3210-8210-SP-0008 REV A2.pdf

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PARADIP REFINERY PROJECT

PROJECT SPECIFICATION A

SPECIFICATION FOR EXTERNALPIPELINE COATINGS

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CONTENTS

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

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UPDATED SECTIONS

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

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1.0 INTRODUCTION

1.1 Scope

This document details the requirements of the external coating to be used for the proposed Raw-water and Product pipelines for the Indian Oil CorporationLtd (IOCL) Paradip Refinery project.

This specification shall be read in conjunction with IS 15659, if there is

divergence between the two documents then the more stringent of the twoshall apply.

1.2 Pipelines Descr ipt ion

1.2.1 Product Pipelines

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

1.2.2 Raw water Pipeline

The Raw Water pipeline will run from the Cuttack water intake location andterminate at the raw water reservoirs at Paradip Refinery. The surveyeddistance of the pipeline is 92.8km.

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2.0 REFERENCES, CODES AND STANDARDS

2.1 Project Specific Documents

3210-8210-RP-0039 Pipeline Sizing Report

3210-8210-RP-0017 Raw Water Pipeline Mechanical Design Report

3210-8210-RP-0007 Product & Crude Oil Pipelines Basic Engineering dataReport

3210-8210-RP-0040 Product pipeline Pipe Wall Thickness Report

3210-8210-RP-0015 Product Pipeline Hyd & Surge Analysis Design Report.

2.2 Codes and Standards

The latest editions of the following codes and standards shall apply:

OISD-STD-141 Design and Construction Requirements for CrossCountry Hydrocarbon Pipelines

IS 15659 External Coatings for Buried or Submerged PipelinesUsed in Pipeline Transportation of Gas and Liquid

Hydrocarbons. ASME B31.4 Pipeline Transportation Systems for Liquid

Hydrocarbons and Other Liquids

ASME B31.8 Gas Transmission and Distribution Piping Systems

ISO 8501-1 Preparation of Steel Substrates before Application of Paints and Related Products





DIN 30670 Polyethylene Coatings of Steel Pipes and Fittings;Requirements and Testing

DIN 30672 Corrosion Protection Tapes and Heat ShrinkableSleeves for Underground Pipelines.

ISO 1133 Plastics Determination of the Melt Mass-flow Rate

(MFR) and the Melt Volume-flow Rate (MVR) of Thermoplastics

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ISO 2808 Paints and Varnishes – Determination of FilmThickness

ASTM D3418 Test Method for Transition Temperatures of PolymersBy Differential Scanning Calorimetry

ASTM G14 Standard Test Method for Impact Resistance of Pipeline Coating

AWWA C151 Standard Pressure Classes - Wall Thickness andNominal Wall Thicknesses

2.3 Abbreviations

CP Cathodic protection

3 LPE Three Layer Polyethylene Coating

PE Polyethylene

IOCL Indian Oil Corporation Ltd.

FBE Fusion Bonded Epoxy

ΔTg Temperature Change

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3.0 SPECIFICATION

3.1 Coating Type

For all pipelines the coating type shall be a three layer polyethylene system (3LPE), epoxy, adhesive and polyethylene (PE) top layer.

All coating is to be classed as Class A2 as stated in IS 15659.

3.2 Line Pipe Steel/Diameters

All line pipe shall be dimensionally in accordance to API 5L, the diametersand grades for each pipeline are stated in Project documents 3210-8210-RP-0040 and 3210-8210-RP-0017.

3.3 Operating Temperature

For the LPG pipelines (excluding vapour return) maximum operatingtemperature for the coating shall be 0°C the minimum shall be -45 °C

For all other pipelines the maximum operating temperature for the coatingshall be 65°C the minimum shall be -5 °C.

3.4 Coating Cutback

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

Figure 3.1 – Typical Coating Cross Section at End of L ine Pipe

150mm 70mm 50mm

Steel

PEFBE

3.5 Visual Inspect ion

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

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3.6 Total Coating Thickness

The minimum thickness of the total coating system shall be as specified inTable 3.1 to 3.3. The coating shall be measured in accordance with ISO2808, method 6A or 6B.

The thickness of the adhesive layer shall between 0.14 to 0.2mm.

