Dep 30.48.40.31-Genthermal Spray Coatings of Aluminium

DEP SPECIFICATION

THERMAL SPRAY COATINGS OF ALUMINIUM

DEP 30.48.40.31-Gen.

February 2012

DESIGN AND ENGINEERING PRACTICE

2012 Shell Group of companies All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior

written permission of the copyright owner or Shell Global Solutions International BV.

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This document has been supplied under license by Shell to:Siemens AG [email protected] 29/04/2013 07:37:25

DEP 30.48.40.31-Gen. February 2012

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PREFACE

DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions International B.V. (Shell GSI) and, in some cases, of other Shell Companies.

These views are based on the experience acquired during involvement with the design, construction, operation and maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international, regional, national and industry standards.

The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help achieve maximum technical and economic benefit from standardization.

The information set forth in these publications is provided to Shell companies for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the information set forth in DEPs to their own environment and requirements.

When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the quality of their work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will typically expect them to follow those design and engineering practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal.

The right to obtain and to use DEPs is restricted, and is granted by Shell GSI (and in some cases by other Shell Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three categories of users of DEPs can be distinguished:

1) Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.

2) Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of a Service Agreement or otherwise).

3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these companies, that may issue DEPs or advise or require the use of DEPs.

Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement.

All administrative queries should be directed to the DEP Administrator in Shell GSI.



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TABLE OF CONTENTS

1. INTRODUCTION ........................................................................................................5 1.1 SCOPE........................................................................................................................5 1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS .........5 1.3 DEFINITIONS .............................................................................................................6 1.4 CROSS-REFERENCES .............................................................................................7 1.5 SUMMARY OF MAIN CHANGES...............................................................................7 1.6 COMMENTS ON THIS DEP.......................................................................................7 1.7 DUAL UNITS...............................................................................................................7 2. GENERAL REQUIREMENTS ....................................................................................8 2.1 GENERAL...................................................................................................................8 2.2 DOCUMENT HIERARCHY.........................................................................................8 2.3 SAFETY ......................................................................................................................8 2.4 COMPANY ACCESS................................................................................................10 2.5 PRE-JOB MEETING.................................................................................................10 3. MATERIALS .............................................................................................................11 3.1 BACKGROUND ........................................................................................................11 3.2 THERMAL SPRAY COATING ..................................................................................11 3.3 SEALER....................................................................................................................11 3.4 TOP COAT................................................................................................................11 4. SURFACE PREPARATION .....................................................................................12 4.1 GENERAL.................................................................................................................12 4.2 CLEANING................................................................................................................12 4.3 ABRASIVE BLAST CLEANING ................................................................................12 5. COATING APPLICATION........................................................................................15 5.1 GENERAL.................................................................................................................15 5.2 EQUIPMENT.............................................................................................................15 5.3 ACCESS ...................................................................................................................15 5.4 HOLDING PERIOD...................................................................................................15 5.5 MASKING..................................................................................................................15 5.6 THERMAL SPRAYING .............................................................................................16 5.7 COATING THICKNESS............................................................................................16 6. QUALIFICATION......................................................................................................18 6.1 GENERAL.................................................................................................................18 6.2 TSA-VENDOR QUALIFICATION..............................................................................18 6.3 THERMAL SPRAYER QUALIFICATION..................................................................19 6.4 QUALIFICATION TESTS..........................................................................................19 6.5 SUMMARY OF QUALIFICATION TESTS AND ACCEPTANCE CRITERIA............20 7. QUALITY ASSURANCE AND CONTROL...............................................................21 7.1 GENERAL.................................................................................................................21 7.2 RESPONSIBILITY OF CONRACTOR AND COATING CONTRACTOR .................21 7.3 QUALITY PLAN ........................................................................................................21 7.4 TESTING OF COATING PROPERTIES...................................................................22 7.5 SUMMARY OF QUALITY CONTROL TESTING AND ACCEPTANCE

CRITERIA .................................................................................................................25 7.6 QUALITY RECORDS................................................................................................25 7.7 INSPECTION PERSONNEL AND EQUIPMENT......................................................25 7.8 FINAL INSPECTION.................................................................................................25 8. COATING REPAIR...................................................................................................27 8.1 GENERAL.................................................................................................................27 8.2 FIELD WELDS ..........................................................................................................27 9. STORAGE AND HANDLING ...................................................................................28 10. REFERENCES .........................................................................................................29



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APPENDICES

APPENDIX 1 INSPECTION AND TEST PLAN THERMAL SPRAY ALUMINIUM APPLICATION NEW EQUIPMENT ................................................................31

APPENDIX 2 EXAMPLE OF INSPECTION FORM FOR TSA APPLICATION ....................34



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1. INTRODUCTION

1.1 SCOPE

This DEP specifies requirements and give recommendations for thermal sprayed aluminium coatings for the purpose of corrosion control for both atmospheric conditions and beneath insulation or fireproofing as applied to onshore and offshore structures, equipment and piping, etc.

TSA coatings are used when the period to first coating maintenance is 25 years or where protection against corrosion under insulation (CUI) is required.

The following aspects of the thermal sprayed aluminium coating system are covered:

surface preparation; thermal spraying; coating materials; prequalification; quality assurance and control, and; repair procedures.

This DEP may also be applied when thermal spray coatings are specified for corrosion control on immersed and buried surfaces, equipment and structures.

The TSA coating may be applied either in the shop or in the field (on-site). The particular coating application system and procedures require approval by the Principal and, if applicable, the Contractor, prior to production coating operations.

Thermal spray coatings use high heat, and aluminium dust can ignite and explode under certain conditions. Rigorous safety precautions are required when thermal spray coatings are applied, particularly automated thermal spray aluminium coatings. See (2.3).

This DEP is a revision of the DEP of the same number dated July 2008; see (1.5) regarding the changes.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated by them. Any authorised access to DEPs does not for that reason constitute an authorization to any documents, data or information to which the DEPs may refer.

This DEP is intended for use in facilities related to oil and gas production, gas handling, oil refining, chemical processing, gasification, distribution and supply/marketing. This DEP may also be applied in other similar facilities.

When DEPs are applied, a Management of Change (MOC) process shall be implemented; this is of particular importance when existing facilities are to be modified.

If national and/or local regulations exist in which some of the requirements could be more stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable with regards to the safety, environmental, economic and legal aspects. In all cases, the Contractor shall inform the Principal of any deviation from the requirements of this DEP which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned, the objective being to obtain agreement to follow this DEP as closely as possible.



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1.3 DEFINITIONS

1.3.1 General definitions

The Contractor is the party that carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor.

The Coating Contractor is the party that manufactures or supplies equipment and services to perform the duties specified by the Contractor.

The Manufacturer/Supplier is the party that manufactures or supplies equipment and services to perform the duties specified by the Contractor.

The Principal is the party that initiates the project and ultimately pays for it. The Principal may also include an agent or consultant authorised to act for, and on behalf of, the Principal.

The Applicator is the party that applies the thermal spray coating.

The word shall indicates a requirement.

The word should indicates a recommendation.

1.3.2 Specific definitions

Term Definition

Arc spray A form of thermal spraying where two consumable metal wires are fed independently into the spray gun. These wires are charged and an arc is generated between them. The heat from this arc melts the incoming wire, which is then entrained in air jet from the gun and deposited onto a substrate

Bend test 180 bending of a sample on a mandrel.

Companion coupon

Rectangular steel coupon, prepared for qualification of thermal spray coating materials and coated concurrently with the workpiece for quality control and inspection.

Dew point The temperature of a given air/water-vapour mixture at which, under atmospheric pressure, condensation starts.

