QP.spc.L.006 R1-Field Applied Fusion Bonded Epoxy Coating for Pipeline Girth Weld Joints

STANDARDS PUBLICATION

QP TECHNICAL TECHNICAL SPECIFICATION SPECIFICATION FOR FIELD APPLIED A PPLIED FUSION BONDED EPOXY COATING FOR PIPELINE GIRTH WELD JOINTS J OINTS DOC. NO.: NO.: QP- SPC- L- 006 REVISION 1

FACILITIES FACIL ITIES QUAL QUALITY ITY ASSURANCE DEPARTMENT DEPARTMENT

STANDARDS STANDARDS PUBLICATIO PUBL ICATION N

QP TECHNICAL TECHNICAL SPECIFICATION SPECIFICATION FOR FIELD APPLIED A PPLIED FUSION BONDED EPOXY COATING FOR PIPELINE GIRTH WELD WELD J OINTS

DOC. NO.: NO.: QP- SPC- L- 006

Doc. File No.: SPC.L006.R1

Page 1 of 24

Custodian Dept.: FQAD

QP TECHNICAL SPECIFICATION FOR FIELD APPLIED FUSION BONDED EPOXY COATING FOR PIPELINE GIRTH WELD JOINTS Doc. No.: QP-SPC-L-006

Rev. 1

TABL E OF CONTENT

Page No. FOREWORD…………………………………………………………………………

4

1.0

OBJECTIVE……………………………………………………………………….…

5

2.0

SCOPE……………………………………………………………………………….

5

3.0

APPLICATION……………………………………………………………………....

5

4.0

GENERAL REQUIREMENT……………………………………………………....

5

5.0

TERMINOLOGY…………………………………………………………………….

6

5.1

Definitions……………………………………………………………………………

6

5.2

Abbreviations……………………………………………………………………..…

7

6.0

REFERENCE STANDARDS AND CODES………………………………..……

7

7.0

HEALTH, SAFETY AND ENVIRONMENT……………………………………….

9

8.0

MATERIALS………………………………………………………………………....

9

9.0

SURFACE PREPARATION……………………………………..…………………

9

9.1

General…………………………………………………………………………….…

9

9.2

Imperfections/Damage Removal…………………………………………….…….

9

9.3

Contaminants Removal…………………………………………………………….

10

9.4

Abrasive Blast Cleaning………………………………………………….…………

10

10.0

INDUCTION HEATING………………………………………….………………….

12

10.1

Heating the Girth Weld……………………………………………………………..

12

10.2

Temperature Control……………………………………………………………….

12

10.3

Equipment Description and Operation……………………………………………

12

11.0

FBE POWDER COATING APPLICATION………………………………………

13

11.1

General……………………………………………………………………………….

13

11.2

Pre-production Trial……….………………………….……………………………..

13

11.3

Coating Equipment Description and Operation………………………………….

13

11.4

Automatic Machine Application……………………………………………………

14

11.5

Curing Time/Temperature………………………………………………………….

15

11.6

Manual Application………………………………………………………………….

15

12.0

INSPECTION AND TESTING……………………………………………………..

15


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Rev. 1

12.1

General……………………………………………………………………………….

15

12.2

Surface Preparation Inspection/Testing…………………………………………..

16

12.3

Induction Heating Temperature Test……………………………………………...

16

12.4

Inspection / Testing of Coated Area……….……………………………………...

16

13.0

REPAIR OF COATING DAMAGE/DEFECTS…………………………………...

18

13.1

General……………………..………………………………………………………..

18

13.2

Repair Procedure.…………………………………………………………………..

19

13.3

Final Holiday Detection Test……………………………………………………….

19

14.0

QUALITY ASSURANCE/QUALITY CONTROL..……………………………….

19

15.0

DOCUMENTATION…………………………………………………………………

20

16.0

QUALITY CONTROL TABLES……………………………………………………

21

16.1

Table 1: Surface Preparation Requirements..……………………………………

21

16.2

Table 2: Field Pre-production Trial…….………………………………………….

21

16.3

Table 3: Applied Field Joint Coating……………………………………….……..

22

17.0 APPENDIX: FBE FIELD JOINT COATING PROGRESS CHART……………

23

REVISION HISTORY LOG………………………………………………………………...

24


Page 3 of 24



Rev. 1

FOREWORD This document has been developed by Facilities Quality Assurance Department, reviewed by User Departments and endorsed by QP Management for use as QP Technical Specification for Field Applied Fusion Bonded Epoxy Coating for Pipeline Girth Weld Joints. This document is the replacement of QGPC-9741, which was first issued as project specification and then converted to a QP specification. Revision 1 of this document, as QP standard specification, will supersede the said specification and serve as a technical guide for generating project specifications on FBE field joint coating of pipelines. This document, in its present numbering, layout and format was prepared in accordance with the corporate endorsed Standardisation Procedure for Identification of QP Technical Standards (QPPRC-A-001) and the Guideline for Drafting QP Technical Standards (QP-GDL-A-003). It reflects, as far as possible, the current QP requirements taking into account the known available industry practices, QP experience and the applicable latest national and international codes and standards. This document is published for QP Departments/ Contractors/ Consultants utilisation. It should be emphasised that the document is intended to be used for QP operations wherever applicable and appropriate. This document is subjected to periodical review to re-affirm its adequacy and to conform to any changes in QP requirements or to include new developments on the subject. It is recognised that there will be cases where addenda, data sheets, or other clarifications need to be attached to the standard to suit a specific application or service environment. As such, the content of the document shall not be changed or re-edited by any user (QP or its Contractors, suppliers, agents, etc.), but any addenda or clarifications entailing major changes shall be brought to the attention of the Custodian Department. The Custodian of this document is Quality Assurance Department. Therefore, all technical comments, views, recommendations, etc on this document should be forwarded to:

MANAGER FACILITIES QUALITY ASSURANCE DEPARTMENT QA DEPARTMENT, BUILDING NO. 5, RAS AB U AB OUD DOHA FAX NO. 4402207


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1.0

Rev. 1

OBJECTIVE The objective of this Specification is to define QP requirements for the corrosion protection of girth weld joints of pipelines by field applied Fusion Bonded Epoxy (FBE) coating. Also, to provide technical guidance for developing project specifications and to set clear requirements to monitor compliance in material, application, inspection and testing with contract requirements.