Pipeline Diameter (mm) Minimum Thickness (mm)

≤ 100 0.3

>100 and ≤ 250 0.3

>250 and <500 0.3≥ 500 and <800 0.3

≥ 800 0.3

Table 3.1 – Minimum FBE Coating Thickness


≤ 100 2.26

>100 and ≤ 250 2.26

>250 and <500 2.66

≥ 500 and <800 3.06

≥ 800 3.76

Table 3.2 – Minimum PE Coating Thickness


≤ 100 2.7

>100 and ≤ 250 2.7

> 250 and <500 3.1

≥ 500 and <800 3.5

≥ 800 4.2

Table 3.3 – Minimum Total Coating Thickness

3.7 Surface Finish After Blast Cleaning

The surface finish after blast cleaning shall be inspected with the followingstandards.

• Surface cleanliness shall be determined in accordance with ISO 8501-1

• Chloride contamination shall be determined in accordance with by meansof ISO 8502-2

• Dust levels shall be determined in accordance with by means of ISO

8502-3• Surface profile shall be determined in accordance with by means of ISO

8503-2

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3.8 FBE Surface Before Application of PE Layer

The surface of the FBE after application shall be cleaned with a solvent washto remove dust and loose particles.

• Surface cleanliness shall be determined in accordance with ISO 8501-1

• Dust levels shall be determined in accordance with by means of ISO8502-3

3.9 Holidays

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

3.10 Adhesion

The coating adhesion shall be determined by DIN 30670. It shall be testedafter the application of the FBE to steel and again after the application of thePE to FBE. The peel tests shall not be carried out on coating over welds,coating overlaps or within 1.5 DN or 300mm, whichever is smaller, from theedge of the coating. The test strips shall be at least 50mm apart. Results shallmeet the minimum requirements has stated in Table 3.4.

Operating Temp. °C Test Temp. °C Peel Resistance N/10mm

< 0 Op temp ± 2 >35

0 - 20 23 ± 2 >35

20 – 50 50 ± 2 >25

50 – 60 60 ± 2 >20

60- 80 80 ± 2 >20> 80 Op temp ± 2 >20

Table 3.4 – Minimum Coating Peel Resistance

3.11 Impact Resistance

The impact performance shall be performed by means as stated in DIN 30670or by ASTM G14. Results shall have minimum impact resistance as stated inTable 3.5 at temperature 23±2 °C. This test shall be completed on the totalcoating system with the impact being located on the PE layer.

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Pipeline Diameter (mm) Minimum Impact Resistance (J)

≤ 100 7.0

>100 and ≤250 8.5

>250 and ≤500 11.0

>500 12.5

Table 3.5 – Minimum Impact Resistance

3.12 Indentation Resistance

The indentation resistance of the coating shall be tested at room temperatureand at a temperature related to the maximum operating temperature as givenin Table 3.6, in accordance to DIN 30670. The maximum allowableindentation shall be as specified in Table 3.4. This test shall be completed onthe total coating system with the impact being located on the PE layer.

Operating Temp. °C Test Temp. °C Max indentation (mm)

< 0 Op temp ± 2 ≤ 0.2

0 - 20 23 ± 2 ≤ 0.2

20 - 50 50 ± 2 ≤ 0.3

50 - 60 60 ± 2 ≤ 0.360 - 80 80 ± 2 ≤ 0.3

>80 Op temp ± 2 ≤ 0.4

Table 3.6 – Indentation Resistance

3.13 Pipe Surface Temp

The temperature of the pipe surface shall be uniform throughout the coatingwrapping process.

3.14 Coating Application Temperature

The temperature of the pipe surface shall be uniform throughout the coatingwrapping process.

3.15 Elongation

The elongation at break of the coating sample when tested at ambienttemperature in accordance with DIN 30670 shall be more than 300%.

3.16 Coating Resistivity

The coating resistivity shall be more than 108Ω.m when tested in accordance

with DN 30670. This test shall only be applied to the PE layer.

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3.17 Thermal Aging

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

3.18 Ageing Under Exposure to Light

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

3.19 Degree of Cure Fusion Bonded Epoxy Primer

The degree of cure of the fusion bonded epoxy primer shall be determined bydifferential scanning calorimetry in accordance with ASTM 3418. The ΔTgvalue shall be between -2°C and +3°C.

3.20 Cathodic Disbonding Resistance

Cathodic disbanding tests shall be carried out in accordance with appendix Aat a test temperature related to the operating temperature as specified inTable 3.7. This test shall only be applied to the FBE layer.

