FINAL PRE- PRODUCTIO

DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 1 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

PRE-PRODUCTION TEST
REPORT
For
3 Layer Polypropylene Coating
On
DUPLEX PIPELINE
 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 2 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

TABLE OF CONTENT

1. INTRODUCTION

2. PROJECT DOCUMENT

2.1 – Khalda DOCUMENT

2.2 – PETROJET DOCUMENT

3. TESTS TO Perform

3.1 Polypropylene coating

4. RESULTS FOR POLPROPYLENE COATING

 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 3 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

1- INTRODUCTION:

This report concerns the qualification of the coating system applied to KHALDA DUPLEX 8" PIPELINE
by PETROJET- Port Said coating yard.
This qualification is commenced to prove that the coating applied is comply with the requirements of the
project specific documents:

The composition of the full coating system is:

1) Layer of epoxy primer : KCC Karuml EX 4413-L300 BATCH NO CT41107001

2) Layer of polymeric adhesive : BOREALIS BORCOAT BB127 BATCH NO 224048
3) Layer of Polypropylene top coat : BOREALIS BB108E-1199 BATCH NO 63120206

The qualification tests has been performed on 5 pipes have the following identification:
- Pipe Size: 8" X 14.3 mm
- Pipe No. : 975 & 983 & 831 & 811 & 245
- Production date: 28/3/2015

2. PROJECT DOCUMENT

2.1 – Khalda DOCUMENT

- Khalda spec. NO. 01-P-1-007 REV. 002

2.2 – PETROJET DOCUMENT

- PETROJET coating procedure for anticorrosion coating ,Doc. No. CP-0110-01-PP-DX Rev.0

3.TESTS TO REALISE

- 3.1 Polypropylene coating

 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 4 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

4.RESULTS FOR POLYPROPYLENE COATING

4.1- PIPE RECIVE
4.1 Bare pipe control and off-loading
4.2- PQT TEST CONTROL
4.2.1 Instrument verification
4.2.2 Precautions run for coating line before coating
4.2.3 Surface condition before blasting
4.2.4 Pipe temperature control before blasting
4.2.5 Relative humidity
4.2.6 washing pipe(only in case of contamination )
4.2.7 surface check after blasting
4.2.8 surface cleanless
4.2.9 Determination of dust grade on pipe surface after blasting cleaning
4.2.10 surface roughness on one location
4.2.11 Salt test after blasting
4.2.12 Blow out control
4.2.13 Pipe surface temperature during application
4.2.14 Pipe speed at coating point
4.2.15 Fusion bond epoxy primer thickness
4.2.16 Copolymer adhesive thickness
4.2.17 Total coating thickness
4.2.18 Visual inspection
4.2.19 Coating continuity verified with holiday detector
4.2.20 Holiday inspection speed check
4.2.21 Cut-back control
4.2.22 Repair control
4.2.23 Pipe marking

4.3- ON LINE TEST

4.3.1 Adhesion test
4.3.2 Impact test
4.4- Off line test
4.4.1 Porosity
4.4.2 DSC
4.4.3 Elongation at break
4.4.4 Tensil strength
4.4.5 Indentation resistance
4.4.6 Bend test
4.4.7 Cathodic disbonding test
4.4.8 Pipe stripping
 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 5 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

3. PROCEDURE QUALIFICATION TESTS ( PQT )

3.1 Polypropylene coating:

Test
Test Specification Requirements
Frequency
1-Pipes Receive
No bevel damage ,dents Each
1-1 Bare pipe control gouge,laminations,contimination and incoming bare
flat ends;traceability ,end caps pipe
4- PQT test control

Compliance with the valid The earliest one hour

4.1 Instrument verification
calibration certificate before the start of PQT

Salt ccntamination Max.4

Surface condition before
4.2 µg/cm2 5 pipes
blasting
No oil , grease,dirt or any other
contimination
Measurement of ambient
conditions:
- Ambient temperature Condittion A&B of ISO 8501 The earliest min. before
4.3
- Ambient relative (PART 1) the start of PQT
humidity
- Ambient dew point
Pipe temperature control
4.4 min 3ºc above dew point 5 pipes
before blasting
Free from sliver,scabs,gougs or
4.5 Surface check after blasting lamination 5 pipes
No slivers or mill scale
4.6 Surface cleanless min SA 2 ½ 5 pipes
Determination of dust grade
Max. class 2
4.7 on pipe surface after blast 5 pipes
Max. Rating 2
cleaning (on one end)
Surface roughness
4.8 Rz :50 – 100 µm 5 pipes
On one location
Salt test
4.9 -after blasting Max.4 µg/cm2 15 (3×5 pipe)

