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PARADIP REFINERY PROJECT PROJECT SPECIFICATION

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SPECIFICATION FOR EXTERNAL PIPELINE COATINGS

CONTENTS 1.0 1.1 1.2 2.0 2.1 2.2 2.3 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 4.0 4.1 4.2 4.3 4.4 4.5 5.0 INTRODUCTION .................................................................................. 4 Scope ................................................................................................... 4 Pipelines Description ......................................................................... 4 REFERENCES, CODES AND STANDARDS ...................................... 5 Project Specific Documents .............................................................. 5 Codes and Standards......................................................................... 5 Abbreviations...................................................................................... 6 SPECIFICATION .................................................................................. 7 Coating Type ....................................................................................... 7 Line Pipe Steel/Diameters.................................................................. 7 Operating Temperature ...................................................................... 7 Coating Cutback ................................................................................. 7 Visual Inspection ................................................................................ 7 Total Coating Thickness .................................................................... 8 Surface Finish After Blast Cleaning.................................................. 8 FBE Surface Before Application of PE Layer................................... 9 Holidays............................................................................................... 9 Adhesion ............................................................................................. 9 Impact Resistance .............................................................................. 9 Indentation Resistance .................................................................... 10 Pipe Surface Temp ........................................................................... 10 Coating Application Temperature ................................................... 10 Elongation ......................................................................................... 10 Coating Resistivity ........................................................................... 10 Thermal Aging................................................................................... 11 Ageing Under Exposure to Light..................................................... 11 Degree of Cure Fusion Bonded Epoxy Primer............................... 11 Cathodic Disbonding Resistance.................................................... 11 QUALITY ASSURANCE .................................................................... 12 Coating System Qualification.......................................................... 12 Application Qualification ................................................................. 14 Quality Control During Application................................................. 15 Coating Repair .................................................................................. 16 Documentation.................................................................................. 17 APPENDIX ......................................................................................... 18

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PARADIP REFINERY PROJECT PROJECT SPECIFICATION

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SPECIFICATION FOR EXTERNAL PIPELINE COATINGS

UPDATED SECTIONS 1.2 Pipeline Description, Lengths of Product Pipelines removed. All other changes highlighted in yellow

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SPECIFICATION FOR EXTERNAL PIPELINE COATINGS

1.0 1.1

INTRODUCTION Scope This document details the requirements of the external coating to be used for the proposed Raw-water and Product pipelines for the Indian Oil Corporation Ltd (IOCL) Paradip Refinery project. This specification shall be read in conjunction with IS 15659, if there is divergence between the two documents then the more stringent of the two shall apply.

1.2 1.2.1

Pipelines Description Product Pipelines The Product Pipelines comprise one (1) Crude Oil pipeline connecting the South Loading Jetty to the Refinery; three (3) Utility Pipelines and eleven (11) Product Pipelines connecting the Refinery to the South Loading Jetty; and four (4) Product Pipelines connecting the Refinery to the Marketing Terminal.

1.2.2

Raw water Pipeline The Raw Water pipeline will run from the Cuttack water intake location and terminate at the raw water reservoirs at Paradip Refinery. The surveyed distance of the pipeline is 92.8km.

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SPECIFICATION FOR EXTERNAL PIPELINE COATINGS

2.0 2.1

REFERENCES, CODES AND STANDARDS Project Specific Documents 3210-8210-RP-0039 Pipeline Sizing Report 3210-8210-RP-0017 Raw Water Pipeline Mechanical Design Report 3210-8210-RP-0007 Product & Crude Oil Pipelines Basic Engineering data Report 3210-8210-RP-0040 Product pipeline Pipe Wall Thickness Report 3210-8210-RP-0015 Product Pipeline Hyd & Surge Analysis Design Report.

