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PARADIP REFINERY PROJECT

PROJECT SPECIFICATION ASPECIFICATION FOR PIPELINE FIELD

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CONTENTS

1.0 INTRODUCTION.................................................................................. 41.1 Scope................................................................................................... 41.2 Pipelines Description ......................................................................... 42.0 REFERENCES, CODES AND STANDARDS...................................... 52.1 Project Speci fic Documents .............................................................. 52.2 Codes and Standards ......................................................................... 52.3 Abbreviations ...................................................................................... 63.0 SPECIFICATION.................................................................................. 73.1 Field Jo int Coating ............................................................................. 73.2 Shrink Sleeve Installation .................................................................. 73.3 Line Pipe Steel/Diameters .................................................................. 73.4 Operating Temperature ...................................................................... 73.5 Coating Interface/Overlaps ................................................................ 83.6 Visual Inspect ion ................................................................................ 83.7 Total Coating Thickness .................................................................... 83.8 Surface Finish After Blast Cleaning .................................................. 93.9 Primer Surface Before Application of HSS PE................................. 93.10 Holidays ............................................................................................... 93.11 Degree of Cure Epoxy Primer ............................................................ 93.12 Adhesion ........................................................................................... 103.13 Impact Resistance ............................................................................ 103.14 Indentation Resistance .................................................................... 113.15 Pipe Surface Temp ........................................................................... 113.16 Coating Application Temperature ................................................... 113.17 Elongation ......................................................................................... 113.18 Coating Resistivity ........................................................................... 113.19 Thermal Aging................................................................................... 113.20 Ageing Under Exposure to Light..................................................... 123.21 Cathodic Disbonding Resistance.................................................... 124.0 QUALITY ASSURANCE .................................................................... 134.1 Coating System Quali fication .......................................................... 134.2 Appl ication Qualif ication ................................................................. 154.3 Quality Control During Application ................................................. 164.4 Coating Repair .................................................................................. 174.5 Documentation.................................................................................. 175.0 APPENDIX ......................................................................................... 18

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UPDATED SECTIONS

1.2 Pipeline Description, Lengths of Product Pipelines removed.

Other changes are highlighted in yellow.

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1.0 INTRODUCTION

1.1 Scope

This document details the requirements of the external field joint coating to beused for the proposed Raw-water and Product pipelines for the Indian OilCorporation Ltd (IOCL) Paradip Refinery project.

This specification shall be read in conjunction with IS 15659, if there isdivergence 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 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 ofPaints 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) ofThermoplastics

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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 ofPipeline 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

Tg Temperature Change

HSS Heat Shrink Sleeve

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3.0 SPECIFICATION

3.1 Field Joint Coating

Pipeline shrink sleeves, as described in this specification, shall bemanufactured using polyethylene as the backing material, irradiation cross-linked and pre-stretched to allow shrinking of the material in thecircumferential direction under the influence of heat to form a bond to the baremetal cutback and factory line pipe coating. The shrink sleeve is applied on tothe steel pipe girth weld joints using suitable primers to obtain the required

coating properties.

The primer application shall be a two pack-epoxy primer (moistureapplicable). The surface of the steel shall be heat treated to remove moisture.The application shall be carried out using a pump to facilitate the mixingoperation and a spatula device in order to cover the exposed bare metal ofthe welded joint plus 30mm minimum onto the adjacent FBE toe.

Field Coating system shall be classed as C50 as stated in DIN 30672.

3.2 Shrink Sleeve Installation

The HSS shall be applied after the epoxy primer has been fully cured to thecorrect preheat temperature (as specified by the manufacturer), or within thegel time window of the epoxy primer (as specified by the manufacturer). In thesame time the shields from the cut back factory coating shall be removed.

Centre the sleeve over the field joint and wrap loosely around the pipe,ensuring the sleeve self-overlap is maintained at shown in Figure 3.1. Gentlyheat, by appropriate torch, the backing and the adhesive of the closure andpress it firmly into place.

Start the shrinkage of the sleeve beginning from the centre of the sleeve untilrecovery is completed. In a similar manner heat and shrink remaining side.

Shrinking has been completed when the adhesive begins to ooze at thesleeve edges all around the circumference. Finish shrinking the sleeve withlong horizontal stokes, over the entire surface to ensure a uniform bond.

3.3 Line Pipe Steel/Diameters

All line pipe shall be in accordance to API 5L, the diameters and grades foreach pipeline are stated in project specific report 3210-8210-RP-0040.

3.4 Operating Temperature

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

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

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3.5 Coating Interface/Overlaps

Figure 3.1 Typical Coating Cross Section at End of L ine PipeThe field primer shall overlap the FBE toe a minimum of 30mm. The fieldapplied HSS PE shall overlap the factory PE a minimum of 100mm from thetaper.

150mm 30mm 100mm

Weld

HSS PEPrimer

Steel

Factory PEFactory FBE

3.6 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.

