用于3LPE管材防腐补口的TU涂料应用规范.doc

Specification for the ApplicationofTar Urethane (TU ) for theField Joint Coating and Repair of Three Layer Polyethylene Coated Linepipe用于3LPE管材防腐补口的TU涂料应用规范Spencer Coatings Limited,Froghall Terrace,Aberdeen,AB24 3JNTel +44 (0) 1224 788400Fax +44 (0) 1224 648116infospencercoatings.co.ukwww.spencercoatings.co.ukCONTENTS1.0Scope范围2.0Codes and Standards规范和标准3.0Field Joint Surface Preparation 补口的表面预处理4.0Field Joint Coating 补口涂敷5.03 Layer Coating Repair 3层涂层修补6.0Field Joint Coating 补口涂敷检查7.0Storage and Handling 储存与运输8.0Safety 安全9.0Acothane TU Properties TU性能10 Coating Properties涂层性能1.0Scope 范围 This specification describes the requirements for preparing field joints and damaged areas on 3 Layer polyethylene coated pipes, and the application of Tar Urethane (TU) as an external protective system. Coating application shall comply with the manufacturers recommendations and be in accordance with this specification.本规范规定了处理3LPE涂层管上的补口和损坏区域，以及使用TU作为外部防护系统时的要求。涂料施工应按照厂家的建议并应遵照本规范来执行。The coating shall normally consist of one layer of rapid cure TU applied using a wet on wet spray technique or multi-layers of longer pot-life material formulated for brush application.涂层一般包括一层有着快速固化作用的TU涂料，它使用湿喷涂技术或多层耐用涂层通过刷涂涂敷。Suitable coating materials are:涂层材料： Metrotect Acothane TU Spray Grade Metrotect Acothane TU 喷涂 Metrotect Acothane TU Brushing Grade Metrotect Acothane刷涂2.0Codes and Standards 规范和标准SSPC - SP1 (Solvent Cleaning) SSPC - SP1（溶剂清洗）SSPC - AB1 (Mineral Slag and Abrasive) SSPC - AB1（矿渣及研磨剂）ASTM-D4417 (Field Measurement of Surface Profile of Blast Cleaned Surfaces)ASTM-D4417 （现场测量喷砂处理过的表面粗糙度）ISO 8501-1 (Preparation of steel substrates before application of paints and related products - Visual assessment of surface cleanliness).ISO 8501-1（涂料及相关产品涂敷前钢基预处理-目测表面净度）DIN 30671 - 埋地钢管的热固性塑料涂层3.0 Field Joint Surface Preparation 补口的表面预处理Oil, grease and other contaminants shall be removed from the steel and adjacent polyethylene surfaces by solvent cleaning in accordance with SSPC SP1 prior to abrasive blast cleaning.根据SSPC SP1的规定，在喷砂处理之前，应当用溶剂将附着在钢材及相邻聚乙烯材料表面的油脂及其他污染物清洗掉。Steel and polyethylene surfaces to receive TU coating shall be abrasive blast cleaned to establish an anchor pattern. The temperature of the substrate shall be a minimum of 3C (5F) above the dew point during surface preparation, coating application and curing. Coating materials shall not be applied when the steel temperature is below 0C (32F). Preheating is required if either of these two conditions are not met.应当对将要涂敷Acothane涂层的钢材及聚乙烯材料的表面进行喷砂处理，使其表面呈粗糙状。底材温度应至少在露点以上3C (5F)。在钢材温度低于0C (32F)时，不应使用涂层材料。如无法满足两个条件中任意一条，则需要进行预热处理。The abrasive blast cleaning shall be performed using compressor units equipped with separators, filters and drains to ensure that contaminants such as oil and water are not deposited onto the surface to be coated. Burrs, slivers, scabs and weld spatter visible following blasting shall be removed and the area re-blasted. The prepared surface shall be coated prior to any visible deterioration of the surface.应采用配备有分离、过滤及排水装置的压缩机组进行喷砂除锈处理，来确保诸如油和水一类的污染物不会沉积在将要进行涂敷的表面上。