2013-6031-2L-0010-Specification for Polyurethane Insulation Coating_Re IDC

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Cuu Long Joint Operating Company

STV EXTENSION – STV SOUTH WEST PROJECT (SVSW)

EPCI FOR WHP-SVSW, PIPELINES AND CPP MODIFICATIONS

SPECIFICATION FOR POLYURETHANE INSULATION

COATING

DOCUMENT NO.: 2013-6031-2L-0010

A ISSUED FOR REVIEW 20/12/13 NTTH GKH DNP NDK

Rev. Description Date Prepared CheckedPVE PTSC MC

CLJOC

ApprovalApproved by

Su Tu Vang South West



STVEXTENSION – STV SOUTH

WEST PROJECT (SVSW)

EPCI FOR WHP-SVSW,

PIPELINES AND CPP

MODIFICATIONS

SPECIFICATION FOR POLYURETHANE

INSULATION COATING

Document No.: 2013-6031-2L-0010

Revision: A

Page:2 of 42

REVISION LOG

Revision No. Section Revision Description

A ALL ISSUED FOR REVIEW




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MODIFICATIONS


INSULATION COATING

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TABLE OF CONTENTS

1.0 INTRODUCTION .......................................................................................................... 5 2.0 PROJECT DEFINITION .............................................................................................. 6 3.0 PURPOSE OF DOCUMENT ........................................................................................ 6 4.0 GENERAL INFORMATION ........................................................................................ 6 4.1 LANGUAGUES AND UNIT OF MEASURES .............................................................. 6 4.2 ABBREVIATIONS .......................................................................................................... 6 4.3 CODES AND STANDARDS ........................................................................................... 7 4.4 REFERENCE DOCUMENT .......................................................................................... 10 5.0 GENERAL REQUIREMENTS ................................................................................... 10 5.1 GENERAL ...................................................................................................................... 10 5.2 QUALITY SYSTEM ...................................................................................................... 10 5.3 HEALTH, SAFETY AND ENVIRONMENT ............................................................... 11 5.4 QUALIFICATION TESTING ........................................................................................ 11 5.5 VENDOR ’S RESPONSIBILITY ................................................................................... 11 5.6 PERFORMANCE OF WORK ....................................................................................... 13 5.7 NON CONFORMANCE ................................................................................................ 13 6.0 COATING SYSTEM .................................................................................................... 14 6.1 GENERAL ......................................................................Error! Bookmark not defined. 6.2 COATING SYSTEM ...................................................................................................... 14 7.0 COATING MATERIAL REQUIREMENT ............................................................... 14 7.1 GENERAL ...................................................................................................................... 14 7.2 PRIMER AND/OR FIRST COAT ................................................................................. 15 7.3 2nd LAYER ..................................................................................................................... 16 7.4 TOP LAYER .................................................................................................................. 17 8.0 MEASUREMENT AND LOGGING .......................................................................... 18 9.0

SURFACE PREPARATION ....................................................................................... 18

9.1 PIPE SURFACE PREPARATION ................................................................................. 18 9.1.1 Metal Surface .................................................................................................................. 18




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9.1.2 Abrasive Blast Cleaning ................................................................................................. 19 9.1.3 Inspection of Surface Cleanliness ................................................................................... 19 9.1.4 Acid Wash ...................................................................................................................... 20 9.2 SURFACE PREPARATION OF FBE COATED PIPES ............................................... 21 9.3 SURFACE PREPARATION OF PUF COATED PIPES ............................................... 21 9.4 MOULD PREPARATION FOR PUF COATING ......................................................... 21 10.0 COATING APPLICATION ........................................................................................ 22 10.1 PIPE HEATING ............................................................................................................. 22 10.2 EPOXY APPLICATION ................................................................................................ 23 10.3 PUF APPLICATION ...................................................................................................... 23 10.3.1 Pre-Mixing of Polyol and Transfer to Conditioning Tank ............................................. 23 10.3.2 Discharge of Isocyanate .................................................................................................. 24 10.3.3 Mixing and Pumping of PUF .......................................................................................... 24 10.3.4 PUF Coating Application ............................................................................................... 24 10.4 HDPE APPLICATION ................................................................................................... 25 10.4.1 Water Stop Application .................................................................................................. 25 10.4.2 HDPE Application .......................................................................................................... 25 10.4.3 Sinter Coat / Rough Coat (FOR CWC COATED PIPES ONLY) .................................. 25 10.4.4 Water Quench, Cooling and Inspection Racks ............................................................... 25 10.5 TYPICAL CUTBACK ................................................................................................... 26 11.0 INSPECTION AND TESTING ................................................................................... 27 12.0

PIPE MARKING .......................................................................................................... 39

13.0 STORAGE, HANDLING AND TRANSPORTATION ............................................ 39 14.0 DOCUMENTATION ................................................................................................... 41 14.1 GENERAL ...................................................................................................................... 41 14.2 REPORT DOCUMENT ................................................................................................. 42




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1.0 INTRODUCTION

Cuu Long Joint Operating has embarked in the development of STV Extension Plan -

STV South West (SVSW) Project located in Block 15-1, offshore Vietnam.

This development consists of an unmanned tripod jacketed platform (SVSW) with

minimum facility which tie-back and operated from the adjacent STV-CPP. The

development of this field will be carried out by utilizing 3 slots consist of one (1)

existing well using single Xmas Tree and two (2) future dual well Xmas Trees.

Processing of the SVSW wellstream fluids will be carried out on the STV-CPP

facilities which will also supply gas to SVSW for gas lifting. STV-CPP will also

control and monitor SVSW.

An overview of the STV Extension Plan – STV South West Project is shown in the

Figure 1 below:

Figure 1: STV Extension Plan – STV South West Project




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2.0 PROJECT DEFINITION

Terms Definitions

CLJOC Cuu Long Joint Operating Company

CONTRACTOR A company that is responsible for the Engineering,

Procurement, Construction and Installation (EPCI)

of the SVSW Project for CLJOC.

VENDOR Any entity appointed by CONTRACTOR to

supply and apply equipment / materials for this

Project.

3.0 PURPOSE OF DOCUMENT

This Specification defines the minimum technical requirements for the Polyurethane

based coating system for the external surface of 10.75-Inch Production Pipeline and

Riser at 120oC maximum design temperature. The coating provides thermal insulation

and anti-corrosion for the 20 years design life of the pipeline. The required U-value of

the coating is 0.27 btu/ft2.hr.oF (1.533 W/m2K maximum).

4.0 GENERAL INFORMATION

4.1 LANGUAGUES AND UNIT OF MEASURES

The content, references, attachments and any supplementary information for all

engineering documents shall be in English unless specified otherwise. The units of

measurement for all engineering documents shall be in the System International (SI).

4.2

ABBREVIATIONSThe following abbreviations will be used throughout this document:

API American Petroleum Institute

APS Application Procedure Specification

ASTM American Society of Testing and Materials

CWC Concrete Weight Coating

ESCR Environmental Stress Crack Resistance

EPC Engineering, Procurement and Construction.

