DEP SPECIFICATION
INTERNAL FUSION-BONDED EPOXY POWDER COATING
FOR WATER INJECTION LINE PIPE
Copyright Shell Group of Companies. No reproduction or networking permitted without license from Shell. Not for resale
DEP 31.40.30.39-Gen.
February 2012 ECCN EAR99
DESIGN AND ENGINEERING PRACTICE
© 2012 Shell Group of companies
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior
written permission of the copyright owner or Shell Global Solutions International BV. This document contains information that is classified as EAR99 and, as a consequence, can neither be exported nor re-exported to any country which is under an embargo of the U.S. government pursuant to Part 746 of the Export Administration Regulations (15 C.F.R. Parts 746) nor can be made available to any national of such country. In addition, the information in this document cannot be exported nor re-exported to an end-user or for an end-use that is prohibited by Part 744 of the Export
Administration Regulations (15 C.F.R. Parts 744).
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PREFACE
DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international, regional, national and industry standards.
The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the quality of their work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will typically expect them to follow those design and engineering practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal.
The right to obtain and to use DEPs is restricted, and is granted by Shell GSI (and in some cases by other Shell Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three categories of users of DEPs can be distinguished: 1) 2) 3)
Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of a Service Agreement or otherwise).
Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these companies, that may issue DEPs or advise or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement. All administrative queries should be directed to the DEP Administrator in Shell GSI.
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TABLE OF CONTENTS
1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 3. 3.1 3.2 4. 4.1 4.2 5. 5.1 5.2 5.3 5.4 6. 7. 8.
INTRODUCTION........................................................................................................4 SCOPE........................................................................................................................4 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS.........4 DEFINITIONS.............................................................................................................4 CROSS-REFERENCES.............................................................................................5 SUMMARY OF MAIN CHANGES...............................................................................5 COMMENTS ON THIS DEP.......................................................................................5 DUAL UNITS...............................................................................................................6 GENERAL INFORMATION........................................................................................7 GENERAL...................................................................................................................7 SAFETY......................................................................................................................7 PRINCIPAL ACCESS.................................................................................................7 PRE-JOB MEETING...................................................................................................8 APPLICATORS TECHNICAL REPRESENTATIVE....................................................8 INFORMATION TO BE SUBMITTED BY THE PRINCIPAL.......................................8 INFORMATION TO BE SUBMITTED BY THE CONTRACTOR................................8 COATING SYSTEM REQUIREMENTS.....................................................................9 GENERAL...................................................................................................................9 FINISHED COATING SYSTEM REQUIREMENTS....................................................9 MATERIALS.............................................................................................................11 GENERAL.................................................................................................................11 POWDER TESTING.................................................................................................11 COATING SYSTEM APPLICATION........................................................................12 SURFACE PREPARATION......................................................................................12 COATING APPLICATION.........................................................................................13 QUALITY CONTROL................................................................................................14 QUALITY PLAN, INSPECTION AND TEST PLAN, MANUFACTURING PLAN......19 DOCUMENTATION..................................................................................................20 STORAGE AND HANDLING...................................................................................21 REFERENCES.........................................................................................................22
APPENDICES
APPENDIX A APPENDIX B APPENDIX C
APPLICATOR QUALIFICATION....................................................................23 COATING SYSTEM QUALIFICATION...........................................................26 DATASHEET...................................................................................................27
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1. INTRODUCTION 1.1 SCOPE
This new DEP specifies the requirements and gives recommendations for the test
procedures for factory-applied internal Fusion-Bonded Epoxy (FBE) powder coating of steel pipes used for submerged water injection flowlines. It specifies the requirements for coating materials, coating application, inspection and testing, repair, handling and storage, and gives procedures for the qualification of coating materials and coating applicators.
This DEP supersedes DEP 31.40.30.39-DWP dated October 2006; see (1.5) regarding the changes.
1.2
DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS
Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated by them. Any authorised access to DEPs does not for that reason constitute an authorization to any documents, data or information to which the DEPs may refer.
This DEP is intended for use in facilities related to offshore pipeline, flowline and riser projects. This DEP may also be applied in other similar facilities.
When DEPs are applied, a Management of Change (MOC) process shall be implemented; this is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements may be more stringent than in this DEP the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable as regards safety, environmental, economic and legal aspects. In all cases, the Contractor shall inform the Principal of any deviation from the requirements of this DEP which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned with the object of obtaining agreement to follow this DEP as closely as possible.
1.3 DEFINITIONS 1.3.1 General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party that manufactures or supplies equipment and services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for it. The Principal may also include an agent or consultant authorised to act for, and on behalf of, the Principal.
The Applicator is the party that applies coating. The word shall indicates a requirement. The word should indicates a recommendation.
1.3.2 Specific definitions
Term Definition Applicator Ambient Batch
The Applicator is the party that applies the coating.
Environmental conditions in the immediate area of coating application work
and upon surfaces being coated.
The amount of materials produced within one uninterrupted production run under constant production conditions.
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Term Definition Chemical Pre-Treatment Holiday Mil Primer Shift Water
Injection (or Waterflood)
Treatment of the blast cleaned pipe surface with a chemical solution before application of the primer or adhesive to improve adhesion of the first coating layer (phosphate, chromate).
A defect penetrating through the coating to the steel pipe surface, of such dimensions that it is detectable by means of the specified procedures. 1/1000 inch
A thin film liquid coating applied prior to application of the FBE
A set of pipes coated in one (1) production run of which the beginning and end coincide with a change in personnel, not to exceed 10 hours.
The injection of deoxygenated, chemically treated seawater to aid recovery of hydrocarbon.