2.0

SCOPE

2.1

This document specifies the minimum requirements for; equipment, surface preparation, application method and inspection/testing of FBE field applied coating of steel pipeline girth weld areas for service at a maximum operating temperature of 85° C (185° F).

2.2

FBE powder material shall be in accordance with QP Technical Specification for Plant Applied External Fusion Bonded Epoxy Coating for Pipelines (QP-SPC-L-005).

2.3

Field-applied coating requirement for girth weld joint areas by Heat Shrink Sleeves, as alternative coating, is covered in QP-SPC-L-007.

3.0

APPLICATION

3.1

This specification shall be used for all field-applied FBE external coating for girth welds of steel pipelines installed in QP operating areas.

3.2

The materials and equipment used for surface preparation, coating application and inspection/testing shall satisfy the requirements of this specification and the referenced standards/codes mentioned herein.

4.0

GENERAL REQUIREMENTS

4.1

All requirements explained in this Specification and the reference documents shall be followed, except as modified or supplemented by project specification or datasheet(s), provided that the project specification/datasheet is of higher specification level (see clause 6.2).

4.2

All works associated with FBE coating manufacturing shall be described in a coating Manufacturing Procedure Specification (MPS) conformed to this document. MPS shall be submitted to QP for approval prior to start of works. It shall include but is not limited to the details of materials (properties, compatibility, handling, storage and safety), surface preparation, field joint coating application (equipment, control and calibration process), inspection and testing (parameters, equipment, personnel), coating repair procedures, Quality Assurance and documentation.

4.3

The Contractor shall perform a Pre -application Qualification Test (PQT). This test shall be based on the approved MPS. PQT shall be submitted for QP approval prior to field joint coating application. The PQT shall qualify the coating materials and the coating procedure against the acceptance criteria specified in this document/MPS and approved by QP. PQT inspection and testing results shall be fully documented and compiled in PQT report.


Page 5 of 24


QP TECHNICAL SPECIFICATION FOR FIELD APPLIED FUSION BONDED EPOXY COATING FOR PIPELINE GIRTH WELD JOINTS Doc. No.: QP-SPC-L-006 5.0

TERMINOLOGY

5.1

Definitions

Rev. 1

For the purpose of this specification the following definitions shall apply: 5.1.1

Contractor

Company, firm or party appointed by QP to perform the works in accordance with this Specification. 5.1.2

Dew poi nt

The temperature at which air has reached the saturation point and condensation starts to occur. 5.1.3

Field Joi nt Area (Weld Zone)

The uncoated area, on the pipeline, that results when two pipe sections with coating Cutback are assembled, by welding, in the field. 5.1.4

Holiday

A discontinuity in a protective coating (cracks, pinholes, voids, etc.) that exhibits electrical conductivity when exposed to a specific voltage. 5.1.5

Cutback (Holdback) Area

The area of each section of steel pipe (at each end) which was left uncoated at the coating plant to facilitate welding of adjacent pipe sections. 5.1.6

Manufacturer

The party that manufactures, fabricates, or produces materials or products. 5.1.7

Repair Area

The area of the original coating system that has been damaged and is being repaired using the same or compatible coating materials. 5.1.8

Relati ve Humidi ty

The mass of water vapour in the air expressed as a percentage of the mass of water that is required to saturate the same volume of air at the same temperature. 5.1.9

Shelf Lif e

Shelf Life is the maximum - allowable storage time for a coating material prior to its use. 5.1.10

Works

The works to be executed in accordance with the contract, as defined in the particular conditions and shall incorporate the permanent works together with the temporary works. Doc. File No.: SPC.L006.R1

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Rev. 1

Abbreviations DFT EMS FBE HSE MPS PQT QP QA/QC RH SMS

Dry Film Thickness Environmental Management System Fusion Bonded Epoxy Health, Safety and Environment Manufacturing (coating) Procedure Specification Pre-production (coating) Qualification Testing Qatar Petroleum and its inspectors, engineers or representatives Quality Assurance/Quality Control Relative Humidity Safety Management System

6.0

REFERENCED STANDARDS AND CODES

6.1

Where reference is made to the following standards and codes, the latest edition shall be applicable.

6.1.1

Surface Preparation

ISO 8501-1 (BS 7079-A1) (SIS 05 5900)

Preparation of Steel Substrate Before Application of Paints and Related Products-Visual Assessment of Surface Cleanliness. Pt 1: Specification for Rust Grades and Preparation Grades of Uncoated Steel Substrates and of Steel Substrates After Overall Removal of previous Coatings. Supp 1: Representative Photographic Examples of the Change of Appearance Imparted to Steel When BlastCleaned with Different Abrasives.

ISO 8502 (2-4) {BS7079 (B2-B4)}

Preparation of Steel Substrate Before Application of Paints and Related Products - Tests Methods for Assessment of Surface Cleanliness.

ISO 11124 (1-4) {BS7079 (E1-E4)}

Preparation of Steel Substrate Before Application of Paints and Related Products - Metallic Blast-Cleaning Abrasives.

SSPC-SP1

Steel Structure Painting Manual - Ch.2, Surface Preparation Specifications - Solvent Cleaning.

SSPC-SP2

Steel Structure Painting Manual - Ch.2, Surface Preparation Specifications – Hand Tool Cleaning.

SSPC-SP3

Steel Structure Painting Manual - Ch.2, Surface Preparation Specifications – Power Tool Cleaning.

SSPC-SP7 (NACE No. 4)

Steel Structure Painting Manual - Ch.2, Surface Preparation Specifications – Joint Surface preparation Standard, Brush-off blast Cleaning NACE No. 4.

SSPC-SP10 (NACE No. 2)

Joint Surface Preparation Standard - Near White Blast Cleaning (Steel Structures Painting Council - Surface Preparation Specifications).

SSPC SP11

Steel Structure Painting Manual - Ch.2, Surface Preparation specifications – Power Tool Cleaning to Bare Metal.

SSPC VIS1

Steel Structure Painting Manual - Ch.2, Surface Preparation Specifications – Visual Standard for Abrasive Blast Cleaned Steel (Standard Reference Photographs).


