STANDARD SPECIFICATION

3 LAYER POLYETHELENE COATING

OF PIPELINES
Page 6 of 33

ISO 9001 : Quality Management Systems - Requirements

ISO 9002 : Quality management systems -- Guidelines for the application of
ISO 9001: 2015
ISO 11124 : Preparation of steel substrates before application of paints and related
products - Specifications for metallic blast-cleaning abrasives
Part 1 - General introduction and classification
Part 2 - Chilled-iron grit
Part 3 - High-carbon cast-steel shot and grit
Part 4 - Low-carbon cast-steel shot
ISO 11357 : Plastics - Differential scanning calorimetry (DSC)
ISO 15512 : Plastics - Determination of water content
ISO 21809 : Petroleum and natural gas industries External coatings for buried or
submerged pipelines transportation systems
Part 2 - Fusion-bonded epoxy coatings
Part 3 - Field joint coatings
SSPC SP1 : Steel Structures Painting Council -Solvent Cleaning
2.2 The Applicator shall be familiar with the requirements of these documents and shall make them
readily available at the coating plant to all persons concerned with carrying out the works
specified in this specification.
2.3 In case of conflict between the requirements of this specification, ISO 21809 —1 and the codes,
standards and specifications referred in clause 2.1 above, requirements of this specification shall
govern.
3.0 COMPLIANCE
3.1 The Applicator shall be responsible for complying with all applicable requirements of ISO
21809-1: 2011 and this specification. The Company reserves the right to make necessary
investigation and, in case of doubt, ask the applicator to conduct additional testing, batch
sampling and manufacturing inspection in order to be satisfied of compliance by the applicator. Any
materials/coating that does not comply with the requirements shall be rejected.
4.0 PLANT SCALE AND INSTALLATION
4.1 The Applicator shall size coating plant(s) after evaluating the scale of work and the time schedule
required for the works. Coating plant(s), both new and existing, shall be installed into a yard whose
geometry and dimensions are such as to allow the execution of a continuous work schedule. For
this purpose, the Applicator shall ensure non-stop work execution owing to prohibitive adverse
weather conditions and install requisite equipment and plant in roofed and adequately weather-
protected areas.
4.2 Plant equipment, machinery and other facilities shall be in finest operating condition to at least
meet the job requirements of quality and production. Worn out and improvised plants are not
acceptable.
4.3 The epoxy spray booth shall be sized to accommodate the number of spray guns required for the
application of required quantity of epoxy powder to be electrostatic ally sprayed on to the

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3 LAYER POLYETHELENE COATING
OF PIPELINES
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pipe to achieve specified thickness. Under no circumstances epoxy powder shall escape from
the booth. This shall be clearly demonstrated by coating applicator during procedure
qualification tests (PQT).
4.4 Plant shall have a powder storage room hermetically controlled with power back up for
Air conditioning capable of storing the coating materials as per coating manufacturer's
recommendations. Temperature and relative humidity shall be recorded continuously.
4.5 The powder system shall have an operational automatic fire suppressant system. Powder
system shall have means to separate virgin and reclaimed powder.
4.6 Plant shall have pipe internal blow-out and debris collection system to remove loose scale,
dirt and abrasive from the pipe interior.
4.7 The air used for the fluidization of epoxy powder shall be free from moisture. For this
purpose dehumidifiers and /or air dryer, as necessary shall be provided along with necessary
monitoring and control system. Fluidized bed shall have magnets adequate to remove iron
and steel shaving contaminant from recycled powder.
4.8 The conductivity of RO water should be less than 35 micro-siemens and rinse water
pressure shall be minimum 1000 psi.
4.9 The Applicator shall, at his own responsibility and cost, provide and prepare all necessary
area for the storage of bare and coated pipe and all other materials, for coating yard, stock-
piling and other temporary installation. For each area, Applicator shall provide necessary
agreements, as required, with the land owner(s)/relevant Authorities, and, on work completion,
to clean and pay settlement and claims for damages, as applicable.
4.10 The Applicator shall at its own responsibility and cost, provide for water supply, power
supply and other utilities, consumables and obtain authorization regarding access roads and
other permits required for the execution of works conforming to all the requirements of the
governing Authorities.
4.11 The Applicator shall at its own expense provide a fully equipped laboratory and test
facilities with adequate inventory to carry out tests required for the procedure qualification and
regular production. Outside testing for qualification and regular production is not
acceptable to Company.
4.12 The Applicator shall be fully responsible for adherence to all statutory regulations
applicable for handling & disposal of the hazardous chemicals during the coating works and
shall obtain all statutory approvals/ clearances from relevant Authorities including Pollution
Control Board, as applicable for the coating plant(s).
5.0 REQUIREMENTS FOR QUALITY
5.1 The Applicator shall have established within his organization and, shall operate for the
contract, a documented Quality System that ensures that the requirements of this
specification are met in all respect. The Quality System shall be based upon ISO 9001/2 or
equivalent.
5.2 The Applicator shall have established a Quality Assurance Group within its organization
that shall be responsible for reviewing the Quality System and ensuring that it is
implemented.
5.3 The Applicator shall submit the procedures that comprise the Quality System to the
Company for agreement.
5.4 The Applicator's Quality System shall pay particular attention to the control of suppliers and

