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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

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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
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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. STV-CPP will also control and monitor SVSW.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:5 of 42 1. PIPELINES AND CPP MODIFICATIONS Document No. 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 . offshore Vietnam.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.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. 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.

Fusion Bonded Epoxy . Construction and Installation (EPCI) of the SVSW Project for CLJOC.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.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. attachments and any supplementary information for all engineering documents shall be in English unless specified otherwise. The units of measurement for all engineering documents shall be in the System International (SI). Procurement and Construction. Procurement. The required U-value of the coating is 0.hr.75-Inch Production Pipeline and Riser at 120oC maximum design temperature.27 btu/ft2.0 4. references.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING 2. VENDOR 3.0 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.0 PURPOSE OF DOCUMENT This Specification defines the minimum technical requirements for the Polyurethane based coating system for the external surface of 10.oF (1. 4. The coating provides thermal insulation and anti-corrosion for the 20 years design life of the pipeline. PIPELINES AND CPP MODIFICATIONS Document No.533 W/m2K maximum). 4. Any entity appointed by CONTRACTOR to supply and apply equipment / materials for this Project.1 GENERAL INFORMATION LANGUAGUES AND UNIT OF MEASURES The content.

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.: 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 4.3 CODES AND STANDARDS High Density Polyethylene Health. Specification for Line Pipe. Safety. Standard Test Method for Density of Plastics by the DensityGradient Technique. PIPELINES AND CPP MODIFICATIONS Document No. . Test Method for Environmental Stress Cracking of Ethylene Plastics.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. 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. 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. Test Method for Carbon Black in Olefin Plastics.

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

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

Surface Preparation Specification No. The Quality Plan shall include procedures for pre-inspection meetings and audits. Society for Protective Coatings (SSPC) SSPC-AB1-2000 SSPC-AB2-2000 SSPC-AB3-2000 SSPC-SP1-2000 4. acceptance criteria and hold/witners/monitor points for both CLJOC and VENDOR. Pipeline Design Basis.8 oC and the surrounding environmental conditions.1 . No. . No.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.: 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. 5. all quality control activities. 2013-6031-2H-0001. and Quality Control of PlantApplied. a Quality Plan for the complete manufacturing process. The VENDOR shall submit to CLJOC for approval together with their bid.Mineral and Slag Abrasives. Fusion-Bonded Epoxy External Pipe Coating. PIPELINES AND CPP MODIFICATIONS Document No. recognised codes and national and industry standards are met.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.4 Abrasive Specification No1 .3 .: 2013-6031-2L-0014.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.0 5. REFERENCE DOCUMENT [1]. Performance.Newly Manufactured or Re manufactured Steel Abrasives. Cleanliness of Recycled Ferrous Metallic Abrasives. 5. Abrasive Specification No. Anodes shall be attached to the line pipe after coating as detailed in document “Specification for Pipeline Anode Installation”. Doc. water depth.Solvent Cleaning. minimum ambient temperature of 18.

The analysis shall take into account the following:  Design life. It shall be VENDOR’S responsibility to supply all materials. safety and environmental issues.  Coatings of weld joints. Data from previous projects may be proposed in place of . 5.4 QUALIFICATION TESTING Where VENDOR has previous experience with the proposed coating system. full procedure qualification may not be required subject to the provision of relevant historic data and acceptance by VENDOR. SAFETY AND ENVIRONMENT Revision: A Page:11 of 42 VENDOR shall at all times maintain awareness of the legislation and regulations concerning health. Only materials with a proven track record of subsea use in the oil and gas industry shall be used. and comply with these in all operations concerning the supply of linepipe.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. equipment and personnel to perform the work in accordance with the requirements of this Specification. 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.  Manufacturing tolerances. 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.  Effect of degradation on thermal conductivity. Contract.  Coating detail at welded joints. VENDOR is required to perform a PQT to demonstrate that this Specification can be met.  Design temperature and effect on materials properties. The details contained within this Specification.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING 5.27btu/ft2.  Water depth.3 HEALTH.5 VENDOR’S RESPONSIBILITY VENDOR shall determine the coating construction and thickness for the insulation coating system for the specified U-value of 0. compression and creep. A specific HSE plan and Inspection & Test Plan shall be submitted as indicated in the purchase requisition.hr.oF. PIPELINES AND CPP MODIFICATIONS Document No. 5.