1.3.3 Abbreviations
Term Definition AFC AUT FBE ID ITP MP OD PQT SCR QC QP RH TLPE
Approved for Construction Automated Ultrasonic Testing Fusion Bonded Epoxy Internal Diameter Inspection and Test Plan Manufacturing Plan Outer Diameter Pre-Qualification Trial Steel Caternary Riser Quality Control Quality Plan Relative Humidity Three Layer Polyethylene
1.4 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section number is shown in brackets ( ). Other documents referenced by this DEP are listed in (8).
1.5
SUMMARY OF MAIN CHANGES
This DEP is a conversion of DEP 31.40.30.39-DWP dated October 2006 into DEP 31.40.30.39-Gen. There are no significant non-editorial changes.
1.6
COMMENTS ON THIS DEP
Comments on this DEP may be sent to the Administrator at standards@shell.com, using the DEP Feedback Form. The DEP Feedback Form can be found on the main page of “DEPs on the Web”, available through the Global Technical Standards web portal http://sww.shell.com/standards and on the main page of the DEPs DVD-ROM.
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1.7 DUAL UNITS
This DEP contains both the International System (SI) units, as well as the corresponding
US Customary (USC) units, which are given following the SI units in brackets. When agreed by the Principal, the indicated USC values/units may be used.
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2. GENERAL INFORMATION 2.1 GENERAL
This coating is used to prevent large-scale generation of corrosion product on the internal
surface of the flowline when there is an upset in the water injection deoxygenation system. The Contractor shall furnish at his cost, all labour, supervision, equipment, materials, and testing necessary to complete coating work. Unless specifically stated as the Principal’s responsibility, the requirements of this DEP shall be the responsibility of the Contractor. All surface cleaning, coating application and pipe handling shall be performed in a safe manner and in accordance with the principles of good workmanship.
This DEP can be used for general qualification purposes or for specific projects.
General qualification is performed for the purpose of an overall qualification of the coating system by the Applicator.
NOTE
Qualification and approval may not be related to a specific project.
The Principal shall approve the Applicator to this DEP prior to production of any pipe coating.
For specific projects the qualification is for the line pipe diameter and wall thickness as detailed in the contract documents, AFC drawings or pipe coating datasheet.
The coating system shall consist of a primer and FBE (AkzoNobel® EP-10 primer and Dupont® 7-0008 FBE or a Principal-approved equivalent). The coating shall be subject to approval by the Principal.
NOTE
The Principal shall determine that the coating system is suitable for the temperature class, based on the maximum operating temperature or design temperature of the pipeline.
The suitability of the coating system has been demonstrated by performing qualification tests given in this DEP. If required, additional testing should be performed at temperatures specified by the Principal.
2.2 SAFETY
This DEP may involve the use of hazardous materials, operations, and equipment, and does not purport to address all of the potential safety concerns associated with its use. It is the responsibility of the Applicator to establish appropriate safety and health requirements, and determine any regulatory requirements or limitations prior to use.
Safety concerns regarding personnel and the environment shall be identified and included in the detailed coating procedure, and pre-job discussions. All surface preparation and coating application systems shall undergo a complete safety inspection and checkout prior to use.
Adequate exhaust/ventilation equipment shall be used, as required, for removal of over-spray and other spray by-products to acceptable air quality standards, and to provide for operator personal protection.
Industry standards recommended safe practices shall be followed. Waste material shall be handled and disposed of properly. Protective equipment requirements on the Manufacturer’s Material Safety Data Sheet(s) shall be followed.
Coating work pieces shall be electrically grounded, as required, to eliminate static charges associated with surface preparation and coating operations.
2.3 PRINCIPAL ACCESS
The Principal’s Representative, including independent inspectors or consultants as may be
contracted by the Principal, shall be permitted access to the coating application site at any time for the purpose of conducting performance analyses, including quality control tests of the materials being used.
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The Principal Representative has the right to reject any and all work or equipment that in his/her opinion does not conform to these requirements. Any work that in the opinion of the Principal Representative does not comply with these requirements shall be rectified at the Contractor’s expense.
The Principal Representative has the right to request quality control tests at any time in addition to those completed at a determined frequency.
2.4 PRE-JOB MEETING
The Applicator shall schedule a pre-job meeting to ensure that job requirements are fully
understood.
NOTE
Clarification of roles and responsibilities shall take place at the pre-job meeting, such as when the Principal deals directly with the Applicator.
The personnel present at the meeting shall include, but not be limited to, the Principal Representative, Applicator’s Technical Representative, Applicator’s Coating Supervisor, Principal Safety Representative, Applicator’s Quality Control (QC) Representative, and Manufacturer’s Technical Representative (as required).
2.5
APPLICATORS TECHNICAL REPRESENTATIVE
The Applicator shall designate a Technical Representative who is fully conversant with the coating material and application techniques. The Technical Representative shall attend the pre-job meeting and other similar meetings, serve as the primary liaison between the Principal and the Applicator, and provide the Principal Representative with copies of all documents and reports required by this specification.
2.6
INFORMATION TO BE SUBMITTED BY THE PRINCIPAL
For a project qualification, the Principal shall supply technical information to the Contractor regarding the project [data sheet in (Appendix C)], in particular the installation and operating conditions. This information shall contain as a minimum: a) Project name;
b) The thickness of coating required; c) Description of steel pipe;
d) The applicable line pipe specification; e) Installation method;
f) Subsequent external coatings to be applied (e.g., FBE, TLPE); g) Storage and handling requirements.
2.7
INFORMATION TO BE SUBMITTED BY THE CONTRACTOR
The Contractor shall submit information to the Principal on the coating system to be used. This information shall contain as a minimum: a) Coating application procedures;
b) The name(s) of the proposed coating applicator(s);
c) The Applicator's qualification information (Appendix A) and (Appendix B); d) Quality Plan; e) Safety Plan.
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3. COATING SYSTEM REQUIREMENTS
3.1 GENERAL
The coating system deemed suitable for the pipeline installation and operating conditions is specified by the Principal in (2.1) and (2.2).