Flame spray A form of thermal spraying where the wire spray material is melted in a gaseous oxygen-fuel flame and deposited onto a substrate.

Feather Smooth tapered transition between thermal spray coating and the adjacent non-coated surface.

Holding period

Time between the completion of the final surface blasting and completion of the thermal spraying.

Overspray The portion of the thermal spray deposit that is not deposited on the desired area of the workpiece.

Rust bloom Discoloration indicating the beginning of rusting, bleeding through the interconnecting pores of the thermal spray coating.

Sealer A thin paint coating, about 40 m thick, that is absorbed into the pores of the thermal spray coating and seals the coating surface.

Shift Production run of which the beginning and end coincide with a change in personnel.

Soluble salt contaminants

Water-soluble salts, such as chlorides and sulphates, which contaminate the steel surface and cause rust bloom and premature coating failure.

Thermal spray

Application of metallic coating by means of arc- or flamespray equipment.



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Term Definition

Topcoat Paint coat applied over a sealed thermal spray coating.

TSA Thermally Sprayed Aluminium.

1.4 CROSS-REFERENCES

Where cross-references to other parts of this DEP are made, the referenced section number is shown in brackets ( ). Other documents referenced by this DEP are listed in (10).

1.5 SUMMARY OF MAIN CHANGES

This DEP is a revision of the DEP of the same number dated July 2008. This has been a major rewrite and it is impractical to list the changes here.

1.6 COMMENTS ON THIS DEP

Comments on this DEP may be sent to the Administrator at [email protected], using the DEP Feedback Form. The DEP Feedback Form can be found on the main page of DEPs on the Web, available through the Global Technical Standards web portal http://sww.shell.com/standards and on the main page of the DEPs DVD-ROM.

1.7 DUAL UNITS

This DEP contains both the International System (SI) units, as well as the corresponding US Customary (USC) units, which are given following the SI units in brackets. When agreed by the Principal, the indicated USC values/units may be used.



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2. GENERAL REQUIREMENTS

2.1 GENERAL

TSA shall be used when the period to first coating maintenance is 25 years or where protection against corrosion under insulation (CUI) is required.

Thermal spray coatings specified in this DEP shall be applied by either arc or flame spraying, using a solid metal wire. Powder consumables, high velocity oxy-fuel (HVOF) and plasma techniques shall not be used.

Thermal spray aluminium coating shall not be sealed when applied:

(i) to immersed components;

(ii) under insulation (to protect against CUI); or

(iii) to buried components (e.g. buried piping).

When TSA is used for immersed conditions, additional cathodic protection by means of sacrificial anodes may be required.

When TSA is used under fireproofing or insulation material, the materials used for fireproofing or insulation shall be selected such that, when exposed to water, the environment that the TSA coating is exposed to remains within a pH range of 4 to 8. However, it is acceptable to use TSA under perlite insulation which, in the presence of water, can develop a pH of approximately 10.

For new construction of equipment, consideration should be given during the design such that the surface which requires TSA should be accessible for grit blasting and TSA application. NACE SP0178 and/or ISO 12944-3 should be taken as a guideline for this. Examples where design for TSA access should be considered in the equipment design are (1) the clearance between insulation support rings and shell should be twice the thickness of the ring to enable grit blasting and TSA coating application of shell section behind the rings and (2) the name plate bracket design should be such that shell can be grit blasted and TSA coated behind bracket.

Finished prefab piping shop welds may be TSA coated in shop prior to (field) hydrotesting as permitted under clause 3.3.1 of DEP 74.00.10.10-Gen.

2.2 DOCUMENT HIERARCHY

In the event of conflicts between contract documents, As For Construction (AFC) drawings, specifications and other referenced standards, the following document hierarchy shall apply:

Contract or agreement (including any approved exceptions); AFC drawings latest revisions; Principals specifications (including project specific information); Industry Standards (e.g. ISO, NACE).

2.3 SAFETY

2.3.1 General

Thermal spray coatings may involve the use of hazardous materials, operations, and equipment. This DEP does not address all of the potential safety concerns associated with their use.

TSA coating application should be considered as hot work and associated safety precautions should be taken.

It is the responsibility of the Contractor and/or Applicator to establish appropriate safety and health requirements, and determine any regulatory requirements or limitations prior to use.



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Health, Safety and Environment concerns should be identified and included in the detailed coating procedure and pre-job discussions. All surface preparation and coating application systems shall undergo a complete safety inspection and checkout prior to use.

Adequate exhaust/ventilation equipment shall be used, as required, for removal of any air contaminated products to achieve acceptable air quality standards and to protect personnel.

When personnel are working in confined spaces, adequate ventilation and spark-proof lighting shall be provided.

All personnel shall be provided with approved personal protection, e.g. protective clothing, safety glasses, safety shoes, hard hats, goggles, respirators, earplugs, fresh-air-fed hood and any other necessary safety equipment. All safety equipment shall be maintained in good working condition.

Adequate warning signs shall be prominently displayed at all access points to areas where abrasive blasting and thermal spraying is in progress.

Thermal spraying is a safe process when performed by an Applicator who follows the recommended precautionary measures, has a proper understanding of thermal spraying practices, has knowledge and skill, and exercises care in using thermal spray equipment.

Thermal spray equipment should have safety devices that stop the spray process as well as the wire feeding when the safety handle is released. For re-starting the process, a two hand operation is required.

Coating work pieces shall be electrically grounded (earthed) as required to eliminate static charges associated with surface preparation and coating operations.

2.3.2 Hazardous components

Potential thermal spray hazards include exposure to flame, heat, vapours, (metal) dust, fumes, gases (CO exposure), noise, (from the spray gun) and arc ultraviolet (UV) radiation. Additionally, improperly used thermal spray equipment can create potential fire and explosion hazards from the fuel and carrier gases and a potential electrical shock hazard from the electrical and electronic equipment and charged wire spools. To minimize hazards, safety precautions should be followed. Thermal sprayers shall comply with the procedures in the safety regulations, the Manufacturer/Suppliers technical manuals, and the material safety data sheets.



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2.3.3 Safety measures

Source of risk factors, consequences, and recommended safety measures for thermal spray coatings are listed below and should include the following barriers:

Source Risk Safety measures

Heat from spray gun Flame from spray gun

Burn injuries Fire CO exposure

Wear non-flammable, heat-resistant clothing, in compliance with ISO 11611 for arc spray and ISO 11612 for flame spray. Wear respirator equipment

Noise from spray gun Ear damage Wear suitable ear protectors

UV-exposure from arc spray

Irritation / damage of eyes

Wear dark (welder's) glasses, face shield or helmet

Metal (spray) dust Irritation of airways / lungs Fire Dust explosions

Wear hood with forced air supply when using arc spray, particulate respirator when using flame spray. Water shall not be used; Use dry sand, or Class D fire-extinguisher. Regular cleaning of floor and equipment to remove metal spray dust (good housekeeping).

Heavy weight of gun Overstraining muscles Regular job rotation during spraying.

Heat from life equiment

Heat stresses Regular job rotation during spraying.

2.4 COMPANY ACCESS

The Principals representative, including independent inspectors or consultants as may be engaged by the Principal, shall be permitted access to the coating application site at any time to conduct performance analyses, including quality control tests of the materials being used.

The Principals representative has the right to reject any or all work or equipment that in his/her opinion does not conform to these requirements. Any work that in the opinion of the Principals representative does not comply with these requirements shall be rectified at the Contractors expense.

The Principals representative has the right to request quality control tests at any time in addition to those completed at pre-determined intervals.

