F: AMTP/CP/QС-01

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Revision: 03
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ACCEPTANCE CRITERIA DOCUMENTS INSTRUMENTS
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PROD QC
SPECIFICATION / QA

CLIENT TENGIZCHEVROIL
TENGIZCHEVROIL SPECIFICATION
STANDARD / SPECIFICATION
COM-SU-4042-TCO Rev0
PIPE SIZE
Ø4” – 26”; Grade: API 5L X60 QS PSL2 PEB

TECHNICAL REQUIREMENTS FOR COATED PIPE DUAL LAYER FUSION BONDED EPOXY COATING

GENERAL TECHNICAL REQUIREMENT OF PRODUCTION

PROCESS MENTION IN
MPS: MPS/CP/DLFBE-02

QAP No 17
DATE: 25.07.2017

PREPARED BY AGREED BY APPROVED BY APPROVED BY

AITASOV NURLAN PATEL PRADHYUMAN KHAIROVA DINARA

ENGINEER QC CP PRODUCTION MANAGER QUALITY MANAGER CLIENT
 F: AMTP/CP/QС-01
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ACCEPTANCE CRITERIA DOCUMENTS INSTRUMENTS
No TECHNICAL FREQUENCY TPI
PROD QC
SPECIFICATION / QA

1.0 SCOPE: REVIEW OF RAW MATERIAL TEST CERTIFICATE

1. Shots & grits: S390/S330, G40 and/or
G25
2. AXALTA Base layer: Nap-Gard 7- Visual inspection
Review of raw material COM-SU-4042-TCO 2500; Top layer: Nap-Gard Gold 7-2504
1.1 Each batch Raw material TC of marking on raw - R R
test certificates Rev0, cl. 9.0
3. AXALTA: Two part repair cartridge material
system Nap-Gard 7-1854
4. Acid wash: Oakite 33
2.0 SCOPE: RAW MATERIAL TESTING OF EPOXY POWDER
COM-SU-4042-TCO
F: AMTP/СP/LAB-
2.1 Gel time Rev0, cl. 12.6; CSA Each batch 1. 22 ±4seconds at 205⁰C (401⁰F) Gel time tester - P W
02
Z245.20-10 cl.12.2
COM-SU-4042-TCO As per manufacturer’s test certificate F: AMTP/СP/LAB- Mettler Toledo
2.2 DSC Analysis Each batch - P W
Rev0, cl. 12.6 03 DSC Machine
COM-SU-4042-TCO Below 0.6% (mass loss method) F: AMTP/СP/LAB- Moister content
2.3 Moisture content Each batch - P W
Rev0, cl. 12.6 01 test machine
3.0% maximum powder retained on 150
COM-SU-4042-TCO µm mesh and F: AMTP/СP/LAB- Sieve analyzer
2.4 Sieve Analysis Each batch - P W
Rev0, cl. 12.6 0.2% maximum powder retained on 250 04
µm mesh
COM-SU-4042-TCO Meets manufacturer’s specification F: AMTP/СP/LAB-
2.5 Density Each batch 100 ml beaker - P W
Rev0, cl. 12.6 within 50 g/L 05
3.0 SCOPE: INSPECTION SUMMARRY FOR PQT OF 8 PIPES
1. Pressure 3000 psi
2. Water shall be less than 200 ppm
High pressure RO water COM-SU-4042-TCO F: AMTP/СP/QC- High pressure
3.1 Each of 8 pipes TDS and 50ppm Chloride P W W
jetting Rev0, cl. 10.2.1; cl. 10.4 12 water wash unit
3. Water temperature 70⁰C
4. No visual defects
COM-SU-4042-TCO
Bare pipe incoming 1. No visual defects F: AMTP/СP/QC-
3.2 Rev0, cl. 8.1; 8.3; 10.2.1; Each of 8 pipes Visual - P R/M
inspection 2. Only rust grade A & B accepted 12
ISO 8501 part 1 A&B
3.2.1 Soluble salts test COM-SU-4042-TCO Each of 8 pipes Maximum acceptable level: 2 µg/cm² F: AMTP/СP/QC- SCM-400 - P R/W
 F: AMTP/CP/QС-01
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Revision: 03
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REF.
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Sr. DESCRIPTION STANDARD / TESTING
ACCEPTANCE CRITERIA DOCUMENTS INSTRUMENTS
No TECHNICAL FREQUENCY TPI
PROD QC
SPECIFICATION / QA

