CONTRACT NO.

GC 11106200

DOC. NO:3392-00-69-00-0011

EPIC OF 16 JET A1 PIPELINE FROM QP REFINERY TO BSV-3

Rev Date

0 23.01.13

Field Application of Fusion Bonded Epoxy (FBE) Coating on the External Girth Weld Areas of Line Pipes

Contents
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Scope Purpose References Definitions Abbreviations Responsibilities Coating Material Equipment accessibility requirements FBE Application Method Details Pre-Production Tests & Quality Control Tests Coating Repairs Records

3392-00-69-00-0011

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CONTRACT NO. GC 11106200

DOC. NO:3392-00-69-00-0011

EPIC OF 16 JET A1 PIPELINE FROM QP REFINERY TO BSV-3

Rev Date

0 23.01.13

Field Application of Fusion Bonded Epoxy (FBE) Coating on the External Girth Weld Areas of Line Pipes

1.

Scope. This Method Statement explains the process details by which a Fusion Bonded Epoxy coating is applied on the external girth weld areas of line pipes in the Field by the Field Construction Department of Al Qahtani Pipe Coating Industries for PETROJET Qatar Petroleum (QP) (EPIC of 16JET A1 FUEL PIPELINE FROM QP REFINERY TO BSV-3)

2.

Purpose. Purpose of this Method Statement is to specify the details of the application process, quality control requirements and to set out the functions & responsibilities that AQPCI-FCD production personnel and AQPCI Quality Services Department personnel and the Client shall undertake during the execution of any job order, which involves the application of FBE on the external girth weld areas of line pipes.

3.

References. QP-SPC-L-006 rev. 1 SSPC-SP1 SSPC PA2 API -5L ISO-8501/ SIS-05-59-00 AWWA C213 NACE RP 0490 CAN-CSA-Z245.20-02 ASTM D4417 ASTM G14 Product data sheets FBE powder Product data sheets FBE repair material AQPCI-LI-536 QP Technical Specification for Field Applied Fusion Bonded Epoxy Coating for Pipeline Girth Weld Joints Steel structures painting council Solvent cleaning Measurements of Dry Coating Thickness with Magnetic Gauges American Petroleum Institute specification for line pipe Surface preparation standards Standard for Fusion Bonded Epoxy for the Interior and Exterior of Steel Water Lines Holiday Detection of Fusion Bonded Epoxy External Pipe Canadian standard for external FBE Field Measurement of Surface Profile of Blast Cleaned Pipe Standard test Method for Impact Resistance of Pipeline Coatings (Falling Weight Test) FBE coatings: Karumel EX4413-F103. Two-Part repair compound: Kopatch PC270 Hempadur 85530 AQPCI procedure for chloride analysis

3392-00-69-00-0011

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CONTRACT NO. GC 11106200

DOC. NO:3392-00-69-00-0011

EPIC OF 16 JET A1 PIPELINE FROM QP REFINERY TO BSV-3

Rev Date

0 23.01.13

Field Application of Fusion Bonded Epoxy (FBE) Coating on the External Girth Weld Areas of Line Pipes

4.

Definitions. Owner company Project Client Clients representative Manufacturer Qatar Petroleum (QP) EPIC of 16JET A1 FUEL PIPELINE FROM QP REFINERY TO BSV-3. PETROJET Resident inspector of the client, who ensures conformance of the coating application process and quality control process with the approved MPS. Manufacturer of the consumable materials

5.

Abbreviations. AQPCI QSD QC TPI NCR FBE Al-Qahtani Pipe Coating Industries Quality Services Department of AQPCI Quality Control Third Party Inspector Non-conformance Report Fusion Bonded Epoxy

6.

Responsibilities.

6. 1 AQPCI-FCD Coating Crew Supervisor: Shall be responsible for the application process and the management of all equipment and personnel. Production personnel shall report to the Crew Supervisor.

6. 2 AQPCI-QC supervisor: Shall be responsible for review of all QC documents and reports. All such documents shall be reviewed and signed by the QC Supervisor.

6. 3 AQPCI-QC inspector: Shall be responsible for inspection and documentation related to this Method Statement. QC inspector shall report to the QC Supervisor.

7.