3.7 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.

Pipeline Diameter (mm) Minimum Thickness (mm)

100 0.3

>100 and 250 0.3

>250 and 250 and

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Pipeline Diameter (mm) Minimum Thickness (mm)

100 2.05

>100 and 250 2.05

> 250 and

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3.12 Adhesion

The PE HSS adhesion shall be determined by DIN 30670. It shall be testedafter the application of the primer to steel and again after the application ofthe HSS PE to primer. The test strips shall be at least 50mm apart. Resultsshall meet 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 >3550 - 60 60 2 >35

60 - 80 80 2 >50

>80 Op temp 2 >50

Table 3.4 Minimum Coating Peel Resistance

For the HSS PE the following locations as shown in Figure 3.2 shall beundertaken.

Weld

Line pipe

FactoryCoating

HSS PE Sleeve

Peel Test Location

Figure 3.2 Adhesion Test Peel Sample Locations HSS PE

3.13 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 232 C. This test shall be completed on the totalcoating system with the impact being located on the HSS PE.

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

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3.14 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 HSS PE.

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

< 0 Op temp 2 >350 - 20 23 2 >35

20 50 50 2 0.3

50 60 60 2 0.3

60- 80 80 2 0.3

>80 Op temp 2 0.4

Table 3.6 Indentation Resistance

3.15 Pipe Surface Temp

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

3.16 Coating Application Temperature

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

3.17 Elongation

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

3.18 Coating Resistivity

The coating resistivity shall be more than 108 .m when tested in accordancewith DN 30670. This test shall only be applied to the HSS PE coating.

3.19 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 HSS PE.

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3.20 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 HSS PE.

3.21 Cathodic Disbonding Resistance

Cathodic disbonding 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 primer layer.

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

< 0 Op temp 2 >35

0 - 20 23 2 >35

20 50 50 2 10

50 60 60 2 15

60- 80 80 2 15

>80 Operation temp 2 15

Table 3.7 Cathodic Disbonding 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 Contractorshall 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);

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

System structure;

Structure Components;

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.

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Adhesive

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 materialThe following data shall be submitted on the polyethylene outer layermaterial:

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

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 orthe 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. These shall be two pup sections (these shall be 6 diameter)welded together, coating to be applied over weld.

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 the

Engineer-in-Charge, by the coating Manufacturer.

The number of pipes to be tested and the test procedures are given in Table4.1.

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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, theApplicator 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;

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 Equipment

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

General description of the equipment available to carry out the coatingprocess;

Details of process control and inspection equipment required for thecoating process such as temperature control, thickness control, holidaytesters, laboratory equipment, etc.;

Applicators quality control procedures.

4.2.4 Qualification

The Applicator shall coat at least 2 pipes, these shall be two pup sections(these shall be 6 diameter) welded together, coating to be applied over weldwith the proposed coating system and shall subject samples from these pipesto the tests given in Table 4.1. These tests may be carried out in theApplicator's own laboratory, or by an independent laboratory.

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Number Of Pipes Required

Property Coating SystemQualification

Appl icatorQualification

Cleanliness of blast cleaned surface 2 Pipe welds 2 Pipe weldsSurface roughness 2 Pipe welds 2 Pipe weldsPipe surface temperature 2 Pipe welds 2 Pipe weldsCoating application temperature 2 Pipe welds 2 Pipe weldsAppearance 2 Pipe welds 2 Pipe weldsCoating thickness 2 Pipe welds 2 Pipe weldsHoliday detection 2 Pipe welds 2 Pipe weldsAdhesion 2 Pipe welds 2 Pipe weldsImpact 2 Pipe welds 2 Pipe weldsIndentation 2 Pipe welds 2 Pipe weldsElongation 2 Pipe welds 2 Pipe weldsCoating Resistivity 2 Pipe welds Not requiredThermal Ageing 1 Pipe welds Not requiredUV Stability 1 Pipe welds Not requiredCathodic Disbonding 1 Pipe welds 2 Pipe weldsDegree of cure of FBE 1 Pipe welds 2 Pipe welds

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.

Property Test frequencyAmbient conditions Once per shift

Surface condition before blasting Each application

Cleanliness of blast cleanedsurface

Each application

Pipe surface temperature Each application

Appearance Each application

Coating thickness Each application

Holiday detection Each application

Adhesion One per delivery batch of PE

Impact One per 20 applications

Table 4.2 Minimum quality control requirements for polyethylenepipeline coating.

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4.4 Coating Repair

The Contractor shall submit detailed procedures for coating repairs.

All coating repair procedures shall be qualified under both coating system andApplicator 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.

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 field joints;

The order of coating, the day and shift of coating of each field joint;

The batch numbers of the coating materials;

Records of any repairs;

The results of all quality control testing;

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

This documentation shall be submitted to the Engineer-in-Charge aftercompletion 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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