FBE Fusion Bonded Epoxy

http://en.wikipedia.org/wiki/Engineering

http://en.wikipedia.org/wiki/Procurement

http://en.wikipedia.org/wiki/Construction

http://en.wikipedia.org/wiki/Construction

http://en.wikipedia.org/wiki/Procurement

http://en.wikipedia.org/wiki/Engineering




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HDPE High Density Polyethylene

HSE Health, Safety, Environment

ISO International Organization for Standardization

MFR Melt Flow Rate

MS Manufacturer Specification

MVR Melt Volume-flow Rate

NACE National Association of Corrosion Engineers

OHTC Overall Heat Transfer Coefficient

PE Polyethylene

PO Purchase Order

PQT Procedure Qualification Trial

PUF Polyurethane Foam

4.3 CODES AND STANDARDS

Unless specified otherwise, the latest edition of the following codes and standards shall

be applied:

American Petroleum Institute (API)

API RP 5LW Transportation of Line Pipe on Barges and Marine Vessels.

API 5L Specification for Line Pipe.

American Society of Testing and Materials (ASTM)

ASTM D792 Standard Test Method of Specific Gravity and Density of

Plastics by Displacement.

ASTM D1505 Standard Test Method for Density of Plastics by the Density-

Gradient Technique.

ASTM D1603 Test Method for Carbon Black in Olefin Plastics.

ASTM D1693 Test Method for Environmental Stress Cracking of Ethylene

Plastics.

http://www.api.org/

http://www.api.org/






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Substrates and of Steel Substrates after Overall Removal of

Previous Coatings.

ISO 8502-3 Preparation of Steel Substrates before Application of Paints and

Related Products - Test for The Assessment of Surface

Cleanliness - Part 3: Assessment of Dust on Steel Surfaces

Prepared for Painting (Pressure-Sensitive Tape Method).

ISO 8502-6 Preparation of Steel Substrates before Application of Paints andRelated Products - Test for the Assessment of Surface

Cleanliness - Part 6: Extraction of Soluble Contaminant for

Analysis - The Bresle Method.


Related Products -Tests for the Assessment of Surface

Cleanliness - Part 9: Field Method for The Conductometric

Determination of Water-Soluble Salt.

ISO 8503-4 Preparation of Steel Substrates before Application of Paints andRelated Products - Surface Roughness Characteristics of Blast-

Cleaned Steel Substrates - Part 4; Method for the Calibration Of

ISO Surface Profile Comparators and for The Determination Of

Surface Profile - Stylus Instrument Procedure.


Related Products - Surface Roughness Characteristics of Blast-

Cleaned Steel Substrates - Part 5: Replica Tape Method for the

Determination of The Surface Profile.

ISO 11124 (all parts) Preparation of Steel Substrates before Application of Paints and

Related Products - Specifications for Metallic Blast-Cleaning

Abrasives.

ISO 11357 (all parts) Plastics - Differential Scanning Calorimetry (DSC).

ISO 15512 Plastics - Determination of Water Content.

ISO-21809-1 Petroleum and Natural Gas Industries - External Coatings for

Buried or Submerged Pipelines Used in Pipeline Transportation

Systems - Part 1: Polyolefin Coatings (3- Layer PE and 3-

Layer PP).

ISO 9001 Quality Management Systems – Requirements.




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National Association of Corrosion Engineers (NACE)

NACE RP 0394 Application, Performance, and Quality Control of Plant-

Applied, Fusion-Bonded Epoxy External Pipe Coating.

Society for Protective Coatings (SSPC)

SSPC-AB1-2000 Abrasive Specification No1 - Mineral and Slag Abrasives.

SSPC-AB2-2000 Cleanliness of Recycled Ferrous Metallic Abrasives.SSPC-AB3-2000 Abrasive Specification No.3 - Newly Manufactured or Re -

manufactured Steel Abrasives.

SSPC-SP1-2000 Surface Preparation Specification No.1 - Solvent Cleaning.

4.4 REFERENCE DOCUMENT

[1]. Pipeline Design Basis, Doc. No. 2013-6031-2H-0001.

5.0 GENERAL REQUIREMENTS

5.1

GENERAL

The insulation coating shall be suitable for use with cathodic protection systems and for

use at the pipeline maximum design temperature of 120oC, water depth, minimum

ambient temperature of 18.8 oC and the surrounding environmental conditions.

Anodes shall be attached to the line pipe after coating as detailed in document

“Specification for Pipeline Anode Installation”, No.: 2013-6031-2L-0014.

5.2 QUALITY SYSTEM

VENDOR shall operate an accredited system of quality management in line with ISO

9001 and demonstrate that effective quality control procedures are in place to ensure

that the requirements of this specification, recognised codes and national and industry

standards are met.

The VENDOR shall submit to CLJOC for approval together with their bid, a Quality

Plan for the complete manufacturing process.

The Quality Plan shall include procedures for pre-inspection meetings and audits, all

quality control activities, acceptance criteria and hold/witners/monitor points for both

CLJOC and VENDOR.




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5.3 HEALTH, SAFETY AND ENVIRONMENT

VENDOR shall at all times maintain awareness of the legislation and regulations

concerning health, safety and environmental issues, and comply with these in all

operations concerning the supply of linepipe. A specific HSE plan and Inspection &

Test Plan shall be submitted as indicated in the purchase requisition.

5.4 QUALIFICATION TESTING

Where VENDOR has previous experience with the proposed coating system, full

procedure qualification may not be required subject to the provision of relevant historic

data and acceptance by VENDOR. VENDOR is required to perform a PQT to

demonstrate that this Specification can be met.

Only materials with a proven track record of subsea use in the oil and gas industry shall

be used.

5.5 VENDOR ’S RESPONSIBILITY

VENDOR shall determine the coating construction and thickness for the insulation

coating system for the specified U-value of 0.27btu/ft2.hr.oF. The analysis shall take

into account the following:

Design life;

Design temperature and effect on materials properties;

Water depth;

Coatings of weld joints;

Manufacturing tolerances;

Coating detail at welded joints;

Effect of degradation on thermal conductivity, compression and creep.

It shall be VENDOR’S responsibility to supply all materials, equipment and personnel

to perform the work in accordance with the requirements of this Specification. The

details contained within this Specification, Contract, Purchase Order or any other

CLJOC/CONTRACTOR document do not in any way relieve VENDOR of his

responsibility to produce a high quality product fit for the intended service.

VENDOR shall demonstrate that the coating system and method of application will

fulfil the requirements of this Specification by supplying technical information and

performing a PQT. Data from previous projects may be proposed in place of




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performing a PQT, provided the data demonstrates the requirements of the

Specification are satisfied. The performance and long term behaviour of the proposed

thermal insulation coating system shall be supported by design calculations which

demonstrate that the proposed coating shall provide the required Overall Heat Transfer

Coefficient (OHTC) for the life of the field.

The VENDOR shall ensure that the proposed coating system buoyancy is suitable for

long term stability of the pipeline i.e. preference should be given to materials with the

highest densities, to minimise buoyancy effects.

All raw materials shall be tested by both VENDOR and his raw material supplier. The

material shall not be applied until released by quality control personnel as meeting test

requirements.

VENDOR shall provide test data to justify the values of physical properties of the

coating components used in the design and the expected behaviour over time under the

service conditions. Where suitable test results are not available to support the

parameters used in design, VENDOR shall perform such qualification testing as is

necessary to support the selection of the values used. VENDOR is required to perform

a PQT at the start of the project.

