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

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

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Sections

  • 1.0 INTRODUCTION
  • 2.0 PROJECT DEFINITION
  • 3.0 PURPOSE OF DOCUMENT
  • 4.0 GENERAL INFORMATION
  • 4.2 ABBREVIATIONS
  • 5.0 GENERAL REQUIREMENTS
  • 5.1 GENERAL
  • 5.2 QUALITY SYSTEM
  • 6.0 COATING SYSTEM
  • 6.1 COATING SYSTEM
  • 7.0 COATING MATERIAL REQUIREMENT
  • 7.1 GENERAL
  • 7.4 TOP LAYER
  • 8.0 MEASUREMENT AND LOGGING
  • 9.0 SURFACE PREPARATION
  • 9.1.2 Abrasive Blast Cleaning
  • 9.1.4 Acid Wash
  • 10.0 COATING APPLICATION
  • 10.3.2 Discharge of Isocyanate
  • 10.5 TYPICAL CUTBACK
  • 11.0 INSPECTION AND TESTING
  • 12.0 PIPE MARKING
  • 13.0 STORAGE, HANDLING AND TRANSPORTATION
  • 14.0 DOCUMENTATION
  • 14.1 GENERAL

Su Tu Vang South West

Cuu Long Joint Operating Company
STV EXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW, PIPELINES AND CPP MODIFICATIONS

SPECIFICATION FOR POLYURETHANE INSULATION COATING
DOCUMENT NO.: 2013-6031-2L-0010

A Rev.

ISSUED FOR REVIEW Description

20/12/13 Date

NTTH Prepared

GKH Checked

DNP PVE

NDK PTSC MC CLJOC Approval

Approved by

STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW, PIPELINES AND CPP MODIFICATIONS
Document No.: 2013-6031-2L-0010

SPECIFICATION FOR POLYURETHANE INSULATION COATING REVISION LOG Revision No.
A

Revision: A Page:2 of 42

Section
ALL

Revision Description
ISSUED FOR REVIEW

STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW, PIPELINES AND CPP MODIFICATIONS
Document No.: 2013-6031-2L-0010

SPECIFICATION FOR POLYURETHANE INSULATION COATING

Revision: A Page:3 of 42

TABLE OF CONTENTS

1.0 2.0 3.0 4.0 4.1 4.2 4.3 4.4 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 6.0 6.1 6.2 7.0 7.1 7.2 7.3 7.4 8.0 9.0 9.1

INTRODUCTION ..........................................................................................................5 PROJECT DEFINITION ..............................................................................................6 PURPOSE OF DOCUMENT ........................................................................................6 GENERAL INFORMATION ........................................................................................6 LANGUAGUES AND UNIT OF MEASURES ..............................................................6 ABBREVIATIONS ..........................................................................................................6 CODES AND STANDARDS...........................................................................................7 REFERENCE DOCUMENT ..........................................................................................10 GENERAL REQUIREMENTS ...................................................................................10 GENERAL ......................................................................................................................10 QUALITY SYSTEM ......................................................................................................10 HEALTH, SAFETY AND ENVIRONMENT ...............................................................11 QUALIFICATION TESTING........................................................................................11 VENDOR’S RESPONSIBILITY ...................................................................................11 PERFORMANCE OF WORK .......................................................................................13 NON CONFORMANCE ................................................................................................13 COATING SYSTEM ....................................................................................................14 GENERAL ...................................................................... Error! Bookmark not defined. COATING SYSTEM......................................................................................................14 COATING MATERIAL REQUIREMENT...............................................................14 GENERAL ......................................................................................................................14 PRIMER AND/OR FIRST COAT .................................................................................15 2nd LAYER .....................................................................................................................16 TOP LAYER ..................................................................................................................17 MEASUREMENT AND LOGGING ..........................................................................18 SURFACE PREPARATION .......................................................................................18 PIPE SURFACE PREPARATION.................................................................................18

9.1.1 Metal Surface ..................................................................................................................18

STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW, PIPELINES AND CPP MODIFICATIONS
Document No.: 2013-6031-2L-0010

SPECIFICATION FOR POLYURETHANE INSULATION COATING

Revision: A Page:4 of 42

9.1.2 Abrasive Blast Cleaning .................................................................................................19 9.1.3 Inspection of Surface Cleanliness ...................................................................................19 9.1.4 Acid Wash ......................................................................................................................20 9.2 9.3 9.4 10.0 10.1 10.2 10.3 SURFACE PREPARATION OF FBE COATED PIPES ...............................................21 SURFACE PREPARATION OF PUF COATED PIPES ...............................................21 MOULD PREPARATION FOR PUF COATING .........................................................21 COATING APPLICATION ........................................................................................22 PIPE HEATING .............................................................................................................22 EPOXY APPLICATION ................................................................................................23 PUF APPLICATION ......................................................................................................23

10.3.1 Pre-Mixing of Polyol and Transfer to Conditioning Tank .............................................23 10.3.2 Discharge of Isocyanate ..................................................................................................24 10.3.3 Mixing and Pumping of PUF ..........................................................................................24 10.3.4 PUF Coating Application ...............................................................................................24 10.4 HDPE APPLICATION ...................................................................................................25 10.4.1 Water Stop Application ..................................................................................................25 10.4.2 HDPE Application ..........................................................................................................25 10.4.3 Sinter Coat / Rough Coat (FOR CWC COATED PIPES ONLY) ..................................25 10.4.4 Water Quench, Cooling and Inspection Racks ...............................................................25 10.5 11.0 12.0 13.0 14.0 14.1 14.2 TYPICAL CUTBACK ...................................................................................................26 INSPECTION AND TESTING ...................................................................................27 PIPE MARKING ..........................................................................................................39 STORAGE, HANDLING AND TRANSPORTATION ............................................39 DOCUMENTATION ...................................................................................................41 GENERAL ......................................................................................................................41 REPORT DOCUMENT .................................................................................................42

This development consists of an unmanned tripod jacketed platform (SVSW) with minimum facility which tie-back and operated from the adjacent STV-CPP. The development of this field will be carried out by utilizing 3 slots consist of one (1) existing well using single Xmas Tree and two (2) future dual well Xmas Trees. Processing of the SVSW wellstream fluids will be carried out on the STV-CPP facilities which will also supply gas to SVSW for gas lifting. An overview of the STV Extension Plan – STV South West Project is shown in the Figure 1 below: Figure 1: STV Extension Plan – STV South West Project .: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:5 of 42 1.0 INTRODUCTION Cuu Long Joint Operating has embarked in the development of STV Extension Plan STV South West (SVSW) Project located in Block 15-1. offshore Vietnam. STV-CPP will also control and monitor SVSW. PIPELINES AND CPP MODIFICATIONS Document No.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.

1 GENERAL INFORMATION LANGUAGUES AND UNIT OF MEASURES The content. VENDOR 3. attachments and any supplementary information for all engineering documents shall be in English unless specified otherwise. 4.oF (1. Fusion Bonded Epoxy .2 ABBREVIATIONS The following abbreviations will be used throughout this document: API APS ASTM CWC ESCR EPC FBE American Petroleum Institute Application Procedure Specification American Society of Testing and Materials Concrete Weight Coating Environmental Stress Crack Resistance Engineering. PIPELINES AND CPP MODIFICATIONS Document No.0 PROJECT DEFINITION Terms CLJOC CONTRACTOR Definitions Revision: A Page:6 of 42 Cuu Long Joint Operating Company A company that is responsible for the Engineering.75-Inch Production Pipeline and Riser at 120oC maximum design temperature. 4.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. references.0 4. The units of measurement for all engineering documents shall be in the System International (SI).: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING 2. The required U-value of the coating is 0.hr. Procurement and Construction. Construction and Installation (EPCI) of the SVSW Project for CLJOC.27 btu/ft2. Procurement.533 W/m2K maximum). The coating provides thermal insulation and anti-corrosion for the 20 years design life of the pipeline. Any entity appointed by CONTRACTOR to supply and apply equipment / materials for this Project.0 PURPOSE OF DOCUMENT This Specification defines the minimum technical requirements for the Polyurethane based coating system for the external surface of 10.

