PHEONWJ-W-SPE-0006~0 (Specification for Pipeline Corrosion Protection Coating)

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PT. PHE ONWJ Specification for Pipeline Corrosion Protection Coating

PHEONWJ-W-SPE-0006 Rev.0 Page 2 of 11

Revision Log Register

Document Number : PHEONWJ-W-SPE-0006

Document Title : Specification for Pipeline Corrosion Protection Coating

Revision : 0

Page Date Revision

PHE ONWJ

Reviewer




Table of Content

Revision Log Register............................................................................................................................ 2

Table of Content .................................................................................................................................... 3

1 . Scope ............................................................................................................................................. 4

2. References..................................................................................................................................... 4

2.1 Local Regulation and Standards .......................................................................................... 4

2.2 Company Specification ........................................................................................................ 4

2.3 International Standards and Codes...................................................................................... 4

3. Definition of Terms ........................................................................................................................ 5

4. Abbreviations ................................................................................................................................. 5

5. General Requirements................................................................................................................... 6

6. Design............................................................................................................................................ 6

7. Liquid Epoxy Coating ..................................................................................................................... 7

8. Bitumen Based Enamel (Asphalt Enamel) Coating........................................................................ 7

9. Fusion Bonded Epoxy Coating (FBE) ............................................................................................. 8

10. Polyethylene Coating (2-layer PE).................................................................................................. 8

11 . Polyolefin Coating (3-layer PE and 3-layer PP) ............................................................................... 8

12. Other Coating ................................................................................................................................ 8

13. Qualification and Application.......................................................................................................... 8

14. Surface Preparation ....................................................................................................................... 9

15. Inspection and Test ....................................................................................................................... 9

15.1 Holiday inspection ............................................................................................................. 10

15.2 Repair................................................................................................................................. 10

15.3 Retest ................................................................................................................................ 10

15.4 Stripping and Recoating..................................................................................................... 11

15.5 Supplementary Test .......................................................................................................... 11

16. Markings ...................................................................................................................................... 11

17. Handling, Storage and Transportation ......................................................................................... 11

18. Documentation ............................................................................................................................ 11




1 . Scope

This specification covers the minimum requirements for the materials, application, inspection

and testing of the corrosion protection coating to be used on pipelines.

2. References

Design, manufacture, performance and testing should be in compliance with the following

codes and standard, except where otherwise specified. The following documents should form

an integral part of this specification:

2.1 Local Regulation and Standards

Decree of Mines and Energy

300.K/38/M.PE/1997

Work Safety of Oil and Gas Distribution Pipelines

Decree 84.K/38/DJM/1998 Inspection Guidelines for Safety on Facilities,

Equipment and Technology Used in Oil and Gas and

Geothermal Activity

Regulation

06P/0746/M.PE/1991

Safety Audit to Inspection, Equipment and Technique

used In Oil and Gas Mining and geothermal Activities.

Regulation Number 11 -

Year 1979

Working safely on Refinery and Processing Oil and Gas

2.2 Company Specification

The following COMPANY Specifications should be applied to the subject work.

PHEONWJ-W-PRC-0012 Guidance on Offshore Pipeline Design

PHEONWJ-W-SPE-0005 Specification for Line Pipe

PHEONWJ-F-PRC-0007 Site Technical Practices (STP) for Painting on Metal

Surfaces

2.3 International Standards and Codes

Except where otherwise noted, the latest edition of the following codes and standards

should apply:

ASTM D257 DC Resistance or Conductance of Insulating Materials

ASTM D1653 Water Vapor Transmission of Organic Coating Films

ASTM G9 Water Penetration into Pipeline Coatings

ASTM G154 Operating Fluorescent Light Apparatus for UV

Exposure of Nonmetallic Materials

EN 10300 Bituminous Hot Applied Materials for External Coating

EN 10339 Internal liquid applied epoxy linings for corrosion

protection

ISO 5256 External and Internal Coating by Bitumen or Coal Tar

Derived Materials

ISO 8502-3 ISO 8502 Part 3-Assessment of Dust on Steel

Surfaces Prepared for Painting (Pressure-Sensitive

Tape Method)