喷砂之后，应当除掉明显的毛刺、裂片、瑕疵和焊渣并对此处再次喷砂。应在有任何明显的劣化现象出现之前对处理过的表面进行涂敷。Abrasive for blast cleaning shall be clean and dry and free of contaminants. The particle size shall be capable of producing the specified surface profile. Slag and mineral abrasives shall meet the requirements of SSPC AB1. Re-circulated abrasives or steel grit may be used if not contaminated with pipe coatings or salts.用于喷砂的研磨料应当清洁干燥且无污染。颗粒的大小应能够形成规定的表面粗糙度。矿渣和矿物研磨料应满足SSPC AB1的要求。如果没有被管材涂料或盐所污染，那么可循环的研磨料或钢砂还可以再次使用。The steel surface shall be blast-cleaned in accordance with ISO 8501-1 Sa2 . Remnants of the first layer of fusion bonded epoxy, or liquid epoxy may remain adjacent to the edge of the polyethylene. The minimum anchor profile on the steel resulting from blast cleaning shall be 75mm (3.0mils). The polyethylene surface shall be roughened by abrasive blast cleaning for a minimum length of 100mm from each cutback area. The polyethylene shall be further abraded with a wire brush or similar implement to achieve a hairy/stringy surface to maximize the surface area and aid adhesion. Residual blast products shall be removed from the cleaned surfaces by using clean, dry, compressed air. The use of rags to wipe clean the prepared surfaces is prohibited. All surfaces to be coated shall be free from contaminants, including moisture. All areas which are not to be coated shall be protected from abrasive blast cleaning.根据ISO 8501-1 Sa2 ，钢材表面应进行喷砂处理。熔结环氧树脂第一层的残余物或液体环氧树脂可能仍残留在邻近聚乙烯材料的边缘。喷砂清理后钢管的最低锚纹应为75微米（3.0密耳）。为使从每个削减面开始最小长度都是100毫米，应通过喷砂处理的方式对聚乙烯材料的表面进行粗糙化。应使用钢丝刷或者类似的工具对聚乙烯材料进行深度研磨以形成毛状/纤维状的表面，这样做可使表面积最大化并有助于粘附。应使用清洁，干燥和压缩空气的方法将残余的喷砂物从清洁的表面去除。禁止使用抹布擦净处理过的表面。所有将要涂敷的表面应免受包括湿气在内的污染物的污染。应保护好所有不准备涂敷的区域不进行喷砂处理。 Profile measurements, to ensure the correct anchor pattern, shall be taken at a minimum of three (3) different locations for each working production shift, i.e. twelve (12) hours. The profile of the steel surface shall be measured with replica tape and a spring micrometer.应采用剖面测量法在每个工作生产换班时间也就是每12小时从3个不同的位置进行测量，以确保准确的表面粗糙度。钢材表面的粗糙度应使用拓模胶带和测微计来测量。Care shall be taken to avoid blast cleaning away identification markings on the pipe. Where such data appears in the area to receive cleaning, it shall be transferred to a location where it will be protected.应当小心以避免喷砂时除掉管子上的识别标记。如此类数据出现在将要进行处理的地方时，应将它转移到一个受保护的位置。4.0Application 涂敷Field joint coating shall be performed only when the surfaces to be coated are clean and dry, and in the absence of airborne contamination that can affect the quality of the joint coating. Heating shall be performed if the surface temperature is less than 3C above the dew point temperature. The coating shall be applied so that the steel surface receives a minimum of 1.5mm (1500mm, 60mils) over the bare steel. Coating shall lap 50mm (2 inches) minimum onto the polyethylene pipe coating. The abraded surface shall extend at least 25mm (1 inch) beyond the coated area. 只有当将要涂敷的表面清洁，干燥且无空气污染时，才可以进行补口涂敷，这些因素都可能影响补口涂层的质量。如果表面温度低于露点以上3C，则应进行加热。应进行涂敷以便钢材表面达到裸钢以上最小1.5毫米（1500微米，60密耳）的厚度。涂敷应覆盖到聚乙烯管涂层周围最小50毫米（2英寸）。磨面应至少扩展到涂敷区域外25毫米（1英才）。