P.T.

Bredero Price Indonesia

Customer Project PTBPI Project No

CONOCO
P.T. Saipem Indonesia 00-0205
Additional Dry Gas Fields

Neoprene Coating For

Riser Pipe

Quality Plan

DOCUMENT NUMBER
QP05-NC

Incorporate Customer’s
1 09/01/02 Mujianto Ali M. Nutter D. Conroy
Comments
0 7/11/01 Issued for Customer Approval Mujianto Ali M. Nutter D. Conroy
Revision Revision
Comments Raised By Approved By Authorized By PTSI CIIL
No. Date

Document Reviewed by:

Herdiansyah Shorenata Widodo

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 
Hercules Rubber & Chemical Industries Pte Ltd
4 Jalan Pesawat, Jurong Town, Singapore 619362
Tel: (65) 265 0955 Fax: (65) 265 9853
Email: hrc41872@singnet.com.sg


Website: http://www.hercules-rubber.com.sg



Cert. No.403030

NEOPRENE COATING
FOR
RISER PIPES

0 07/11/01 Julia Issue for Client Review/Approval

Rev Date By Description Checked Approved

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 SPECIFICATION

FOR

SEALINES

CHLOROPRENE (CR)

ANTI-CORROSION COATING

FOR RISERS

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 TABLE OF CONTENTS

1.0 GENERAL

1.1 Scope of Specification

1.2 Reference Standards And Documents

2.0 MATERIAL CHARACTERISTICS

2.1 Material Composition

2.2 Coating Thickness

3.0 QUALITY ASSURANCE

3.1 Adhesion
3.2 Ageing

4.0 APPLICATION OF COATING

4.1 Pipe Surface Preparation

4.2 Application of Bonding Agent
4.3 Application of Polychloroprene
4.4 Vulcanisation

5.0 INSPECTION

5.1 Inspection of Coating Materials And Repair Product

5.2 Inspection of Coating Process
5.3 Inspection of Polychloroprene Coated Pipes

6.0 COATING REPAIRS

7.0 NON-CONFORMANCE

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1.0 GENERAL

1.1 Scope of Specification

This specification covers the Polychloroprene (CR) anti-corrosion protection coating to

be applied on all risers.

1.2 Reference Standards And Documents

This specification is to be read together with the latest edition/revision of the following
standards and documents. In case of conflict between the standards/documents and
this specification, the latter shall apply.

- BS 903 Methods of testing vulcanised rubber

- BS 903-A1 Determination of density and specific gravity

- BS 903-A2 Determination of tensile stress - strain properties

- BS 903-A3 Determination of tear strength

- BS 903-A6 Determination of compression set

- BS 903-A16 Determination of swelling in liquids

- BS 903-A26 Determination of hardness

- DIN 53516 Testing of rubber and elastomer. Determination of abrasion

resistance

- ASTM D1149 Test for rubber deterioration - surface ozone cracking in a

chamber (flat specimen)

- SSPC - SP1 Steel structures painting council

- SIS 05 59 00 Pictorial surface preparation standard for painting steel structures.

2.0 MATERIAL CHARACTERISTICS

The Polychloroprene material shall be a curable elastomer with improved temperature

resistance such that it is suitable for operating at temperatures up to 100°C (207°F).

The material shall meet the requirement listed in Table 2.1.

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 2.1 Material Composition
Composition of the anti-corrosion coating shall include:
a) Polychloroprene
b) Fillers and reinforcing
c) Activators
d) Curing agents
e) Others (Anti-ozone, etc)

2.2 Coating Thickness

The final coating thickness shall be 12.7mm + 2mm, - 0mm.

3.0 QUALITY ASSURANCE

The Polychloroprene material furnished under this specification shall form a system which
has been tested and has passed tests specified in Table 2.1.

3.1 Adhesion

The strength of the chemical bond between the coating and the bare pipe metal - shall be in
excess of the tear strength of the coating and shall be tested by tearing a section of bonded
coating from the steel. A coating of rubber shall still adhere to the steel.