ISO 8502-6 ISO 8502 Part 6-Extraction of Soluble Contaminants for

Analysis-The Bresle Method




ISO 8502-9 ISO 8502 Part 9-Field Method for the Conductometric

Determination of Water-Soluble Salts

ISO 8501-1 ISO 8501 Part 1 -Rust grades and preparation grades of

uncoated steel substrates and of steel substrates after

overall removal of previous coatings

ISO 8503-5 ISO 8503 Part 5-Replica tape method for the

determination of the surface profile

ISO 11124 Metallic Blast-Cleaning Abrasives

ISO 21809-1 ISO 21809 Part 1 -Polyolefin coatings (3- layer PE and 3-

layer PP)

ISO 21809-2 ISO 21809 Part 2-Fusion-bonded epoxy coatings

ISO 21809-4 ISO 21809 Part 4-Polyethylene coatings (2-layer PE)

NACE RP0288 Inspection of Linings on Steel and Concrete

NACE RP0394 Application, Performance, and Quality Control of Plant-

Applied, Fusion-Bonded Epoxy External Pipe Coating

NACE RP0399 Plant-Applied External Coal Tar Enamel Pipe Coating

Systems-Application, Performance, and Quality Control

NACE SP0185 Extruded Polyolefin Resin Coating Systems with Soft

Adhesives for Underground or Submerged Pipe

SSPC-AB-1 Mineral and Slag Abrasives

SSPC-AB-2 Cleanliness of Recycled Ferrous Metallic Abrasives

SSPC-AB-3 Ferrous Metallic Abrasive

SSPC-SP1 Solvent Cleaning

SSPC-SP-10 Near-white Blast Cleaning

3. Definition of Terms

COMPANY PT. Pertamina Hulu Energi ONWJ

CONTRACTOR The party that carries out all or part of the design, engineering,

procurement, construction, commissioning or management of a

project. The COMPANY may undertake all or part of the duties of

the CONTRACTOR.

VENDOR The party that manufactures or supplies equipment and/or services

to perform the duties specified by the CONTRACTOR.

4. Abbreviations

ASTM American Society for Testing and Materials

EN European Standard

ISO International Organization for Standardization

SSPC Steel Structures Painting Council

NACE National Association of Corrosion Engineers




5. General Requirements

The purchase requirement will indicate:

pipe quantity, length, outside diameter, wall thickness, pipe standard (e.g.ISO 3183/API 5L)

type, minimum thickness and tolerances of the coating

maximum design temperature

If applicable, the purchase requirement will specify the following additional information:

cutback length if different from this specification

additional requirement (e.g. test frequency, test ring location, increased test ring length,

supplementary test, marking, and additional surface treatments)

whether approval of the application procedure is to be by review of previous production

data or by testing

Unless noted otherwise, these requirements shall apply to the applied coating:

cathodic disbondment : < 10 mm radius after 28 days

flexibility : no cracking at 2,0 angle per pipe diameter length

electrical resistivity : > 10

8

ohm.m

adhesion : as per applicable standard mentioned in Section 7 to 11

impact strength : 1 .5 J/mm

cutback length : 50 mm for internal pipe coating and 150 mm for external pipe

coating.

minimum thickness will be specified but shall not be less than as follows:

internal pipe coating : 320 m for liquid epoxy, or 250 m for liquid epoxy-polyamide

(modified epoxy).

external pipe coating : (a) 550 m for liquid epoxy

(b) 4.0 mm for bitumen based enamel (asphalt enamel)

(c) 500 m for fusion bonded epoxy

(d) as per Table 2 of ISO 21809-4 for polyethylene (2-layer PE),

which shall be coating thickness class A for pipe to be

concrete coated, and class C for pipe not to be concrete

coated (pipe with polyethylene alone).

(e) as per Table 2 of ISO 21809-1 for polyolefin (3-layer PE/PP),

which shall be coating thickness class:

-A1 , B1 , or C1 for pipe to be concrete coated.

-A3, B3, or C3 for pipe not to be concrete coated (pipe with

polyolefin alone).

notes: (a) cutback shall be measured from the root face of the pipe to the beginning of

the coating.

(b) precautions shall be taken to avoid disbondment on the cutback.