Prior to beginning any production run, the Contractor or the Applicator shall demonstrate that the final coating system will fulfil the finished coating system requirements (3.2) and application qualification requirements in accordance with (Appendix A), (Appendix B) if necessary, and (5.3). Any modification of the application shall require re-qualification. The Contractor or the Applicator shall demonstrate by effective quality control procedures in accordance with (5.3) that the coating system, as applied during normal production, fulfils the requirements of this DEP.
3.2
FINISHED COATING SYSTEM REQUIREMENTS
The coating shall be free from blisters, pinholes, scratches or any other irregularities detrimental to coating performance and shall have a uniform colour and gloss when inspected from each end.
NOTE
All other irregularities shall be brought to the attention of the Principal Representative who will advise on the disposition of the pipe.
3.2.1 Visual appearance
3.2.2 Degree of cure
The degree of cure shall be determined by differential scanning calorimetry in accordance
with ISO 21809-2, Section A.8.4. The ∆Tg value shall be between +3°C (37°F) and -1.5°C (29°F).
3.2.3 Microscopic examination
The coating interface shall have no more than 10% contamination by foreign matter.
Foaming shall not be present in either through-film or across-film. Occasional voids can be present in the cross-section and at the interface but shall not exceed a number 1 rating in accordance with NACE RP0394-2002 (Appendix G; Figure G2).
3.2.4
Total coating thickness
The average thickness of the total coating system shall be 177 µm (8 mils) to 305 µm (12 mils). No individual thickness reading shall be below 6 mils (150 µm) or greater than 14 mils (350 µm). The dry film thickness of the EP10 primer component shall be between 6.4 – 4.5 µm (0.25 – 1.0 mil).
The coating thickness shall be measured in accordance with (5.3.8).
3.2.5 Holidays
Holiday detection shall be used to monitor consistency of coating applications. The method of holiday detection shall be as per this DEP. The number of holidays shall be reported per pipe joint. Excessive holidays shall require the Applicator to review the application process.
3.2.6 Adhesion
Pull-off adhesion when tested in accordance with ASTM 4541-02 shall exceed 20 MPa (3000 psi) and the failure mode shall be cohesive for more than 75% of surface area.
3.2.7 Flexibility
The flexibility of the coating shall be such that holidays, cracks and disbondment do not appear when tested in accordance with a modified ISO 21809-2, Section A.12 test at 3.0°/PD minimum, total strain (arc matching). (A1.2) shall also be considered.
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3.2.8 Hot water resistance
When tested in accordance with ISO 21809-2, Section A.15 for 48 hrs at 95 ± 3°C
(200 ± 5°F), the coating shall not blister or disbond and the pull-off adhesion, when tested in accordance with ASTM 4541-02, shall exceed 20 MPa (3000 psi) and the failure mode shall be cohesive for more than 75% of surface area.
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4. MATERIALS 4.1 GENERAL
The Applicator shall obtain from the Manufacturer, copies of their most recent technical data sheets describing the product, its general performance, and application requirements. The Applicator shall obtain from the Manufacturer, certification for each batch or lot of powder used to coat the Principal line pipe. A batch will be defined by the Manufacturer, but shall not exceed the quantity of powder produced by the Manufacturer in an eight-hour period from one production line. The certification shall include: • •
Product name, designation and batch number;
Product quality control test results in accordance with (4.2).
A statement from the Manufacturer that no changes have been made in the formulation, raw materials, or manufacturing procedure since the product was last tested and/or approved by the Principal. When advised of any such changes, the Principal shall promptly review and/or test the product for re-approval. Coating materials acceptable for use shall be: a) In Manufacturer original, unopened containers;
b) Stored in a dry, clean location, controlled at or below the Manufacturer
recommended maximum temperature; c) Clearly marked with the batch number and date of manufacture; d) Applied six months or less from the date of manufacture.
4.2 POWDER TESTING
The Applicator shall test each batch of powder prior to production coating, according to the
following procedures:
a) Gel time – ISO 21809-2, Section A.3 b) Density - ISO 21809-2, Section A.7
c) Glass transition and heat of reaction - ISO 21809-2, Section A.8 d) Sieve analysis – per the Manufacturers standard procedure. e) Criteria: All values to be within the Manufacturer published ranges.
f) Duplicate samples of powder shall be supplied to the Principal, upon request, for
testing.
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5. COATING SYSTEM APPLICATION
5.1 SURFACE PREPARATION 5.1.1 Initial inspection
Before blast cleaning and application of the coating system all pipe shall be visually
inspected for the presence of oil, grease, dirt, mill lacquers, or primers on the internal surface. Oil, grease and other contaminants shall be removed before blast cleaning by a suitable solvent, detergent, fresh water, or combination of these.
The presence of dirt, mill lacquer, or primer may require the use of additional cleaning steps such as pre-blasting prior to beginning the normal process.
Chemical cleaning agents and remaining detergents shall be washed off by means of deionized water.
Salt contamination shall be measured using an Elcometer® SCM 400 or Principal-approved equivalent. If salt contamination is greater than 1.5 µg/cm2 the pipe ID shall be blast cleaned followed by a high-pressure wash with deionized water [20.7 MPa (3000 psi)]. If blast cleaning followed by a high-pressure wash with deionized water [20.7 MPa (3000 psi)] is part of the cleaning process, then the initial salt contamination measurement can be waived.
The pipe surface shall be dried before the final blast cleaning and surface preparation.
5.1.2
Cleanliness and profile
The pipe shall be blast cleaned using abrasive air blasting or centrifugal, mechanical cleaning with abrasives to achieve the minimum specified surface cleanliness and profile. The specific blasting program and rate required to meet the specified surface requirements shall be determined prior to production operations and require the Principal Representative approval. Each pipe shall be subjected to a minimum of two (2) complete blasting passes, one into and one out of the pipe.
