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AICO Job No: 4/T/2/S/1685 Job For: Seder Group Company for Trading

and Contracting
Report No.-NWC/SEDER/WMEPC-02 Project : Riyadh Strategic Water Supply Scheme
MONTHLY Coating Applicator: Welspun Middle East Pipes
Coating LLC.-Dammam

For additional Information contact


Engr. Fadul Al-Imam

Description of the Job : Third Party Inspection Services


Reference Notification No: E-Mail

Place of Intervention : Welspun Middle East Pipes Coating LLC-Dammam

Date (S) Of Intervention : May 1st TO 31st May /2011-MONTHLY

Inspection Engineer : Engr.Mohammad Sazid Alam-1,2,3,4,5,7,8,9,10,11,12,14,


16,17,18,19-May/2011
Engr. Astan Jr Abao -28,29,30/May-2011
Engr. Allan.R.Abdullah-31May/2011-1 day Only

Inspected Items : External 3Layers Polyethylene Coated Spiral Welded


Carbon Steel Pipes.

Specification : Specification#M02-REV-03. Dated-03.09.2007


MITPS/CP/10-11/006-01 REV.00 Dated-07.02.2011

Distributions: Conclusion :
Inspection carried out for production of 3 layers
NWS/Seder Group polyethylene coating on steel pipes as per Client
Company for Trading and Specification M02/Rev-03 and as per MITPS/CP/10-
Contracting. 11/006-01 Rev.00/Dated 07.02.2011.
WEMEPC LLC. STARTED PRODUCTION WITH
MPQT FOR (64” DIAX W.T.9.5MM XGRADE-X52
)FROM DATED 14/05/11
TOTAL PIPES EXTERNAL COATED-397 PIPES
Including 3 MPQT pipes.
TOTAL FINAL ACCEPTED PIPES- 406 PIPES
Including from previous coated pipes.
TOTAL RELEASE PIPES IN THIS MONTH:-388 PIPES.
Engr. Mohammad Sazid Alam Engr. Fadul Al Imam
Inspection Engineer Technical
Manager
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INSPECTION REPORT

CLIENT : NATIONAL WATER COMPANY


PROJECT : Riyadh Strategic Water Supply Scheme
CONTRACTOR : Seder Group Company for Trading and Contracting
SUB CONTRACTOR : AZIZ EUROPEAN PIPE FACTORY-DAMMAM
SUB-SUB CONTRACTOR : Welspun Middle East Pipes Coating LLC.
MATERIAL : 3 Layers polyethylene Coated Carbon Steel Pipes.
SPECIFICATION : Specification#M02-REV-3-Dated 03.09.2007
MITPS/CP/10-11/006-01 REV.00 Dated-07.02.2011
DATE OF INSPECTION : 1st May to 31st May -2011/-DAY SHIFT ONLY
INSPECTION ENGINEER : Engr. Mohammad Sazid Alam
Engr.Allan R Abdullah
Engr. Astan Jr. Abao

1. INSPECTED ITEMS:-
External 3-layers Polyethylene coating on spiral welded carbon steel pipes.
(88ӯ X 12.7mm W.T.X-Grade X52)& (64ӯ X 9.5mm W.T.X-Grade X52)

2. APPLICABLE STANDARD OF INSPECTION:


• Project Specification No. M02/Rev. 03
• Surface Preparation Standards (SS-EN ISO 8501-1:2007)
• Inspection and Test Plan Document No. MITPS/CP/10-11/006-01Rev 0 Dated 07.02.2011
• ILF- QC10 – H – 042 Rev 03 Dated 03.09.2007
3. SCOPE OF INSPECTION:
• Review of Documents.
• Check of climatic condition, equipment calibration and visual inspection of bare pipe for any surface
defects.
• Surface preparation (compress air contamination, abrasive blast contamination, residual surface chloride,
surface salt level, phosphoric acid, fresh water, surface profile).
• 3 Layers coating application (pipe drying, pre-heating, and FBE, copolymer, PE application).
• Visual check and coating thickness inspection. End cut back and cleaning.
• Holiday detection test.
• Stenciling and cut back Primer application
• Peel test, cathodes disbandment, penetration.
Contd. /page-2

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4. INSPECTION ACTIVITIES PERFORMED:

REVIEW OF DOCUMENTS:

• Reviewed material certificates for blast abrasive, the products (FBE, Copolymer, and polyethylene) used
for the coating.
• Checked and reviewed the calibration certificates for the equipments

Results: Found Satisfactory after getting the confirmation for shelf life of material and calibration date was
valid for the equipments used.

CLIMATIC CONDITION, EQUIPMENTS CALIBRATION AND VISUAL INSPECTION OF


BARE STEEL SURFACE DEFECTS:

•Checked climatic condition (temperature, relative humidity, dew point, steel temperature etc.) are recorded
at the specified intervals.
•Performed visual inspection external surface of bare pipe before blasting of gouges and other defects
likely to have a detrimental effect on coating are removed by grinding without reducing the wall thickness.
Results: Satisfactory

•The pipes are then blasted to a cleanliness of SA2 1/2 and blast profile was measured Acceptance criteria
50-100 micrometers-results found within acceptance range.
•Air supply check, abrasive contamination test, no contamination detected. Residual surface chloride before
blasting –found satisfactory (required < 2 μg/cm2) and after blasting found satisfactory (required: N/A), salt
level before blasting found satisfactory (required 3≤ μg /cm2) and after blasting found satisfactory.