(c) coating shall be beveled to an angle not exceeding 30 measured in direction to

the pipe axis.

(d) coating thickness may be reduced by a maximum of 10% on the weld seam for

SAW welded pipes

6. Design

Selection of the most appropriate coating is a first priority to ensure the long term integrity of

the pipeline. The selection shall take into account the storage, transport, handling, laying and

service conditions (high temperature, harsh conditions, etc.). Selected coating system shall

have properties and performance characteristics that are required for satisfactory coating

performance.




Typically, maximum service temperature of coating as follows (specific product improvement

may achieve better performance):

liquid epoxy : 90 C

oxidized bitumen : 75 C

modified bitumen : 90 C

fusion bonded epoxy (single layer) : 90 C

polyethylene (2-layer PE) : 50 C

polyolefin: 3-layer PE (low density) : 60 C

3-layer PE (medium/high density) : 80 C

3-layer PP : 110 C

7. Liquid Epoxy Coating

The material is generally composed of a base (epoxy resin) and a curing agent. A primer may

be used when recommended by the product manufacturer. The base (epoxy resin) and curing

agent should have different colours allowing the verification of the correct mixing by checking

the uniformity of the colour of the mixed product.

All materials shall be prepared and applied strictly in accordance with the coating

manufacturers recommendations. All materials shall be handled and stored in accordance

with the manufacturers recommendations. Use of thinner shall be limited as far as possible

and the ratio shall always be less than the maximum allowed by coating manufacturers

recommendations.

Coatings shall not be applied during fog, mist or rain, when the surfaces are less than 3C

above dew point or when the air relative humidity is greater than 85%. Checking of the

temperature, humidity and dew point shall be done twice a day minimum and particularly

every starting of the work.

For internal pipe, application and tests of liquid epoxy shall conform to EN 10339 or equivalent.

For external pipe, the coating shall be of an abrasion resistant (glass flake reinforced polyester

or modified epoxy). For pipe not to be concrete coated (pipe with liquid epoxy coating alone),

the coating shall be with marine anti-fouling system.

8. Bitumen Based Enamel (Asphalt Enamel) Coating

Asphalt enamel coating system shall consist of primer, bitumen enamel, inner-wraps (for

oxidized bitumen enamel only), and outer-wraps. Modified bitumen enamel does not require

the use of inner-wrap.

The primer shall be primer type 2 (hydrocarbon resins) conforming to EN 10300 which

compatible with the asphalt enamel.

The bitumen material either oxidized bitumen enamel (category 1 material) or modified

bitumen enamel (category 2 material) shall be a minimum grade b conforming to EN 10300

Table J.1 .

The inner-wrap shall be a non-woven glass fibre tissue, hydrolytic class 3 quality comprises a

continuous sheet bonded by a suitable resin and reinforced by continuous longitudinal glass

yarns at maximum 30 mm spacing. The characteristics of inner-wrap shall meet the

requirements of EN 10300 Table 6.

The outer-wrap shall have a uniform porosity which allows the air and fumes to escape and

the hot coating to bleed through the outer-wrap ensuring it is fused into the outer surface. The

characteristics of outer-wrap shall meet the requirements of EN 10300 Table 7.




All coated pipes, other than those that will be immediately concrete coated or stored

undercover, should be protected from ultraviolet deterioration by whitewash or craft paper.

The whitewash shall be emulsion latex paint, pigmented dispersions of water-insoluble, film-

forming, and synthetic polymeric materials. The whitewash shall not be applied to wet

surfaces or to surfaces that may be exposed to rain before the paint is dry. Minimum dry film

thickness (DFT) of whitewash shall be 25 m.

9. Fusion Bonded Epoxy Coating (FBE)

Coating Applicator shall use epoxy powder that is certified by the powder manufacturer. The

powder shall have moisture content not exceed 0.6%, particle size within the manufacturers

specification maximum (or must retained on 150 m and 250 m sieves), and the curing

temperature shall not exceed 275 C. Coating application and tests shall conform to ISO

21809-2 or equivalent.

10. Polyethylene Coating (2-layer PE)

The polyethylene coating system shall consist of adhesive as 1

st

layer (asphaltic-modified

rubber, non-asphaltic-modified rubber, or hot melt/polymeric) and polyethylene as 2

nd

layer.

