CoProNoStandardRecommended Practice

Field-Applied Fusion-Bonded Epoxy (FBE) PipeCoating Systems for Girth Weld Joints:

Application, Performance, and Quality ControlThis NACE International standard represents a consensus of those individual members who havereviewed this document, its scope, and provisions. Its acceptance does not in any respectpreclude anyone, whether he has adopted the standard or not, from manufacturing, marketing,purchasing, or using products, processes, or procedures not in conformance with this standard.Nothing contained in this NACE International standard is to be construed as granting any right, byimplication or otherwise, to manufacture, sell, or use in connection with any method, apparatus, orproduct covered by Letters Patent, or as indemnifying or protecting anyone against liability forinfringement of Letters Patent. This standard represents minimum requirements and should in noway be interpreted as a restriction on the use of better procedures or materials. Neither is thisstandard intended to apply in all cases relating to the subject. Unpredictable circumstances maynegate the usefulness of this standard in specific instances. NACE International assumes noresponsibility for the interpretation or use of this standard by other parties and acceptsresponsibility for only those official NACE International interpretations issued by NACEInternational in accordance with its governing procedures and policies which preclude theissuance of interpretations by individual volunteers.

Users of this NACE International standard are responsible for reviewing appropriate health, safety,environmental, and regulatory documents and for determining their applicability in relation to thisstandard prior to its use. This NACE International standard may not necessarily address allpotential health and safety problems or environmental hazards associated with the use ofmaterials, equipment, and/or operations detailed or referred to within this standard. Users of thisNACE International standard are also responsible for establishing appropriate health, safety, andenvironmental protection practices, in consultation with appropriate regulatory authorities ifnecessary, to achieve compliance with any existing applicable regulatory requirements prior to theuse of this standard.

CAUTIONARY NOTICE: NACE International standards are subject to periodic review, and may berevised or withdrawn at any time without prior notice. NACE International requires that action betaken to reaffirm, revise, or withdraw this standard no later than five years from the date of initialpublication. The user is cautioned to obtain the latest edition. Purchasers of NACE Internationalstandards may receive current information on all standards and other NACE Internationalpublications by contacting the NACE International Membership Services Department, 1440 SouthCreek Drive, Houston, Texas 77084-4906 (telephone +1 [281] 228-6200).

Approved 2002-02-17NACE International

1440 South Creek Dr.Houston, Texas 77084-4906

+1 (281)228-6200ISBN 1-57590-150-1

2002, NACE International

NACE Standard RP0402-2002Item No. 21096

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CPNRP0402-2002

NACE International i

________________________________________________________________________

Foreword

This NACE standard recommended practice provides the most current technology and industrypractices for the use of field-applied, fusion-bonded epoxy (FBE) external pipe coating systems forgirth weld joints. This standard is intended for use by corrosion control personnel, designengineers, project managers, purchasing personnel, and construction engineers and managers. Itis applicable to underground steel pipelines in the oil and gas gathering, distribution, andtransmission industries.

This standard was prepared by NACE Task Group 249 on Fusion-Bond Epoxy Coatings for WeldJoints on Pipelines. This Task Group is administered by Specific Technology Group (STG) 03 onCoatings and LiningsImmersion/Buried. It is also sponsored by STG 04 on Protective Coatingsand LiningsSurface Preparation, and STG 35 on Pipelines, Tanks, and Well Casings. Thisstandard is issued by NACE International under the auspices of STG 03.

In NACE standards, the terms shall, must, should, and may are used in accordance with thedefinitions of these terms in the NACE Publications Style Manual, 4th ed., Paragraph 7.4.1.9. Shalland must are used to state mandatory requirements. The term should is used to state somethingconsidered good and is recommended but is not mandatory. The term may is used to statesomething considered optional.

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ii NACE International

________________________________________________________________________

NACE InternationalStandard

Recommended Practice

Field-Applied Fusion-Bonded Epoxy (FBE) Pipe CoatingSystems for Girth Weld Joints: Application, Performance, and

Quality Control

Contents

1. General.......................................................................................................................... 12. Definitions...................................................................................................................... 13. Coating Systems ........................................................................................................... 14. Coating Material ............................................................................................................ 15. Coating and Applicator Performance ............................................................................ 26. Surface Preparation of Pipe .......................................................................................... 37. Coating Application ....................................................................................................... 48. Inspection and Repair ................................................................................................... 5References.......................................................................................................................... 5

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Approved FBE Powder: A fusion-bonded epoxy powder

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Pthat has the authority over the pipe to which the coating is to

Shelf Life: The maximum-allowable storage time for a coat-

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(e) Any other technical information regarding theFBE powder that is normal and customary.