VENDOR procedures shall as a minimum address the following:

Environmental control, temperature, relative humidity, dew point;

Pipe and fitting handling, storage and stacking procedures;

Procedure for the receipt and storage of coating materials;

Procedure for calibration and measuring of testing equipment, including frequencies;

Pipe preheating and temperature control;

Surface preparation;

Application of FBE first coat;

Inspection of FBE first coat;

Intermediate preparatory processes between first coat application and thermal

insulation application;

Procedures for mixing coating components in correct ratios including productioncontrols and tests;




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Method of coating application and description thereof, e.g. casting in mould,

rotational casting, spray application etc;

Application procedures including measures to ensure uniformity of coating density

and thermal conductivity, concentricity of pipe and external surface of coating;

Procedure for coating at pipe ends;

Repair procedures;

Procedure for storage and handling of coated pipes.

VENDOR shall provide with the bid a detailed design calculation and report which

addresses the items described above.

5.6 PERFORMANCE OF WORK

VENDOR shall guarantee the work performed when manufacturing and installing the

coating is in accordance with this specification.

CLJOC shall be notified in advance of all work to be performed, which is subjected to

CLJOC hold or witness points. Any such work performed without notification of

CLJOC may be rejected by CLJOC.

CLJOC Representative(s) shall be given ready access to inspect the VENDOR's quality

control procedures, methods and results, the equipment, and VENDOR's fabrication

process. CLJOC and CLJOC approved third party, reserves the right to witness all

phases of the coating manufacturing testing and installation at the VENDOR's works.

VENDOR shall afford CLJOC Representatives all reasonable access to facilities at no

cost to CLJOC, to ensure the insulation coating is manufactured and installed in

accordance with this Specification. Such inspection by CLJOC shall not relieveVENDOR of his responsibility to ensure quality control.

Following insulation, it shall be responsibility of VENDOR to ensure that the insulation

remains undamaged and does not degrade in any respect prior to the load-out following

completion of the work.

Any insulation coating that in CLJOC's judgment does not comply with this

Specification and is rejected by CLJOC shall become the property of VENDOR and the

replacement cost of the rejected insulation coating shall be borne by the VENDOR.

5.7

NON CONFORMANCE

Non-conformity reports shall be prepared and submitted in accordance with

VENDOR's QA/QC Plan. Non-conformity reports shall be provided to CLJOC's




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Representative for acceptance. Completed non-conformity reports shall be provided to

CLJOC as part of the permanent records. CLJOC reserves the right to disapprove non-

conformity reports and to require revised reports when the non-conformity was not

resolved by a method or procedure that was pre-approved by CLJOC. Common repair

procedures and potential applications shall be submitted to CLJOC for approval in

advance of their use.

6.0

COATING SYSTEM6.1 COATING SYSTEM

The coating must be able to withstand a maximum design temperature up to 120oC .

Insulation coating shall consists of three layers as follows:

1st layer: Epoxy;

2nd layer: Polyurethane foam (PUF);

3rd layer: PE top layer (HDPE).

Minimum total thickness and properties of the finished insulation coating system is

presented in Table 6.1 unless otherwise specified by CLJOC.

Table 6.1. Minimum Thickness of PU Foam Insulation Coating

Coating LayerU-value (0.27 btu/ft

2.hr.

oF)

Minimum Thickness, mm

1st layer Fusion Bonded Epoxy (FBE) 0.35

2nd layer Polyurethane Foam (PUF) 30

3rd layer Polyethylene (HDPE) 5

Total 35.35

7.0 COATING MATERIAL REQUIREMENT

7.1 GENERAL

VENDOR shall propose coating materials and Material Manufacturers for CLJOC

acceptance. Only CLJOC approved materials and Material Manufacturers shall be used.

Materials used for coating shall be clearly marked with the following details:

Name of Coating Manufacturer;

Material identification;




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Batch number;

Date of manufacture;

Quantity;

Manufacturing standard;

Shelf life;

Hazardous information.

Materials shall be handled and stored in accordance with applicable safety regulations

and the Material Manufacturer's recommendations, and shall be used according to the

Material Manufacturer's batch sequence.

All materials to be used on the project shall comply with Material Manufacturer ’s

specifications and shall be taken from new un-opened and undamaged containers and

shall be within Material Manufacturer ’s shelf life. VENDOR shall demonstrate

compliance with Material Manufacturer ’s specifications by testing if so requested by

CLJOC.

All material with damaged packaging, with an expired shelf life, without full

traceability or suspected of contamination / deterioration, shall be rejected and not

applied to the pipe.

7.2 PRIMER AND/OR FIRST COAT

If FBE is proposed as first coat the materials, application and quality requirements shall

be in accordance with NACE RP0394, approved VENDOR procedures and this

Specification.

Inspection and documentation of the FBE layer shall be completed in accordance with

NACE RP0394 prior to commencement of thermal insulation coating application.

The epoxy powder shall be selected only when the following minimum requirements

are satisfied.




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Table 7.1: Minimum Requiremments for Epoxy Material

Property Test Method Value Limits

Moisture content

(% mass)ISO 21809-1, Annex K ≤ 0.6

Thermal characteristic (oC) ISO 21809-1, Annex D≥ 95 oC and within

manufacturer’s specification

Gel time at

205 oC ±3 oCISO 21809-1, Annex J

Within 20% of the nominal

value specified by the

manufacturer

Density (g/cm3) ISO 21809-1, Annex N

Within ± 0.05 of the

manufacturer’s specified

nominal value

Particle sizeCAN/CSA Z245-20,

Clause 12.5

According to manufacturer ’s

specification

7.3 2nd LAYER

Polyurethane foam (PUF) is proposed as thermal insulation coating for pipeline. The

application, testing and quality requirements shall be in accordance with EN 253.

The polyurethane foam shall be selected only when the following minimum

requirements are satisfied.

Table 7.2: Minimum Requiremments for PUF


Core density BS EN489min. 200 kg/m3

max. 225 kg/m3

Compressive Strength ISO 844Min. 2.0 MPa at 10%

relative deformation

Water Absorption BS EN 489 Max. 10%

Ratio of open to closed

cells, min closed cell

content

EN253 Min 95%




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7.4 TOP LAYER

The requirements of PE shall be in accordance with ISO 21809-1.

The top coat polyethylene used shall be a black compound with carbon black content of

2.5 ± 0.5 % (mass fraction) as specified in ISO 4437. This can prevent influence of

ultraviolet radiation, oxygen in air and heat under the open sunlight. Moreover,

polyethylene layer maintains it flexibility and toughness over the design life time of the

project.

The PE material shall be selected only when the following minimum requirements are

satisfied.

Table 7.3: Minimum Requirements for PE


Density of the base resina ASTM D792

or ASTM D1505≥ 0.930 g/cm3

Elongation at break at 23°C ± 2°CISO 527-2

Or ISO 527-3≥ 600 %

Tensile yield strength at 23°C ± 2°Ca ISO 527-2 or

ISO 527-3≥ 15 MPa

Vicat softening temperature A/50

(9,8 N)ISO 306 ≥ 110°C

Water content ISO 15512 ≤ 0.05 %

Hardness (Shore D) ISO 868 ≥ 55

Environmental Stress Crack

Resistance (ESCR) (50ºC, F50, 10%

Igepal

CO630 or 100% Igepal CO630) b

ASTM D1693

≥ 1000 H cond. A

or ≥ 300 H cond. B

if

density > 0.955

g/cm3

Oxidation induction time (interceptin the tangent method)

ISO 11357

(all parts)

> 30 min at 210°C

or >10 min at

220°C




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UV resistance and thermal ageingISO 21809-1,

Annex GMFR < 35 %

Black carbon contentASTM D1603

or ISO 6964

2.5 ± 0.5 %

(mass fraction)

Note:

a 2 mm thick compression moulded sheet, specimen ISO 527-2, strained at 50

mm/min.

b In order to validate the ESCR values, data shall be provided by manufacturers as to

know the limit in density (MFR) to pass that requirement. This limit shall not be

wider than what is commonly known as fit for purpose PE grades for pipe coating.

