Wheatstone Upstream Project –

Trunkline
Sutitleubtitl
Package
INSPECTION AND TEST PLAN
PQT AND PRODUCTION FOR
CONCRETE WEIGHT COATING
OF LINEPIPE (KABIL)

1 17/11/12 Issued for Use SAS RW/DM DC

0A 11/10/12 Issued for Review SAS RW/DM DC

0 07/09/12 Issued for Use SAS RW/DM DC

D 12/06/12 Issued for Review SAS RW/DM DC

C 14/05/12 Issued for Review SAS RW/DM DC

B 15/03/12 Issued for Review AR RW/DM DC

A 05/01/12 Issued for Review AR RW/DM DC

REV DATE DESCRIPTION ORIG CHK APPR

IP Security Company Confidential Total number of Pages (including Cover sheet): 22

Contractor
For Contract No Contractor Document No Rev.
Contractor
Documents C900855 ITP 08-2 4

COMPANY Project Area Discipline Originator Package Sequence-Sht Revision

DOCUMENT
CONTROL NO. WS2 3321 QAC ITP BRS TLC 00009-000 1
Data Center Controlled Copy - Uncontrolled in Printed Format unless carry a Document Control stamp
 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating & Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08 – 02 Revision Date : 05 – 10 – 12 Page Number 2 of 20

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Test
Acceptance Criteria
Approval

Item
Process/
Description of Inspection Test
Spec.
Insp/Test Freq.
Verifying

Method /
(WS2-3321-PPL-SPC-ITS-000-00006-000 rev.1 / WS2-
Inspection

No.
Location
Activity
Reference
Document

Code
PQT
Production
3002-PPL-DAS-ITS-000-00009-000 rev.2)
BSI CVX
IVB

Certificate from Manufacturer to ASTM C150 Type I.

Cement
C3A content shall less than 9%.

IRF033 &

The cement shall be Ordinary

Alkali content < 0.6%.

Spec cl.
ASTM C
Every
Certificate

Portland Cement. Cement on

Every Batch

VC R

1.0
3.1 and DS
150
Batch
from

delivery shall be blown directly

Cement shall be stored in silos for a maximum period of

Manufacturer

into the storage silos.

three months. Hardened, partially set or lumpy cement

shall be rejected and removed from the coating site.

Aggregates
· Gradation of aggregate shall be monitored and

Aggregates shall be stockpiled

controlled for oversize.

on a well drained and

compacted area. The

Typical Gradation of Iron Ore

aggregates shall be segregated

WS2-3321-
Sieve Size Ideal Passing

and stored separately.

TEC-CR-
6.3 mm 99-100%

ASTM C33,

BRS-TLC-
4.75mm 75-100%

ASTM C136
Every
Every
V N

(4)
1.1
Aggregate shall be based on
00018-000

2.36mm 40-65%
IRF033
MR

and ASTM
delivery
delivery
C

standard supplied which will

C 87
1.18mm 20-50%

Spec cl. 3.2

meet the required concrete “As

and DS
600mm
15-40%

Applied” density and

300mm
5-30%

compressive strength.

Material
150mm
0-15%

Aggregate shall be tested by

Receipt

BSI
· Aggregate shall be checked for cleanliness,

gradation, SG and moisture content.

Spec cl.
IRF033 &

· Acid-soluble sulphates, SO3: ≤ 0.4 % (wt)

1.2
3.2.1 and
- One off ---
Laboratory
HRC R

Aggregate shall be tested by

Calcium Chloride, CaCl2: ≤ 0.4 % (wt)

DS
· test report

BSM or their appointed

independent laboratory and

ASTM C294
· Conform to ASTM C33, with exception of grading.
IRF033 &

results provided
Spec cl. 3.2

1.3
and ASTM
One off ---
· Test to ASTM C294 and ASTM C295 or equivalent
Laboratory
HRC R

and DS

C295
standard
test report

IRF033 &

Every
Certificate
V D

1.4
At PQT
Certificate from Manufacturer shall conform to BS 4482.
RW

delivery
from
C

Reinforcement Steel Cage

Manufacturer

Welded cage shall be used for

Spec cl. 3.3

At PQT, shear load test on welded cage samples shall

this process in order to

BS 4483

and DS
be performed in accordance with BS 4483.

increase the strength in tension

5 samples

Laboratory

1.5
for shear
---
Minimum shear strength: 0.25 Afy
TC RW
resistance of concrete
2
test report

testing
A: Cross sectional area of wire (mm
)

Fy: Yield stress of wire (MPa)

 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating & Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08 – 02 Revision Date : 05 – 10 – 12 Page Number 3 of 20

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Test
Acceptance Criteria
Approval

Item
Process/
Description of Inspection Test
Spec.
Insp/Test Freq.
Verifying

Method /
(WS2-3321-PPL-SPC-ITS-000-00006-000 rev.1 / WS2-
Inspection

No.
Location
Activity
Reference
Document

Code
PQT
Production
3002-PPL-DAS-ITS-000-00009-000 rev.2)
BSI CVX
IVB

Reinforcement Wire Mesh

Minimum diameter : 2mm.

IRF033 &

Reinforcement steel shall be

ASTM A185
Certificate from Manufacturer conform to ASTM A185,

Spec cl. 3.3

Every
Every
Certificate
V D

1.6
used for this process in order to
and ASTM
ASTM A82 or BS 4483.
-

and DS
delivery
delivery
from
C

increase the strength in tension

A82
At PQT, shear load test on wire mesh samples shall be
Manufacturer

resistance of concrete
performed in accordance to ASTM A185 or BS 4483.