2.5 PRE-JOB MEETING

The Applicator shall schedule a pre-job meeting to ensure that job requirements are fully understood.

The personnel present at the meeting shall include, but not be limited to, the Principals representative, and the Applicators representatives for coating supervision, quality control and safety. If required a technical representative of the Manufacturer/Supplier shall be present.

Roles and responsibilities shall be clarified at the pre-job meeting, such as when the Principal deals with the Applicator, who are the focal points and how administration procedures are executed. Technical aspects, such as: qualification of vendors/sprayers, application procedures, equipment, Inspection Test Plan (ITP) shall be discussed. It shall be confirmed that all parties have the latest version of the Contract, technical specifications, AFC drawings and ITP.



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3. MATERIALS

3.1 BACKGROUND

Aluminium and its alloys provide both barrier and cathodic protection to a steel substrate. Thermal spray aluminium coatings may be specified as protective coatings for atmospheric exposure, under thermal insulation, hot surface and (sea) water immersion applications.

The recommended service temperature of aluminium for non-immersion services is -45C to 595C (50F to 1,100F).

3.2 THERMAL SPRAY COATING

For application of thermal spray coating in accordance with this DEP, the chemical composition of the metallic wire material used shall meet the following requirements:

Aluminium in accordance with ISO 209 Grade 1100. Alternative Grade 1350 aluminium shall only be used with specific approval of the Principal.

3.3 SEALER

Sealers are designed to fill the porosity of the thermal spray coating, and not to build film thickness.

The sealer shall have sufficiently low viscosity to penetrate into the pores and seal the surface of the thermal spray coating. The dry-film thickness (DFT) of the sealer shall not exceed 40 m (1.5 mils). TSA coating shall not be sealed when applied:

To components that are to be immersed (e.g. in sea water); Under insulation (to protect against CUI); To components (e.g. piping) that are to be buried.

TSA coatings may be sealed when used under atmospheric conditions, e.g. to prevent fouling of the surface, or when a particular decorative finish, or safety colours are required.

The following sealer materials shall be used:

Epoxy: to a maximum temperature of 120C (248F); Silicone: to a maximum temperature of 450C (840F).

3.4 TOP COAT

Topcoats applied on thermal spray coating shall be chemically compatible with the sealer and shall be applied according to the instructions of the paint Manufacturer/Supplier.

TSA coatings may be topcoated when used under atmospheric conditions, and when a finishing colour is required, e.g. for safety markings, visual appearance, etc. The following coating system shall be used:

Epoxy sealer, maximum DFT 40 m (1.5 mils); Aliphatic polyurethane topcoat, maximum DFT 40 m (1.5 mils).



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4. SURFACE PREPARATION

4.1 GENERAL

All edges to be coated shall be rounded off by grinding to a radius of 2 mm (1/8 in) minimum. Flame cut areas and weld spatter shall be ground flush.

Cleaning of surfaces shall be done by dry blast cleaning, in accordance with ISO 8504-2.

Fabrication should be complete before surface preparation begins.

Alternative surface preparation, such as power tool cleaning, grinding, etc., shall be permitted only by specific approval of the Principal and when the surface preparation acceptance criteria, as specified in this DEP, can be achieved. The Applicator shall provide a detailed application procedure and the ITP shall have QA/QC to verfy the surface profile.

Stainless steel surfaces shall not be treated with carbon steel cleaning tools or tools previously used on carbon steel.

4.2 CLEANING

Prior to the blast cleaning and/or thermal spraying, the surface shall be free of any contamination and any excessive rust scale shall be removed. Salt contamination of parts that have been stored in and exposed to the open air shall be removed prior to blast cleaning.

If emulsion or detergent type degreasers or Teepol/fresh water solutions are used, this treatment shall be followed by copious rinsing with fresh and clean potable water or pressure water/steam wash.

All welded areas and appurtenances shall be given special attention for removal of welding flux in crevices. Welding spatter, slivers, de-laminations and underlying mill scale not removed during fabrication and exposed before and during blast cleaning operations shall be removed by the best mechanical means. Edges shall be smoothed or rendered flush.

If non-conformances occur on blast-cleaned surfaces and reblasting is required these areas shall be pre-cleaned as initially specified.

4.3 ABRASIVE BLAST CLEANING

4.3.1 General

No blasting work shall be carried out when the temperature of the steel surfaces is less than 3C (5F) above dew point of the surrounding air, or the relative humidity of the air is greater than 85%. Dew point determination shall be in accordance with ISO 8502-4.

Blast cleaned steel surfaces shall not be touched by bare hands.

If the surface being cleaned lies adjacent to a coated surface, the blast cleaning shall overlap the coated surface by at least 50 mm (2-1/8 in). The edges of the existing coating system shall be feathered. The remainder of the existing coated surface shall be properly protected with shields or screens to prevent any over blast damage.

No acid washes, cleaning solvents or other chemical treatments shall be used on metal surfaces after they have been blast cleaned. This restriction includes inhibitive washes intended to prevent rusting.

If present, contaminants (including salts) shall be removed by solvent washing, by water washing or steam cleaning, and the affected areas re-blasted. The luminance for visual examination for contaminations shall be at least 500 lux.

If non-conformances occur on blast-cleaned surfaces and reblasting is required the areas shall be re-blasted to minimum Sa 2, in accordance with ISO 8501-1.



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4.3.2 Abrasives

Abrasives for blast-cleaning steels shall be in accordance with Table 1. Test methods shall be in accordance with the tests specified in ISO 11127. Abrasives shall be supplied with certification documentation traceable to batches of material to check that the abrasive meets the requirements as specified in the relevant ISO standard.

The conductivity of abrasives to be used shall be a maximum of 50 S/cm. The Principal shall approve the use of alternative abrasive materials.

The abrasives shall be free from oil, grease, moisture, chloride contamination, etc.

For blasting stainless steel, non-(free) iron containing abrasive shall be used, e.g. Garnet, or aluminium oxide.

Shot blasting material shall not be used.

Table 1 Abrasives specification

Type Generic Name Characteristics Standard

Iron grit > 1.7 % carbon ISO 11124-2 Metallic

Steel grit 0.8% to 1.2% carbon ISO 11124-3

Staurolite Iron/aluminium silicate ISO 11126-9 Natural mineral Garnet Calcium iron silicate ISO 11126-10

Coal slag Aluminium silicate ISO 11126-4 Synthetic mineral Aluminium oxide Crystalline corundum ISO 11126-7

4.3.3 Blasting equipment

The compressed air shall be free of water and oil. Adequate separators and traps shall be provided, installed in the coolest part of the system. The presence of oil and water shall be determined in accordance with ASTM D 4285 at least two (2) times per twelve (12) hours and following every compressor start-up. The air discharge temperature shall not exceed 100C (210F).

Blasting nozzles shall be replaced when the specified minimum blast pressure, surface cleanliness and surface profile can no longer be achieved.

Blasting equipment, its operators and the object being blasted shall be properly earthed to prevent the occurrence of electrostatic discharges.

Abrasive blast cleaning equipment shall be of an intrinsically safe construction and equipped with a remote shut-off valve triggered by the release of a dead man's handle at the blasting nozzle.

If air-operated equipment is used, the operator's hood or headgear shall be positive pressure fed by clean, cool air supplied through a filter, to prevent blast cleaning residues from being inhaled.

4.3.4 Surface cleanliness

At the time of application of the thermal spray coating, the surface finish shall be minimum Sa 2, in accordance with ISO 8501-1.

4.3.5 Surface roughness

Checks on surface roughness shall be made at least once per 100 m (1070 ft) of prepared surface, with a minimum of three measurements per day per shift.