2.2

Codes and Standards The latest editions of the following codes and standards shall apply: OISD-STD-141 IS 15659 Design and Construction Requirements for Cross Country Hydrocarbon Pipelines External Coatings for Buried or Submerged Pipelines Used in Pipeline Transportation of Gas and Liquid Hydrocarbons. Pipeline Transportation Systems Hydrocarbons and Other Liquids for Liquid

ASME B31.4 ASME B31.8 ISO 8501-1 ISO 8502-2 ISO 8502-3 ISO 8503-1 ISO 8503-2 DIN 30670 DIN 30672 ISO 1133

Gas Transmission and Distribution Piping Systems Preparation of Steel Substrates before Application of Paints and Related Products Preparation of Steel Substrates before Application of Paints and Related Products Preparation of Steel Substrates before Application of Paints and Related Products Preparation of Steel Substrates before Application of Paints and Related Products Preparation of Steel Substrates before Application of Paints and Related Products Polyethylene Coatings of Steel Pipes and Fittings; Requirements and Testing Corrosion Protection Tapes and Heat Shrinkable Sleeves for Underground Pipelines. Plastics Determination of the Melt Mass-flow Rate (MFR) and the Melt Volume-flow Rate (MVR) of Thermoplastics

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3210-8210-SP-0008 PAGE : 6 of 20 REV : A2 Determination of Film

SPECIFICATION FOR EXTERNAL PIPELINE COATINGS

ISO 2808 ASTM D3418 ASTM G14 AWWA C151

Paints and Thickness

Varnishes

Test Method for Transition Temperatures of Polymers By Differential Scanning Calorimetry Standard Test Method for Impact Resistance of Pipeline Coating Standard Pressure Classes - Wall Thickness and Nominal Wall Thicknesses

2.3

Abbreviations CP 3 LPE PE IOCL FBE Tg Cathodic protection Three Layer Polyethylene Coating Polyethylene Indian Oil Corporation Ltd. Fusion Bonded Epoxy Temperature Change

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SPECIFICATION FOR EXTERNAL PIPELINE COATINGS

3.0 3.1

SPECIFICATION Coating Type For all pipelines the coating type shall be a three layer polyethylene system (3 LPE), epoxy, adhesive and polyethylene (PE) top layer. All coating is to be classed as Class A2 as stated in IS 15659.

3.2

Line Pipe Steel/Diameters All line pipe shall be dimensionally in accordance to API 5L, the diameters and grades for each pipeline are stated in Project documents 3210-8210-RP0040 and 3210-8210-RP-0017.

3.3

Operating Temperature For the LPG pipelines (excluding vapour return) maximum operating temperature for the coating shall be 0C the minimum shall be -45 C For all other pipelines the maximum operating temperature for the coating shall be 65C the minimum shall be -5 C.

3.4

Coating Cutback The FBE toe shall be cut back 150mm from each end of the line pipe and shall be 70mm in length. The PE coating shall be cut back 220mm from each end of the line pipe. The surface of the PE coating shall then be roughed for 50 mm from the taper.
150mm 70mm 50mm PE FBE Steel

Figure 3.1 Typical Coating Cross Section at End of Line Pipe

3.5

Visual Inspection The polyethylene coating system shall be free from blisters, pinholes, scratches or any other irregularities and shall have a uniform colour and gloss. Each pipe shall be checked for cleanliness of the pipe ends and for damage to the bevelled ends.

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3.6

Total Coating Thickness The minimum thickness of the total coating system shall be as specified in Table 3.1 to 3.3. The coating shall be measured in accordance with ISO 2808, method 6A or 6B. The thickness of the adhesive layer shall between 0.14 to 0.2mm.
Pipeline Diameter (mm) 100 >100 and 250 >250 and <500 500 and <800 800 Minimum Thickness (mm) 0.3 0.3 0.3 0.3 0.3

Table 3.1 Minimum FBE Coating Thickness

Pipeline Diameter (mm) 100 >100 and 250 >250 and <500 500 and <800 800

Minimum Thickness (mm) 2.26 2.26 2.66 3.06 3.76

Table 3.2 Minimum PE Coating Thickness

Pipeline Diameter (mm) 100 >100 and 250 > 250 and <500 500 and <800 800

Minimum Thickness (mm) 2.7 2.7 3.1 3.5 4.2

Table 3.3 Minimum Total Coating Thickness

3.7

Surface Finish After Blast Cleaning The surface finish after blast cleaning shall be inspected with the following standards. Surface cleanliness shall be determined in accordance with ISO 8501-1 Chloride contamination shall be determined in accordance with by means of ISO 8502-2 Dust levels shall be determined in accordance with by means of ISO 8502-3 Surface profile shall be determined in accordance with by means of ISO 8503-2