The pipe surface shall be cleaned of mill scale, rust and other foreign matter by a blast cleaning or other Principal-approved abrasive cleaning method to achieve a minimum surface cleanliness of Sa 2½ in accordance with ISO 8501-1, or SSPC-SP 10 (NACE No. 2, near white cleanliness). The anchor profile shall be 50 – 100 µm (2 – 4 mils), measured by comparator and X-coarse Testex Press-O-Film® replica tapes, or Principal-approved equivalent, in accordance with ISO 8503-2 and ISO 8503-5. The cleanliness and anchor profile shall be monitored and recorded.
The abrasive used for the final blast cleaning shall be metallic grit. New abrasive shall be added in small quantities as required to replenish consumed abrasive. Infrequent large additions of new abrasive shall be avoided.
During coating operations, conductivity of the abrasive material extracts shall be monitored. If the conductivity of the abrasive material extract exceeds 50.0 µmhos/cm, further testing shall be performed on blast-cleaned pipe surfaces to determine the residual chloride concentration on the pipe surface. Grit samples shall be taken and examined through a microscope to establish the presence of new angular grit.
Line speed and blasting parameters shall not cause any over blasting of the pipe surface and result in microscopic steel laminations that may disbond from the pipe surface.
5.1.3 Compressed air
Compressed air used for blast cleaning, dust removal, or other purposes where contact is
made with the pipe surface, shall be free of oil and water according to ASTM D4285.
5.1.4
Temperature during blasting
During blast cleaning the pipe surface temperature shall be simultaneously higher than 5°C (41°F) and more than 3°C (5°F) above the ambient dew point. Blast cleaning shall not be carried out when the pipe surface to be blasted is wet.
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The ambient Relative Humidity (RH) shall be monitored and recorded. Below 85% RH, up to four hours may be allowed after blasting and prior to coating. Above 85% RH, one hour is allowed. Pipe that exceeds these limits shall be re-blasted. Any pipe with visible rusting, or which has not been coated within the specified time above, shall be re-blasted.
5.1.5 Contamination
Blast cleaning residue, loose dust and dirt shall be removed from the pipe surface by means of clean dry compressed air or vacuum cleaning prior to coating application. The dust level on the blast-cleaned surface shall be of class 1 when evaluated in accordance with ISO 8502-3.
The maximum residual chloride level on the blast-cleaned surface shall be 1.5 µg/cm2 when evaluated by the use of an Elcometer® SCM 400 or Principal-approved equivalent. Pipe shall be handled in such a way as to prevent contamination.
5.1.6 Pipe damage
Pipe that has damaged bevels or dents shall be set aside for inspection by the Principal
Representative, and the Principal Representative will advise the Applicator of the disposition of damaged pipe.
5.2 COATING APPLICATION 5.2.1 Primer application
During primer application the pipe surface temperature shall be as recommended by the
Manufacturer and, as a minimum, simultaneously higher than 5°C (41°F) and more than 3°C (5°F) above the ambient dew point.
The ambient RH shall be monitored and recorded. Below 85% RH, up to 4 hours may be allowed after blasting and prior to coating. Above 85% RH, one hour is allowed. Pipe that exceeds these limits shall be re-blasted. Any pipe with visible rusting, or which has not been coated within the specified time above, shall be re-blasted.
The primer shall be uniformly applied to the pipe surface. Application parameters to achieve the desired primer thickness shall be set prior to application of the primer to production pipe.
The primer thickness shall be in accordance with (3.2.4).
The coating cutback shall be 20 cm (8 in) unless otherwise stated.
5.2.2
Heating for FBE application
Pipe shall be uniformly heated so the internal temperature immediately prior to coating application is 199°C to 216°C (390°F to 420°F). External and internal pipe temperature shall not exceed 260°C (500°F).
Uniform heat on the external pipe surface shall be verified and recorded. Temperature of the internal surface at the ends shall be verified and recorded.
Pipe heated to application temperature and not coated shall be reblasted after cooling to ambient temperature.
Pipe temperature shall be monitored just before coating application and recorded. The pipe temperature shall be 199°C to 216°C (390°F to 420°F).
NOTE
The pipe can be either heated by being retained in a heating oven for a period of time sufficient to heat the pipe to the application temperature, or passing through one or more induction coils to achieve the application temperature. Heating parameters shall be set prior to coating production pipe.
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5.2.3
FBE powder application
The coating shall be uniformly applied to the internal pipe surface. The coating lance and its movement mechanism shall not damage or scratch the internal surface. Powder delivery to the pipe surface shall take place via a coating lance as the lance is being removed from the pipe. The lance shall move at a continuous uniform speed until it is completely removed from the pipe.
The FBE thickness shall be in accordance with (3.2.4).
The coating cutback shall be 20 cm (8 in) unless otherwise stated.
The internal pipe surface temperature shall be continually monitored. Once coated the pipe temperature shall remain above 193°C (380°F) and below 216°C (420°F) for a minimum of 15 minutes.
NOTE
The pipe can be either heated by being retained in a heating oven for a period of time sufficient to heat the pipe to the cure temperature, or passing through one or more induction coils to achieve the cure temperature range. Heating parameters shall be set prior to coating production pipe.
The internal coating shall be fully cured within 2 hours of the application.
NOTE
During the development of this coating system, it has been found that the internal coating system should be fully cured prior to any heating for an external FBE application, i.e., cured immediately following application and allowed to cool to ambient temperature prior to heating for the external coating.
5.3 QUALITY CONTROL 5.3.1 General
During production application of the coating, the Applicator shall carry out all quality control
activities needed to ensure that the coating is being applied in accordance with the approved coating application procedures and that the final product complies with the requirements of this DEP.
The minimum quality control tests to be performed shall be as indicated in (5.3.16).