Water

st
Water shall be potable, free from acids, alcohols, alkali,
rd

Water used for concrete mixing

Spec cl. 3.4
BS 3148
Prior to
1
day of
3
party
V N

1.7
oil, salt and any organic material, conform to BS 3148
M

shall be local mains supply

and DS
App. A
PQT
production
report
C

App. A.

(potable) water.

Plastic Spacers

Non metallic, electrically

Packaging secure.

insulating, flat based spacers

Spec cl.
Visual,
Every
Every

1.8
Flat base area minimum 15 mm x 15 mm
IRF 033 DC R

used to isolate the pipe from

3.3.4
Dimensional
delivery
delivery

Spacer height shall be referred to attachment 2

the cage reinforcement and to

Material

hold the cage firmly in place.

Receipt

(cont)

Plastic Tape Cutback

Packaging Secure.

All CWC
All CWC

1.9
Plastic clear tape used to cover
--- Visual
Dimension of plastic tape according to anti corrosion
--- DC -

PQT pipes
pipes

the anti corrosion and cutback

cutback.

End Ring
Dimension of end ring :

All CWC
All CWC

1.10
Wooden end ring used to block
--- Visual
· ID based on OD pipe and anti corrosion coat
--- DC -

PQT pipes
pipes

the concrete end application

· Packaging Secure, Marking Legible

Adhesive
· Certificate from Manufacture
IRF033 &

(R)
Spec cl.

(Sikadur
32, Hi-Mod)
Every
Every
· Product within shelf life (2 years in unopened
Certificate

(4)
1.11
3.6, 3.7 and
---
VC R

This is being applied to

delivery
delivery
containers)
from

DS

enhance the anti slip system.

Manufacturer

· Mixing ratio by weight

· Contact Time (Cure Time)

 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating & Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08 – 02 Revision Date : 05 – 10 – 12 Page Number 4 of 20

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Test
Acceptance Criteria
Approval

Item
Process/
Description of Inspection Test
Spec.
Insp/Test Freq.
Verifying

Method /
(WS2-3321-PPL-SPC-ITS-000-00006-000 rev.1 / WS2-
Inspection

No.
Location
Activity
Reference
Document

Code
PQT
Production
3002-PPL-DAS-ITS-000-00009-000 rev.2)
BSI CVX
IVB

PQT pipe size, type of anti corrosion coating and

Concrete thickness listed the table below:

No.
Anti

OD
WT
CWC

Corrosion

PQT Pipe Size and Concrete

(mm)
(mm)
Thickness

2.0
--- --- ---
Coating
PQT Report HC W/R

thickness

1 1117.6 24.6 FBE 55

2 1117.6 24.6 FBE 75

3 1117.6 24.6 FBE 110

4 1126.6 29.1 3LPP 55

WS22-

3002--
110mm Concrete – 11 pipes

PPL-DAS-
2 x shear test ( No Facing Plate)

ITS-
3 x impact test (2 also used for lifting weight test)

000-00009
3 x bend test (Non-slotted ) - 11.5 length of pipe

Pg 8, 9 , 10

3 x bend test (slotted) - 11.5 length of pipe

and 11

55mm Concrete – 5 pipes

Number of Pipes to be coated

N T

2.1
--- --- ---
2 x Shear Test (No Facing Plate)
PQT Report
W

for each PQT

D C

PQT
3 x impact test (also used for repair qualification)

75mm Concrete – 8 pipes

2 x Wash off test - (No facing plate, No Sikadur)

3 x Field Joint test - (No facing plate, No Sikadur)-

(Sectioned) - 11.8m of length of pipe)

3 x Bend test (11.5m length of pipe)

At least 60 days before start of production, the materials,

coating process, equipment and procedures to be used

Project

2.2 PQT Timing

Spec cl. 4 --- --- ---
shall be qualified through a PQT. Pipes with concrete
HC R

Schedule

weight coating that meet this specification will be

accepted as production pipes.

The PQT report with all QC inspection/tally forms and

test results included shall be submitted and approved by

2.3
PQT Reporting
Spec cl. 4 --- --- ---
COMPANY before production is allowed to start. PQT
PQT Report C R

report shall be submitted at least 3 weeks before

production.

 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating & Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08 – 02 Revision Date : 05 – 10 – 12 Page Number 5 of 20

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Test
Acceptance Criteria
Approval

Item
Process/
Description of Inspection Test
Spec.
Insp/Test Freq.
Verifying

Method /
(WS2-3321-PPL-SPC-ITS-000-00006-000 rev.1 / WS2-
Inspection

No.
Location
Activity
Reference
Document

Code
PQT
Production
3002-PPL-DAS-ITS-000-00009-000 rev.2)
BSI CVX
IVB

Visual Inspection
Contamination & defect free. All damaged areas shall be

PQT Report/

3.0
The whole coated pipes shall
repaired as per the coating specific ITP (i.e. ITP05-1 for
VC

QF08-2-1

be visual inspected.
FBE or ITP07-2 for 3LPP).

SOP-

Verify pipe identity

IDKBL-
Confirm Pipe No., Heat No., & Length is still legible on

Spec cl. 5.1

All PQT
PQT Report/

3.1
The legibility of pipe
CWC-CWC-
All pipes
stencil. Confirm Hard Stamp is still legible. Reinstate
VC

and DS
pipes
QF08-2-1

20-OP2-

identification shall be verified.

where necessary.

REV001

Holiday test

PQT Report/

(4)
3.2
Pre Coating
The anti corrosion coated pipes
All Holidays detected shall be repaired and re-tested.
VC W R

QF08-2-1

Inspection
shall be holiday tested.