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`NACE International 1

physical properties of the coating materials;(c) Batch certificates;(d) Material safety data sheets (MSDS); and

stored according to recommendations from the sup-plier, and so that contamination or adverse effects onthe coating are avoided.

right NACE International 4.1 Coating Material Supplier Information

4.1.1 Upon request, the coating material supplier shallfurnish the following information in writing to the pur-chaser and/or applicator:

(a) Instructions for handling and storing the coatingmaterial;(b) Laboratory performance test results of the basiced by IHS under license with NACE LicNoproduction or networking permitted without license from IHS4.2 Handling of Coating Materials

4.2.1 Coating material batches shall be identified by abatch coding system devised by the supplier. Thebatch code shall include a reference to the date ofmanufacture. Coating materials shall be shipped and________________________________________________________________________

Section 4: Coating Material

--``,,,`,`,,,,``,``,```,Cutback Area: Area of each section of line pipe that wasleft uncoated at the coating mill/plant to facilitate welding ofadjacent pipe joints.Field Joint Area: The area of pipe over which the coating isapplied in the field after welding of adjacent pipes.Holiday: A discontinuity in a protective coating that exposesunprotected surface to the environment.

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Section 3: C

3.1 The standard FBE required for normal conditions con-tains the following components:ing material prior to its use.

Supplier: The manufacturer and/or distributor of the coatingmaterial and its authorized technician.

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ating Systems

(a) FBE powder in accordance with NACE StandardRP0394.

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Coating Materials: Fusion-bonded epoxy powder (FBE).be applied.

Repair Area: Area of original coating system that has beendamaged and is being repaired using the coating materials.Applicator: The organization responsible to the purchaserfor the coating application.enseet for Rnspector: The authorized agent of the purchaser.

urchaser: The owner company or the authorized agency________________________________________________________________________

Section 2: Definitions_____________________________________

Section 1

1.1 This standard presents guidelines for establishing mini-mum requirements to ensure proper application and perfor-mance of a field-applied fusion-bonded epoxy (FBE) coatingsystem to the external surfaces of pipe at girth weld joints.Included are methods for qualifying and controlling the qual-ity of FBE, guidelines for its proper application, and inspec-tion and repair techniques to ensure its long-term perform-ance.__________________________________

General

1.2 This standard is applicable to FBE coating systemsused to prevent corrosion in conjunction with cathodicprotection.

1.3 All applicable safety and environmental codes, rules,and regulations must be followed when using this standard.RP0402-2002=Instituto Mexicanos Del Petroleo/3139900001 esale, 06/12/2009 12:25:50 MDT

exceeded the recommended shelf life may be rejectedby the purchaser.

4.2.2.1 At the discretion of the purchaser, anybatch of coating material that has exceeded therecommended shelf life may be tested to verify

The expense of such tests shall not be the respon-sibility of the purchaser. The purchaser shall notbe under any obligation to accept material that hasexceeded its shelf life.

4.2.2.2 Any rejected coating material shall be

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5.6 A new FBE coating system with no service history shall off for these test rings shall be borne by the purchaser.

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Not for Resroduction or networking permitted without license from IHS5.5 An established FBE coating system to be used in anew service or environment may be required to have addi-tional performance testing.

are sampled to reduce the size of the failed lot, allcosts except for the cost of the pipe sample shall beborne by the applicator. The purchaser may requireadditional test rings. The cost of pipe, coating, and cut-that it meets or exceeds the requirements as setforth herein or by other industry standards as

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Section 5: Coating and

5.1 Recommended characteristics, properties and perform-ance of an applied coating system are outlined in NACEStandards RP0394 and RP0169.2

5.2 The need for performance testing shall be determinedaccording to performance history. Three categories shallbe used:

5.2.1 Established FBE coating system to be used inthe established service or environment.

5.2.2 Established FBE coating system to be used in anew service or environment.

5.2.3 New FBE coating system with no service history.

5.3 An FBE coating system that meets one or more of thefollowing criteria for a period of at least five years, withoutformulation change, shall be considered an establishedFBE coating system:

5.3.1 No significant increase in the cathodic protectioncurrent density, attributable to deterioration of thecoating, required to maintain the pipe-to-soil potential inaccordance with NACE Standard RP0169.

5.3.2 No significant decrease in the coatings effective-ness as a result of moisture transmission.

5.4 An established FBE coating system to be used in theestablished service or environment shall not require addi-tional performance testing.immediately removed from the job site.