Operating Temp. °C Test Temp. °C Max Disbonding Radius (mm)

<0 Op temp ± 2 10

10 - 20 23 ± 2 10

20 - 50 50 ± 2 1050 - 60 60 ± 2 15

60 - 80 80 ± 2 15

>80 Operation temp ± 2 15

Table 3.7 – Cathodic Disbanding Resistance

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4.0 QUALITY ASSURANCE

4.1 Coating System Qualification

Before a coating system may be applied in a production run, the Contractor shall submit all the data specified in 4.1.2 and 4.1.3 and shall ensure that boththe coating system and the Applicator have been qualified in accordance withthe procedures.

4.1.1 System Identification

The Contractor shall submit all details to identify the coating system. Detailsshall include:

• System designation or trade name;

• Name of coating Manufacturer(s);

• Generic type of system (polyethylene or polypropylene);

• Coating process (sintering, side extrusion or crosshead extrusion);

• System structure;

• Structure Components (primer, adhesive, outer layer) ;

• Service temperature range;

• Total nominal coating thickness;

• Relevant international/national coating standard approvals.

4.1.2 Manufacturer's Data

Primer

The following data shall be submitted on the primer (if applicable):

• The generic type of primer;

• For liquid primers the solids content, the type of solvent and the density;

• For powder epoxy primers the density, gel time, particle size,recommended film thickness, colour;

• Typical film properties (flexibility, cathodic disbonding resistance, etc.);

• The method of application (brush, roller, spray, electrostatic spray, etc.);

• Storage conditions and shelf life;

• The nominal dry film thickness or spreading rate;

• Application procedures, temperature, pot life, overcoating times;

• HSE datasheets.

Adhesive

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The following data shall be submitted on the adhesive (if applicable):

• The generic type of adhesive;

• The method of application (powder spray, extrusion etc.);

• The nominal thickness;

• Storage conditions and shelf life.

Coating material

The following data shall be submitted on the polyethylene or polypropyleneouter layer material:

• Generic type of material (e.g. high/medium/low density PE/PP);

• Delivered product (powder, granules, liquid etc.);

• Storage conditions, shelf life;

• Colour;

• Nominal thickness of the outer layer;

• Mechanical properties of the outer layer film (tensile strength, elongation);

•

Data on resistance to bio-degradation.Chemical pre-treatment

If any chemical pre-treatment of the blasted steel is carried out the followingdata shall be submitted:

• Generic type of chemical;

• Preparation, concentration, etc.;

• Application procedure, including spreading rate (m2/l), and drying times.

4.1.3 Qualification

Before a coating system can be specified for an application, the Contractor or the coating Manufacturer shall apply for qualification of the coating system.Qualification shall be carried out according to the following procedures.

The Contractor or the coating Manufacturer shall submit all data specified inSection 4.1.

The Contractor or the coating Manufacturer shall show that samples of thecoating system applied on pipes of the specified pipe material have beensuccessfully subjected to the tests as specified in Table 4.1. The tests shallbe carried out by an independent test laboratory or, if approved by theEngineer-in-Charge, by the coating Manufacturer.

The number of pipes to be tested and the test procedures are given in Table

4.1.

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If agreed by the Engineer-in-Charge, previous qualification data can be usedprovided that the referred tests have been carried out using the same coatingsystem and the same coating process as specified in the contract.

4.2 Application Qualification

4.2.1 General

Before production application of a coating system may commence, the Applicator shall be qualified to apply the coating system. The qualificationshall be carried out according to the following procedures:

4.2.2 Coating Process and Applicator Selection

The Contractor shall submit to the Engineer-in-Charge information on therequired coating process and recommended applicators. The informationshall include:

• Description of the coating process for line pipe, bends and fittings;

• Pipe cleaning and surface preparation (cleanliness, profile, chemical pre-treatment, etc.);

• Required surface and material application temperatures;

• Recommended applicators;

• Coating repair procedures;

4.2.3 Coating Plant

To demonstrate that the available equipment is capable of applying thespecified coating according to the required standards, each recommended Applicator shall submit full details of the coating plant, including:

• Layout diagram of the coating plant and plant flow scheme;

• General description of the equipment available to carry out the coating

process;• Details of process control and inspection equipment required for the

coating process such as temperature control, thickness control, holidaytesters, laboratory equipment, etc.;

• Details on the line pipe marking, handling, storage and transportequipment and procedures;

• Applicator’s quality control procedures.