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

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

0 7.hr. 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.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:14 of 42 Representative for acceptance. PIPELINES AND CPP MODIFICATIONS Document No. Table 6. Minimum total thickness and properties of the finished insulation coating system is presented in Table 6. 6. Common repair procedures and potential applications shall be submitted to CLJOC for approval in advance of their use. Minimum Thickness of PU Foam Insulation Coating U-value (0.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. Fusion Bonded Epoxy (FBE) Polyurethane Foam (PUF) Polyethylene (HDPE) 0.oF) Coating Layer Minimum Thickness.1 unless otherwise specified by CLJOC. Completed non-conformity reports shall be provided to CLJOC as part of the permanent records.1 COATING MATERIAL REQUIREMENT GENERAL VENDOR shall propose coating materials and Material Manufacturers for CLJOC acceptance.  2nd layer: Polyurethane foam (PUF). Insulation coating shall consists of three layers as follows:  1st layer: Epoxy.0 6.  Material identification.1. Only CLJOC approved materials and Material Manufacturers shall be used.35 30 5 35.1 COATING SYSTEM COATING SYSTEM The coating must be able to withstand a maximum design temperature up to 120oC . Materials used for coating shall be clearly marked with the following details:  Name of Coating Manufacturer. mm 1st layer 2nd layer 3rd layer Total 7.35 .27 btu/ft2.  3rd layer: PE top layer (HDPE).

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

Annex D Density (g/cm ) 3 ISO 21809-1. Annex N CAN/CSA Z245-20. Annex K (% mass) Thermal characteristic ( C) Gel time at 205 oC ±3 oC ISO 21809-1.2: Minimum Requiremments for PUF Property Core density Test Method BS EN489 Value Limits min. testing and quality requirements shall be in accordance with EN 253. PIPELINES AND CPP MODIFICATIONS Document No.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:16 of 42 Table 7. The application.5 Particle size 7.05 of the manufacturer’s specified nominal value According to manufacturer’s specification ISO 21809-1.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. min closed cell content ISO 844 BS EN 489 EN253 . Table 7.3 2nd LAYER Polyurethane foam (PUF) is proposed as thermal insulation coating for pipeline.1: Minimum Requiremments for Epoxy Material Property Moisture content ISO 21809-1.0 MPa at 10% relative deformation Max. 10% Min 95% Compressive Strength Water Absorption Ratio of open to closed cells. Annex J o Test Method Value Limits ≤ 0. 200 kg/m3 max.6 ≥ 95 oC and within manufacturer’s specification Within 20% of the nominal value specified by the manufacturer Within ± 0. The polyurethane foam shall be selected only when the following minimum requirements are satisfied. Clause 12. 225 kg/m3 Min. 2.

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. B if density > 0. The PE material shall be selected only when the following minimum requirements are satisfied. A ASTM D1693 or ≥ 300 H cond. PIPELINES AND CPP MODIFICATIONS Document No.5 % (mass fraction) as specified in ISO 4437. The top coat polyethylene used shall be a black compound with carbon black content of 2.955 g/cm3 ISO 11357 (all parts) > 30 min at 210°C or >10 min at 220°C ≥ 15 MPa ≥ 600 % Value Limits ≥ 0.5 ± 0.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. F50. oxygen in air and heat under the open sunlight. This can prevent influence of ultraviolet radiation. Table 7.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING 7.8 N) Water content Hardness (Shore D) Environmental Stress Crack Resistance (ESCR) (50ºC.05 % ≥ 55 ≥ 1000 H cond.930 g/cm3 Oxidation induction time (intercept in the tangent method) .4 TOP LAYER Revision: A Page:17 of 42 The requirements of PE shall be in accordance with ISO 21809-1. 10% Igepal CO630 or 100% Igepal CO630)b ISO 527-2 or ISO 527-3 ISO 306 ISO 15512 ISO 868 ≥ 110°C ≤ 0. Moreover. polyethylene layer maintains it flexibility and toughness over the design life time of the project.