PIPELINES AND CPP MODIFICATIONS Document No. American Society of Testing and Materials (ASTM) ASTM D792 ASTM D1505 ASTM D1603 ASTM D1693 Standard Test Method of Specific Gravity and Density of Plastics by Displacement. Specification for Line Pipe. the latest edition of the following codes and standards shall be applied: American Petroleum Institute (API) API RP 5LW API 5L Transportation of Line Pipe on Barges and Marine Vessels. .3 CODES AND STANDARDS High Density Polyethylene Health.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:7 of 42 HDPE HSE ISO MFR MS MVR NACE OHTC PE PO PQT PUF 4. Test Method for Carbon Black in Olefin Plastics. Test Method for Environmental Stress Cracking of Ethylene Plastics. Safety.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. Standard Test Method for Density of Plastics by the DensityGradient Technique. Environment International Organization for Standardization Melt Flow Rate Manufacturer Specification Melt Volume-flow Rate National Association of Corrosion Engineers Overall Heat Transfer Coefficient Polyethylene Purchase Order Procedure Qualification Trial Polyurethane Foam Unless specified otherwise.

Determination of Tensile Properties .20 CSA-Z245.Preinsulated Bonded Pipe Systems for Directly Buried Hot Water Networks .21 European Standard (EN) EN 253 District Heating Pipes . ASTM D4940 CSA CSA-Z245. Polyurethane Thermal Insulation and Outer Casing of Polyethylene.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. External Polyethylene Coating for Pipe. Paints and Varnishes . Preparation of Steel Substrates before Application of Paints and Related Products .Determination of Tensile Properties .Pipe Assembly of Steel Service Pipe. Polyolefin Pipes and Fittings .Determination of Carbon Black Content by Calcination and Pyrolysis . Plastics . Determination of Vicat Softening Temperature (VST).Test Method and Basic Specification. International Standards Organization (ISO) ISO 306 ISO 527-2 ISO 527-3 ISO 868 ISO 2808 ISO 4437 ISO 6964 Plastics . External Fusion Bond Epoxy Coating for Steel Pipe. Standard Test Method for Conductimetric Analysis of Water Soluble Ionic Contamination of Blasting Abrasives.Determination of Film Thickness.Visual Assessment of Surface Cleanliness Part 1: Rust Grades and Preparation Grades of Uncoated Steel ISO 8501-1 . Buried Popyethylene (PE) Pipes for the Supply of Gaseous Fuels-Metric Series-Specification. Plastics .: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING ASTM D4138 Revision: A Page:8 of 42 Standard Practices for Measurement of Dry Film Thickness of Protective Coating Systems by Destructive. Plastics and Ebonite . PIPELINES AND CPP MODIFICATIONS Document No.Part 3: Test Conditions for Films and Sheets.Hermoplastic Materials.Determination of Indentation Hardness by Means of A Durometer (Shore Hardness).Part 2: Test Conditions for Moulding and Extrusion Plastics. Cross-Sectioning Means.

Preparation of Steel Substrates before Application of Paints and Related Products . ISO 15512 ISO-21809-1 Plastics .External Coatings for Buried or Submerged Pipelines Used in Pipeline Transportation Systems .Determination of Water Content.Part 1: Polyolefin Coatings (3. ISO 9001 .Surface Roughness Characteristics of BlastCleaned Steel Substrates .Stylus Instrument Procedure.Test for the Assessment of Surface Cleanliness .The Bresle Method.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. ISO 8502-3 Preparation of Steel Substrates before Application of Paints and Related Products . PIPELINES AND CPP MODIFICATIONS Document No. Quality Management Systems – Requirements.Part 3: Assessment of Dust on Steel Surfaces Prepared for Painting (Pressure-Sensitive Tape Method).Part 6: Extraction of Soluble Contaminant for Analysis .Part 5: Replica Tape Method for the Determination of The Surface Profile.Layer PE and 3Layer PP).: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:9 of 42 Substrates and of Steel Substrates after Overall Removal of Previous Coatings. ISO 11357 (all parts) Plastics .Test for The Assessment of Surface Cleanliness .Differential Scanning Calorimetry (DSC). ISO 8502-6 ISO 8502-9 ISO 8503-4 ISO 8503-5 ISO 11124 (all parts) Preparation of Steel Substrates before Application of Paints and Related Products .Surface Roughness Characteristics of BlastCleaned Steel Substrates . Petroleum and Natural Gas Industries .Part 4. Method for the Calibration Of ISO Surface Profile Comparators and for The Determination Of Surface Profile . Preparation of Steel Substrates before Application of Paints and Related Products -Tests for the Assessment of Surface Cleanliness . Preparation of Steel Substrates before Application of Paints and Related Products .Specifications for Metallic Blast-Cleaning Abrasives.Part 9: Field Method for The Conductometric Determination of Water-Soluble Salt. Preparation of Steel Substrates before Application of Paints and Related Products .

Anodes shall be attached to the line pipe after coating as detailed in document “Specification for Pipeline Anode Installation”. Performance.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING National Association of Corrosion Engineers (NACE) NACE RP 0394 Revision: A Page:10 of 42 Application. Abrasive Specification No. Surface Preparation Specification No. a Quality Plan for the complete manufacturing process. recognised codes and national and industry standards are met. 5.4 Abrasive Specification No1 .8 oC and the surrounding environmental conditions. 2013-6031-2H-0001.: 2013-6031-2L-0014. 5. and Quality Control of PlantApplied.3 . Cleanliness of Recycled Ferrous Metallic Abrasives. minimum ambient temperature of 18. REFERENCE DOCUMENT [1]. .2 QUALITY SYSTEM VENDOR shall operate an accredited system of quality management in line with ISO 9001 and demonstrate that effective quality control procedures are in place to ensure that the requirements of this specification. Pipeline Design Basis. water depth. Society for Protective Coatings (SSPC) SSPC-AB1-2000 SSPC-AB2-2000 SSPC-AB3-2000 SSPC-SP1-2000 4. No. PIPELINES AND CPP MODIFICATIONS Document No. The Quality Plan shall include procedures for pre-inspection meetings and audits. Doc.Solvent Cleaning.1 GENERAL REQUIREMENTS GENERAL The insulation coating shall be suitable for use with cathodic protection systems and for use at the pipeline maximum design temperature of 120oC.1 . all quality control activities. Fusion-Bonded Epoxy External Pipe Coating.0 5.Newly Manufactured or Re manufactured Steel Abrasives.Mineral and Slag Abrasives.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. No. acceptance criteria and hold/witners/monitor points for both CLJOC and VENDOR. The VENDOR shall submit to CLJOC for approval together with their bid.