All grit residual and any other

Blow out control
4.10 foreign matter shall be removed 5 pipes
from the inside of the pipe
Pipe surface temperature Steel temp. min.200°c
4.11 Continuosly
during coating application Steel temp. max. 220° c
4.12 Pipe speed at coating point To be determind during PQT Each pipe
 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 6 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

4.13 Fusion bonded epoxy primer 200 to 400 µm 24(12×2pipe)

thickness
2 pipes coated partially
4.14 Copolymer adhesive thickness 250 - 400 µm with FBE and partially
FBE+PP adhesive
Min. 3 mm at pipe body
4.15 Total coating thickness 60 (12×5pipe)
Reasonably uniform
appearance. There shall be no
4.16 Visual inspection coating imperification such 5 pipes 3 LPP coated
flat,spots,dents,air
bubbles,wrinkles
Coating continuity verified Pass at 25 kv Max.detection
4.17 5 pipes 3 LPP coated
with a holiday detector speed 0.3m/s
4.18 Holiday inspection speed Max. detection speed 0.3 m/s Once
Cut-back control (each cut-
4.19 C.B .= 150 + 20 mm/-0 5 pipes
back on each pipe)
4.20 Repair control As per ITP for PQT Every repaired pipe
4.21 Pipe marking Hand
PTJ no.,pipe no as per recivied 5 pipes
tally list from pipe,heat
no.,length

Record tally list details on

4.22 Tally record completeness Every pipe
PTS
5- ON LINE TEST
Adhesion test
100 N/cm At 50°c &
5.1 -on cutback area 5 pipes
80 N/cm At 90°c.
-both ends
≥ 18 J
5.2 Impact test at ambient Temperature range 15°c to25°c 8 ( 2×4pipes)
temperature for 3layer PE (no holiday at 25kv)
 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 7 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

6- OFF LINE TEST

No void or air entrapment

Porosity 3 layer PP coated
inspection the coating sample
6.1 (air entrapment) 5 pipes
from the side view

6.2 DSC for FBE only ∆ Tg:-2 / +3°C 2 pipes

Min.400 % at temperature
6.3 Elongation at break Once per PP batch
20°C±2°c
Max.0.3 mm at 50°C±2°c
6.4 Indentation resistance Once per PP batch
Max.0.2 mm at 20°C±2°c
No cracking ,no disbondment
6.5 Bend test at 23 ± 2°C after testing as per CAN 2 pipes
CSAZ245.20 standared

Hot water resistance 1 day at

R < 2 mm
6.7 @ 90°C 2 pipes

Cathodic disbonding :
R < 5 mm hole edge
2 day test @ 90°C 2 pipes

7- Documentation Control
According to Q.C. & Production As per
7.1 Verify the daily production report PTJ Procedure
Documentation Management
According to Q.C. & Production As per
7.2 Verify the test report PTJ Procedure
Documentation Management
 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 8 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

4- QUALIFICATION TEST RESULTS FOR POLYPROPYLENE COATING:

4.1 PIPE RECEIVE AND OFF-LOADING
4.1.1 The bare pipes deliveried is visually inspected for bevel damage ,dents ….etc.
Remarks : No bevel damage dents,gouges, lamination, contamination and flat ends
The results of bare pipe control fulfill the requirements of project specific document item No.2
And there are some pictures for off-loading pipes

4.2 RAW MATERIAL RECEIVE

4.2.1: Delivery of raw materials

The deliveried raw material are the following
1) Layer of epoxy primer : Kcc Karumeal Ex4413-L300 Batch No. CT41107001
2) Layer of polymeric adhesive : BOREALIS BORCOAT BB127 BATCH NO 224048
3) Layer of PP top coat: BOREALIS BB108E-1199 BATCH NO 63120206