Rev0, cl. 10.2.1 at 3 location 12

COM-SU-4042-TCO F: AMTP/СP/QC-
3.2.2 Oil contamination Each of 8 pipes No indication of oil contamination Visual - P R/M
Rev0, cl. 10.3 12
Pre-heating of bare COM-SU-4042-TCO 50-70⁰C and pipe temperature shall be F: AMTP/СP/QC- Roller type
3.3 Each of 8 pipes P M R/M
pipes Rev0, cl. 10.3 3°C above the dew point 12 thermometer
1. A uniform pH of 1 or less
2. Treatment dwell time min 20 sec. at
temp min 49C
pH meter
COM-SU-4042-TCO 3. High pressure RO water rinse min F: AMTP/СP/QC-
3.3.1 Acid wash Each of 8 pipes Roller type P M R/M
Rev0, cl. 10.4 500psi 12
thermometer
4. pH level 6 or greater
5. Water shall be less than 200 ppm
TDS and 50ppm Chloride
COM-SU-4042-TCO F: AMTP/СP/QC- Conductivity
3.4 Blast material test Once per shift Maximum 100 micro-siemens - P W
Rev0, cl. 10.2.2 12 meter
Pipe surface visual
COM-SU-4042-TCO No visual defects; if grinding is F: AMTP/СP/QC-
3.5 inspection after blasting Each of 8 pipes Visual - P W
Rev0, cl. 10.3 required, reestablish profile 12
#2
RH Elapse time
85% 0.5hours Digital
Relative humidity & 80% 1.0hours F: AMTP/СP/QC- hygrometer;
3.6 COM-SU-4042-TCO Once per shift - P R/W
Elapsed time 70% 1.5hours 12 Dew point
Rev0, cl. 10.3
60% 1.75hours apparatus
50% 2.0hours
COM-SU-4042-TCO F: AMTP/СP/QC-
3.7 Surface Cleanliness Each of 8 pipes Sa2½ as per ISO 8501-1 ISO Comparator - P M
Rev0, cl. 10.3 12

COM-SU-4042-TCO Each of 8 pipes F: AMTP/СP/QC- Replica tape /

3.8 Surface Roughness 75- l20 μm (Rz) - P W
Rev0, cl. 10.3 at 3 locations 12 Rugosity meter
Dust and Oil COM-SU-4042-TCO No indications of dust or oil F: AMTP/СP/QC- Pressure sensitive
3.9 Each of 8 pipes - P W
contamination Rev0, cl. 10.3 contamination 12 tape
COM-SU-4042-TCO Clean, dry, free of oil and condensed F: AMTP/СP/QC-
3.9.1 Air quality check Once per shift Blotter test - P W
Rev0, cl. 10.3.4 water (60 sec.) 12
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ACCEPTANCE CRITERIA DOCUMENTS INSTRUMENTS
No TECHNICAL FREQUENCY TPI
PROD QC
SPECIFICATION / QA

Optical pyrometer
Bare pipe temperature COM-SU-4042-TCO Minimum 218ºC F: AMTP/СP/QC- Roller type
3.10 Each of 8 pipes - P R/M
before epoxy application Rev0, cl. 11.1 Maximum 260⁰C 09 contact
thermometer
Base layer FBE COM-SU-4042-TCO 12 locations 200µm –300µm F: AMTP/СP/QC- Digital thickness
3.11 - P R/M
thickness Rev0, cl. 13.0 (12x1 pipe) 12 gauge
COM-SU-4042-TCO 12 locations 400µm –500µm F: AMTP/СP/QC- Digital thickness
3.12 Top layer FBE thickness - P W
Rev0, cl. 13.0 (12x1 pipe) 12 gauge
Total coating thickness COM-SU-4042-TCO 96 locations 600µm –800µm F: AMTP/СP/QC- Digital thickness
3.13 - P W
Rev0, cl. 13.0 (12x8 pipes) 12 gauge
Temperature of pipes COM-SU-4042-TCO Digital
3.14 after quenching 1 of 8 pipes Below 80°C - P W W
Rev0, cl. 11.3 thermometer