Check ambient temperature and / temperature of the

pipe / reinforcement / concrete material. If the pipe, anti-

Concrete
Contact
corrosion coating, reinforcement or concrete material

Ambient and material

At start up
At start up
PQT Report/

(4)
3.3
coating
thermo-
temperature exceeds 35 °C, The coated pipes shall be
D C

temperature check
of the PQT
of the shift
QF08-2-3

data sheet
couple
transported to the fog cure area and immediately covered

by tarpaulins to protect the fresh concrete from direct

sunlight and prevent drying of the surface.

Longitudinal rebar size shall be selected to achieve a

minimum 0.08% CSA

WS22-3002

Bar size min 4.5mm diameter, and 50 – 250mm spacing.

-PPL-DAS-

Reinforcement – welded cage

Type text here

All pipes,

ITS-000 -
All PQT
Circumferential rebar size shall be selected to achieve a
PQT Report/

4.0
Reinforcement Cross Sectional
Calculation
record
C R R

00009 Pg
pipes
QF08-2-3

Area
every hour
minimum 0.5% CSA. Bar size min 6mm diameter, with a

5, Spec Cl

pitch < 120 mm, and 50mm pitch double hoop at cage

3.3

ends (including anode locations).

See Attachment 2 below.

· Approximate centre of concrete (within middle third of

concrete).

Cage

Installation
All pipes,
· Min. 15 mm from anti corrosion coating.

Reinforcement welded cage

Spec cl. 5.2
All PQT
PQT Report/
V D

4.1
Visual
record
· Terminate 15 – 30 mm from the end of concrete.
W R

and
placement
and DS
pipes
QF08-2-3
C

every hour
· Terminate 30 – 50 mm adjacent to anode installation.

Pegging

· Minimum concrete cover over any reinforcement shall

be ≥ 15mm

Overlap splices ≥ 75 mm. At cage overlaps extend

longitudinal wires to achieve at least 200 mm overlap and

WS22-3002
such that adjacent wires have at least 25 mm between

- PPL-DAS-

them, with bars side by side and spot welded together.

Overlap of split cages / Broken

ITS- 000-
Tape / Rule,
Where
Where
Applicable
V D

4.2
Lap wires shall be bent down and secured.
W R R
welds
00009 Pg 4
Visual
Applicable
Applicable
Report
C

& 5, Spec
Hand wire repairs of broken welds is acceptable. Cage

Cl 3.3.1
weld breaks: Repaired by wire limited to a maximum

number of 5% of welds and limited to a total of 3 pipes

per shift.

 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating & Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08 – 02 Revision Date : 05 – 10 – 12 Page Number 6 of 20

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Test
Acceptance Criteria
Approval

Item
Process/
Description of Inspection Test
Spec.
Insp/Test Freq.
Verifying

Method /
(WS2-3321-PPL-SPC-ITS-000-00006-000 rev.1 / WS2-
Inspection

No.
Location
Activity
Reference
Document

Code
PQT
Production
3002-PPL-DAS-ITS-000-00009-000 rev.2)
BSI CVX
IVB

Reinforcement – wire mesh

For the 110mm concrete

thickness only, this shall be

st
All pipes,

applied in two passes. The 1

All PQT
· Terminate 30 – 50 mm adjacent to anode installation.
PQT Report/
V D

4.3
Spec Cl 3.3 Visual
record
M R

pass shall be reinforced with a

pipes
· Overlap minimum 12mm.
QF08-2-6
C

every hour

welded cage and the second

pass (wet on wet) shall be

reinforced with wire mesh.

Cage
SOP-

Installation
IDKBL-
End rings shall be installed at the correct location from

End Ring Installation

All PQT
V D

4.4
and
---
CWC-CWC-
All pipes
the pipe ends to ensure that the desired concrete
---
-

pipes
H

60-OP5
cutback is achieved.

Pegging

Rev.001

Plastic tape shall cover the circumferential area of

Plastic Cutback
All PQT
V D

4.5
---
All pipes
anticorrosion cutback to keep the coating free from
---
-

pipes
H

concrete splatter.

Concrete Cutback
WS2-3320-

PPL-DTL-
All pipes,

The length of uncoated area at

All PQT
Cutback 395mm – 415mm. as measured from the end of
PQT Report/
V D

4.6
ITS-000-
---
record
W R

both pipe ends shall be

pipes
the pipe.
QF08-2-3
H

00004-001,
every hour

measured
Rev.1

Verified
Rebound may be used provided it is documented that the

Spec cl.

during
specified properties are met, i.e. through PQT testing.
V D
WFO

5.0 Rebound material

5.4.5 and
--- At PQT
---

early
When breaks in operation exceed 30 minutes, then the
H
M R

DS

production
rebound material shall be discarded.

The outer surfaces of the anodes shall be masked with

Outer surface of pipes fitted

All PQT

Spec Cl
All anode
polythene / canvas to protect them from concrete, grout

5.1
with anodes prior to
Visual
pipe fitted
--- V M

5.4.2
pipes
and any other foreign materials during application. These

concrete application
with anodes

shall be removed after application.

Concrete
Material shall be set in Cup.

Application
If material does not set in cup, do not proceed with

Adhesive Cup Shots

production and perform ratio checks at the pump.

Cup shot tests shall be

At start up
Twice per
PQT Report/

5.2
---
Cup Test
No Temperature Cure Time (Contact Time)
C -

performed to check the cure

of PQT
shift
QF08-2-4

1 4° C 12 hours

and set time

2 23 °C 3 – 4.5 hours

3 32 °C 1.5 – 2 hours

Adhesive Mix Ratio

At start up
Ratio check at the pump.