The adhesive shall meet the requirements of Table 3 or 4 of ISO 21809-4. Polyethylene top

layer shall meet the requirements of 5 of ISO 21809-4. Coating application and tests shall

conform to ISO 21809-4 or equivalent.

11 . Polyolefin Coating (3-layer PE and 3-layer PP)

The polyolefin coating system shall consist of epoxy (liquid or powder, as 1

st

layer), adhesive

(powder sprayed or extruded, as 2

nd

layer), and PE (polyethylene) or PP (polypropylene) top

layer (applied by extrusion, as 3

rd

layer). The epoxy, adhesive, and PE/PP top layer shall meet

the requirements of Table 3, 4, and 5 of ISO 21809-1 respectively. Coating application and

tests shall conform to ISO 21809-1 or equivalent.

12. Other Coating

Other coating (e.g. composite coating, multi layer PE/PP, etc) shall be subject to further

engineering assessment. Coating Specialist should be consulted on the feasibility, suitability

and performance of the coating.

13. Qualification and Application

A coating being applied during production shall have been previously qualified in accordance

with the applicable standard.

Coating shall be applied at a temperature in accordance with the manufacturers

recommendations.

Coating Applicator shall submit his application procedure to COMPANY for review and

approval. Coating work and associated inspection and testing shall be carried out in

accordance with the application procedure. The steel surface preparation shall conform to

Section 14.




14. Surface Preparation

All dirt, deleterious matter and contaminants shall be removed from the pipe prior to coating.

Oil and grease on the surface shall be cleaned in accordance with SSPC-SP1. All steel defects

and irregularities (e.g. laminations, slivers, scratches) shall be removed by an approved

grinding method. Grinding of steel defects shall not reduce the wall thickness below the

specified minimum wall thickness of the pipe.

All pipes shall be dry prior to entering the abrasive blast cleaning unit. Pipe temperature shall

be at least 3C above the dew point immediately prior to abrasive blast cleaning. The abrasives

used in the coating plant shall be in accordance with ISO 11124. The abrasives shall be

maintained clean, dry and free from contaminants in accordance to SSPC-AB 1 , SSPC-AB 2

and SSPC-AB 3 so as not to contaminate the substrate.

The cleanliness achieved at entry to the coating application shall be in accordance with ISO

8501-1 grade Sa 2 (near white metal) minimum. The degree of dust remaining on the

surface shall be level Class 2 in accordance with ISO 8502-3. Dust shall be removed by a

vacuum or clean-dry air lance techniques. Brushes shall not be used as they spread the dust,

rather than remove it.

The surface profile attained shall be within the height of between 50 m and 100 m peak-to-

peak in accordance with ISO 8503-5 at 5 random locations over the pipe length.

If grinding is required after blast cleaning, the maximum allowable area of grinding shall be 10

cm per 1 m pipe length

If surface pre-treatment is not used, testing for the presence of soluble salts on pipe shall be

undertaken in accordance with ISO 8502-6 or ISO 8502-9. If surface pre-treatment is used

(e.g. deionised water, phosphoric acid and/or chromate pre-treatment), the pre-treatment

process shall have COMPANY approval. If surface pre-treatment is used for pre-qualification it

must be used for production. The maximum allowable level after blasting shall be 20 mg/m.

15. Inspection and Test

All materials shall be certified by means of the manufacturers certificate of analysis for each

batch of material supplied.

All stages of the work shall be subject to full time inspection by COMPANYs Inspector.

Coating Applicator shall give reasonable access and facilities required for inspection to the

COMPANYs Inspector. COMPANY reserves the right to require additional testing at any time

to confirm or further investigate a suspected fault.

The general appearance of the coating shall be evaluated visually. The coating shall be of

uniform appearance and free from any wrinkling, pinholes, voids, laminations, holidays, dry

wrap and contamination. The coating shall be completely bonded to the pipe surface.

Inspection and testing shall be carried out in accordance with the application procedure and/or

the applicable standard. COMPANY has the option of using alternative standards of

acceptability, e.g. NACE RP0288 for internal pipe coating, NACE RP0394 for fusion bonded

epoxy coating, NACE RP0399 for asphalt enamel coating. NACE SP0185 for polyolefin coating.