Visual inspection of COM-SU-4042-TCO

3.15 Each of 8 pipes Smooth with no surface defects - Visual P W M/R
coated pipes Rev0, cl. 12.5
1. Max 4 holidays for pipe Ø 273 and
below
Each of 8 pipes
COM-SU-4042-TCO 2. Max 6 holidays for pipe Ø 323 to F: AMTP/СP/QC-
3.16 Holiday test (100% coated Holiday detector - P M
Rev0, cl. 13.1 Ø559 12
surface)
3. Max 8 holiday for pipe Ø 610 and
above
Detection capability of holiday tester
3.16. COM-SU-4042-TCO F: AMTP/СP/QC- Holiday detector
Holiday test calibration Prior to PQT shall be demonstrated on 0.8mm drilled - P R/W
1 Rev0, cl. 13.1 12 and Voltmeter
hole and voltage checked with a DVM
COM-SU-4042-TCO F: AMTP/СP/QC-
3.17 Cut back length Each of 8 pipes 60mm,+20 / -0mm Steel rule P W R/M
Rev0, cl. 11.3 12
COM-SU-4042-TCO
Refusal to peel or a cohesive failure F: AMTP/СP/LAB- Cross-cut with the
3.18 Adhesion test Rev0, cl. 13.2; 2 out of 8 pipes - P W
(substrate and layer to layer) 16 knife
ASTM D 1002
COM-SU-4042-TCO
3.18. F: AMTP/СP/LAB- Cross-cut with the
Foaming test Rev0, cl. 13.2; 2 out of 8 pipes The acceptance rating shall be ≤ level 3 - P W
1 16 knife
ASTM D 1002
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Revision: 03
TUBULAR PRODUCTS Page 5 of 10
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ACCEPTANCE CRITERIA DOCUMENTS INSTRUMENTS
No TECHNICAL FREQUENCY TPI
PROD QC
SPECIFICATION / QA

COM-SU-4042-TCO
Penetration 4 samples from F: AMTP/СP/LAB- Coesfeild
3.19 Rev0, cl. 13.3; ASTM G 25µm max at 25⁰C - W W
(indentation) testing 2 out of 8 pipes 13 Penetrometer
17
COM-SU-4042-TCO 1. No Holidays F: AMTP/СP/LAB-
3.20 Impact resistance test 2 out of 8 pipes Impact tester - P W
Rev0, cl. 13.4 2. 1.5 J at +25°C; Pass 9 of 10 points 21
COM-SU-4042-TCO F: AMTP/СP/LAB-
3.21 Hardness Test 2 out of 8 pipes 85-90 Shore – D as per ISO 3856/4 Shore - D - P W
Rev0, cl. 13.5 11
1. 48 hours at 95 ±5°C
COM-SU-4042-TCO
2. Maximum acceptable level 8 mm F: AMTP/СP/LAB-
3.22 Cathodic Disbondment Rev0, cl. 13.6; 2 out of 8 pipes CD tester - P W
3. 3% NaCl 14
ASTM G 42
4. Reference hole diameter: 6 mm
COM-SU-4042-TCO 1. 48 hours at 95 ±5°C F: AMTP/СP/LAB-
3.23 Hot water resistance test 2 out of 8 pipes Hot water bath - P W
Rev0, cl. 13.7 2. No disbonding or blisters. 22
Degree of cure COM-SU-4042-TCO 1. -2⁰C < ΔTg < + 3ºC F: AMTP/СP/LAB- Mettler Toledo
3.24 2 out of 8 pipes - P W
(DSC) & % of Cure Rev0, cl. 13.8 2. % of cure: > 95% 20 DSC Machine
COM-SU-4042-TCO 2% and 3% strain at temperature -30°C,
F: AMTP/СP/LAB-
3.25 Flexibility (Bend) test Rev0, cl. 13.9 and 2 out of 8 pipes 0°C and +20°C; No cracking / UTM machine - P W
17
Appendix C disbondment & pinholes
4.0 SCOPE: INSPECTION SUMMARY FOR PRODUCTIONS TESTING
1. Pressure 3000 psi
2. Water shall be less than 200 ppm
High pressure RO water COM-SU-4042-TCO F: AMTP/СP/QC- High pressure
4.1 Each pipe TDS and 50ppm Chloride P W W
jetting Rev0, cl. 10.2.1; 12 water wash unit
3. Water temperature 70⁰C
4. No visual defects
COM-SU-4042-TCO
Bare pipe incoming 1. No visual defects F: AMTP/СP/QC-
4.2 Rev0, cl. 8.1; 8.3; 10.2.1; Each pipe Visual - P R/M
inspection 2. Only rust grade A & B accepted 12
ISO 8501 part 1 A&B
COM-SU-4042-TCO 1 per 100 pipe at F: AMTP/СP/QC-
4.2.1 Soluble salts test Maximum acceptable level: 2 µg/cm² SCM-400 - P R/W
Rev0, cl. 10.2.1 3 locations 12
COM-SU-4042-TCO F: AMTP/СP/QC-
4.2.2 Oil contamination Each pipe No indication of oil contamination Visual - P R/M
Rev0, cl. 10.3 12
 F: AMTP/CP/QС-01
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Revision: 03
TUBULAR PRODUCTS Page 6 of 10
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Sr. DESCRIPTION STANDARD / TESTING
ACCEPTANCE CRITERIA DOCUMENTS INSTRUMENTS
No TECHNICAL FREQUENCY TPI
PROD QC
SPECIFICATION / QA