The surface roughness shall be measured by means of replica tape, in accordance with ISO 8503-5. Other, proprietary testing techniques may be used, as agreed by the Principal.



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The surface roughness for thermal spray coatings shall be between 75 m and 110 m (3 mils and 4.5 mils), in accordance with ISO 8503-5. The surface shall have a sharp angular profile.

4.3.6 Dust contamination

Dust levels shall be checked at least once per 100 m (1070 ft) of prepared surface, with a minimum of three measurements per day per shift.

The dust level of the blast cleaned surface at the time of coating shall not exceed quantity rating 1 in accordance with ISO 8502-3.

4.3.7 Soluble salt contamination

The level of salts shall be tested at least once per 100 m (1070 ft) of prepared surface, with a minimum of three measurements per day per shift.

The maximum total allowable soluble salts level on the surface shall not exceed 20 mg/m2, and shall be measured in accordance with ISO 8502-6 and ISO 8502-9. Other, proprietary field-testing techniques may be used if agreed by the Principal.



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5. COATING APPLICATION

5.1 GENERAL

The following items shall not be coated:

Valve stems, flange faces, instrumentation components (pressure gauges, etc), and any other machined contact surfaces.

Electrical wiring and cabling, plastics, rubber, and glass. Nameplates, permanent labels, or instruction decals.

At areas where TSA cannot be applied due to equipment geometry or inaccessible due to spacing between the TSA gun and surface to be sprayed, a technical assessment should be performed to determine the appropriate coating system to be applied. These areas shall be kept to a minimum.

5.2 EQUIPMENT

The TSA coating should be applied using either a manual, fully automated, or semi automated system, depending on the particular piping or component geometry and area(s) requiring coating. The TSA coating may be applied either in the shop or in the field (on-site). The particular coating application system and procedures shall require approval by the Principal and, if applicable, by the Contractor, prior to production coating operations.

Generally, arc spray application should be used for new equipment in the shop and flame spray application for maintenance and on-site application.

The thermal-spray equipment shall be set up, adjusted and operated according to the instructions and technical manuals of the Manufacturer/Supplier or thermal spray Applicator.

The thermal-spray equipments spray-parameter set-up shall be validated with a bend test (8.2.5) at the beginning of each shift or crew change. The Principal shall receive a copy of the spray parameters set-up.

5.3 ACCESS

All surfaces of the structure that have to be coated shall be visible and within reach of the operator by a safe method. Personnel involved in surface preparation, coating application, and inspection shall be able to move safely and easily on all parts of the structure in conditions of good lighting.

Scaffolding shall be constructed in accordance with local regulations and the requirements of the Principal.

Surfaces which are to be blasted and coated should be sufficiently accessible to allow the operator adequate space to work in.

5.4 HOLDING PERIOD

Time between blasting of the steel surface and thermal spraying shall be no greater than four (4) hours. If the holding period exceeds 4 hours, the surface cleanliness shall be re-checked and when the surface cleanliness is not in agreement with this DEP, the surface shall again be cleaned and abrasive blasted in compliance with this DEP.

5.5 MASKING

Areas not to be covered by thermal spray coating shall be protected by masking. Self-bonding tapes, hardwood, rubber, silicone rubber, or metallic masks should be used. Precautions shall be taken to ensure that the masking material does not contaminate the surface to be sprayed. If contamination has occurred, the surface shall again be cleaned and abrasive blasted in compliance with this DEP.



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5.6 THERMAL SPRAYING

No thermal spray coating work shall be carried out when the temperatures of the steel surfaces is less than 3C (5F) above dew point of the surrounding air, or the relative humidity of the air is greater than 85%. Dew point determination shall be in accordance with ISO 8502-4.

Before starting, and during flame spraying, the surface to be coated shall be warm enough to prevent moisture (present in flame) from condensing on the substrate. If condensation on the substrate occurs, the surface should be preheated up to minimum 60C (140F). In any case, oxidation of the surface during preheating shall be avoided. This pre-heating can also be required to minimise the internal stresses of the TSA layer on the steel substrate. This can be validated with the bend test on companion coupons.

The specified coating thickness shall be applied in several crossing passes. The coating tensile bond strength is greater if the spray passes are kept thin. Laying down an excessively thick spray pass increases the internal stresses in the TSA and decreases the ultimate tensile bond strength of TSA. The suitability of the crossing-pass thickness shall be confirmed with a bend test.

TSA coated surfaces shall not be in direct contact with carbon steel, e.g. TSA coated pipe and steel support. A non-metallic layer, e.g. PTFE, or elastomer strip should be used to avoid direct contact between a TSA coated surface and its steel counterpart.

The spray equipment shall be operated in accordance with the Manufacturer/Suppliers instructions and thermal sprayers procedures.

5.6.1 Rust bloom

If rust bloom, blistering or a degraded coating appears at any time during thermal spraying, the following procedure shall apply:

Stop spraying; Mark the rejected sprayed area; Re-prepare the rejected areas to the requirements of (8).

5.6.2 Feathering

The edges of the existing thermal spray coating shall be feathered by abrasive blasting to provide a 50 mm to 75 mm (2 in to 3 in) overlap with the newly applied thermal spray coating.

5.7 COATING THICKNESS

Thickness of the TSA coating systems shall be in the range of 250 m to 500 m (10 mils to 20 mils);

The sealer coating shall have a maximum DFT of 40 m (1.6 mils). The topcoat shall have the following DFT:

Epoxy sealer: maximum DFT 40 m (1.6 mils); Aliphatic polyurethane finish coat: maximum DFT 50 m (2 mils).

5.8 SEALER AND TOPCOAT

Sealers shall be applied within 24 h after thermal spraying, if the sealer application is performed indoors the time between thermal spraying and sealer application may be increased to 48 h.

If moisture is present or suspected in the TSA pores, the steel shall be heated up to 65C (149F) to remove moisture prior to the sealer application. If possible, the steel from the reverse side of the TSA shall be heated to minimize oxidation and contamination of the TSA prior to sealing.



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Sealer, thinners (to lower viscosity of sealer), and topcoats (paint) shall be supplied in unopened, clearly identified containers. Handling, mixing and storage of sealer, thinner, and coating materials shall be in accordance with the coating Manufacturer's/Suppliers specifications. Sealers and coating shall meet the local restrictions on Volatile Organic Compound (VOC) content.



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6. QUALIFICATION

6.1 GENERAL

Each TSA-vendor and each individual TSA-sprayer shall be pre-qualified before they are allowed to apply TSA for Shell projects and operating companies.

This DEP may be used for general qualification purposes or for specific projects.

General pre-qualification is performed for the purpose of an overall qualification of the TSA-vendor, but is not necessarily related to a specific project. Note: For this purpose Shell companies may use the list of Technically Accepted Manufacturers and

Products maintained by Shell Projects and Technology.

6.2 TSA-VENDOR QUALIFICATION

The TSA-Vendor qualification consists of the following points:

a) review of application equipment and coating material information, with as a minimum: Abrasives - name of product and Manufacturer/Supplier, mesh size,

cleanliness report; Blasting and thermal spray equipment - type and name of the

Manufacturer/Supplier; Spray material - name of Manufacturer/Supplier, wire size, chemical

composition; Sealer - name of product and Manufacturer/Supplier.

b) review of quality plan including surface preparation and application procedures

c) review coating repair method

d) witness the coating application on the required test panels and coupons

e) witness the coating testing, including sealer inspection.

f) witness coating repair application

The surface preparation shall be as specified in (4) of this DEP. During the qualification the surface preparation procedure and testing shall also be witnessed.