Bharat Petroleum Corporation Limited

 STANDARD SPECIFICATION
3 LAYER POLYETHELENE COATING
OF PIPELINES
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sub-contractors and shall ensure that the requirements of this specification are satisfied by the suppliers
and sub-contractors operating Quality system in their organization.
5.5 The Applicator shall, prior to the commencement of work, prepare and issue a Quality Plan for all
of the activities required satisfying the requirements of this specification. The plan shall include
any sub-contracted work, for which the sub-contractors Quality Plans shall be submitted. The
plan shall be sufficiently detailed to indicate sequentially for each discipline the requisite quality
control, inspection, testing and certification activities with reference to the relevant procedures and the
acceptance standards.
5.6 The Applicator's Quality system and associated procedures may, with due notice, be subject to
formal audits. The application of quality control by the Applicator will be monitored by the Company
Representatives who will witness and accept the inspection, testing and associated work required
by this specification.
6.0 COATING CLASSIFICATION
6.1 General
The three layer coating as per this specification shall belong to coating Class B of ISO 21809-
1: 2011 and shall be suitable for design temperature range of (-) 40 °C to (+) 80 °C.
6.2 Coating thickness
Minimum overall thickness of finished coating shall be as per Table 1 below:

Table 1- Minimum thickness of finished coating

Pipe Size Minimum Coating Thickness

(Specified Outside Diameter) (mm)
< 10 /4” (273.1 mm)
3
2.5
> 12 /4” ( 323.9 mm) to < 18” (457 mm)
3
2.8
> 20" (508.0 mm) to < 30" (762 mm) 3.0
> 32" (813.0 mm) 3.3

All coating thickness readings must meet the minimum requirements. However, localized
coating thickness of less than the permissible minimum thickness can be tolerated on the
condition that it does not attain a total extent of more than 5 cm2 per meter length of coated pipe,
and the actual coating thickness does not drop more than 10% below the permissible minimum
coating thickness at these locations.
7.0 MATERIALS
7.1 The three layer coating system shall comprise of a powder epoxy primer, copolymeric or
grafted adhesive and a high density polyethylene (HDPE) topcoat. Coating materials shall be
suitable for the service conditions and the pipe sizes involved.
7.2 Pipe
Details of line pipe such as specification, diameter, wall thickness, length, material, grade etc.,
on which coating is to be applied as per this specification, shall be as given in Purchase Order.

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3 LAYER POLYETHELENE COATING
OF PIPELINES
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7.3 Coating Material

7.3.1 The coating materials i.e. epoxy powder, copolymeric or grafted adhesive and polyethylene
compound shall have proven compatibility.
7.3.2 Applicator shall choose brand of epoxy powder and adhesive as per `Annexure I' of this
specification that will achieve the functional requirements and properties of coating system as
specified in clause 7.3.1 and Table 5 of this specification.
7. 4 Qualification of coating materials
7.4.1 The coating system and materials shall be pre-qualified and approved by Company in
accordance with provisions of Annexure I of this specification. Applicator shall obtain prior
approval from Company for the coating system and coating materials.
7.4.2 The coating materials manufacturer shall carry out tests for all properties specified in Table 2,
Table 3 and Table 4 of this specification for each batch of epoxy, adhesive and polyethylene
compound respectively. In addition, the manufacturer shall also furnish infra-red scan for each
batch of epoxy powder. The manufacturer shall issue Inspection Certificate 3.1B in accordance
with EN 10204 for each batch of materials supplied to Applicator and same shall be submitted
to Company for approval prior to their use.
7.4.3 Epoxy properties
Epoxy properties shall meet the properties listed in Table 2 below:

Table 2 — Epoxy properties

SI. Test
Properties Unit Requirement
No. Method
Raw material
Density g/l Within +/- 0.05 of the
1. ISO 21809-1
manufacturer's specified Annex N
nominal value
Gel time at 205° C ± 3° C s Within 20% of the
2. nominal ISO 21809-1
value specified by the Annex J
manufacturer
Particle size -- Within
3. ISO 21809-2
manufacturer's Annex A.6
specification
Moisture Content % mass < 0.5 ISO 21809-1
4. Annex K
°C > 95 and within
5. Minimum glass transition ISO 21809-1
temperature (To) manufacturer's Annex D
specification
Infrared scan % As per manufacturer's __
6. transmittance specification

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 STANDARD SPECIFICATION
3 LAYER POLYETHELENE COATING
OF PIPELINES
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As — applied
Hot water ISO 21809-2,
7. adhesion 24 h @ -- Rating of 1 to 2
65 °C Clause A.16
Table 2 — Epoxy properties

SI. Test
Properties Unit Requirement
No. Method
Hot water adhesion ISO 21809-2,
8. -- Rating of 1 to 3
28 d @ 65 °C Clause A.16
Flexibility at 0 °C -- No cracking, tears,
9. disbondment or ISO 21809-2,
delamination at 2.0° ppd Clause A.13
length
Impact resistance at 0 °C J > 1.5 ISO 21809-2,
10. Clause A.14

The colour of epoxy powder shall be either green or dark red or any other colour approved by
Company except grey colour.
7.4.4 Adhesive material properties
Copolymeric or grafted adhesive material shall meet the properties listed in Table 3 below:
Table 3 — Copolymeric or grafted adhesive material properties

SI. Test
Properties Unit Requirement
No. Method
Raw material
Density kg/m3 > 930 and within
1. manufacturer's ISO 1183
specification
Melt flow rate g/10 > 1.0 and within
2. minutes manufacturer's ISO 1133
specification
%
Water Content < 0.1 ISO 15512
3.
As — applied
Elongation at break
4. % > 600 ISO 527-2
at 23 °C± 2 °C
Tensile yield strength
5. MPa >8 ISO 527-2
at 23°C ± 2 °C
Vicat softening °C
6. temperature A/50 (9.8 > 100 ISO 306
N)
Flexural Modulus MPa > 450 ASTM D790
7.

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