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COATING PROCEDURE
FOR
EXTERNAL PROTECTION OF STEEL PIPELINES
USING SIDE-EXTRUSION POLYETHYLENE
THREE LAYER SYSTEM
27/12/2011
20/11/2011
A.Elsamahy
S.Rezk
E.Eisa
REV.
DATE
DESCRIPTION
BY
CH'D
APPR.
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TABLE OF CONTENTS
1.
INTRODUCTION
2.
2.1 Definitions
2.2 Abbreviations
5
6
3.
4.
5.
6.
9
11
6.1
6.2
6.3
6.4
11
12
12
13
7.
7.
25
14
14
15
15
15
15
16
16
16
16
17
17
17
17
17
18
18
18
20
8.
9.
REPAIR OF COATING
STRIPPING OF COATING
21
22
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10.
11.
12.
PIPE MARKING
PROCEDURE QUALIFICATION TRAIL ( PQT )
DOCUMENTATION
24
27
29
APPENDIXES
Appendix A
Appendix B
30
33
Appendix C
36
Appendix D
37
Appendix E
38
Appendix F
39
Appendix G
37
Appendix H
39
Appendix I
40
Appendix K
44
Appendix L
46
Appendix M
47
Appendix N
48
Appendix O
50
Appendix P
51
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1-
INTRODUCTION
This procedure describes the process of the application, testing and repair of workshop side-extruded
Polyethylene coatings ( 3 layer system ) which shall be applied on the external surface of AQP NEW 16"
SEALINE JOINING NAQP-2 PLATFORM
The coating covered by this procedure is to comply the requirements of NF A 49-710 and DIN 30 670
standards and Company spec. DOC. No. 4222-430-630-03 Rev.1 Where conflict occures between
requirement of company specification and referenced codes and standards; the requirements of
specification shall apply
The coating system shall consist of three layers and shall be applied in accordance with this procedure,
the composition of the three layers is :
1) Layer of Fusion bonded epoxy powder.
2) Layer of Polyethylene polymeric adhesive .
3) Layer of Polyethylene top coat .
4) Layer of Polyethylene Powder (Rough Coat)
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2-
Within the application of this procedure the following definitions and abbreviations shall be apply:
2.1 DEFINITIONS
Coating system The coating technique or process system consisting of the same type of coating
material .
Side extrusion Coating process whereby a hot extruded films of coating materials are wrapped
around the pipe in layers. The pipe is moved past the extrusion head in a spiral motion. The extruded
coating films are fused together to form a continuous adherent sheath around the pipe .
Three layer system Coating system consists of three layers which are epoxy primer, adhesive and
outer layer.
Procedure qualification trial PQT application of a coating and subsequent inspection/testing to
confirm that the coating system is adequate to produce a coating with the specified properties,
carried out prior to the start of production.
Epoxy primer The first coating layer ( the anti-corrosion layer )
Adhesive The intermediate coating layer to improve the adhesion between the primer and the outer
layer .
Outer layer The Polyethylene ( PE ) layer .
Coating thickness Understood to be the average thickness of the coating system ( summation of
average thickness for the applied top coat, adhesive and primer layers ) .
Unit of production Set of pipes have the same DN and coated with the same coating system and
Any production process have the same DN and coated with the same coating
system, and not interrupted more than 3 days .
Test ring
Day
Shift
Batch No. Quantity of coating material not more than 50 tons and have the same source and grade.
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2.2 ABREVIATIONS
DN
FBE
PE
RH
Tg
Tg
J
UV
DSC
MEK
M.D.S
FIFO
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.. (
Steel Tubes and Fittings for On and Off-shore Pipelines External Three Layer
Extruded Polyethylene Based Coatings.
CEN )
.. (
AFNOR )
.. (
DIN )
DIN 53 505
DIN 53 455
DIN 30 670
Polyethylene Coatings For Steel Pipes and Fittings, Requirements and Testing
.. (
ASTM )
ASTM D 543
ASTM D 638
ASTM D 1238
ASTM D 2240
ASTM D 3359
ASTM D 4752
ASTM D 5402
ASTM G 42
.. ( NACE )
Standard Recommended Practice - Application, Performance, and Quality Control
Of Plant-Applied, Fusion Bonded Epoxy External Pipe Coating .
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Technical Specification For The External Protection Of Steel Line Pipe and
Fittings Using Fusion Bonded Powder and Associated Coating Systems
( Part 1 : Requirements For Coat materials and Methods Of Test .
International Standard
ISO 8501-1
.. (
ISO )
( SIS 05 59 00 )
ISO 8502-1
ISO 8502-3
ISO 8502-4
ISO 8502-6
ISO 1133
ISO 21809-1
Plastics - Determination of the Melt Mass-Flow Rate ( MFR ) and Melt VolumeFlow Rate ( MVR ) of Thermoplastics .