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SPECIFICATION FOR EXTERNAL PIPELINE COATINGS

3.8

FBE Surface Before Application of PE Layer The surface of the FBE after application shall be cleaned with a solvent wash to remove dust and loose particles. Surface cleanliness shall be determined in accordance with ISO 8501-1 Dust levels shall be determined in accordance with by means of ISO 8502-3

3.9

Holidays The coating system shall be free from holidays when tested. It shall be tested after the application of the FBE to steel and again after the application of the PE to FBE. Holiday detection shall be carried out be means of an adjustable high voltage holiday tester. The test voltage shall be 1kV for each 0.1mm of coating thickness with a maximum of 25kV. The electrode shall be moved over the pipe surface at a speed of no more 0.3m/s. the entire pipe surface shall be covered by the test.

3.10

Adhesion The coating adhesion shall be determined by DIN 30670. It shall be tested after the application of the FBE to steel and again after the application of the PE to FBE. The peel tests shall not be carried out on coating over welds, coating overlaps or within 1.5 DN or 300mm, whichever is smaller, from the edge of the coating. The test strips shall be at least 50mm apart. Results shall meet the minimum requirements has stated in Table 3.4.
Operating Temp. C <0 0 - 20 20 50 50 60 60- 80 > 80 Test Temp. C Op temp 2 23 2 50 2 60 2 80 2 Op temp 2 Peel Resistance N/10mm >35 >35 >25 >20 >20 >20

Table 3.4 Minimum Coating Peel Resistance 3.11 Impact Resistance The impact performance shall be performed by means as stated in DIN 30670 or by ASTM G14. Results shall have minimum impact resistance as stated in Table 3.5 at temperature 232 C. This test shall be completed on the total coating system with the impact being located on the PE layer.

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SPECIFICATION FOR EXTERNAL PIPELINE COATINGS

Pipeline Diameter (mm) 100 >100 and 250 >250 and 500 >500

Minimum Impact Resistance (J) 7.0 8.5 11.0 12.5

Table 3.5 Minimum Impact Resistance 3.12 Indentation Resistance The indentation resistance of the coating shall be tested at room temperature and at a temperature related to the maximum operating temperature as given in Table 3.6, in accordance to DIN 30670. The maximum allowable indentation shall be as specified in Table 3.4. This test shall be completed on the total coating system with the impact being located on the PE layer.
Operating Temp. C Test Temp. C Max indentation (mm)

<0 0 - 20 20 - 50 50 - 60 60 - 80 >80

Op temp 2 23 2 50 2 60 2 80 2 Op temp 2

0.2 0.2 0.3 0.3 0.3 0.4

Table 3.6 Indentation Resistance 3.13 Pipe Surface Temp The temperature of the pipe surface shall be uniform throughout the coating wrapping process. 3.14 Coating Application Temperature The temperature of the pipe surface shall be uniform throughout the coating wrapping process. 3.15 Elongation The elongation at break of the coating sample when tested at ambient temperature in accordance with DIN 30670 shall be more than 300%. 3.16 Coating Resistivity The coating resistivity shall be more than 108 .m when tested in accordance with DN 30670. This test shall only be applied to the PE layer.

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SPECIFICATION FOR EXTERNAL PIPELINE COATINGS

3.17

Thermal Aging After exposure to elevated temperatures in accordance with DIN 30670 the melt mass flow rate of the coating material shall vary not more than 35% from the melt mass flow rate before the exposure, or the elongation at failure of the radiated coating material shall be >50% of the elongation of the unexposed coating material. This test shall only be applied to the PE layer.

3.18

Ageing Under Exposure to Light After exposure to ultraviolet light radiation in accordance with DIN 30670 the melt mass flow rate of the coating material shall vary by not more than 35% from the melt mass flow rate before the exposure, or the elongation at failure of the radiated coating material shall be >50% of the elongation of the unexposed coating material. This test shall only be applied to the PE layer.

3.19

Degree of Cure Fusion Bonded Epoxy Primer The degree of cure of the fusion bonded epoxy primer shall be determined by differential scanning calorimetry in accordance with ASTM 3418. The Tg value shall be between -2C and +3C.