The DFT of the TU coating shall transition from the above specified thickness measured over the steel (no polyethylene beneath) to a thickness of zero observed at the termination of the TU. The blast cleaning profile on the polyethylene surface shall be visible beneath the feathered out (tapered) overlapping TU coating or beyond the edge of the TU coating.TU涂层的干膜厚度应从上述规定的在钢材上测量的厚度（无聚乙烯）过度到在涂层终端观测到的零厚度。应当在逐渐消失的重叠的TU涂层下方或者超出TU涂层边缘的位置来目测聚乙烯表面上喷砂处理后的粗糙度。 When rubbed with the finger, there shall be a continuous circumferential band of roughness evident in the edge of the cured joint coating due to the roughened, overlapped, polyethylene pipe coating beneath.在用手指摩擦时，应明显在补好的补口层边缘有一个连续的粗糙圆周带，这取决于下面的表面粗糙且相互重叠的聚乙烯管涂层。TU overspray that is not a consolidated film may be present on unprepared surfaces downwind of the joint. The overlap of the consolidated film of TU shall extend onto the prepared surface at least 50mm, but not over the unprepared polyethylene surface. If the consolidated film does overlap onto the unprepared portion of the polyethylene pipe coating, cut back the joint coating until the edge terminates on polyethylene that has been roughened to the specified anchor profile.在补口的下风处，未经处理的表面可能会出现TU超范围的喷涂，这不是一个加固膜层。TU加固膜层的重叠应至少扩展到处理后的表面50毫米的区域，但不能覆盖到未处理过的聚乙烯的表面。如果加固膜层真的覆盖到了聚乙烯管涂层上未处理的部分，那么就缩减补口直到边缘终止在已粗化到指定粗糙度的聚乙烯上。4.1Spray Coating 喷涂Coating equipment shall comply with the coating manufacturers recommendation. The spray equipment shall be adjusted so that coating is applied in a smooth and uniform coat. All joints coated with hand-held spray equipment shall be checked as soon as possible to ensure that the minimum DFT of the coating is satisfactory. Wet film thickness gauges may be used during coating to ensure correct coating thickness.涂敷设备应遵照涂敷厂商的建议。应调整好喷涂设备以便涂敷操作可以在平滑均匀的涂层上进行。所有采用便携式喷涂设备涂敷的补口都应尽快检查以确保涂层的最小干膜厚度满足要求。在涂敷时应采用湿膜测厚仪以确定准确的涂层厚度。Filters shall be installed as part of the equipment to ensure that particles which would be detrimental to the coating application shall be cleaned using only manufacturer recommended solvents. Solvent flushing of spray equipment shall be allowed when spray operations cease. Solvent shall not be flushed onto the coated joint. When coating operations are resumed, contractor shall ensure that only solvent-free material is applied. 应将过滤器安装在设备上以确保可能对涂料施工不利的颗粒被过滤掉。应只采用厂商推荐的溶剂进行清洗。当喷射操作停止时，允许对喷射设备进行溶剂冲洗。溶剂不应冲洗到涂好的补口上。当涂敷操作再次开始时，施工方应保证只应用无溶剂的材料。If multiple coats are required to achieve the specified thickness, the over-coating may be performed to the previously coated clean, dry surface within the manufacturers recommended over-coating period with no special surface preparation. If the time between coats exceeds the recommended maximum, the surface shall be abraded prior to applying an additional coat.如果要求多层涂敷以达到指定厚度的话，则应在厂商推荐的保护涂层期限内在原来涂好的清洁干燥的表面上加上保护涂层，而无需特殊的表面处理。如果在相邻涂层操作的间隔时间超过推荐的最小值，则表面应在补涂之前进行打磨。4.2Brush Coating 刷涂Brush coating shall be used at locations where spray application is not feasible or at tie-in locations. Brush application is approved for repairs to spray applied coating.在喷涂不可行的位置或者在固定的位置上，应采用刷涂。对于喷涂过的涂层的修补，允许使用刷涂。