3.2 Ageing

Changes in hardness, tensile strength and elongation at break under accelerated ageing, as
for ASTM D573 (70 hours, 212F) shall not exceed the following values:

Hardness : 0 to +15
Tensile Strength : -15% to 15%
Elongation at break : -40% to 0

4.0 APPLICATION OF COATING

The coating shall be plant applied on each pipe except at pipe ends.

The ambient conditions shall be monitored prior to surface preparation and also prior to
adhesive and chloroprene sheet application

4.1 Pipe Surface Preparation

The surface preparation procedure specified within this section is common to all
corrosion coating systems. Surface preparation shall generally be in accordance with the
requirements of ISO 8501-1 (SIS 05 59 00).

Linepipe shall be free all mill applied oils, grease, lacquer or preservatives with the
exception of a protective coating over the mill / heat identification numbers.

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 4.1.1 Pre-Blasting Preparation
The vendor shall thoroughly clean and dry the line pipe. All subsequent minor
contamination such as dint, dust, rust, scale, mill lacquer, moisture, oil, grease
and other impurities shall be removed from the line pipe surface by the Vendor.

The ends of the pipe shall be protected by the Vendor with plugs or other
means to prevent entry of abrasives into the pipe during blast cleaning. Special
care shall be exercised to ensure that the pipe number on the inside of the pipe
is protected, and that contamination of the internal liners of CRA Lined pipe is
avoided. Any abrasives entering the pipe shall be removed prior to coating. The
method of protection shall not utilise any oil or grease compounds that may
affect welding on the lay barge.

4.1.2 Blast Cleaning

The external surface of the line pipe shall be cleaned by rotary blast cleaning.
After blast cleaning treatment, the external surface of the line pipe shall
correspond to Grade Sa 2.5 of ISO 8501-1 (SIS 05 59 00). The blast cleaning
abrasives used shall be manufactured iron grit or copper slag. Sand shall not be
used as a blast cleaning abrasive. The cleaning of the line pipe shall be so
controlled as to prevent burnishing or injurious abrasion of the line pipe metal

The permissible degree of surface roughness or “maximum profile” after blast

cleaning shall be in the average range of 0.05mm to 0.10mm as measured by
TESTEX or an approved equivalent. The “ maximum profile” is defined as the
greatest vertical distance between the summit of any peak on the blast cleaned
surface and the bottom of an immediately adjacent trough. Profile
measurements shall be performed by the Vendor at least once per shift / day at
three random locations of a pipe length.

Any surface which shows signs of contamination from blasting and / or handling
after blasting shall be cleaned and reblasted. If necessary, the contaminated
surface shall be brushed with a clean brush made of hair, bristle or fibre, or
blown off with compressed air (free from oil, grease and water) or cleaned by
vacuum to remove all traces of the blast cleaning products from the surface.

The blast cleaning operation shall not be conducted on surfaces that are less
than 3°C above the dew point or when the relative humidity is greater than 85
percent, unless preheating of the line pipe is performed. Blast cleaning under
these conditions may be performed provided the line pipe can be warmed to a
temperature (not to exceed 50°C) sufficient to perform the blasting operation.

4.2 Application of Bonding Agent

The application of the primer and bonding system shall be carried out in a covered
workshop. The primer and bonding agent shall be thoroughly stirred and mixed before
use.
The first primer coat shall be applied to the pipe within two hours after the pipe has been
prepared as per Section 4.1. Failing which the pipe shall be recleaned before priming.

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 The primer and bonding agent shall be applied to the pipe surface such that it provides a
consistently smooth and uniform coverage.

4.3 Application of Polychloroprene

The application of Polychloroprene coating to pipe/bend shall be carried out in a covered

workshop. Layer of sheets of Polychloroprene shall be milled to the required thickness
and then lined to the riser pipe/bend.
The Polychloroprene sheet shall be partially tacked in position. The sheet shall then be
rolled around the pipe/bend with a steady firm overlapping stroke.

The total thickness of the Polychloroprene coating shall be 12.7mm with tolerances of +
2mm and - 0mm.

After the Polychloroprene has been applied, the coated riser pipe/bend shall then be
wrapped with nylon bandages.