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Applicator Performance

shall be tested for the following properties as required byNACE Standard RP0394:

5.6.1 Electrical resistance;

5.6.2 Dielectric strength;

5.6.3 Coating adhesion (hot water soak);5.6.4 Water vapor permeability (perms);5.6.5 Maximum cathodic disbondment;

5.6.6 Adhesion;

5.6.7 Impact resistance; and

5.6.8 Glass transition temperature.

5.7 Applicator Performance

5.7.1 Test rings are required to qualify the applicator.Coating shall be applied to a test pipe according toSections 6 and 7 of this standard. Ring samples cutfrom test pipe should be approximately 30 cm (12 in.)long. After samples are cut from the ring, the appli-cator shall mark the date of coating application on theunused portion of the ring sample. Testing of the sam-ples shall commence on the same day as the coatingapplication. Required tests are listed in Paragraphs5.6.1 to 5.6.8. Cutting and rebeveling shall be at theapplicators expense. Pipe used shall be provided atthe purchasers expense. When additional test pipesRP0402-2002

4.2.2 Shelf Life: Any batch of coating material that has agreed on by the purchaser and the applicator.

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Section 6: Surface Preparation of Pipe

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___________________________

(1) SSPC: The Society for Protective Coatings (SSPC), 40 24th St, 6th Floor, Pittsburgh, PA 15222-4656.

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6.2 Prior to abrasive blasting, all weld spatter shall beremoved using a file or other acceptable method. NACEStandard RP01784 provides a good representation of aproper weld area. Any blast profile with an altered(destroyed) area greater than 3 cm2 (0.5 in.2) shall bereblasted prior to induction heating.

6.3 All sharp edges of the weld bead or any raised portionof the weld crown shall be rounded by hand filing or a pur-chaser-approved method.

6.4 Prior to abrasive blasting, preheating may be neces-sary to bring the steel temperature above the dewpoint.

6.5 On each side of the weld joint, the bare metal cutbackand a strip of mill-applied coating shall be prepared by abra-sive blasting. The mill-applied coating shall not be removedduring abrasive blasting, but cleaned and roughened(slightly etched, feathered, or sugared) by brush blasting fora minimum of 5 cm (2 in.) with a taper toward the weldbead. The mill-applied coating may be hand abraded usingabrasive paper, pads, or wheels in lieu of abrasive blasting,according to the purchasers specification.

6.6 The bare metal in the girth weld area shall be abrasiveblasted to a minimum NACE No. 2/SSPC-SP 105 near-whitemetal finish. A photographic or visual standard, such asSSPC-VIS 1,6 shall be used to verify that a near-white finishhas been achieved. The blast abrasive chosen should beselected to achieve a blast profile of 64 to 100 m (2.5 to4.0 mils). This profile shall be verified in accordance withNACE Standard RP0287.7 The purchaser may make stan-dards available for comparison with the anchor pattern.

6.7 Water/oil traps and filters shall be used on all blast-cleaning apparatus. The water/oil traps and filters must bechecked and drained or replaced periodically as necessary.Any blast-cleaned surface contaminated with water or oilshall be cleaned and reblasted until the appropriate stan-dard of cleanliness has been achieved.

6.8 The abrasive blast operation should be at least threewelds ahead of the coating application operation to prohibitcontamination of the powder application, but in no caseshall the abrasive blasted weld joints be allowed to visiblyed by IHS under license with NACE LNproduction or networking permitted without license from IHSrust prior to coating. If flash rusting does occur, the areashall be reblasted.

6.9 If jagged or rough areas remain along the edge of themill-applied coating after blast cleaning, or if any of thecoating has disbonded, these areas shall be removed untila sound coating has been obtained. The areas shall thenbe recleaned.

6.10 File or abrasive sanders shall remove raised slivers,scabs, laminations, or bristles of steel remaining on thenewly cleaned surface. This cleaning operation shall notburnish or completely destroy the anchor pattern.

6.11 During periods of inclement weather, cleaning andcoating operations shall be discontinued unless tents, shel-ters, wind shields, etc., can be erected. The shelters mustfully exclude the weather conditions to provide an accept-able environment for the coating operation.

6.12 Just prior to heating, the area to be coated shall beblown clean of all dust, sand, etc., using clean, dry, high-pressure air. It is recommended that this area also bebrush-cleaned with a clean, dry bristle-type paintbrush.

6.13 The pipeline on either side of the weld joint area shallbe blown free of all standing dust, sand, etc. with clean, dry,high-pressure air.