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

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

The phosphoric acid wash shall be applied after the blast and before the heating process. once per shift. PIPELINES AND CPP MODIFICATIONS Document No.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.  Dust levels shall be determined by means of ISO 8502-3.4 Acid Wash Phosphoric acid wash and rinse may be used for further surface cleaning. . At regular intervals. The mixture shall be rinsed from the pipe surface with a high-pressure rinse system. etching.  Surface profile measured from peak to trough shall be determined by means of ISO 8503-4 & ISO 8503-5. If the measured value is not in this allowed range. 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. All rinse water shall be removed and the surface shall be dried by a high pressure air knife. A uniform pH of 1 or less shall be maintained on the pipe for a minimum of 20 seconds between 15oC to 65oC. This pH shall be checked a minimum of every 2 hours during production. Phosphoric acid shall be mixed with deionized or reverse osmosis water according to the manufacturer’s recommendations. unless otherwise approved by CLJOC.  The wetted surface of the rinsed pipe shall have a pH of 6 (minimum) to 7. the maximum allowable level shall be Class 2.5 (maximum).  The soluble salts content shall not exceed 20mg/m².: 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 8501-1.500 psi). 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. Deionized or reverse osmosis water shall be used for the mixture and for rinsing the pipe after the wash.  CLJOC shall have the final approval on the disposition of the pipe. 9. After the appropriate surface cleanliness has been achieved in accordance with ISO 8501-1. and removal of soluble salts. The high-pressure rinse shall have a minimum tip pressure of 220 kPa (1. that pipe shall be rejected and blasted again. the blasted surface shall be checked for residual chloride contamination.1.

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. Where excessive contamination is present.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. The pipe number and heat number and length shall be recorded and verified against client tally list.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING 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. no contamination and no defect. pipe shall be removed from the system. 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. All coating defects shall be marked using a grease free marker pen. pipe shall be removed from the system. PIPELINES AND CPP MODIFICATIONS Document No.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. Pipes are then passed onto the holiday inspection station where each pipe shall be 100% holiday detected in-line for coating defects. Pipe requiring repairs shall be conveyed to a holding rack for repair and re-holiday inspection. 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. . The individual pipe number shall be transferred to the internal pipe surface by use of white paint marker. The individual pipe number shall be transferred to the internal pipe surface by use of white paint marker. 9. Where excessive contamination is present.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. disbonding. quarantined and brought to the attention of the CLJOC Site Representative for clarification and agreement of further action to be taken. dust or residual coating matter. be washed by using a cotton cloth saturated with a cleaning agent for removing traces of PUF coating. The mould shall then.

Oilfired pre-heating is not acceptable.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.: 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. The heat source shall not leave a residual or contaminant on the pipe surface. while maintaining the minimum specified wall thickness requirement. the preheating temperature of the pipe shall be monitored and recorded using optical pyrometers or contact thermometers. PIPELINES AND CPP MODIFICATIONS Document No. in no case. The temperature range depends on factory Application Procedure Specification (APS). or other contaminants shall be on the pipe surface. and shall be validated for temperature control during qualification and production of the coating system. shall be blastcleaned again. The heating temperature shall. dust accumulation. Any pipe which is heated to above 275oC (527oF) shall be replaced at VENDOR’s expense. No detectable oxidation. During coating. Non-conforming pipe shall be recoated.0 COATING APPLICATION The coating shall be applied in accordance with the Application Proceduce Specification (APS).1 PIPE HEATING The pipe to be coated shall be heated over its entire length by electrical induction. Uncoated pipe ends shall receive a temporary protective coating for transit.  During the application of the coating components. 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. exceed 275oC (527oF). 10. Appropriate induction heating frequency shall be used to ensure “deep” heating. the bevelled ends of the pipes and the pipe bore shall be protected against mechanical damage and against contamination with coating material. In general the procedure shall be as follows: 10. the pipe identification marks shall be re-applied to the coated pipe using a method reviewed by CLJOC. or pipes showing any visible rust stains. . Pipes delayed beyond this period. Temperature-measuring crayons may be used to measure temperature only if agreed upon prior to coating. 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 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. Immediately after all coating is completed. Additional identification shall be applied as required to monitor the coating and test batches.