All raw materials delivery shall inspected as per purchase order requirments
Remarks: The raw material delivered meet the purchase order requirments
4.2.2: Condition of goods /packing delivered
All raw material shall be inspected for the condition of goods and packing
Remarks: All raw material inspected for the condition of goods and packing and accepted
4.2.3: Storage of coating material
All raw materials shall be inspected for the condition of storage as per manfacture data sheet
Remarks: All deliverd material storage condition meet the manufacture requirement
4.2.4: Epoxy powder primer manufacturer certificates (gel time,moisture content,density,DSC)
 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 9 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

The data sheet of epoxy powder shall be inspected for the tests gel time,moisture content,density
and DSC
Remarks: all the above meet per manufacture data sheet.
4.2.5: Adhesive PP manufacturer certificate (specific gravity,melt flow index)
The adhesive PP data sheet shall be inspected for the test of specific gravity and melt flow
index
Remarks: All the above test meet the manufacture data sheet .

4.2.6 :PP manufacture certificate (specific gravity and melt flow index )
The PP data sheet shall be inspected for the test of specific gravity and melt flow index
Remarks: All the above test meet the manufacture data sheet.
4.3 RAW MATERIALS TEST
4.3.1: Epoxy powder primer (DSC)
The epoxy primer powder DSC as per manfacturer certificate (KCC Karumeal Ex4413-L300
batch No.CT 41107001
Sample no 1 Tg1: 60.5 °C Tg2: 105.5 °C
Sample no 2 Tg1: 60 °C Tg2: 106.1 °C
Remarks: DSC test meet the manufacture certificate
4.3.2 :Epoxy powder primer gel time
The value of gel time of epoxy primer powder used (KCC Karumeal Ex4413-L300 batch
No.CT 41107001
was measured in external lab.by using hot plat test
Required value = 23±5 sec at 204 °C

Remarks: Gel time =21 sec/204 °C

.

4.3.3:Epoxy powder primer moisture content

The epoxy powder primer shall be inspected for the value moisture content ((KCC Karumeal
Ex4413-L300 batch No.CT 41107001
Required value =max 0.5 %
Remarks: moisture content = 0.27 %
 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 10 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

4.3.4:Adhesive melt flow index

The melt flow index for adhesive shall be performed according the method defined in PTJ procedure
BOREALIS BORCOAT BB127 BATCH NO 224048
Requirment : 8(±5)g/ 10 min
Remarks: Melt flow index for adhesive =7.9 g/10min
4.3.5 : PP melt flow index
The melt flow index for PP shall be performed according the method defined in PTJ
procedure
BOREALIS BB108E-1199 BATCH NO 63120206

Requirement : 0.3 -1 g / 10 min

Remarks: PP melt flow = 0.8 g / 10 min
4.4 :PQT TEST CONTROL
4.4.1: Instrument Verification
All instrument calibration certificate shall be inspected for the validity
Result:All calibration certificate are valid
4.4.2 : Precaution run for coating line Before coating
As per client requirements for handling , storage , coating and transportation of duplex pipes ,
there are some precautions shall be run before the coating which is as follow:
- The off-loading of the container of pipes is run as client procedure
- The transportation of pipes bundle is run by using forklift
- The material used for blasting is non-ferrous materials and the blasting machine is cleand well
from the forigen material
- For handling the pipes using a special hocks
- All blasting line wheel are washed by thinner to remove all forigen deposits

- All pipe rack are coverd with plastic sheets

- All coating line wheel are washed by thinner
- All hand tools used are made from stainless steel
- The quenching area are cleand and exchange the water by fresh water
- After quenching all racks are coverd with plastic sheets
- All tools used for destructive test are made from stainless steel
- All brushs used for adjust the bevel of the coating are made from stainless steel
 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 11 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

- All stacking racks are coverd with plastic sheets

Remarks : all the above item are done as per client specs.
 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 12 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