6.14 Preheating

6.14.1 The area to be coated shall be heated byhigh-frequency induction-heating coils to a temperaturewithin a range defined in accordance with the supplierswritten recommendations.

6.14.2 The heating equipment shall be approved bythe purchaser and shall be sized to ensure that theentire area to be coated reaches the required temp-erature. The induction coil shall have been tested forheat profile and should have a difference across theweld joint not exceeding 10C (18F). The heating timeto reach the required temperature shall be established.

6.14.3 The temperature of the steel shall be checkedusing temperature-indicating crayons or by an ap-proved heat-measuring device.

6.14.4 At no time during the entire coating processshall the pipe be heated to a temperature in excess of260C (500F). If the pipe temperature exceeds 260C(500F), the purchaser must be informed immediately.RP0402-2002

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g7.5.2 The FBE powder shall be fluidized, then flock- sharp knife blade through the fully cured coating to the

CopProvNo r4 NACE International

applied to the girth weld area to a minimum thicknessof 640 m (25 mils), measured dry on the apex of theweld. Maximum thickness shall be as specified by the

surface of the pipe in a whittling motion. Attempts shallbe made to remove the coating from the surface. The

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Section 7: Coatin

7.1 Prior to coating the pipe, the surface must be in compli-ance with Section 6 of this standard.

7.2 Machine Application of Powder

7.2.1 The powder application machine shall be placedaround the heated weld joint immediately after theheater is removed.

7.2.2 The coating machine shall travel at a uniformspeed and apply a correct width of coating, centered onthe girth weld.

7.2.3 To prevent differential curing of the resin powder,the total thickness of coating required shall be appliedby the coating machine in the least number of passespossible. At least two passes are required.

7.3 Manual Application of Powder

7.3.1 The powder shall be applied to the heated weldarea from the delivery hose on the flocking unit.

7.3.2 Holding the delivery hose by hand and using thespraying technique, the powder flow can be directedonto the area to be coated. As the spraying operationis continued around the circumference of the weldarea, the thickness of the coating can be controlled bythe speed at which the delivery hose is fanned over thehot surface. The FBE powder shall be applied to thegirth weld area to a minimum thickness of 640 m (25mils), measured dry on the apex of the weld. Maximumthickness shall be as specified by the purchaser, butnot exceeding the manufacturers recommendations.The coating shall overlap the mill-applied coating aminimum of 5 cm (2 in.) on each side of the weld area.Maximum thickness at the overlap should be 1 mm (40mils).

7.4 Application of Powder with Dual FBE Coating Systems

7.4.1 The powder shall be applied to the heated weldarea by either the mechanical method or the manualmethod as detailed in Paragraphs 7.2 and 7.3.

7.5 General Procedures

7.5.1 The coating operation shall immediately followthe heating operation. The coating material shall be anapproved FBE powder, preferably the same categoryas used on the initial coating of the line pipe, but maybe of contrasting color.ided by IHS under license with NACE LicensNot foeproduction or networking permitted without license from IHS_________________________________

Application

purchaser, but not exceeding the manufacturersrecommendations. The coating shall overlap the mill-applied coating a minimum of 5 cm (2 in.) on each sideof the weld area. Maximum thickness at the overlapshould be 1 mm (40 mils).7.5.3 Care shall be taken to prevent the spray head,braces, hoses, etc., from dragging on the groundduring application operations.

7.5.6 Dirt, dust, or deleterious material must not beallowed to contaminate the powder-coated area duringthe application and curing stages.

7.5.7 The powder container, hoses, etc., on theapplication unit shall be cleaned after each workday.

7.5.8 The FBE powder shall be stored at a stockwarehouse location in such a manner that itstemperature is in accordance with the manufacturerswritten recommendations and it is protected from anymoisture contamination.

7.5.9 The FBE powder shall be transported and storedalong the right-of-way in such a manner that itstemperature is never below freezing and is inaccordance with the manufacturers writtenrecommendations. The powder containers shouldnever be in direct sunlight or near hot equipment. Thepowder shall be taken from the warehouse to the right-of-way only in quantities to be used for one day. Thepowder shall always be protected from any moisturecontamination. The inspector shall advise thepurchaser when improper conditions are beingencountered. Open containers of powder shall eitherbe disposed of daily or, if the purchaser allows,resealed and reused within 24 hours.

7.5.10 If the ambient air temperature falls, it may benecessary to increase the heating temperature, subjectto limits of Paragraph 6.14, to provide adequate curingenergy.