The feed line from the Polyol tank to the metering pump should be of sufficient diameter and as short as possible (e. the Polyol has a high viscosity. The Polyol tank should be pressurised sufficiently to give sufficient feed (e.When mixed. and as short as feasible (e. 10. the production shall be stopped until cause of deviation has been removed. care should be taken to ensure that the metering pump has adequate feed. Due to this.3. 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.: 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.g. The pipe temperature during surface preparation and coating application shall be in accordance with the requirements presented in Table 11. Any pipe coated in the duration of temperature deviation shall be identified by marking and rejected. Mixed Polyol shall be discharged within 120 minutes of mixing. or in more severe cases of separation a power mixer. To keep the Polyol dispense line pressure low. 4 Bar).g.g. 15-20 mm diameter and 3 metres long). Monitoring equipment shall be calibrated twice every shift unless otherwise agreed by CLJOC. the coating temperature shall be continuously monitored and recorded once every half hour. The thickness of the epoxy layer and all other requirements are shown in Table 6.1. the dispense line between the metering pump and the mixing head should be of sufficient diameter.5 metre long). 25 mm diameter. 10.1.1 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.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. when processing on the dispensing machine. Such rejected pipes shall be stripped. If immediate rectification is not feasible. re-cleaned and recoated. 0. PIPELINES AND CPP MODIFICATIONS Document No. Checks shall be done to ensure the feed is adequate:  A pressure gauge at the metering pump inlet.  Throughout production. cleaning and coating application shall be adequate to avoid oxidation or contamination of the pipe surface (This time shall be less than 4 hours). .2 EPOXY APPLICATION The elapsed time between surface preparation by abrasive blasting.

and temperatures before ratio checking and dispensing.3.2 Discharge of Isocyanate To avoid contact or exposure to moisture each container when opened for use shall be discharged immediately after opening into the conditioning tank. On completion of the coating cure. 10. the pipe shall be subjected to Quality Control testing as detailed in the Inspection & Testing Final work after foaming process. the pipe shall be left at an incline to allow for initial coating cure of approximately 20 minutes prior to removal. After the injection process. then feed may be deficient and require further adjustment). and then injected into the "port". As per manufacturer's recommendation. During the injection period. As a guide. 10.e.  Ratio check (if ratio of Polyol: Isocyanate varies with increasing/decreasing machine output.  When hardening time is over the foamed steel pipe is taken out of the mould. 10. 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.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. . PIPELINES AND CPP MODIFICATIONS Document No.3 Mixing and Pumping of PUF The compressibility of the Polyol means attention must be paid to certain areas of processing. Prior to application of the foam insulation. material processing temperatures should be in the range of 20-35°C. care must be taken that the system is stable with regard to flow rates.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:24 of 42  Checking feed rate at pump inlet (i.3. The PUF components are machine mixed to the required ratio.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. but less than 80°C. the pipe and mould shall be inclined at an angle of 20° ±10° to the horizontal. 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. pressures. ensuring flow into pump from tank exceeds the required output from the pump). the coated pipe shall be preheated to a temperature at least 3°C above dew point.3. the optimum temperature shall be automatic control by mixing Machine on site. In particular.