Records of all coating application and quality control test results shall be kept in accordance with (6.0).
5.3.2
Identification of materials
The Applicator shall ensure that all materials supplied for the coating operation have been marked in accordance with (4.0). Material that is not marked shall be removed from the site.
5.3.3 Ambient conditions
The Applicator shall measure the ambient conditions at regular intervals during blasting and
coating and keep records of prevailing temperature, humidity and dew point. If the conditions are outside the limits specified in this DEP, the process shall be suspended until the requirements are met.
5.3.4
Inspection of uncoated pipes before blasting
Before surface preparation starts, each pipe shall be visually examined for dents, laps, defective bevels and any other defects to avoid coating unusable pipes. Defective pipes shall be removed from the coating line for repair or, if repair is not possible, rejection. The internal pipe surface shall be visually checked for contamination with salts, oil or grease. Contaminated pipes shall be cleaned by a solvent or detergent washing procedure proposed by the Contractor and approved by the Principal.
Salt contamination shall be evaluated by the use of an Elcometer® SCM 400 or Principal-approved equivalent.
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5.3.5 Inspection after blasting
Each pipe shall be inspected for surface cleanliness. Pipes that do not comply with the requirements in (5.1.2) and (5.1.5) shall be reblasted.
The surface profile shall be measured on the first five (5) production pipes at every start-up, and every one (1) in 10 pipes following at each end. If the surface roughness is outside the specified limits, the blasting material shall be checked and replaced as necessary. The Principal Representative shall advise on the disposition of the rejected pipe.
The conductivity of the blasting material shall be checked at a frequency of four (4) times per shift. If the blasting material conductivity is greater than 50 µS/cm then the blasting material shall be replaced. The internal surface of one pipe per shift shall be checked for chloride contamination.
5.3.6 Application temperatures
The temperature of the pipe surface shall be monitored and recorded by means of suitable
instruments, e.g., infrared sensors, contact thermometers or thermocouples.
The monitoring instruments shall be independent of the temperature control equipment. The instruments shall be calibrated prior to each unit of production.
Any deviation from the recommended application temperature range shall be rectified. If immediate rectification is not possible, the production shall be stopped until the cause of the deviation has been eliminated.
Any pipes coated during the duration of the temperature deviation shall be identified by marking and subjected to additional quality control tests in accordance with (5.3.16). Pipes that do not comply with the quality control requirements shall be rejected, cleaned and recoated.
5.3.7 Coating appearance
Immediately following FBE coating application, each coated pipe shall be visually checked
for imperfections and irregularities of the coating (3.2.1). Pipes that do not comply with the requirements shall be marked and removed from the coating line for repair or recoating. If subsequent pipes do not comply with the requirements, the coating process shall be checked or stopped to eliminate the cause of the problem.
5.3.8 Coating thickness
Total dry film thickness for the coating system shall be measured using a calibrated digital
gage approved by the Principal.
Calibration of digital thickness gauges shall be carried out with plastic calibration shims on a steel plate having a similar surface profile height as the samples to be measured. The plate thickness shall be a minimum of 6.35 mm (¼ in). For gauges that allow calibration with two shims of different thickness, the thickness of the shims shall bracket the nominal thickness of the coating system to be measured. For gauges that allow only one shim for calibration, the shim thickness shall be ±20% of the nominal thickness of the coating system.
For quality control purposes the coating thickness shall be measured at each end of the pipe. At each location, the thickness shall be measured at four positions, equally spaced around the internal circumference of the pipe.
Pipes that do not comply with the requirements shall be marked and removed from the coating line for rejection, repair or recoating. If subsequent pipes do not comply with the requirements, the coating process shall be checked or stopped to eliminate the cause of the problem.
5.3.9 Holiday detection
A holiday test shall be carried out by means of a low-voltage 67½ V holiday detector and a
wet sponge that is cut to fit snugly in the ID of the pipe. The sponge shall be supported so that it maintains constant contact with the full circumference of the pipe.
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Alternatively holiday detection shall be carried out using a high voltage detector with an internal conductive rubber electrode. The inspection voltage shall be 5 V/mm (125 V/mil). The Contractor shall request approval from the Principal for holiday detection method. Excessive holidays shall require the Applicator to review the application process. Excessive holidays are defined as more than five (5) per pipe joint. The earth connection shall be made directly on the pipe.
The test voltage shall be checked at least once per shift by means of a special voltage meter.
When the holiday test is carried out the internal pipe surface shall be free of moisture. The electrode shall be moved over the pipe surface at a speed of not more than 0.3 m/s (1 ft/s). The entire pipe surface shall be covered by the test.
5.3.10 Destructive testing
At predetermined intervals, one pipe shall be selected for destructive testing of the coating.
A sample length of approximately 0.5 m (18 in) shall be cut from one end of this pipe and subjected to the tests indicated in (5.3.16; Table 6).
The tests shall commence as soon as possible after coating to allow readjustment of the coating process if required.
After cutting of the test sample, the remaining pipe shall be marked with the remaining length and the coating cutback reinstated in accordance with (5.2). The pipe end bevel shall be re-machined to the original pipe specification.
Alternatively a test ring may be attached to a dedicated host joint, subject to Principal approval.
5.3.11
Degree of cure of FBE
The degree of cure shall be determined by differential scanning calorimetry in accordance with ISO 21809-2 Section A.8.4. The ∆Tg value shall be between +3°C (37°F) and -1.5°C (29°F).
5.3.12 Flexibility
Flexibility shall be determined in accordance with ISO 21809-2, Section A.12. The test straps shall be cooled to 0°C (32°F) by immersing in an ice/water bath for a minimum of 30 minutes. Final examination of the test straps shall take place 24 hours following the bending. The requirements are stated in (3.2.8).