Results: Satisfactory

PHOSPHORIC ACID WASH, PIPE DRYING / PRE-HEATING AND FBE, COPOLYMER, PE


APPLICATION:
Checked the PH for acid wash, PH for total dissolved solids (TDS), for fresh water residual acid on the
pipes for:
• Phosphoric acid wash (The pipes are washed with acid solution as they pass through the acid application booth for
the removal of contamination from the pipes).
Results:
Ph of phosphoric acid wash found satisfactory within acceptance criteria (required <2 Ph)
• PH & TDS fresh water
Results: Ph of fresh water found satisfactory (required ≥6 and ≤8 Ph)
TDS-found satisfactory (required ≤200 ppm)
Water chloride found satisfactory within acceptance range (required ≤50 ppm)
• Residual acid on pipe
Results: Ph found satisfactory (required <2 Ph)

Contd. /page-3

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• Residual rinse water


Results: Ph found satisfactory within acceptance criteria (required ≥ 6 and ≤8 Ph)
• Checked acid contact time, pipe drying, pre-heating
• Checked the pre-heating (found between 200 – 220 0 C)

Results: Inspection results within tolerance


Satisfactory for the blasting requirements and the pipe surface found OK for coating application.

5. THREE LAYERS COATING APPLICATIONS:

After ensuring heating of pipe checked FBE / Co-polymer and polyethylene application

START PIPE:
As per ITP, before the startup of production, 5 pipes were proceed, 1 pipe fully coated with epoxy, 1 pipe partly
coated with epoxy, adhesive (co-polymer),and polyethylene and the rest of three pipes ware coated with full 3
layer polyethylene coating system.
Visual inspection of FBE & co-polymer is carried out on the pipe and production was started after satisfactory
results on test pipe.
After satisfactory results on test pipe, it is ensured that the same thickness of FBE, co-polymer thickness is
measured checked on partially coated pipe (whenever there is breakdown in production) and found satisfactory
results.

VISUAL CHECK AND COATING THICKNESS INSPECTION:

• FBE
Acceptance criteria 250- 300 micrometer – Found within acceptance range-Satisfactory.
• Copolymer
Acceptance criteria 150-250 micrometers – Found within acceptance range-Satisfactory.
• Polyethylene
Dry Film Thickness found between 3.5mm for weld to 4.60 mm for body. Acceptance criteria
3.5mm minimum on pipe body and 3.25mm minimum on weld seam – Found Satisfactory.

• End cut back, cleaning, painting and stenciling.


Checked stenciling and found as per the specification

Checked cut back found between Acceptance criteria (150+10/-10 mm)


Results: Within range – Satisfactory

Contd. /page-4

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6. TESTING:

• Holiday Detection Test


Holiday was carried out at 30 KV on 3 Layer polyethylene coated pipes
Holiday was carried out at 1.25 KV on Fusion Bonded Epoxy pipe.
Results: No holiday found
• Adhesion and Peel Test
Adhesion was checked sharp knife and two incisions were made in the form of X and at the intersection
of X an attempt was made to force the coating to remove from the steel surface with the knife point.
Peel test at 20±5ºC for 3 layers PE found within acceptance limit (required > 100 N/cm)
Peel test at 50±5ºC for 3 layers PE found within acceptance limit (required > 50 N/cm)
Results: Satisfactory.
• Cathodic Disbondment
Sample were taken with coating and kept in salt solution for 48 hours @ 65 +20 C at voltage – 1.50 volts
DC
Results: Average disbondment found within acceptance range (acceptance criteria ≤15 mm)

7. REMARKS:

Total 130 Pipes (88ӯ X 12.7mm W.T.X-Grade X52) External coated in this Month.
Total Pipes accepted in Final/TPI cleared-149 pipes in this Month including from previous
coated pipes.

Total Coated Released Pipes (88ӯ X 12.7mm W.T.X-Grade X52)-170 pipes


Two Coated Pipe rejected –Pipe no.-E11001316 due to DFT & Pipe no.-F11-001056 due to
End open.

Total 267 Pipes (64ӯ X 9.5mm W.T.X-Grade X52) External coated in this Month.
Total Pipes accepted in Final/TPI cleared-257 coated pipes

Total Coated Released Pipes (64ӯ X 9.5mm W.T.X-Grade X52)-218 pipes.


Four coated pipe rejected due to low film thickness and due to Ends open.

Pipe No.-F11-001601 rejected due to DFT and Pipe No.-F11-001486, F11-001338,


F11-001460, F11-001448 rejected due to Ends Open.

Note:-Pipe (64”dia X W.T.-9.5mm X Grade-X52 accepted by TPI in final subject to satisfactory


MPQT28 Days cathodic Disbondment test (CD TEST) to be completed that started from 17/05/11.

Attachment: ---
(1.) Monthly Report
(2.) Release certificates with MTC
(3.) Daily Inspection report

ENGINEER MOHAMMAD SAZID ALAM


AICO-INSPECTOR

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