10.  Grinding sharp foam edges on foamed pipe.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. The minimum thickness of HDPE coating system shall be 5 mm.4. PIPELINES AND CPP MODIFICATIONS Document No. 10. The hot return water is pumped through the cooling tower and fed into the cold water sump. The quenching water is flow back from the quench tunnel to the cooling towers.4. As coated pipe exits the quenching tunnel.  Visual Control of foam surface.1 Water Stop Application Before processing to HDPE coating PUF pipe shall be apply with Water Stop Tape at two ends FBE toe. It is rolled on to the pipe surface to ensure no air is trapped under this layer.4 Water Quench.: 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.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. Register on report. After quenching pipe temperature shall not exceed 60°C. The operating parameter of the HDPE extruder will be maintained within the range recommended by the HDPE manufacturer's data.4 HDPE APPLICATION 10.  Cutting off the edges of PE foil.4. the lifting arm buggy raise the pipe onto the inspection station racks. if there are holes and bubbles at the foam surface. they must be filled with free rise foam according to procedure.4. FBE surface shall be dry and clean to make sure stop tape tight and adhesive. which are configured with automated pipe indexes. 10. 10. The pipe is cooled by a drenching flood of water on the external surface. Sinter coatings shall be applied to produce a rough coating surface to enhance shear resistance for concrete coatings and surface anti-slip properties. excess material to be removed for a flush finish. . Cooling and Inspection Racks Coated pipe shall then be conveyed and pass through the water quench tunnel.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. From there the water is pumped to the quench tunnel.

1. The cut-back end preparation should include 30° .45° taper. Corrosion protection shall be provided by fast drying steel primer such as red oxide alkyd to be approved by CLJOC. PIPELINES AND CPP MODIFICATIONS Document No. 10. 100% visual appearance check on every pipe is done at frequency mentioned in Table 11. The cutback length shall be free of any coating materials (including FBE tails) and / or contaminants detrimental to the welding.75-Inch Production Pipeline Bare pipe ends shall be protected from corrosion for a period of up to 1 year. Figure 10.5 TYPICAL CUTBACK The cut-back length for the insulation coating shall be 370mm (±10mm) from the ends of the pipe.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.1 Typical Cutback of 10. The insulation coating cutback shall leave a minimum 100mm visible ring of FBE first coat. 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. pipe coupling is removed from the coated pipe and cutback paper removal for FBE (without insulation) is done prior to cutback cleaning.

clearly marked containers. Inspection and Testing Plan for Insulation Coating Process 1. -Isocyanate tank shall be storage under cover shade or in the warehouse. Marking Legible H.T.M 1. -Polyol tank shall be storage under cover shade or in the warehouse.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:27 of 42 11. Packaging Secure. V.1. Approval Inspection V. PIPELINES AND CPP MODIFICATIONS Document No. -Verify against PO & Certification and ensure materials are supplied in sealed.R. Isocyanate Data from Manufacturer Frequency Every Batch - Requirements -Verify colour/appearance: Homogeneous mix and uniform brown colour. damage free.R. clearly marked containers.0 INSPECTION AND TESTING Table 11. 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. HDPE Data from Manufacturer Every Batch Perform Melt Flow Index Test.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.Material Receipt Description 1.1.C .3. damage free.2.M 1.

Visual Inspection of Blasted Surface 2. Water-soluble Contamination of Abrasives 2. All pipes All pipes ISO 8501. Surface Preparation of Pipe Description Test Freq. 85% relative humidity. 2.6 .: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:28 of 42 Process /Location 2. Presence of Dust after Dust Removal 2.3 ISO 8502 .4. Every 1 h ISO 8503 . Salt Contamination Test Every 1 h Every 4h for each pipe. Surface Roughness - 3oC above Dew point. Phosphoric acid washing and new abrasive required if level exceeded. Max. Testing before and after blast ISO 8502 . (Production) Every 4 h Test Method Acceptance Criteria Approval Inspection 2.1 ASTM D4940 Grade Sa 2 ½. Conductivity max.5 50 to 100 μm (measured from peak to trough).3.2. 60.4 ISOI 8503 .1.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. (PQT) All PQT pipes All PQT pipes All PQT pipes All PQT pipes All PQT pipes All PQT pipes Test Freq. Temperature and Air Humidity (Ambient Conditions) 2.5. PIPELINES AND CPP MODIFICATIONS Document No. 2. Rating max. 20 mg/m2 or less.6.