At start up
PQT Report/

5.3
Mix ratio of two component
--- Cup Test
of
Mix ratio of component A and B weight shall be
C
-
of PQT
QF08-2-4

shall be performed
production
1.14 : 1.7 ( Within ± 5 % tolerance)

 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating & Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08 – 02 Revision Date : 05 – 10 – 12 Page Number 7 of 20

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Test
Acceptance Criteria
Approval

Item
Process/
Description of Inspection Test
Spec.
Insp/Test Freq.
Verifying

Method /
(WS2-3321-PPL-SPC-ITS-000-00006-000 rev.1 / WS2-
Inspection

No.
Location
Activity
Reference
Document

Code
PQT
Production
3002-PPL-DAS-ITS-000-00009-000 rev.2)
BSI CVX
IVB

Continuous layer of adhesive shall be applied to the anti-

corrosion coated line pipe immediately prior to applying

At start up

concrete.

of the shift
PQT Report/

All PQT
CWC shall be applied within 30 mins of Sikadur

5.4 Adhesive application
Spec Cl 2.5 Visual
and after
QF08-2-5
V M

pipes
application. if not anti corrosion coat pipe will be

any

stoppages
stripped.

Pictorial standard to be established during PQT.

Adhesive for CWC over 3LPP coated pipe not required.

Water spraying prior to

Spec Cl
All PQT
No water spraying shall be permitted where Sikadur

5.5
Visual
All pipes
--- V M

concrete application
5.1.3
pipes
adhesive is being used.

At start up

Spec cl.
of the shift

Time limitation after adding

At start up
Time from water addition to placing concrete: ≤ 30 mins
PQT Report/
V D
WFO

5.6
5.4.3 and
Stopwatch
and after

water
of the PQT
Total time for concrete application: ≤ 30 mins
QF08-2-5
C
M R

DS
any

stoppages

6 readings along the pipe length, with 2 end

Diameter measurement

SOP-
measurements approx. 600 mm from the concrete ends.
PQT:

The outer diameter of the pipe

Spec cl.
IDKBL-

TF08-2-1
W R

shall be measured using a girth

All PQT
V D

(4)
5.7
5.4.4 and
CWC-CWC-
All pipes
Average thickness
(Computer
Prod:

tape to verify the coated

pipes
C

DS
210-QC1 –
For concrete thickness ≤ 60mm: ± 6 mm thickness
Database)
WFO

diameter is within the desired

REV001

Concrete
For concrete thickness > 60mm: ± 8% of concrete
M R

range.

Application
thickness

Ohm meter,
2 Anode

Spec cl.
All Anode
PQT Report/
N H

5.8 Electrical Resistance
after OD
Pipe
Between pipe and the inner reinforcement: > 1000 ohms.
-

7.3.2
Pipe
QF08-2-7
C

check
per shift

Tolerance :

For micro tunnel scope (check the scope of CWC

thickness).

· -2.5 to +10 % for individual pipe.

· -0 to +5 % for 25 pipes rolling average.

PQT:

Negative Buoyancy of concrete

W R

TF08-2-1

coated section shall be

Spec cl. 7.4
Girth Tape,
All PQT
For offshore scope.
D H

(4)
5.9
All pipes
(Computer

calculated (based on 2.5%

and DS
Weigh Scale
pipes
· -5 to +15 % for individual pipe.
C
Prod:

Database)

water absorption)
WFO

· -0 to +5 % for 25 pipes rolling average (70mm CWC).

M R

For tie in / spools scope (check the scope of CWC

thickness).

· 0 to +15 % for individual pipe.

(Refer to attachment 5)

Calculated nominal as applied

Weigh
TF08-2-1

Spec. cl.
All PQT
To allow 1% water absorption over and above the green
D H

(4)
5.10
dry weight of the concrete
Scale,
All pipes
(Computer
R
2.3
pipes
concrete condition. Maximum 25 tonnes.
C

coating (individual pipe)

calculation
Database)

 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating & Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08 – 02 Revision Date : 05 – 10 – 12 Page Number 8 of 20

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Test
Acceptance Criteria
Approval

Item
Process/
Description of Inspection Test
Spec.
Insp/Test Freq.
Verifying

Method /
(WS2-3321-PPL-SPC-ITS-000-00006-000 rev.1 / WS2-
Inspection

No.
Location
Activity
Reference
Document

Code
PQT
Production
3002-PPL-DAS-ITS-000-00009-000 rev.2)
BSI CVX
IVB

Free from damage, cracks, spalling, voids and other

defects.

PQT:

For pipe fitted with anode, the concrete coating outer

W R

Spec cl. 4.1

All PQT
surface may be either be profiled such that there is a
V D

5.11 Concrete finish

---
TBA
PQT Report
Prod:

and DS
pipes
smooth transition down to the anode surface or square
H

WFO

cut to the pipe.

M R

The concrete finish (after vibrating plate) shall be a set at

PQT with agreed pictorial standard.

Concrete

Every cutback shall be cleaned

SOP-
No damage to FBE or steel and no traces of concrete

Application
IDKBL-

with water just after concrete

Spec cl. 4.1
All PQT
adhesive on steel cutback. Concrete shall finish 395 –
V D

5.12
CWC-CWC-
All pipes
PQT Report
W

coating application to remove

and DS
pipes
415mm from the end of the pipe, with a square face and
H

150-OP1-

any concrete deposit.

REV001
rounded shoulder.