The coating components shall be mixed and applied in accordance with the manufacturers recommendation. No thinner shall be used. Surfaces shall be prepared in accordance with this specification. Where multiple layers of coating are required to achieve the specified thickness, each layer shall be applied at right angles to the preceding layer. If the time between coats exceeds the manufacturers stated maximum， the surface shall be abraded prior to applying an additional coat.涂层成分的配制及应用须严格按照厂家的建议，不得使用任何稀释剂。表面预处理须按照本规范的要求来进行。多层涂层应达到规定的厚度，每一层应与前一层成直角。如果在相邻涂层操作的间隔时间超过厂商推荐的最小值，则表面应在补涂之前进行打磨。Contractor shall ensure that flash rusting has not occurred prior to applying the coating material. Should flash rusting be present, contractors shall blast-clean the area in accordance with standard ISO 8501-1 Sa2 .承包方应确保在应用涂敷材料前不会出现薄锈。根据ISO 8501-1 Sa2 的标准.如出现薄锈，则应对该区域进行喷砂除锈。4.3Curing 固化After completion of application, the TU coating shall be allowed to cure overnight before final holiday testing or lowering-in. The coating must reach fingernail hardness. The contractor may elect to holiday test on the day of application, using a lower voltage than specified in Section 6.0 of this specification, for his own control procedure.在涂敷完毕后，应允许TU涂层在进行最终漏涂测试或表面凹陷检查之前固化一夜。涂层必须达到手指甲的硬度。承包商可以选择在涂敷日用低于本规范第6部分规定的电压来进行漏涂检查，按照他们自己的操作程序。5.0 Polyethylene Coating Repair PE涂层修补The repair of holidays or damaged areas which are discovered in the polyethylene pipe coating shall be made with approved TU products. All loose or damaged polyethylene shall be trimmed back to sound coating prior to cleaning, and the edge of the polyethylene shall be bevelled at an angle of 30 with the steel surface. The surface preparation shall ensure that the area to receive the coating material is clean, free from contamination and abraded so that the anchor pattern described in Section 3 is achieved. The holiday or damaged area shall be cleaned and the TU applied so it overlaps at least 75 millimetres (3 inches) beyond the perimeter of the holiday. The abraded area must extend at least 25 millimetres (1”) beyond the area to receive the coating. Following the cure time for the repair product, as described above, the repair shall be re-tested.漏涂部位或在聚乙烯管涂层上发现的损坏区域的补修应使用经许可的TU产品。所有损坏的聚乙烯应在清洁之前对其涂层进行测深，且聚乙烯边缘应与钢材表面成30度角。表面处理时应当确保涂敷的区域清洁，无污染且已打磨过，这样才能达到第三部分描述的粗糙效果。漏涂或损坏区域应保持清洁并用TU产品涂敷，超出漏涂区域的周长至少75毫米（3英寸）。研磨区域应扩展到要涂敷的区域之外至少25毫米（1英寸）。在上述修补产品固化后，应再次检查修补部位。 6.0Inspection 检验Coated field joints shall be free from holidays and major runs, sags, blistering or delamination, and roughness caused by embedded dust. The DFT shall be checked on each joint using a film thickness gauge such as an Elcometer 345 or Elektro-Physik “Mikrotest” film thickness gauge or approved equal. The contractor shall ensure that the thickness gauge is in good working condition and calibrated at least twice daily.涂敷的补口应避免漏涂以及和由嵌入的灰尘引起的粗糙。应在每一个补口处使用油膜厚度计来检测干膜厚度，诸如Elcometer 345 or Elektro-Physik “Mikrotest” 油膜厚度计或者经批准的同等产品。承包方应确保测厚计处于良好的工作状态并每天至少2次进行校准。Any area of the coating found to be off-ratio or uncured shall be repaired by removal of all defective coating, and re-prepared and re-coated in accordance with the specification described herein. 