Preference of inspection frequency is as Table 1 follows:

Table 1 - Preference of inspection frequency

Properties Requirement

Frequency

qualification

Frequency

production

Pipe temperature prior to blasting min. 3C above

dew point

once every 4 hours

Surface condition after blasting salt content

max. 20 g/m

once 5 pipes at start

of production

and 1 pipe/shift

Surface roughness of blasted surface 50 m to 100 m once every 1 hour

Visual inspection of blasted surface grade Sa 2 once each pipe

Presence of dust after dust removal max. class 2 once every 1 hour

Pipe temperature prior to coating min. 3C above

dew point

once Continuously

Total thickness of coating Section 5 once every 10 pipes

Appearance and continuity Visual once Continuously

Impact resistance Section 5 once once per

coating batch

Adhesion Section 5 once 1 pipe/shift

Cathodic disbondment Section 5 once 1/week

Flexibility Section 5 once ---

Coating repairs no holidays once for

demonstration

each defect

15.1 Holiday Inspection

The entire coated surface of each length of pipe shall be inspected with a holiday

detector having a search electrode made of conducting material. The direct-current

potential of the detector shall be set to exceed 5 volts per micrometre of nominal

coating thickness. The detector shall be calibrated at least once every working shift. No

holidays shall be permitted in finished coating.

15.2 Repair

Coating Applicator shall submit detailed procedures for coating repairs to COMPANY

for review and approval. The repair shall conform to the manufacturers recommended

procedures. Repair materials shall be compatible with the applied coating.

Defects in the finished coating caused by the application process, transportation,

handling and storage in the coating plant or in the storage area as well as those which

have been subjected to destructive testing shall be repaired.

The defect area shall not exceed 10 cm and the total number of defects to be repaired

shall not exceed 1 defect/m of the coated surface unless otherwise specified. If the

size or number of defects exceeds these limits the affected pipe shall be stripped and

recoated.

15.3 Retest

Pipes which fail to meet the required test shall be retested. If the retest also fails, one

pipe in the coating sequence prior to the pipe which failed and one pipe in the

sequence after that pipe shall be retested.




If the results of all retested pipes are satisfactory, the coating shall be considered

acceptable excluding the pipe that failed. If the tests fail, the total production back to

the last passed test shall be blocked.

15.4 Stripping and Recoating

The pipe surface shall be cleaned by a combination of heating to a temperature not to

exceed 275 C, scraping brushing and/or abrasive blast cleaning. All previous coating

shall be removed prior to the normal cleaning and coating process prior to recoating.

The identity of each stripped pipe shall be recorded.

15.5 Supplementary Test

If specified, the purchase requirement will indicate which supplementary testing shall

be applied, such as:

conductance and resistivity, in accordance with ASTM D257 or equivalent

water absorption, in accordance with ASTM G9 or equivalent

water vapour transmission, in accordance with ASTM D1653 or equivalent

ultra violet stability, in accordance with ASTM G154 or equivalent

16. Markings

All marking on inside of pipe in the as received condition shall not be removed. Coating

identification shall be marked on the inside of one end of the pipe.

If specified in the particular specification, coated pipe shall be color-coded in order to readily

identify the different categories of pipe thickness, coating thickness and attachments. The

paint shall be marine paint and suitable for long-term storage at the designated final delivery

location. These bands shall be 50mm wide starting at 150mm from each end of the coating.

17. Handling, Storage and Transportation

Refer to PHEONWJ-W-PRC-0009 for the pipe handling, storage and transportation.

18. Documentation

At completion of work, Coating Applicator shall submit a MDR (manufacturing data record) that

contain, as a minimum:

pipe information (identification number, pipe length, repair if any, etc)

coating procedure, qualification, and application (date application, batch identification

number, etc)

certificates of compliance stating that the coating has been manufactured, applied,

inspected, and tested in accordance with the requirements specified, and the results of the

coating tests and other required tests have been found to conform to such requirements.


PHEONWJ-W-SPE-0006~0 (Specification for Pipeline Corrosion Protection Coating)

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