Petroleum and natural gas industries External coatings for buried or submerged pipelines used in pipeline transportation systems
Part 1:Polyolefin coatings (3-layer PE and 3-layer PP)
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4.2 HANDLING
4.2.1 COATING RAW MATERIALS/ANODES
4.2.1.1 All material shall be carefully handled in the way not damage the material or the packing.
4.2.1.2 Old received material shall be used before new received material ( FIFO).
4.2.2 PIPE HANDLING
4.2.2.1 BARE PIPE
4.2.2.1.1 Bare pipe shall be carefully removed from the truck using a crane and stacked on concrete
or sand beams.
4.2.2.1.2 Fork lift shall carefully remove the pipe from the storage yard and with equal care place the
pipe on the blast machine incoming rack.
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4.3 STORAGE/STACKING
4.3.1 Storage of Coating Materials
4.3.2.1.1 Periodically, the visual inspection shall be performed in order to verify that the coating
materials have been stored in conditions as recommended by the material Manufacturer.
4.3.2 Pipe Storage/Stacking ( Bare and Coated )
4.3.2.1 Pipe shall be stacked in such a manner that prevents damage to the pipe or coating.
4.3.2..2 The pipes (bare and coated) shall be stacked on a leveled ground, free from foreign
materials, stones. Pipes shall be suitably spaced from the soil (minimum 150mm) to prevent
any contact with the ground and to prevent surface water from entering during the entire
storage period.
3.3.2.3 The pipes shall be stacked off ground on well prepared beams.
4.3.2.4 Stacks of pipes of different type shall be clearly separated.
4.3.2.5 For safety reasons for pipes of any diameter the maximum height for stacking pipes shall
not exceeds the maximum number of layers shown in the following table and for any reason
the allowed height of any stack shall be not exceeds 3.5 meters.
Pipe Dia.
16
16"
4.4 LOAD-OUT
4.4.1 Only accepted pipes shall be loaded onto trucks from the storage area.
4.4.2 Pipes shall not be stacked onto the truck any higher than 2.5 meters or any higher than the law
permits or is safe.
4.4.3 The loaded pipes shall not exceed the maximum allowable weight for the truck or by law or is
safe.
4.4.4 The loaded pipes shall be tied down using Nylon straps or other means to avoid damage to the
coating during transportation .
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1- Powder epoxy primer, applied as anti-corrosion layer for coating of carbon steel pipe line by
polyethylene 3 layer system .
2- Possess good similarity and compatibility with the polymeric adhesive, and react with it, so that the
reciprocal anchorage is increased.
3- Show high capability to minimize cathodic disbondment when steel pipe is subjected to negative
polarization as per ASTM G 8 standard [ the maximum radius of disbonding 5 mm. ] .
PROPERTY
UNIT
3
Specific Gravity
g / cm
Sieve Analysis
% ( retained )
250 m mesh
% ( retained )
150 m mesh
TEST METHOD
VALUE
CSA Z 245.20
CSA Z 245.20
1.3 - 1.6
0.5 % max.
CSA Z 245.20
3.0 % max.
Sec.
CSA Z 245.20
10 50
CSA Z 245.20
100
CSA Z 245.20
100
Moisture Content
CSA Z 245.20
max. 0.3
Radius( mm )
EN 10288
Cathodic Disbonding
- @ 65 c , 2 days
5.1.2
PROPERTIES OF ADHESIVE
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PROPERTY
UNIT
g / cm3
Density
g / 10 min.
190 c / 2.16 Kg
TEST METHOD
ASTM D 1505
VALUE
0.910 - 0.940
ASTM D 1238
0.5 6
ASTM D 1525
>100
Melting point
ASTM D 2117
110
Mpa
ASTM D 638
17
ASTM D 638
400
Elongation at Break
5.1.3
PROPERTIES OF POLYETHYLENE
1- Fully stabilized PE, in granular state, contains additives for stability and resistance to weather
conditions and its combined action of oxygen, sunlight and temperature.
2- Designed for coating of steel pipe, three layer system, where it is side-extruded directly in multiple
wraps to build-up the requested thickness.
3- Possess the following properties...
PROPERTY
Density, compound
Melt Flow Index
Carbon Black
UNIT
TEST METHOD
g / cm3
ASTM D 1505
0.948 0.955
ASTM D 1238
0.15 1.0
ASTM D 1603
23
ASTM D 2240
50
g / 10 min.
190 c / 2.16 Kg
Durometer Hardness
shore D
VALUE
Brittleness Point
ASTM D 746
- 70
ESCR
hr
ASTM D 1693
> 1000
ASTM D 1525
>115
ASTM D 2117
>120
Kg/cm2
ASTM D 638
150
ASTM D 638
> 400
Melting point
Tensile Strength at Break
Elongation at Break
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The surface preparation operation and prevailing parameters shall be measured in accordance with
ISO 8501 and at the frequencies indicated in para. 6.4 and in accordance with the method defined in
Appendix A.
- Ambient conditions ( prevailing temperature, relative humidity, dew point ).
- Pipe Surface Temperature ( before blast).
- Surface cleanliness.