Pre-heating of bare COM-SU-4042-TCO 50-70⁰C and pipe temperature shall be F: AMTP/СP/QC- Roller tape
4.3 Each pipe P M R/M
pipes Rev0, cl. 10.3 3°C above the dew point 12 thermometer
1. A uniform pH of 1 or less
2. Treatment dwell time min 20 sec. at
temp min 49C
pH meter
COM-SU-4042-TCO 3. High pressure RO water rinse min F: AMTP/СP/QC-
4.3.1 Acid wash Once per shift Roller type P M R/M
Rev0, cl. 10.4 500psi 12
thermometer
4. pH level 6 or greater
5. Water shall be less than 200 ppm
TDS and 50ppm Chloride
COM-SU-4042-TCO F: AMTP/СP/QC- Conductivity
4.4 Blast material test Once per shift Maximum 100 micro-siemens - P W
Rev0, cl. 10.2.2 12 meter
Pipe surface visual
COM-SU-4042-TCO No visual defects; if grinding is F: AMTP/СP/QC-
4.5 inspection after blasting Each pipe Visual - P R/M
Rev0, cl. 10.3 required, reestablish profile 12
#2
RH Elapse time
85% 0.5hours Digital
Relative humidity & 80% 1.0hours F: AMTP/СP/QC- hygrometer;
4.6 COM-SU-4042-TCO Once per shift - P R/W
Elapsed time 70% 1.5hours 12 Dew point
Rev0, cl. 10.3
60% 1.75hours apparatus
50% 2.0hours

COM-SU-4042-TCO F: AMTP/СP/QC-
4.7 Surface Cleanliness Each pipe Sa2½ as per ISO 8501-1 ISO Comparator - P R/M
Rev0, cl. 10.3 12

3 locations on
the first 10
joints, then 1
COM-SU-4042-TCO pipe at 3 F: AMTP/СP/QC- Replica tape /
4.8 Surface Roughness 75- l20μm (Rz) - P R/M
Rev0, cl. 10.3 locations every 12 Rugosity meter
2 hours, then
last joint of the
shift
Dust and Oil COM-SU-4042-TCO No indications of dust or oil F: AMTP/СP/QC- Pressure sensitive
4.9 Each pipe - P R/M
contamination Rev0, cl. 10.3 contamination 12 tape
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ACCEPTANCE CRITERIA DOCUMENTS INSTRUMENTS
No TECHNICAL FREQUENCY TPI
PROD QC
SPECIFICATION / QA