8.0 MEASUREMENT AND LOGGING

All necessary information of line pipes, coating materials, coated pipes and qualitycontrol of them must be recorded.

The VENDOR shall submit the template and content for CLJOC’s approval. The

records must be traceable for further investigation.

9.0 SURFACE PREPARATION

9.1 PIPE SURFACE PREPARATION

9.1.1 Metal Surface

Before the surface preparation starts, each pipe shall be visually examined for dents,laps, defective bevels, and any other defects to identify defective pipes. Defective pipes

shall be removed from the coating line for repair or if repair is not possible, these pipes

may be rejected. Pipe surface is suitable for coating when:

Sharp edges, fillets, corners, and welds shall be rounded or smoothened by grinding.

Hard surface layers (e.g. resulting from flame cutting) shall be removed by grinding

prior to blast cleaning;

Residue, slivers, oil, grease, salt etc... shall be removed from the pipe prior to

coating per SSPC-SP1. All surfaces should be washed with clean fresh water prior to

blast cleaning;




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After cleaning and prior to grit blasting, the pipe shall be stored under cover and

kept warm and dry. The pipe shall be handled and transported in such a manner as to

ensure that no further contamination occurs.

All moisture shall be removed by preheating of pipe to between 40ºC and 85ºC. The

pipe and components shall then be maintained, until after coating, at a temperature at

least 3ºC above the ambient dewpoint temperature prior to entering the abrasive blast

cleaning unit(s). The ambient relative humidity should not exceed 85%. The pipesurface temperature shall be checked with a thermocouple or other approved methods.

Suitable temporary caps or coupling shall be applied to both pipe ends to prevent

abrasives and coating materials from damaging the bevels and entering the pipe during

coating process. These end caps shall be removed on completion of the coating process.

9.1.2 Abrasive Blast Cleaning

The abrasives used in the coating plant shall be in accordance with the requirements of

ISO 11124 (all parts). The abrasives shall be maintained clean, dry and free from

contaminants in accordance with SSPC-AB1, SSPC-AB2 and SSPC-AB3 or ASTM

D4940 so as not to contaminate the substrate. Expendable abrasives shall not be

recycled.

The cleanliness achieved prior to application shall be in accordance with the

requirements of ISO 8501-1, grade Sa 2½ “near white metal”.

The surface profile attained shall be within the range 50 μm to 100 μm. The surface

profile, peak to trough height, shall be measured in accordance with the requirements of

ISO 8503-4 (Stylus) or ISO 8503-5 (Replica Tape).

If grinding is required after blast cleaning, the maximum allowable area of grindingshall be 10 cm² per 1 m pipe length. In case of any excessive grinding, the remaining

wall thickness shall be measured by ultrasonic inspection and shall not be less than the

specified minimum wall thickness. The ground area shall merge smoothly with the

surrounding pipe surface.

9.1.3 Inspection of Surface Cleanliness

Each pipe shall be inspected for surface cleanliness. Pipes that do not comply with the

requirements shall be rejected and cleaned again.

The surface profile shall be measured at regular intervals. If the surface profile isoutside the specified limits, the blasting material shall be checked and replaced if

necessary. The affected pipes shall be re-blasted.




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The surface finish after blast cleaning shall be inspected with the following

International Standards:

Surface cleanliness shall be determined by means of ISO 8501-1;

Dust levels shall be determined by means of ISO 8502-3, the maximum allowable

level shall be Class 2;

Surface profile measured from peak to trough shall be determined by means of ISO

8503-4 & ISO 8503-5. If the measured value is not in this allowed range, that pipe

shall be rejected and blasted again;

The soluble salts content shall not exceed 20mg/m². At regular intervals, once per

shift, the blasted surface shall be checked for residual chloride contamination.

CLJOC shall have the final approval on the disposition of the pipe, whether or not to

release the pipe for coating or to return the pipe for re-cleaning or to reject the pipe

for excessive surface defects.

9.1.4

Acid WashPhosphoric acid wash and rinse may be used for further surface cleaning, etching, and

removal of soluble salts. Phosphoric acid shall be mixed with deionized or reverse

osmosis water according to the manufacturer’s recommendations. Deionized or reverse

osmosis water shall be used for the mixture and for rinsing the pipe after the wash. The

phosphoric acid wash shall be applied after the blast and before the heating process.

After the appropriate surface cleanliness has been achieved in accordance with ISO

8501-1, the pipe shall be acid washed in accordance with the following procedure or

alternative procedure proposed by VENDOR and approved by CLJOC:

Application of the phosphoric acid mixture shall be at the rate and percent

recommended by the phosphoric acid supplier, unless otherwise approved by

CLJOC. A uniform pH of 1 or less shall be maintained on the pipe for a minimum

of 20 seconds between 15oC to 65oC. This pH shall be checked a minimum of every

2 hours during production. The mixture shall be rinsed from the pipe surface with a

high-pressure rinse system. The high-pressure rinse shall have a minimum tip

pressure of 220 kPa (1,500 psi);

The wetted surface of the rinsed pipe shall have a pH of 6 (minimum) to 7.5

(maximum). All rinse water shall be removed and the surface shall be dried by a

high pressure air knife.




WEST PROJECT (SVSW)

EPCI FOR WHP-SVSW,

PIPELINES AND CPP

MODIFICATIONS


INSULATION COATING

Document No.: 2013-6031-2L-0010

Revision: A

Page:21 of 42

9.2 SURFACE PREPARATION OF FBE COATED PIPES

All pipes shall be received at the PUF coating plant incoming rack. The pipe number

and heat number and length shall be recorded and verified against client tally list. The

individual pipe number shall be transferred to the internal pipe surface by use of white

paint marker.

Each pipe shall be prepared for PUF coating by first drying the FBE coated pipe

surface using dry cloths and any contamination identified shall be removed by proprietary solvent washing in accordance with SSPC-SP-1. Where excessive

contamination is present, pipe shall be removed from the system, quarantined and

brought to the attention of the CLJOC Site Representative for clarification and

agreement of further action to be taken.

Pipes are then passed onto the holiday inspection station where each pipe shall be 100%

holiday detected in-line for coating defects. All coating defects shall be marked using a

grease free marker pen. Pipe requiring repairs shall be conveyed to a holding rack for

repair and re-holiday inspection.

9.3 SURFACE PREPARATION OF PUF COATED PIPES

All pipes shall be received at the HDPE coating plant incoming rack. The pipe number

and heat number and length shall be recorded and verified against client tally list. The

individual pipe number shall be transferred to the internal pipe surface by use of white

paint marker.

Each pipe shall be prepared for HDPE coating by first drying the PUF coated pipe

surface using dry cloths and any contamination identified shall be removed by

proprietary solvent washing in accordance with SSPC-SP-1. Where excessive

contamination is present, pipe shall be removed from the system, quarantined and

brought to the attention of the CLJOC Site Representative for clarification and

agreement of further action to be taken.

Inspection PUF surface to ensure no crack, disbonding, no contamination and no

defect.

9.4 MOULD PREPARATION FOR PUF COATING

The internal surface of the mould shall be cleaned by using a compressed air to blow

out any debris, dust or residual coating matter.