- Surface profile.
- Surface salt contamination .
- Dust control .
6.1.2 PRE-HEATING TEMPERATURE
The preheating temperature of the coating materials shall be measured at the frequencies indicated in
para. 6.4 to insure that the application is comply with the manufacturer recommendation.
- Pipe temperature .
- PE temperature .
- Adhesive temperature .
6.1.3 COATING SYSTEM THICKNESS
The coating thickness of the system shall be measured at the frequencies indicated in para. 6.4 and
in accordance with the method defined in Appendix B.
- Thickness of primer layer
- Thickness of adhesive layer
- Total coating thickness
6.1.4 COATING CONTINUITY ( HOLIDAY DETECTION )
The coated pipes shall be holiday detected 100 % at voltage set at 10 Kv per millimeter of nominal
thickness of coating and not exceeding 25 Kv.
The holiday detection shall be performed in accordance with the method defined in Appendix C.
6.1.5 IMPACT RESISTANCE TEST
The impact resistance of the coating system shall be measured at the frequencies indicated in para. 6.4
and in accordance with the method defined in Appendix D .
6.1.6 ADHESION ( PEEL OFF ) TEST
The peel-off resistance of the coating system shall be measured at the frequencies indicated in para.
6.4 and in accordance with the method defined in Appendix E .
6.1.7 MELT FLOW RATE
The melt flow rate of the PE and adhesive for the new and extruded material shall be measured at the
frequencies indicated in para. 6.4 and in accordance with the method defined in Appendix P.
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The indentation resistance of the PE shall be measured at the frequencies indicated in para. 6.4 and
in accordance with the method defined in Appendix G.
6.1.9 TENSILE STRENGTH and ULTIMATE ELONGATION
The tensile strength at yield and at break and the ultimate elongation of the PE shall be measured at
the frequencies indicated in para. 6.4 and in accordance with the method defined in Appendix H.
6.1.10 DUROMETER HARDNESS - SHORE D
The hardness shore D of the PE shall be measured at the frequencies indicated in para. 6.4 and in
accordance with the method defined in Appendix O.
6.1.11 DEGREE OF CURE OF PWODER EPOXY
The degree of cure of the F.B.E layer shall be measured at the frequencies indicated in para. 6.4 and in
accordance with the method defined in Appendix A.
6.1.12
FLEXIBILITY
The flexibility of the coating shall be performed at the frequencies indicated in para. 6.4 and in
accordance with the method defined in Appendix M.
6.1.13
The air entrapment in the coating shall be measured at the frequencies indicated in para. 6.4 and in accordance with the method defined in Appendix N .
6.1.14 CATHODIC DISBONDING TEST
The cathodic disbonding test for the coating shall be performed at the frequencies indicated in para. 6.4
and in accordance with the method defined in Appendix K .
6.1.15 HOT WATER IMMERSION TEST
The Hot water immersion test for the coating shall be performed at the frequencies indicated in para.
6.4 and in accordance with the method defined in Appendix L .
6.2 Sampling
Petrojet QC representative or the Client representative shall select, on random bases, the pipes on
which the specified tests shall be carried out.
To minimize repair of coating, all destructive testing shall be carried out on the ends of the pipes ( cut
back area ).
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6.3 Re-tests
In the event that a production coated pipes fails to meet the acceptance criteria of a specified test or if
the no. of holidays detected is excessive the pipe length shall be rejected unless approval is given by
the company to accept said pipe.
The preceding and following pipe lengths in the same production run shall then be similarly tested and
if both are accepted, than the remainder of the pipe length shall provide a test schedule for company
approval this schedule shall determine which pipes may be defective since the last passing test pipe.
Subclause
7.1
7.1
7.1
7.1
7.1
7.1
7.1
7.1
7.1
7.2
7.3
7.4.1
7.4.2
7.4.3
7.5.1
7.5.2
7.6
7.7
7.8
7.9
7.10
7.10
7.11
7.12
7.13
7.14
7.14
7.15
7.16
7.17
Reference
Test method
Appendix A
Appendix A
Appendix A
Appendix A
Appendix A
Appendix A
Appendix B
Appendix B
Appendix B
M.D.S
M.D.S
Appendix C
Appendix E
Appendix D
Appendix G
Appendix H
Appendix H
Appendix O
Appendix P
Appendix N
Appendix A
Appendix A
Appendix M
Appendix K
Appendix L
Frequency At Regular
Production
Every pipe
test / hr
test / hr
test / hr
test / hr
Every pipe
First 5/1 tests Every 30pipe
First 5/1 tests Every 30pipe
First 5/1 tests Every 30pipe
test/shift
Every pipe
Every pipe
test / day
test / day
1 pipe out 20 pipes
test/hr
test/hr
Every pipe
First pipe / 1 test per shift.
Test/ PE batch No.
Test/ PE batch No.
Test/ PE batch No.
Test/ PE batch No.
Test/ PE batch No.
test / day
test / shift.
test / day
test / shift.