Page 7 of 24


QP TECHNICAL SPECIFICATION FOR FIELD APPLIED FUSION BONDED EPOXY COATING FOR PIPELINE GIRTH WELD JOINTS Doc. No.: QP-SPC-L-006 6.1.2

Rev. 1

FBE Coating Appl icat ion

ASTM A 972/A972M

Standard Specification for Fusion Bonded Epoxy Coated Pipe Piles. AWWA C213 Standard for Fusion-Bonded Epoxy Coating for the Interior and Exterior of Steel Water Lines. CAN/CAS - Z245.20 External Fusion Bonded Epoxy Coating for M92 Steel Pipe. NACE RP0169

6.1.3

Inspect ion and Testing

ASTM G14 ASTM D4417 ISO 9000-2-4 NACE RP0490

NACE RP 0287 SSPC - PA2

6.1.4

Standard Test Method for Impact Resistance of Pipeline Coatings (Falling Weight Test). Field Measurement of Surface Profile of Blast Cleaned Pipe. Quality Management Systems and Quality Assurance Standards Standard Recommended Practice for Holiday Detection of FusionBonded Epoxy External Coating of 250 to 760 Microns (10 to 30 mils). Field Measurements of Surface Profile of Abrasive Blast Cleaned Steel Surface Using Replica Tape. Measurements of Dry Coating Thickness with Magnetic Gauges (Steel Structure Painting Manual–Ch.5, Paint Application Specifications).

QP Standards and Specifi catio ns

QP-PRC-A-001 QP-GDL-A-003

Procedure for Identification of QP Technical Standards. Guidelines for Drafting QP Technical Standards.

QSP-QC-09 QP-SPC-L-002 (ES-Q-12) QP-SPC-L-004

QP-PHL-S-001

Quality Requirements for Projects. QP Technical Specification for Painting and Wrapping of Metal Surfaces (New Construction and Maintenance). QP Technical Specification for External Coating of Offshore Steel Pipelines Using Coal Tar Enamel and Concrete Weight Coating System. QP Technical Specification for Plant Applied External Fusion Bonded Epoxy Coating For Pipeline. QP Technical Specification for Field Joints Coating For Pipeline Girth Welds Using Heat Shrink Sleeves. QP Corporate Philosophy for Fire and Safety.

QP-REG-Q-001 QP-SPC-V-001

QP Lifting Equipment Technical Regulations. QP EMS Specifications for Waste Management.

QP-SPC-L-005 QP-SPC-L-007

6.2

Standard Recommended Practice for Control of External Corrosion on Underground or Submerged Metallic Piping Systems.

In the event of conflict between this document and the standards/ codes referenced herein or other purchase or contractual requirements, the most stringent requirement shall apply unless otherwise specified. User departments shall apply to the Custodian Department for guidance or direction.


Page 8 of 24



Rev. 1

7.0

HEALTH, SAFETY AND ENVIRONMENT

7.1

All necessary health, safety and environmental procedures shall be employed to protect personnel and the surrounding environment during on-site/field works. The Contractor shall submit his HSE/SMS manual for QP approval.

7.2

All relevant safety requirements of QP Corporate Philosophy for Fire and Safety (QP-PHL-S001), QP Safety Regulations for Contractors, and QP Lifting Equipment Regulations (QPREG-Q-001) shall be adhered to while performing works within QP operating areas.

7.3

Materials Safety Datasheets (MSDS) for all chemicals and coating materials to be used within QP operating areas shall be submitted to QP for review and approval. Health and safety precautions shall be clearly described on each material container/package.

7.4

All wastes (i.e., degreasing agents, solvents, abrasive blasting residues, coating materials) resulting from surface preparation and coating application, shall be contained, collected and properly disposed of in accordance with the relevant clauses of QP EMS Specification for Waste Management (QP-SPC-V-001) and the state of Qatar Environmental Regulations.

8.0

MATERIALS

8.1

All material general requirements and the requirements for packing, handling and storage, detailed in Clauses 7.1 and 7.2 of QP Technical Specification for Plant applied Fusion Bonded Epoxy External Coating (QP-SPC-L-005), shall be applied to the materials used for field surface preparation and coating application of girth weld joints.

8.2

The FBE powder material requirements, physical properties, performance test results and certification shall be in accordance with Clause 7.3 of QP-SPC-L-005.

8.3

The Contractor shall employ all necessary arrangements to maintain FBE powder quality within the above-mentioned QP Technical Specification during all phases of storage, handling, transportation and application.

9.0

SURFACE PREPARA TION

9.1

General

9.1.1

The Contractor shall submit a surface preparation procedure and details of equipment and materials to be used in the process for QP approval. The Contractor shall take into account the following requirement in his procedure. Summary of surface preparation requirements, test methods and frequency of testing are shown in Table 1-Clause16.1.

9.1.2

The coating of field joints shall not take place until the weld has undergone NDT or any other required tests and is approved by QP.

9.2

Imperfecti ons/ Damages Removal

9.2.1

Before starting any surface preparation, steel surface to be coated shall be inspected for general condition, weld condition and the presence of defects/damage, which should be referred to the QP representative to establish whether they can be satisfactorily removed.

9.2.2

All surface imperfections/defects that may have arisen in the weld area during installation/welding and/or handling/transportation/storage such as weld spatter, slivers,


Page 9 of 24



Rev. 1

dents, gouges, flattening, etc, shall be removed by suitable methods approved by QP in accordance with SSPC-SP2, SSPC-SP3 or SSPC-SP11. All sharp edges of weld beads or any raised portion of the weld crown shall be smoothed by suitable method approved by QP. If QP-approved grinding method is used to remove imperfections, the pipe wall thickness shall be checked to ensure that the pipe wall thickness is not reduced.

9.3

Contaminants Removal

9.3.1

Prior to surface preparation , oil, grease and other contaminants shall be removed from the steel surface to be coated by a suitable method approved by QP in accordance with SSPC-SP1. Heavy deposits of oil, grease and other fatty matter should initially be broken up by means of an appropriate solvent using clean rags before the above procedure is adopted. Solvent cleaning shall be in accordance with SSPC-SP1. Only solvents that do not leave any residues on the surface shall be used.

9.3.2

Pipe joints that have been contaminated with salt, soil, dust or other atmospheric contamination shall be washed with high-pressure (minimum 3000 psi) fresh water. The surface shall then be allowed to dry before further surface preparation activities are carried out. Air blast can be used for drying. All compressed air shall be free of oil and water.

9.3.3

The Contractor shall submit detailed procedures for contaminants removal works to be done for QP approval. If chemicals are used to clean the pipe joints, no residue that may impair the bonding of the coating system shall be left. QP shall approve all chemicals used in these procedures.