Arc or flame spraying application and both manual and mechanised application techniques are allowed.

For each application process the qualification program is required. This means that per application method, the following test panels/coupons shall be coated:

i. two test pieces B1 according ISO 14918.

ii. at least 3 test coupons (150 mm x 150 mm, thickness 1.8 mm) (6 in x 6 in, thickness thickness 70 mils) for bend testing.

iii. test panel, thickness 6 mm (1/4 in), with minimum surface area of 1 m2 (1070 ft2 ) (also for sealer application).

iv. 2 test panels (200 mm x 200 mm x 6 mm), (8 in x 8 in x 1/4 in).

The applied coating thickness shall be 250 m minimum and 500 m maximum (10 mils to 20 mils).

Testing shall be done according the test procedures in this DEP.



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6.3 THERMAL SPRAYER QUALIFICATION

Before an individual thermal sprayer is qualified by the Principal, it shall be shown that the individual applicator is qualified in compliance with ISO 14918 for both manual and mechanised application techniques. The qualification tests, as specified in ISO 14918, Annex B.1 and B.9, shall be witnessed and certified by an independent third party authority.

Individual sprayers shall be qualified in accordance with ISO 14918 requirements. Additional qualification tests as specified in (6.4) shall be executed, and shall be witnessed by the Principal or a delegate of the Principal. This qualification can be done during the TSA-Vendor qualification.

For the test coupons, the same type of base steel shall be used as the actual component, or structure to be coated. Surface preparation, coating material, spray technique, coating thickness, etc., shall comply with this DEP.

The coating repair methods proposed by the Contractor shall also be qualified, in compliance with this DEP.

6.4 QUALIFICATION TESTS

6.4.1 Visual inspection of TSA-coating

The TSA coated surface on all test plates shall have a uniform appearance, no blisters, bare patches, defects, or non-adhering coating.

6.4.2 TSA-coating thickness

The coating thickness on all test plates shall be minimum 250 m (10 mils). Local thickness of the thermal sprayed coating, e.g. at corners, shall be maximum 2x the specified minimum thickness.

At least five measurements are taken at every 500 cm2 (78 in2) of the test plates.

6.4.3 Bend test

Each thermal sprayer shall prepare and spray a minimum of three companion bend test coupons [dimensions 150 mm x 50 mm, thickness 1.8 mm (6 in x 6 in, thickness thickness 70 mils)]. The thermal spray bend test coupons shall not be sealed or topcoated. The coating thickness shall be as specified in this DEP.

The bend test entails bending at least three thermal spray coated steel coupons through 180 on a 13 mm (1/2 in) diameter steel mandrel.

Should any one of the bend tests fail the acceptance criteria specified in Table 2, the thermal sprayer may make one additional attempt to qualify by spraying and testing a further three coupons. Should any one these fail, the sprayer shall be deemed to have failed the qualification test.

6.4.4 Adhesion test

Each thermal sprayer shall apply TSA at the required thickness onto a test panel (thickness 6 mm (0.25 in)), with a minimum surface area of approximately 1 m2 (10.7 ft2). The coated surface shall not be sealed or topcoated.

The adhesion strength between the thermal spray coating and the steel substrate shall be measured by means of a portable, self-aligning, hydraulic controlled adhesion tester in accordance with ISO 4624. The adhesive between the dolly and the thermal spray coating shall be an epoxy.

A minimum of three pull-off adhesion tests shall be conducted. Should any one of the pull off adhesion tests fail the acceptance criteria, specified in Table 2, the thermal sprayer may make one additional attempt to qualify by spraying and testing a further panel. Should any one of the subsequent pull-off adhesion tests fail, the sprayer shall be deemed to have failed the qualification test.



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6.4.5 Sealer

If a sealer is specified, then following completion of the pull-off adhesion tests, the test panel used shall be sealed with the same sealer material that is to be used for the thermal sprayed component or structure, and which shall comply with this DEP.

The sealed surface area of the thermal spray coated test panel shall be examined by means of a microscope with minimum 10x magnification. The sealed surface shall show 100% coverage, and no open pores shall be present at the surface.

6.5 SUMMARY OF QUALIFICATION TESTS AND ACCEPTANCE CRITERIA

Table 2 Qualification test requirements for TSA vendor and sprayer

Property Test method Measurements Acceptance criteria ISO Qualification

ISO 14918, Annex B.1 and B.9

Thickness, visual, adhesion

Full compliance with ISO 14918

Coating appearance

Visual inspection 100% of surface Uniform appearance, no blisters, bare patches, defects, or non-adhering coating

Coating Thickness

ISO 2808 (6.4.2) All surfaces 250 to 500 m (10 to 20 mils)

Coating Adhesion

ISO 4624 (6.4.4) At least 3, at random

> 7 MPa (1000 psi) (single measurement)

Overall quality

Bend test (6.4.3) At least 3 Minor cracks, with no coating lifting or spalling, see Figure 1.

Sealer Visual inspection (6.8)

100% of surface 100% coverage, no open pores present at the surface



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7. QUALITY ASSURANCE AND CONTROL

7.1 GENERAL

The Principal or their Representative shall have the right to inspect, check or review, at all times, any or all of the activities, equipment, inspection equipment or product designated for the work. All parts of the work shall be accessible for this purpose.

An independent third party authority to be agreed by the Principal shall carry out regular quality checks. However, in no way does this relieve the Contractor of any responsibility with respect to the quality of the coating work.

The Principals Representative assigned to the coating application work shall be given at least four hours' notice of any change in the schedule of the coating activities.

Whenever any section is to be assembled that will prevent subsequent inspection of an area, the Principals Representative shall be notified in time, so that inspection and repair activities can be carried out before proceeding with the assembly.

Both the applicator and the Manufacturer/Supplier of the coating materials should implement a quality management system in accordance with ISO 9001.

7.2 RESPONSIBILITY OF CONRACTOR AND COATING CONTRACTOR

The Coating Contractor is responsible for the quality of the work, which shall be performed in accordance with this DEP, and all other relevant documents such as site regulations, safety rules and requirements, product data sheets, referenced standards and codes.

The Contractor shall be responsible for all Quality Assurance and Control activities.

The Contractor shall schedule a pre-job meeting to ensure that job and quality requirements are fully understood. Attendees shall include a representative of the Principal, the Contractors job superintendent, the Coating Contractor, his coating supervisor and the Contractors coating inspector.

For all coating work, the Contractor shall submit appropriate work plans and a quality plan for implementing the requirements of this DEP for review by the Principal. The quality plan shall fully reflect the requirements of this DEP.

Unless otherwise agreed, the Contractor shall supply all the weather protection, scaffolding and any other equipment necessary to ensure that the work is carried out in accordance with this DEP and the agreed programme. This includes, for example, heating and air-drying equipment.

The Coating Contractor shall protect all equipment, structures and any other areas from mechanical damage, environmental damage, blockage or obstruction, or damage, caused by the coating work.

Copies of this DEP, the work plans and the quality plan shall be made available to the coating Contractor's representative at the site and the Contractor shall be familiar with their contents.

7.3 QUALITY PLAN

The quality plan of the Coating Contractor shall comply with ISO 14922-1 and ISO 14922-2.