NOTE
As the strap will be ID coated there will be stress risers at the edge of the strap. These edges shall be machined down so that they are level with the centre of strap, but still maintain around 90% of the coating width at that point (Appendix A, Figure A1.2)
5.3.13 Microscopic examination
Surface contamination shall be evaluated in accordance with ISO 21809-2, Section A.10.
The maximum acceptable level is stated in (3.2.3).
NOTE
The visual surface contamination should be identified by percentage of steel dust versus oxide or
other particles. Addition of a saturated copper sulphate solution to the back of the chip will cause steel dust to be plated with copper to make it easily identifiable. This definition of contaminant types should help the Applicator adjust the surface preparation procedures to minimize the amount of surface contamination.
Porosity shall be evaluated in accordance with NACE RP0394-2002 Appendix G. The requirements are stated in (3.2.3).
NOTE
The thru-film porosity evaluation shall be made on the edges of coating chips that were fractured during low-temperature bending. The interfacial porosity shall always be reported. If necessary, note that there is significant fracture at the interfacial porosity layer, and that the porosity level is estimated. Fracture through interfacial porosity will influence visual contamination ratings as well.
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5.3.14 Acceptance of suspect coating
In the event of pipes failing to meet the requirements of (5.3.16), preceding pipes coated after the last acceptable pipes and the pipes coated following the failed pipe shall be considered suspect and shall be marked for further testing.
The Applicator shall propose and agree with the Principal a test program to trace any of the suspect pipes affected by the same failure. Further testing shall involve inspection and examination similar to that carried out on the original rejected test pipe(s). Based on the test results, the final acceptance or rejection of the suspect pipes shall be made by the Principal.
No pipes shall be dispatched from the coating yard before the Principal has approved the quality control results.
The Principal retains the right to reject any shifts' or days’ production if the reject rate of that production is more than 10 % and/or if sample tests are found to be outside the specification in this DEP.
In addition, the Applicator may be required to stop production and carry out a full investigation into the source of the problem; he shall submit the results to the Principal before receiving permission from the Principal to recommence production.
5.3.15 Traceability of pipes and coating
The Applicator shall ensure that individual pipes are fully traceable during and after the coating process. If the serial number of the pipe as given in the pipe mill is removed or obliterated, it shall be reapplied. The Applicator's own serial number shall be indicated on the pipe and records shall be kept to identify the sequence and time of coating and the batch of materials used for each pipe.
5.3.16 Test frequency
Table 1
Property
Identification of Materials Initial Visual Inspection Salt contamination prior to
blasting
Table 2
Property
Conditions during blasting Cleanliness of compressed air
Pipe temperature during blasting
Surface cleanliness Surface profile Dust contamination Conductivity of blast media
Receipt of materials
Test Frequency All Materials All pipe 10% of pipe
DEP Section
(4.0) (5.1.1) (5.1.1)
Surface preparation
Test Frequency Two (2) per shift and after obvious changes in weather conditions
After every compressor start-up and every 10 pipes Four (4) per shift and after change in environment conditions All pipe
First five (5) pipes after every start-up and every 10 pipes Every 10 pipes
Four (4) per shift or every
DEP Section
(5.5.3) (5.1.3) (5.1.4) (5.1.2) (5.1.2), (5.3.5)
(5.1.5) (5.1.2), (5.3.5)
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Property
DEP Section
Test Frequency 10 pipes Every 10 pipes All pipe
Salt contamination following blasting Pipe damage
Table 3
Property
Conditions during primer application
Pipe temperature during primer application Primer thickness
(5.3.5) (5.1.6)
Primer application
Test Frequency Two (2) per shift and after obvious changes in weather conditions
DEP Section
(5.5.3)
(5.2.1) All pipe (3.2.4)
First five (5) pipes at start-up
then every five (5) pipes (coupons or direct)
Cut-back (5.2.1) All pipe
Table 4
Property
Conditions during FBE application
Pipe temperature prior to FBE application Lance operation
Pipe temperature during FBE application
Pipe temperature during FBE cure
Table 5
Property
Conditions appearance Coating thickness Holiday detection
Table 6
Property
Degree of cure Flexibility
Destructive testing
Test Frequency Two (2) per shift Two (2) per shift
Non-destructive testing DEP Section (3.2.1), (5.3.7) (3.2.4), (5.3.8)
(5.3.9)
Test Frequency All pipe All pipe All pipe
FBE application
Test Frequency Two (2) per shift and after obvious changes in weather conditions All pipe At start-up All pipe All pipe
DEP Section
(5.3.3) (5.2.2), (5.3.6)
(5.2.3), (5.3.6) (5.2.3), (5.3.6)
DEP Section (5.3.11) (5.3.12)
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Property
DEP Section
(3.2.9) (3.2.6) (3.2.3), (5.3.13)
Test Frequency Two (2) per shift Two (2) per shift Two (2) per shift
Hot water soak Adhesion
Microscopic examination
NOTE
Destructive testing frequency may be reduced to one (1) per shift after 10 consecutive ring samples that meet the requirements of this DEP.
5.4 QUALITY PLAN, INSPECTION AND TEST PLAN, MANUFACTURING PLAN
The Contractor shall develop and implement a quality system (e.g., ISO 9001 or ISO 9002) or approved equivalent.
A Quality Plan (QP) in compliance with ISO 10005 or approved equivalent, consisting of an Inspection and Test Plan (ITP) and Manufacturing Plan (MP), as a minimum, shall be developed specifically for all aspects of work and shall be approved prior to commencement of manufacturing operations. The ITP shall provide columns or spaces for the Principal to indicate the Principal’s and the Principal’s third-party-inspector inspection activity, for example the monitor, witness, hold points, etc., for the operations to be undertaken.
The MP shall clearly define the sequence of operations and process controls to be implemented at each operation. Unless specifically annotated otherwise in the approved MP, all procedures, processing parameters, requirements, etc., stipulated in this Technical Specification shall be applied. Alternatively, one combined document consisting of an ITP and MP is acceptable provided the guidelines stated above are followed.
