1、Oktober 2011DEUTSCHE NORM Normenausschuss Gastechnik (NAGas) im DINNormenausschuss Erdl- und Erdgasgewinnung (NG) im DINPreisgruppe 23DIN Deutsches Institut fr Normung e. V. Jede Art der Vervielfltigung, auch auszugsweise, nur mit Genehmigung des DIN Deutsches Institut fr Normung e. V., Berlin, gest
2、attet.ICS 23.040.10; 23.040.99; 75.200!$t0,955 N.A. Oxidation induction time (intercept in the tangent method) min ISO 11357 (all parts) 30 at 210 C 30 at 210 C or 10 at 220 C 30 at 220 C UV resistance and thermal ageingc% Annex G MFR 35 MFR 35 MFR 35 aPreparation of the test specimen in accordance
3、with ISO 1872-2 for PE and ISO 1873-2 for PP (2 mm thickness), strained at 50 mm/min. bIn order to validate the ESCR values, data shall be provided by manufacturers to define the limit in density (MFR) to pass that requirement. This limit shall not be wider than what is commonly known as fit-for-pur
4、pose PE grades for pipe coating. cChoice of test condition should be with approval of end user. If the compounding is done during the application process, the applicator shall perform the qualification tests for the product in accordance with Table 5. The batch certificate, produced in accordance wi
5、th Table 6, shall be issued. NOTE The applicator sometimes performs compounding with additives against UV and thermal ageing or other purposes. 8.3 Batch certificate 8.3.1 The applicator shall provide batch certificates supplied by the manufacturer of each material and shall contain the information
6、given in Table 6. The batch certificate shall state test methods and acceptance criteria. The applicator shall identify the materials and shall confirm that the certificates comply and relate to the specified materials. DIN EN ISO 21809-1:2011-10 EN ISO 21809-1:2011 (E) 19 Table 6 Batch certificate
7、Coating material Content Liquid epoxy FBE Adhesive PE/PP top coat Identification of the manufacturer x x x x Product identification x x x xBatch identification x x x x Date and place of manufacturing x x x x Density x x x x Viscosity of base and hardener x Solid content of base and hardener x Melt f
8、low rate x x Gel time x x Particle size x Moisture/water content x x xCarbon black content Only PEaPigment dispersion xaThermal characteristic x x Reactive site content xbaIf applicable. bDirect and indirect methods can be proposed by the manufacturer. 8.3.2 The manufacturers specification for epoxy
9、 materials shall include the following: trade name; generic type; mix ratio (if any); maximum thickness, expressed in millimetres or micrometres (see Annex A); maximum and minimum storage temperatures, expressed in degrees Celsius; shelf-life at storage temperature, expressed in months; technical pr
10、operties, in accordance with Table 3. 8.3.3 The manufacturers specification for adhesive and PE/PP materials shall include the following: trade name; description of the adhesive; colour; maximum and minimum storage temperatures, expressed in degrees Celsius; shelf-life at storage temperature, expres
11、sed in months; technical properties, in accordance with Tables 4 and 5. DIN EN ISO 21809-1:2011-10 EN ISO 21809-1:2011 (E) 20 8.4 Storage and handling of coating materials Storage and handling of coating materials shall be in accordance with the manufacturers specification. 9 Coating system qualific
12、ation 9.1 General Each coating system shall be qualified by the applicator. Qualification shall be carried out separately for each coating line. The applicator shall carry out and report the coatings qualification in accordance with the requirements of this part of ISO 21809. The test report shall c
13、ontain the results of the qualification tests and data required in Tables 6, 7 and 8. The applicator shall apply coating materials qualified in accordance with the requirements of 8.2. Qualification shall be repeated in case of modifications to the coating line, coating materials or application proc
14、edures. 9.2 Application procedure specification Prior to the start of coating production and any specified PQT, the applicator shall prepare an APS, including: incoming inspection of pipes and pipe tracking; data sheets for coating materials, including any materials used for coating repairs; data sh
15、eets for abrasive blasting materials; certification, receipt, handling and storage of materials for coating and abrasive blasting; cleaning procedure for all application equipment; preparation of the steel surface including monitoring of environmental parameters, methods and tools for inspection, gr
16、inding of pipe surface defects and testing of surface preparation; coating application, including tools/equipment for control of process parameters essential for the quality of the coating; lay-out sketch or flow diagram for the coating plant; methods and tools/equipment for inspection and testing o