4.4.3 : Surface condition before blasting

The surface of the bare shall be inspected before blasting
Acceptance status: No oil , grease , dirt or any other contimination
Remarks: No oil grease ,dirty or any other contamination
4.4.4 :Pipe temperature control before blasting
Before surface preparation the following points have been checked
Acceptance status: min. 3° C abov dew point
4.4.1:Relative humidity
Before surface preparation the value of relative humidity has been checked
Remarks: The value of RH = 65 %
4.4.2:Surface check after blasting
The exterior surface of the blasted pipe is verified to check the surface
Remarks:The surface of the blasted pipes is free from sliver,scabs,gouges or lamination
4.4.3 :Surface cleanliness
The blasted pipe exterior surface is visually inspected by visual comparison with photographs in SIS 05
59 00 standard to check the degree of surface cleanliness in accordance with ISO 8501 PART I .
Cleanliness grade: min sa 2 ½
Remarks: The surface of blasted pipes are checked and degree of cleanliness is sa 2½
Details of measuring equipment used: (visual and SIS 05 5900 STANDARD)
 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 13 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

4.3.4:Determination of dust grade

The exterior surface of the blasted pipe is verified to check the dust level using adhesive tape.
Dust contamination level actually detected: (density and size of dust particles)
Acceptance criteria: max. Rat . 2
Remarks: The dust level of blasted pipes is Rat. 1

4.3.5:Surface roughness
The exterior surface of the blasted pipe is verified to check the pipe surface profile using press-O- testex
tape.
Acceptance criteria: Rz =50 : 100 µm
Details of measuring equipment used: (manufacturer Mitutoyo, model testex, serial number 1

Remarks: The surface roughness of the pipe within the range as the following table

Pipe No 975 983 831 811 245

Value
73 75 70 72 75
µm

4.3.6 : Salt test after blasting

The Chloride contamination was measured by Elcometer 130 SCM-400 salt contamination meter.
Acceptance criteria: max. 4 µg/cm2
Details of measuring equipment used: (manufacturer Elcometer, model SCM 400, serial
number 400/100270)
Remarks:the salt level found within the range as the following table

Pipe No 975 983 831 811 245

Value
0.7 0.5 0.4 0.6 0.5
µg/cm2
 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 14 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

4.3.7 :Blow out control

All blasted pipes shall be inspected from the interior surface to be sure all grit residual and any
other matter are removed from the inside of the pipe
Remarks: The interior surface of the pipe is free from all grit residual or any other matter
4.3.8:Pipe surface temperature during coating application
The pipe surface temperature is measured after the induction heater and before the FBE application
booth using the TEMPIL STICK temperature indicating crayons and optical pyrometer
Temperature recorded :
Pipe No 975 983 831 811 245
Temple stick 204 200 202 204 205
Details of measuring equipment used: (manufacturer Raytek, model THERMALERT TXTM,
serial number 6B487)
Remarks: The pipe surface temperature is 200 - 210 c
4.3.9:Pipe speed at coating point
The pipe speed shall be determined
Remarks: The pipe speed is 4.8 m/min

4.3.10:Fusion bonded epoxy primer thickness

The coating thickness of FBE layer is measured in accordance with the method defined in coating
procedure No.CP-0110-01-PP-DX Rev.0
Thickness measurement at each location:
Acceptance criteria: min. 200 µm to 400 µm
Remarks: The average thickness of the FBE layer = 270-320 µm
Details of measuring equipment used: (manufacturer Elekro Physik , model mini test 1100,
serial number 6639)
4.3.11:Copolymer adhesive thickness
The coating thickness of adhesive layer is measured in accordance with the method defined in coating
procedure No. CP-0110-01-PP-DX Rev.0
Thickness measurement at each location: see the table below
Acceptance criteria: min. 250 µm -400 µm
Remarks: The average thickness of the adhesive layer = 280-350 µm
Details of measuring equipment used: (manufacturer Elekro Physik , model mini test 1100,
serial number 6639)
 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 15 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

4.3.12:Total thickness of the coating system

The total coating thickness is measured in accordance with the method defined in coating procedure
No. CP-0110-01-PP-DX Rev.0 and the value is according the following table:
Thickness measurement at each location:
Details of measuring equipment used: (manufacturer Elekro Physik , model mini test 1100,
serial number 6639)
Acceptance criteria: MIN. thickness 3 mm
Remarks: The coating thickness of the total system is:
Coating THK. On the body = 3.2-3.4 mm.