COM-SU-4042-TCO Clean, dry, free of oil and condensed F: AMTP/СP/QC-

4.9.1 Air quality check Once per shift Blotter test - P W
Rev0, cl. 10.3.4 water (60 sec.) 12
Optical pyrometer
Bare pipe temperature COM-SU-4042-TCO Minimum 218ºC F: AMTP/СP/QC- Roller type
4.10 Every four hours - P R/M
before epoxy application Rev0, cl. 11.1 Maximum 260⁰C 09 contact
thermometer
Base layer FBE COM-SU-4042-TCO First pipe per 200µm –300µm F: AMTP/СP/QC- Digital thickness
4.11 - P R/M
Thickness Rev0, cl. 13.0 shift 12 gauge
COM-SU-4042-TCO First pipe per 400µm –500µm F: AMTP/СP/QC- Digital thickness
4.12 Top layer FBE thickness - P W
Rev0, cl. 13.0 shift 12 gauge
Total coating thickness COM-SU-4042-TCO 600µm –800µm F: AMTP/СP/QC- Digital thickness
4.13 Each pipe - P W
Rev0, cl. 13.0 12 gauge
Temperature of pipes COM-SU-4042-TCO Digital
4.14 after quenching Once per shift Below 80°C - P W R/M
Rev0, cl. 11.3 thermometer

Visual inspection of COM-SU-4042-TCO

4.15 Each pipe Smooth with no surface defects - Visual P W R/W
coated pipes Rev0, cl. 12.5

1. 4 holidays from pipe size Ø 273 and

below
Each pipe of
COM-SU-4042-TCO 2. 6 holidays from pipe size Ø 323 to F: AMTP/СP/QC-
4.16 Holiday test 100% coated Holiday detector - P R/M
Rev0, cl. 13.1 Ø559 12
surface
3. 8 holiday from pipe size Ø 610 and
above
Detection capability of holiday tester
4.16. COM-SU-4042-TCO F: AMTP/СP/QC- Holiday detector
Holiday test calibration Each shift shall be demonstrated on 0.8mm drilled - P R/W
1 Rev0, cl. 13.1 12 and Voltmeter
hole and voltage checked with a DVM
COM-SU-4042-TCO F: AMTP/СP/QC-
4.17 Cut back length Each pipe 60mm,+20 / -0mm; for PWHT 800mm Steel rule P W R/M
Rev0, cl. 11.3 12
COM-SU-4042-TCO
Refusal to peel or a cohesive failure F: AMTP/СP/LAB- Cross-cut with the
4.18 Adhesion test Rev0, cl. 13.2; 1 per 50 pipes - P W
(substrate and layer to layer) 16 knife
ASTM D 1002
4.18. Foaming test COM-SU-4042-TCO 1 per 50 pipes The acceptance rating shall be ≤ level 3 F: AMTP/СP/LAB- Cross-cut with the - P W
 F: AMTP/CP/QС-01
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Revision: 03
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REF.
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Sr. DESCRIPTION STANDARD / TESTING
ACCEPTANCE CRITERIA DOCUMENTS INSTRUMENTS
No TECHNICAL FREQUENCY TPI
PROD QC
SPECIFICATION / QA

Rev0, cl. 13.2;

1 16 knife
ASTM D 1002
COM-SU-4042-TCO 1. No Holidays F: AMTP/СP/LAB-
4.19 Impact resistance test Twice per shift Impact tester - P W
Rev0, cl. 13.4 2. 1.5 J at +25°C; Pass 9 of 10 points 21
COM-SU-4042-TCO F: AMTP/СP/LAB-
4.20 Hardness Test Twice per shift 85-90 Shore – D as per ISO 3856/4 Shore - D - P W
Rev0, cl. 13.5 11
1. 48 hours at 95 ±5°C
COM-SU-4042-TCO
2. Maximum acceptable level 8 mm F: AMTP/СP/LAB-
4.21 Cathodic Disbondment Rev0, cl. 13.6; 1 per 100 pipes CD tester - P W
3. 3% NaCl 14
ASTM G 42
4. Reference hole diameter: 6 mm