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6. DOCUMENTATION
The Contractor shall keep accurate records of all relevant data of the coating process. This documentation shall, as a minimum, consist of:
a) Copies of the coating system information as specified in (2);
b) Copies of qualification information as requested in (Appendix A) and (Appendix B)
if necessary; c) Copies of, or reference to, all procedures for coating of the pipes;
d) Serial numbers of all pipes as given by the Pipe Manufacturer (e.g., by copies of the
pipe mill data sheets); e) Serial numbers as given by the Coating Applicator (if applicable) correlated with the
Manufacturer's serial numbers; f) The order of coating, the day and shift of coating of each pipe;
g) The batch numbers of the coating materials, the day and time of loading of each
batch; h) Serial numbers of rejected pipes and the reason for rejection; i) The results of all quality control testing in accordance with (5.3);
j) Records of temperatures during the coating process for each pipe, with the
processing time of every tenth pipe marked on the temperature chart with the pipe number; k) Names and signatures of the responsible persons for the coating process and quality
control. This documentation shall be submitted to the Principal after completion of the coating work, together with the testing and inspection instruments’ calibration certificates.
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7. STORAGE AND HANDLING
Coated pipe shall be stored and handled in such a manner as to prevent damage to the
pipe, pipe ends, bevels and applied coating.
All pipe shall be stored in a manner to provide for safe stacking and unstacking operations. Pipe without an external coating shall be stacked off the ground on berms covered with a plastic sheeting material, or on timbers with a minimum 15 cm (6 in) wide bearing surface. The berms, or timbers shall be of sufficient height to prevent the pipe ends from coming into contact with the ground and to keep the pipe clear of any localized surface water.
All pipe shall be stored at an angle to allow water to drain from the interior. Exposure of the internally coated pipe to water should be minimized where possible.
Externally coated pipe shall be handled in accordance with the DEP for the external coating.
Internally coated pipe shall be stored so that debris, oil or other contamination detrimental to the internal pipe coating comes in contact with the internal surface.
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8. REFERENCES
In this DEP, reference is made to the following publications:
NOTES:
1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto. 2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards/.
SHELL STANDARDS
External polyethylene and polypropylene coating for line pipe (amendments/supplements to ISO/DIS 21809-1:2009) External fusion-bonded epoxy powder coating for line pipe (amendments/supplements to ISO 21809-2:2007) AMERICAN STANDARDS
Standard Test Method for Indicating Oil or Water in Compressed Air
Standard Practice for the Preparation of Substitute Ocean Water Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers
Application, Performance, and Quality Control of Plant-Applied, Fusion-Bonded Epoxy External Pipe Coating - Item No. 21064 Near White Metal Blast Cleaning INTERNATIONAL STANDARDS
Preparation of Steel Substrates before Application of Paints and Related Products - Visual Assessment of Surface Cleanliness - Part 1: Rust Grades and Preparation Grades of Uncoated Steel Substrates and of Steel Subtrates after Overall Removal of Previous Coatings
Preparation of Steel Substrates before Application of Paint and Related Products - Tests for the Assessment of Surface Cleanliness - Part 3: Assessment of Dust on Steel Surfaces Prepared for Painting (Pressure-Sensitive Tape Method) (ISO 8502-3:1992)
Preparation of Steel Substrates Before Application of Paints and Related Products - Surface Roughness Characteristics of Blast - Cleaned Steel Substrates Part 2: Method for the Grading of Surface Profile of Abrasive Blast-Cleaned Steel - Comparator Procedure-AMD 8661: December 15, 1995
Replica Tape Method for the Determination of the Surface Profile
Quality Management Systems - Requirements
Quality Management Systems – Model for Quality Assurance in for Quality Assurance in Production, Installation and Servicing Petroleum and Natural Gas Industries - External Coatings for Buried or Submerged Pipelines Used in Pipeline Transportation Systems - Part 2: Fusion-Bonded Epoxy Coatings
Quality Management Systems – Guidelines for Quality Plans
DEP 31.40.30.31-Gen. DEP 31.40.30.32-Gen.
ASTM D4285 ASTM D1141 ASTM 4541 NACE RP0394-2002 SSPC-SP10 (NACE No. 2)
ISO 8501-1
ISO 8502-3
ISO 8503-2
ISO 8503-5 ISO 9001 ISO 9002 ISO 21809-2
ISO 10005
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APPLICATOR QUALIFICATION
APPENDIX A
A1.1 GENERAL
Before production application of a coating system may commence, the Applicator shall be qualified to apply the coating system. Applicator qualification shall take place on the production equipment with an approved coating. The qualification shall be carried out according to the following procedures:
A1.2
COATING PROCESS AND APPLICATOR SELECTION
The Contractor shall submit to the Principal information on the required coating process and recommended applicators. The information shall include:
a) Description of the coating process for line pipe, bends and fittings;
b) Pipe cleaning and surface preparation (cleanliness, profile, chemical pre-treatment,
etc.); c) Required surface and material application temperatures; d) Recommended applicators.
A1.3 COATING PLANT
To demonstrate that the available equipment is capable of applying the specified coating according to the required standards, each recommended Applicator shall submit full details of the coating plant, including:
a) Layout diagram of the coating plant and plant flow scheme;
b) General description of the equipment available to carry out the coating process; c) Details of process control and inspection equipment required for the coating process
such as temperature control, thickness control, holiday testers, laboratory equipment, etc.; d) Details on the line pipe marking, handling, storage and transport equipment and
procedures; e) Applicator’s quality control procedures.
A1.4 QUALIFICATION
After approval of the process and plant details (A1.2), (A1.3) and before production starts, the Applicator shall submit evidence that he has successfully applied the coating system before on pipes of the specified material, and that the product complied with the requirements of this DEP for the tests indicated in (5.3.16).