涂层上任何区域发现未固化时都应靠去除所有带瑕疵的涂层的方式来修补，并应根据本规范的规定来进行再处理及再涂敷。Defects from runs and sags shall be corrected by sanding to remove the defect.有下陷或小点等瑕疵的地方应通过砂纸打磨去除瑕疵的方法来修补。If the DFT is reduced to less than specified, the area shall be abraded as described above and an additional layer of coating shall be applied until sufficient thickness is achieved. If noticed during application, the sags or runs can be brushed out. Slight sags or runs, less than 0.2 millimeters (8 mils) thick shall not be considered as defects.如果干膜厚度缩减到低于指定时，该区域按照之前描述的进行研磨，并应再涂敷额外的一层保护层直到达到足够厚度。如果在涂敷过程中发现有下陷或小点现象，则可立即刷掉。低于0.2毫米（8密耳）厚的轻度下陷或溶化不应视为瑕疵。Defects from blistering, cracking, delamination or pin-holes shall be corrected by removing the defective coating to bare steel. Following re-preparation, additional coating shall then be applied until the correct DFT is achieved. The repaired surface must be lapped at least 75 millimeters (3 inches) onto the sound coating.防腐层如出现起泡、裂化、分层或针孔等瑕疵，应通过去除裸钢表面带瑕疵的涂层的方式来修补。再次处理后，应涂敷额外涂层直到达到正确干膜厚度。补好的表面一定要搭接原涂层上至少75毫米（3英寸）。The finished joints shall be inspected with a holiday detector set at 8kV DC. The holiday detector shall be checked with a DC voltmeter at least once each shift to ensure accuracy.补好的补口应使用带8千伏直流电的漏涂检测仪来检测。应至少在每次换班时用直流电伏特计检查一次漏涂检测仪以确保其准确度。The repair of defective coating that requires an additional layer to be applied can be made by either spray or brush application. The surface preparation as described in Section 4 shall apply if the additional layer is applied outside the manufacturers recommended maximum over coating period.要求涂敷额外涂层的有毛病的涂层的修补可通过喷涂或者刷涂来执行。如果额外涂层的涂敷时间超出厂商推荐的最大涂敷期限的话，应进行第4部分提到的表面预处理。7.0Storage and Handling 储存与运输Materials shall be in the manufacturers containers bearing the original labels identifying the type and batch number. The coating components shall be stored in accordance with the manufacturers latest published instructions. Materials shall be protected from damage, weather, moisture, direct sunlight and temperatures below 4C (40F). The materials shall be stored in a well-ventilated area and protected from sources of ignition.涂料应储存在厂家提供的带有标明类型和批号的原始商标的容器中。涂料应根据厂家最新版的使用说明来储存。涂料应避免损坏，腐蚀及日光直射并应远离湿气和低于4摄氏度（40华氏度）的环境，应储存在通风良好的环境下，且远离火源。Any material which has exceeded the recommended shelf life, or in which is in containers which are damaged to the point of compromising the contents shall not be used. Containers of coatings or components shall not be opened except for immediate use.任何超过推荐保存期限或者放在破损程度达到危机产品安全的容器中的材料均不应使用。容器中的涂料或混合成分一经打开，需立即使用。Pipe which has been double-jointed and joint coated shall be stacked in such a manner to prevent the coated joint from direct contact with the pipe support by cushioning medium, such as a number of pieces of rope on each row of pipe. During transport to the pipeline construction site, care shall be taken to ensure that the coated joints are not placed on unprotected bolsters. Pipe which has been checked for holidays at the double-joint yard shall be re-checked prior to installation in the trench.涂敷双面补口和单面补口的管子应通