The mould shall then, be washed by using a cotton cloth saturated with a cleaning agent

for removing traces of PUF coating.




WEST PROJECT (SVSW)

EPCI FOR WHP-SVSW,

PIPELINES AND CPP

MODIFICATIONS


INSULATION COATING

Document No.: 2013-6031-2L-0010

Revision: A

Page:22 of 42

The end rings used to mould the cutback must be coated with an appropriate mould

release agent.

10.0 COATING APPLICATION

The coating shall be applied in accordance with the Application Proceduce

Specification (APS). The external surface of the cleaned pipe conforming to Section 9

of this specification shall be coated within 4 hours if the relative humidity is below

80% or within 1 hour if the relative humidity is 80% or greater. No detectableoxidation, dust accumulation, or other contaminants shall be on the pipe surface. Pipes

delayed beyond this period, or pipes showing any visible rust stains, shall be blast-

cleaned again, while maintaining the minimum specified wall thickness requirement.

Extruded PE top coat shall be applied within the time limit established during PQT

stage and within the time/temperature range recommended by the manufacturer. During

coating, the bevelled ends of the pipes and the pipe bore shall be protected against

mechanical damage and against contamination with coating material. Immediately after

all coating is completed, the pipe identification marks shall be re-applied to the coated

pipe using a method reviewed by CLJOC. Additional identification shall be applied asrequired to monitor the coating and test batches. Uncoated pipe ends shall receive a

temporary protective coating for transit. Non-conforming pipe shall be recoated. In

general the procedure shall be as follows:

10.1 PIPE HEATING

The pipe to be coated shall be heated over its entire length by electrical induction. Oil-

fired pre-heating is not acceptable. Appropriate induction heating frequency shall be

used to ensure “deep” heating.

The surface to be coated shall be heated over its entire length to a temperature

between 225oC and 240oC or as specified by the powder manufacturer. The

temperature range depends on factory Application Procedure Specification (APS).

The heating temperature shall, in no case, exceed 275oC (527oF). Any pipe which is

heated to above 275oC (527oF) shall be replaced at VENDOR’s expense. The heat

source shall not leave a residual or contaminant on the pipe surface;

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 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;




WEST PROJECT (SVSW)

EPCI FOR WHP-SVSW,

PIPELINES AND CPP

MODIFICATIONS


INSULATION COATING

Document No.: 2013-6031-2L-0010

Revision: A

Page:23 of 42

Any deviation from the application temperature range recommended by

manufacturer shall be rectified. If immediate rectification is not feasible, the

production shall be stopped until cause of deviation has been removed. Any pipe

coated in the duration of temperature deviation shall be identified by marking and

rejected. Such rejected pipes shall be stripped, re-cleaned and recoated;

Throughout production, the coating temperature shall be continuously monitored and

recorded once every half hour. Monitoring equipment shall be calibrated twice everyshift unless otherwise agreed by CLJOC.

10.2 EPOXY APPLICATION

The elapsed time between surface preparation by abrasive blasting, cleaning and

coating application shall be adequate to avoid oxidation or contamination of the pipe

surface (This time shall be less than 4 hours).

The pipe temperature during surface preparation and coating application shall be in

accordance with the requirements presented in Table 11.1. The thickness of the epoxy

layer and all other requirements are shown in Table 6.1.

10.3 PUF APPLICATION

10.3.1 Pre-Mixing of Polyol and Transfer to Conditioning Tank

The Polyol contains polymeric microspheres which may separate and float to the top of

the Polyol: These microspheres should be re-distributed in the Polyol by thorough

mixing by drum rolling, or in more severe cases of separation a power mixer.

Each container when opened for use shall be thoroughly mixed before use by means of

mechanical drum roller or power mixer for at least 10 minutes. Mixed Polyol shall be

discharged within 120 minutes of mixing.When mixed, the Polyol has a high viscosity.

Due to this, when processing on the dispensing machine, care should be taken to ensure

that the metering pump has adequate feed. The feed line from the Polyol tank to the

metering pump should be of sufficient diameter and as short as possible (e.g. 25 mm

diameter, 0.5 metre long). The Polyol tank should be pressurised sufficiently to give

sufficient feed (e.g. 4 Bar).

To keep the Polyol dispense line pressure low, the dispense line between the metering

pump and the mixing head should be of sufficient diameter, and as short as feasible

(e.g. 15-20 mm diameter and 3 metres long).

Checks shall be done to ensure the feed is adequate:

A pressure gauge at the metering pump inlet;




WEST PROJECT (SVSW)

EPCI FOR WHP-SVSW,

PIPELINES AND CPP

MODIFICATIONS


INSULATION COATING

Document No.: 2013-6031-2L-0010

Revision: A

Page:24 of 42

Checking feed rate at pump inlet (i.e. ensuring flow into pump from tank exceeds the

required output from the pump);

Ratio check (if ratio of Polyol: Isocyanate varies with increasing/decreasing machine

output, then feed may be deficient and require further adjustment).

10.3.2 Discharge of Isocyanate

To avoid contact or exposure to moisture each container when opened for use shall be

discharged immediately after opening into the conditioning tank.

10.3.3 Mixing and Pumping of PUF

The compressibility of the Polyol means attention must be paid to certain areas of

processing. In particular, care must be taken that the system is stable with regard to

flow rates, pressures, and temperatures before ratio checking and dispensing. As a

guide, material processing temperatures should be in the range of 20-35°C. As per

manufacturer's recommendation, the optimum temperature shall be automatic control

by mixing Machine on site.

10.3.4 PUF Coating Application

The pipes shall be lifted to the coating preparation area where two spacers

manufactured from the same material as the PUF coating shall be installed along the

length of the pipe.

Prior to application of the foam insulation, the coated pipe shall be preheated to a

temperature at least 3°C above dew point, but less than 80°C. The pipe shall then be

placed into the mould (concentricity shall be maintained by each end ring and by

utilizing sufficient PUF spacers located along the pipe.

The PUF components are machine mixed to the required ratio, and then injected into

the "port". During the injection period, the pipe and mould shall be inclined at an angle

of 20° ±10° to the horizontal.

After the injection process, the pipe shall be left at an incline to allow for initial coating

cure of approximately 20 minutes prior to removal.

The pipe is then re-moulded and transferred to a holding area where the pipe shall be

supported on padded supports to prevent damage to the coating. On completion of the

coating cure, the pipe shall be subjected to Quality Control testing as detailed in the

Inspection & Testing Final work after foaming process.

When hardening time is over the foamed steel pipe is taken out of the mould;




WEST PROJECT (SVSW)

EPCI FOR WHP-SVSW,

PIPELINES AND CPP

MODIFICATIONS


INSULATION COATING

Document No.: 2013-6031-2L-0010

Revision: A

Page:25 of 42

Dismounting sealing gaskets and flanges at the ends of steel pipe;

Cutting off the edges of PE foil;

Grinding sharp foam edges on foamed pipe;

Visual Control of foam surface, if there are holes and bubbles at the foam surface,

they must be filled with free rise foam according to procedure, excess material to be

removed for a flush finish. Register on report.

10.4 HDPE APPLICATION

10.4.1 Water Stop Application

Before processing to HDPE coating PUF pipe shall be apply with Water Stop Tape at

two ends FBE toe. FBE surface shall be dry and clean to make sure stop tape tight and

adhesive.