WS22-3002

-PPL-DAS-
Internal pipe surface and cutback (internal and external)

ITS-000-

Finishing (inside and

shall be free from concrete splatter, free from any

00009 Pg 6
All PQT

5.13
outside, on the uncoated
---
All pipes
damage and any traces of adhesives.
--- V M

& 9, Spec
pipes

section and anode)

Cl 5.4.2,
Exterior surface of anodes shall be clean and free from

5.4.6, 7.3.9,
concrete or other foreign material.

7.8

Fog Curing

The freshly coated pipe shall be

Immediately upon placement of the pipe in curing bay, a

transported to the “Fog curing”

tarpaulin cover shall be used to enclose the pipe in each

bays by pole trailers fitted with

bay.

wide sand box bolsters, to

Curing shall start no later than 30mins from concrete

provide adequate support

Spec Cl
All PQT
placing completion.

6.0
Monitor
All pipes
--- M M

during transportation. On arrival

5.6.1
pipes
The concrete coating shall be kept continuously moist by

Curing
at the curing bays, the pipe
Fog mist spraying for a minimum duration of 24 hrs to

shall be off loaded by crane

ensure that the initial compressive strength is achieved

fitted with adequately padded

prior to stacking.

hooks and placed onto sand

Cutback shall be checked after end stop removal.

berms in the curing bays.

Colour code on concrete

All PQT
All markings and colour bands shall be based on Pipe

6.1
Surface / Colour code for
Spec Cl 9.1 Visual
All pipes
--- DV M
pipes
Identification Procedure QP 01-D

Anode pipe

 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating & Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08 – 02 Revision Date : 05 – 10 – 12 Page Number 9 of 20

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Test
Acceptance Criteria
Approval

Item
Process/
Description of Inspection Test
Spec.
Insp/Test Freq.
Verifying

Method /
(WS2-3321-PPL-SPC-ITS-000-00006-000 rev.1 / WS2-
Inspection

No.
Location
Activity
Reference
Document

Code
PQT
Production
3002-PPL-DAS-ITS-000-00009-000 rev.2)
BSI CVX
IVB

Cores shall be drilled not earlier than 3 days after

coating. Core shall be cured alongside the parent pipe at

all times. Cores shall be drilled at 3 locations on the pipe

body, between one and two metres from each end and

within the middle 2 metres. The set of 3 cores for each

Compressive Strength –
SOP-

testing shall consist of one core from each location.

Core Samples
Spec cl.
IDKBL-

7 days and
Once per

PQT Report/
T D

7.0

7.7.1 and
CWC-CWC-
WR

28 days
25 pipes
3 cores for 7 days (Information Only)
QF08-2-8
H C

Applicable for concrete thickness ≥

DS
100-QC2 –

REV001
3 cores for 28 days

60mm

3 cores spare for 28 days

Minimum individual core: 32 MPa

Minimum average of 3 cores: 40 MPa

Minimum 25 test pipe rolling average: 45 MPa

Compressive Strength –
3 cubes for 7 days (Information Only)

Cubes
Spec cl.
3 cubes for 28 days

Twice per
PQT Report/
T D

7.1
7.7.2 and
3 cubes spare for 28 days

3 cubes for 7 days

shift
QF08-2-8
H C

Inspection
DS

PQT:

3 cubes for 28 days

SOP-

&
At PQT
Minimum average of 3 cubes: 50 MPa
W R

3 cubes for spare for 28 days

IDKBL-

Laboratory

CWC-CWC-

Testing
Stacking Strength –
Prod:

Spec cl.
100-QC2 –
At start up

Cube Sample
PQT Report/
T D
WFO

7.2
7.7.2 and
REV001
of each
Minimum 15 MPa after 24 hours curing.

QF08-2-8
H C
M R

DS
shift

1 cube for test and 1 cube for spare

Repair Material –
1 set of 3
PQT Report/

7.3
Spec cl. 8
At PQT
7 day test for information only
T C

Cube Sample
per day
QF08-2-8

6 cores and

6 cubes

Correlation between cube and

7.4
Spec Cl 4.1 Calculation
from each
---
Report findings.
PQT Report C R

core strength
PQT

thickness

SOP-

Spec cl.
IDKBL-

Concrete density shall be

2 PQT
Twice per
3
PQT Report/
T H
PQT:

7.5
7.3.5 and
CWC-CWC-
> 95% of calculated density, as applied 3040 kg/m
.

measured on core sample.

pipes
shift
QF08-2-9
C
W R

DS
140-QC1-

REV001

SOP-

Prod:

Spec cl.
IDKBL-

Water absorption shall be

Twice per
Maximum 3% water absorption, rolling average 25 test
PQT Report/
T H
WFO

7.6
7.3.6 and
CWC-CWC-
1 PQT pipe

measured on core sample.

shift
pipe.
QF08-2-9
C
M R

DS
100-QC1 –

REV001

 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating & Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08 – 02 Revision Date : 05 – 10 – 12 Page Number 10 of 20

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Test
Acceptance Criteria
Approval

Item
Process/
Description of Inspection Test
Spec.
Insp/Test Freq.
Verifying

Method /
(WS2-3321-PPL-SPC-ITS-000-00006-000 rev.1 / WS2-
Inspection

No.
Location
Activity
Reference
Document

Code
PQT
Production
3002-PPL-DAS-ITS-000-00009-000 rev.2)
BSI CVX
IVB

The core sample shall be drilled

st

Spec cl.
1
core

from concrete coated pipe for

Volume of voids : <20%.
PQT Report/
V D

7.7
7.3.8 and
ASTM C642 1 PQT pipe
pipe at

voids test in accordance with

Specific gravity range to be determined at PQT.
QF08-2-9
C

DS
each shift

ASTM C642.