17、f the applied coating; repairs of coating defects and any associated inspection and testing; stripping of defective coating; preparation of coating cutback areas; marking and traceability; handling and storage of pipes; any special conditions for dispatch of coated pipes, including protection of pip
18、e ends; documentation. DIN EN ISO 21809-1:2011-10 EN ISO 21809-1:2011 (E) 21 The APS shall cover all items associated with quality control as defined in this part of ISO 21809 and any agreed amendments. It shall be available to the purchaser on request at any time during production. If specified, th
19、e APS, including any revisions, shall be approved by the purchaser prior to the start of production and any specified PQT. Table 7 Properties of the applied coating Properties Unit Test method Class A Class B Class C Continuity Annex B Free of defects and discontinuities, delaminations,separations a
20、nd holidays Impact strength at 23 C 3 CaJ/mm Annex E 5 7 10 at 23 C 3 C 0,3 0,2 0,1 Indentation at maximum design temperature mm Annex F 0,4 0,4 0,4 Elongation at break of PE/PP at 23 C 3 Cb% ISO 527-3 400 400 400 Peel strengthb,c,d,hN/mm Annex C C.5 (hanging mass) 10 at 23 C 2 at 60 C 15 at 23 C 3
21、at 80 C 25 at 23 C 4 at 90 C or at maximum operating temperature if above 90 C Degree of cure of the epoxy (1st layer)eTgC Annex DAccording to the manufacturers specification and 5 C Product stability during application of the PE/PP top layer process % ISO 1133 20 MFR for Classes A and B; 35 for Cla
22、ss C (virgin compounded granulate before application/coating after application of the same batch) at 23 C/28 d; 1,5 V 7 at 65 C/24 h; 3,5 V 7 Average radius of cathodic disbondmentfMaximum operationgtemperature/28; 1,5 V mm Annex H15 Flexibility Annex I No cracking at an angle of 2,0 per pipe diamet
23、er length Hot water immersion test mm Annex M Average 2 and maximum 3 aLower test temperature may be agreed upon using the same acceptance criteria. bNo single recorded peeling value shall be lower than 30 % of the requirements. cCohesive failure mode in the adhesive if a non-grafted adhesive is use
24、d, no disbonding between steel and epoxy. dIn case of break at 23 C, the maximum peel force shall be recorded. The minimum requirements at 23 C shall be fulfilled and the test shall then be carried out only at 90 C (or at maximum operating temperature if higher than 90 C). eFor FBE with a glass tran
25、sition temperature above 120 C, testing shall be according to the manufacturers recommendation. fIn production, test only at 65 C/24h/3,5 V condition is required. gMaximum test temperature shall not be greater than 90 C. hHanging weight method may be used if agreed with end user. DIN EN ISO 21809-1:
26、2011-10 EN ISO 21809-1:2011 (E) 22 9.3 Procedure qualification trial If specified, the APS shall be verified by a PQT in accordance with Annex L. 9.4 Inspection and testing plan If specified, the applicator shall prepare an ITP and a daily log to record quality control data in accordance with Annex
27、L. 10 Application of the coating system 10.1 Surface preparation 10.1.1 Initial preparation All dirt, deleterious matter and contaminants, such as oil and grease, shall be removed from the pipe prior to coating. If necessary, the pipe shall be cleaned in accordance with the requirements of SSPC-SP1.
28、 All steel defects and irregularities (e.g. laminations, slivers, scratches) shall be removed in accordance with the APS. Grinding of steel defects shall not reduce the wall thickness below the specified minimum wall thickness of the pipe. All pipe shall be dry prior to entering the abrasive blast c
29、leaning unit(s). Pipe temperature shall be at least 3 C above the dew point immediately prior to abrasive blast cleaning. 10.1.2 Abrasive blast cleaning The abrasives used in the coating plant shall be in accordance with the requirements of ISO 11124 (all parts). NOTE If the pipe being coated is of
30、a high-strength grade, e.g. X80, X100 or X120, harder abrasives can be required to provide the required cleanliness and surface profile. The abrasives (including recycled materials) shall be maintained clean, dry and free from contaminants in accordance with SSPC-AB 1, SSPC-AB 2 and SSPC-AB 3 or AST
31、M D4940 so as not to contaminate the substrate. The cleanliness achieved at entry to the application line shall be in accordance with the requirements of ISO 8501-1:2007, grade Sa 21/2 (“near-white metal”). The height of the surface profile attained shall be within 50 m and 100 m, as measured in acc
32、ordance with the requirements of ISO 8503-4 (Stylus method) or ISO 8503-5 (Replica tape method). The Stylus method shall be used for verification. The Replica tape method may be used when a correlation is established with the Stylus (Profilometer) method with a cut-off length of 2,5 mm. If grinding