10.4.2 HDPE Application

The HDPE layer shall be applied using an appropriately designed extruder to melt and

extrude the polypropylene in a flat film which is then wrapped around the pipe in aspiral overlapping fashion. It is rolled on to the pipe surface to ensure no air is trapped

under this layer. The operating parameter of the HDPE extruder will be maintained

within the range recommended by the HDPE manufacturer's data.

The minimum thickness of HDPE coating system shall be 5 mm.

10.4.3 Sinter Coat / Rough Coat (FOR CWC COATED PIPES ONLY)

Additional 'sinter powder coat' shall be spray applied onto coated surface immediately

after top coat application. Sinter coatings shall be applied to produce a rough coating

surface to enhance shear resistance for concrete coatings and surface anti-slip properties.

10.4.4 Water Quench, Cooling and Inspection Racks

Coated pipe shall then be conveyed and pass through the water quench tunnel. The

quenching water is flow back from the quench tunnel to the cooling towers. The hot

return water is pumped through the cooling tower and fed into the cold water sump.

From there the water is pumped to the quench tunnel. The pipe is cooled by a drenching

flood of water on the external surface. After quenching pipe temperature shall not

exceed 60°C.

As coated pipe exits the quenching tunnel, the lifting arm buggy raise the pipe onto the

inspection station racks, which are configured with automated pipe indexes.




WEST PROJECT (SVSW)

EPCI FOR WHP-SVSW,

PIPELINES AND CPP

MODIFICATIONS


INSULATION COATING

Document No.: 2013-6031-2L-0010

Revision: A

Page:26 of 42

On the inspection rack, pipe coupling is removed from the coated pipe and cutback

paper removal for FBE (without insulation) is done prior to cutback cleaning. 100%

visual appearance check on every pipe is done at frequency mentioned in Table 11.1.

10.5 TYPICAL CUTBACK

The cut-back length for the insulation coating shall be 370mm (±10mm) from the ends

of the pipe. The cut-back end preparation should include 30° - 45° taper. The cutback

length shall be free of any coating materials (including FBE tails) and / or contaminantsdetrimental to the welding, NDT and field joint coating operations. The insulation

coating cutback shall leave a minimum 100mm visible ring of FBE first coat.

Figure 10.1 Typical Cutback of 10.75-Inch Production Pipeline

Bare pipe ends shall be protected from corrosion for a period of up to 1 year. Corrosion protection shall be provided by fast drying steel primer such as red oxide alkyd to be

approved by CLJOC.



STVEXTENSION – STV SOUTH WEST PROJECT (SVSW)


SPECIFICATION FOR POLYURETHANE INSULATION COATING

Document No.: 2013-6031-2L-0010

Revision: A

Page:27 of 42

11.0 INSPECTION AND TESTING

Table 11.1. Inspection and Testing Plan for Insulation Coating

Process Description Frequency Requirements Approval

Inspection

1.Material

Receipt

1.1. Isocyanate

Data from

Manufacturer

Every Batch -Verify colour/appearance: Homogeneous mix and uniform brown colour.

-Verify against PO & Certification and ensure materials are supplied in sealed,

damage free, clearly marked containers.

-Isocyanate tank shall be storage under cover shade or in the warehouse.

V.R.M

1.2. Polyol

Data from

Manufacturer

Every Batch -Verify colour/appearance: Homogeneous mix and uniform yellow colour

-Verify against PO & Certification and ensure materials are supplied in sealed,

damage free, clearly marked containers.

-Polyol tank shall be storage under cover shade or in the warehouse.

V.R.M

1.3. HDPE

Data from

Manufacturer

Every Batch Perform Melt Flow Index Test, Packaging Secure, Marking Legible H.T.C






Document No.: 2013-6031-2L-0010

Revision: A

Page:28 of 42

Process

/Location

Description Test Freq.

(PQT)

Test Freq.

(Production)

Test Method Acceptance Criteria Approval

Inspection

2. Surface

Preparation

of Pipe

2.1. Temperature and

Air Humidity (Ambient

Conditions)

All PQT

pipes

Every 4 h - 3oC above Dew point.

Max. 85% relative humidity.

2.2. Visual Inspection

of Blasted Surface

All PQT

pipes

All pipes ISO 8501- 1 Grade Sa 2 ½.

2.3. Water-soluble

Contamination of

Abrasives

All PQT

pipes

All pipes ASTM D4940 Conductivity max. 60.

2.4. Surface Roughness All PQT

pipes

Every 1 h ISO 8503 - 4

ISOI 8503 - 5

50 to 100 μm (measured from peak

to trough).

2.5. Presence of Dust

after Dust Removal

All PQT

pipes

Every 1 h ISO 8502 - 3 Rating max. 2.

2.6. Salt Contamination

Test

All PQT

pipes

Every 4h for

each pipe.

Testing before

and after blast

ISO 8502 - 6 20 mg/m2 or less. Phosphoric acid

washing and new abrasive required if

level exceeded.






Document No.: 2013-6031-2L-0010

Revision: A

Page:29 of 42

Process

/Location


(PQT)

Test Freq.

(Production)


Inspection

cleaning on

same pipe.

2.7. Phosphoric Acid

Wash

All PQT

pipes

Once per hour Measure coverage,

dwell time,

temperature, and

solution pH.

100% coverage, pH 6 to 7.5 at rinse

of the wet pipe.

3. FBE

Application

3.1. Material

Temperature Prior to

Application

PQT batch Each batch Check temperature of

materials prior to

application.

As a guide, material processing

temperatures should be in the range

of 25-35°C. As per manufacturer

recommendation, the optimum

temperature shall be established

experimentally on site.

M,C

4. FBE

Inspection

4.1. Minimum FBE

Thickness

All PQT

pipes

All pipes ISO 2808 or ASTM

D4138

0.35 mm

4.2. Degree of Cure All PQT

pipes

All pipes Differential scanning

calorimetry analysis

of sample taken from

Tg2 - Tg1 shall be between -2°C to

+3°C to ensure coating is fully cured.






Document No.: 2013-6031-2L-0010

Revision: A

Page:30 of 42

Process

/Location


(PQT)

Test Freq.

(Production)


Inspection

pipe. MEK Rubs Test

shall be performed.

4.3. Cathodic

Disbondment

All PQT

pipes

All pipes ASTM G42 or

CAN/CSA- Z245.201

- M92

0.20 inch (5 mm) radius from edge

of / inch (12.7 mm) diameter hole in

48 hours at 194°F (90°C).

5. PUF

Incoming

Rack

5.1.Visual Inspection

FBE Surface

All PQT

pipes

All pipes Visual Contamination & defect Free. All

damaged areas shall be repaired as

per the coating MPP.

V,M,C

5.2.Verify Pipe Identity All PQT

pipes

All pipes Visual Confirm Pipe No., Heat No., &

Length is still legible. Reinstate

internal stencil where necessary.

V.M

5.3.Holiday Detection All PQT

pipes

All pipes Holiday detection

shall be carried out

with a full contact

electrode at the travel

speed equal to 300

mm/s at 1.5 KV.

No Holiday.

The entire external surface of the

FBE coating shall be holiday

detected and any holidays detected

shall be marked up for repair using a

non- grease marker pen and repair as

V.M.C






Document No.: 2013-6031-2L-0010

Revision: A

Page:31 of 42

Process

/Location


(PQT)

Test Freq.

(Production)


Inspection

per FBE Repair Procedure.

6. PUF

Application

6.1. Material

Temperature Prior to

Application

PQT batch Each batch Check temperature of

materials prior to

application.