Before commencing any work, a written project-specific quality plan shall be submitted to the Principal for approval, at least 4 weeks prior to start executing work. This plan shall include:

a) A sequence for the various activities in relation to the total work to be done;

b) Detailed scope of the work to be done including, per item or area, the required surface preparation and coating system to be applied;



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c) Full details of the blast and thermal spray equipment including, where appropriate: dehydration, temperature, any other environmental control measures, methods of access, etc.;

d) Details of coating materials used, including datasheets, certificates;

e) Details of the personnel involved in the work together with a clear definition of their responsibilities and lines of communication;

f) Detailed procedures and plans for testing and inspection including the methods and equipment to be used and the frequency of their application and acceptance criteria; a typical Inspection and Test Plan (ITP) is shown in Appendix 1.

g) Details documenting the essential steps in achieving quality;

h) Dew point determination table;

i) Calibration methods of the inspection equipment;

j) Qualification of abrasive blasting and thermal spraying personnel.

Following review and approval by the Principal, the project quality plan may be updated and revised during the work, as and when required. All revisions shall be submitted to the Principal for approval prior to being included in the quality plan.

7.4 TESTING OF COATING PROPERTIES

7.4.1 Coating appearance

The thermal spray coating shall be free from defects such as blisters, spatter, cracks, loose particles, areas with bare substrate steel, etc., when examined with a microscope with 10x or higher magnification.

Sealer visual inspection shall be performed for every 50 m2 (538 ft2) of manually sprayed, and for every 100 m2 (1076 ft2) of mechanised sprayed coating. The sealed surface shall show 100% coverage, and no open pores shall be present at the surface, when examined with 10x or higher magnification.

7.4.2 Coating thickness

The specified TSA thickness range is 250 m to 500 m (10 mils to 20 mils). Spot checks shall be carried out during thermal spraying of the coating to ensure that the specified coating thickness is being maintained

The coating thickness shall be measured by means of a thickness meter based on eddy-current or electromagnetic techniques, in accordance with ISO 2808, methods 7B (magnetic-flux), 7C (magnetic-induction) or 7D (Eddy-current).

For duplex stainless steel, continuous calibration is required and for austenitic stainless steel, it is required to use the Eddy-current method.

When TSA thickness readings are not possible on non-magnetic substrates such as stainless steel, the use of companion coupons made of carbon steel should be considered.

The coating thickness gauge shall be calibrated on the blasted steel surface.

Based on the shape and size of the surface the number of measurements shall be specified in agreement with the Principal.

For flat surfaces, coating thickness measurements shall be taken along a straight line. The average value of five readings taken in a line at 25 mm (1 in) intervals shall be determined.

For complex geometries, a spot measurement shall be taken. Thickness is determined by the average value of five readings taken on a local area of approximately 10 cm2 (1.6 in2).

For the acceptance of an inspected area the following thickness criteria shall apply:

Local thickness of the thermal sprayed coating shall not be lower than 90% of the specified minimum thickness (7.5);



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Local thickness of the thermal sprayed coating, e.g. at corners, shall be maximum 2x the specified minimum thickness.

If the thermal spray coating local thickness is less than 90% of the specified minimum value (7.5), the thermal sprayer shall apply additional layers to meet the thickness requirement.

If the local thickness is greater than the specified maximum value, the Principal shall be notified for resolution of this discrepancy. The pull-off adhesion test may be performed on a coating with excessive thickness to check its integrity (maximum thickness is 1000 m (40 mils)).

Any unacceptable applied thermal spray coating shall be blasted off and a new coating applied, in compliance with this DEP.

The thermal sprayer shall record all areas with coating thickness outside the specified minimum or maximum value.

7.4.3 Adhesion strength

The adhesion strength between the thermal spray coating and the steel substrate shall be measured by means of a portable, self-aligning, hydraulic controlled adhesion tester in accordance with ISO 4624.

The adhesive between the dolly and the thermal spray coating shall be an epoxy.

On test panels, the pull-off adhesion strength for thermal spray coating shall be minimum 7 MPa (1000 psi) for any single measurement. Three measurements shall be performed per test panel. If one of the three measurements falls below the minimum specified value of 7 MPa (1000 psi), but not lower than 6.3 MPa (900 psi), the coating shall be accepted.

If any one value is less than 6.3 MPa (900 psi) or if two or more readings are below 7 MPa (1000 psi), the thermal sprayed surface shall be blasted off and a new coating applied, starting from the location where the last acceptable pull-off strength was measured.

Pull-off adhesion tests directly on the work piece shall be performed at least once per 100 m (1070 ft2) of prepared surface, with a minimum of three measurements per sprayer per shift. The adhesion strength shall be minimum 8.4 MPa (1200 psi) (no cut shall be made around the dolly). The adhesion test shall be stopped when the value of 8.4 MPa (1200 psi) is reached, so no damage to the work piece is taken place.

7.4.4 Bend test

During the thermal spray operation, steel companion coupons shall be used to monitor the quality of the thermal spray coating.

The bend test entails bending at least three steel coupons (dimensions 150 mm x 150 mm, thickness 1.8 mm) (6 in x 6 in, thickness thickness 70 mils) through 180 on a 13 mm (1/2 in) diameter steel mandrel.

For the test coupons, the same type of steel shall be used as for the actual component or structure to be coated. Surface preparation, coating material, spray technique, coating thickness, etc., shall comply with this DEP.

Three companion coupons shall be abrasive blasted and sprayed to the specified minimum thickness range and a minimum of three bend tests shall be performed once per 100 m (1070 ft2) of thermal sprayed surface, with a minimum of three bend tests per day per shift, and/or after any change in parameter settings of the spray apparatus. When the test has shown a repeatable sufficient performance, the Principal may decide to reduce the test frequency. The thermal sprayed coupons for the bend test shall not be sealed, or topcoated.

Typical bend test arrangement, visual appearance of pass and fail samples and acceptance criteria are shown in Figure 1.



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Figure 1 Bend test arrangement: visual appearance and acceptance criteria for pass and fail samples

If the bend test is failed, the thermal spray operation shall be stopped, and corrective action shall be taken before thermal spraying is continued.

7.4.5 Water spray test

When specified by the Principal, the water spray test should be executed immediately after TSA application. The TSA coated surfaces shall be wetted with potable water. After 24 hours, continuous wetting the surface shall be re-examined for any signs of rusting or bleed thru. If these areas are present, the coating thickness in these areas shall be measured. If the coating thickness is below 250 micron (10 mils) the section needs to be repaired. A low pressure sweep blast on this area should be performed and additional TSA shall be applied.

The water spray test is applicable to 100 % of the coated surface.



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7.5 SUMMARY OF QUALITY CONTROL TESTING AND ACCEPTANCE CRITERIA

Table 3 Test requirements for TSA coating during TSA coating production

Property Test method Measurements Acceptance criteria

Coating appearance

Visual inspection 100 % of surface Uniform appearance, no blisters, bare patches, defects, or non-adhering coating

Coating Thickness

ISO 2808 (7.4.2) All surfaces 250 to 500 m (10 to 20 mils)

Coating Adhesion

ISO 4624 (7.4.3) At least 3, at random > 7 MPa (1000 psi) on test plate > 8.4 MPa (1200 psi) on work piece

Overall quality

Bend test (7.4.4) At least 3 Minor cracks, with no coating lifting or spalling, see Figure 1.

Coating thickness

Water spray test (7.4.5) 100 % of surface No discolouration, rusting or bleed thru

7.6 QUALITY RECORDS

The coating Contractor or Applicator shall keep and submit to the Principal accurate records of all relevant data of the surface preparation, spray process, sealer and topcoat materials.

The documentation shall include as a minimum:

Record of contract / design review; Surface preparation abrasive material type and size, cleanliness of abrasive,

compressed air cleanliness, surface cleanliness, surface profile;

Material certification; Thermal spraying procedure specification; Thermal spraying procedure approval test records; Thermal sprayer approval certification; Pre and post treatment and procedures specification records; Dimensional reports, including coating thickness; Records of repairs or new thermal spraying.