4.4 Vulcanisation

Polychloroprene coated riser pipe/bend shall be vulcanised in an autoclave. In cases

where the riser pipe/bend cannot fit into autoclave, vulcanisation shall be performed
using exhaust steam method.

Vulcanisation of Polychloroprene coating in an autoclave shall be carried out at

Temperature :- Range ( 132°C to 155°C ) and Pressure Range ( 40 to 60 psi ). Duration
of Vulcanisation shall not be less than 2 hours.

Vulcanisation of Polychloroprene coating using exhaust steam method shall be carried

out at Temperature Range ( 90°C to 100°C ). Duration of vulcanisation shall not be less
than 12 hours.

5.0 INSPECTION

The client representative shall have free access to inspect the coating materials, equipment
and the coating work.

Coating inspection shall be carried out in the presence of client representative.

5.1 Inspection of Coating Materials and Repair Product

Coating materials and repair product shall be inspected upon delivery to ensure that
packaging is in accordance with instructions and marking is in accordance with this
specification.

Non-conformity with any of the specified requirement shall cause the immediate rejection
of the delivery concerned.

Quality of the coating material and repair products shall be ascertained by checking all
the documents.

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5.2 Inspection of Coating Process

This inspection shall be performed during coating application in order to check the
following parameters:

- Finished or prepared surface

- Total roughness of prepared surface
- Vulcanisation
- Vulcanisation temperature
- Vulcanisation pressure

5.2.1 Finished or Prepared Surface

Material : As per SIS 05 99 00

Method : Comparison of prepared surface finish with the illustration

corresponding to SA2 surface finish according to the initial
metal rust degree (A,B,C or D) or pipe metal

Inspection : 100% of the prepared surface of each pipe

Specification
requirements: The inspection of each pipe shall be considered as acceptable
when the whole prepared surface shows the same aspect as
the relevant illustration

Failing this, the pipe shall be reblasted.

5.2.2 Total Roughness of Prepared Surface

Material : Surface profile gauge.

Method : Place the gauge at the prepared surface. Measure peak to

peak heights on the blast cleaned surfaces on the dial.

Inspection : 100%.

Specification
requirements: The inspection of each pipe will be considered as acceptable
when the 4 total roughness value are within the range of 50 to
100 microns. In the case of value out of range, 4 additional
measurement shall be taken around the critical point.

If the total roughness obtained from one of the 4 new measurement is:

- Below 50 microns, the pipe shall be reblasted

- Above 100 microns, the pipe shall be examined by the inspector. If the
inspector deems that more than 10% of the surface has a total roughness
value exceeding 100 microns, the pipe shall be rejected and reblasted.

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 5.2.3 Vulcanisation

Method : Visual

Inspection : 100% of the coating

Specification
requirements: The coating shall not be contaminated by sand, dust moisture,
rain or other substances during vulcanisation. Each
Polychloroprene coat shall be bonded to the previous one. The
complete coating shall adhere firmly to the riser pipe/bend.

5.2.4 Vulcanisation Temperature

Material : Temperature recording device

Method : Specific to the instrument used which shall be calibrated before

use.

Inspection : Continuous monitoring

Specification
requirements: The inspection of the vulcanisation temperature shall be
considered as acceptable when the temperature recorded does
not deviate more than  10°C from that specified

5.2.5 Vulcanisation Pressure

Material : Pressure recording device

Method : It shall be verified against a master gauge prior to be used.

Specification
requirements: The inspection of the vulcanisation pressure shall be
considered as acceptable when the pressure does not deviate
more than 10 PSI from that specified.

5.3 INSPECTION OF POLYCHLOROPRENE COATED PIPES

The inspection shall be performed after coating application on each coated pipe cooled
down at ambient temperature which shall be less than 35°C and more than 10°C in order
to check the following:

- Aspect
- Thickness
- Cut-back
- Hardness test
- Holiday detection test
- Adhesion

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5.3.1 Aspect

Method : Visual

Inspection : 100% of the pipe coated surface

Specification
requirements: The coating shall be inspected for imperfections, lack of bond
at joints, blister, lamination and apparent irregularity.

5.3.2 Thickness

Method : Diameter measuring tape

Inspection : Minimum of four locations equally spaced along riser

pipe/bend. Sets of four measurements around the pipe/bend
shall be taken at each location.

Specification
requirements: The Polychloroprene coating thickness shall be 12.7mm +
2mm, -0mm.

5.3.3 Cut back

Method : Ruler/measuring tape or template

Inspection : At both ends of each coated pipe/bend.

Specification
requirements: Cut back length shall be as specified from each end.

5.3.4 Hardness test

Method : Indentor comprising a vertical plunger terminating in a rigid ball.

Inspection : Four equally spaced, diametrically opposed pairs of hardness

measurement on the Polychloroprene coating shall be taken
per riser pipe/bend.

Specification
requirements: The measurement shall fall within 60° - 70° Shore A.

Failing this the Polychloroprene coating shall be rejected.

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 5.3.5 Holiday Detection Test

Method : Adjustable DC holiday detector with voltage indicator and

electrode consisting of:
- One circular metal searching coil
- one elastomer element for possible defect location.

The holiday detector shall be calibrated once per shift.

Inspection : Continuous over the entire coated pipe surface.

Specification
requirements: No pinhole shall be detected for an applied voltage of 30 KV.
Should a holiday occur, it shall be repaired in accordance with
Section 7.0

5.3.6. Adhesion

Method : A sample mild steel plate ( ~ 25mm x 140mm ) shall be prepared

in the same procedure and application. It shall be subjected to
vulcanisation together with the actual riser pipe/bend. After
curing, it shall be tested by tearing the coated rubber from the
steel plate.

Specification
requirements : A thin layer of rubber elastomer will still be bonded to the steel
plate to show that the strength of chemical bond between the
rubber coating and the plate exceeded the tear strength of the
coating.

6.0 COATING REPAIRS

Any defective part of the coating at pipe, bend or field joint such a holidays, tears or
damaged spots shall be clearly marked with waterproof coloured crayon and repaired
immediately.

Repair procedure shall be as follows:

- Cut the damaged area of coating down to bare metal and remove coating.

- Remove surrounding coating to establish that the bond is correct and chamfer all edges
of coating to an approximate 45° angle.

- The metal surface shall be cleaned using power tools.

- Primer and bonding agent shall be applied.

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 - Sheets of uncured Polychloroprene shall be fitted into the area and the edges blended to
the existing coating with hand stitches. This is repeated until the coating is built up to
finished thickness.

- The repair shall then be wrapped with nylon tape and vulcanised.

- The repaired area will be tested again as described in Section 6.0

7.0 NON-CONFORMANCE

Any coated pipe joint shall be rejected and no repair allowed to it if:

- There are more than 3 defective parts located for repair per joint.
- The defect is greater than 0.093 square meter (1 square foot).

Any rejection of coated pipe length which does not meet the specified requirements of this
specification shall be recleaned and recoated.

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 TABLE 2.1

POLYCHLOROPRENE ACCEPTANCE TEST REQUIREMENT

PRODUCT SPECIFICATION

PRESS-CURED AT 145°C FROM 30 MINUTES

PROPERTY TEST ACCEPTABLE REPORT TEST

METHOD CRITERIA EQUIPMENTS

Hardness BS903 A26 60°-70° Shore A Test Report Tester

(Needle Type)
Specific Gravity BS903 A1 1-1.45 Test Report Balance
Tensile Strength BS903 A2 13 Nmm2 ( Min ) Test Report Tensometer
Elongation at Break BS903 A2 390% ( Min ) Test Report Tensometer
Tear Strength BS903 A3 40N/mm (min) Test Report Tensometer
Hot Sea Water BS 903 A16 2% (max) Compliance N.A
Resistance 80°C Letter
Ozone Resistance ASTM D1149 No crack Compliance N.A
100 hrs at Letter
40°C
50pphm
Compression Set BS903 A6 22% (max) Test Report Apparatus
22 hrs at Compression
70°C set
Abrasion Loss DIN 53516 180mm3 (max) Test Report Din Abrasion
Machine

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