FBE Application 3. Check temperature of materials prior to application. FBE Inspection 4.Tg1 shall be between -2°C to calorimetry analysis +3°C to ensure coating is fully cured. material processing M. Phosphoric Acid Wash All PQT pipes Measure coverage.35 mm 4.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. As per manufacturer recommendation.1.1. Degree of Cure FBE All PQT pipes All PQT pipes All pipes All pipes ISO 2808 or ASTM D4138 Differential scanning Tg2 . 100% coverage. Material Temperature Prior to Application PQT batch Each batch As a guide.2. 0. Minimum Thickness 4.7. pH 6 to 7. temperature. and solution pH.5 at rinse of the wet pipe. Once per hour Test Method Acceptance Criteria Approval Inspection 2. dwell time. (Production) cleaning on same pipe.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:29 of 42 Process /Location Description Test Freq. of sample taken from . PIPELINES AND CPP MODIFICATIONS Document No. (PQT) Test Freq.C temperatures should be in the range of 25-35°C. the optimum temperature shall be established experimentally on site. 3.

1. The entire external surface of the FBE coating shall be holiday detected and any holidays detected shall be marked up for repair using a non.grease marker pen and repair as V.M92 Visual 0. Reinstate internal stencil where necessary.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:30 of 42 Process /Location Description Test Freq.201 . Contamination & defect Free. MEK Rubs Test shall be performed.C All pipes All pipes Visual 5...20 inch (5 mm) radius from edge of / inch (12. PUF Incoming Rack 5. & V.7 mm) diameter hole in 48 hours at 194°F (90°C).M. Acceptance Criteria Approval Inspection 4.Z245. (Production) Test Method pipe. Heat No. All V.3. Confirm Pipe No. Cathodic Disbondment 5.5 KV. PIPELINES AND CPP MODIFICATIONS Document No.2.Visual Inspection FBE Surface 5. (PQT) Test Freq. .Verify Pipe Identity All PQT pipes All PQT pipes All PQT pipes All PQT pipes All pipes ASTM G42 or CAN/CSA.M.M Length is still legible.C damaged areas shall be repaired as per the coating MPP.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 1.3. No Holiday.

PIPELINES AND CPP MODIFICATIONS Document No.2 Polyol Mixing Each container when opened for use All PQT pipes Each container when opened for use Record time opened.M from damage.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. the optimum temperature shall be established experimentally on site.C least 10 minutes using a drum tumbler or other mechanical means. Material Temperature Prior to Application PQT batch Each batch Check temperature of materials prior to application. 6.C All PQT All pipes Measuring . (Production) Test Method Acceptance Criteria per FBE Repair Procedure. (PQT) Test Freq. As a guide. Mould shall be inclined at an angle of 20° ± 10° to the horizontal. Surface All pipes Visually Mould shall be dry.4. material processing M. PUF Application 6. time finished mixing. 6. Visual Inspection of the Mould Prior Loading the Pipe 6. Prior to application of the foam N. As per manufacturer recommendation. Mix thoroughly prior to use for at M. Approval Inspection 6.C temperatures should be in the range of 25-35°C.M.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:31 of 42 Process /Location Description Test Freq.1. clean and free V.3.