oF.5 VENDOR’S RESPONSIBILITY VENDOR shall determine the coating construction and thickness for the insulation coating system for the specified U-value of 0. equipment and personnel to perform the work in accordance with the requirements of this Specification.  Effect of degradation on thermal conductivity. compression and creep. The details contained within this Specification. safety and environmental issues.  Coatings of weld joints. and comply with these in all operations concerning the supply of linepipe. 5. It shall be VENDOR’S responsibility to supply all materials. PIPELINES AND CPP MODIFICATIONS Document No.3 HEALTH. SAFETY AND ENVIRONMENT Revision: A Page:11 of 42 VENDOR shall at all times maintain awareness of the legislation and regulations concerning health.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. Contract.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING 5.  Manufacturing tolerances. VENDOR is required to perform a PQT to demonstrate that this Specification can be met. VENDOR shall demonstrate that the coating system and method of application will fulfil the requirements of this Specification by supplying technical information and performing a PQT. Data from previous projects may be proposed in place of . Only materials with a proven track record of subsea use in the oil and gas industry shall be used. Purchase Order or any other CLJOC/CONTRACTOR document do not in any way relieve VENDOR of his responsibility to produce a high quality product fit for the intended service. 5. full procedure qualification may not be required subject to the provision of relevant historic data and acceptance by VENDOR. The analysis shall take into account the following:  Design life.4 QUALIFICATION TESTING Where VENDOR has previous experience with the proposed coating system.hr. A specific HSE plan and Inspection & Test Plan shall be submitted as indicated in the purchase requisition.  Coating detail at welded joints.  Water depth.27btu/ft2.  Design temperature and effect on materials properties.

to minimise buoyancy effects. The performance and long term behaviour of the proposed thermal insulation coating system shall be supported by design calculations which demonstrate that the proposed coating shall provide the required Overall Heat Transfer Coefficient (OHTC) for the life of the field.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:12 of 42 performing a PQT.  Procedure for the receipt and storage of coating materials. preference should be given to materials with the highest densities.  Pipe and fitting handling. storage and stacking procedures. VENDOR procedures shall as a minimum address the following:  Environmental control.  Procedures for mixing coating components in correct ratios including production controls and tests.  Inspection of FBE first coat. The VENDOR shall ensure that the proposed coating system buoyancy is suitable for long term stability of the pipeline i. VENDOR shall perform such qualification testing as is necessary to support the selection of the values used.  Intermediate preparatory processes between first coat application and thermal insulation application.  Pipe preheating and temperature control. Where suitable test results are not available to support the parameters used in design. . VENDOR is required to perform a PQT at the start of the project. dew point. The material shall not be applied until released by quality control personnel as meeting test requirements. provided the data demonstrates the requirements of the Specification are satisfied.  Procedure for calibration and measuring of testing equipment. PIPELINES AND CPP MODIFICATIONS Document No. including frequencies. relative humidity.e.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. VENDOR shall provide test data to justify the values of physical properties of the coating components used in the design and the expected behaviour over time under the service conditions.  Surface preparation.  Application of FBE first coat. All raw materials shall be tested by both VENDOR and his raw material supplier. temperature.

it shall be responsibility of VENDOR to ensure that the insulation remains undamaged and does not degrade in any respect prior to the load-out following completion of the work. Non-conformity reports shall be provided to CLJOC's . e. 5.  Procedure for coating at pipe ends. reserves the right to witness all phases of the coating manufacturing testing and installation at the VENDOR's works. Any such work performed without notification of CLJOC may be rejected by CLJOC. casting in mould. VENDOR shall afford CLJOC Representatives all reasonable access to facilities at no cost to CLJOC. CLJOC shall be notified in advance of all work to be performed. CLJOC Representative(s) shall be given ready access to inspect the VENDOR's quality control procedures. CLJOC and CLJOC approved third party.  Repair procedures. Any insulation coating that in CLJOC's judgment does not comply with this Specification and is rejected by CLJOC shall become the property of VENDOR and the replacement cost of the rejected insulation coating shall be borne by the VENDOR. PIPELINES AND CPP MODIFICATIONS Document No.  Application procedures including measures to ensure uniformity of coating density and thermal conductivity.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. concentricity of pipe and external surface of coating. rotational casting.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:13 of 42  Method of coating application and description thereof. to ensure the insulation coating is manufactured and installed in accordance with this Specification.6 PERFORMANCE OF WORK VENDOR shall guarantee the work performed when manufacturing and installing the coating is in accordance with this specification. Following insulation. VENDOR shall provide with the bid a detailed design calculation and report which addresses the items described above. and VENDOR's fabrication process. Such inspection by CLJOC shall not relieve VENDOR of his responsibility to ensure quality control.7 NON CONFORMANCE Non-conformity reports shall be prepared and submitted in accordance with VENDOR's QA/QC Plan. spray application etc. the equipment. 5.g. methods and results.  Procedure for storage and handling of coated pipes. which is subjected to CLJOC hold or witness points.

Only CLJOC approved materials and Material Manufacturers shall be used.35 30 5 35. Minimum total thickness and properties of the finished insulation coating system is presented in Table 6. Minimum Thickness of PU Foam Insulation Coating U-value (0. Common repair procedures and potential applications shall be submitted to CLJOC for approval in advance of their use.0 7.  Material identification. Insulation coating shall consists of three layers as follows:  1st layer: Epoxy.1 COATING SYSTEM COATING SYSTEM The coating must be able to withstand a maximum design temperature up to 120oC . PIPELINES AND CPP MODIFICATIONS Document No.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:14 of 42 Representative for acceptance.27 btu/ft2.oF) Coating Layer Minimum Thickness.0 6.1 COATING MATERIAL REQUIREMENT GENERAL VENDOR shall propose coating materials and Material Manufacturers for CLJOC acceptance.1. Materials used for coating shall be clearly marked with the following details:  Name of Coating Manufacturer.  3rd layer: PE top layer (HDPE). Table 6. 6. Completed non-conformity reports shall be provided to CLJOC as part of the permanent records.hr.1 unless otherwise specified by CLJOC.  2nd layer: Polyurethane foam (PUF). CLJOC reserves the right to disapprove nonconformity reports and to require revised reports when the non-conformity was not resolved by a method or procedure that was pre-approved by CLJOC. Fusion Bonded Epoxy (FBE) Polyurethane Foam (PUF) Polyethylene (HDPE) 0. mm 1st layer 2nd layer 3rd layer Total 7.35 .STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.

. shall be rejected and not applied to the pipe.2 PRIMER AND/OR FIRST COAT If FBE is proposed as first coat the materials.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING  Batch number. with an expired shelf life.  Manufacturing standard. The epoxy powder shall be selected only when the following minimum requirements are satisfied. VENDOR shall demonstrate compliance with Material Manufacturer’s specifications by testing if so requested by CLJOC.  Date of manufacture. without full traceability or suspected of contamination / deterioration. Revision: A Page:15 of 42 Materials shall be handled and stored in accordance with applicable safety regulations and the Material Manufacturer's recommendations. All materials to be used on the project shall comply with Material Manufacturer’s specifications and shall be taken from new un-opened and undamaged containers and shall be within Material Manufacturer’s shelf life.  Quantity. PIPELINES AND CPP MODIFICATIONS Document No. Inspection and documentation of the FBE layer shall be completed in accordance with NACE RP0394 prior to commencement of thermal insulation coating application. All material with damaged packaging.  Shelf life. approved VENDOR procedures and this Specification.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. application and quality requirements shall be in accordance with NACE RP0394.  Hazardous information. and shall be used according to the Material Manufacturer's batch sequence. 7.