SOP-
Cement and aggregates to be weighed to an accuracy ±

Spec cl.
IDKBL-
1%.

Once per
PQT Report/
N H

7.8 Concrete Mix Analysis
7.3.4 and
CWC-CWC-
At PQT
Added water (weight or volume) to an accuracy ± 1%.
PQT:

shift
QF08-2-10
C

Inspection
DS
100-QC3-
Water / cement ratio ≤ 0.4
W R

&
REV001
Record obtained moisture content.

Laboratory
Prod:

Testing
WFO

Gradation
M R

WS2-3321-

TEC-CR-

6.3 mm : 99 - 100% passing

BRS-TLC-
4.75 mm : 75-100% passing

00018-000
2.36 mm : 40-65% passing

ASTM C33 /
Once per
PQT Report/

(4)
7.9
Iron Ore Analysis

At PQT
1.18 mm : 20-50% passing
N C

ASTM C40
shift
QF08-2-12

WS22-3002
600 microns : 15-40% passing

-PPL-DAS-
300 microns : 5-30% passing

ITS-000-

150 microns : 0-15% passing

00009 Pg 7

Cleanliness: Monitor

 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating & Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08 – 02 Revision Date : 05 – 10 – 12 Page Number 11 of 20

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Test
Acceptance Criteria
Approval

Item
Process/
Description of Inspection Test
Spec.
Insp/Test Freq.
Verifying

Method /
(WS2-3321-PPL-SPC-ITS-000-00006-000 rev.1 / WS2-
Inspection

No.
Location
Activity
Reference
Document

Code
PQT
Production
3002-PPL-DAS-ITS-000-00009-000 rev.2)
BSI CVX
IVB

For each single core below the minimum strength, three

additional cores shall be drilled from the same location as

the failing core(s) if all these cores meet the minimum

single core requirements and the average strength for

the cores drilled from the pipe are within the minimum

average specified, the coating represented by the test

will be accepted.

- If any of the test cores fail, the coating cannot be

accepted and pipes on either side of the rejected joint (in

the coating sequence) shall then be tested to the same

parameters as above. This operation will continue until

acceptable pipes are found.

Test
Spec cl.
As
As
- If the average strengths are below the minimum

(4)
8.0
Retest / Rejection Criteria
---
QF08-2-8
C MR
Failures
7.7.3
applicable
applicable
requirements, a further two pipes from the same

production shall be tested. If the average using the

original three results plus the additional six cores, satisfy

the requirements, coating will be accepted.

- If any of the new cores fail to meet the minimum

requirements, or the new average is below the minimum

average requirement, the total coating production

represented by the test shall be cored and evaluated on

an individual pipe basis.

- In the event that concrete cubes do not meet the

minimum compressive strength requirement, the

customer has the right to order additional testing of the

suspect pipe coatings or to reject the pipes coated with

concrete from the same batch.

 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating & Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08 – 02 Revision Date : 05 – 10 – 12 Page Number 12 of 20

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Test
Acceptance Criteria
Approval

Item
Process/
Description of Inspection Test
Spec.
Insp/Test Freq.
Verifying

Method /
(WS2-3321-PPL-SPC-ITS-000-00006-000 rev.1 / WS2-
Inspection

No.
Location
Activity
Reference
Document

Code
PQT
Production
3002-PPL-DAS-ITS-000-00009-000 rev.2)
BSI CVX
IVB

Wash off test shall be performed on FBE coated pipe

only. No adhesive will be applied to the pipes designated

Wash off test

Spec cl.
2 full pipe
1st pipe on

as wash off pipe.

Applicable
V D

9.0
(Offshore and Tie – in/Spools
7.3.10 and
---
joints at
first day
W R

report
C

scope)
DS
PQT
production

Maximum 20 holidays, voltage setting of holiday test in

accordance with the FBE ITP05-1.

Gradually the force shall be increased until the limit of the

equipment is reached or slippage occurs (continuous

Shear Test
SOP-

2 Joints of
2 pipes
movement). Dial gauges attached to the concrete jacket

Shear testing shall be

IDKBL-

Spec cl. 2.5

PQT pipes,
from 1st
shall be monitored for any movement.
T D

9.1
performed on 28 day cured
CWC-CWC-
PQT report
W R

& 4.1.1
1 m length
day
Minimum requirement 0.5 MPa.
C

concrete coated pipe.

140-QC7-

samples
production
Max. safe limit from shear test equipment hoses and

(See Attachment 3)
REV001

fittings is 9500 psi (65 MPa). With the current equipment

assembly, this equates to a test load of 1.06 MPa.

8 blows within a 0.5m length of coating.

1 pipe at 11 kJ (Hammer Weight 2.68 Tones & Height

418 mm)

1 pipe at 15 kJ (Hammer Weight 2.68 Tones & Height

570 mm)

Field
Impact Test
1 pipe at 20 kJ (Hammer Weight 2.68 Tones & Height

SOP-
3 Joints of

Testing
Impact testing shall be
IDKBL-
PQT
761 mm)

performed on 28 days cured

CWC-CWC-
(highest and

concrete coated pipe. Pipes

140-QC4-
lowest
Report anti corrosion damage, steel damage, concrete
T D

9.2

---
PQT report
W R

used for this test shall be

REV001
concrete
spalling/ crack patterns. Test to be stopped if/ when FBE
C

scrapped and not repaired for

thickness
is exposed. Recording of impact locations shall include:

DNV RP F
and each

incorporation into the pipeline.