Coating Material. Material for external girth weld coating application shall be KCC Karumel EX4413-F103 for the job order.
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3392-00-69-00-0011

CONTRACT NO. GC 11106200

DOC. NO:3392-00-69-00-0011

EPIC OF 16 JET A1 PIPELINE FROM QP REFINERY TO BSV-3

Rev Date

0 23.01.13

Field Application of Fusion Bonded Epoxy (FBE) Coating on the External Girth Weld Areas of Line Pipes

AQPCI shall provide the client a batch certificate issued by the FBE manufacturer for every batch of the material being used. The batch certificate shall contain the test results of geltime, particle size, specific gravity, percentage of moisture contents, infra-red scan and a DSC scan. FBE powder shall be stored at a temperature less than 77 F. QC inspector shall verify that the batches utilized for each days production are within the shelf life period recommended by the manufacturer. QC inspector shall keep daily records of the name of FBE manufacturer, batch number and date of manufacture. Repair material for FBE coating shall two part repair material Kopatch PC-270. Large mechanical damages (if occurs) shall be repaired using Hempadur 8553 liquid epoxy coating.

8.

Equipment Accessibility Requirements.

8. 1 Over the ditch access requirement for the external FBE coating application unit is 24" (0.61 meter) from bottom of the pipe and all around the pipe and 10 Lf. (3.04 meter) from any skid, sand bag or rubber tires utilized to support the pipe. 8. 2 If the external FBE coating application unit is to be used in the ditch, a minimum of 36" (0.91 meters) clearance around the pipe from the trench wall and 10 feet from any obstruction in the ditch are required for the equipment. Client shall be responsible to ensure the requirements mentioned in sections 8.1 and 8.2 are provided.

9.

FBE Application Method Details.

9.1 Surface Preparation 9.1.1. 9.1.2. Surface preparation shall meet the requirements of sections 9.1.3 & 9.1.4 of this Method Statement. All girth weld areas shall be limited to a maximum band width of 75 15 mm according to cutback distance as QP spec. each side of the weld. The client shall remove weld spatter, weld slag, sharp edges, burrs and any other sharp surface discontinuities by grinding. Surface shall achieve a minimum cleanliness of Sa 2 (near white metal) of Swedish Standards SIS 05-59-00 using garnet abrasive and shall have surface profile 2 to 4 mils (50 - 100 microns). If the Client carries out the surface preparation, AQPCI QC inspector shall verify the cleanliness and profile through the clients records and may verify himself on a random selection basis. Profile shall be checked using Testex Press-O-Film replica tape and results shall be recorded. The parent FBE coating on each side of the weld shall be abraded 25 mm as per QP spec.

9.1.3.

9.1.4.

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CONTRACT NO. GC 11106200

DOC. NO:3392-00-69-00-0011

EPIC OF 16 JET A1 PIPELINE FROM QP REFINERY TO BSV-3

Rev Date

0 23.01.13

Field Application of Fusion Bonded Epoxy (FBE) Coating on the External Girth Weld Areas of Line Pipes

9.1.5.

AQPCI-FCD Crew supervisor shall inspect the prepared welds and shall accept those welds which are suitable for coating application. If, due to improper preparation, any weld is not fit for application the QC inspector shall issue a NCR and copy to AQPCI-FCD-Crew supervisor. QC inspector shall discuss with AQPCI-FCD Crew supervisor the reason for rejection. Rejected welds shall be reprocessed. If AQPCI is responsible for surface preparation then they shall monitor the quality of the compressed air to ensure that it is oil free and that adequate moisture traps are fitted to the air system. QC inspector shall visually examine the girth weld surface of the pipe and ensure that the external surface is free from oil, grease, lubricant or any other contaminants, which are deleterious to the coating application. Such contamination shall be removed by solvent washing as per SSPC-SP1 or solvent wiping prior to blast cleaning.

9.1.6.

9.1.7.

The abrasive used shall be tested for chlorides (max. 100 ppm) a test certificate shall be furnished for each batch of used abrasive. In Subkha and other areas where chloride contamination of the pipe surface is possible, the first girth weld area blasted on each shift shall be tested for chlorides as per AQPCI-LI-536 procedure. Thereafter, test one out of each successive 40 girth weld areas. Residual chloride on the surface shall not exceed 20 mg/m. Failure to meet the residual chloride limitation requires that the girth weld be water washed and retested until the chloride limitation is met. Subsequent girth weld areas shall be similarly treated, with testing being conducted on one out of each successive 40 girth weld area. Alternatively, if 5 consecutive girth weld areas are tested and meet the chloride limitation without the use of water washing, then the Method Statement in paragraph 9.1.8 may be used.