200 kg/m3 max. Table 7. Annex N CAN/CSA Z245-20.2: Minimum Requiremments for PUF Property Core density Test Method BS EN489 Value Limits min.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:16 of 42 Table 7.6 ≥ 95 oC and within manufacturer’s specification Within 20% of the nominal value specified by the manufacturer Within ± 0. 2. Annex D Density (g/cm ) 3 ISO 21809-1. Annex K (% mass) Thermal characteristic ( C) Gel time at 205 oC ±3 oC ISO 21809-1. Clause 12.0 MPa at 10% relative deformation Max. Annex J o Test Method Value Limits ≤ 0. testing and quality requirements shall be in accordance with EN 253.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.05 of the manufacturer’s specified nominal value According to manufacturer’s specification ISO 21809-1. min closed cell content ISO 844 BS EN 489 EN253 . PIPELINES AND CPP MODIFICATIONS Document No.3 2nd LAYER Polyurethane foam (PUF) is proposed as thermal insulation coating for pipeline. The polyurethane foam shall be selected only when the following minimum requirements are satisfied. 225 kg/m3 Min. 10% Min 95% Compressive Strength Water Absorption Ratio of open to closed cells. The application.5 Particle size 7.1: Minimum Requiremments for Epoxy Material Property Moisture content ISO 21809-1.

955 g/cm3 ISO 11357 (all parts) > 30 min at 210°C or >10 min at 220°C ≥ 15 MPa ≥ 600 % Value Limits ≥ 0.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. F50. Moreover. polyethylene layer maintains it flexibility and toughness over the design life time of the project. PIPELINES AND CPP MODIFICATIONS Document No.5 % (mass fraction) as specified in ISO 4437.3: Minimum Requirements for PE Property Density of the base resina Test Method ASTM D792 or ASTM D1505 ISO 527-2 Elongation at break at 23°C ± 2°C Or ISO 527-3 Tensile yield strength at 23°C ± 2°Ca Vicat softening temperature A/50 (9. 10% Igepal CO630 or 100% Igepal CO630)b ISO 527-2 or ISO 527-3 ISO 306 ISO 15512 ISO 868 ≥ 110°C ≤ 0. The top coat polyethylene used shall be a black compound with carbon black content of 2.05 % ≥ 55 ≥ 1000 H cond. This can prevent influence of ultraviolet radiation. Table 7. B if density > 0. A ASTM D1693 or ≥ 300 H cond. oxygen in air and heat under the open sunlight.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING 7.930 g/cm3 Oxidation induction time (intercept in the tangent method) . The PE material shall be selected only when the following minimum requirements are satisfied.4 TOP LAYER Revision: A Page:17 of 42 The requirements of PE shall be in accordance with ISO 21809-1.8 N) Water content Hardness (Shore D) Environmental Stress Crack Resistance (ESCR) (50ºC.5 ± 0.

g. strained at 50 mm/min.5 % (mass fraction) Black carbon content or ISO 6964 Note: a 2 mm thick compression moulded sheet.5 ± 0. Pipe surface is suitable for coating when:  Sharp edges. each pipe shall be visually examined for dents.0 9. corners. coating materials. PIPELINES AND CPP MODIFICATIONS Document No. b In order to validate the ESCR values. grease. The VENDOR shall submit the template and content for CLJOC’s approval.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.0 MEASUREMENT AND LOGGING All necessary information of line pipes.1 SURFACE PREPARATION PIPE SURFACE PREPARATION 9. fillets. Hard surface layers (e. shall be removed from the pipe prior to coating per SSPC-SP1. coated pipes and quality control of them must be recorded. salt etc. and any other defects to identify defective pipes. . slivers. This limit shall not be wider than what is commonly known as fit for purpose PE grades for pipe coating..1 Metal Surface Before the surface preparation starts. data shall be provided by manufacturers as to know the limit in density (MFR) to pass that requirement. Annex G ASTM D1603 Value Limits MFR < 35 % 2. laps.. 8.  Residue.1. Defective pipes shall be removed from the coating line for repair or if repair is not possible. these pipes may be rejected. specimen ISO 527-2. All surfaces should be washed with clean fresh water prior to blast cleaning. and welds shall be rounded or smoothened by grinding. defective bevels. The records must be traceable for further investigation. resulting from flame cutting) shall be removed by grinding prior to blast cleaning.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:18 of 42 Property UV resistance and thermal ageing Test Method ISO 21809-1. 9. oil.

. These end caps shall be removed on completion of the coating process. The abrasives shall be maintained clean. Pipes that do not comply with the requirements shall be rejected and cleaned again. the blasting material shall be checked and replaced if necessary. peak to trough height. the pipe shall be stored under cover and kept warm and dry. The pipe surface temperature shall be checked with a thermocouple or other approved methods. Expendable abrasives shall not be recycled. The affected pipes shall be re-blasted.2 Abrasive Blast Cleaning The abrasives used in the coating plant shall be in accordance with the requirements of ISO 11124 (all parts).1. grade Sa 2½ “near white metal”. The surface profile.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. at a temperature at least 3ºC above the ambient dewpoint temperature prior to entering the abrasive blast cleaning unit(s). PIPELINES AND CPP MODIFICATIONS Document No. dry and free from contaminants in accordance with SSPC-AB1. 9. The surface profile attained shall be within the range 50 μm to 100 μm.1. until after coating. In case of any excessive grinding. All moisture shall be removed by preheating of pipe to between 40ºC and 85ºC. SSPC-AB2 and SSPC-AB3 or ASTM D4940 so as not to contaminate the substrate. shall be measured in accordance with the requirements of ISO 8503-4 (Stylus) or ISO 8503-5 (Replica Tape). The ambient relative humidity should not exceed 85%. The ground area shall merge smoothly with the surrounding pipe surface.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:19 of 42  After cleaning and prior to grit blasting. If the surface profile is outside the specified limits. the remaining wall thickness shall be measured by ultrasonic inspection and shall not be less than the specified minimum wall thickness.3 Inspection of Surface Cleanliness Each pipe shall be inspected for surface cleanliness. 9. The pipe and components shall then be maintained. The cleanliness achieved prior to application shall be in accordance with the requirements of ISO 8501-1. The surface profile shall be measured at regular intervals. The pipe shall be handled and transported in such a manner as to ensure that no further contamination occurs. Suitable temporary caps or coupling shall be applied to both pipe ends to prevent abrasives and coating materials from damaging the bevels and entering the pipe during coating process. the maximum allowable area of grinding shall be 10 cm² per 1 m pipe length. If grinding is required after blast cleaning.

5 (maximum). PIPELINES AND CPP MODIFICATIONS Document No.  Surface profile measured from peak to trough shall be determined by means of ISO 8503-4 & ISO 8503-5. whether or not to release the pipe for coating or to return the pipe for re-cleaning or to reject the pipe for excessive surface defects. The phosphoric acid wash shall be applied after the blast and before the heating process. Deionized or reverse osmosis water shall be used for the mixture and for rinsing the pipe after the wash. If the measured value is not in this allowed range. once per shift. .STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. 9. The high-pressure rinse shall have a minimum tip pressure of 220 kPa (1. After the appropriate surface cleanliness has been achieved in accordance with ISO 8501-1.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:20 of 42 The surface finish after blast cleaning shall be inspected with the following International Standards:  Surface cleanliness shall be determined by means of ISO 8501-1.1. Phosphoric acid shall be mixed with deionized or reverse osmosis water according to the manufacturer’s recommendations. At regular intervals. the blasted surface shall be checked for residual chloride contamination.500 psi).  Dust levels shall be determined by means of ISO 8502-3. A uniform pH of 1 or less shall be maintained on the pipe for a minimum of 20 seconds between 15oC to 65oC. that pipe shall be rejected and blasted again.  The wetted surface of the rinsed pipe shall have a pH of 6 (minimum) to 7. the pipe shall be acid washed in accordance with the following procedure or alternative procedure proposed by VENDOR and approved by CLJOC:  Application of the phosphoric acid mixture shall be at the rate and percent recommended by the phosphoric acid supplier.  CLJOC shall have the final approval on the disposition of the pipe.  The soluble salts content shall not exceed 20mg/m². The mixture shall be rinsed from the pipe surface with a high-pressure rinse system. etching. This pH shall be checked a minimum of every 2 hours during production. All rinse water shall be removed and the surface shall be dried by a high pressure air knife. and removal of soluble salts. unless otherwise approved by CLJOC.4 Acid Wash Phosphoric acid wash and rinse may be used for further surface cleaning. the maximum allowable level shall be Class 2.