1st. pipe
1st. pipe
1st. pipe
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TIME
0.50 hr
1.00 hr
1.50 hrs.
60
1.75 hrs.
50
2.00 hrs.
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at weld
Min 2.5 mm
at body
Min 3 mm
The average total thickness is the summation of the thickness of individual layers, The coating
thickness shall be measured in accordance with the method defined in Appendix C.
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@ 80 C 5 C
150 N / 10mm
40 N / 10mm
@ 80 C 3 C
0.2 mm
0.3 mm
Tensile Strength
( Break)
Ultimat Elongation
126 Kg/cm2
170 Kg/cm2
400 %
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Test Duration
Max. Disbonding Radius
@ 60 C 2 C
2 days
7 mm
2 mm
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Requirements
min SA 2
40 -100 m
max 10 mg/ m2
3c above dew point
Rating 2
200 -400 m.
250-350m
at weld
at body
min 2.5mm
min 3mm
@ 80 oC
@ 23 oC
150 N/10mm
40 N/10mm
max. 5 holidays / pipe @ 25 Kv
120mm +20/- 0mm
5 J per mm coating thickness
@ 80 oC
@ 23 oC
0.2 mm
0.3 mm
400
@ Yield
@ break
126 Kg/cm2
170 Kg/cm2
50
20%
MEK
DSC
rating 2
between -2 oC
and +3 oC
no visible cracks
@ 60 C/2 days
7 mm
@ 80 C/7 days
2 mm
Subclause
7.1
7.1
7.1
7.1
7.1
7.4
7.4
@ 50 oC
7.7
7.6
7.3
7.8
7.9
7.10
7.10
7.11
7.13
7.14
7.15
7.16
7.17
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In Case of Off-shore pipe lines: Following the extrusion of the polyethylene layer and before cooling,
the surface of polyethylene shall be finished in a way that will improve the friction coefficient and
enhance the bonding of concrete coating to prevent slipping of concrete weight coatings.
The external surface of the coating system shall be roughened by applying polyethylene powder. The
maximum length allowed for missing of rough finish per coated pipe 1 meter.
The shear strength required between the concrete and the anti-corrosion protection coating is to be
higher than 3 Mpa (at ambient temperature).
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8- REPAIR OF COATING
In theory, no coating defect or damage should ever be found during the coating process, but at
practical level it can not however be excluded, so .. some defects may occasionally show up in pipe
coating . Taking the above into consideration , the following repair methods are applied for in plant
damaged coated pipe .
8.1 For local defects ( scratches, cuts, dents, etc. ) of any dimension and any quantity where the
defect not reach the metal surface ( the remaining coating thickness is not less than 80%
of the specified thickness ), no repair is required .
8.2 For same defect mentioned above, where the remaining coating thickness is less than 80% of
the specified thickness, OR where the defect reach the metal surface, No single defect
shall exceeded a pipe area of 625mm2 , all defects exceeding this value shall be cause for
rejection of the coating. These defects could be repaired using Spot Patch Method :
8.2.1 Remove rust or other contaminants, if any, with a hand brush .
8.2.2 Preheat the steel surface of the damaged part .
8.2.3 Apply a piece of sealant material smaller than the size of the damage on the steel
surface .
8.2.4 Heat the sealant then extending the hot sealant with trowel and Apply a piece of sealant
material more and more to mold the damaged part with a sealant more or less thicker than
the polyethylene coating .
8.2.5 Cut a piece of the patch sheet larger by 5 cm than the damaged part, cut the corner of the
patch piece .
8.2.6 Apply the patch piece centering in the damaged part and heat from the center to each
edge.
8.2.7 Tapping from the center to the edge to drive away the trapped air and heat again and
tapping again .
8.2.8 Immediately after heating the repair patch, press all the edges by finger to get an adequate
adhesive strength .
8.3 The maximum level for repair of coating ( exclude repair due to QC tests ) is 5 repairs .
8.4 External coating damages and the relevant repair are not allowed at the cutback area where the
coating has been beveled (at the coating bevel angle).
8.5 The quality of the repair shall be examined and tested for appearance and holidays. Each repair
shall be inspected for
- Visual inspection 100% of repaired coating, the repaired coating shall be smooth, and free of
folds or bubbles .
- Holiday detection shall be performed on each repair using a voltage of 25 Kv.
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9- STRIPPING OF COATING
In the event of pipes failing to meet the requirements of sections 6 and 7, the coating of these
pipes shall be stripped and the pipes shall be recoated and re-inspected.
The coating removal shall be performed using any of the following methods:
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11.
Acceptance
Criteria
Appendix A
Appendix
Appendix
Appendix
Appendix
No contaminations
No surface defects
min SA 2
40 - 100 m
max 10 mg/ m2
Rating 2
Appendix C
200 -400 m.
Appendix C
250 - 350 m.