: 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. Cut-backs PU Foam All PQT pipes All pipes As per project specification. (PQT) pipes Test Freq.M.M.C crack. PUF Inspection 7. but less than 80 °C.2.N. No disbondment from the pipe. Injection Time and Moulding Time All PQT pipes All pipes Check the elapsed time of pipe left in the moulding prior to removal. Visual Using PI tape to measure at 3 locations along the pipe length (Convert PI reading to thickness). PIPELINES AND CPP MODIFICATIONS Document No. Measuring Coated pipe shall be left in the mould N. the coated pipe shall be preheated to a temperature at least 3 °C above dew point.1.C . PU Foam Thickness Measurement All PQT pipes All PQT pipes All pipes All pipes 7.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. Visual Inspection for PUF Coated Pipe 7. tear or buckle.C approximately 20 minutes prior to removal. Min.5. 30 mm PUF thickness D.C 7.3. Approval Inspection 6. D. (Production) Test Method Acceptance Criteria insulation. V.N.

225kg/m3 Min. (Production) All pipes All pipes All pipes All pipes All pipes All pipes Test Method Acceptance Criteria Approval Inspection 7. (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. Max.2. 50oC BS EN489 ISO 844 BS EN 489 BS EN253 Min. min closed cell content 8.9. Strength Compressive 7. FBE surface at apply location shall V. HDPE Application 8. Visual Inspection PUF Coated Pipes 8. 2. Conductivity Thermal Every 300 mm with a 1kg hammer. Ratio of open to closed cells.M crack. Sounding Test 7. 200kg/m3 / Max. tear or buckle.6.0 MPa at 10% relative deformation. PIPELINES AND CPP MODIFICATIONS Document No.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:33 of 42 Process /Location Description Test Freq.M . 10% Min.1. Core density 7. CMB Insulation All pipes All pipes at both Visual Visual No disbondment from the pipe.8. V.5.4.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. 95% 7.7. Water Absorption 7.

(Convert PI reading to thickness). PIPELINES AND CPP MODIFICATIONS Document No.2. 9. V. HDPE Thickness Measurement All PQT pipes All pipes Using PI tape to The minimum thickness of the D. pinholes. Tensile All PQT pipes All PQT pipes All pipes All pipes . Temperature after Quenching All PQT pipes All pipes Digital thermometer gauge (with surface probe).: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:34 of 42 Process /Location Description Tape Application Test Freq.1. Measuring BS EN 253 As per project specification. Pipe cool enough safety handled M. Cut-backs HDPE 9.N. 9. Visual Inspection Coated Pipes Visual Free from blisters.M scratches or any other irregularities and shall have a uniform colour and gloss. (Production) ends All pipes Test Method Acceptance Criteria be dry and clean. Min. HDPE Inspection 9.C measure at 6 locations protective polyethylene layer shall be along the pipe length 5.3.N.C without causing damage coating (< 60°C). Approval Inspection 9.4.C 9.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.5. (PQT) pipes All PQT pipes Test Freq. 15N/mm2 D.0 mm.

7. (Production) All pipes All pipes All pipes All pipes Test Method Acceptance Criteria Approval Inspection 9.C . Using a mallet to knock the cube until it comes off.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:35 of 42 Process /Location Description Test Freq.1.9. using chisel. knife cut of PUF around until FBE surface and leave a cube shape test specimen has the dimension: 50mm x50mm x PUF thickness. Repairs FBE.2 N/mm2 for 28 days ISO 868 or ASTM D2240 Measuring >55 Shore D 48 hours after PUF coating. Shear 9. PIPELINES AND CPP MODIFICATIONS Document No. Repairs 10. PUF All Repairs All Repairs According to Coating According to repair procedure of M.6.8.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. 0. (PQT) All PQT pipes All PQT pipes All PQT pipes All PQT pipes Test Freq. select a PUF area 150mm x 150mm. Elongation 9. The test fails if PUF come of clean (no adhesive residue on FBE surface). Adhesion between PUF and FBE EN 253 350% at 23oC Min. 10. Hardness 9.