7.6 Curing

7.6.1 To prevent coating damage, the pipe shall not behandled until the field joint coating is sufficiently cured.During the pre-job meeting the purchaser andapplicator shall agree on the definition of sufficientlycured.

7.6.2 Adhesion of the cured coating to the surface ofthe pipe shall be checked periodically by pushing aRP0402-2002ee=Instituto Mexicanos Del Petroleo/3139900001 r Resale, 06/12/2009 12:25:50 MDT

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yright NACE International Considerations for Tanks and Vessels to Be Lined forImmersion Service (Houston, TX: NACE).ided by IHS under license with NACE LicenNot feproduction or networking permitted without license from IHSVoltage Electrical Inspection of Pipeline Coatings Prior toInstallation (Houston, TX: NACE).(Pittsburgh, PA: SSPC).4. NACE Standard RP0178 (latest revision), Fabrication

Steel Surfaces Using a Replica Tape (Houston, TX:NACE).All holidays and other coating defects shall bemarked with a marker in a manner that shall notadversely affect the patching operation.

8.1.2 The purchaser reserves the right to supply anonpulsating holiday detector set at 2,000 volts DC,and to recheck the coating. If holidays are found, theyshall be repaired by the applicator.

8.1.3. If there is any evidence or indication that the millcoating is being damaged during heating or coating ofthe weld joint, it must be brought to the attention of thepurchasers inspector immediately.

8.1.4 The thickness of the finished cured coating sys-tem shall be checked and verified using a dry-film thick-ness gauge that has been properly calibrated usingcertified coating thickness calibration standard chips.

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Refer

1. NACE Standard RP0394 (latest revision), Application,Performance, and Quality Control of Plant-Applied, Fusion-Bonded Epoxy External Pipe Coating (Houston, TX:NACE).2. NACE Standard RP0169 (latest revision), Control ofExternal Corrosion on Underground or Submerged MetallicPiping Systems (Houston, TX: NACE).3. SSPC-SP 1 (latest revision), Solvent Cleaning8.2 Coating System Repairs

8.2.1. All coating defects should be repaired using mat-erials that are compatible with and shall adhere well tothe FBE powder coating and are approved by the pur-chaser. All holidays shall be repaired utilizing a pur-chaser-approved technique. Patched areas shouldoverlap the parent coating a minimum of 13 mm (0.50in.). The surface to be repaired should be suitably pre-pared to ensure adhesion of the patch material. Mini-mum thickness of the repaired coating shall be inaccordance with Section 7 of this standard.

8.2.2 Holidays along the pipe joint shall be inspectedand repaired to the satisfaction of purchasers author-ized representative.

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5. NACE No. 2/SSPC-SP 10 (latest revision), Near-WhiteBlast Cleaning (Houston, TX: NACE and Pittsburgh. PA:SSPC).6. SSPC-VIS 1 (latest revision), Visual Standard forAbrasive Blast Cleaned Steel (Pittsburgh, PA: SSPC).7. NACE Standard RP0287 (latest revision), FieldMeasurement of Surface Profile of Abrasive Blast Cleanedexcessive holidays. There shall be no gaps in theelectrode or separations between the electrodeand the surface of the coating. The detector oper-ation shall readily and audibly indicate all holidays.

8.1.6 Cured coating shall be of uniform color, gloss,and thickness, and shall be free of blisters, pinholes,fisheyes, sags, or other irregularities.coating shall fully adhere and shall not easily strip,chip, or peel from the steel.

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Section 8: Insp

8.1 Coating System Inspection and Tests

8.1.1 The entire coated surface of each length of pipeshall be inspected with a holiday detector in accord-ance with NACE Standard RP0274.8

8.1.1.1 Inspection is best performed when thetemperature of the coating is less than 90C(194F). Higher temperatures may be acceptableas long as the holiday detector does not create7.6.3 All areas tested for adhesion shall be repaired inaccordance with Section 8 of this standard.

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ction and Repair

The FBE coating shall have a minimum dry thicknessof 640 m (25 mils) and a maximum thickness asspecified by the purchaser, measured on the apex ofthe girth weld, when used with dual FBE powders.

8.1.5 At various times during the coating operation thepurchaser may request complete cure tests of the coat-ing. Third-party laboratory tests shall be conductedwith the complete cooperation of the applicator. Thepurchaser shall specify the testing vendor. -

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NACE Standard RP0402-2002ForewordContentsSection 1:Section 2:Section 3:Section 4:Section 5:Section 6:Section 7:Section 8:References