9.1.8.

9.1.9.

The blasted surface shall be clear tape tested to ensure that the surface is free of dust particles. The test shall be carried out on the cut back area. Frequency of testing shall be the first girth weld area blasted on each shift. The area being tested shall be blown using dry, oil/moisture free compressed air. A piece of clear tape, which does not leave any residue on the surface, shall be blot on the surface and removed. Examine the adhesive side for dust and free debris. Residual particulates shall not be more than class 2 rating 2 of ISO 8502-3 standard.

9.2 Coating Application: 9.2.1 QC inspector shall check the surface temperature, relative humidity and dew point every two hours. Dew point shall be at least 3 C lower than the surface temperature of the item. Any weld showing flash rusting or rust blooming shall be rejected and re-blasted prior to the commencement of preheating.
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3392-00-69-00-0011

CONTRACT NO. GC 11106200

DOC. NO:3392-00-69-00-0011

EPIC OF 16 JET A1 PIPELINE FROM QP REFINERY TO BSV-3

Rev Date

0 23.01.13

Field Application of Fusion Bonded Epoxy (FBE) Coating on the External Girth Weld Areas of Line Pipes

9.2.2

The weld shall be heated to a temperature range of 425 to 475 F using external induction heating coils. QC inspector shall verify and record the temperature on a random basis using contact pyrometers immediately before powder application. The FBE powder use shall be checked the percentage of moisture contents. Powder with moisture content of more than 0.5 % should not be used. The QC shall ensure that the FBE powder shall be stored at a room temperature of less than 77 F. As soon as the application temperature is achieved, the induction coil shall be removed and external FBE coating unit shall be placed in position, centered on the weld and FBE powder application shall start immediately. The coating application unit shall be rotated around the weld at a uniform rate. A minimum dry film thickness of 18 mils and maximum dry film thickness of 22 mils shall be applied. The field applied coating shall overlap the factory applied coating by a minimum of 1" (25 mm).

9.2.3

9.2.4

10. Pre-production Tests and Quality Control Tests.

10.1 Prior to production coating, two representative field joints per pipe diameter shall be coated in accordance with the manufacturers recommendation and the QP approved Method Statements to establish that the coating operation and the joint coating meet the requirements of this Method Statement. The pre-production trial shall be witnessed by the clients representative. During the pre-production run, all the operating parameters of coating application shall be optimized and documented. Pre-production trial shall be repeated if there is a change in powder manufacturer or when there is a change in application Method Statement. 10.2 Quality Control tests on the pre-production pipes shall be done as listed below cure test Cross-section Porosity test Impact resistance test Adhesion test Visual inspection of applied coating Holiday detection Thickness test

10.3 Test methods are given in clauses 10.4.1 through 10.4.7 of this Method Statement. 10.4 Quality Control tests: 10.4.1 Visual Appearance: The finished coating shall have a uniform appearance and be free of defects such as holidays, fish eyes, lumps, dry spray, sags and runs. 10.4.2 Thickness Test: QC inspector shall measure and record the coating film thickness on each weld using a magnetic type thickness gauge such as Microtest or equivalent. A minimum of 6 readings on the
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CONTRACT NO. GC 11106200

DOC. NO:3392-00-69-00-0011

EPIC OF 16 JET A1 PIPELINE FROM QP REFINERY TO BSV-3

Rev Date

0 23.01.13

Field Application of Fusion Bonded Epoxy (FBE) Coating on the External Girth Weld Areas of Line Pipes