Appendix C
Test
A
A
A
A
conditions A&B
at weld
Subclause 6.3
Continuity-holiday- control
Appendix D
Appendix G
Appendix F
Appendix E
Hardness, Shore D
Appendix P
at body
min
min 3mm
2.5 mm
Uniform appearance,
no coating
imperification ( flat,
spots,dents,air
bubbles,... etc.
Verified with a
holiday detector
Pass at 25 kv.
Rating 2
@ 20 c 5c
150N/cm
@ 80 c 5c
40N/cm
5 j / mm coating
Temperature range
23 c -2c /+10c
(no holiday at 25 kv)
10 pipes.
10 pipes.
10 pipes.
10 pipes.
10 pipes.
Partially 1 pipe coated
with FBE.
- 12 measurements.
Partially 1 pipe coated
with adhesive.
- 12 measurements.
10 fully coated pipes.
- 12 on pipe body
- 12 on weld seem.
50
2 samples
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Test
Degree of Cure of primer, DSC
Degree of Cure of primer, MEK
Tensile strength at Yield
Tensile strength at Break
Ultimate elongation
Test
Reference
Appendix B
Appendix B
Appendix I
Appendix I
Appendix I
Indentation Resistance
Appendix H
Air Entrapment
Appendix O
Flexibility
Appendix N
Appendix M
Appendix L
Acceptance
Criteria
between -2 oC and
+3 oC
rating 2
126 Kg/cm
170 Kg/cm2
400
Max.0.1 mm at
20C5c
Max.0.3 mm at
80C2c
No air entrapment
No cracking ,no
disbondment
2 mm
7 mm
1 sample
3 samples
1 samples
1 sample
2 pipes (first and last pipes)
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12. DOCUMENTATION
Prior to the start of Production Operations, the following documentation, written in the English
Language, shall be submitted to the client for review.
1.
2.
3.
4.
5.
Repair Procedure;
6.
7.
8.
9.
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A-2 Standard
ISO 8501-1 Pictorial Surface Preparation Standards For Painting Steel Surfaces.
( SIS 05 59 00 )
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Appendix B
B-1 General
This test method covers the procedure of determination of the degree of cure of the FBE epoxy film, the
test shall be performed on a test specimen taken from the coated pipe or carried out on the coated pipe .
B-2.2 Apparatus
The apparatus used for this test is a differential scanning calorimeter with sufficient calorimetric
sensitivity to determine the glass transition temperature of the epoxy products .
Moreover the following accessories are necessary :
- laboratory scale, accurate to the nearest 0.1 mg.
- sharp tool.
- Sample crucible.
B-2.3 Sampling
Immediately after application , a sample of the epoxy film shall be taken from the coated pipe without
adhesive by using a sharp tool to provide flakes of the coating care shall be taken to remove the sample
from the whole thickness of the film while , at the same time , the inclusion of steel fragments shall be
avoided. the sample may be taken at be broken into small pieces .
Accurately weight sample between 10 mg and 15 mg, sample of weight not exceeding 25 mg , can be
used if necessary for obtaining the required sensitivity.
B-2.4
procedure
The test procedure and the setting up of the instruments may differ according to the equipment used
.however , the main characteristics of the test method shall be satisfied in order to obtain valid and
comparable results.
1- An empty aluminum pan shall be used as a reference .
2- Weight the sample, put on lid and seal in sample press.
3- Place the sample crucible in the DSC cell together with an empty reference crucible.
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B-2.5 RESULTS :
The glass transition temperature is defined as being the temperature ( or range of temperatures ) at
which the polymer passes from a hard and often brittle state ( glass ) to a rubbery type .
The transition of the polymer product is visible in the form of a jump in the baseline giving a marked
variation in the steps of the specific heat at Tg . this step usually represents several degrees.
By convention , temperature shall be taken as the point of inflection of the curve .
The curing of the coating is acceptable when variation of the glass transition temperature Tg ( Tg2
Tg1 ) between -2 oC and +3 oC.
Standard Test Method For Measuring MEK Resistance of Ethyl Silicate ( Inorganic)
Zinc-Rich Primers by Solvent Rub .
Standard Test Method For Assessing the Resistance of Organic Coatings Using
Solvent Rubs .
B-3.2 Apparatus
- MEK Methyl-Ethyl Ketone.
- Cotton Cloth
B-3.3
procedure
1-Place the forefinger in a cotton cloth in such a manner that the forefinger is covered by the cloth.
2-Saturate the cloth with MEK and rub the coating with the forefinger using back and forth motion, the
length of the stroke is to be approximately 2 inches.
3-Sufficient pressure is to be exerted by the finger to ensure good contact to the film.
4-Rub 30 double rubs ( 30 rubs in each direction ), if the cloth become dry during the test, re-saturate
with MEK .
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B-3.4 RESULTS :
The degree of cure of the FBE coating tested using MEK double rubs shall be rating 2 after 30
double rubs .
Rating
Criteria
Removal of coating
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Appendix C
C- 1 General
This test method covers the procedure of determination of the dry film thickness ( DFT ) of applied
coatings on magnetic steel substrates .