Quality records shall be submitted to the Principal after completion of the coating work together with the calibration certificates of the testing and measuring instruments. Quality records should be retained for a minimum period of 5 years.

7.7 INSPECTION PERSONNEL AND EQUIPMENT

All inspection personnel shall be individually certified by a recognized Accreditation / Inspection Agency, e.g. NACE, Lloyds, DNV, TV or Velosi, to be agreed by the Principal.

The Contractor shall provide and use all inspection equipment necessary to ensure that the specified conditions and quality requirements are achieved.

7.8 FINAL INSPECTION

As part of the Quality Assurance (QA), a final inspection shall be conducted prior to acceptance of the thermal spray coating work. This final inspection shall include a visual check of the appearance and overblast of the coating work, and checks on total thickness of coating system, when completed.



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The Contractor and the Principal shall both be represented and they shall sign an agreed acceptance form as part of the warranty agreement.

As part of the acceptance procedure, the Contractor shall prepare a report including the following:

1. General

Name of the Contractor / Applicator and the responsible personnel. Scope of work. Dates when work was carried out. Copies of the work and quality plan. Deviations from this DEP and the quality plan.

2. Inspection equipment

Type and calibration of instruments used. 3. Surface preparation:

Condition of surface before preparation. Checks of surface cleaning as specified in this DEP.

4. Coating application

Information on coating materials being applied (i.e. spray material, sealer, topcoat, etc.).

Checks of coating application as specified in this DEP. Check on thickness of the applied coating.

5. Inspection reports

Copy of the inspection reports of the Contractor. Inspection reports from an independent third party. Qualification and production test results.



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8. COATING REPAIR

8.1 GENERAL

The Applicator shall produce a coating repair procedure, to be agreed by the Principal. Only qualified coating repair methods shall be used, in compliance with this DEP. This repair procedure shall be verified and approved during the qualification trials (6)

If the thermal spray coating has been mechanically damaged and bare substrate metal is observed, the coating shall be repaired, including the local (repair) application of a new sealer, and/or topcoat, if applicable.

The damaged area shall be pre-cleaned, followed by local blast cleaning to a minimum of Sa 2.5, in compliance with this DEP.

Edges of the remaining existing coating system shall be feathered by abrasive blasting, and the remainder of the adjacent coated surface shall be properly protected.

Local (repair) application of thermal spray coating shall be in compliance with this DEP, including local (repair) application of new sealer and topcoat.

When the size of the defects is small, it may be acceptable to use a liquid paint to repair the damage. The maximum defect size allowable for liquid paint repair shall be 10 cm2 (1.55 in2). The use of liquid paint repairs shall be approved by the Principal.

If the thermal spray coating only shows local surface damage, the area shall be pre-cleaned, followed by local sweep blasting. The adjacent coated surface shall be properly protected (masking). The locally restored thermal spray coating, including sealer / top coat, shall meet the minimum thickness requirements.

Arc-spray coating should not be applied on existing flame-sprayed coating because of the risk of coating delamination damage. However, flame-sprayed coating applied on existing arc-sprayed coating is acceptable.

If only the sealer or topcoat has been damaged, the surface shall be prepared by abrasion with medium coarse abrasive paper until a clean bright surface is visible. Edges of the remaining coating at the location of the repair shall be feathered. The re-applied sealer / topcoat system shall be compatible with the existing coating system.

8.2 FIELD WELDS

It is recommended to have a cutback length of 100 mm to 200 mm (4 in to 8 in) to prevent disbonding issues with the TSA applied on the pipe body during welding.

Weld spatter shall be ground flush.

Prior to the blast cleaning and/or thermal spraying, the surface at the field weld to be coated shall be free of any contamination and any excessive rust scale shall be removed.

Cleaning of the field weld surface shall be done by dry (vacuum) blast cleaning, to at-least Sa 2.5, in accordance with ISO 8501-1.

The steel surface roughness shall be between 75 m and 110 m (3 and 4.5 mils), in accordance with ISO 8503-5. The surface shall have a sharp angular profile.

Edges of the remaining existing coating system shall be feathered by abrasive blasting, and the remainder of the adjacent coated surface shall be properly protected.

Surface preparation and coating application for field welds shall comply with this DEP.

Arc-spray coating shall not be applied on existing flame-sprayed coating because of the risk of coating delamination damage. However, flame-spray coating applied on existing arc-sprayed coating is acceptable.

Prior to commencement of field weld application, the Coating Contractor shall perform a qualification trial based on the proposed work method and equipment used for the field weld application.



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9. STORAGE AND HANDLING

For coated components, canvas or nylon slings should be used for lifting, and wooden, rubber or plastic blocks shall be applied during transportation. Coated objects, pipes, etc. should be stored and handled in such a manner as to prevent damage.

To avoid damage of the coating, the Contractor should supply all the necessary protection when storing coated components in the open air prior to construction.



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10. REFERENCES

In this DEP, reference is made to the following publications: NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,

together with any amendments/supplements/revisions thereto.

2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell Wide Web) at http://sww.shell.com/standards/.

SHELL STANDARDS

Shop and Field Pressure Testing of Piping Systems DEP 74.00.10.10-Gen

AMERICAN STANDARDS

Design, Fabrication, and Surface Finish Practices for Tanks and Vessels to Be Lined for Immersion Service

NACE SP0178

Standard Test Method for Indicating Oil or Water in Compressed Air ASTM D 4285

INTERNATIONAL STANDARDS Aluminium and Aluminium Alloys Chemical Composition ISO 209

Paints and Varnishes - Determination of Film Thickness ISO 2808

Paints and Varnishes Pull-off Test for Adhesion ISO 4624

Preparation of Steel Substrates Before Application of Paints and Related Products. Visual Assessment of Surface Cleanliness. Rust grades and preparation grades of uncoated steel substrates and of steel substrates after overall removal of previous coatings

ISO 8501-1

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 (Presssure-Sensitive Tape Method)

ISO 8502-3

Preparation of Steel Substrates Before Application of Paints and Related Products - Tests for the Assessment of Surface Cleanliness - Part 4: Guidance on the Estimation of the Probability of Condensation Prior to Paint Application

ISO 8502-4

Preparation of Steel Substrates Before Application of Paints and Related Products - Tests for the Assessment of Surface Cleanliness - Part 6: Extraction of Soluble Contaminants for Analysis - The Bresle Method

ISO 8502-6

Preparation of Steel Substrates Before Application of Paints and Related Products - Group B: Methods for the Assessment of Surface Cleanliness - Part B9: Field Method for the Conductometric Determination of Water-Soluble Salts

ISO 8502-9

Preparation of steel substrates before application of paints and related products Surface roughness characteristics of blast-cleaned steel substrates Part 5: Replica tape method for the determination of the surface profile

ISO 8503-5

Preparation of Steel Substrates Before Application of Paints and Related Products - Surface Preparation Methods - Part 2: Abrasive Blast-Cleaning

ISO 8504-2

Quality Management Systems - Requirements ISO 9001

Preparation of Steel Substrates Before Application of Paints and Related Products - Specifications for Metallic Blast-Cleaning Abrasives

ISO 11124-2



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Preparation of Steel Substrates Before Application of Paints and Related Products - Specifications for Metallic Blast-Cleaning Abrasives - Part 3: High-Carbon Cast-Steel Shot and Grit

ISO 11124-3

Preparation of Steel Substrates Before Application of Paints and Related Products - Specifications for Non-Metallic Blast- Cleaning Abrasives - Part 4: Coal Furnance Slag