As a guide, material processing

temperatures should be in the range

of 25-35°C. As per manufacturer

recommendation, the optimum

temperature shall be established

experimentally on site.

M,C

6.2 Polyol Mixing Each

container

when

opened for

use

Each container

when opened for

use

Record time opened,

time finished mixing.

Mix thoroughly prior to use for at

least 10 minutes using a drum

tumbler or other mechanical means.

M,C


of the Mould Prior

Loading the Pipe

All PQT

pipes

All pipes Visually Mould shall be dry, clean and free

from damage. Mould shall be

inclined at an angle of 20° ± 10° to

the horizontal.

V,M

6.4. Surface All PQT All pipes Measuring Prior to application of the foam N,M,C






Document No.: 2013-6031-2L-0010

Revision: A

Page:32 of 42

Process

/Location


(PQT)

Test Freq.

(Production)


Inspection

Temperature of Steel

Pipes and Casing Pipes

pipes insulation, the coated pipe shall be

preheated to a temperature at least 3

°C above dew point, but less than 80

°C.

6.5. Injection Time and

Moulding Time

All PQT

pipes

All pipes Check the elapsed

time of pipe left in the

moulding prior to

removal.

Coated pipe shall be left in the mould

approximately 20 minutes prior to

removal.

N,M,C

7. PUF

Inspection


for PUF Coated Pipe

All PQT

pipes

All pipes Visual No disbondment from the pipe,

crack, tear or buckle.

V,M,C

7.2. PU Foam

Thickness

Measurement

All PQT pipes

All pipes Using PI tape tomeasure at 3 locations

along the pipe length

(Convert PI reading to

thickness).

Min. 30 mm PUF thickness D,N,C

7.3. Cut-backs PU

Foam

All PQT

pipes

All pipes Measuring As per project specification. D,N,C






Document No.: 2013-6031-2L-0010

Revision: A

Page:33 of 42

Process

/Location


(PQT)

Test Freq.

(Production)


Inspection

7.4. Sounding Test All PQT

pipes

All pipes Every 300 mm with a 1kg hammer.

7.5. Thermal

Conductivity

All PQT

pipes

All pipes 50oC

7.6. Core density All PQT

pipes

All pipes BS EN489 Min. 200kg/m3 / Max. 225kg/m3

7.7. Compressive

Strength

All PQT

pipes

All pipes ISO 844 Min. 2.0 MPa at 10% relative

deformation.

7.8. Water Absorption All PQT

pipes

All pipes BS EN 489 Max. 10%

7.9. Ratio of open to

closed cells, min closed

cell content

All PQT

pipes

All pipes BS EN253 Min. 95%

8. HDPE

Application


PUF Coated Pipes

All PQT

pipes

All pipes Visual No disbondment from the pipe,

crack, tear or buckle.

V,M

8.2. CMB Insulation All PQT All pipes at both Visual FBE surface at apply location shall V,M






Document No.: 2013-6031-2L-0010

Revision: A

Page:34 of 42

Process

/Location


(PQT)

Test Freq.

(Production)


Inspection

Tape Application pipes ends be dry and clean.

9. HDPE

Inspection


Coated Pipes

All PQT

pipes

All pipes Visual Free from blisters, pinholes,

scratches or any other irregularities

and shall have a uniform colour and

gloss.

V,M

9.2. Temperature after

Quenching

All PQT

pipes

All pipes Digital thermometer

gauge

(with surface probe).

Pipe cool enough safety handled

without causing damage coating (<

60°C).

M,C

9.3. HDPE

Thickness

Measurement

All PQT

pipes

All pipes Using PI tape to

measure at 6 locations

along the pipe length

(Convert PI reading to

thickness).

The minimum thickness of the

protective polyethylene layer shall be

5.0 mm.

D,N,C

9.4. Cut-backs HDPE All PQT

pipes

All pipes Measuring As per project specification. D,N,C

9.5. Tensile All PQT

pipes

All pipes BS EN 253 Min. 15N/mm2






Document No.: 2013-6031-2L-0010

Revision: A

Page:35 of 42

Process

/Location


(PQT)

Test Freq.

(Production)


Inspection

9.6. Elongation All PQT

pipes

All pipes EN 253 350% at 23oC

9.7. Shear All PQT

pipes

All pipes Min. 0.2 N/mm2 for 28 days

9.8. Hardness All PQT

pipes

All pipes ISO 868 or ASTM

D2240

>55 Shore D

9.9. Adhesion between

PUF and FBE

All PQT

pipes

All pipes Measuring 48 hours after PUF coating, select a

PUF area 150mm x 150mm, using

chisel, knife cut of PUF around until

FBE surface and leave a cube shape

test specimen has the dimension:

50mm x50mm x PUF thickness.

Using a mallet to knock the cube

until it comes off. The test fails if

PUF come of clean (no adhesive

residue on FBE surface).

10. Repairs 10.1. Repairs FBE, PUF All Repairs All Repairs According to Coating According to repair procedure of M,C






Document No.: 2013-6031-2L-0010

Revision: A

Page:36 of 42

Process

/Location


(PQT)

Test Freq.

(Production)


Inspection

and HDPE applicator/operator

Repair Procedure.

manufacturer and coating contractor.

11. Field

Tests

11.1. Adhesion between

FBE and PUF

1 pipe 2 test pipe per

shift

Visual examination

after peeling back

PUF layer from FBE

layer.

The test failed if PUF come-of clean

(No adhesive residue on FBE

surface).

H,T,M,C

11.2. PUF Sounding

Test

1 pipe All Pipes The coating shall be

sounded over its entire

length and along four

different planes, every

300 mm with 1 kg

hammer.

Any marked difference in audible

pitch shall be note.

H,T,M,C

11.3. Shore D Hardness

of HDPE

1 pipe All Pipes Shore D meter ASTM

D2240

Min. 55 Shore D

11.4. Shear Test 1 pipe N/A According to Coating

applicator/operator

Minimum required shear strength 0.2

N/mm2.

12. 12.1. Core Density of 1 pipe 2 test pipe per BS EN 489 The density of the foam shall be a H,T,M ,C






Document No.: 2013-6031-2L-0010

Revision: A

Page:37 of 42

Process

/Location


(PQT)

Test Freq.

(Production)


Inspection

Laboratory

Test

PUF shift minimum of 200 kg/m and a

maximum of 225 kg/m3.

12.2. Water Absorption

of PUF


shift

BS EN 489 Max 10% H,T,M,C

12.3. Compressive

Strength of PUF


shift

According to ISO 844 The compressive strength at 10%

relative deformation shall be min. 2.0

MPa in radial direction.

H,T,M,C

12.4. Polyethylene

Tensile

1 pipe One per batch

PE

BS EN 253 The minimum tensile strength shall

be 15N/mm2 at 23 °C.

H,T,M,C

12.5. Polyethylene

Elongation

1 pipe One per batch

PE

BS EN 253 Elongation at break min 350% at

23°C.

H,T,M ,C

12.6. Melt Flow Index

Test

PQT batch One per batch

PE

BS EN 253 As per manufacture datasheet. H,T,M,C

13.

Laboratory

Test

13.1. Thermal

Conductivity of PUF


Production

3rd Party Testing accordance with ASTM

C518.

The thermal conductivity shall be

R






Document No.: 2013-6031-2L-0010

Revision: A

Page:38 of 42

Process

/Location


(PQT)

Test Freq.