C- 2 Apparatus
1- Electronic thickness gauge.
2- Standardized calibration foils.
C- 3 Procedure
1- Before thickness measurements are carried out the instrument shall be adjusted and verified using a
calibrated shim of the same thickness range as the coating as follows:
- The coating thickness meter shall be calibrated on a clean steel plate and the display value must be
0.00 mm.
- In case any other value is displayed, the instrument shall be calibrated manually until 0.00 mm value
is obtained.
- Choose a calibration plate of a thickness close to the thickness you expect to fined.
- At least measurements shall be taken and each displayed value is within the range specified by the
instrument's manufacturer.
- If the displayed value is within the range is not specified the following acceptance criteria shall be
apply: Displayed value = Nominal value of the calibration plate 5%.
2- A series of 12 individual measurements shall be carried out on each pipe to be inspected, the measurements shall be regularly distributed along 3 transverse sections of the tested pipe .
3- At each section the thickness shall be measured at 4 positions, equally spaced around the
circumference of the pipe and at a distance of at least 200 mm from the end of the coating .
4- When a weld seam is visible, one measurement per section shall be executed on the top of the weld
seam .
C- 4 Results
A calculation of the arithmetic mean of the series of 12 individual measurements shall be made and shall
be the specified thickness .
NOTE : In case of dispute of results , recalibration of the instrument should be undertaken and five
measurements at this pipe should be carried out again . The arithmetic mean of the result of the five
measurements should be calculated.
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Appendix D
D-1 General
This test method covers the procedure of determination of the degree of porosity present in the coating
using a scanning electrode energized by a high arc voltage.
The Porosity shall be detected by a spark occurring between the steel of the pipe and the electrode of
the detector .
D-2 Standard :
DIN 30 670:
Polyethylene Coatings For Steel Pipes and Fittings, Requirements and Testing.
NF A 49-710:
D-3 Apparatus
-
D-4 Procedure :
1- Calibrate the holiday detector as following :
A series of 5 holes of around 1 mm diameter shall be made in the coating, down to the pipe metal,
with a needle; these holes shall be spaced by about 10 cm .
The detector is switched on, the voltage shall be set at 10 Kv per millimeter of nominal thickness of
coating and not exceeding 25 Kv and the electrode is set to pass the test holes .
A spark discharge must be correspondence with every hole .
2- Adjust the test voltage to 25 Kv .
3- The conductive scanning electrode ( brush or ring ) shall be maintained in good contact to the tested
pipe.
4- The coating system shall be holiday detected 100 % ..
5- The maximum number of holidays is 5 per pipe .
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E-2 Standard :
DIN 30 670:
Polyethylene Coatings For Steel Pipes and Fittings, Requirements and Testing.
NF A 49-710:
E-3 Apparatus :
- Heavy duty impact tester 25 mm spherical end.
- Holiday detector 0 30 Kv.
- Coating thickness gauge.
E-4 Procedure :
1- The impact resistance of the coating shall be tested at temperature 25 5 C.
2- A minimum of 30 points shall be selected on the surface of the test pipe/ring, the distance
between each two impact points shall be at least 30 mm .
3- Drop the impact weight with hemispherical steel head with diameter of 25 mm from approximately 1
meter height.
4- the weight required to produce the specified energy to the coating is calculated using the following
formula : H = J / 9.81 * W
Where
H = impact height, m.
W = impact mass, Kg.
J = Impact energy, joules.
E-5 Results :
1-This described body shall produce an impact energy, E, equal to ( 5 x ) J per mm of
coating thickness
2- The impacted coating shall not crack or disbond at the point of impact and shall inspected for failure
using holiday detector set at 25 Kv ( see Appendix C ) .
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F-2 Standard :
DIN 30 670:
Polyethylene Coatings For Steel Pipes and Fittings, Requirements and Testing.
NF A 49-710:
F-3 Apparatus :
-
F-4 Procedure :
1- The test shall be performed at temperatures of 23 C 3 C and 80 C 3 C.
2- For test at elevated temperature >23 C, the back side of the steel shall be heated to the test
temperature which shall be measured at the root the peeled strip by means of optical pyrometer .
3- A strip of coating of minimum length of 160 mm shall be cut in circumferential direction and 50 mm
wide perpendicular to the axis of the pipe shall be isolated from the coated pipe.
4. Manually peel off the coating strip at an angle of 45 to the pipe surface .
5. The test weight ( see sub-clause 5.7 ) shall be suspended to the coating strip, the time ( in minutes )
required to peel off the coating with a pulling rate of 10mm/min. shall be 0.4D +20%/-10% ( where D
= pipe diameter mm ).
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6- Any pipe that exhibits a peel off value below the required value, the pipe shall receive 2 additional
peel tests to verify the accuracy of the first test .
6.1 If the 2 additional peel tests meet the required value, the pipe is accepted .
6.2 If the 1 out of the 2 additional peel tests is below the required value, the pipe is rejected then 5
previously coated pipes and 5 new coated pipes shall be tested, if below the required value is
detected, the production line shall stopped until the defect is determined .