TOTAL COATING THICKNESS READING

pipe no 975 983 831 811 245

Body Body Body Body Body

3 3.3 3.3 3.1 3

3.2 3.2 3.3 3.3 3.2
3.1 3.4 3.2 3.2 3.3
3.3 3.2 3.5 3.3 3.2
3.2 3.3 3.4 3.5 3.5
3.3 3.3 3.4 3.1 3
3.2 3.2 3.3 3.4 3.3
3.3 3.3. 3.4 3.5 3.2
3.2 3.5 3.2 3.3 3.3
3.4 3.4 3.3 3.4 3.4
3.2 3.3 3.4 3.1 3.3
3.3 3.2 3.3 3.2 3.2
3.4 3.4 3.4 3.3 3.2
3.5 3.3 3.2 3.5 3.1
3.3 3.2 3.2 3.4 3.4
3.3 3 3.3 3.4 3.3
3.4 3.3 3.4 3.5 3.2
3.2 3 3.3 3.2 3.4
3.5 3.2 3.4 3.3 3.2
3.1 3.4 3.5 3.2 3.1

average 3.27 3.27 3.34 3.31 3.24

total
3.28
average
 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 16 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

4.3.13 Visual inspection

The coating is visually inspected for check of absence of surface irregularities
Acceptance criteria: Reasonably uniform appearance .There is shall be no coating
imperfections such flat spots , dents , air bubbles , wrinkles , pockets , breakaway zone , deep
ridging ,runs , tears , inclusion or incision
Remarks: The coating is smooth and no surface defects
Details of measuring equipment used: (visual)

4.3.14 :Coating continuity

The coated pipes is holiday tested in accordance with the method defined in coating procedure
CP-0110-01-PP-DX Rev.0 using at voltage set at 25 kV.
Test results: pass at 25 kv
Remarks: No electrical breakdown or surface defects are detected
Details of measuring equipment used: (manufacturer PIPELINE INSPECTION, model SPY 125
, serial number 125-330 )

4.3.16: Cut-back control

The coating is fully removed completely from pipe ends over length ( 150 + 20 mm/-0) mm
and beveled at angle 30º to 45º
Cutback length measured: see the table below
Acceptance criteria: C.B = 150 + 20 mm/-0

Remarks : The cut back length is as follow.

Pipe
975 983 831 811 245
No

155 160 155 158 163

Value mm
165 163 157 160 155
 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 17 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

4.3.17: Repair control

Every pipes has damaged during production shall be repaired as per the method define in coating
procedure No. CP-0110-01-PP-DX Rev.0
Remarks: No repair during PQT during 3 LPP coating

4.3.18:Pipe marking

All identification data ( heat number,mill pipe number,and pipe length ) are recorded after coating
process on th external surface of the coated pipe in addition to PETROJET serial no
Remarks : All pipe are marked with PTJ No , pipe No . Heat No and lenght

4.3.19:Recorded tally list details

All coated pipes shall be recorded in tally list with all indentification data
Remarks : All coated pipes are recorded in tally list with all indentification data

﴾The results of PQT test control is fulfill the requirements of All project specific document item No.2﴿

4.4:ON LINE TEST

4.4.1 : Adhesion test

The adhesion of the coating is determined in accordance with the methode defined in coating procedure
No. CP-0110-01-PP-DX REV.0 The adhesion of the coating is determined by measuring the peel-off
resistance and the result as the following table.
Remarks: The minimum force required to lift the coating At 50 ºC ≥ 100 N/ cm & At 90ºC ≥ 80N/cm

Mill Pipe
975 983 831 811 245
No

At 50 ºC 100 N/ cm > 100 > 100 > 100 > 100 > 100

At 90ºC ≥ 80 N/cm > 80 > 80 > 80 > 80 > 80

 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 18 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

4.4.2: IMPACT RESISTANCE TEST FOR 3 LAYER COATED

The impact resistance of the PP coating system is tested in accordance with DIN 30 678 and the
method defined in coating procedure No. CP-0110-01-PP-DX Rev.0 .
The test is performed using an impact body  18 J
Topcoat material batch number: 1208374
Impact energy:≥ 18 J
Test result: The impact energy have not caused any perforation inspected with holiday detector
set at 25 kV.