9.3.4

Any frayed or loosened coating at the edge of the plant-applied coating cutback shall be removed. All grease, oil, mud, dirt or other contaminant shall be removed from the pipe within a 300 mm wide band adjacent to the weld area, prior to blast cleaning. The external surface of the pipe joint shall be cleaned to a finish in accordance with the degree specified for plant-applied coatings.

9.4

Abrasi ve Blast Cleaning

9.4.1

The abrasive material used for blast cleaning operations shall be QP approved type, brand and size of grit abrasives selected in accordance with ISO11124 parts 1 – 4. The particle size range of the abrasive shall be selected to achieve the required standard surface cleanliness and surface profile height specified in Sub-clauses 9.4.5 and 9.4.6 respectively. Abrasive blasting materials shall be clean, dry and suitably stored to maintain excellent condition prior to use. It shall be continually checked and sieved to maintain it free of contamination. In case of oil/grease contamination, the abrasive material shall be completely replaced. Under no circumstances shall sand, contaminated and/or recycled abrasives be allowed for blast cleaning. The grit shall be kept dry at all times. Particle size and abrasive type shall be regularly checked.

9.4.2

Equipment for grit blasting shall be of a suitable type to obtain the degree of cleanliness and surface profile specified. It must be in a good working order and shall be kept in a sufficiently clean condition to avoid surface and/or coating contamination.

9.4.3

The compressed air supply used for surface preparation must be of sufficient pressure and volume to prepare the surface to the degree specified and shall be free of water and oil. The air pressure measured at the blasting nozzle shall be 7 bars minimum. Adequate separators and traps for water and oil shall be provided and these shall be kept emptied by regular purging.


Page 10 of 24


QP TECHNICAL SPECIFICATION FOR FIELD APPLIED FUSION BONDED EPOXY COATING FOR PIPELINE GIRTH WELD JOINTS Doc. No.: QP-SPC-L-006 9.4.4

9.4.5

Rev. 1

Each side of weld joint, the bare metal Cutback and the strip of plant-applied coating shall be prepared by abrasive blasting. The plant-applied coating shall not be removed during abrasive blasting, but cleaned and roughened/etched and feathered by the blasting operation to a minimum of 15 mm from its edge, such that no sharp shoulders exist at the edge of the plant coating and the bare steel. The coating strip of 15 to 30 mm wide beyond the edge of plant-applied coating, on either side of the joint shall be swept blasted to roughen the coating to provide a key for overlapping of the field joint coating. Sweep blasting shall be in accordance with NACE 4/SSPC-SP7. Adjacent plant-applied coating shall be protected; a canopy and covers shall be fixed during blast cleaning so that blasting does not contaminate powder application or any welding operations on the adjacent joints. The bare metal of the girth weld shall be blast cleaned to achieve a standard of surface cleanliness conforming to ISO 8501-1- Sa 2 ½ or SSPC equivalent SP10 standard (NACE No. 2). A photographic or visual standard such as SSPC-VIS1 shall be used to verify that a near-white finish has been achieved.

9.4.6

The abrasive blast cleaning shall produce a surface profile height (anchor pattern) of 50 – 100 microns. The profile shall be inspected using a replica film-type tape in accordance with ASTM D4417 or NACE RP0287. The test tape shall be attached to the daily report (for record purpose) submitted to QP.

9.4.7

After blast-cleaning, all residual particulate matter, dust and blasting materials shall be removed from the blast-cleaned surface area by vacuum cleaning or using clean, dry, oil and moisture free compressed air before proceeding to further operations. The external surface shall be tested for residual dust particles using transparent self adhesive tape as per ISO 8502-3. A minimum acceptance standard of class 2 rating 2 shall apply. At the discretion of QP a Potassium Ferricyanide test may be carried out to confirm a contamination free surface.

9.4.8

Abrasive blast-cleaned surface area shall be protected from wet, rain or humid conditions. The cleaned surface shall be tested for condensation as per ISO 8502-4. Weld area prepared surface shall be checked for rust blooming prior to coating application. If rust blooming occurs, the pipe surface must be blast cleaned as explained in Clause 9.4. All prepared weld joint surface area, in any case, shall be coated within maximum 4 hours of blast cleaning.

9.4.9

Abrasive blast-cleaned surface shall be protected from salt/chloride contamination. The blast-cleaned surface shall be tested for chloride contamination. The Contractor shall submit a test procedure for QP approval. The acceptance criteria shall be maximum 20 mg NaCl/m² or as recommended by coating manufacturer.

9.4.10

Abrasive blast-cleaned pipe surface shall be inspected immediately for defects after blast cleaning. All slivers, scabs, slag, etc., made visible by blast cleaning shall be referred to QP representative to establish whether they can be satisfactorily removed by a suitable method within the corrosion allowance of the pipe. This cleaning operation shall not burnish or completely destroy the anchor pattern. If required, abrasive blast cleaning should be used to reinstate anchor pattern. The Contractor shall submit a procedure to QP for checking wall thickness. At no time shall the blast-cleaning be performed when the relative humidity exceeds 85% or when the steel temperature is less than 3°C higher than the dew point. It shall be checked for dryness and temperature using suitable QP-approved instrument. Dew point measurements shall be taken before, during and after blasting operations The pipe surface may be heated prior to blasting, utilizing a uniform pre-heating of the steel pipe to a minimum temperature as required to remove condensation and to ensue that the pipe temperature is at least 3ºC above the ambient dew point. This is to maintain dry steel

9.4.11


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Rev. 1

surface prior to blast cleaning. The pre-heating equipment and procedure are subject to QP approval, prior to commencement of blast cleaning. 9.4.12

Just prior to induction heating, the area to be coated shall be blown clean of all dust, sand, etc., using clean, dry, high-pressure air. It is recommended that this area be brushcleaned with a clean, dry bristle-type paintbrush. In no case shall the abrasive blasted weld joints be allowed to rust before they are coated.

10.0

INDUCTION HEATING

10.1

Heating the Girth Weld

10.1.1

The weld area shall be heated by high frequency induction heating coil to a temperature within a range of 225 oC to 250oC. The actual temperature range shall be in accordance with the powder manufacturer’s recommendation. Under no circumstances shall the field joint area be heated above 260 oC.