Pipe requiring repairs shall be conveyed to a holding rack for repair and re-holiday inspection. disbonding. The individual pipe number shall be transferred to the internal pipe surface by use of white paint marker.2 SURFACE PREPARATION OF FBE COATED PIPES Revision: A Page:21 of 42 All pipes shall be received at the PUF coating plant incoming rack. 9. 9. Each pipe shall be prepared for HDPE coating by first drying the PUF coated pipe surface using dry cloths and any contamination identified shall be removed by proprietary solvent washing in accordance with SSPC-SP-1. Where excessive contamination is present.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING 9. no contamination and no defect. The pipe number and heat number and length shall be recorded and verified against client tally list. PIPELINES AND CPP MODIFICATIONS Document No. All coating defects shall be marked using a grease free marker pen.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. The individual pipe number shall be transferred to the internal pipe surface by use of white paint marker. pipe shall be removed from the system. dust or residual coating matter. Inspection PUF surface to ensure no crack. .3 SURFACE PREPARATION OF PUF COATED PIPES All pipes shall be received at the HDPE coating plant incoming rack. Each pipe shall be prepared for PUF coating by first drying the FBE coated pipe surface using dry cloths and any contamination identified shall be removed by proprietary solvent washing in accordance with SSPC-SP-1. Pipes are then passed onto the holiday inspection station where each pipe shall be 100% holiday detected in-line for coating defects. The mould shall then. quarantined and brought to the attention of the CLJOC Site Representative for clarification and agreement of further action to be taken. The pipe number and heat number and length shall be recorded and verified against client tally list.4 MOULD PREPARATION FOR PUF COATING The internal surface of the mould shall be cleaned by using a compressed air to blow out any debris. Where excessive contamination is present. be washed by using a cotton cloth saturated with a cleaning agent for removing traces of PUF coating. pipe shall be removed from the system. quarantined and brought to the attention of the CLJOC Site Representative for clarification and agreement of further action to be taken.

The external surface of the cleaned pipe conforming to Section 9 of this specification shall be coated within 4 hours if the relative humidity is below 80% or within 1 hour if the relative humidity is 80% or greater. The temperature range depends on factory Application Procedure Specification (APS). Extruded PE top coat shall be applied within the time limit established during PQT stage and within the time/temperature range recommended by the manufacturer.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. The heating temperature shall. During coating. Appropriate induction heating frequency shall be used to ensure “deep” heating. No detectable oxidation. Oilfired pre-heating is not acceptable. PIPELINES AND CPP MODIFICATIONS Document No. Additional identification shall be applied as required to monitor the coating and test batches. or other contaminants shall be on the pipe surface. Immediately after all coating is completed. or pipes showing any visible rust stains. the pipe identification marks shall be re-applied to the coated pipe using a method reviewed by CLJOC. in no case. the bevelled ends of the pipes and the pipe bore shall be protected against mechanical damage and against contamination with coating material.0 COATING APPLICATION The coating shall be applied in accordance with the Application Proceduce Specification (APS).: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:22 of 42 The end rings used to mould the cutback must be coated with an appropriate mould release agent.1 PIPE HEATING The pipe to be coated shall be heated over its entire length by electrical induction. and shall be validated for temperature control during qualification and production of the coating system. shall be blastcleaned again. Pipes delayed beyond this period.  The surface to be coated shall be heated over its entire length to a temperature between 225oC and 240oC or as specified by the powder manufacturer. The heat source shall not leave a residual or contaminant on the pipe surface. . Non-conforming pipe shall be recoated. the preheating temperature of the pipe shall be monitored and recorded using optical pyrometers or contact thermometers. Temperature-measuring crayons may be used to measure temperature only if agreed upon prior to coating. dust accumulation. exceed 275oC (527oF). while maintaining the minimum specified wall thickness requirement. Uncoated pipe ends shall receive a temporary protective coating for transit. 10. Any pipe which is heated to above 275oC (527oF) shall be replaced at VENDOR’s expense.  During the application of the coating components. In general the procedure shall be as follows: 10.

g. Any pipe coated in the duration of temperature deviation shall be identified by marking and rejected.1. The thickness of the epoxy layer and all other requirements are shown in Table 6. and as short as feasible (e. Each container when opened for use shall be thoroughly mixed before use by means of mechanical drum roller or power mixer for at least 10 minutes. the production shall be stopped until cause of deviation has been removed.g.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:23 of 42  Any deviation from the application temperature range recommended by manufacturer shall be rectified. the dispense line between the metering pump and the mixing head should be of sufficient diameter.1 Pre-Mixing of Polyol and Transfer to Conditioning Tank The Polyol contains polymeric microspheres which may separate and float to the top of the Polyol: These microspheres should be re-distributed in the Polyol by thorough mixing by drum rolling.3 PUF APPLICATION 10. The feed line from the Polyol tank to the metering pump should be of sufficient diameter and as short as possible (e.2 EPOXY APPLICATION The elapsed time between surface preparation by abrasive blasting. 15-20 mm diameter and 3 metres long). care should be taken to ensure that the metering pump has adequate feed. To keep the Polyol dispense line pressure low.5 metre long). Such rejected pipes shall be stripped.  Throughout production. Checks shall be done to ensure the feed is adequate:  A pressure gauge at the metering pump inlet. when processing on the dispensing machine.3. 10. The Polyol tank should be pressurised sufficiently to give sufficient feed (e. 4 Bar).When mixed. Mixed Polyol shall be discharged within 120 minutes of mixing. 10. or in more severe cases of separation a power mixer.g. . the Polyol has a high viscosity. 25 mm diameter. 0.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. cleaning and coating application shall be adequate to avoid oxidation or contamination of the pipe surface (This time shall be less than 4 hours). PIPELINES AND CPP MODIFICATIONS Document No. Monitoring equipment shall be calibrated twice every shift unless otherwise agreed by CLJOC. The pipe temperature during surface preparation and coating application shall be in accordance with the requirements presented in Table 11. If immediate rectification is not feasible.1. the coating temperature shall be continuously monitored and recorded once every half hour. Due to this. re-cleaned and recoated.