4.5:OFF-LINE TESTING

4.5.1:Porosity
The coating is examined for check the presence of interfacial porosity, air entrapment and voids, the
coating shall examined using X 30 microscope in accordance with CAN/CSA Z 245.20-M92 standard and
the method defined in coating procedure No. CP-0110-01-PP-DX Rev.0.
Remarks : No air entrapped or voids between coating layers
4.5.2:DSC
The degree of cure of the FBE primer layer is tested using Differential Scanning Calorimetry (DSC) test
by determination of the glass transition temperatures, The test is performed in accordance with NACE RP
0394 standard and the method defined in coating procedure No PTJ-PE-SEQ-01 Rev.A-Annex B.
Acceptance criteria: = -2° c ≤ ∆ Tg ≤ +3° c
Remarks: The DSC value see the table bleow and attached reports
Graphs showing the glass transition temperature Tg1 and Tg2: see attached graphs
Details of measuring equipment used: (manufacturer METTLER TOLEDO, model DSC 822 E,
serial number 5121482486)
RESULT: the glass transition temperature ΔTg ( Tg2 – Tg1 ) is as the following

SAMPLE FBE ONLY FBE ONLY

VALUE -2° c ≤ ∆ Tg ≤ +3° c
0.06 0.39
 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 19 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

4.5.3:ELONGATION AT BREAK
The ultimate elongation ( elongation at break ) of the PP material has been tested in accordance with
the method defined in coating procedure CP-0110-01-PP-DX Rev.0
- The sample shall be Dumbbell shape No. 4 as descriped in ASTM D 638.
- The grips shall be moved away at constant speed = 50 mm / min.
Material name: BOREALIS BB 108E-1199
Material batch number: 63120206
Testing equipment: Tensil and elongation equipment
Acceptanca criteria: min. 400 % at ambient temperature
Remarks: Ultimate elongation = 1315%
Tensile at yeild =220 kg/cm2
Tensile at yeild =290 kg/cm2
Details of measuring equipment used: (manufacturer LLOYD, model LR5K MK4 01/2530, serial number
102274)
4.5.4:INDENTATION RESISTANCE

The indentation resistance of the PP material has been tested in accordance with DIN 30 678 , NFA
49-711 standards and the methode defined in coating procedure No. CP-0110-01-PP-DX Rev.0
Material name: BOREALIS BB 108E-1199
Material batch number: 63120206
Testing equipment: Indentation equipment
Acceptanca criteria: Max. 0.1 mm at 23○c & Max 0.3 mm at 50○c

Remarks: The maximum indentation resistance recorded is shown following.

Sample 23○c 50○c

Value(mm) 0.01 0.11

Details of measuring equipment used: (manufacturer Selmers, model BINDER , serial number 513)
 FINAL PRE- PRODUCTIO
DOCUMENT DESCRIPTION
REPORT
DOCUMENT No. PTJ/PPT/DXX /KHAL-01

REPORT DATE:1/4/2015 SHEET

Rev.0 20 of 20

The Petroleum Projects & Technical Consultations Co. ( PETROJET )

CLIENT : KHALDA PETROLEUM CO PROJECT: KHALDA DUPLEX PIPELINE 8"

4.5.5: Bend test

The degree of flexibility of the PP coating shall be tested when a test ring is bent over a mandrel
At ambient temperature in accordance with CAN/CSA Z 245.20-M92 standard and the method defined in
coating procedure No CP-0110-01-PP-DX Rev.0
Testing equipment: Bending equipment
Test results: No visible cracks is shown in coating when bending performed to ambient
temperature.
Details of measuring equipment used: (manufacturer EUROMAC, model DIGI360, serial
number 513388)

4.5.6:CATHODIC DISBONDING TEST FOR 3 LAYER PE

The coating is examined for check the resistance to cathodic disbondment when subjected to a
potential of – 1.5 V, in a 3% NaCl electrolyte solution in accordance with Pr En 10286 standards and the
method defined in coating procedure No CP-0110-01_PE Rev.0
Equipment used: cathodic disbonding equipment
Solution used: NaCl 3%
Test temperature: 90°C
Potential, current and pH at the beginning of the test, after 48hours and at the end of the test:-1.5 v
Test result: the maximum increase in Radial Defect .

Disbonding value mm
TEST SAMPLE

3.5
48 hr @ 90°C

Details on the measuring equipment: (manufacturer Selmers)

This is a final report for the qualification of 3LPP coating system performed on 8" DUPLEX and
the obtained results so far reported in this report meet the requirements of The All project
specific document item No.2


PETROJET KHALDA REP.

Name: Name:
Sign .: Sign .: