Q. P.

PTJ-QA-SQR-CO 01

Page 1 OF 11

Revision 1

Quality Procedure Date 25/02/2007

TITLE : 16" PIPELINE FIELD JOINT COATING PROCEDURE

SAQQARA ONSHORE PROJECT

ONSHORE PIPELINE "16

FIELD JOINT COATING PROCEDURE

Copy No. Holder

Stamp

Prepared by Reviewed by Approved by

Job Title:

Name:

Signature:

Revision No. : 0 1 2 3 4 5

Date : 22/02/2007 25/02/07

Page/Pages of Rev. : 9,11

TABLE OF CONTENTS
 Q. P. PTJ-QA-SQR-CO 01

Page 2 OF 11

Revision 1

Quality Procedure Date 25/02/2007

TITLE : 16" PIPELINE FIELD JOINT COATING PROCEDURE

1- INTRODUCTION

2- DEFINITIONS

3- REFERENCE DOCUMENTS

4- MATERIAL TYPE AND STORAGE PRECUTIONS

5- STEEL SURFACE PREPARATION

6- POSITIONAL MARKING

7- INSULATION HEAT-SHIELDS

8- PRE – WARMING

9- EPOXY PRIMER APPLICATION, CURING AND PRE-HEAT

10-QC CHECKS AND TEST.

11- HEAT SHIELDS REPLACEMENT

12-HEAT SHRINKABLE SLEEVES APPLICATION

13-QUALITY CHECKS
 Q. P. PTJ-QA-SQR-CO 01

Page 3 OF 11

Revision 1

Quality Procedure Date 25/02/2007

TITLE : 16" PIPELINE FIELD JOINT COATING PROCEDURE

13.1 ADHESION TESTS

13.2 INSPECTION.

14-HOLIDAY TEST

15- HEAT SHRINKABLE SLEEVE REPAIR

16 -PIPELINE REPAIR PRODUCTS AND PROCEDURE

17- PAINTING AND COATING INSPECTION BAG CONTENT.

18- GFVE COATING FOR BENDS

19-TSA COATING FOR ANCHOR FLANGES

20- SAFETY GUIDELINES

21- APPENDICES

1. INTRODUCTION
This document describes the procedure that will be followed for applying the field joint
coating system for the onshore girth weld areas on the 16” Multiphase carbon steel Pipeline
during the installation phase to ensure providing a sufficient protection of the steel substrate
at the girth weld areas against corrosion.
 Q. P. PTJ-QA-SQR-CO 01

Page 4 OF 11

Revision 1

Quality Procedure Date 25/02/2007

TITLE : 16" PIPELINE FIELD JOINT COATING PROCEDURE

The field joint coating operation shall be performed and by a fully experienced and qualified
coating inspector by PETROJET.
All materials supplied by PETROJET shall be furnished with an appropriate manufacture
certification. This certification shall clearly defines the product, its specification, date of
manufacture and expiry date in addition to all the necessary information needed to ensure
both the integrity and high performance of the product .

2. DEFINITIONS

Company: (BP/GUPCO)

Contractor: (PETROJET)

3. REFERENCE DOCUMENTS

Drawings :

Onshore pipeline And Umbilical GSP-E-FA-KL-PL-DTL-0001 Rev.C2

Saqqara Pipeline System GSP-O-GN-KL-PL-GAS-0006 Rev.C4

Onshore Field Joint Coating Details For 16" GSP-E-GN-KL-PL-DTL-0001-002-C1

pipeline .

Onshore Field Joint Coating Details For 16" GSP-E-GN-KL-PL-DTL-0001-001-C2

pipeline .

Specifications : KBR Specs.

General Coating Specification GSP -O -GN -KL -MT -SPE -0004 -C3

4. MATERIAL TYPE AND STORAGE PRECUTIONS

 The type of shrinkable sleeve to be used shall be CANUSA GTS-PP-WRAPID SLEEVE
 The sleeves must be delivered in boxes or containers.
 All materials must be supplied and robust packing cases.
 Q. P. PTJ-QA-SQR-CO 01

Page 5 OF 11

Revision 1

Quality Procedure Date 25/02/2007

TITLE : 16" PIPELINE FIELD JOINT COATING PROCEDURE

 On delivery, the packing of the sleeves must be examined and inspected for obvious
damage, integrity and acceptance for installation.
 The packing shall be stored in dry, ventilated warehouse, sheltered from direct sunlight
and far from any external heat source or other adverse environmental elements to
ensure maximum performance and to avoid any kind of explosion could be occurred.
 Avoid storage at temperature above 35oC or below 20oC.
 The sleeves must be raised from the ground to avoid contamination from water and any
other foreign substances.
 All materials supplied by PETROJET shall be stored in strict compliance with the
material manufacturers written recommendations at all times.

5. STEEL SURFACE PREPARATION

 Upon successfully completion of the line pipes field weld and performing the non-
destructive tests, Clean any exposed steel and adjacent pipe coating with a solvent
cleanser to remove the presence of oil, grease and other contaminants taking into
consideration a strict safety precautions that sources of ignition are not allowed to be
existed inside the vicinity of the field joint coating station especially during the solvent
cleanser applications .
 Only non-flammable detergents are allowed to be applied for the pipe surface cleaning
and rinsing with clean, fresh water and drying the pipe surface shall be followed.
 Weld area to be thoroughly cleaned and blasted using a Grit abrasive or Garnet abrasive,
the Grit abrasive to be used once then disposed off and shall be of the Iron-Silicate or
equivalent having a suitable grain size to achieve a near white metal (SIS SA 2 1/2)
or equivalent. Surface shall be cleaned till achieving a surface profile from 65-100
microns. Immediately prior to installation, each 75mm of the 3LPP from each side of
the girth weld shall be mechanically abraded to 15o from the horizontal, cleaned and
roughened by using a sand disk to reveal a fresh surface of coating over the length to
be covered by the heat shrink sleeves.
 The preparation and grinding of the PP shall not damage or remove the factory applied
FBE primer which shall be exposed beyond the termination of the PP coating for a
distance of at least 10 mm.
 Maximum total cutback length is 300mm.
 Air blast the steel and pipe coating to remove foreign contaminants.
 The cleaned surfaces shall be 100% visually inspected to ensure no contamination or
surface irregularity are exist, In addition surface peak to trough height shall be
measured using Testex tape or equivalent and the measurement shall be carried out on
a minimum of the first ten joints then hourly and the tape shall be retained for record.
 Q. P. PTJ-QA-SQR-CO 01

Page 6 OF 11

Revision 1

Quality Procedure Date 25/02/2007

TITLE : 16" PIPELINE FIELD JOINT COATING PROCEDURE

 Moreover, random measurements of blast / anchor profile shall be made at a

minimum frequency of five (5) per shift per work area, or one per ten (10)
square meters if greater, using Testex tape or other approved method.

6. POSITIONAL MARKING
 Measure and mark the sleeve width edges (450mm) of the wrapid sleeve
CANUSA-GTS-PP across the joint. Also measure and mark the induction coil so
it is centered over the joint and sleeve.

7. INSULATION HEAT-SHIELDS
 Wrap the insulation heat-shields around the coating ensuring the shields are
placed at the cutback edges.

8. PRE – WARMING
 Using the appropriate sized induction coil or propane torch, pre-warm the joint
area to (50o -65o C).
 The pre-heating temperature shall be checked using a temperature needle
gauge to ensure that the correct temperature is reached on the steel.

9. EPOXY PRIMER APPLICATION, CURING AND PRE-HEAT

 The mixing ratio for the primer is 4 parts base, 1 part cure by volume and 5.3 parts
base, 1 part cure by weight.
 Mixed epoxy primer to be applied of 150-230 µm on all exposed bare metals only at
the cut back areas.
 Epoxy primer to be cured and pre-heated using an induction coil to 190-210 o C within
a time of 2-3 minutes.

10. QC CHECKS AND TEST FOR APPLIED EPOXY PRIMER.

Following QC checks shall be performed on the applied primer to ensure the material
is applied at the best way.

 The QC engineer shall check that the epoxy primer kit is exist and equipped with all
the necessary tools like gloves, application pad ………etc.
 Q. P. PTJ-QA-SQR-CO 01

Page 7 OF 11

Revision 1

Quality Procedure Date 25/02/2007

TITLE : 16" PIPELINE FIELD JOINT COATING PROCEDURE

 The QC engineer shall witness the mixing operation to ensure that the two
components of the primer are mixed together in accordance with the manufacturer
recommendations. Mixing ratio to be as mentioned here above in section 9.

The applied epoxy primer shall be checked for proper thickness using a wet film
thickness gauge in order to ensure the correct and uniform thickness is achieved.

11. HEAT SHIELDS REPLACEMENT

Move the insulation heat shields to a distance of 15mm from the edge of the sleeve width,
which was previously marked.

12. HEAT SHRINKABLE SLEEVES APPLICATION

 Gently heat the under lap approximately 150mm from the edge.
 Under lap of the sleeve to be placed onto the joint, centering the sleeve such
that the sleeve overlap is positioned at either the 10 or 2 o'clock position,
accordingly under lap to pressed firmly into place.
 Wrap the sleeve loosely around the pipe, ensuring the appropriate overlap.
Before finishing wrapping the sleeve, following procedures shall be applied:
 Heat the packing side of the under lap until the backing starts to recover.
 Heat the adhesive side of the overlap until the adhesive appears glossy.
 Heat the adhesive side of the closure until the adhesive appears glossy.
 Press the closure and overlap firmly into place.
 Gently heat the closure and pat it down with a gloved hand, repeating this
procedure, move from one side to the other. Smooth and wrinkles by gently
working them outward from the center of the closure with a roller.
 Using the torch, being heating at the center of the sleeve and heat circumferentially
around the pipe. If the backing becomes shiny or gives off smoke, move the torch
away from the area.
 Continue heating from the center toward one end of the sleeve until recovery is
complete. In a similar manner, heat and shrink the remaining side.
 There is no need at all to pre heat the PP outer surface (see attached GTS PP
installation guide). However the PP coating has enough durability to withstand a
temperature up to 120C.
 Initial shrinking has been completed when the sleeve fully conforms to the entire pipe
profile. Finish shrinking the sleeve with long circumferential strokes over the
 Q. P. PTJ-QA-SQR-CO 01

Page 8 OF 11

Revision 1

Quality Procedure Date 25/02/2007

TITLE : 16" PIPELINE FIELD JOINT COATING PROCEDURE

coating overlap surface to ensure a uniform bond. Adhesive should being to

ooze at the sleeve edges all around the circumference.
 The application of the sleeve shall ensure that the sleeve is installed squarely to the joint
and also the overlap is in the upper quadrant of the pipe, facing downwards. Any creases
or air entrapment shall be removed to leave a smooth surface.
 Sleeve dimensions are 450mm in width including the overlapped distance applied on the
external anti-corrosion coating on either side of the girth weld area by at least 75mm,
and length of 150cm enough to ensure sufficient overlapped portion of the shrink
sleeve. this length ensures an over lab of 10cm approximately

13- QUALITY CHECKS

13.1 ADHESION TESTS
On completion of heat shrinkable sleeves application, test sleeve adhesion by gently
pressing the sleeve edge with a gloved finger. The sleeve is well bonded when the
adhesive and coating remain intimately contacted. If required to improve bonding,
additional heat should be applied to the sleeve.
Slack there should be between the bottom of the PP coating and the sleeve to be
from 3cm to 5cm.

13.2 INSPECTION.
Installed sleeves shall be visually inspected for the following:
-Sleeve is in full contact with the steel joint.
-Adhesive flows beyond both sleeve edges.
- No cracks or holes in sleeve backing.
In addition, the backing shall be pulled back at the edges immediately once the
sleeve is been shrink down. This is to ensure that the adhesive is completely molten,
wet out and does not pull back with the backing. This assures that the adhesive will
be bonded once the product cools. Normally as part of the standard inspection plan,
an adhesion test is completed every 100th joint or on one joint per shift to ensure
that the product is still being applied properly.

14-HOLIDAY TEST

 Holiday detection shall be carried out to each field joint coating after the shrinkage
completion of the installed heat shrink sleeve at 15 KV using a high voltage holiday
detector.
 Q. P. PTJ-QA-SQR-CO 01

Page 9 OF 11

Revision 1

Quality Procedure Date 25/02/2007

TITLE : 16" PIPELINE FIELD JOINT COATING PROCEDURE

 The pipeline 3 layer pp coating and the field joint coating shall be free from holiday
before lowering into trench.

15- HEAT SHRINKABLE SLEEVE REPAIR

 If the field joint coating does not pass inspection, the sleeve shall be removed while
being hot and a new sleeve shall immediately being applied.
 The repair procedure will be defined on site according to the type of defect and
Company’s Site Representative will approve such procedure; otherwise, the sleeve
will be removed and a new one shall applied.

16- PIPELINE REPAIR PRODUCTS AND PROCEDURE

 Pipeline repair products and procedure shall be according to the manufacture

data sheet (copy attached)

17-PAINTING AND COATING INSPECTION BAG

CONTENT.
The painting and coating inspection bag contents includes the surface profile measurement,
the instrument shall be used for checking the pre-heating temperature on the steel substrate
and the 3LPP and other tools and instruments required to carry out the job in accordance with
the project specifications and requirements.
 Q. P. PTJ-QA-SQR-CO 01

Page 10 OF 11

Revision 1

Quality Procedure Date 25/02/2007

TITLE : 16" PIPELINE FIELD JOINT COATING PROCEDURE

(1) – HYGOROMETER INSTRUMENT MEASURING:

 SURFACE TEMPERATURE. (MAX. 250°C)
 AIR TEMPERATURE °C.
 WET TEMPERATURE °C.
 DEW POINT TEMPERATURE °C.

(2) – SURFACE PROFILE INSTRUMENT (DIAL MICROMETER AND REPLICA TAPE)

(3) – TESTEX TAPE (COARSE GRADE & EXTRA COARSE GRADE)
(4) – SURFACE PROFILE NEEDLE GAUGE
(5) – DRY FILM THICKNESS GAUGE
(6) –ADHESION INSTRUMENT
(7) –PAINTING & COATING INSPECTION BAG

18- GFVE COATING FOR BENDS

 Glass flake vinyle ester (GFVE) coating shall be carried out for all elbows before
welding and to be in accordance with specs no. GSP-O-GN-KL-MT-SPE-004.

19-TSA COATING FOR ANCHOR FLANGES

 Q. P. PTJ-QA-SQR-CO 01

Page 11 OF 11

Revision 1

Quality Procedure Date 25/02/2007

TITLE : 16" PIPELINE FIELD JOINT COATING PROCEDURE

 Thermally sprayed alluminium (TSA) coating shall be carried out for all anchor
flanges before welding and to be in accordance with specs no. GSP-F-GN-KL-PL-
SPE-0010.

20- SAFETY GUIDELINES

Avoid inhalation if possible solvent vapors or paint mist, as well as paint contact with skin
and eyes. All the personnel involved in such scope of work must be committed with the
Personal protective equipments (PPE) to avoid inhalation or contact with the used chemicals.
Always take precautions against the risks of fire or explosions, in addition sources of ignition
are forbidden to be existed inside the vicinity of the filed joint application.
All the products used for the field joint coating application shall be stored in dry, ventilated
areas and kept in original cartoons and well sealed bottles to avoid any leak that might be
occurred during the transportation of such bottles, Moreover these products shouldn't be
exposed to direct sun light, rain, snow, dust or other adverse environmental elements.
Storage temperature to be in accordance with the product data sheet to ensure the maximum
performance of such products.

21. APPENDICES
DOCUMENT TITLE
o CANUSA – CPS (GTS – PP – Wrapped Sleeve) --Technical Data Sheet.

o CANUSA – CPS – Pipeline Repair Products And Procedure

o COATING REPORT FORM