7- The adhesion test shall be carried out at the cut back area at both ends per test.
F-5 Results :
The adhesion of the coating shall be determined by measuring the peel-off resistance and shall be
calculated as following:
( 9.81 x M x 10 ) / W
( N/10mm )
where: M is the mass of the suspended weight in Kg.
W is the width of the coating strip in mm
The minimum force required to lift the coating shall be as indicated in the table below
Force @ 23 C 3 C
150 N / 10mm
Force @ 80 C 3 C
40 N / 10mm
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G.2 Standard :
ASTM D 3359 : Standard Test Method For Measuring adhesion by Tape Test .
G.3 Apparatus :
- Utility knife ( sharp cutter )
- Adhesive tape.
G.4.2 Results :
The adhesion of the coating shall satisfy the requirements of rating 1 or 2 When starting at the 30 Vee
intersection, the blade shall be used to attempt to peel the coating from the steel .
Rating
Criteria
No removal of coating other than that caused by insertion of the flat point of
the knife blade at the intersection point ( nominally less than 1 mm ).
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Polyethylene Coatings For Steel Pipes and Fittings, Requirements and Testing.
NF A 49-710:
H-3 Apparatus :
The apparatus shall consist of :
1- Chamber or a bath thermostatically to ( up to 75 C )
2- Penetrometer comprising:
- Cylindrical punch of diameter 1.8 mm, on the top of which is mounted a weight . the assembly ,
punch plus weight , shall produce a force of 25 N ;
- Dial gauge or any other measurement system accurate to 10 - 2 mm .
H-4 Procedure
1- A sample of PE of thickness 4 mm shall be taken from a pipe where neither the primer nor the
adhesive have been applied .
2- The sample shall be subjected to an indentor with flat face and 1.8 mm diameter , The total mass
of the indentor assembly shall be 25 N .
3- The indentor shall be slowly and carefully lowered on the test sample , the Zero ( T0 ) reading set
at penetometer within 5 sec. then after 24 h, the final reading ( T ) of the penetometer is recorded
The indentation depth is given by the following equation :Indentation ( mm ) = T - T0
H-5 Results :
Indentation resistance of the PE material shall be as following
@ 23 C 3 C
0.1 mm
@ 80 C 3 C
0.3 mm
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Appendix I-
I-1 General
This test procedure covers the determination of the tensile strength at yield, tensile strength at break and
ultimate elongation of Polyethylene material.
Polyethylene Coatings For Steel Pipes and Fittings, Requirements and Testing.
NF A 49-710:
ASTM D 638:
I-3 Apparatus :
-
Tensile testing machine The apparatus shall consist of a tensile testing machine which makes it
possible to record the force and which can operate constant speed .
Micrometer
I-4 Sampling
The test sample shall be free from FBE, adhesive and taken from a pipe in the extruded direction .
The sample shall be of type IV in ASTM D 638.
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I-6 Results :
The tensile strength and ultimate elongation ( elongation at break ) of the PE material shall be as
following :
Tensile Strength
( Yield )
Tensile Strength
( Break)
Ultimate
Elongation
126 Kg/cm2
150 Kg/cm2
400 %
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L-2 Standard
NF A 49-710:
ASTM G 8:
ASTM G 42:
Standard Test Method For Cathodic Disbonding Of Pipe Lines Coatings at elevated
temperature.
L-3 Apparatus
- Stabilized DC power supply .
- Digital voltmeter /Digital Ammeter.
- Variable resistor.
- Reference electrode ( saturated CuCuso4 or AgAgCl ).
- Platinum anode.
- Heating Equipment
- Sharp knife
L-4 Electrolyte
L.4-1 The electrolyte shall consist of a solution of 3% NaCI concentration in potable water
L-4-2 The PH of the electrolyte shall be maintained during the test period in the range of 6 to 8.5 ( at
ambient temperature).
L-6 Procedure :
1. Three holes of 6 mm diameter shall be drilled through the coating to the metal surface .
2. A rigid plastic container of 100 mm diameter from which the bottom is cut-out, the container is fixed
to the coated sample using a silicon rubber adhesive.
3. The container filled with electrolyte, the electrolyte shall be maintained during test period at the PH
as described in ( K-4-2 ) and the test temperature as per ( K-5 ).
4. A voltmeter is connected with the reference electrode , the variable resistor is adjusted until the
voltmeter reads ( 1.5V ) with respect to the calomel electrode.
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5. At intervals of 24 hr the voltmeter reading is recorded and the variable resistor is adjusted to
correct any drift from the ( 1.5V ) setting .
6. After Test period the container shall removed and the sample is dried, the degree of disbonding is
evaluated as following
6.1 A series of 2 radial cuts are made through the coating in the longitudinal direction of the pipe
and 2 similar cuts shall be made in the circumferential direction.