4.2.4 Qualification

After approval of the process and plant details before production starts, he Applicator should submit evidence that he has successfully applied thecoating system before on pipes of the specified material, and that the productcomplied with the requirements of this specification for the tests indicated inTable 4.1.

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The Applicator shall coat at least 2 pipes with the proposed coating systemand shall subject samples from these pipes to the tests given in Table 4.1.These tests may be carried out in the Applicator's own laboratory, or by anindependent laboratory.

When this specification is used for the coating of bends and/or fittings, the Applicator shall coat at least one fitting or bend as agreed with the Engineer-in-Charge and subject this coating to the same qualification tests.

Number Of Pipes Required

Property Coating SystemQualification

Appl icator Qualification

Cleanliness of blast cleaned surface 5 pipes 2 pipesSurface roughness 5 pipes 2 pipesPipe surface temperature 5 pipes 2 pipesCoating application temperature 5 pipes 2 pipes Appearance 5 pipes 2 pipesCoating thickness 5 pipes 2 pipesHoliday detection 5 pipes 2 pipes Adhesion 5 pipes 2 pipesImpact 5 pipes 2 pipes

Indentation 5 pipes 2 pipesElongation 5 pipes 2 pipesCoating Resistivity 5 pipes Not requiredThermal Ageing 2 pipes Not requiredUV Stability 2 pipes Not requiredCathodic Disbonding 2 pipes 1 pipeDegree of cure of FBE 2 pipes 1 pipe

Table 4.1 – Number of pipes required during qualification

4.3 Quality Control During Application

During production application of the coating, the Applicator shall carry out allquality control activities needed to ensure that the coating is being applied inaccordance with the approved coating application procedures and that finalproduct complies with the requirements of this specification.

The minimum quality control tests to be performed shall be as indicated inTable 4.2.

Records of all coating application and quality control tests results shall bekept in accordance with Section 4.5.

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Property Test frequency Ambient conditions Once per shift

Surface condition before blasting Each pipe

Cleanliness of blast cleaned surface Each pipe

Surface profile One per 20 pipes

Surface cleanliness Chlorides One per 100 pipes

Blast cleaning materials & process Once per shift

Pipe surface temperature Continuous

Coating application temperature Continuous

Appearance Each pipeCoating thickness Each pipe

Holiday detection Each pipe

Pipe ends Each pipe

Adhesion One per 100 pipes

Impact One per 100 pipes

Indentation One per 100 pipes

Elongation One per 100 pipes

Cathodic disbonding One per 200 pipes

Degree of FBE cure One per 200 pipes

Table 4.2 – Minimum quality control requirements for polyethylenepipeline coating.

4.4 Coating Repair

The Contractor shall submit detailed procedures for coating repairs.

All coating repair procedures shall be qualified under both coating system and Applicator qualification.

These procedures shall contain as a minimum:

• Repair of surface defects;

• Repair of pinholes, scratches and small defects (e.g. by means of a melt

stick);

• Removal of rejected coating and cleaning the pipe to the requiredstandard for recoating;

• Testing to prove the effectiveness of the repairs.

All pipes that have been repaired shall be fully re-examined in accordancewith the quality control procedures.

Records shall be kept of all repaired pipes and shall include the repair and re-test details.

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4.5 Documentation

The Contractor shall keep accurate records of all relevant data of the coatingprocess.

This documentation shall, as a minimum, consist of:

• Copies of the coating system information as specified;

• Copies of qualification information as requested;

• Copies of, or reference to, all procedures for coating of the pipes;

• Serial numbers of all pipes as given by the pipe Manufacturer (e.g. bycopies of the pipe mill data sheets);

• Serial numbers as given by the coating Applicator (if applicable)correlated with the Manufacturer's serial numbers;

• The order of coating, the day and shift of coating of each pipe;

• The batch numbers of the coating materials, the day and time of loadingof each batch;

•

Serial numbers of rejected pipes and the reason for rejection;• Records of any repairs;

• The results of all quality control testing;

• Records of temperatures during the coating process for each pipe, withthe processing time of every tenth pipe marked on the temperature chartwith the pipe number;

• Names and signatures of the responsible persons for the coating processand quality control.

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

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5.0 APPENDIX

A – Cathodic disbonding resistance test procedure

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