10.1.2

The heating equipment shall be approved by QP and shall be sized to ensure the entire area to be coated reaches the required temperature. The induction coil shall have been tested for heat profile and should have a difference across the weld joint not exceeding 10 o C. The heating time to reach the required temperature shall be defined.

10.1.3

Allowance must be made for the reduction in temperature due to the coil "switch off", and the time delay between coil "switch off" and the coating application starting.

10.1.4

The pipe surface will be inspected to assure no rust bloom or other contamination is on the surface of the pipe joint prior to application of heat. All defects shall be removed by a suitable method before the coating operation commences.

10.2

Temperature Contro l

10.2.1

The temperature profile across the uncoated joint area shall be such that the heat does not damage the plant-applied coating. The temperature measurement arrangement should be such as to ensure the necessary temperature control.

10.2.2

Temperature of the steel bare area shall be checked using a QP approved calibrated temperature measuring device, e.g. digital contact thermometer. Temperature indication crayons shall not be used in any case due to the crayons residue being imparted on the prepared surface. Measurements at several locations shall be required to ensure uniform heating.

10.3

Equipm ent Descr iption and Operation

10.3.1

Induction heating equipment shall comprise a generator, power source, control unit and split heating coil. The generator, power source and control unit shall be mounted on a movable trailer with a boom which supports the induction coil and power cables. The coil shall be a split type with manual or automatic clamps.


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Rev. 1

10.3.2

The induction coil shall be lowered over the girth weld area, and clamped to the pipe so that it is centrally positioned over the weld. The heating cycle can then commence. It shall rapidly heat the substrate to an overall even heat band.

10.3.3

After the specified temperature has been reached, the power shall be switched off, the coil unclamped, raised off the pipe and moved away.

11.0

FBE POWDER COATING APPLICATION

11.1

General

11.1.1

All surfaces to be coated shall be dry and free from any dust, abrasive remains or any other contaminants before any coating operation is started. Vacuum dust extractor shall be used to remove the same. Also, the surfaces shall be checked for conformance with clause 9.4.

11.1.2

All coating materials to be used in coating operations shall be checked for conformance with Clause 8.3 above before coating application starts.

11.1.3

The application process shall be designed to achieve a coating that is free of inhomogeneities, porosity, inclusions, laminations or poor bonding. Cured properties shall be consistent throughout the thickness.

11.1.4

The equipment and methods used for FBE field joint coating application shall be in accordance with the recommendations of the coating material manufacturer and the minimum requirements of this Specification.

11.1.5

Coating works shall not commence until QP approves the QA/QC requirements explained in Clause 14.0.

11.2

Pre-produc tion Trial

11.2.1

Prior to production coating, two (2) representative field joints per pipe diameter shall be coated in accordance with the manufacturer’s recommendations and the QP approved procedures to establish that the coating operation and the joint coating meet the requirements of this specification. QP representative shall witness this pre-production trial.

11.2.2

Quality control tests shall be performed on all pre-production-coated joints. The required tests, test method, acceptance criteria and frequency of testing shall be in accordance with Table 2 -Clause 16.2 of this Specification.

11.2.3

No production shall commence until Contractor has performed all the above tests to the satisfaction of QP. The field test joint shall be repaired in accordance with Clause 13.0 of this Specification and inspected for compliance to the Specification and for approval of the procedure.

11.3

Coating Equipment Descript ion and Operation

11.3.1

The coating equipment shall consist of a powder hopper and feed machine, control cabinet, vacuum extraction machine, air compressor, rotary traversing machine and spray heads.

11.3.2

The number of spray heads shall depend on pipe diameter. There should be sufficient spray heads to deliver the required FBE powder to the heated area, in a controlled manner, before the temperature drops below the application temperature.


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Rev. 1

11.3.3

The powder hopper and feed machine, control cabinet, vacuum extraction machine and air compressor shall be mounted on a trailer with the induction heating equipment.

11.3.4

A booms shall support the air hoses, cables, and spraying machine.

11.3.5

This equipment shall be located alongside the induction heating equipment and shall be weather proof. 11.3.6 Where automatic machine application equipment explained above is not practical, the field joints shall be manually coated using electrostatic spraying guns approved by QP.

11.4

Auto matic Machi ne Appl ication

11.4.1

Contractor shall notify QP in writing at least seven (7) working days prior to the coating work commencing.

11.4.2

FBE powder shall be transported to the site and stored in accordance with the manufacturer’s recommendations. The powder containers shall never be in direct sun or near hot equipment. The powder shall be taken from the storage area to the point of application in quantities to be used for one day only. The powder shall always be protected from any moisture/dirt contamination. The Contractor shall advise QP when improper conditions are being encountered.

11.4.3

Coating operation shall immediately follow the heating operation. The powder application machine shall be placed around the girth weld immediately after the heater is removed.

11.4.4

If a delay results in the surface cooling to, or below a temperature specified by the powder manufacturer before coating, the weld area shall be re-heated to the specified temperature.

11.4.5

The FBE powder shall be fluidized then flock-applied to the girth weld area. A minimum of four (4) passes shall be made by the application machine, which shall circumscribe the pipe at a steady and uniform speed by motorized or similar drive method. The coating thickness at joint shall be the same as specified for the plant-applied coating (450-550 micron). Any weld joint coating, which fails to meet the QP, specified thickness requirement shall be removed and reprocessed.

11.4.6

The joint coating shall overlap the plant-applied coating by a minimum of 25mm on each side of the weld area.

11.4.7

Care should be taken to prevent the spray head, braces, hoses, etc., from dragging on the ground during application. Dirt, dust or deleterious material must not be allowed to contaminate the powder-coated areas during application and curing stages.

11.4.8

Whenever coating application system is shut down for prolonged periods of time, or overnight, it shall be completely cleaned of all powder. All hoses shall be completely purged, and removed powder shall be disposed of.


Page 14 of 24



Rev. 1

Curi ng Time/Temperatur e The curing temperature/time shall be strictly in accordance with powder Manufacturer’s specification, established during pre-production runs and subject to QP approval. If the ambient air temperature falls, it may be necessary to increase the heating temperature to provide adequate curing energy. If required and subject to powder manufacturer approval, the induction coil may be replaced over the coated area to bring the coating up to the curing temperature.

11.6

Manual Appli cation

11.6.1

Where automatic machine application of powder is not practical, and subject to QP approval, the field joints can be manually coated using electrostatic spraying guns. The powder shall be applied to the weld area from the delivery hose on the flocking unit.