ISO 11126-4

Preparation of Steel Substrates Before Application of Paints and Related Products - Specification for Non-Metallic Blast-Cleaning Abrasives Part 7: Fused Aluminium Oxide

ISO 11126-7

Preparation of Steel Substrates Before Application of Paints and Related Products - Specification for Non-Metallic Blast-Cleaning Abrasives Part 9: Staurolite

ISO 11126-9

Preparation of Steel Substrates Before Application of Paints and Related Products - Specifications for Non-Metallic Blast-Cleaning Abrasives - Part 10: Almandite Garnet

ISO 11126-10

Preparation of Steel Substrates Before Application of paints and Related Products - Test Methods for Non-Metallic Blast-Cleaning Abrasives

ISO 11127

Protective Clothing for Use in Welding and Allied Processes ISO 11611

Protective Clothing - Clothing to Protect Against Heat and Flame ISO 11612

Paints and Varnishes - Corrosion Protection of Steel Structures by Protective Paint Systems

ISO 12944-3

Thermal Spraying - Approval Testing of Thermal Sprayers ISO 14918

Thermal Spraying - Quality Requirements of Thermally Sprayed Structures - Part 1: Guidance for Selection and Use

ISO 14922-1

Thermal Spraying - Quality Requirements of Thermally Sprayed Structures - Part 2: Comprehensive Quality Requirements

ISO 14922-2



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APPENDIX 1 INSPECTION AND TEST PLAN THERMAL SPRAY ALUMINIUM APPLICATION NEW EQUIPMENT

No Item/Process Process description

Requirement Test Frequency Project Specification section

DEP 30.48.40.31 section

Responsible parties (HOLD points, etc)

Remarks

1.0 Pre-job meeting Check quality

plan As per specification

7.3

Qualification of TSA sprayers

Pass test criteria as per specification

6.3 to 6.5

Safety issues 2.3 2.0 Checks before Surface preparation Visual

inspection and cleaning before blasting

Free from oil grease and other contamination

All 4.2

Check blasting equipment

Per shift 4.3.3

Check blasting material

Per shift 4.3.2

Atmospheric conditions

Per shift 4.3.1

Tool air conditions

Free from oil and water

Per shift/daily 4.3.3

3.0 Inspection after surface preparation Cleanliness Sa2.5 All 4.3.4 Surface

roughness 75 110 m (3 - 4,5 mils)

Once per 100 m2 (1070 ft2) Minimum 3 measurements per day per shift

4.3.5



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Remarks

Chloride contamination

< 20 mg/m2 Once per 100 m2 (1070 ft2) Minimum 3 measurements per day per shift

4.3.7

Dust level Class 1 Once per 100 m2 (1070 ft2) Minimum 3 measurements per day per shift

4.3.6

4.0 Checks before TSA application Atmospheric

conditions Per shift 5.6

Verification of TSA-application apparatus

Per shift 5.2

Verification of Al-wire

Per shift 3.1

Tool air conditions

Free from oil and water

Per shift/daily

5.0 TSA application 5.6 6.0 Inspection after TSA application Visual

inspection Free from blisters, cracks, spatters, etc.

all 7.4.1

Coating thickness

250 500 m (10 20 mils)

7.4.2



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Remarks

Adhesion

Duplicate pull-off test on plate Duplicate pull-off test on equipment

> 7 MPa (1000 psi) > 8.4 MPa (1200 psi) (non-destructive)

Per sprayer per day, i.e. 2 dollies on testplate per sprayer Per shift/daily

7.4.3

Bend test Pass acceptance criteria

3 coupons per sprayer per day

7.4.4

Water spray test

No rusting or bleeding through

After TSA application

7.4.5

7.0 Final inspection 7.8



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APPENDIX 2 EXAMPLE OF INSPECTION FORM FOR TSA APPLICATION

Inspection results:

Clint : Inspector :

Project : Coordinator :

Sprayer Location : Date :

Contractor /main supplier:

Present during inspection:

example

No Process description Requirement Results Item OK NOK NA

1 Checks before Surface preparation Preparation of welds No sharp edges, radius >3 mm

min.

Visual inspection and cleaning before blasting

Free from oil grease and other contamination

Checkblastingequipment

Checkblastingmaterial

Atmospheric conditions Max 85% RH min. 5C max 35C surface 3 above DP.

Tool Air conditions Free from oil and water



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2 Checks after surface preparation Atmospheric conditions Max 85% RH min. 5C max

35C surface 3 above DP.

Cleanliness Sa 2

Surface roughness 75 110 m (3 4.5 mils)

Chloride contamination < 20 mg/m2

Dust level Class 1

3 Checks before TSA application Atmospheric conditions Max 85% RH min. 5C max

35C surface 3 above DP.

Verification of TSA-application apparatus

Verification of Al-wire AA1100

Tool Air conditions Free from oil and water

4 Checks after TSA application Visual inspection Free from blisters, cracks,

spatters, etc.

Coating thickness 250 500 m (10 20 mils) See general

Adhesion > 7 MPa (1000 psi) on test coupon min 8.4 MPa (1200 psi) on workpiece (none destructive)

See general

Bend test Pass acceptance criteria

Water spray test

5 Checks contractors QA/QC documentation Check reports from applicator Complete and up to date



Page 36

The following Items have been inspected: Description:

No. No. of test dollies

Item Pull-off adhesion test.

Pull off adhesion testing 1 1




1. INTRODUCTION1.1 SCOPE1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS1.3 DEFINITIONS1.4 CROSS-REFERENCES1.5 SUMMARY OF MAIN CHANGES1.6 COMMENTS ON THIS DEP1.7 DUAL UNITS

2. GENERAL REQUIREMENTS2.1 GENERAL2.2 DOCUMENT HIERARCHY2.3 SAFETY2.4 COMPANY ACCESS2.5 PRE-JOB MEETING

3. MATERIALS3.1 BACKGROUND3.2 THERMAL SPRAY COATING3.3 SEALER3.4 TOP COAT

4. SURFACE PREPARATION4.1 GENERAL4.2 CLEANING4.3 ABRASIVE BLAST CLEANING

5. COATING APPLICATION5.1 GENERAL5.2 EQUIPMENT5.3 ACCESS5.4 HOLDING PERIOD5.5 MASKING5.6 THERMAL SPRAYING5.7 COATING THICKNESS

6. QUALIFICATION6.1 GENERAL6.2 TSA-VENDOR QUALIFICATION6.3 THERMAL SPRAYER QUALIFICATION6.4 QUALIFICATION TESTS6.5 SUMMARY OF QUALIFICATION TESTS AND ACCEPTANCE CRITERIA

7. QUALITY ASSURANCE AND CONTROL7.1 GENERAL7.2 RESPONSIBILITY OF CONRACTOR AND COATING CONTRACTOR7.3 QUALITY PLAN7.4 TESTING OF COATING PROPERTIES7.5 SUMMARY OF QUALITY CONTROL TESTING AND ACCEPTANCE CRITER7.6 QUALITY RECORDS7.7 INSPECTION PERSONNEL AND EQUIPMENT7.8 FINAL INSPECTION

8. COATING REPAIR8.1 GENERAL8.2 FIELD WELDS

9. STORAGE AND HANDLING10. REFERENCESAPPENDIX 1 INSPECTION AND TEST PLAN THERMAL SPRAY ALUMINIUM APPENDIX 2 EXAMPLE OF INSPECTION FORM FOR TSA APPLICATION

Documents

Dep 30.48.40.31-Genthermal Spray Coatings of Aluminium