girth weld coating (two each on both sides of the weld and two on the weld) shall be taken in four places around the welds. The thickness shall be minimum 18 mils and maximum dry film thickness of 22 mils, including the weld seam. The thickness measurement gauge shall be calibrated at least twice per 8-hour shift on certified shims in the expected range of thickness. 10.4.3 Holiday Test: One hundred percent of the coated weld area shall be holiday tested in presence of QC inspector, using a pulse type, calibrated, DC holiday detector unit provided with an audible signaling device, rolling spring probe and ground trail lead. The holiday detector shall be set at 2400 50 V and shall be calibrated twice per shift. The travel speed of holiday detector probe shall not exceed 1 ft. (305 mm) per second. All holidays shall be marked and shall be repaired as per section 11.0 of this Method Statement. Holiday detection shall not be carried out if the coated surface temperature is above 80 C. 10.4.4 Adhesion Test: QC inspector shall perform an adhesion test on the girth weld coating as described below. This test shall be performed one joint per shift or one in twenty joints whichever is more frequent. The test shall be carried out at ambient temperature. Two incisions of (13 mm) long shall be made through the coating using a sharp knife of narrow width blade to form an X mark. The knife point shall be forced under the coating at the intersection of the X and levered away from the steel surface. Refusal of the coating to peel off from the substrate constitutes a PASS. Partial or complete removal of the coating from the substrate shall constitute a FAILURE. Cohesive failure within the coating shall also be recorded as a PASS. However, cohesive failures caused by voids within the coating film and leaving a honey comb appearance constitute a FAILURE condition. Failure of adhesion of up to 1 mm from the intersection of X shall be ignored. If a coating fails to meet the acceptance criteria in paragraph 9.4.4.1, the adjacent field girth weld areas shall also be tested until acceptable coatings are found on both sides of the defective weld. The defective coatings shall all be completely removed and the areas recoated. At least one of the repaired areas shall be re-inspected, and the subsequent inspection frequency shall be as given in paragraph 10.4.4. Adhesion tested area shall be repaired as per clause 11.0 of this Method Statement.

10.4.5 Cure Test: The cure of the FBE coating on the girth weld area shall be determined by the QC inspector as described in section 10.4.5.1. This test shall be performed on the first five weld joints and twice per day thereafter. Cure shall be checked by maintaining a MEK soaked pad in contact with the coating surface. Rub the film with 2inch long (50 mm) firm strokes. Fifty double rubs (50rubs in each direction). There shall be no softening of the coating or substantial color removal from the coating. The frequency of testing shall be 10 weld joints then once per shift.

10.4.6 Foaming (Cross-Section Porosity) Test: Test shall be carried out on production test joint. Foaming level of the applied FBE coating shall be established by viewing the cross section of the coating film under a microscope with 40X magnification. The method of evaluation shall be in accordance with Canadian standard CAN/CSA-Z245.20-02. The acceptable number of voids shall be Rating 1 to 3 of CAN/CSA-Z245.20-02 inclusive. The frequency of test shall be one joint per shift.
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CONTRACT NO. GC 11106200

DOC. NO:3392-00-69-00-0011

EPIC OF 16 JET A1 PIPELINE FROM QP REFINERY TO BSV-3

Rev Date

0 23.01.13

Field Application of Fusion Bonded Epoxy (FBE) Coating on the External Girth Weld Areas of Line Pipes

10.4.7 Impact Resistance Test: This test shall be carried out on joint per shift at two random locations. The impact resistance test shall be carried out using a Gardner impact tester or equivalent in accordance with ASTM G14. The coating shall withstand 1.5 joules minimum, without causing any holidays. (Holiday test method as per clause 10.4.3).

11. Coating Repairs.

11.1 Repairs of all pinholes and coating defects shall be performed using two part repair material or patch stick. Pinholes and larger areas shall be repaired using Kopatch PC-270 two-part repair material. Alternately, Hempadur 85530 may be used for touch up. 11.2 Defects shall be repaired in accordance with the criteria and methods below. If any girth weld area coating contains more than 5 holidays, the coating shall be completely blasted off and the area recoated. 11.3 The pipe surface to be repaired shall be cleaned to remove all dirt and damaged or disbanded coating using spot blasting, pneumatic disc grinder or other suitable means. The edges of the original coatings shall be "feathered out" approximately 50 mm wide around the specific area to be coated, and all dust wiped off before applying the patch coating. The patch coating shall not be applied if the surface temperature is less than 3 C above the dew point. 11.4 The patch compound shall be mixed, applied and cured as per the recommendations of the patch compound manufacturer. 11.5 After complete curing, the repaired areas shall be holiday tested as per clause 10.4.3. No holidays are permitted on the repaired areas.

12. Records.
All records of the functions described in this Method Statements shall be in forms attached to the ITP

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