!qfpira00nvuqcoating specs for 13176

7/30/2019 !Qfpira00nvuqcoating Specs for 13176

1/24

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


2/24

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


3/24

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


4/24




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


5/24




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


6/24




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


7/24




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


8/24



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


9/24

DOCT.#MP140-003

REVISION NO.2


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.


10/24

DOCT.#MP140-003

REVISION NO.2


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.


11/24

DOCT.#MP140-003

REVISION NO.2


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.


12/24

DOCT.#MP140-003

REVISION NO.2


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


Conductivity mhos(S) TM 140-045 200 (200) max

3.3.3 Chromate


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


Cure Time seconds CSA Z245.20 (12.1) Manufacturer'sSpecification


13/24

DOCT.#MP140-003

REVISION NO.2


ISSUED BY:QA Dept.

PAGE:6 OF 17


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


Cure Time seconds CAN/CSA Z245.20 (12.1) ManufacturersSpecification

Gel Time seconds CAN/CSA Z245.20 (12.2) Manufacturer'snominalSpecification 20%


14/24

DOCT.#MP140-003

REVISION NO.2


ISSUED BY:QA Dept.

PAGE:7 OF 17


% 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


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


15/24

DOCT.#MP140-003

REVISION NO.2


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


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


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


16/24

DOCT.#MP140-003

REVISION NO.2


ISSUED BY:QA Dept.

PAGE:9 OF 17


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


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 ---


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.


17/24

DOCT.#MP140-003

REVISION NO.2


ISSUED BY:QA Dept.

PAGE:10 OF 17

Figure 1Process Description


18/24

DOCT.#MP140-003

REVISION NO.2


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).


19/24

DOCT.#MP140-003

REVISION NO.2


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.


20/24

DOCT.#MP140-003

REVISION NO.2


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.


21/24

DOCT.#MP140-003

REVISION NO.2


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.


22/24

DOCT.#MP140-003

REVISION NO.2


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


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


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


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


* 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.


23/24

DOCT.#MP140-003

REVISION NO.2


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.


24/24

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.