3.20

Cathodic Disbonding Resistance Cathodic disbanding tests shall be carried out in accordance with appendix A at a test temperature related to the operating temperature as specified in Table 3.7. This test shall only be applied to the FBE layer.
Operating Temp. C Test Temp. C Max Disbonding Radius (mm)

<0 10 - 20 20 - 50 50 - 60 60 - 80 >80

Op temp 2 23 2 50 2 60 2 80 2 Operation temp 2

10 10 10 15 15 15

Table 3.7 Cathodic Disbanding Resistance

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SPECIFICATION FOR EXTERNAL PIPELINE COATINGS

4.0 4.1

QUALITY ASSURANCE Coating System Qualification Before a coating system may be applied in a production run, the Contractor shall submit all the data specified in 4.1.2 and 4.1.3 and shall ensure that both the coating system and the Applicator have been qualified in accordance with the procedures.

4.1.1

System Identification The Contractor shall submit all details to identify the coating system. Details shall include: System designation or trade name; Name of coating Manufacturer(s); Generic type of system (polyethylene or polypropylene); Coating process (sintering, side extrusion or crosshead extrusion); System structure; Structure Components (primer, adhesive, outer layer) ; Service temperature range; Total nominal coating thickness; Relevant international/national coating standard approvals.

4.1.2

Manufacturer's Data Primer The following data shall be submitted on the primer (if applicable): The generic type of primer; For liquid primers the solids content, the type of solvent and the density; For powder epoxy primers the density, gel time, particle size, recommended film thickness, colour; Typical film properties (flexibility, cathodic disbonding resistance, etc.); The method of application (brush, roller, spray, electrostatic spray, etc.); Storage conditions and shelf life; The nominal dry film thickness or spreading rate; Application procedures, temperature, pot life, overcoating times; HSE datasheets.

Adhesive

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SPECIFICATION FOR EXTERNAL PIPELINE COATINGS

The following data shall be submitted on the adhesive (if applicable): The generic type of adhesive; The method of application (powder spray, extrusion etc.); The nominal thickness; Storage conditions and shelf life.

Coating material The following data shall be submitted on the polyethylene or polypropylene outer layer material: Generic type of material (e.g. high/medium/low density PE/PP); Delivered product (powder, granules, liquid etc.); Storage conditions, shelf life; Colour; Nominal thickness of the outer layer; Mechanical properties of the outer layer film (tensile strength, elongation); Data on resistance to bio-degradation.

Chemical pre-treatment If any chemical pre-treatment of the blasted steel is carried out the following data shall be submitted: 4.1.3 Generic type of chemical; Preparation, concentration, etc.; Application procedure, including spreading rate (m2/l), and drying times.

Qualification Before a coating system can be specified for an application, the Contractor or the coating Manufacturer shall apply for qualification of the coating system. Qualification shall be carried out according to the following procedures. The Contractor or the coating Manufacturer shall submit all data specified in Section 4.1. The Contractor or the coating Manufacturer shall show that samples of the coating system applied on pipes of the specified pipe material have been successfully subjected to the tests as specified in Table 4.1. The tests shall be carried out by an independent test laboratory or, if approved by the Engineer-in-Charge, by the coating Manufacturer. The number of pipes to be tested and the test procedures are given in Table 4.1.

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SPECIFICATION FOR EXTERNAL PIPELINE COATINGS

If agreed by the Engineer-in-Charge, previous qualification data can be used provided that the referred tests have been carried out using the same coating system and the same coating process as specified in the contract. 4.2 4.2.1 Application Qualification General Before production application of a coating system may commence, the Applicator shall be qualified to apply the coating system. The qualification shall be carried out according to the following procedures: 4.2.2 Coating Process and Applicator Selection The Contractor shall submit to the Engineer-in-Charge information on the required coating process and recommended applicators. The information shall include: 4.2.3 Description of the coating process for line pipe, bends and fittings; Pipe cleaning and surface preparation (cleanliness, profile, chemical pretreatment, etc.); Required surface and material application temperatures; Recommended applicators; Coating repair procedures;

Coating Plant To demonstrate that the available equipment is capable of applying the specified coating according to the required standards, each recommended Applicator shall submit full details of the coating plant, including: Layout diagram of the coating plant and plant flow scheme; General description of the equipment available to carry out the coating process; Details of process control and inspection equipment required for the coating process such as temperature control, thickness control, holiday testers, laboratory equipment, etc.; Details on the line pipe marking, handling, storage and transport equipment and procedures; Applicators quality control procedures.