Degree of cure COM-SU-4042-TCO 1. -2⁰C < ΔTg < + 3ºC F: AMTP/СP/LAB- Mettler Toledo
4.22 Twice per shift - P W
(DSC) & % of Cure Rev0, cl. 13.8 2. % of cure: > 95% 20 DSC Machine

COM-SU-4042-TCO 2% and 3% strain at temperature -30°C,

F: AMTP/СP/LAB-
4.23 Flexibility (Bend) test
Rev0, cl. 13.9 and 1 per 100 pipes 0°C and +20°C; No cracking / UTM machine - P W
17
Appendix C disbondment & pinholes
5.0 SCOPE: FINAL INSPECTION
1) Manufacturer’s name
2) API Spec 5L
3) Pipe diameter
4) Pipe wall thickness
5) X60QS PSL2 SMLS
6) Heat number
COM-SU-4042-TCO 7) Manufacturer’s pipe number F: AMTP/СP/QC- Hand jet EBS 250
5.1 Marking on coated pipes Each pipe - P R/M
Rev0, cl. 11.3.4 8) Mill order number 19 machine
9) Pipe length
10) P.O. number
11) Item code (900XXX)
12) ArcelorMittal Aktau
13) Coating plant’s unique coating #
14) Type of coating
CAN / CSA Z245.20 F: AMTP/СP/QC-
5.2 Residual magnetism 3 times per shift 20 gauss or less Gauss gauge - P R/M
Series 10, cl. 7.4.1.6 12
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Revision: 03
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REF.
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Sr. DESCRIPTION STANDARD / TESTING
ACCEPTANCE CRITERIA DOCUMENTS INSTRUMENTS
No TECHNICAL FREQUENCY TPI
PROD QC
SPECIFICATION / QA

Installation of separation COM-SU-4042-TCO Min 4 full encirclement separation ropes

5.3 Each pipe N/A N/A P W M
pads Rev0, cl.8.2 on 12 meter joints
6.0 SCOPE: COATING REPAIR
Maximum quantity of allowable repairs:
Max 4 for Ø273 and below
Max 6 for Ø323 to 559
Max 8 for Ø610 and above
Where required the profile shall be
Repair after reestablished. No single defect shall
COM-SU-4042-TCO exceed an area of 625 mm2. Pipes with F: AMTP/СP/QC-
6.1 Repair of coating holiday - P W R/M
Rev0, cl. 13.1 a defect exceeding 625 mm2 shall be 14
detection
cause for rejection. If the cumulative
damaged area on a pipe is equal to or
greater than 250 cm2 (38.8 in2), the
existing FBE coating shall be removed
and the pipe re-blast cleaned and
recoated.
7.0 SCOPE: LOADING
Stowing in ‘pyramid’ way as per
loading scheme per size (ODxWT);
P: AMTP/DISP-01 wood bearing strips in the trailer; nylon
Single joint pipes Procedure for Storage, ropes for pipe separation; separation
7.1 Each shipment F: AMTP/DISP-03 - P W W
shipment by road trucks Handling and between successive layers; pipes with
Transportation OD 12” and above shall have hookable
end protectors, pipes with OD 10” and
below shall have plastic end plugs

8.0 SCOPE: BOUND DOCUMENTATION DATABOOK

8.1 Manufacturing databook Per shipment As per approved MRB index - P H
8.2 Inspection release Per shipment - - P
H Hold point NO further steps may be undertaken before the intervention of designated responsible take place;
W Witness point The designated responsible has to be notified of the operation in advance, but production will continue whether the intervention took place or not;
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ACCEPTANCE CRITERIA DOCUMENTS INSTRUMENTS
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PROD QC
SPECIFICATION / QA

M Monitoring Monitoring to be done continuously;

R Review Point for which a control report or a recording has to be made;
R/W Random Witness Random witness & frequency at the sole discretion of the owner's representative;
P Performing Performing the activity.