 Ratio check (if ratio of Polyol: Isocyanate varies with increasing/decreasing machine output. Prior to application of the foam insulation. ensuring flow into pump from tank exceeds the required output from the pump). As a guide. During the injection period. care must be taken that the system is stable with regard to flow rates. 10. the pipe shall be subjected to Quality Control testing as detailed in the Inspection & Testing Final work after foaming process. material processing temperatures should be in the range of 20-35°C.3. The pipe shall then be placed into the mould (concentricity shall be maintained by each end ring and by utilizing sufficient PUF spacers located along the pipe. The pipe is then re-moulded and transferred to a holding area where the pipe shall be supported on padded supports to prevent damage to the coating.3. and then injected into the "port". As per manufacturer's recommendation. the pipe shall be left at an incline to allow for initial coating cure of approximately 20 minutes prior to removal. In particular. .: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:24 of 42  Checking feed rate at pump inlet (i.3 Mixing and Pumping of PUF The compressibility of the Polyol means attention must be paid to certain areas of processing. the optimum temperature shall be automatic control by mixing Machine on site. On completion of the coating cure.3.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. 10. the pipe and mould shall be inclined at an angle of 20° ±10° to the horizontal. 10.4 PUF Coating Application The pipes shall be lifted to the coating preparation area where two spacers manufactured from the same material as the PUF coating shall be installed along the length of the pipe. then feed may be deficient and require further adjustment). but less than 80°C. pressures. and temperatures before ratio checking and dispensing. PIPELINES AND CPP MODIFICATIONS Document No.e.  When hardening time is over the foamed steel pipe is taken out of the mould.2 Discharge of Isocyanate To avoid contact or exposure to moisture each container when opened for use shall be discharged immediately after opening into the conditioning tank. The PUF components are machine mixed to the required ratio. the coated pipe shall be preheated to a temperature at least 3°C above dew point. After the injection process.

The quenching water is flow back from the quench tunnel to the cooling towers. excess material to be removed for a flush finish.  Cutting off the edges of PE foil. .4.  Visual Control of foam surface.4. As coated pipe exits the quenching tunnel.4 HDPE APPLICATION 10.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:25 of 42  Dismounting sealing gaskets and flanges at the ends of steel pipe. FBE surface shall be dry and clean to make sure stop tape tight and adhesive. The hot return water is pumped through the cooling tower and fed into the cold water sump.4 Water Quench. Cooling and Inspection Racks Coated pipe shall then be conveyed and pass through the water quench tunnel. PIPELINES AND CPP MODIFICATIONS Document No. they must be filled with free rise foam according to procedure. Sinter coatings shall be applied to produce a rough coating surface to enhance shear resistance for concrete coatings and surface anti-slip properties.2 HDPE Application The HDPE layer shall be applied using an appropriately designed extruder to melt and extrude the polypropylene in a flat film which is then wrapped around the pipe in a spiral overlapping fashion. if there are holes and bubbles at the foam surface. the lifting arm buggy raise the pipe onto the inspection station racks. The minimum thickness of HDPE coating system shall be 5 mm. From there the water is pumped to the quench tunnel. The operating parameter of the HDPE extruder will be maintained within the range recommended by the HDPE manufacturer's data. which are configured with automated pipe indexes.1 Water Stop Application Before processing to HDPE coating PUF pipe shall be apply with Water Stop Tape at two ends FBE toe.3 Sinter Coat / Rough Coat (FOR CWC COATED PIPES ONLY) Additional 'sinter powder coat' shall be spray applied onto coated surface immediately after top coat application. The pipe is cooled by a drenching flood of water on the external surface.4.4.  Grinding sharp foam edges on foamed pipe. It is rolled on to the pipe surface to ensure no air is trapped under this layer. 10. 10. 10.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. After quenching pipe temperature shall not exceed 60°C. 10. Register on report.

The cut-back end preparation should include 30° . 10.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.75-Inch Production Pipeline Bare pipe ends shall be protected from corrosion for a period of up to 1 year. Figure 10. Corrosion protection shall be provided by fast drying steel primer such as red oxide alkyd to be approved by CLJOC. NDT and field joint coating operations.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:26 of 42 On the inspection rack. The cutback length shall be free of any coating materials (including FBE tails) and / or contaminants detrimental to the welding.5 TYPICAL CUTBACK The cut-back length for the insulation coating shall be 370mm (±10mm) from the ends of the pipe.1 Typical Cutback of 10. pipe coupling is removed from the coated pipe and cutback paper removal for FBE (without insulation) is done prior to cutback cleaning.45° taper. .1. PIPELINES AND CPP MODIFICATIONS Document No. The insulation coating cutback shall leave a minimum 100mm visible ring of FBE first coat. 100% visual appearance check on every pipe is done at frequency mentioned in Table 11.

clearly marked containers. damage free. Marking Legible H. -Isocyanate tank shall be storage under cover shade or in the warehouse. clearly marked containers. Packaging Secure. V. -Polyol tank shall be storage under cover shade or in the warehouse.2.1. Approval Inspection V. Polyol Data from Manufacturer Every Batch - -Verify colour/appearance: Homogeneous mix and uniform yellow colour -Verify against PO & Certification and ensure materials are supplied in sealed.T.1. Inspection and Testing Plan for Insulation Coating Process 1.M 1.Material Receipt Description 1.C .0 INSPECTION AND TESTING Table 11.R.R.M 1. HDPE Data from Manufacturer Every Batch Perform Melt Flow Index Test. PIPELINES AND CPP MODIFICATIONS Document No.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. damage free.3. -Verify against PO & Certification and ensure materials are supplied in sealed.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:27 of 42 11. Isocyanate Data from Manufacturer Frequency Every Batch - Requirements -Verify colour/appearance: Homogeneous mix and uniform brown colour.

Salt Contamination Test Every 1 h Every 4h for each pipe.1 ASTM D4940 Grade Sa 2 ½.2.5.5 50 to 100 μm (measured from peak to trough). Surface Preparation of Pipe Description Test Freq. 20 mg/m2 or less. Surface Roughness - 3oC above Dew point. Conductivity max. Testing before and after blast ISO 8502 .3. Phosphoric acid washing and new abrasive required if level exceeded.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:28 of 42 Process /Location 2. Rating max. Water-soluble Contamination of Abrasives 2. 60. PIPELINES AND CPP MODIFICATIONS Document No.4 ISOI 8503 .6.4.3 ISO 8502 . Max. (PQT) All PQT pipes All PQT pipes All PQT pipes All PQT pipes All PQT pipes All PQT pipes Test Freq. (Production) Every 4 h Test Method Acceptance Criteria Approval Inspection 2. All pipes All pipes ISO 8501. Visual Inspection of Blasted Surface 2.6 . 2. 85% relative humidity.1. Temperature and Air Humidity (Ambient Conditions) 2. Every 1 h ISO 8503 . Presence of Dust after Dust Removal 2. 2.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.

100% coverage. material processing M. (Production) cleaning on same pipe. of sample taken from . As per manufacturer recommendation. Once per hour Test Method Acceptance Criteria Approval Inspection 2.C temperatures should be in the range of 25-35°C. the optimum temperature shall be established experimentally on site. Material Temperature Prior to Application PQT batch Each batch As a guide. temperature. Check temperature of materials prior to application.1.Tg1 shall be between -2°C to calorimetry analysis +3°C to ensure coating is fully cured. Degree of Cure FBE All PQT pipes All PQT pipes All pipes All pipes ISO 2808 or ASTM D4138 Differential scanning Tg2 . and solution pH.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:29 of 42 Process /Location Description Test Freq.7. PIPELINES AND CPP MODIFICATIONS Document No.5 at rinse of the wet pipe. Minimum Thickness 4. dwell time. FBE Inspection 4.1. (PQT) Test Freq. 3. pH 6 to 7. FBE Application 3. 0.2.35 mm 4.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. Phosphoric Acid Wash All PQT pipes Measure coverage.