6.2 Each pair of cuts being 5 mm apart and approx. following the tangent of the test defect, the
length of the cuts shall be aprox. 20 mm each side of the defect.
6.3 Using a sharp knife, the strips of coating between the cuts shall be peeled from the pipe
surface as far as possible starting at the test defect .
6.4 The distance over which the coating is detached and the metal is exposed is measured from
the edge of the original test defect.
6.5 record the measurements for all directions, The result of the cathodic disbondment test is
defined as the arithmetic mean value of at single values for the radial lengths in millimeters.
L-7 Results :
The coating should show the a maximum disbondment as following
Test Duration
Max. Disbonding Radius
@ 60 2 c
2 days
7 mm
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M.2 Standard :
GBE/CW6 : part 1 : Technical Specification For The External Protection Of Steel Line Pipe and
Fittings Using Fusion Bonded Powder and Associated Coating Systems ( Part 1
: Requirements For Coat materials and Methods Of Test .
M.3 Apparatus :
-
M.4 Procedure :
1. Three holes having diameter 5 mm are drilled through the coating material to the metal surface .
2. A rigid plastic container of 100 mm diameter from which the bottom is cut-out, the container is fixed to
the coated sample using a silicon rubber adhesive .
3. The container shall be filled with potable water .
4. Heat the test sample to 80 C 2 C in a thermostatically sand or grit bath The bath temperature
shall be adjusted and controlled to maintain the required test temperature on steel surface.
5. After Test period ( 7 days ) the container shall removed and the sample is dried, the degree of
disbonding is evaluated as following
5.1 A series of 8 radial cuts are made through the coating at the area subjected to cathodic
disbonding.
5.2 Using a sharp knife, the strips of coating between the cuts shall be peeled from the pipe surface
as far as possible starting at the test defect .
5.3 The distance over which the coating is detached and the metal is exposed is measured from the
edge of the original test defect.
5.4 record the measurements for all directions, The result of the disbondment test is defined as the
arithmetic mean value of at single values for the radial lengths in millimeters.
M.5 Results :
The coating shall not show disbonding greater than 2 mm or blistering ( a slight discoloration of the
coating is acceptable ).
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N.2 Standard
NF A 49-710:
CAN/CSA Z 245.20-M92:
N.3 Apparatus :
-
Hydraulic press.
Freezer
Bending mandrel
N.4 Procedure :
1- Smooth the coating on the edge of the sample to remove any potential stress riser.
2- Determine the sample thickness ( t )
3- Place the test specimen in the freezer, cool it to 0 O c or 10 3 Oc and for minimum 1 h .
4- Determine the mandrel radius that corresponds to the angle of deflection of 3O per pipe
diameter length by using the following formula
R = 19.6 t
where :
R = required mandrel radius mm
t = sample thickness
5- Bend the specimen over the radius determine in the above step. The bending rate shall be such
that the specimen is bent within 10 s and the dent shall be completed within 30 s of removal of
specimen from the freezer
6- Warm the bent specimen to 20 5 Oc and hold this temperature for a minimum of 2 hour before
visual inspection.
N.5 Results :
The coating shall accepted when no visible cracks is shown when bending performed to 3 PD .
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O-2 Apparatus :
- Knife ( sharp cutter ).
O-3 Procedure :
1- A strip of coating from the adhesion test shall be used to determine the level of air entrapment on the
body of the pipe or in the saw weld. .
2- The strip shall be visually inspected.
3- Evaluate the edge of the sample and rate the cross section and interface porosity using the scale
provided.
O-4 Results :
The coating should show not more than 20% ( rating 2 ) of the observed area contains air entrapment,
bubble size in the PE layer shall be limited to less than 1/2 the thickness of the PE layer in height or
circumference and not linked together.
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P.1 General :
This test procedure covers the determination of the Durometer Hardness of Polyethylene material.
P.2 Standard
ASTM D 2240: Standard Test Method For Rubber Property- Durometer Hardness .
P.3 Apparatus :
-
P.4 Procedure:
- Sample of PE of thickness 3 mm shall be taken from a pipe free from FBE, adhesive.
- Place the sample on the steel plates of the tester
- The sample shall be subjected to a durometer dial to which total mass of 5 kg is attached.
- The durometer shall be placed without shock on the sample making a firm contact with it.
- The hardness SHORE D shall be read off 3 second after the presser foot of the duometer has
made complete contact with the sample
P.5 Results :
The hardness shore D of the PE material shall be 50 shore D
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Q.2 Standard
ASTM D 1238: Standard Test Method For Flow Rates Of Thermoplastic By Extrusion Plastometer.
Q.3 Apparatus :
-
Extrusion Plastometer.
Stop watch
Electronic balance
Q.4 Specimen
The test specimen may be in any form that can be introduced into the bore of cylinder for example
powder, granules, and strips of film
Q.5 Procedure
12345-
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Q.6 Results :
The melt flow rate ( MFR ), expressed in grams per 10 minutes and is given by the following equation :MFR ( , mnom ) = tref . m / t
Where :