The Applicator shall coat at least two (2) pipes with the coating system and shall subject samples from these pipes to the tests given in (5.3.16). The quality control tests may be carried out in the Applicator's own laboratory, or by an independent laboratory. The Principal shall witness the application and the tests. The results of the tests shall be reported to the Principal, signed by the head of the laboratory and the witness. Additional testing, given in (A1.5), shall be carried out by the Principal.
When this DEP is used for the coating of bends and/or fittings, the Applicator shall coat at least one fitting or bend as agreed with the Principal and subject this coating to the same qualification tests.
A1.5 TESTING REQUIREMENTS A1.5.1
Quality control testing to be completed by the Contractor All test in accordance with (5.3).
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A1.5.2 Additional testing to be completed by the Principal Test
Autoclave Test
Description and Pass Criteria
Triplicate samples from both qualification pipes shall be placed in an autoclave and fully immersed in synthetic seawater (ASTM D1141) with a headspace containing methane gas with 5% CO2. The temperature shall be 65.5°C (150°F), pressure 62.05 MPa (9,000 psi), and the test duration shall be 7 days. The sample dimensions shall be 25 mm wide x minimum 127 mm long (1 in wide x minimum of 5 in long). Release of pressure at the end of the test shall be completed in less than 30 minutes and as quickly as safely possible.
Samples shall not exhibit blistering or cracking when removed from the autoclave and over a 24-hour period following removal at the end of the test.
Adhesion after Long Water Soak
Triplicate samples from both qualification pipes shall be immersed in synthetic seawater (ASTM D1141) at 65.5°C (150°F) for 2 and 4 weeks. Following removal the adhesion is evaluated in accordance with (3.2.6). Sample dimensions are a minimum of 100 mm x 100 mm (4 in x 4 in).
Adhesion values shall be greater than 17.2 MPa (2500 psi) or at least 75% of their original adhesion values (before immersion).
Resistance to Flow
Triplicate samples from both qualification pipes shall be immersed in synthetic seawater (ASTM D1141) at 32.2°C (90°F) for 2 and 4 weeks. The sample surfaces shall be exposed to the synthetic seawater moving at 3.65 m/s (12 ft/sec).
NOTE:
Velocity of seawater shall be a project requirement.
Sample dimensions shall be 25 mm wide x minimum 127 mm long (1 in wide x minimum of 5 in long). A 76.2 mm long x 2 mm wide (3 in long x 80 mils wide) gouge shall be made in the coating through to the metal substrate.
At the end of the test, the samples are removed and observed for deterioration at the gouge. Two parallel cuts shall be made perpendicular to the original gouge and 6 mm (¼ in) apart. An attempt is made to lift the coating, inside the two (2) cuts, with the point of a knife, starting at the edge of the original gouge.
No sample shall have disbonding, uplifting, cracking or peeling on either side of the cut. The knife test shall not remove more than 2 mm length of a coating chip.
Flexibility
Triplicate samples from both qualification pipes are tested in accordance with (5.3.12).
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A1.5.3 Samples for testing
Samples for qualification testing by the Principal shall be prepared from the two
qualification joints by cold cutting the pipe at the following locations:
Figure A1.1 Location for qualification test samples
Figure A1.2 Removal of stress risers for flexibility
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COATING SYSTEM QUALIFICATION
APPENDIX B
B1.1 GENERAL
The Contractor shall seek Principal approval for the use of any coating system not already qualified to this DEP. The Contractor shall supply all relevant datasheets and written confirmation that the Manufacturer recommends the coating system for the intended service.
The Contractor/Applicator shall apply the coating system to the internal surface of two (2) pipes to demonstrate that the coating system meets the requirements of the coating. See (3). Testing of the proposed coating shall be carried out by the Principal in accordance with (A1.5).
If the proposed coating is accepted for use the Contractor/Applicator shall be required to qualify the application in accordance with (Appendix A). If the proposed coating is not accepted for use, the Contractor Application shall be required to qualify the application of an approved coating system in accordance with (Appendix A).
NOTE
Application of a coating for coating qualification may be completed using pilot equipment rather than the equipment that would be used during production. Applicator qualification shall take place on the production equipment with an approved coating. Unless stated by the Principal, a coating qualification and applicator qualification shall not take place using the same pipe.
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DATASHEET
APPENDIX C
PROJECT:
PIPE USED FOR:
INQUIRY/P.O. NO.:
GENERAL
SPECIFICATION:
Internal Fusion-Bonded Epoxy Powder Coating for Water Injection Line Pipe DEP 31.40.30.39-Gen. PREPARED BY:
ITEM NO.:
SCHEDULE
PIPE ARRIVAL DATE____________________________
TRANSPORTATION MEANS______________________
REQ. COATING COMPLETION DATE_______________
ADDITIONAL
INFORMATION___________________________________________________________________________________________________________________________________________________________________________
ADDITIONAL REQUIREMENTS
{ QUALIFICATION REQUIRED
{ OTHER
__________________________________________________________________________________________________________________________________________
ADDITIONAL SERVICES
External FBE (DEP 31.40.30.32-Gen.) { NOT REQUIRED { REQUIRED
External TLPE (DEP 31.40.30.31-Gen.) { NOT REQUIRED { REQUIRED
DATE PREPARED:
QUANTITY____________________________________
JOINT LENGTH/TOLERANCE_____________________
PIPE SIZE/WALL THICKNESS_____________________
PIPE MANUFACTURER__________________________
COATING THICKNESS
{ AS SPECIFIED (Total coating thickness 7-11 mils) { OTHER
__________________________________________________________________________________________________________________________________________
COATING CUTBACK
______________________+/-______________________
COLOR CODING ________________________________________________________________________________________________________________________________________________________________________________________
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