.1.6, and 5.1.7) are out of specification, the followingprocedures shall be followed:
5.3.1.7 The pipe produced in the 12-hour shift shall be deemedacceptable if acceptance criteria are met for 5.1.1, 5.1.2, 5.1.4and 5.1.5.
5.3.1.8 Corrective action shall be taken to determine and remedy thecause of the failures.
5.3.2 Rejection
5.3.2.1 All joints found to be out of specification when tested according to5.3.1 will be rejected.
5.3.2.2 All rejected pipes shall be stripped and recoated as per 4.0.
5.3.3 Control of Nonconforming Product
As specified in Management Procedures.
5.3.4 Corrective and Preventive Action
As specified in Management Procedures.
6.0 Reporting Procedures
All In-Process and Finished Product Inspections shall be documented as specified inManagement Procedures.
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