No Holiday. The entire external surface of the FBE coating shall be holiday detected and any holidays detected shall be marked up for repair using a non.1.5 KV.3. All V.2.3. Contamination & defect Free.M. Acceptance Criteria Approval Inspection 4.20 inch (5 mm) radius from edge of / inch (12.C damaged areas shall be repaired as per the coating MPP.M Length is still legible. PIPELINES AND CPP MODIFICATIONS Document No. MEK Rubs Test shall be performed.Holiday Detection All pipes Holiday detection shall be carried out with a full contact electrode at the travel speed equal to 300 mm/s at 1.7 mm) diameter hole in 48 hours at 194°F (90°C).201 . (Production) Test Method pipe.grease marker pen and repair as V..STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. Reinstate internal stencil where necessary.Verify Pipe Identity All PQT pipes All PQT pipes All PQT pipes All PQT pipes All pipes ASTM G42 or CAN/CSA.M.M92 Visual 0. & V. (PQT) Test Freq.C All pipes All pipes Visual 5.Visual Inspection FBE Surface 5.. Heat No. PUF Incoming Rack 5.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:30 of 42 Process /Location Description Test Freq.Z245. . Cathodic Disbondment 5. Confirm Pipe No.

4.C least 10 minutes using a drum tumbler or other mechanical means. (PQT) Test Freq. Approval Inspection 6.C All PQT All pipes Measuring . As a guide.C temperatures should be in the range of 25-35°C.M from damage.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. clean and free V. Mix thoroughly prior to use for at M. 6. Material Temperature Prior to Application PQT batch Each batch Check temperature of materials prior to application. Mould shall be inclined at an angle of 20° ± 10° to the horizontal.1. 6. PIPELINES AND CPP MODIFICATIONS Document No. Surface All pipes Visually Mould shall be dry. Visual Inspection of the Mould Prior Loading the Pipe 6.3. PUF Application 6. the optimum temperature shall be established experimentally on site. (Production) Test Method Acceptance Criteria per FBE Repair Procedure.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:31 of 42 Process /Location Description Test Freq. As per manufacturer recommendation.M. Prior to application of the foam N. material processing M.2 Polyol Mixing Each container when opened for use All PQT pipes Each container when opened for use Record time opened. time finished mixing.

C approximately 20 minutes prior to removal.M. but less than 80 °C. (PQT) pipes Test Freq.N. PIPELINES AND CPP MODIFICATIONS Document No. the coated pipe shall be preheated to a temperature at least 3 °C above dew point.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:32 of 42 Process /Location Description Temperature of Steel Pipes and Casing Pipes Test Freq. tear or buckle. D. No disbondment from the pipe. Min.C crack. (Production) Test Method Acceptance Criteria insulation. Injection Time and Moulding Time All PQT pipes All pipes Check the elapsed time of pipe left in the moulding prior to removal.1.M. Measuring Coated pipe shall be left in the mould N. Visual Using PI tape to measure at 3 locations along the pipe length (Convert PI reading to thickness). V. PU Foam Thickness Measurement All PQT pipes All PQT pipes All pipes All pipes 7. 30 mm PUF thickness D.C 7.N. Approval Inspection 6.3. Visual Inspection for PUF Coated Pipe 7.C . PUF Inspection 7. Cut-backs PU Foam All PQT pipes All pipes As per project specification.2.5.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.

Core density 7.7.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:33 of 42 Process /Location Description Test Freq.8. HDPE Application 8. 200kg/m3 / Max. CMB Insulation All pipes All pipes at both Visual Visual No disbondment from the pipe. Sounding Test 7. 50oC BS EN489 ISO 844 BS EN 489 BS EN253 Min. (Production) All pipes All pipes All pipes All pipes All pipes All pipes Test Method Acceptance Criteria Approval Inspection 7. PIPELINES AND CPP MODIFICATIONS Document No. FBE surface at apply location shall V. Visual Inspection PUF Coated Pipes 8. (PQT) All PQT pipes All PQT pipes All PQT pipes All PQT pipes All PQT pipes All PQT pipes All PQT pipes All PQT Test Freq. min closed cell content 8. Ratio of open to closed cells.M . tear or buckle. 2.6.5. 225kg/m3 Min. 95% 7.M crack. Conductivity Thermal Every 300 mm with a 1kg hammer.2. Water Absorption 7. Strength Compressive 7. Max.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. V. 10% Min.0 MPa at 10% relative deformation.4.1.9.

pinholes.2.3. Min.N. Temperature after Quenching All PQT pipes All pipes Digital thermometer gauge (with surface probe).M scratches or any other irregularities and shall have a uniform colour and gloss. Pipe cool enough safety handled M. Cut-backs HDPE 9. Approval Inspection 9. Visual Inspection Coated Pipes Visual Free from blisters. (Production) ends All pipes Test Method Acceptance Criteria be dry and clean. 15N/mm2 D. V. HDPE Inspection 9. (PQT) pipes All PQT pipes Test Freq. HDPE Thickness Measurement All PQT pipes All pipes Using PI tape to The minimum thickness of the D.1.N.C measure at 6 locations protective polyethylene layer shall be along the pipe length 5.0 mm. 9. PIPELINES AND CPP MODIFICATIONS Document No.C 9. Measuring BS EN 253 As per project specification. Tensile All PQT pipes All PQT pipes All pipes All pipes . 9.C without causing damage coating (< 60°C).STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. (Convert PI reading to thickness).4.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:34 of 42 Process /Location Description Tape Application Test Freq.5.

select a PUF area 150mm x 150mm.2 N/mm2 for 28 days ISO 868 or ASTM D2240 Measuring >55 Shore D 48 hours after PUF coating.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:35 of 42 Process /Location Description Test Freq. knife cut of PUF around until FBE surface and leave a cube shape test specimen has the dimension: 50mm x50mm x PUF thickness.1.8. (Production) All pipes All pipes All pipes All pipes Test Method Acceptance Criteria Approval Inspection 9. PIPELINES AND CPP MODIFICATIONS Document No. PUF All Repairs All Repairs According to Coating According to repair procedure of M. Elongation 9. Repairs 10.C . Adhesion between PUF and FBE EN 253 350% at 23oC Min. 10. (PQT) All PQT pipes All PQT pipes All PQT pipes All PQT pipes Test Freq.7.9.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. Hardness 9. Using a mallet to knock the cube until it comes off. 0.6. Repairs FBE. The test fails if PUF come of clean (no adhesive residue on FBE surface). using chisel. Shear 9.

Acceptance Criteria manufacturer and coating contractor. 12. Approval Inspection 11. Field Tests 11.C (No adhesive residue on FBE surface).T. length and along four different planes.3.1.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:36 of 42 Process /Location Description and HDPE Test Freq. Adhesion between FBE and PUF 1 pipe 2 test pipe per shift Visual examination after peeling back PUF layer from FBE layer. 11. (Production) Test Method applicator/operator Repair Procedure. Shore D Hardness of HDPE 11. The density of the foam shall be a H.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.M. PIPELINES AND CPP MODIFICATIONS Document No. 55 Shore D Minimum required shear strength 0. every 300 mm with 1 kg hammer. Shore D meter ASTM D2240 According to Coating applicator/operator BS EN 489 Min. Shear Test 12.2 N/mm2.T.M . Test PUF Sounding 1 pipe All Pipes The coating shall be Any marked difference in audible H.M. The test failed if PUF come-of clean H. (PQT) Test Freq.4.1. Core Density of 1 pipe 1 pipe 1 pipe All Pipes N/A 2 test pipe per .T.C 11.C sounded over its entire pitch shall be note.2.