33、is required after blast cleaning, the maximum allowable area of grinding shall be 10 cm2per metre of pipe length or 0,5 % of the pipe surface area, whichever is lower. If the grinding area required exceeds these limits, the pipe shall be reblasted. 10.1.3 Surface dust contamination The dust level sh
34、all be measured in accordance with the requirements of ISO 8502-3. The maximum allowable level shall be Class 2 (for both size and quantity). DIN EN ISO 21809-1:2011-10 EN ISO 21809-1:2011 (E) 23 10.1.4 Surface cleanliness and pre-treatment If the applicator chooses a surface pre-treatment (e. g. de
35、ionized water, phosphoric acid and/or chromate pre-treatment), the pre-treatment process shall be agreed with the purchaser. If surface pre-treatment is used for a PQT, it shall be used for production. If surface pre-treatment is not used, testing for the presence of soluble salts on the pipe shall
36、be undertaken in accordance with the requirements of ISO 8502-6 and ISO 8502-9. The maximum allowable level shall be 20 mg/m2after blasting. If levels above 20 mg/m2of soluble salts are measured, a surface pre-treatment cleaning process shall be agreed upon by the applicator and the purchaser. 10.2
37、Coating application 10.2.1 General The coating shall be applied in accordance with the APS. During the application of the coating components, the preheating temperature of the pipe shall be monitored and recorded using optical pyrometers or contact thermometers. Temperature-measuring crayons may be
38、used to measure temperature only if agreed upon prior to coating, and shall be validated for temperature control during qualification and production of the coating system. Throughout production, the coating temperature shall be continuously monitored and recorded once every half hour unless otherwis
39、e agreed with the end user/purchaser. 10.2.2 Epoxy application Following surface preparation, the surface being coated shall not be exposed for a length of time that can result in flash rust and under no circumstance shall the time be more than 4 h. The pipe temperature prior to and during epoxy app
40、lication shall be in accordance with the APS. The thickness of the epoxy layer after curing shall be in accordance with Table 9. The degree of cure shall be in accordance with Table 7. 10.2.3 Adhesive application The elapsed time between epoxy application and adhesive application shall be in accorda
41、nce with the APS. 10.2.4 PE/PP application The application of the PE/PP layer shall be in accordance with the APS. The applied coating shall be cooled to a temperature that prevents handling damage during finishing and final inspection. The total coating thickness shall be in accordance with Table 2
42、. 10.3 Cutback The coating at the pipe ends shall be removed to expose a length of bare metal as specified in the purchase order. The polyolefin shall be bevelled to an angle not exceeding 30 measured in the direction of the pipe axis. The cutback length shall be measured from the root face of the p
43、ipe to the beginning of the coating bevel. DIN EN ISO 21809-1:2011-10 EN ISO 21809-1:2011 (E) 24 11 Inspection and testing 11.1 General Inspection and testing shall be carried out in accordance with the APS, and ITP if applicable, and meet the requirements of Tables 8 and 9. Table 8 Requirements for
44、 inspection of surface preparation Properties Unit Test method Requirements Frequency qualification Frequency production Surface condition before blasting Visual inspection Free of contaminations Each pipe Each pipe Environmental conditions Calculation and direct measurement As determined at time of
45、 measurement Once Every 4 h Pipe temperature before blasting C Thermocouple Minimum 3 above the dew point Once Every 4 h Size, shape and properties of virgin abrasive Visual + certificationISO 11124 (all parts) (metallic) ISO 11126 (all parts)(non-metallic) Conformity to certificate and compliance w
46、ith manufacturing/ working procedures Once Every batch Water-soluble contamination of abrasives mS/cm ASTM D4940 Conductivity max. 60 Once 1/shift Soluble salt after blasting Potassium ferricyanide indicator in accordance with AS 3894-6 Each pipe Every 4 h Soluble salt after blasting mg/m2Conductive
47、 measurement, ISO 8502-9 and ISO 11127-6 Salt content (as NaCl) max. 20 Each pipe Every 4 h, if salt presence is indicated Surface roughness of blasted surface (Rz/Ry5) m ISO 8503-4 or ISO 8503-5 50 to 100 5 pipes Every 1 h Visual inspection of blasted surface ISO 8501-1 Grade Sa 21/2 Each pipe Each
48、 pipe Presence of dust after dust removal ISO 8502-3 Max. Class 2 5 pipes Every 1 h Visual inspection of pipe prior to introduction to coating line Visual No rust Each pipe Each pipe Temperature of extruded adhesive and polyolefin C Thermometer Compliance to APS Once Every 1 h Preheating temperature before coating C Pyrometer Compliance to APS Each pipe Every 0,5 h DIN EN ISO 21809-1:2011-10