(Production)


Inspection

(3rd Party)within the specified Coating Supplier

range for the material with a mean

sample temperature of 50° C and

satisfy the requirement of 0.27

btu/ft2.hr.oF.

14.

Calibration

14.1. Holiday

Detection equipment

At start of

the PQT

At start of shift Crest Voltmeter Adjustable to ± 5% of Target Value. M,C

Legend C Record & Raise Document N Non-Destructive Testing M Monitor

D Dimensional Inspection R Review T Destrutive Testing

H Hold Point V Visual Inspection

I Random Inspection W Witness




WEST PROJECT (SVSW)

EPCI FOR WHP-SVSW,

PIPELINES AND CPP

MODIFICATIONS


INSULATION COATING

Document No.: 2013-6031-2L-0010

Revision: A

Page:39 of 42

12.0 PIPE MARKING

The marking to be applied on the pipes shall be agreed between VENDOR and CLJOC.

Unless otherwise agreed the marking shall be applied on the pipes as stated below.

VENDOR shall plan his works in the best manner with the aim to preserve the marking

already made by the pipes' manufacturer. In case the marking made by the pipes'

manufacturer is not visible any more or it is covered by coating material, VENDOR

shall apply a new marking for compliance with the specified requirements.

Marking shall be applied on the pipe coating using suitable paint or stencil in a

contrasting colour to the pipe coating, suitable for subsea use. The paint/stencil shall be

weatherproof and waterproof and shall be compatible with the insulation coating.

Marking shall not be applied on the coating within the first 500 mm from the pipe end.

The following shall be marked on the pipe's coating at one pipe end with exception of

the pipe number which shall be marked on both pipe ends:

Project name;

Pipe manufacturer;

Coating applicator;

Pipe material;

Pipe nominal external diameter * pipe nominal wall thickness;

Pipe number (to be applied on both sides);

Pipe heat number;

Pipe length;

Pipe weight.

The letters shall have a minimum height of 50mm.

13.0 STORAGE, HANDLING AND TRANSPORTATION

VENDOR shall take receipt of the pipes delivered by the pipe supplier and shall keep a

record of the serial numbers of the delivered pipes. Upon receipt, the pipes shall be

inspected for transport damage or other defects. Damaged pipes shall be separately

stored and reported to CLJOC. Repairs shall only be carried out with CLJOC

permission.




WEST PROJECT (SVSW)

EPCI FOR WHP-SVSW,

PIPELINES AND CPP

MODIFICATIONS


INSULATION COATING

Document No.: 2013-6031-2L-0010

Revision: A

Page:40 of 42

Coated pipes shall be handled, stored and transported in accordance with specification

for transportation, handling and storage of pipeline material, Doc. No: 2013-6031-2L-

0008 and in a manner that the pipe steel and pipe coating shall not be damaged.

Depending on the mean of the transport, the transport shall be performed in accordance

with the standards API 5L1 and API 5LW.

All foreign substances such as excessive dirt, debris of coating materials or any other

foreign objects shall be removed from internal pipe surface before stacking and loadout.

Coated pipes can be handled using slings, lifting hooks padded with soft material with

suitable spreader bars, forklifts having lifting forks padded with soft material, front

loaders padded with soft material and vacuum lifting. Chains or wire ropes or any other

device that may damage the pipe steel or pipe coating shall not be used.

When more than one pipe is lifted, separate slings or hooks shall be used for each pipe.

Pipes shall be picked up from the stacking point and at no time shall be dragged or

rolled. Coated line pipe shall not be subjected to jar or impact and all pipe supportsshall be padded. Pipe supports shall be spaced to avoid bending of line pipes.

Coated line pipes shall always be stacked to avoid surface contact with the ground. The

pipes shall be stacked on approved supports which shall be free of any material that

could potentially damage the applied coating.

Supports shall be padded and spaced along the pipe at distances which avoid pipe

bending. They shall be free of any material potentially dangerous for the pipe coating

(stones, nails, sharp edged materials etc.)

The stacking height of line pipes shall be limited to avoid damage of the coated line pipes due to the weight of other ones. The maximum number of stacking layers for the

coated line pipes shall be calculated by VENDOR and relevant calculation showing

calculation steps and results shall be submitted to CLJOC for review and approval

however, for safety reasons the maximum height of any stack shall be 3 m. In case

VENDOR does not provide any calculation note related to stacking of coated pipes

acceptable for CLJOC, the coated pipes shall be stacked in maximum 6 rows.

The stacks of coated pipes shall be separated for each of the following combinations:

pipe nominal external diameter x pipe nominal wall thickness type of applied coating.

Coated pipes shall be stacked at a slight angle to allow drainage of any rainwater.




WEST PROJECT (SVSW)

EPCI FOR WHP-SVSW,

PIPELINES AND CPP

MODIFICATIONS


INSULATION COATING

Document No.: 2013-6031-2L-0010

Revision: A

Page:41 of 42

Coated pipes shall not be stacked below and near electrical lines or near any facility

which may increase residual magnetism in the pipes (at all times it shall be kept the

minimum distance of 30 m between the stored pipes and any electrical cable measured

from the vertical projection to the ground of the nearest electrical cable).

After completion of coating works, plastic caps shall be reinstalled on coated pipes

before their delivery (if application of plastic caps is required by CLJOC).

14.0 DOCUMENTATION

14.1 GENERAL

VENDOR shall furnish all documentation in the English Language.

VENDOR shall prepare an inspection and test plan which clearly details each activity,

the test method, inspection frequency, acceptance criteria, relevant document & report

form and intervention points.

Procedures shall be designed to ensure full traceability of pipe and coating materials

through all stages of preparation, coating and testing.

Procedures and inspection and test plans shall be subject to review and approval by

CLJOC.

All VENDOR's documentation of any nature shall clearly reference the Contract

Number together with component or material batch identification as appropriate.

VENDOR shall maintain complete and accurate records of the work performed. These

records shall be kept safe in a single location at VENDOR's site and shall be accessible

to CLJOC at all times. One copy of the VENDOR's daily records shall be handed to

CLJOC s Site Representative by the end of the working day upon which the work is

performed.

On a daily basis, the following information shall be maintained for each insulated pipe

and provided to CLJOC:

Date of insulation application;

Inner and outer pipe diameter, wall thickness, length, material grade and pipe

numbers;

Total length of all pipe coated today and to date;

Total number of pipe lengths sent for repair today and to date; and

Nature of insulation defects.




WEST PROJECT (SVSW)

EPCI FOR WHP-SVSW,

PIPELINES AND CPP

MODIFICATIONS


INSULATION COATING

Document No.: 2013-6031-2L-0010

Revision: A

Page:42 of 42

All records shall be fully identified with the pipe or materials they represent. All

records shall be available for COMPANY examination at the time and place of

inspection, whether at the point of manufacture or CONTRACTOR’s location. These

records shall be kept for 5 years after the insulation application.

14.2 REPORT DOCUMENT

Documentation submissions shall be in English language and in accordance with the

requirements of tender documents. All documentation required by prior sections of thisspecification shall be submitted. Documentation to be included in a final data book

shall include the following:

Thermal design report;

Material data sheets;

Historic data;

Approved procedures;

Approved inspection and test plan (signed and stamped by VENDOR's and CLJOC's authorised QC personnel/inspectors);

PQT or PQT test report;

Daily production report;

Inspection reports;

Repair records;

Non conformance reports;

Deviations and concessions.

Documents

2013-6031-2L-0010-Specification for Polyurethane Insulation Coating_Re IDC