11.6.2

Holding the delivery hose by hand and using the spray technique, the powder flow can be directed onto the area to be coated. As spraying operation is continued around the circumference of the weld area, the thickness of the coating can be controlled by the speed at which the delivery hose is fanned over the hot surface.

11.6.3

All FBE powder application requirements mentioned under Clause 11.4 (not related to equipment) shall apply under this Clause.

12.0

INSPECTION AND TESTING

12.1

General

12.1.1

At any time, QP shall have the right to inspect tools, materials or equipment used in surface preparation, coating application and inspection and testing to ensure compliance with this document.

12.1.2

The Contractor shall perform inspection and testing at all stages of surface preparation and coating application to ensure conformance with this Specification and the approved procedures. Persons qualified by experience and internationally recognized training/certification in coating inspection shall perform the required inspection. All these stages will be subject to continuous inspection/monitoring by QP.

12.1.3

QP shall have the right to carry out inspection and testing during surface preparation and coating application works. QP shall be the final authority on the acceptability of surface preparation and coating application.

12.1.4

QP may use a third party inspection authority to carry out the inspections mentioned under Sub-clauses 12.1.1 and 12.1.3.

12.1.5

All coating materials shall be checked to ensure conformance with the requirements of this Specification. Samples of the coating materials, test certificates and coated sample plate shall be submitted to QP for approval prior to application.


Page 15 of 24



Rev. 1

12.1.6

The powder manufacturer’s representative shall have access to the Contractor’s facilities during the progress of the work to undertake any inspection and testing deemed necessary to ensure that the coatings are properly applied.

12.1.7

The Contractor shall submit procedures for all inspection and testing works to be carried out for QP review and approval. The results of all tests performed shall be recorded, tabulated and retained with inspection records. The Contractor shall keep these records and submit to QP on a daily basis, for verification and approval. The period between the test performed and the test report shall be 72 hours maximum. This daily record keeping and submittal to QP is important to ensure continuing compliance with this specification and approved procedures. The Contractor shall notify QP in writing, at least seven (7) working days prior to the coating work commencing.

12.1.8

Inspection/testing and repair of field joint coating shall commence after the heat zone has cooled down to 90°C or below unless other wise specified and approved by QP.

12.2

Surface Preparation Inspectio n/Testi ng The surface preparation shall be checked for conformance with the requirements of this specification. The qualification tests required and the test method, acceptance criteria and frequency of testing should be in accordance with Table1-Clause 16.1. Failure to comply with specified range mentioned in this Table shall be grounds for rejection by QP .

12.3

Induct ion Heating Temperatur e Test The temperature control shall be carried out continuously at the induction heater and at the point of powder application. Infrared pyrometers or approved equivalent shall be used to assure correct pipe temperature. The temperature shall be within the powder Manufacturer’s recommendation, but shall not exceed 260°C.

12.4

Inspectio n/Testi ng of Coated Area

12.4.1

Visual Inspect ion

12.4.2

a)

All coated steel pipe girth weld area shall be visually inspected to ensure that the FBE powder coating has been applied in a manner representing high quality workmanship and that the material has cured correctly. The finished coating shall be of uniform colour and gloss and free from orange peeling, sags and runs.

b)

The coating shall be inspected for surface imperfections, lack of bond, voids, breaks, blisters, de-laminations, cuts, indentations or any other defects or apparent irregularities. Any visually detected defects shall be marked and brought to the attention of QP. Failure to satisfy QP as to the integrity of the coating shall be grounds for rejection and recoating of all defective field joints.

Foam Void Test (Cros s-Sect ion por osi ty)

The foaming level of the applied FBE coating shall be established by viewing the cross section of the coating film under a microscope (40X magnification). The frequency of testing shall be one joint per shift. The Contractor shall provide photographic visual standards for levels of foaming for QP approval. The acceptable number of voids shall comply with “Rating 1 to 3” as per CAN/CSA-Z245.20 or NACE RP 394.


Page 16 of 24



12.4.3

12.4.4

Cure Tests

a)

The Contractor shall perform a Methyl Ethyl Ketone (MEK) double rub test, by placing a cotton cloth soaked with MEK. Rub the film with 2-inch long (50 mm) firm strokes. Fifty double rubs (50 rubs in each direction) should not cause softening or removal of the coating. The frequency of testing shall be first 10 weld joints then once per shift.

b)

Contractor shall ensure that adequate safety clothing and equipment are available to the operator, during this test. The frequency of the test shall be once per shift.

Adhesion Test

a)

b)

c)

12.4.5

Rev. 1

Bond (adhesion) tests shall be performed on the cured coating to ensure that the adhesion is satisfactory. Adhesion test shall initially be checked on one joint per shift or one in twenty whichever is more frequent. The adhesion testing shall be checked by pushing a sharp narrow width knife blade through the coating, two approximately 13mm long incisions shall be made through to the steel surface at 45 degrees to form an X. At the intersection of the X, an attempt shall be made to force the coating from the steel substrate with the knifepoint. Refusal of the coating to disbond from the steel substrate constitutes a pass and the coating in this case shall be considered acceptable. Any partial or complete peel-off exposing bare metal constitutes a failure and the coating shall be considered rejected. In addition, the steel/coating interface shall be examined by using a low magnification microscope (20-60X) to establish that the coating has remained in the pits of the surface profile. If QP Engineer considers the coating adhesion is not acceptable, further joints shall be tested to establish the extent of the adhesion failure. The Contractor shall recoat all rejected coated weld joints. The bond test area shall be repaired in accordance with the Contractor’s procedure approved by QP.

Film Thick ness Measur ement

a)

Dry film thickness (DFT) measurements of the cured coating shall be made at ambient temperature using a non-destructive DFT gauge, or suitable approved instrument. The DFT gauge shall be calibrated at least twice per shift. There shall be at least 4 equally spaced readings around the circumference of the joint and across the width of the joint.

b)

The DFT measurements shall be in accordance with the method described in SSPC PA2 or as per the QP-approved Contractor’s procedure.

c)

The DFT of the field joint FBE coating shall be the same as specified for the plantapplied coating (450-550 micron). Thickness average shall be recorded and included in the Contractor’s inspection report. Should the actual thickness be less than the minimum specified value, the coating shall be rejected. The defective coating area shall be re-blasted and re-coated in accordance with this specification.