H.5.T. Compressive Strength of PUF 12. Testing accordance with C518. BS EN 253 BS EN 253 BS EN 253 3rd Party The minimum tensile strength shall H.M. (Production) shift 2 test pipe per shift 2 test pipe per shift One per batch PE One per batch PE One per batch PE 1 test pipe per Production Test Method Acceptance Criteria minimum of 200 kg/m3 and a maximum of 225 kg/m3.M.T. As per manufacture datasheet.M . Elongation at break min 350% at H. Approval Inspection 12. Melt Flow Index Test 13. Thermal Conductivity of PUF The thermal conductivity shall be . (PQT) Test Freq.M.2. Water Absorption of PUF 12. Polyethylene Elongation 12.C relative deformation shall be min.3.4.M.T.C 23°C.C be 15N/mm2 at 23 °C.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:37 of 42 Process /Location Laboratory Test PUF Description Test Freq. PIPELINES AND CPP MODIFICATIONS Document No.0 MPa in radial direction.1.6.C According to ISO 844 The compressive strength at 10% H.C ASTM R 1 pipe 1 pipe PQT batch 1 pipe 12.T. 2. Tensile Polyethylene 1 pipe 1 pipe BS EN 489 Max 10% H.T. Laboratory Test 13.

M.oF. Holiday Detection equipment At start of the PQT At start of shift Crest Voltmeter Adjustable to ± 5% of Target Value.hr.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. Calibration Legend 14.C C Record & Raise Document D Dimensional Inspection H Hold Point I Random Inspection N Non-Destructive Testing R Review V Visual Inspection W Witness M Monitor T Destrutive Testing . (Production) Test Method Acceptance Criteria within the specified Coating Supplier range for the material with a mean sample temperature of 50° C and satisfy the requirement of 0.1.27 btu/ft2. (PQT) Test Freq. Approval Inspection 14.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:38 of 42 Process /Location (3rd Party) Description Test Freq. PIPELINES AND CPP MODIFICATIONS Document No.

.  Pipe length. the pipes shall be inspected for transport damage or other defects. Marking shall not be applied on the coating within the first 500 mm from the pipe end.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:39 of 42 12. 13. VENDOR shall plan his works in the best manner with the aim to preserve the marking already made by the pipes' manufacturer.  Pipe number (to be applied on both sides).  Pipe weight.0 PIPE MARKING The marking to be applied on the pipes shall be agreed between VENDOR and CLJOC. Damaged pipes shall be separately stored and reported to CLJOC. VENDOR shall apply a new marking for compliance with the specified requirements.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. The paint/stencil shall be weatherproof and waterproof and shall be compatible with the insulation coating. The following shall be marked on the pipe's coating at one pipe end with exception of the pipe number which shall be marked on both pipe ends:  Project name. HANDLING AND TRANSPORTATION VENDOR shall take receipt of the pipes delivered by the pipe supplier and shall keep a record of the serial numbers of the delivered pipes. Marking shall be applied on the pipe coating using suitable paint or stencil in a contrasting colour to the pipe coating. suitable for subsea use. Upon receipt. Repairs shall only be carried out with CLJOC permission.  The letters shall have a minimum height of 50mm.0 STORAGE.  Coating applicator.  Pipe manufacturer. PIPELINES AND CPP MODIFICATIONS Document No. In case the marking made by the pipes' manufacturer is not visible any more or it is covered by coating material.  Pipe material.  Pipe nominal external diameter * pipe nominal wall thickness.  Pipe heat number. Unless otherwise agreed the marking shall be applied on the pipes as stated below.

: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:40 of 42 Coated pipes shall be handled. Supports shall be padded and spaced along the pipe at distances which avoid pipe bending. front loaders padded with soft material and vacuum lifting. Coated pipes shall be stacked at a slight angle to allow drainage of any rainwater. Coated pipes can be handled using slings. the coated pipes shall be stacked in maximum 6 rows.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. Pipes shall be picked up from the stacking point and at no time shall be dragged or rolled. In case VENDOR does not provide any calculation note related to stacking of coated pipes acceptable for CLJOC. the transport shall be performed in accordance with the standards API 5L1 and API 5LW. Depending on the mean of the transport. Doc. The pipes shall be stacked on approved supports which shall be free of any material that could potentially damage the applied coating. No: 2013-6031-2L0008 and in a manner that the pipe steel and pipe coating shall not be damaged. Coated line pipe shall not be subjected to jar or impact and all pipe supports shall be padded. The maximum number of stacking layers for the coated line pipes shall be calculated by VENDOR and relevant calculation showing calculation steps and results shall be submitted to CLJOC for review and approval however. . PIPELINES AND CPP MODIFICATIONS Document No. for safety reasons the maximum height of any stack shall be 3 m. separate slings or hooks shall be used for each pipe. When more than one pipe is lifted. Chains or wire ropes or any other device that may damage the pipe steel or pipe coating shall not be used.) The stacking height of line pipes shall be limited to avoid damage of the coated line pipes due to the weight of other ones. lifting hooks padded with soft material with suitable spreader bars. nails. debris of coating materials or any other foreign objects shall be removed from internal pipe surface before stacking and load out. Coated line pipes shall always be stacked to avoid surface contact with the ground. They shall be free of any material potentially dangerous for the pipe coating (stones. handling and storage of pipeline material. stored and transported in accordance with specification for transportation. All foreign substances such as excessive dirt. sharp edged materials etc. Pipe supports shall be spaced to avoid bending of line pipes. The stacks of coated pipes shall be separated for each of the following combinations: pipe nominal external diameter x pipe nominal wall thickness type of applied coating. forklifts having lifting forks padded with soft material.

STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. plastic caps shall be reinstalled on coated pipes before their delivery (if application of plastic caps is required by CLJOC). After completion of coating works. Procedures shall be designed to ensure full traceability of pipe and coating materials through all stages of preparation. VENDOR shall maintain complete and accurate records of the work performed. VENDOR shall prepare an inspection and test plan which clearly details each activity. relevant document & report form and intervention points. wall thickness. acceptance criteria. and  Nature of insulation defects.1 DOCUMENTATION GENERAL VENDOR shall furnish all documentation in the English Language.  Inner and outer pipe diameter. material grade and pipe numbers. On a daily basis. One copy of the VENDOR's daily records shall be handed to CLJOC s Site Representative by the end of the working day upon which the work is performed.  Total length of all pipe coated today and to date. These records shall be kept safe in a single location at VENDOR's site and shall be accessible to CLJOC at all times. All VENDOR's documentation of any nature shall clearly reference the Contract Number together with component or material batch identification as appropriate.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:41 of 42 Coated pipes shall not be stacked below and near electrical lines or near any facility which may increase residual magnetism in the pipes (at all times it shall be kept the minimum distance of 30 m between the stored pipes and any electrical cable measured from the vertical projection to the ground of the nearest electrical cable). inspection frequency. Procedures and inspection and test plans shall be subject to review and approval by CLJOC.  Total number of pipe lengths sent for repair today and to date. length. PIPELINES AND CPP MODIFICATIONS Document No. 14. .0 14. the following information shall be maintained for each insulated pipe and provided to CLJOC:  Date of insulation application. coating and testing. the test method.

 Repair records.  Deviations and concessions.  Approved procedures. 14. These records shall be kept for 5 years after the insulation application.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.  PQT or PQT test report.  Non conformance reports.  Historic data. All documentation required by prior sections of this specification shall be submitted. whether at the point of manufacture or CONTRACTOR’s location.  Material data sheets.  Inspection reports.  Daily production report. Documentation to be included in a final data book shall include the following:  Thermal design report.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:42 of 42 All records shall be fully identified with the pipe or materials they represent.  Approved inspection and test plan (signed and stamped by VENDOR's and CLJOC 's authorised QC personnel/inspectors). All records shall be available for COMPANY examination at the time and place of inspection. .2 REPORT DOCUMENT Documentation submissions shall be in English language and in accordance with the requirements of tender documents. PIPELINES AND CPP MODIFICATIONS Document No.

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