· Photograph after each blow and in particular any areas

111
coating type

(See Attachment 4)
where the anticorrosion coating is exposed

· Diagram of concrete crack patterns and spalled areas

including dimensions of major cracks (length and width)

· Dimensional changes and damage assessment of the

pipe; detected by visual internal inspection and

subsequent external measurement.

TP 08-1P
PQT Only
>0.22% strain to destruction to COMPANY approved
Heriott

Spec cl. 7.6

T D

9.3 Full Scale Bend Test

&
as stated
---
procedure.
Watt
WR

and DS
C

ITP08-1P
above
For Concrete Thickness 75 mm and 110mm
Report

2 Joints of
To be measured after 1 month curing.

5 pipe per

Spec. cl. 6
110mm
Customer approved weight basis: as applied 'green'

9.4
Maximum dry weight
Weigh Scale
week of
QF08-2-11 MC W R

and DS
Concrete
weight versus 'cured' (28 days) weight at different times

production

thickness
of the year.

 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating & Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08 – 02 Revision Date : 05 – 10 – 12 Page Number 13 of 20

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Test
Acceptance Criteria
Approval

Item
Process/
Description of Inspection Test
Spec.
Insp/Test Freq.
Verifying

Method /
(WS2-3321-PPL-SPC-ITS-000-00006-000 rev.1 / WS2-
Inspection

No.
Location
Activity
Reference
Document

Code
PQT
Production
3002-PPL-DAS-ITS-000-00009-000 rev.2)
BSI CVX
IVB

‘Green’ Concrete Repairs

Areas of spalling at the time of

Monitor Green repairs

concrete application shall be

attended to immediately prior to

Concrete Spalling

concrete cure. All loose debris

Machine repair on ‘green’ concrete:

shall be removed from the area

0.8m
up to 10% of total area / 250kg max.

by scraper and the

reinforcement undercut to
Hand repair on ‘green’ concrete :

provide a key for the repair

<0.8m
, per 3m length (maximum 2 areas per joint).

patch. The cavity shall then be

filled by manual application of

Cracks

the concrete mix of original mix

Longitudinal cracks in excess of 1000mm in length or

proportions. The water content

extending the full depth of the coating are not

may be increased to improve

acceptable.

Spec cl. 8
Every
Every
PQT Report/
V D
W R

(4)
10
Repair
workability. Repair shall then
---

and DS
Repair
Repair
QF08-2-13
C

be allowed to cure in the fog

Annular cracking visible at pipe ends are not acceptable.

cure enclosures.

Where excessive spalling

Annular cracks (body of joint) <50mm do not require

occurs during which would

repair.

prove impractical to repair

manually, the concrete shall be

Repairable cracking:

removed around the entire

circumference and the pipe

· Cracks / Crazing of ≤ 5% of total area.

placed back onto the coating

buggy for re-application over

· Circumferential >3mm wide and extend >180

the effected area. This type of

around pipe.

machine repair should be

conducted within 30 minutes

· Longitudinal >1.5mm wide and >250mm long.

time of the initial application.

All tests/

Final

Manufacturing data records /

BSI
QA-QC
BSI

11
Documen-
---
As committed in these and reference documents. --- CE M E

reports
Standard
records –
Standard

tation

All pipes

Weight Bridge
Spec cl.

Prior to
Once per
Using Certified Test Weight.
PQT Report/

12.0
The accuracy of weight bridge
7.3.3 and
---
C R

PQT
shift
Adjustable to ± 0.5% of Target Value.
QF08-2-14

shall be verified.
DS

Plant Calibration
SOP-

IDKBL-
Calibrate for each component of mix design for each

The composition of each

Prior to
Once per
PQT Report/

12.1
Calibration
---
CWC-CWC-
component.
C R

component of mix design shall

PQT
week
QF08-2-14

110-QC1-
Tolerances same with concrete mix analysis.

be checked.
REV001

Spec cl
Prior to
Prior to
Visually check that tape free from damaged, marking

12.2
Tapes
Visual
QF500-1 HNC R

7.3.3
use
use
clear and legible.

 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating & Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08 – 02 Revision Date : 05 – 10 – 12 Page Number 14 of 20

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Test
Acceptance Criteria
Approval

Item
Process/
Description of Inspection Test
Spec.
Insp/Test Freq.
Verifying

Method /
(WS2-3321-PPL-SPC-ITS-000-00006-000 rev.1 / WS2-
Inspection

No.
Location
Activity
Reference
Document

Code
PQT
Production
3002-PPL-DAS-ITS-000-00009-000 rev.2)
BSI CVX
IVB

Calibration
Spec cl
External

12.3
Compression Test Machine
Yearly Yearly Third party calibration report Report NC R

(Cont.)
7.3.3
Calibration

C Record & Raise Documents H Hold Point N Non-Destructive Testing V Visual Inspection

D Dimensional Inspection I Random Inspection R Review W Witness Continously (written notification required)

Legend

E Examine / Endorse Documents M Monitor T Destructive Testing WFO Witness First Of (written notification required)

WP 7 days notice provided to site inspector * Verbally advise senior inspector prior to each repair

 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating and Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08-2 Revision Date : 05 – 10 – 2012 Page Number 15 of 20

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(4) Attachment 1

Concrete Cutback Sketch

Cutback 395mm - 415mm

Nylon Strand

End Ring Height shall be

no less than 5mm below

the coating thickness.