Page 17 of 24



12.4.6

Rev. 1

Impact Test

Impact resistance of the coating shall be checked on one joint per shift at two random locations. The impact resistance test shall be carried out using a "Gardner" impact tester or equivalent with a 16 mm diameter cup in accordance with ASTM G14. The minimum acceptable value shall be 1.5 J. 12.4.7

Holid ay Detection

a) All surface area of the coated pipeline shall be subjected to100% holiday detection prior to lowering in the trench. The detector shall be a pulse-type recommended by the coating manufacturer and approved by QP. The test voltage shall be set to a value depending upon coating thickness, in accordance with NACE RP 0490. Calibration of the detector shall be at least twice per 8 hours, at start of shift and midway through shift. b) The electrode used for locating holidays shall be designed to ensure direct contact with the coating, (with no visible gaps) and provide complete coverage of the whole coated surface area. Holiday detection shall be conducted only after the surface temperature of the pipe has fallen below 90 oC. The travel rate of the detector electrode shall not exceed 0.30 m/s and shall not be allowed to remain stationary while the power is on. c) The allowable holiday acceptance criteria for a coated pipe, to avoid complete rejection, will be specified by the project specification and agreed by QP and the Contractor The maximum number of holidays, which are permitted to be repaired per field joint shall be two (2). All joints having more than two (2) holidays shall be stripped, re-blasted and recoated in accordance with this specification. d)

The Contractor shall mark the allowable detected holidays for repair in accordance with his defect repair procedure based on clause 13.0 of this Specification and approved by QP. The defective areas shall be electrically re-tested after coating repair. No holidays shall be permitted in finished coating.

e)

The Contractor shall provide a holiday detection procedure for QP approval. It shall be based on the above requirements. Any item not specified under this sub-clause shall be in accordance with NACE RP490.

13.0

REPAIR OF COATING DAMAGE/DEFECT

13.1

General

13.1.1

Damaged/defective coating areas and the allowable holidays as per Sub-clause 12.3.7 shall be repaired, and re-tested to the satisfaction of QP.

13.1.2

The repair material for coating damages shall be epoxy compound recommended by the FBE powder manufacturer and approved by QP. It shall have same performance of the FBE coating and have good adherence to the existing coating. Also, it shall be specially formulated to allow application and curing in a minimum time for pipe laying operations reasons.


Page 18 of 24



Rev. 1

13.1.3

Prior to coating repair works, the Contractor shall submit to QP, for approval, his detailed damage/defect coating repair procedures. All repair procedures shall follow the requirements of this Specification and the epoxy compound manufacturer’s recommendation. Also, the coating manufacturer’s technical data sheets shall be adhered to regarding the limitations relating to relative humidity, dew point, surface/atmospheric temperatures, etc.

13.2

Repair Procedure

13.2.1

Coating areas to be repaired or patched, shall be prepared by suitable hand tool cleaning for areas less than 100 mm² or by blast cleaning (ISO 8501-1/Sa2½), using mini pot grit blasting equipment, for areas 100 mm² and above. Preparation shall overlap onto existing sound coating by 13mm.

13.2.2

The entire coating area to be repaired/patched shall be free of rust, grease, dirt, dust, sharp edges, weld spatter, etc .

13.2.3

Where pinholes and larger areas of damaged coating are to be repaired, a 100% solids liquid epoxy compound, recommended by the FBE powder manufacturer and approved by QP shall be mixed as per the manufacturer's instructions and applied to the area to a thickness equal to the plant applied coating. Care should be taken in proportioning the twopart repair compound such that they are mixed thoroughly.

13.2.4

The Epoxy compound material shall be applied to the prepared area using a clean spatula/filling knife or brush or as recommended by coating manufacturer. The epoxy compound shall be applied such that a continuous and smooth patch is obtained. The applied material shall overlap the adjacent parent coating for approximately 13mm. Adequate material to repair the affected area should be mixed together at the same time.

13.3

Final Holiday Detecti on Test Upon completion of all coating repairs and prior to laying of the pipeline, a final holiday detection test shall be made on the entire coated surface. Test shall be in accordance with Sub-clause 12.3.7 of this Specification.

14.0

QUALITY ASSURANCE/QUALITY CONTROL

14.1

The Manufacturer/Contractor shall operate a Quality Management System based on the relevant part of ISO 9000 series of standards to satisfy the requirements of this Specification.

14.2

The Manufacturer/Contractor shall demonstrate compliance by providing a copy of the accredited certificate or the Manufacturer's/Contractor's Quality Manual.

14.3

Prior to commencement of works, the Contractor shall submit his QA/QC documentation for QP approval as per the requirements of QSP- QC-09. This shall include his Quality plan and


Page 19 of 24



Rev. 1

quality control system including inspection and testing method and reporting/recording formats. 14.4

The Contractor shall prepare and submit to QP for approval a detailed procedures manual of all works, sufficiently in advance of commencement of coating operation, outlining, but not limited to, the following: a) b) c) d) e) f) g) h)

FBE Powder system to be used and manufacturer data sheets and test results. Pipe cleaning, blast cleaning medium and procedures, blast cleaning degree and surface profile (anchor pattern), metal defect removal and dust removal procedures. Induction heating coil details, pipe heating method and temperature profiles, control and curing. FBE Powder application method for field joints. Coating equipment and machinery details and production rates. Coating repair technique Sample log-sheets of material receipts, measurement, logging, and despatches. Field joint FBE coating progress chart. Sample of the same is defined in the Appendix.

The work shall commence only after QP approval of the procedures manual. After approval, no change shall be made unless authorised, in writing, by QP. 14.5

Sampling and testing of all materials supplied for field joint coating operations shall be in accordance with QP-SPC-L-005 and to a plan agreed between the Contractor and QP.

14.6

Only skilled, qualified and experienced personnel, acceptable to QP, shall be used to meet the required duties in this specification. Adequate supervision shall be employed at all times.

15.0

DOCUMENTATION

15.1

All correspondence, drawings, instructions, data sheets, design calculations, and all other written information shall be in English language. In the case of dual languages, one language shall be English and the other Arabic.

15.2

All dimensions, measurements, physical constants, etc. shall be in SI units, unless otherwise specified.

15.3

The Contractor shall provide QP with his, Quality Manual, work proposals, procedures, material datasheets, material test results and test certificates.