4.2.4

Qualification After approval of the process and plant details before production starts, he Applicator should submit evidence that he has successfully applied the coating system before on pipes of the specified material, and that the product complied with the requirements of this specification for the tests indicated in Table 4.1.

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SPECIFICATION FOR EXTERNAL PIPELINE COATINGS

The Applicator shall coat at least 2 pipes with the proposed coating system and shall subject samples from these pipes to the tests given in Table 4.1. These tests may be carried out in the Applicator's own laboratory, or by an independent laboratory. When this specification is used for the coating of bends and/or fittings, the Applicator shall coat at least one fitting or bend as agreed with the Engineerin-Charge and subject this coating to the same qualification tests.
Number Of Pipes Required Coating System Applicator Qualification Qualification 5 pipes 2 pipes 5 pipes 2 pipes 5 pipes 2 pipes 5 pipes 2 pipes 5 pipes 2 pipes 5 pipes 2 pipes 5 pipes 2 pipes 5 pipes 2 pipes 5 pipes 2 pipes 5 pipes 2 pipes 5 pipes 2 pipes 5 pipes Not required 2 pipes Not required 2 pipes Not required 2 pipes 1 pipe 2 pipes 1 pipe

Property
Cleanliness of blast cleaned surface Surface roughness Pipe surface temperature Coating application temperature Appearance Coating thickness Holiday detection Adhesion Impact Indentation Elongation Coating Resistivity Thermal Ageing UV Stability Cathodic Disbonding Degree of cure of FBE

Table 4.1 Number of pipes required during qualification 4.3 Quality Control During Application During production application of the coating, the Applicator shall carry out all quality control activities needed to ensure that the coating is being applied in accordance with the approved coating application procedures and that final product complies with the requirements of this specification. The minimum quality control tests to be performed shall be as indicated in Table 4.2. Records of all coating application and quality control tests results shall be kept in accordance with Section 4.5.

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SPECIFICATION FOR EXTERNAL PIPELINE COATINGS

Property Ambient conditions Surface condition before blasting Cleanliness of blast cleaned surface Surface profile Surface cleanliness Chlorides Blast cleaning materials & process Pipe surface temperature Coating application temperature Appearance Coating thickness Holiday detection Pipe ends Adhesion Impact Indentation Elongation Cathodic disbonding Degree of FBE cure

Test frequency Once per shift Each pipe Each pipe One per 20 pipes One per 100 pipes Once per shift Continuous Continuous Each pipe Each pipe Each pipe Each pipe One per 100 pipes One per 100 pipes One per 100 pipes One per 100 pipes One per 200 pipes One per 200 pipes

Table 4.2 Minimum quality control requirements for polyethylene pipeline coating. 4.4 Coating Repair The Contractor shall submit detailed procedures for coating repairs. All coating repair procedures shall be qualified under both coating system and Applicator qualification. These procedures shall contain as a minimum: Repair of surface defects; Repair of pinholes, scratches and small defects (e.g. by means of a melt stick); Removal of rejected coating and cleaning the pipe to the required standard for recoating; Testing to prove the effectiveness of the repairs.

All pipes that have been repaired shall be fully re-examined in accordance with the quality control procedures. Records shall be kept of all repaired pipes and shall include the repair and retest details.

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4.5

Documentation The Contractor shall keep accurate records of all relevant data of the coating process. This documentation shall, as a minimum, consist of: Copies of the coating system information as specified; Copies of qualification information as requested; Copies of, or reference to, all procedures for coating of the pipes; Serial numbers of all pipes as given by the pipe Manufacturer (e.g. by copies of the pipe mill data sheets); Serial numbers as given by the coating Applicator (if applicable) correlated with the Manufacturer's serial numbers; The order of coating, the day and shift of coating of each pipe; The batch numbers of the coating materials, the day and time of loading of each batch; Serial numbers of rejected pipes and the reason for rejection; Records of any repairs; The results of all quality control testing; Records of temperatures during the coating process for each pipe, with the processing time of every tenth pipe marked on the temperature chart with the pipe number; Names and signatures of the responsible persons for the coating process and quality control.

This documentation shall be submitted to the Engineer-in-Charge after completion of the coating work, together with the testing and inspection instruments calibration certificates.

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5.0

APPENDIX A Cathodic disbonding resistance test procedure

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SPECIFICATION FOR EXTERNAL PIPELINE COATINGS

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