12. Adhesion between FBE and PUF 1 pipe 2 test pipe per shift Visual examination after peeling back PUF layer from FBE layer. 55 Shore D Minimum required shear strength 0.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:36 of 42 Process /Location Description and HDPE Test Freq.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. PIPELINES AND CPP MODIFICATIONS Document No. Field Tests 11.4.C 11. Shore D meter ASTM D2240 According to Coating applicator/operator BS EN 489 Min.T. The density of the foam shall be a H. 11.C (No adhesive residue on FBE surface). Acceptance Criteria manufacturer and coating contractor.M . Shear Test 12. (PQT) Test Freq. Test PUF Sounding 1 pipe All Pipes The coating shall be Any marked difference in audible H. Approval Inspection 11.2.M. The test failed if PUF come-of clean H.3. every 300 mm with 1 kg hammer.T.1.M.1.C sounded over its entire pitch shall be note. Shore D Hardness of HDPE 11. (Production) Test Method applicator/operator Repair Procedure. Core Density of 1 pipe 1 pipe 1 pipe All Pipes N/A 2 test pipe per .2 N/mm2. length and along four different planes.T.

3.T.5.M. PIPELINES AND CPP MODIFICATIONS Document No.C According to ISO 844 The compressive strength at 10% H. Compressive Strength of PUF 12.1. Tensile Polyethylene 1 pipe 1 pipe BS EN 489 Max 10% H.C ASTM R 1 pipe 1 pipe PQT batch 1 pipe 12. Laboratory Test 13. (PQT) Test Freq.6.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. Water Absorption of PUF 12. Testing accordance with C518.C be 15N/mm2 at 23 °C. Thermal Conductivity of PUF The thermal conductivity shall be . Melt Flow Index Test 13.C relative deformation shall be min.T. BS EN 253 BS EN 253 BS EN 253 3rd Party The minimum tensile strength shall H. Approval Inspection 12.M .M. 2. H.T. Elongation at break min 350% at H.2.T.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. Polyethylene Elongation 12. As per manufacture datasheet.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:37 of 42 Process /Location Laboratory Test PUF Description Test Freq.0 MPa in radial direction.M.4.C 23°C.T.

hr. PIPELINES AND CPP MODIFICATIONS Document No.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 .27 btu/ft2. Holiday Detection equipment At start of the PQT At start of shift Crest Voltmeter Adjustable to ± 5% of Target Value. (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.: 2013-6031-2L-0010 SPECIFICATION FOR POLYURETHANE INSULATION COATING Revision: A Page:38 of 42 Process /Location (3rd Party) Description Test Freq. M.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW. (PQT) Test Freq.1.oF. Approval Inspection 14. Calibration Legend 14.

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

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

wall thickness. material grade and pipe numbers. PIPELINES AND CPP MODIFICATIONS Document No. On a daily basis. the test method. the following information shall be maintained for each insulated pipe and provided to CLJOC:  Date of insulation application.  Total length of all pipe coated today and to date. inspection frequency. VENDOR shall maintain complete and accurate records of the work performed. 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. VENDOR shall prepare an inspection and test plan which clearly details each activity. Procedures and inspection and test plans shall be subject to review and approval by CLJOC. After completion of coating works.: 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). relevant document & report form and intervention points. 14.  Total number of pipe lengths sent for repair today and to date. . acceptance criteria. All VENDOR's documentation of any nature shall clearly reference the Contract Number together with component or material batch identification as appropriate. coating and testing. length.  Inner and outer pipe diameter.0 14. Procedures shall be designed to ensure full traceability of pipe and coating materials through all stages of preparation. These records shall be kept safe in a single location at VENDOR's site and shall be accessible to CLJOC at all times. plastic caps shall be reinstalled on coated pipes before their delivery (if application of plastic caps is required by CLJOC).1 DOCUMENTATION GENERAL VENDOR shall furnish all documentation in the English Language. and  Nature of insulation defects.STVEXTENSION – STV SOUTH WEST PROJECT (SVSW) EPCI FOR WHP-SVSW.

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