15.4

The Contractor shall maintain a comprehensive recording and reporting system on all aspects of surface preparation, coating application, Quality Assurance inspection and testing. A final report shall be submitted to QP summarising works performed and inspection and testing results for approval.

15.5

All documents (texts, specifications, data sheets, drawings etc.) shall be provided with electronic files in the approved software (i.e., MS Word, Excel, Auto-Cad). Design calculations shall be submitted in the approved and widely used software agreed by QP.


Page 20 of 24



Rev. 1

16.0

QUALITY CONTROL TABL ES

16.1

Table1: Surface Preparatio n Requirements

16.2

Test Method

Requirement

Frequency

N.

Item/ Property

1

Initial steel surface condition

Dry and free from contamination, rust and weld spatters/defect.

2

Steel temperature and RH

Temperature minimum 3º C As per Contractor above dew point. RH less procedure than 85%.

Start of each shift and then every 4 hours (Min.)

4

Surface Cleanliness (Salt /chloride contamination)

Maximum 20 mg NaCl /m² or as recommended by coating manufacturer

Contractors approved procedure

First 10, then one joint /shift

5

Surface Cleanliness (Visual Standard)

Sa 2½ - SSPC-Vsi1

Visual examination ISO 8501-1/SPC10

Every joint

6

Surface Cleanliness (residual dust particles)

Class 2 Rating 2

ISO 8502-3

First 10, then one joint /shift

7

Surface Profile

50–100 Micron

ASTM D4417 NACE RP0287

8

Final Surface Condition

Free from surface defects, dust, rust blooming

Visual examination

Visual inspection

Every joint

or

First 10, then one joint /shift Every joint

Table2: Field Pre-production Trial Test Method

Item/ Property

1

Steel surface induction heat

Induction Coil heat profile between 225º C -250º C

Contractor’s approved procedure

One Coil

2

Steel temperature and RH

Temperature minimum 3º C above

Contractor's approved procedure

Each joint

3

Surface cleanliness (Visual Standard)

Sa 2½ - SSPC-Vis1

Visual examination ISO 8501-1/SP10

Each joint

4

Surface Profile

50–100 Micron

ASTM D4417 NACE RP0274

or

Each joint

5

Joint coating -Visual

Uniform colour/gloss, smooth & Visual examination blemish free. No sign of runs, uncured Approved procedure powder or other defects.

Each joint

6

Dry Film Thickness

450-550 microns. Four readings at SSPC-PA2 equally spaced locations Approved procedure

Each joint

7

Adhesion Test

No Disbonding (100% adhesion)

Each joint

8

Impact Test (45º)

Minimum 1.5J (2 random locations)

ASTM G14

Each joint

9

Foam Test

Rating 1 to 3 - Acceptable photographic visual standard

CAN/CAS-Z245.20 or NACE RP0394

Each joint

10

Cure Test

No softening or removal of coating

MEK Rub Test Approved procedure

Each joint

11

Holiday Detection

100% holiday holidays

NACE RP0490 Approved procedure

Each joint


Requi rement

Frequency

N.

dew point. RH less than 85%.

free

–

Repaired

Page 21 of 24

45º Cross-cut test Approved procedure

Induc.



16.3

Rev. 1

Table3: Applied Field Joint Coating Test Method

Item/ Property

1

Joint coating -Visual

Uniform colour/gloss, smooth & Visual examination blemish free. No sign of runs, Approved procedure uncured powder or other defects.

Every Joint

2

Dry Film Thickness

450-550 microns. Four readings at SSPC-PA2 equally spaced locations Approved procedure

Every Joint

3

Adhesion Test

No Disbonding (100% adhesion)

One/shit or one /twenty

4

Impact Test (45º)

Minimum 1.5J (2 random locations)

ASTM G14

One/shift at two random locations

5

Foam Test

Rating 1 to 3 - Acceptable photographic visual standard

CAN/CAS-Z245.20 or NACE RP0394

One/shift

6

Cure Test

No softening or removal of coating

MEK Rub Test - First 10 Approved procedure joints then One/shift

7

Holiday Detection

100% holiday holidays

NACE RP 0490 Approved procedure


Requirement

Frequency

N.

free

–

Repaired

Page 22 of 24

45º Cross-cut test Approved procedure

Every Joint



Rev. 1

APPENDIX: FBE FIELD JOINT COATING PROGRESS CHART

Nomin al Pipe Size (NPS): Pipe Outer Diameter: Pipe Grade: Project: Project Spec. No.:

Contr actor : Contract No.: Contractor Procedure Ref: Drawing No.: Location:

Sheet Prepared by: Reviewed by: Appro ved by: Date:

of

Pipe Line Identification Pipeline Length (Km) Pipeline Name No. of Girth Welds Girth Weld Zone surface Area Pre-produ ction Trial Date Test Results/Approval Date of FBE Joint Coating Surface Preparation Contaminants Removal Imperfection Removal Pre-heating Blast Cleaning Method Visual Standard Surface Profile Surface cleanliness Testing Results/ Approval Coating Materials Manufacturer Batch No. /Product ID Packing/Handling/Storage Testing / Approval (As per QP-SPC-L-005) FBE Powder Applicatio n Coating Procedure Manual Induction Heating (Temperature) Curing Time/Temperature Application Method (Automatic/Manual) Inspection/Testing – Coated Field Join ts Visual Inspection Holiday Detection (joint and whole line) Thickness Test Adhesion (Bond) Test Foam Test Cure Test Impact Test Tests Results/ Certificates/ Approval Quality Assurance/ Quality Contro l Records Coating Completion Date Final Approval

Observations/Comments:


Page 23 of 24



Rev. 1

REVISION HISTORY LOG

Revisio n Number: 1

Item Revised:

Date: 10/3/2002

Reason for Change/Amendment: Major Updating and Rewriting Changes/Amendments Made:

This is a new specification based on the project specification (QGPC-9741). The whole document was revised to satisfy the requirements of the standardization documents (QP-PRC-A-001 and QP-PRC-A-003). It was also revised to include the latest developments in the worldwide standards referenced in the document, the latest market research and the QP specific requirements.

Note:

The revision history log shall be updated with each revision of the document. It shall contain a written audit trail of the reason why the changes/amendments have occurred, what the changes/amendments were, and the date at which the changes/amendments were made.


Page 24 of 24


QP.spc.L.006 R1-Field Applied Fusion Bonded Epoxy Coating for Pipeline Girth Weld Joints

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