Pipe

Plastic Spacer

Anti-Corrosion Coat

Longitudinal Hard Drawn Wire

Continuous Circumferential (Hoop) Hard Drawn Wire

Wooden End Rings

Minimum clearance

 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating and Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08-2 Revision Date : 05 – 10 – 2012 Page Number 16 of 20

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Attachment 2 : Reinforcement Wire as per Approved Calculation

Reinforcement Steel Welded Cage Details – Single Layer (Refer to CAL-RC (CAL-RC1 to CAL-RC8))

Pipe Diameter (mm) 1135.4 1126.6 1117.6 1117.6 1126.6 1117.6 1126.6 1117.6

Wall thickness (mm) 33.5 29.1 24.6 24.6 29.1 24.6 29.1 24.6

Nominal Concrete Thickness (mm) 55 55 55 60 60 75 75 95

Circumferential wire Diameter (mm) 6 6 6 6 6 7 7 8

Maximum Pitch (mm) 103 103 103 94 94 103 103 106

Long. Wire Diameter (mm) 5 5 5 5 5 5 5 5

Number of Long. Wires 15 15 15 15 15 15 15 16

Spacer Height (mm) 20 20 20 25 25 30 30 40

Reinforcement Steel Welded Cage & Wire Mesh Details – Multiple Layers (Refer to CAL-RW (CAL-RW1 to CAL-RW2))

110 mm Concrete

Pipe Diameter (mm) 1126.6 1117.6

Wall thickness (mm) 29.1 24.6

st

1
Pass (60mm)

Circumferential wire Diameter (mm) 7 7

Maximum Pitch (mm) 98 98

Long. Wire Diameter (mm) 5 5

Number of Long. Wires 15 15

Spacer Height (mm) 30 30

nd

2
Pass (50mm)

Wire mesh circumferential Diameter (mm) 2.0

Wire mesh long. Diameter (mm) 2.0

Layer 1 Layer

 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating and Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08-2 Revision Date : 05 – 10 – 2012 Page Number 17 of 20

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Attachment 3

Shear Test

Direction of Applied Force

Gauge for

Anti Corrosion coating

Base Plate

movement

with Sinter rough coat

monitoring

Hydraulic Jacks x 8

7”

Gusset

Concrete Coating

Pressure Gauge

Face Plate

Hydraulic

Pump

 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating and Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08-2 Revision Date : 05 – 10 – 2012 Page Number 18 of 20

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Attachment 4

Impact Test Rig Assembly Sketch

Impact Test Rig Assembly

Note :8 blows within a 0.5m length of coating

Side Elevation
(Reference : DNV RP F 111)

Plan View

1 pipe at 11 kJ

1 pipe at 15 kJ

300mm
1 pipe at 20 kJ

R = 10mm

50mm

Impact Hammer Tip

 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating and Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08-2 Revision Date : 05 – 10 – 2012 Page Number 19 of 20

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Attachment 5

(4) Table Summary of Pipe

A. Line Pipe

Item
Pipe Size Coating

Description
Remarks

No.

OD (mm) WT (mm) FBE/3LPP/HBE Internal CWC

FBE min 600 mic exclude

1.3 Linepipe, DNV SAWL 450 F D 1117.6 24.6

min 75 mic 75 mm Offshore

rough coat

FBE min 600 mic exclude

1.4 Linepipe, DNV SAWL 450 F D 1117.6 24.6

min 75 mic 95 mm Offshore

rough coat

FBE min 600 mic exclude

1.5 Linepipe, DNV SAWL 450 F D 1117.6 24.6

min 75 mic 110 mm Offshore

rough coat

3LPP min 2.5 mm

Microtunnel (Include Buckle

1.7 Linepipe, DNV SAWL 450 F D 1126.6 29.1

min 75 mic 55 mm

(exclude Sinter)**
arrestor Pipe)

FBE min 600 mic exclude

Offshore (Include Buckle

1.10
Linepipe, DNV SAWL 450 F D 1126.6 29.1
min 75 mic 60 mm

rough coat
arrestor Pipe)

FBE min 600 mic exclude

Offshore (Include Buckle

1.11
Linepipe, DNV SAWL 450 F D 1126.6 29.1
min 75 mic 75 mm

rough coat
arrestor Pipe)

FBE min 600 mic exclude

1.12
Linepipe, DNV SAWL 450 F D 1126.6 29.1
min 75 mic 110 mm Offshore/Tie In Spool

rough coat

FBE min 600 mic exclude

1.13
Linepipe, DNV SAWL 450 F D* 1126.6 29.1
min 75 mic 110 mm Offshore/Tie In Spool

rough coat

FBE min 600 mic exclude

Offshore (Include Buckle

1.16
Linepipe, DNV SAWL 450 F D 1135.4 33.5
min 75 mic 55 mm

rough coat
arrestor Pipe)

Note : (*) Linepipe, DNV SAWL 450 F D,-20°C, 1126.6mm OD x 29.1mm WT

(**) 3LPP Coating system >> FBE min 300 mic; Adhesive min 250 mic; Sintercoat surface profile min 75 mic, maximum to be qualified at PQT

FBE required roughness min 75 mic, maximum profile to be qualified at PQT

CWC as applied Density = 3040 Kg/m

 Purchaser : Chevron Australia Pty Ltd / Worley Parsons (for Procurement)

Project : Wheatstone Upstream Project – Supply of Trunkline Coating and Bracelet Anodes (C900855)

Project No : 08-0158 Revision : 4

BSI Doc No. : ITP – 08-2 Revision Date : 05 – 10 – 2012 Page Number 20 of 20

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(4) Pictorial Standard of Sikadur Application

Pictorial Standard of Concrete Surface after Pressing Plate

Wednesday, November 14, 2012 05:21:19

- Changemarks ( 1

No changemarks applied

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